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Engine and peripherals


10A

ENGINE AND LOWER ENGINE ASSEMBLY TOP AND FRONT OF ENGINE FUEL MIXTURE TURBOCHARGING FUEL SUPPLY DIESEL INJECTION PREHEATING ANTIPOLLUTION STARTING - LOAD IGNITION PETROL INJECTION
X84, and B84 or C84 or G84 or S84

11A

12A

12B

13A

13B

13C

14A

16A

17A

17B

77 11 318 022

FEBRUARY 2003
All copyrights reserved by Renault.

Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

Renault s.a.s. 2005

19A

COOLING SYSTEM EXHAUST RESERVOIR ENGINE MOUNTING

19B

19C

19D

X84, and B84 or C84 or G84 or S84


77 11 318 022 FEBRUARY 2003
All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Renault s.a.s. 2005

Mgane II - Section 1ContentsPage

Mgane II - Section 1
Contents
Page

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine identication Engine oil: Draining Relling Oil consumption Check Oil lter: Removal - Retting Exchanger: Removal Retting Oil pressure Oil pressure sensor: Removal - Retting Oil level sensor: Removal Retting Sump: Removal - Retting Oil pump: Removal Retting Multifunction support: Removal - Retting Engine/gearbox assembly: Removal - Retting Engine speed and position sensor: Removal - Retting Crankshaft seal at timing end Removal - Retting 10A-1 10A-2 10A-3 10A-4 10A-10 10A-16 10A-17 10A-20 10A-21 10A-42 10A-45 10A-55 10A-131 10A-132

11A

TOP AND FRONT OF ENGINE Timing chain: Removal Retting Cylinder head gasket : Removal - Retting Tightening the cylinder head Cylinder head: Removal Retting

11A-116 11A-117 11A-199 11A-205

12A

FUEL MIXTURE Specications Air inlet Air resonator: Removal Retting Air lter: Replacement Air lter: Removal - Retting Air lter unit: Removal Retting Air owmeter: Removal Retting Air inlet ap: Removal Retting Air inlet duct: Removal Retting 12A-1 12A-11 12A-22 12A-23 12A-25 12A-26 12A-39 12A-41 12A-49 12A-52 12A-58 12A-64

11A

TOP AND FRONT OF ENGINE Accessories belt: Removal Retting Timing belt: Removal Retting

Inlet manifold: Removal Retting 11A-1 11A-11 Injector holder shim: Removal - Retting Manifolds: Removal Retting

Contents

12A

FUEL MIXTURE Exhaust manifold: Removal Retting Throttle valve: Removal Retting Throttle valve: Cleaning Engine stop device

13B

DIESEL INJECTION Diesel injection: Precautions for repair Description

12A-67 12A-86 12A-94 12A-96

13B-16 13B-31 13B-33 13B-36 13B-61 13B-62 13B-64 13B-67 13B-69 13B-71 13B-73 13B-76 13B-83 13B-84 13B-113 13B-130

Operation Location of components Immobiliser function Injection warning light

12B

TURBOCHARGING Turbocharging: Precautions for repair Turbocharger: Removal Retting Pressure regulator: Checking Turbocharging pressure regulation valve Intercooler: Removal Retting

Injection / air conditioning programming Idling speed 12B-1 Centralised coolant temperature management 12B-6 Computer conguration 12B-37 High pressure pipe: Checking 12B-43 High pressure pipe: Replacement 12B-46 Diesel injector: check High pressure pump: Removal - Retting

13A

FUEL SUPPLY Petrol supply circuit Diesel fuel supply circuit Petrol lter: General information Diesel lter: Removal Retting Injector rail - Injectors: Removal - Retting Electric fuel: Checking 13A-1 13A-2 13A-6 13A-7 13A-14 13A-20 Diesel injector: Removal Retting Injectors: Conguration High-pressure pipe between the rail and injector: Removal - Retting Injector rail: Removal Retting Rail pressure sensor Rail pressure sensor: Removal - Retting Fuel ow actuator: Removal Retting

13B-132 13B-143 13B-160 13B-161 13B-164 13B-170 13B-174

13B

DIESEL INJECTION Specications Diesel injection: Specications 13B-1 13B-11

Leak ow from injectors: Check Fuel pressure regulator: Removal - Retting

Contents

13B

DIESEL INJECTION Diesel temperature sensor: Removal - Retting Accelerometer: Removal Retting Venturi: Removal - Retting Accelerator pedal potentiometer: General information Accelerator pedal potentiometer: Removal Retting Diesel injection computer: Removal - Retting

14A

ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal Retting Intercooler: Removal Retting Exhaust gas recirculation mounting: Removal Retting Exhaust gas recirculation rigid pipe: Removal Retting

13B-179 13B-189 13B-190

14A-29 14A-31

13B-194

14A-36

13B-195 13B-196 16A

14A-37

STARTING - LOAD Alternator: General information Alternator: Removal Retting Alternator pulley: Removal Retting Starter: Identication Starter: Removal - Retting

13C

PREHEATING Pre/postheating unit: Removal - Retting Heater plugs Removal Retting Pre-postheating control

16A-1 16A-2 16A-20 16A-24 16A-25

13C-1 13C-2 13C-11

14A

ANTIPOLLUTION 17A Petrol vapour rebreathing: Operation Fuel vapour recirculation circuit: check Fuel vapour canister: Removal - Retting Fuel vapour canister:Checking Oil vapour rebreathing Exhaust gas recirculation: Operating diagram Exhaust gas recirculation: Description Exhaust gas recirculation unit 14A-17 14A-23 14A-1 14A-3 14A-4 14A-5 14A-6 IGNITION Coils Removal - Retting Spark plugs 17A-1 17A-5

17B

PETROL INJECTION Location of components Oxygen sensors: Removal Retting Accelerator pedal potentiometer: Removal Retting Position and speed sensor 17B-1 17B-14

17B-16 17B-17

Contents

17B

PETROL INJECTION Petrol injection computer: Removal - Retting Special notes Injection warning light Immobiliser function Injection - air conditioning programming Throttle valve: Operating Idle speed correction Adaptive idle speed correction Richness regulation Adaptive richness correction Central coolant temperature management Camshaft dephaser: Description Fault nding warning light activation conditions (when driving) Conditions for carrying out fault nding (when driving) Combustion misre fault nding Catalytic converter fault nding Oxygen sensor fault nding Speed limiter: Operating principle

19A

COOLING SYSTEM Cooling circuit: Draining Relling Engine cooling circuit: Cleaning Cooling circuit: Bleeding Cooling radiator: Removal Retting Water pump: Removal Retting Plenum chamber: Removal Retting

17B-19 17B-21 17B-24 17B-25 17B-26 17B-30 17B-31 17B-34 17B-35 17B-39 17B-41 19B

19A-12 19A-14 19A-15 19A-16 19A-22 19A-40

EXHAUST General information Pipe assembly 19B-1 19B-5 19B-10 19B-15 19B-29 19B-30 19B-31 19B-32 19B-38 19B-42 19B-45 19B-46

17B-42

Catalytic pre-converter: Removal - Retting Catalytic converter: Removal - Retting Expansion chamber: Removal - Retting Silencer: Removal - Retting

17B-44 17B-45 17B-46 17B-47 17B-48 17B-49

Particle lter: Function Particle lter: Removal Retting Particle lter pressure sensor: Removal - Retting Particle lter temperature sensors: Removal - Retting Connecting hose: Removal Retting

19A

COOLING SYSTEM General information Specications Checking Diagram 19A-1 19A-2 19A-3 19A-4

Particle lter: Cleaning

Contents

19C

RESERVOIR Draining the fuel tank Fuel tank: Description Fuel tank: Removal Retting Filler neck: Removal Retting Sender unit: Removal Retting Pump-sender unit-lter: Removal - Retting Petrol lter: General information Fuel level sensor: Checking 19C-1 19C-6 19C-12 19C-15 19C-17 19C-20 19C-22 19C-23

19D

ENGINE MOUNTING Suspended engine mounting Suspended engine mounting: Tightening torque Left-hand suspended engine mounting: Removal Retting Right-hand suspended engine mounting: Removal Retting Rear suspended engine mounting: Removal Retting 19D-1 19D-9

19D-12

19D-14

19D-16

ENGINE AND LOWER ENGINE ASSEMBLY Engine identification

10A
Compression ratio

Vehicle type XM0B XM0H XM1A XM08 XM0C XM0J XM1B XM05 XM0U XM1M XM1N XNOW XM0F XM0T XM02 XM13 XM02 XM1E XM0G XM1G XM0L XM1D XM00

Engine type

Engine sufx 730

Cubic capacity (cc)

Bore (mm)

Stroke (mm)

K4J 732 760 K4M 761

1390

79.5

70

10/1

1598

79.5

80.5

9.8/1

770 771 F4R 1998 82.7 93 9.8/1

776 722

9.5/1

728 K9K 729 732 800 1461 76 80.5

17.9/1

15.3/1 18.4/1

F9Q

804

1870

80

93

17/1

808

18.4/1

List of engine Workshop Repair Manuals to be consulted 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.

10A-1

ENGINE AND LOWER ENGINE ASSEMBLY Engine oil: Draining - Refilling


M9R, and 700 Copper seal Tightening torquesm drain plug 44 Nm

10A

Average oil capacity (check and adjust with dipstick) (l) Engine Draining Oil change with oil lter replacement 6.7

M9R I - OIL SERVICE

6.4

Remove the oil filler plug and the dipstick. Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray.
113764

Refit the new seal on the plug, positioning the groove (2) towards the plug. Tighten to torque the drain plug ( 44 Nm ) . II - FILLING

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 before delivering the vehicle to the customer. When filling up the engine oil, always leave at least 10 minutes for the oil to drain down before checking with a dipstick. Fill up the engine with oil. Refit the engine undertray.
114651

Remove the drain plug (1) . Let the oil run into a drain tray.

10A-2

ENGINE AND LOWER ENGINE ASSEMBLY Oil consumption Check


PROCEDURE FOR MEASURING OIL CONSUMPTION

10A

1 - Filling to the maximum level

Note: The operation should be carried out with the engine warm after the fan unit has started operating. Turn the engine off. Wait two minutes for all of the oil to flow into the oil sump. Check the level on the dipstick. Top up to the "MAX" mark. Make a paint mark on both the fuel filler cap and the sump drain plug in order to be able to check later that they have not been removed. 2 - Customer driving Ask the customer to drive approximately 1,200 miles (2,000 km) in the vehicle without letting the oil level reach the "MIN" mark.

3 - Topping up

Note: The operation should be carried out with the engine warm after the fan assembly has started operating. Turn the engine off. Wait two minutes for all of the oil to flow into the oil sump. Check the level on the dipstick. Top up to the "MAX" mark. Note the quantity of oil added and the mileage covered since the last top-up to maximum level. 4 - Measurement of the oil consumption Oil consumption = Quantity of topping up oil (in litres) / number of kilometres (in thousands).

10A-3

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


K9K, and 722 or 728 or 729 or 732 Special tooling required Mot. 1329 76 mm diameter oil lter removing tool III - FINAL OPERATION Top up the engine oil. Wipe any oil run-off with a cloth. Refit the engine undertray.

10A

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray.

111850

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 with the oil filter seal on the engine. Tighten the oil filter three-quarters of a turn by hand.

10A-4

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


F4R, and 770 or 771 or 776 Special tooling required Mot. 1329 76 mm diameter oil lter removing tool

10A

Tightening torquesm air conditioning compressor stay mounting bolts 44 Nm

REMOVAL
Position the vehicle on the two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray.

111852

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 with the 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 compressor stay mounting bolts ( 44 Nm ) . Top up the engine oil. Wipe any oil run-off with a cloth.
111851

Remove: - the mounting bolts (1) from the air conditioning compressor stay. - the air conditioning compressor stay.

Refit the engine undertray.

10A-5

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


K4M, and 760 or 761 K4J, and 730 or 732 Special tooling required Mot. 1329 76 mm diameter oil lter removing tool

10A

REMOVAL
Position the vehicle on the two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray.

110385

Position tool (Mot. 1329) (1) on the oil filter. Remove the oil filter.

REFITTING
Apply new engine oil to the oil filter seal. Tighten the oil filter until it comes into contact with the 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.

10A-6

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


M9R, and 700

10A

Tightening torquesm cover 25 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine undertray.

114779

Remove the filter element - cover assembly. II - OPERATION FOR REMOVAL OF PART CONCERNED

114653

Loosen the cover (1) slightly. Let the engine oil flow out before removing the filter element - cover assembly.

113320

Remove: - the filter element (2) from the cover (3) , - the O-ring (4) from the cover (3) .

10A-7

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


M9R, and 700

10A

REFITTING
I - REFITTING PREPARATION OPERATION Clean the cover.

II - REFITTING OPERATION FOR PART CONCERNED

114780

Refit:
113869

- 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.

Position the new O-ring (5) correctly on the cover. Apply new engine oil to the O-ring.

10A-8

ENGINE AND LOWER ENGINE ASSEMBLY Oil filter: Removal - Refitting


F9Q Special tooling required Mot. 1329 76 mm diameter oil lter removing tool

10A

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 - Fillingup ). Refit:

If the AC pipe is significantly deformed when the oil filter is removed, there may be a refrigerant leak. To reduce the risk of a leak in the MEGANE II and SCENIC II equipped with F9Q engine, the ADVICE in this Technical Note relating to the removal of the oil filter from the TOP OF THE ENGINE must be strictly followed.

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the engine covers, - the engine undertray. Drain the engine oil (see 05A, Draining/Filling-up ). II - REMOVING THE OIL FILTER

- the engine undertray, - the engine covers.

115078

From the top of the engine, position the (Mot. 1329) on the oil filter using an open-jawed spanner 27 mm in width. Remove the oil filter.

10A-9

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips 22 mm socket for removing/retting oxygen sensors Equipment required lling station

10A

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal and Refitting ) Remove: - the engine protectors, - the engine undertray,

Mot. 1202-02 Mot. 1448

Mot. 1495-01

- the oil filter (see 10A, Engine and peripherals, Oil filter: Removal - Refitting ). - the front bumper (see MR365 Bodywork, 55A Exterior protection, Front bumper ) Drain the coolant circuit using filling station (see 62A, Air conditioning, Maintenance ).

Tightening torquesm oil cooler mounting bolts coolant inlet union mounting bolts oil pressure sensor intercooler downstream duct clip on the intercooler intercooler downstream duct clip on the damper valve intercooler upstream hose clip front end panel upper mounting bolts front end panel lower mounting bolts 25 Nm 24 Nm 44 Nm 5.5 Nm

5.5 Nm

5.5 Nm 21 Nm Remove: 44 Nm - the mounting bolts (1) from the Protection and Switching Unit, - the Protection and Switching Unit cover.
112658

10A-10

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700

10A

102504

102365

Disconnect the connectors (2) from the Protection and 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.

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 ).

102473 114933

Unclip the air inlet scoop.

Loosen the clip (8) from the intercooler upstream hose. Disconnect the intercooler upstream hose.

10A-11

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700

10A

114649

112661

Remove the bolt (9) mounting the intercooler downstream duct on the cooling radiator. Loosen: - the clip (10) on the intercooler downstream duct on the intercooler, - the intercooler downstream duct clip on the damper valve. Move the downstream duct away from the intercooler.

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.

10A-12

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700

10A

109537

114929

Disconnect: - the hoses from the expansion bottle on the cooling radiator side (12) , - the pressure switch connector on the condenser lower air conditioning pipe (13) . Unpick the wiring harness from the pressure switch connector on the fan unit. Remove the air conditioning pipes from the condenser (14) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system. Remove the cooling assembly.

Disconnect the hose (15) from the oil cooler coolant outlet 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. 120202) or (Mot. 1448) : - the hose (17) from the coolant inlet union on the union, - the hose (18) from the cylinder block coolant inlet pipe, Remove the hose from the coolant inlet union.

10A-13

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

10A

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED

114928

Remove: - the mounting bolts (19) from the oil cooler, - the oil cooler. 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

10A-14

ENGINE AND LOWER ENGINE ASSEMBLY Exchanger: Removal - Refitting


M9R, and 700 II - FINAL OPERATION Connect, using the (Mot. 1202-01) or (Mot. 120202) 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 ( 44 Nm ) . Refit the cooling assembly. Refit the air conditioning pipes to the condenser. Attach the pressure switch connector wiring harness to the fan unit. Connect, using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) : - the expansion bottle hoses on the cooling radiator side, - the cooling radiator top and bottom hose. Connect: - the pressure switch connector on the condenser lower 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 intercooler, - the intercooler downstream duct clip on the damper valve. Tighten to torque: - the intercooler downstream duct clip on the intercooler ( 5.5 Nm ) , - the intercooler downstream duct clip on the damper valve ( 5.5 Nm ) . Tighten the bolt mounting the intercooler downstream duct on the cooling radiator. Connect the intercooler upstream hose. - the engine protectors, - the air inlet scoop, - the front end panel, - the clips,

10A

Tighten to torque the intercooler upstream hose clip ( 5.5 Nm ) . Refit:

- the front end panel mounting bolts. Tighten to torque: - the front end panel upper mounting bolts ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) . Connect the Protection and Switching Unit connectors. Clip the bonnet opening cable. Disconnect the screen washer tubes. Refit: - the Protection and Switching Unit cover, - the Protection and Switching Unit cover mounting bolts, - the oil filter (see 10A, Engine and peripherals, Oil filter: Removal - Refitting ). - the engine undertray. Refit:

- the front bumper (see MR365 Bodywork, 55A Exterior protection, Front bumper ). Refill: - the coolant circuit using the filling station (see 62A, Air conditioning, Maintenance ), - the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

10A-15

ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure


Special tooling required Mot. 836-05 Oil pressure gauge kit

10A

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Start the vehicle. Carry out the check.

I - ADAPTERS FOR USE WITH VARIOUS ENGINES

Check the values.

Engine K4J K4M F4R K9K F9Q M9R

Adapters E+C+F E+C+F B+F E+C+F B+F C+F F4R K4M 782 770 1 K4J 730 760 1 Engine Engine sufx

Minimum pressure (bar) Idle speed 1 3000 rpm 3 3

3 3.5

II - PRECAUTIONS TO TAKE DURING CHECKS The oil pressure check must be carried out with the engine warm ( 80C ). III - CHECKING PROCEDURE Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the oil pressure sensor (see 10A, Engine and peripherals, Oil pressure sensor: Removal - Refitting ).

771 776 722 1.2

K9K

728 732 804

1.2

3.5

F9Q 812 M9R 700

1.2 0.9

3.5 4

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 peripherals, Oil pressure sensor: Removal - Refitting ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

87363

Position the (Mot. 836-05) with the appropriate adapters.

10A-16

ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure sensor: Removal - Refitting
M9R, and 700 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

10A

- the engine accessories unit cover.

Tightening torquesm oil pressure sensor front end panel upper mounting bolts front end panel lower mounting bolts 44 Nm 21 Nm

44 Nm
115585

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the engine protectors, - the engine undertray, - the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ).

Disconnect the connectors (2) from the engine accessories unit. Unfasten the bonnet opening cable (3) . Remove: - the clips (4) , - the front end panel upper mounting bolts (5) , Disconnect the screen washer tubes.

114933

Unclip the air inlet scoop (6) .

112658

Remove: - the engine accessories unit cover mounting bolts (1) ,

10A-17

ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure sensor: Removal - Refitting
M9R, and 700

10A

102365

Remove: - the front end panel lower mounting bolts (7) . - the front end panel.
115022

II - OPERATION FOR REMOVAL OF PART CONCERNED

115021 114061

Remove the oil pressure sensor using the (Mot. 1495-01) (1) . Note: Be careful not to damage the air conditioning compressor connector.

Disconnect the oil pressure sensor connector (8) .

10A-18

ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure sensor: Removal - Refitting
M9R, and 700

10A

REFITTING
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 ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) . 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 Exterior protection, Front bumper ), - the engine undertray, - the engine protectors.

10A-19

ENGINE AND LOWER ENGINE ASSEMBLY Oil level sensor: Removal - Refitting
M9R, and 700 II - FINAL OPERATION Tightening torquesm oil level sensor front right-hand wheel 25 Nm 110 Nm

10A

Refit the heat insulating material around the oil level sensor. Refit the front right-hand wheel. Tighten to torque the front right-hand wheel ( 110 Nm ) .

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A Lifting equipment, Underbody lift ). Remove the front right-hand wheel. Move the heat insulating material away from the oil level sensor. II - OPERATION FOR REMOVAL OF PART CONCERNED

114932

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.

10A-20

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

Equipment required safety belt

Tightening torquesm sump mounting bolts sump mounting bolts are tightened to torque gearbox - sump mounting bolts sump mounting bolts sump mounting bolts are tightened to torque gearbox - sump mounting bolts bolt mounting the sump on the multifunction support half sub-frame mounting bolts half sub-frame mounting nuts wheel bolts battery cover bolts 14 Nm 14 Nm 44 Nm 14 Nm 14 Nm 44 Nm 21 Nm

101212

Remove the half sub-frame side reinforcements (1) . Attach the cooling assembly to the upper cross member using a safety belt . Note: When positioning the safety belt , be careful not to: - pinch the cooling hoses, 110 Nm 4 Nm - strap the half sub-frame.

105 Nm 21 Nm

REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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,

10A-21

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

Apply the product to the section to be cleaned: wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could cause damage to certain components (engine, radiator, etc.).

2
102008

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 driveshaft bracket on the relay bearing, - the bolts mounting the relay bearing on the sump.

CA or CAREG Remove the mounting bolt of the sump on the multifunction support.

Remove: - the sump mounting bolt, - the sump.

REFITTING
Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering.

10A-22

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761 I - FIRST FITTING

10A

3
20167 20170

Refit the oil splash plate onto the cylinder block.

5
Note: When retting the sump, check that:

- the tabs (6) on the oil splash plate are positioned correctly in the notches (7) , - the cylinder block and the sump at the ywheel end are aligned to prevent deformation of the clutch housing.

4
20166

Apply: - four beads at (3) and (4) of SILICONE ADHESIVE SEALANT which are 5 mm in diameter . - two points of SILICONE ADHESIVE SEALANT at (5) which are 7 mm in diameter , at the joint between the crankshaft closure panel and the cylinder block.

10A-23

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

9 10 11

12 13 14

15

16

20

19 18 17
20171

Refit the oil sump with a new seal. Fit: - the sump mounting bolts without tightening, - the gearbox - sump mounting bolts without tightening. Tighten to torque and in order the sump mounting bolts ( 14 Nm ) . Check that all the sump mounting bolts are tightened to torque ( 14 Nm ) . Tighten to torque the gearbox - sump mounting bolts ( 44 Nm ) .

10A-24

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761 II - SECOND FITTING bolts ( 44 Nm ) .

10A

III - REFITTING (FOR FIRST AND SECOND FITTINGS) CA or CAREG Refit the bolt mounting the sump on the multifunction support. Tighten to torque the bolt mounting the sump on the 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 ) .
108881

Proceed in the reverse order to removal.

9 10 11 12 13 14

Top up the engine oil (see 05A, Draining - Filling, Engine ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

15

16

20 19

18 17
20171

Refit the oil sump with a new seal. Fit: - the sump mounting bolts without tightening, - the gearbox - sump mounting bolts without tightening. Tighten to torque and in order the sump mounting bolts ( 14 Nm ) . Check that all the sump mounting bolts are tightened to torque ( 14 Nm ) . Tighten to torque the gearbox - sump mounting

10A-25

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F9Q, and 800 or 804 or 808

10A

Equipment required safety belt

Tightening torquesm half sub-frame mounting bolts half sub-frame mounting nuts wheel bolts battery cover mounting bolts 105 Nm 21 Nm

110 Nm 4 Nm

REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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, Note: When positioning the safety belt , be careful not to: - pinch the cooling hoses, - strap the half sub-frame.
101212

Remove the half sub-frame side reinforcements (1) . Attach the cooling assembly to the upper cross member using a safety belt .

10A-26

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F9Q, and 800 or 804 or 808

10A

Apply the product to the section to be cleaned: wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could cause damage to certain components (engine, radiator, etc.).

2
102008

Note: There are two tting procedures for preparing the cylinder block gasket face when retting:

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.

- the rst tting procedure is used if SILICONE ADHESIVE SEALANT has been used to seal the crankshaft closure panel, - the second tting is used if a seal is used for the crankshaft closure panel sealing.

REFITTING
Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering.

10A-27

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F9Q, and 800 or 804 or 808 I - FIRST FITTING II - SECOND FITTING

10A

15159

15159

Apply a bead of SILICONE ADHESIVE SEALANT : - at (A) , both sides of bearing No.1, - at (B) , the joint between the cylinder block and the crankshaft closure panel. Refit the sump fitted with a new seal.

Apply a bead of SILICONE ADHESIVE SEALANT at (A) , on the joint between the crankshaft closure panel and the cylinder block. Note Do not cut the two crankshaft closure panel seal tabs which sit higher than the cylinder block gasket face (B) . Refit the sump fitted with a new seal.

10A-28

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F9Q, and 800 or 804 or 808 III - REFITTING (FOR THE FIRST AND SECOND FITTINGS)

10A

1 22 21

10 11 12 13

20 19 18 17

16 15

14
15195

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 ( 15 Nm ). Refit the lower engine tie-bar (see 19D, Engine mounting, 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: Removal - Refitting ).

10A-29

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

10A

REMOVAL
Equipment required safety belt I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Tightening torquesm sump mounting bolts sump mounting bolts are tightened to torque sump mounting bolts sump mounting bolts sump mounting bolts are tightened to torque sump mounting bolts bolt mounting the sump on the multifunction support catalytic converter upstream stay mounting bolts half sub-frame mounting bolts half sub-frame mounting nuts half sub-frame side reinforcement mounting bolts wheel bolts 14 NM 14 NM 44 NM 14 NM 14 NM 44 NM 21 Nm 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 Exterior protection, Front bumper ), - the front wheels, - the wheel arch liners. Drain the engine oil (see 05A, Draining - Filling, Engine ). 21 Nm

105 Nm 21 Nm 21 Nm

110 Nm

10A-30

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

10A

101212

102008

Remove the half sub-frame side reinforcements (1) . Attach the cooling assembly to the upper cross member using a safety belt . Note: When positioning the safety belt , be careful not to: - pinch the cooling hoses, - strap the half sub-frame.

Remove: - the mounting nuts from the half sub-frame, - the mounting bolts from the half sub-frame, - the half sub-frame (2) .

K9K, and 732 Remove: - the lower engine tie-bar mounting bolts,

K9K, and 732 Move the diesel drain pipe away from the injection rail protector.

- the lower engine tie-bar, - the lower engine tie-bar support lower mounting bolts. Loosen the lower engine tie-bar upper bolt.

Remove: - the bolts mounting the right-hand driveshaft bracket on the relay bearing, - the bolts mounting the relay bearing on the sump, - the relay bearing, - the catalytic converter upstream stay mounting bolts, - the catalytic converter upstream stay. Disconnect the oil level sensor.

10A-31

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

10A

CA or CAREG Remove the mounting bolt from the sump on the multifunction support.

II - OPERATION FOR REMOVAL OF PART CONCERNED Remove: - the sump mounting bolt, - the sump.

REFITTING
3
I - REFITTING PREPARATION OPERATION
20167

K9K, and 732 Clean the strainer with a soft, lint-free cloth.

Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering. WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could cause damage to certain components (engine, radiator, etc.). Apply the product to the section to be cleaned: wait approximately ten minutes, then remove the residue using a wooden spatula. Apply: - four beads at (3) and (4) of SILICONE ADHESIVE SEALANT which are 5 mm in diameter . - two points of SILICONE ADHESIVE at (5) which are, 7 mm in diameter , at the joint between the crankshaft closure panel and the cylinder block.

4
20166

10A-32

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732 II - REFITTING OPERATION FOR PART CONCERNED 1 - FIRST FITTING

10A
12 13 14

9 10 11

15 6 16

7 5 4 3 2 1 20 19 18 17
20171

Refit the oil sump with a new seal. Fit:


20170

- the sump mounting bolts without tightening, - the gearbox - sump mounting bolts without tightening. Tighten to torque and in order the sump mounting bolts ( 14 NM ) . Check that all the sump mounting bolts are tightened to torque ( 14 NM ) . Tighten to torque and in order the sump mounting bolts ( 44 NM ) .

Refit the oil splash plate onto the cylinder block. Note: When retting the sump, check that: - the tabs (6) on the oil splash plate are positioned correctly in the notches (7) , - the cylinder block and the sump at the ywheel end are aligned to prevent deformation of the clutch housing.

10A-33

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732 2 - SECOND FITTING bolts ( 44 NM ) .

10A

III - FINAL OPERATION Connect the oil level sensor.

CA or CAREG Refit the bolt mounting the sump on the multifunction support. Tighten to torque the bolt mounting the sump on the multifunction support ( 21 Nm ) .

Refit the catalytic converter upstream stay. Tighten the mounting bolts of the catalytic converter upstream stay until contact is made. Tighten to torque the catalytic converter upstream stay mounting bolts ( 21 Nm ) . Refit: - the relay bearing, - the bolts mounting the relay bearing on the sump, - the bolts mounting the right-hand driveshaft bracket on the relay bearing.

108881

K9K, and 732 Refit the lower engine tie-bar support lower mounting bolts (see 19A, Engine mounting, Suspended engine mounting ). Tighten the lower engine tie-bar support lower mounting bolts (see 19A, Engine mounting, Suspended engine mounting ). Refit the lower engine tie-bar (see 19A, Engine mounting, Suspended engine mounting ).

20171

Refit the oil sump with a new seal. Fit: - the sump mounting bolts without tightening, - the gearbox - sump mounting bolts without tightening. Tighten to torque and in order the sump mounting bolts ( 14 NM ) . Check that all the sump mounting bolts are tightened to torque ( 14 NM ) . Tighten to torque and in order the sump mounting

Note: Apply a drop of LOCTITE FRENBLOC to the half sub-frame mounting bolts.

10A-34

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732 Refit: - 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 ) .

10A

K9K, and 732 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 mounting bolts. Tighten to torque the half sub-frame side reinforcement 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: Removal - Refitting ). Top up the engine oil (see 05A, Draining - Filling, Engine ). Refit: - the dipstick, - the engine protectors.

10A-35

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F4R, and 770 or 771 or 776

10A

Equipment required safety belt

Tightening torquesm half sub-frame mounting bolts half sub-frame mounting nuts wheel bolts (F4R 776) wheel bolts battery cover mounting bolts 105 Nm 21 Nm

130 Nm 110 Nm 4 Nm

REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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.

101212

Remove: - the half sub-frame side reinforcement mounting bolts, - the side reinforcements (1) . Attach the cooling assembly to the upper cross member using the safety belt . Note: When positioning the safety belt , be careful not to: - pinch the cooling hoses, - strap the half sub-frame.

10A-36

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F4R, and 770 or 771 or 776

10A

2
102008

15159

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.

Apply a bead of SILICONE ADHESIVE SEALANT at (A) , at the joint between the crankshaft closure panel and the cylinder block. Note: Do not cut the two tabs on the crankshaft closure panel seal, which sit higher than the joint face of the cylinder block (B) . Refit the sump with a new gasket.

REFITTING
Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering. Apply the product to the section to be cleaned: wait approximately ten minutes, then remove the residue using a wooden spatula.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could cause damage to certain components (engine, radiator, etc.).

10A-37

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


F4R, and 770 or 771 or 776

10A

1 22 21

10 11 12 13

20 19 18 17

16

15 14
15195

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, Engine mounting, 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: Removal - Refitting ).

10A-38

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1716 Removes housing with silicone seals.

10A

Tightening torquesm sump mounting bolts half sub-frame mounting bolts half sub-frame mounting nuts the side reinforcement lower mounting bolts 16 Nm 105 Nm 21 Nm 21 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a lift (see 02A, Lifting equipment, 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 Exterior protection, Front bumper ). Remove:

102008

- the lower mounting bolts (1) from the side reinforcements, - the half sub-frame (2) . Drain the engine oil (see 10A, Engine and peripherals, Engine oil: Draining-refilling ).

10A-39

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

10A

Check that the base plate is not scratched.

IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles. - Wear gloves during the operation.

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and uid could cause damage to cer tain components (engine, radiator, etc.).

WARNING The sealing surfaces must be clean, dry and free from grease (avoid nger marks).
114997

Remove the sump mounting bolts. Remove the sump using the (Mot. 1716) . Remove the lower cover.

II - REFITTING OPERATION FOR PART CONCERNED

REFITTING
I - REFITTING PREPARATION OPERATION Check that the sump is not: - scratched, - deformed. If this is the case, replace the sump.

114410

Apply a bead of SILICONE ADHESIVE SEALANT (77 11 227 484) with a diameter of 5 mm 2 to the sump to make a seal. Fit the sump. Tighten the sump mounting bolts until contact is made. Tighten to torque and in order the sump mounting bolts ( 16 Nm ) .

10A-40

ENGINE AND LOWER ENGINE ASSEMBLY Sump: Removal - Refitting


M9R, and 700 III - 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 lower mounting bolts ( 21 Nm ) . Refit: - the front bumper (see MR 365 Bodywork, 55A Exterior 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 peripherals, Engine oil: Draining-refilling ). Refit: - the dipstick, - the engine protectors.

10A

10A-41

ENGINE AND LOWER ENGINE ASSEMBLY Oil pump: Removal - Refitting

10A

Connect the battery, starting with the positive terminal. Tightening torquesm oil pump mounting bolts battery cover bolts 25 Nm 4 Nm WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover bolts ( 4 Nm ) .

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the under-engine protectors Drain the engine oil. Remove the sump (see 10A, Engine and peripherals, Sump ).

Example for F9Q engine

2 1

23224

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 ( 25 Nm ) . Refit the sump (see 10A, Engine and peripherals, Sump ). Top up the engine oil.

10A-42

ENGINE AND LOWER ENGINE ASSEMBLY Oil pump: Removal - Refitting


M9R, and 700

10A

II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pump mounting bolts on the cylinder block oil pump mounting bolts on the anti-splash plate strainer mounting bolts 25 Nm 10 Nm 10 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the sump (see 10A, Engine and peripherals, Sump: Removal - Refitting ).
113157

Remove: - the oil pump mounting bolts on the anti-splash plate, - 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 the oil pump chain to the oil pump sprocket. II - REFITTING OPERATION FOR PART CONCERNED Finger tighten: - the oil pump mounting bolts on the anti-splash plate, - the oil pump mounting bolts on the cylinder block. Tighten to torque the oil pump mounting bolts on the cylinder block (5 Nm) . Tighten to torque: - the oil pump mounting bolts on the cylinder block ( 25 Nm ) , - the oil pump mounting bolts on the anti-splash plate ( 10 Nm ) ,

113156

Remove: - the strainer mounting bolts , - the strainer.

10A-43

ENGINE AND LOWER ENGINE ASSEMBLY Oil pump: Removal - Refitting


M9R, and 700 III - FINAL OPERATION

10A

113156

Replace the oil strainer O-ring. Fit the strainer to the oil pump and finger tighten the two mounting bolts in the following tightening order -. Tighten the strainer mounting bolts ( 10 Nm ) in the 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 peripherals, Engine oil: Draining-refilling ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Start the engine and wait until the engine oil warning light goes out. Check the engine oil level. Refit the engine undertray.

10A-44

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

Tightening torquesm multifunction support mounting bolts multifunction support mounting bolt on the sump 44 Nm 21 Nm

CA or CAREG

REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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 of engine, Accessories belt: Removal - Refitting ), - the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ). Remove: - the multifunction support mounting bolts (1) , - the bolt (2) mounting the multifunction support on the sump, - the multifunction support.
102265

10A-45

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

REFITTING
CHAUFO CA or CAREG

111057

Remove: - the multifunction support mounting bolts (3) , - the multifunction support. Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order:

102265

- the multifunction support mounting bolts ( 44 Nm ) , - the multifunction support mounting bolt on the sump ( 21 Nm ) .

10A-46

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

10A

CHAUFO

111057

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (44 Nm) .

Refit: - the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ). - the accessories belt (see 11A, Top and front of engine, 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: Removal - Refitting ). Refit the engine protectors.

10A-47

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

10A

II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm multifunction support mounting bolt on the sump multifunction support mounting bolts 21 Nm CA or CAREG

44 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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,
102265

- 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 of engine, Accessories belt: Removal - Refitting ). - the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ).

Remove: - the multifunction support mounting bolts (1) , - the bolt (2) mounting the multifunction support on the sump, - the multifunction support.

10A-48

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

10A

REFITTING
CHAUFO I - REFITTING OPERATION FOR PART CONCERNED CA or CAREG

111057

Remove: - the multifunction support mounting bolts (3) , - the multifunction support. Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order: - the multifunction support mounting bolt on the sump ( 21 Nm ) . - the multifunction support mounting bolts ( 44 Nm ) ,
102265

10A-49

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

10A

CHAUFO

111057

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (44 Nm) .

II - FINAL OPERATION Refit: - the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ). - the accessories belt (see 11A, Top and front of engine, 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.

10A-50

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting

10A

F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG

Equipment required lling station

Tightening torquesm multifunction support mounting bolts air conditioning compressor mounting bolts air conditioning compressor strut mounting bolts battery cover bolts 44 Nm 25 Nm

3 1

44 Nm

4 Nm

REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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 - Charging, Alternator ). Disconnect: - the air conditioning compressor connector, - the pressure switch connector (1) . Remove: - the air conditioning compressor pipe (2) ,

109537

- the air conditioning pipe between the compressor and the dehydration canister (3) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system. Remove: - the air conditioning compressor mounting bolts, - the air conditioning compressor.

10A-51

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting

10A

F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG

104337

Remove: - the multifunction support mounting bolts (4) , - the multifunction support.

REFITTING
Refit the multifunction support. Tighten to torque: - the multifunction support mounting bolts ( 44 Nm ) , - the air conditioning compressor mounting bolts ( 25 Nm ) . - the air conditioning compressor strut mounting bolts ( 44 Nm ) Refit the alternator (see 16A, Starting - Charging, Alternator ). Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque the battery cover bolts ( 4 Nm ) . Fill the coolant circuit using the filling station (62A, Air conditioning, Maintenance).

10A-52

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


M9R, and 700

10A

II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm multifunction support mounting bolts air conditioning compressor mounting bolts 44 Nm 25 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ).

114862

Remove: - the multifunction support mounting bolts (3) , - the multifunction support.

114861

Disconnect the connector (1) from the air conditioning compressor. Remove the air conditioning compressor mounting bolts (2) . Move the air conditioning compressor to one side. Attach the air conditioning compressor to the half sub-frame.

10A-53

ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support: Removal - Refitting


M9R, and 700

10A

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED

114862

Position the multifunction support. Finger tighten (until contact is made) the three mounting 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 mounting 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 compressor mounting bolts ( 25 Nm ) Refit the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

10A-54

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner

10A

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). IMPORTANT

Mot. 1202-02 Mot. 1448

During this operation, secure the vehicle to the lift with a safety belt , to avoid any imbalance. 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, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt half sub-frame front mounting bolt half sub-frame rear mounting bolt wheel bolt battery cover bolts 21 Nm 44 Nm 105 Nm 21 Nm 110 Nm 4 Nm

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

101212

Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ),

10A-55

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761 - the half sub-frame side reinforcements (1) , - the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ).

10A

2 4 5 7
102504

Disconnect the two connectors (2) . Unclip the front bonnet opening cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes. - 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 petrol inlet pipe from the injector rail (7) ,
101795

102365

11 8 9

Remove: - the front end panel mounting bolts (6) , - the front end panel. Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).

10
109537

Disconnect the hoses from the expansion bottle on the cooling radiator side (8) .

10A-56

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761

10A

CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe on the condenser (9) . Remove: - the air conditioning pipes from the condenser (10) . - the air conditioning pipe between the air conditioning compressor and the dehydration canister (11) , Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

13 14

Remove the cooling assembly. Disconnect the computer connectors (13) . Remove the battery tray mounting bolts (14) . Remove: - the battery tray, - the computer mounting.

101822

12 15
101807

Remove the air filter outlet duct (12) .

104553

Remove the air filter unit (15) .

10A-57

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761

10A

17

101978

101812

Disconnect the wiring harness connectors from the relay board.

Remove the brake servo pipe (17) .

19 18

16

104240 111051

Disconnect: - the hoses (18) and (19) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , - the downstream oxygen sensor connector.

Disconnect the earth strap on the body.

10A-58

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761

10A

K4M, and 760

K4M, and 761

22 B

A C 21 A

101743

103409

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 multifunction switch cable ball joint (21) , - the multifunction switch cable (22) by unlocking the sleeve stop.

20

101699

Remove the gearbox controls (20) .

10A-59

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761

10A

K4M, and 760

24 23
102008

Remove:
101740

Pull out clip (23) . Disconnect the hydraulic clutch supply pipes. Note: Plug the pipes to prevent uid from escaping.

- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ), - the front right-hand driveshaft (see 29A, Driveshafts, 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 positioner or a chain.

10A-60

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761

10A

K4M, and 761

101866

Mark the suspended engine mounting in relation to the body. Remove the suspended engine mounting. K4M, and 760 Remove the suspended gearbox mounting.

103273

Rotate the engine and gearbox assembly in order to remove it.

REFITTING
To carry out a normal engine replacement operation (see Technical Note 3784A, Petrol engine - 4 cylinders - K4, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ), - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ),
102112

Remove the suspended gearbox mounting.

- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ), - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ). Proceed in the reverse order to removal.

10A-61

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4M, and 760 or 761 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 brake fluid to the brake fluid reservoir.

10A

Tighten to torque the battery cover bolts ( 4 Nm ) . Note: If the vehicle is tted with xenon lamps, it is essential to initialise the system (see 80C, Xenon bulbs, Xenon headlights: Adjustment ). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment) .

K4M, and 760 Bleed the clutch system (see 37A, Mechanical component controls, Bleeding the clutch system: ).

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, Cooling system: Draining-refilling ).

CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

IMPORTANT Correctly attach the brake hose and the sensor wiring for the ABS system. Do not twist the brake hose. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).

10A-62

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner WARNING

10A

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, or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - ret the clip in the same recess in the event that the hoses are not replaced, - it is essential to replace the hoses and/or the intercooler if they are damaged. If this procedure is not followed the hoses may leak or come undone.

Mot. 1202-02 Mot. 1448

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). 21 Nm 44 Nm 110 Nm 105 Nm - the front wheels, 321 Nm 4 Nm - the right and left-hand wheel arch liners, - the engine undertray. Drain: - the gearbox (see 05A, Draining-Refilling, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt wheel mounting bolt half sub-frame front mounting bolt half sub-frame rear mounting bolt battery cover bolts

IMPORTANT During this operation, secure the vehicle to the lift with a safety belt , to avoid any imbalance. Remove: - the engine covers,

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

10A-63

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A
6

1
Remove: - the front end panel mounting bolts (6) , - the front end panel.
101212

102365

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 ).

Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).

3 2 4 5

7
104338

Remove: - the fuel supply pipe (7) , - the fuel return pipe (8) .

102504

Disconnect the connectors (2) . Unclip the bonnet release cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes.

WARNING Follow the cleanliness guidelines closely (see 13B, Diesel injection, Cleanliness guidelines ). Be aware of the residual pressure and the quantity of diesel fuel in the pipes. Disconnect the electrical connector (9) . Fit plugs into the openings.

10A-64

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A

CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe from the condenser (12) . Remove: - the air conditioning pipes from the condenser (13) . - the air conditioning pipe between the air conditioning compressor and the dehydration canister (14) . Note:
106275

10
Disconnect: - the intercooler hose (10) , - the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) . - the fan unit connectors. Unclip the wiring harness from the fan unit.

Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

14 11 12

15

102473

13
109537

Disconnect the air duct from the intercooler (15) . Remove the cooling assembly.

Disconnect the hoses from the expansion bottle on the cooling radiator side (11) .

10A-65

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A

16

20 19

102500

104245

Remove the air filter outlet duct (16) .

Remove: - the Protection and Switching Unit mounting bolt, - the fuse box (19) , - the relay box (20) . Disconnect the connectors from the Protection and Switching Unit.

17 18

21
101822

Disconnect the computer connectors (17) . Remove: - the battery tray mounting bolts (18) , - the battery tray, - the computer mounting.

22

104340

Remove: - the earth strap (21) , - the pre-postheating unit (22) .

10A-66

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A

23

24 C A

104322

101743

Remove the brake servo pipe (23) from the vacuum pump. Disconnect the heater radiator top hose (24) on the scuttle panel side using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

Unclip the lever cables on the gearbox: - clip the gearbox control at (A) , - pull the pin at (B) , - raise the gearbox control at (C) .

25
101699

Remove the gearbox controls (25) .

10A-67

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A

26 27

102513

102008

Press the clip (26) . Disconnect the supply pipes. Remove the clutch hydraulic control at the bulkhead. Note: Plug the pipes to prevent uid from escaping.

Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, 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 positioner or a chain.

10A-68

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808

10A

REFITTING
To replace the engine (see Technical Note 3652A, High pressure diesel engine - Common Rail 4 cylinder cast iron, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks, - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ) - the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ),
102742

- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ). - the front left-hand driveshaft (see 29A, Driveshafts, 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.

102419

Mark the suspended engine mounting in relation to the 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 order to remove it.

IMPORTANT Correctly attach the brake hose and the sensor wiring for the ABS system. Do not twist the brake hose. Perform the following operations: - bleed the clutch (see 37A, Mechanical component 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 ),

10A-69

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 800 or 808 - fill up the coolant (see 19A, Cooling, Cooling system: Draining-refilling ). CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

10A

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Note: Always initialise the xenon bulb system (if tted to the vehicle; see 80C, Xenon bulbs, Xenon headlight: Adjustment ). 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 ).

10A-70

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner WARNING

10A

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, or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - ret the clip in the same recess in the event that the hoses are not replaced, - it is essential to replace the hoses and/or the intercooler if they are damaged. If this procedure is not followed the hoses may leak or come undone.

Mot. 1202-02 Mot. 1448

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). 21 Nm 44 Nm 110 Nm 165 Nm - the front wheels, 21 Nm 4 Nm - the right and left-hand wheel arch liners, - the engine undertray. Drain: - the gearbox (see 05A, Draining-Refilling, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt wheel mounting bolts half sub-frame front mounting bolt half sub-frame rear mounting bolt battery cover bolts

IMPORTANT During this operation, secure the vehicle to the lift with a safety belt , to avoid any imbalance. Remove: - the engine covers,

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

10A-71

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

1
Remove: - the front end panel mounting bolts (6) , - the front end panel.
101212

102365

Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the side reinforcements (1) from the half sub-frame cross member, - the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ).

Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).

3 2 4 5

102504

Disconnect the connectors (2) . Unclip the bonnet opening cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes.

10A-72

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

9
106275

7 8
102514

Remove: - the fuel supply pipe (7) - the fuel return pipe (8) . WARNING Follow the cleanliness guidelines closely (see 13B, Diesel injection, Cleanliness guidelines ). Be aware of the residual pressure and the quantity of diesel fuel in the pipes. 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.
102473

10

Remove the intercooler air ducts (9) and (10) .

10A-73

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

16 14 11 12 15

13
109537 101822

Disconnect the hoses from the expansion bottle on the cooling radiator side (11) . CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe on the condenser (12) . Remove: - the air conditioning pipes on the condenser (13) , - the air conditioning pipe between the air conditioning compressor and the dehydration canister (14) , Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

Disconnect the computer connectors (15) . Remove the battery tray mounting bolts (16) . Remove: - the battery tray, - the computer mounting. K9K, and 728 Move the turbocharger pressure regulation solenoid valve to one side.

Disconnect: - the air filter outlet duct, - the flow meter connector (if fitted to the vehicle).

Remove the cooling radiator assemblies.

10A-74

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

18 19

17

104553

104340

Remove the air filter unit (17)

Disconnect: - the pre-postheating unit (18) , - the earth strap on the body (19) .

20

101978

21
102263

Disconnect the wiring harness connectors from the relay board. Remove the brake servo pipe (20) . Disconnect the heater radiator hoses from the scuttle panel (21) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

10A-75

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

B 22 A C
102264

Disconnect the heater radiator hoses from the scuttle panel (2 2) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
101743

Unclip the lever cables on the gearbox: - grip the gearbox control at (A) , - pull the pin at (B) , - raise the gearbox control at (C) .

23
101699

Remove the gearbox controls (23) .

24

101701

Remove the clutch hydraulic control (24) .

10A-76

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

25
102008 101866

Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, 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 positioner or a chain.

102112

Mark the suspended engine mounting in relation to the body. Remove: - the lower engine tie-bar, - the suspended engine mounting, - the gearbox suspended mounting, Rotate the engine and gearbox assembly in order to remove it.

10A-77

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 722 or 728

10A

REFITTING
To replace the engine (see Technical Note 6006A, High pressure diesel engine Common Rail - 4 cylinder cast iron, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ), - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, 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. IMPORTANT Correctly attach the brake hose and the sensor wiring for the ABS system. Do not twist the brake hose. Perform the following operations: - bleed the clutch system (see 37A, Mechanical component controls, Bleeding the clutch system: ), - 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, Cooling system: Draining-Refilling . Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Note: Always initialise the xenon bulb system (if tted to the vehicle; see 80C, Xenon bulbs, Xenon headlight: Adjustment ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ). Tighten to torque the battery cover bolts ( 4 Nm ) . CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

10A-78

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Support for removing and retting the engine and gearbox assembly Equipment required lling station

10A
21 Nm 8 Nm

Tightening torquesm battery tray bolts wiring harness mounting nuts

Mot. 1202-02 Mot. 1448

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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,

Mot. 1390

Tightening torquesm rounded bracket bolts with their spring half sub-frame rear mounting nuts half sub-frame front mounting bolts intercooler upstream hose intercooler tream pipe downs21 Nm 21 Nm 105 Nm 5.5 Nm 5.5 Nm 8 Nm

- the engine undertray, - the front bumper (see MR 365, Bodywork, 55A, Exterior protection, Front bumper ), Drain: - the gearbox (see 05A, Draining-Refilling, Gearbox ), - the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

intercooler downstream pipe on the air inlet valve air conditioning pipes on the condenser air conditioning pipe between the air conditioning compressor and the dehydration canister front end panel upper mounting bolts front end panel lower mounting bolts

8 Nm 8 Nm

21 Nm 44 Nm

10A-79

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700

10A

112658

112659

Remove: - the Protection and Switching Unit cover mounting bolts (1) , - the Protection and Switching Unit cover.

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.

102504

Disconnect the connectors (2) from the Protection and 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. Unclip the air inlet scoop (9) .
114933

10A-80

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700

10A

102365

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 inlet duct (12) .
115019

114659

115020

Remove the air resonator (11) .

Remove the air filter unit.

10A-81

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700

10A

102473

Loosen the intercooler upstream hose clip (13) . Disconnect the intercooler upstream hose.

112661

Disconnect: - the fan unit resistor connector (14) , - the fan unit connector. Unclip the wiring harness from the fan unit.

10A-82

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 Remove the cooling assembly. Disconnect: - the fuel supply pipe,

10A

- the fuel return pipe from the diesel filter, - the fuel return pipe. WARNING Follow the cleanliness guidelines closely (see 13B, Diesel injection, Cleanliness guidelines: Precautions during repair ). Watch out for diesel fuel splashing when disconnecting the supply union. Insert plugs into the openings.

115023

Remove the bolt (1 5) mounting the intercooler downstream pipe on the cooling radiator. Loosen: - the clip (16) securing the intercooler downstream pipe on the intercooler, - the clip securing the intercooler downstream pipe on the air inlet valve. Move aside the intercooler downstream pipe on the intercooler. 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 cooling radiator side (17) , - the pressostat connector on the condenser lower air conditioning pipe (18) . Release the wiring harness from the pressostat connector on the fan unit. Remove: - the air conditioning pipes from the condenser (19) . - the air conditioning pipe between the air conditioning compressor and the dehydration canister (20) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.
104340

Disconnect: - the pre-postheating unit connector (21) , - the earth strap on the body (22) .

10A-83

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700

10A

115003

101743

Remove the clutch hydraulic control pipe at the bulkhead (23) . Remove the brake assistance pipe from the vacuum pump. Disconnect: - the heater radiator hose from the scuttle panel outlet, - the heater radiator hose from the scuttle panel outlet using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

Unclip the lever cables on the gearbox: - grip the gearbox control at (A) , - pull the pin at (B) , - raise the gearbox control at (C) .

102008

Remove: - the side reinforcement mounting bolts (25) , - the side reinforcements,
115001

- the half sub-frame mounting bolts (26) , - the half sub-frame mounting nuts (27) ,

Remove the gearbox controls (24) .

10A-84

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 - the half sub-frame.

10A

114650

Remove: - the rear mounting (28) (see 19D, Engine mounting, Rear mounting: Removal and Refitting )

114991

Remove the rounded bracket bolts with their springs (29) . Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ),

10A-85

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

10A

114989

Position the (Mot. 1390) . Remove: - the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ). - the mounting nut on the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting: Removal - Refitting ). Rotate the engine and gearbox assembly in order 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 vehicle. Refit: - the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ). - the mounting nut on the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting: Removal - Refitting ).

10A-86

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 II - FINAL OPERATION Refit: - the rear mounting (see 19D, Engine mounting, Rear mounting: Removal - Refitting ). - the front right-hand driveshaft (see 29A, Driveshafts, 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 with their 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 ( 105 Nm ) . 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 outlet, - the heater radiator hose from the scuttle panel outlet 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 pipe, - the intercooler upstream hose, - the intercooler downstream pipe. Tighten to torque:

10A

- the intercooler upstream hose ( 5.5 Nm ) , - the intercooler downstream pipe ( 5.5 Nm ) , - the intercooler downstream pipe on the air inlet valve ( 8 Nm ) . Refit: - the air conditioning pipes to the condenser. - the air conditioning pipe between the air conditioning compressor and the dehydration canister. Tighten to torque: - the air conditioning pipes on the condenser ( 8 Nm ) , - the air conditioning pipe between the air conditioning compressor and the dehydration canister ( 8 Nm ) . Secure the wiring harness to the pressostat connector on the fan unit. Connect - the hoses from the expansion bottle on the cooling radiator side, - the pressostat connector on the condenser lower air 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 ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) . Clip on the air inlet scoop.

10A-87

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


M9R, and 700 Refit: - the battery tray, the injection computer and its mounting, - 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 their spring (see 19A, Exhaust ), - the rear mounting (see 19D, Engine mounting, Rear mounting: Removal - Refitting ). Perform the following operations: - bleed the clutch system (see 37A, Mechanical component controls, Bleeding the clutch system: ), - 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: Removal and Refitting ) - the engine protector.

10A

10A-88

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner WARNING

10A

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, or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - ret the clip in the same recess if the hoses are not replaced, - it is essential to replace the hoses and/or the intercooler if they are damaged. If this procedure is not followed the hoses may leak or come undone.

Mot. 1202-02 Mot. 1448

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). 21 Nm 44 Nm 110 Nm 130 Nm 105 Nm 21 Nm 4 Nm

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt wheel bolts wheel bolt (F4R 776) half sub-frame front mounting bolt half sub-frame rear mounting bolt battery cover mounting bolts

Note: During this operation, strap the vehicle to the lift using a safety belt , to avoid any imbalance. 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, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

10A-89

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

1
102365

Remove: - the front end panel mounting bolts (6) , - the front end panel.
101212

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 ).

Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ). F4R, and 770 or 771

2 4 5

102504

101795

Disconnect the connectors (2) . Unclip the bonnet opening cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes.

Disconnect the fuel supply pipe (7) from the injector rail.

10A-90

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

F4R, and 776

10 13 8 11 12

106271

Disconnect: - the injector rail (8) from the fuel supply pipe - the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) , - the fan unit connectors. Unclip the wiring harness from the fan unit. 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. F4R, and 776
109536

F4R, and 770 or 771

9
106275

Disconnect the intercooler hose (9) .

14

101807

Remove the air filter outlet duct (14) .

10A-91

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

19 18 15 16

20

17
109537 101822

Disconnect the hoses from the cooling radiator expansion bottle (15) . CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe from the condenser (16) . Remove: - the air conditioning pipes from the condenser (17) . - the air conditioning pipe between the compressor and the dehydration canister (18) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

Disconnect the computer connectors (19) . Remove the battery tray mounting bolts (20) . Remove the battery tray.

Remove the cooling assembly.

10A-92

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

F4R, and 776

25

21
106278 106280

Remove the computer and its mounting (25) .

24 22

23

106632 104553

Move the fuel vapour recirculation solenoid valve to one side (21) . Undo the bolt (22) . Pull the mounting bracket away from the electric coolant pump. Move the electric water pump (23) to one side. Remove the electric pump mounting (24) .

Remove the air filter unit.

10A-93

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

F4R, and 770 or 771

27

101978

Disconnect the wiring harness connectors from the relay board. Remove the brake servo pipe (27) .

101812

Disconnect the downstream oxygen sensor connector.

F4R, and 776

26

28

111051

Disconnect the earth strap (26) .


106787

Remove the brake servo pipe (28) .

10A-94

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

B 29 30 A C

104240

101743

Disconnect hoses (29) and (30) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) . F4R, and 770 or 776

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) .

F4R, and 771

33

31

101699

32

Remove the control cables from the gearbox (31) .

103409

Remove: - the multifunction switch cable ball joint (32) ,

10A-95

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776 - the multifunction switch cable (33) by loosening the sleeve stop.

10A

F4R, and 770 or 776

34

102008

33

Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ),
101740

- 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 positioner or a chain.

Place a cloth under the master cylinder. Remove the clip (33) from the union on the master cylinder return. Disconnect the pipes from the slave cylinder. Fit plugs into the openings. Withdraw the slave cylinder feed pipes.

10A-96

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776

10A

F4R, and 771

102742

Mark the suspended engine mounting in relation to the body. Remove the suspended engine mounting. F4R, and 770 or 776 Remove the suspended gearbox mounting.

103273

Rotate the engine and gearbox assembly in order to remove it.

REFITTING
To carry out a normal engine replacement operation (see Technical Note 6027A, Petrol engine - 4 cylinders - F4, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks, - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ),

102112

Remove the suspended gearbox mounting.

10A-97

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F4R, and 770 or 771 or 776 - the front left-hand driveshaft (see 29A, Driveshafts, 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. IMPORTANT Correctly attach the exible brake pipe and ABS sensor wiring. Do not twist the brake hoses. Note:

10A

Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

Be sure to initialise the xenon bulb system (if tted to the vehicle) see 80C, Xenon bulbs, Xenon headlights: Adjustment ). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment ).

F4R, and 770 or 776 Bleed the clutch system (see 37A, Mechanical component controls, Bleeding the clutch system: ).

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, Cooling system: Draining-refilling ). CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).

10A-98

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner WARNING

10A

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, or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - ret the clip in the same recess if the hoses are not replaced, - it is essential to replace the hoses and/or the intercooler if they are damaged. If this procedure is not followed the hoses may leak or come undone.

Mot. 1202-02 Mot. 1448

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). 21 Nm 44 Nm 105 Nm 210 Nm 110 Nm 4 Nm

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt half sub-frame front mounting bolt half sub-frame rear mounting bolt wheel bolts battery cover mounting bolts

IMPORTANT During this operation, secure the vehicle to the lift with a safety belt , to avoid any imbalance. 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, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

10A-99

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

1
102365

Remove: - front end panel mounting bolts (6) , - the front end panel.
101212

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 ).

Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).

2 4 5

102504

Disconnect the connectors (2) . Unclip the bonnet opening cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes.

10A-100

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

106275

7 8
102514

Remove: - the fuel supply pipe (7) , - the fuel return pipe (8) . WARNING Follow the cleanliness guidelines closely (see 13B, Diesel injection, Cleanliness guidelines ). Be aware of the residual pressure and the quantity of diesel fuel in the pipes. 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.
102473

10

Disconnect the intercooler hoses (9) and (10) .

10A-101

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

14 15 11 12
101807

Remove the air filter outlet duct (15) .

13
109537

Disconnect the hoses from the cooling radiator expansion bottle (11) . CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe from the condenser (12) . Remove: - the air conditioning hoses from the condenser (13) , - the air conditioning hose between the air conditioning compressor and the dehydration canister (14) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system. Disconnect the computer connectors (16) . Remove the battery tray mounting bolts (17) . Move the turbocharger pressure solenoid valve to one side. Remove: Remove the cooling radiator assemblies. - the battery tray, - the computer and its support. Disconnect the flowmeter connector (if fitted to the vehicle).
101822

16

17

10A-102

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

104245

104553

Disconnect: - the relay plate harness connectors, - the relay, - the fuse box, - the earth strap from the body,

Remove the air filter unit.

20 21

18

103409

Remove:

19

- the multifunction switch cable ball joint (20) , - the multifunction switch cable (21) by unlocking the sleeve stop. Disconnect: - the engine speed sensor, - the connector by releasing the slide from the connector.

102263

Remove the brake servo pipe from the vacuum pump (18) . Disconnect the heater radiator hose from the scuttle panel (19) using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) .

10A-103

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

22

23

25

26

110681

103749

Disconnect: - the pre-postheating unit (22) , - the automatic transmission computer connector (23) .

Remove: - the exhaust mounting nuts (25) , - the lower engine tie-bar (26) .

24

103413

Open the gearbox computer wiring harness mounting bracket (24) .

10A-104

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

27
102008 102114

Remove: - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ), - the half sub-frame (27) . Position the hydraulic crane fitted with a load positioner .

103273

Mark the suspended engine mounting in relation to the body. Remove: - the lower engine tie-bar, - the suspended engine mounting, - the suspended gearbox mounting, Rotate the engine and gearbox assembly in order to remove it.

10A-105

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 729, and DP0

10A

REFITTING
To replace the engine (see Technical Note 6006A, High pressure diesel engine Common Rail - 4 cylinder cast iron, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks, - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ). - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, 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. Bleed the engine cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Note: Always initialise the xenon bulb system (if tted to the vehicle; see 80C, Xenon bulbs, Xenon headlights: Adjustment ). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment ). CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

IMPORTANT Correctly attach the exible brake pipe and ABS sensor wiring. Do not twist the brake hoses. 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, Bleeding the cooling circuit ),

10A-106

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required safety belt lling station hydraulic crane load positioner

10A

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). IMPORTANT

Mot. 1202-02 Mot. 1448

During this operation, secure the vehicle to the lift with a safety belt , to avoid any imbalance. 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, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm front end panel upper mounting bolt front end panel lower mounting bolt half sub-frame front mounting bolt half sub-frame rear mounting bolt wheel bolt battery cover bolts 21 Nm 44 Nm 105 Nm 21 Nm 110 Nm 4 Nm

CA or CAREG Drain the refrigerant circuit using the filling station (see 62A, Air conditioning, Maintenance ).

101212

Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ).

10A-107

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732 - the half sub-frame side reinforcements (1) , - the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ).

10A

3 7 2

5
Disconnect the fuel supply union (7) . Disconnect:
102504

101802

Disconnect the connectors (2) . Unclip the bonnet opening cable (3) . Remove: - the clip (4) , - the fastening (5) . Disconnect the screen washer tubes.

- the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) . - the fan unit connectors, Unclip the wiring harness from the fan unit.

11 6 8 9

102365

10
109537

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 hoses from the cooling radiator expansion bottle (8) .

10A-108

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732

10A

CA or CAREG Disconnect the pressostat connector on the lower air conditioning pipe from the condenser (9) . Remove: - the air conditioning pipes from the condenser (10) . - the air conditioning pipe between the compressor and the dehydration canister (11) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

13

14

Remove the cooling assembly. Disconnect the computer connectors (13) . Remove the battery tray mounting bolts (14) . Remove: - the battery tray,

101822

12

- the computer mounting.

101103

Remove: - the air resonator mounting bolt (12) , - the air resonator.

101978

Disconnect the wiring harness connectors from the relay board.

10A-109

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732

10A

17 15

18

111051

104240

Disconnect the earth strap from the body.

Disconnect: - the hoses (17) and (18) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , - the downstream oxygen sensor connector.

16

C
101812

Remove the brake servo pipe (16) .

101743

Unclip the lever cables on the gearbox: - grip the gearbox control at (A) , - pull the pin at (B) , - raise the gearbox control at (C) .

10A-110

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732

10A

19

21

101699

102008

Remove the gearbox controls (19) .

Remove: - the front left-hand driveshaft (see 29A, Driveshaft, Front left-hand driveshaft ), - the front right-hand driveshaft (see 29A, Driveshafts, 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 positioner or a chain.

20

101740

Pull out clip (20) . Disconnect the hydraulic clutch supply pipes. Note: Plug the pipes to prevent uid from escaping.

10A-111

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732

10A

REFITTING
To carry out a normal engine replacement operation (see Technical Note 3784A, Petrol engine - 4 cylinders - K4, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ), - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the front left-hand driveshaft (see 29A, Driveshaft, Front left-hand driveshaft ),
101866

- the front right-hand driveshaft (see 29A, Driveshafts, 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, Mechanical component controls, Bleeding the clutch system: ),

102112

Mark the suspended engine mounting in relation to the body. Remove: - the suspended engine mounting, - the suspended gearbox mounting, Rotate the engine and gearbox assembly in order to remove it. Remove the engine and gearbox assembly .

- 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, Bleeding the cooling circuit ). IMPORTANT Correctly attach the brake hose and the sensor wiring for the ABS system. Do not twist the brake hose.

10A-112

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K4J, and 730 or 732 Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit: ). CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

10A

Tighten to torque the battery cover bolts ( 4 Nm ) . Note: If the vehicle is tted with xenon bulbs, it is essential to initialise the xenon bulb system (see 80C, Xenon bulbs, Xenon headlights: ). Adjustment ). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment) .

10A-113

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Support for removing and retting the engine and gearbox assembly Equipment required safety belt lling station WARNING

10A

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, or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - ret the clip in the same recess if the hoses are not replaced, - it is essential to replace the hoses and/or the intercooler if they are damaged. If this procedure is not followed the hoses may leak or come undone.

Mot. 1202-02 Mot. 1448

Mot. 1390

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Tightening torquesm IMPORTANT 21 Nm 44 Nm 105 Nm 21 Nm 130 Nm 4 Nm During this operation, strap the vehicle to the lift using a safety belt , to avoid any imbalance. Remove: - the engine covers,

front end panel upper mounting bolt front end panel lower mounting bolt half sub-frame front mounting bolt half sub-frame rear mounting bolt wheel bolt battery cover mounting bolts

- the front wheels, - the right-hand and left-hand wheel arch liners, - the engine undertray. Drain: - the gearbox (see 05A, Draining-Refilling, Gearbox ), - the engine (see 05A, Draining-Refilling, Engine ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). CA or CAREG 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 ).

10A-114

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804 Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior protection, Scuttle panel grille ). CA or CAREG

10A

Disconnect the pressostat connector from the lower air conditioning pipe on the condenser. Remove: - the two air conditioning pipes from the condenser, - the air conditioning pipe between the air conditioning compressor and the dehydration canister.

2
Note:

1 4 3

Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

Disconnect the screen washer tubes.


102504

Disconnect the connectors (1) . Unclip the bonnet opening cable (2) . Remove: - the clip (3) , - the fastening (4) .

102365

Remove: - the front end panel mounting bolts (6) , - the front end panel.

101212

Remove: - the half sub-frame side reinforcements (5) , - the front bumper (see MR 371, Bodywork, 55A, Exterior protection, Front bumper ).

10A-115

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804

10A

8 9

7 10
104338 106275

Remove: - the fuel supply pipe (7) , - the fuel return pipe (8) . WARNING Follow the cleanliness guidelines closely (see 13B, Diesel injection, Cleanliness guidelines ). Watch out for diesel fuel splashing when disconnecting the supply union. Disconnect the electrical connector (9) . Insert plugs into the openings.

Disconnect. Disconnect: - the intercooler hose (10) - the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) . - the fan unit connectors, - the hoses from the expansion bottle on the cooling radiator side. Unclip the wiring harness from the fan unit.

11

102473

Disconnect the duct (11) .

10A-116

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804

10A

12 13 17

16

102500

104245

Disconnect the connector (12) . Remove the air filter outlet duct (13) .

Remove: - the Protection and Switching Unit mounting bolt, - the fuse box (16) , - the relay box (17) . Disconnect the connectors from the Protection and Switching Unit.

14

15

19

18
101822

Disconnect the computer connectors (14) . Remove: - the battery tray mounting bolts (15) , - the battery tray, - the computer mounting.
104340

Remove: - the earth strap (18) , - the pre-postheating unit (19) .

10A-117

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804

10A

20

23

21

104322

101740

Remove the brake servo pipe (20) from the vacuum pump. Disconnect the heater radiator hoses (21) from the scuttle panel side using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

Pull the clip (23) from the clutch pipes. Disconnect the hydraulic clutch supply pipes. Note: Plug the pipes to prevent uid from escaping.

24 22

104085

Remove the gearbox controls (2 2) , using a screwdriver. Remove:

102008

- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ),

10A-118

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804 - the exhaust downpipe mountings, - the lower engine tie-bar, - the upper engine tie-bar. - the half sub-frame (24) .

10A

111879

102742

111880

Position the (Mot. 1390) .

102419

Mark the suspended engine mounting in relation to the body. Remove: - the suspended engine mounting, - the suspended gearbox mounting, Rotate the engine and gearbox assembly in order to remove it. Remove the engine and gearbox assembly .

10A-119

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


F9Q, and 804

10A

REFITTING
To replace the engine (see Technical Note 3652A, High pressure diesel engine - Common Rail 4 cylinder cast iron, 10A, Engine and peripherals, Normal replacement ). Position the engine and gearbox assembly in the vehicle. Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks, - the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, 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. IMPORTANT Correctly attach the exible brake pipe and ABS sensor wiring. Do not twist the brake hoses. Perform the following operations: - bleed the clutch system (see 37A, Mechanical component controls, Bleeding the clutch system: ), - 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, Bleeding the cooling circuit ). CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the engine cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Note: If the vehicle is tted with xenon bulbs, it is essential to initialise the system (see 80C, Xenon bulbs, Xenon headlights: ). Adjustment ). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment ).

10A-120

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732 Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Support for removing and retting the engine and gearbox assembly Equipment required lling station WARNING

10A

Procedure for removing the air inlet duct on the intercooler (there is a danger of leakage and dislocation if this procedure is not complied with): - detach the hose using the (Car. 1363) , - do not use a degreaser, brake cleaning product, or any other product, - clean the bearing face on the intercooler and on the hose with a dry, lint-free cloth, - always replace the clip with a new one,

Mot. 1202-02 Mot. 1448

Mot. 1390

- replace the new clip in the same position if the hose is not replaced, - it is essential to replace the hose and/or the intercooler if they are damaged,

REMOVAL
Tightening torquesm I - REMOVAL PREPARATION OPERATION 105 Nm 21 Nm IMPORTANT 21 Nm 44 Nm 110 Nm During this operation, secure the vehicle to the lift with a strap, to avoid any imbalance. 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 ). CA or CAREG Drain the coolant circuit using the filling station . Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).

half sub-frame front mounting bolt half sub-frame rear mounting bolt front end panel upper mounting bolt front end panel lower mounting bolt wheel bolts

10A-121

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

102504

Remove: - the relay plate cover mounting bolts.


101212

- 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: - the battery, - the side reinforcements (1) , - the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ).

102365

Remove: - front end panel mounting bolts (6) , - the front end panel. Drain the cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).

10A-122

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

106275

112656

Remove: - the fuel supply pipe (7) , - the fuel return pipe (8) . WARNING - Follow the cleanliness guidelines closely. - Beware of diesel fuel splashing when disconnecting the supply unions. Place plugs in the holes (see 13B, Diesel injection, Cleanliness guidelines ).
112661

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.

10A-123

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

109537

101822

Disconnect the hoses from the cooling radiator expansion bottle (11) . CA or CAREG Disconnect the pressostat connector from the lower air conditioning pipe on the condenser. (12) Remove: - the air conditioning pipes from the condenser (13) . - the air conditioning pipe between the air conditioning compressor and the dehydration canister (14) . Note: Plugs must be tted to the hoses and the expansion valve to prevent moisture from entering the system.

Disconnect the computer connectors (15) . Unclip: - the wiring harness from the battery negative terminal, - 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 to one side. Disconnect: - the connector from the flowmeter, - the air duct between the air filter unit and the turbocharger.

Remove the cooling radiator assemblies.

10A-124

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

112657

101978

Disconnect the wiring harness connectors from the relay board.

104553

Loosen the air filter unit upstream air duct retaining tabs slightly (17) . Remove: - the air filter unit upstream air duct, - the air filter unit (18) .
104340

Disconnect: - the pre-postheating unit connector (19) , - the earth strap from the body (20) .

10A-125

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

112946

101743

Remove the brake servo pipe (21) from the vacuum pump. 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. WARNING Do not touch the gearbox control slides.

101740

Pull clip (24) . Disconnect the clutch hydraulic control. Remove: - the lower engine tie-bar, - the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ),

10A-126

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732 - 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

10A

112814

112813

Position the (Mot. 1390) .

10A-127

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

Rotate the engine and gearbox assembly in order to remove 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 - 4 cylinder cast iron, 10A, Engine and peripherals, Normal replacement ). II - REFITTING OPERATION FOR PART CONCERNED Position the engine and gearbox assembly in the vehicle. Refit:
113927

- the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ), - the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting: Removal - Refitting ), - the rear suspended mounting (see 19D, Engine suspension, Rear suspended mounting: Removal / Refitting ). Remove the (Mot. 1390) . III - FINAL OPERATION Refit: - the half sub-frame, - the half sub-frame mounting bolts. Tighten to torque:

112655

Mark the suspended engine mounting in relation to the body. Remove: - the rear suspended mounting (see 19D, Engine suspension, Rear suspended mounting: Removal - Refitting ), - the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting: Removal - Refitting ), - the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ),

- 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, Driveshafts, Front right-hand driveshaft ), - the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ). IMPORTANT Correctly attach the exible brake pipe and ABS sensor wiring.

10A-128

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732 Connect: - 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 panel using 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 turbocharger. - the connector from the flowmeter. Reposition the turbocharging pressure regulating solenoid 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. Refit the fan unit wiring harness. Refit: - the front end panel, CA or CAREG Connect:

10A

- the air conditioning pipes to the condenser. - the air conditioning pipe between the air conditioning compressor and the dehydration canister. - the pressostat connector on the condenser lower air conditioning pipe

- 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 Manual 365 Bodywork, 55A, Exterior protection, Front bumper ), - 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: Removal - refitting) .

10A-129

ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly: Removal - Refitting


K9K, and 732

10A

CA or CAREG Fill the refrigerant circuit using the filling station (see 62A Air conditioning, Maintenance ).

Perform the following operations: - bleed the clutch system (see 37A, Mechanical component 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, Cooling system: Draining-refilling ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ). Adjust the headlights (see, depending on equipment, 80B, Headlights, Halogen headlights: Adjustment or 80C, Xenon bulbs, Xenon headlights: Adjustment ). You must initialise the xenon bulb system (if tted to the vehicle). Refit the engine covers.

10A-130

ENGINE AND LOWER ENGINE ASSEMBLY


Engine speed and position sensor: Removal - Refitting
M9R, and 700 IV - FINAL OPERATION Tightening torquesm engine speed and position sensor mounting bolt 10 Nm Refit:

10A

- the heat insulating material around the engine speed and position sensor, - the engine undertray.

REMOVAL
I - REMOVAL PREPARATION OPERATION Remove the engine undertray. Move the heat insulating material to one side. II - OPERATION FOR REMOVAL OF PART CONCERNED

114979

Disconnect the engine speed and position sensor. Remove: - the engine speed and position sensor mounting bolt (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 sensor mounting bolt until contact is made. Tighten to torque the engine speed and position sensor mounting bolt ( 10 Nm ) .

10A-131

ENGINE AND LOWER ENGINE ASSEMBLY Crankshaft seal at timing end Removal - Refitting
M9R, and 700

10A

II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm the crankshaft timing end sealing ring 47 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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.
114853

Remove the crankshaft sealing ring using the (2) supplied in the spare parts kit for the new gasket.

101212

Remove: - the right-hand side reinforcement mounting bolts on the half sub-frame cross member, - the right-hand side reinforcement from the half subframe cross member (1) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

10A-132

ENGINE AND LOWER ENGINE ASSEMBLY Crankshaft seal at timing end Removal - Refitting
M9R, and 700

10A

REFITTING
I - REMOVAL PREPARATION OPERATION

II - REFITTING OPERATION FOR PART CONCERNED

114850 113656

Position the sealing ring notches opposite the notches in the timing cover.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

114851

Engage the sealing ring notches in the timing cover notches. Tighten the sealing ring by hand using the tool supplied in the new gasket spare parts kit.

10A-133

ENGINE AND LOWER ENGINE ASSEMBLY Crankshaft seal at timing end Removal - Refitting
M9R, and 700

10A

114852

Using tool supplied in the new gasket spare parts kit tighten to torque the crankshaft timing end sealing ring ( 47 Nm ) . III - FINAL OPERATION Refit: - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). - the right-hand side reinforcements on the half subframe, - the front right-hand wheel arch liner, - the front right-hand wheel. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

10A-134

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting

11A

K4J, and 730 or 732, and CA or CAREG K4M, and 760 or 761, and CA or CAREG C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732, and CA or CAREG

Tightening torquesm tensioning roller mounting bolt wheel bolts battery cover bolts 40 Nm

110 Nm 4 Nm

IMPORTANT Wear protective gloves during every operation.

1
WARNING Never turn the engine in the opposite direction to its normal operation.
101212

WARNING It is imperative to replace the accessories belt and the tensioning rollers.

Remove the right-hand side reinforcement (1) .

WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft and the accessories pulley.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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.
101878

Turn the accessories belt auto tensioner clockwise using a 16 mm spanner. Remove: - the accessories belt, - the tensioning roller.

11A-1

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting

11A

K4J, and 730 or 732, and CA or CAREG K4M, and 760 or 761, and CA or CAREG C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732, and CA or CAREG

REFITTING
Use a brush to remove any deposits from the crankshaft pulley V-grooves. Refit the tensioning roller. Tighten to torque the tensioning roller mounting bolt ( 40 Nm ) .

22

106000

WARNING The accessories belt has ve teeth, but the air conditioning compressor pulley has six grooves. When tting the accessories belt, it is essential to check that the groove (2) remains free. Refit the accessories belt. Rotate the crankshaft twice to position the accessories belt correctly. Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque: - the wheel bolts ( 110 Nm ) . - the battery cover bolts ( 4 Nm ) .

11A-2

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting

11A

K9K, and 722 or 728 or 729, and CHAUFO K4J, and 730 or 732, and CHAUFO K4M, and 760 or 761, and CHAUFO Special tooling required Mot. 1638 Mot. 1505 Mot. 1715 Accessories belt tensioning tool Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter) - the front right-hand wheel, - the front right-hand wheel arch liner.

Tightening torquesm tensioning roller mounting bolt wheel bolts battery cover mounting bolts 35 Nm 110 Nm 4 Nm

IMPORTANT Wear protective gloves during the operation. Remove the side reinforcement (1) .

101212

Loosen the tensioning roller bracket mounting bolts. Remove: WARNING Never turn the engine in the opposite direction to its normal operation. - the accessories belt, - the tensioning roller.

REFITTING
WARNING It is imperative to replace the accessories belt and the tensioning rollers. Use a brush to remove any deposits from the crankshaft pulley V-grooves. WARNING WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft and the accessories pulley. - The two Torx mounting bolts of the tensioning roller must be replaced by M8 x 20 bolts (part number 77 03 002 059 ). Refit the accessories belt. Refit the tensioning roller fitted with new bolts.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the engine covers,

11A-3

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting

11A

K9K, and 722 or 728 or 729, and CHAUFO K4J, and 730 or 732, and CHAUFO K4M, and 760 or 761, and CHAUFO

20845

WARNING The accessories belt has ve teeth, but the pulleys have six grooves. It is essential to check that groove (2) remains free when the belt is tted.

21861

Tension the accessories belt using the (Mot. 1638) by tightening nut (3) (with the two tensioning roller mounting bolts loosened). Check (4) and using the (Mot. 1505) or the (Mot. 1715) , that the accessories belt tension is between 223 and 245 Hz . It is essential to turn the engine through two revolutions to position the accessories belt correctly. Check that the accessories belt tension is between 223 and 245 Hz at the measuring point (4) . If not, readjust the tension. Tighten to torque the tensioning roller mounting bolt ( 35 Nm ) . Proceed in the reverse order to removal Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque: - the wheel bolts ( 110 Nm ) , - the battery cover mounting bolts ( 4 Nm ) .

11A-4

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting

11A

F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG

Tightening torquesm tensioning roller mounting bolt wheel bolts battery cover bolts 50 Nm 110 Nm 4 Nm

IMPORTANT Wear gloves throughout the operation.

WARNING Never turn the engine in the opposite direction to its normal operation.

101212

Remove the right-hand side reinforcement (1) . WARNING It is imperative to replace the accessories belt and the tensioning rollers.

WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft and the accessories pulley.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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.
104339

Turn the accessories belt auto tensioning roller anticlockwise using a 16 mm spanner. Remove: - the accessories belt, - the tensioning roller.

REFITTING
Use a brush to remove any deposits from the crankshaft pulley V-grooves.

11A-5

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting


Tighten to torque the tensioning roller mounting bolt ( 50 Nm ) . Rotate the crankshaft twice to position the accessories belt correctly. Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque: - the wheel bolts ( 110 Nm ) , - the battery cover bolts ( 4 Nm ) .

11A

F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG

11A-6

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1770 Crankshaft pulley locking tool

11A

- the right-hand side reinforcement from the half subframe cross member (1) . II - OPERATION FOR REMOVAL OF PART CONCERNED

Tightening torquesm tensioning roller mounting bolt tensioning roller mounting bolt crankshaft accessories pulley mounting bolt 44 Nm 25 Nm 50 Nm + 85 6

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the engine undertray.

114854

Place a 3 mm Allen key in the tensioning roller hole (2) . Move accessories belt tensioning pulley clockwise until the Allen key is fully inserted. Remove the accessories belt.

101212

Remove: - the front right-hand wheel, - the front right-hand wheel arch liner; - the right-hand side reinforcement mounting bolts on the half sub-frame cross member,

11A-7

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting


M9R, and 700

11A

114856

114849

Remove: - the tensioning roller mounting bolts (3) , - the tensioning roller.

Remove: - the crankshaft accessories pulley mounting bolt using the (Mot. 1770) (1) , - the washer, - the crankshaft accessories pulley.

114857

Remove: - the fixed roller mounting bolt plastic cover (4) , - the fixed roller mounting bolts (5) , - the fixed roller (6) .

11A-8

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting


M9R, and 700

11A

REFITTING
I - REMOVAL PREPARATION OPERATION Use a brush to remove any deposits from the crankshaft pulley V-grooves. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles.

II - REFITTING OPERATION FOR PART CONCERNED Refit the fixed roller. Tighten to torque the tensioning roller mounting bolt ( 44 Nm ) Refit the plastic cover on to the fixed roller mounting bolt. Note: The Parts Department supplies the tensioning roller pin. Refit the tensioning roller. . Tighten to torque the tensioning roller mounting bolt ( 25 Nm ) .

WARNING Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley.

WARNING When replacing the accessories belt recommended by the manufacturer, always replace: - the accessories belt, - the tensioning roller and xed roller, - the crankshaft accessories pulley bolt, - the crankshaft accessories pulley.

Refit the crankshaft accessories pulley by inserting it onto the two crankshaft flat surfaces. Refit the washer inside the crankshaft accessories pulley by inserting it onto the two crankshaft flat surfaces. WARNING Check that the washer ts properly on the crankshaft at surfaces. Finger tighten the crankshaft accessories pulley mounting bolt. Tighten to torque and angle the crankshaft accessories 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 well positioned in the V-grooves of all the pulleys.

11A-9

TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting


M9R, and 700 III - FINAL OPERATION Refit: - the right-hand side reinforcement from the half subframe cross member. - the right-hand side reinforcement mounting bolts on 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: Removal - Refitting ).

11A

11A-10

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 TDC locating pin Tool for tightening tensioner bolt. 8 mm Torx wrench 12.7 mm square Timing gear wheel immobiliser Camshaft setting tool Adapter for camshaft setting tool Mot. 1496 Locking and adjusting camshaft pulleys Tool for retting camshaft covers (57 mm diameter) Tool for retting camshaft covers (43 mm diameter)

11A
Tightening torquesm 27 Nm 40 Nm + 145 15 27 Nm 27 Nm

tensioning roller mounting nut crankshaft accessories pulley mounting bolt tensioning roller mounting nut tensioning roller mounting nut xed roller mounting bolt tensioning roller mounting nut tensioning roller mounting nut accessories mounting bolt pulley

Mot. 1453-01

Mot. 1489 Mot. 1368

45 Nm 27 Nm 27 Nm 40 Nm + 115 15 30 Nm + 84 4 27 Nm 20 Nm 41 Nm 110 Nm 4 Nm

Mot. 799-01 Mot. 1496 Mot. 1750 Mot. 1490-01 Mot. 1487

new camshaft pulley nuts tensioning roller mounting nut TDC setting pin plug upper timing cover bolts and nuts wheel bolts

Mot. 1488

Tightening torquesm xed roller mounting bolt tensioning roller mounting nut crankshaft accessories pulley mounting bolt tensioning roller mounting nut tensioning roller mounting nut xed roller mounting bolt 45 Nm 27 Nm 40 Nm + 145 15 27 Nm 27 Nm

battery cover mounting bolts

IMPORTANT Wear protective gloves during every operation.

WARNING Never turn the engine in the opposite direction to its normal operation.

WARNING 45 Nm The belt must be replaced with a new one if it has been removed.

11A-11

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

WARNING When replacing the belt, be sure to replace the tensioning rollers and xed rollers.

Note: The timing belt procedure is the same for engines with or without camshaft dephasers

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the engine undertray, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).
102450

102451

Position the (Mot. 1453) and the (Mot. 1453-01) with retaining straps.

11A-12

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

101866

101103

Mark the suspended engine mounting in relation to the body. Remove: - the engine and suspended engine mounting assembly, - the lower engine tie-bar. WARNING Do not damage the air conditioning pipe.

Remove: - the air resonator mounting, - the air resonator,

14491

Pierce the middle of the plugs on the end of the camshaft using a screwdriver. Remove: - the sealing plugs at the camshaft end with a screwdriver, - the TDC pin plug (1) , - the engine lifting eye (flywheel end),

11A-13

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 ADJUSTING THE TIMING

11A

14490 14491-1

Position the camshaft grooves (2) almost horizontally and offset downwards, turning the crankshaft in its normal operating direction (timing end clockwise). Screw in the TDC setting pin (3) (Mot. 1489) .

Check that the camshaft grooves are horizontal and offset downwards.

4
14487

Remove:
14489

- the crankshaft accessories pulley (4) , locking the flywheel with a screwdriver, - the upper timing cover (5) , - the lower timing cover (6) .

Turn the crankshaft in its operating direction (timing end clockwise), until the crankshaft comes into contact with TDC setting pin.

11A-14

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

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 timing component that does not require one or more camshaft pulleys to be loosened.

WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the xed roller.

101872

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 and accessories pulley. This is to avoid timing slippage. This slippage causes engine damage.

Undo the nut (7) on the tensioning roller to slacken the timing belt. Remove: - the fixed roller (8) using the (Mot. 1368) , - the timing belt, taking care not to drop the crankshaft sprocket, - the timing sprocket, - the tensioning roller.

14490

Set the camshaft grooves horizontally and below the centre line by turning the camshafts with the (Mot. 799-01) if necessary.

11A-15

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

111337

14489

Fit the (Mot. 1496) with the (Mot. 1750) (9) .

108875 111336

Position the TDC setting pin (Mot. 1489) (10) . Check that the crankshaft is in contact with the TDC setting pin (Mot. 1489) (10) (crankshaft groove (11) should be at the top).

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts.

11A-16

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 2 - REFITTING

11A

14487-2 108879

Refit the tensioning roller by positioning the tensioning roller lug in rib (12) .

Tighten to torque the fixed roller mounting bolt ( 45 Nm ) using the (Mot. 1368) . 3 - BELT TENSION

14487-3

Refit: - the crankshaft timing sprocket (13) , - the timing belt, - the fixed roller (14) .

103263

Using a 6 mm Allen key, bring the adjustable index (15) opposite the notch (16) , by turning the eccentric (17) clockwise.

11A-17

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 Tighten to torque the tensioning roller mounting nut ( 27 Nm ) . Refit the crankshaft accessories pulley. Tighten to torque and angle the crankshaft accessories 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) through two revolutions and before completing the second revolution. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. Remove the TDC setting pin (Mot. 1489) .

11A

4 - CHECKING THE TIMING AND TENSION a - Checking the tension Rotate the crankshaft clockwise through two revolutions (timing end). Screw in the TDC setting pin (Mot. 1489) . Move the crankshaft slowly and smoothly to rest on the TDC setting pin (Mot. 1489) . Remove the TDC setting pin. Check the tensioning roller indexes are aligned; if not readjust the tension by loosening the tensioning roller eccentric by a single turn. Correctly align the adjustable index with the fixed index or the notch (depending on the type of tensioning roller). Tighten to torque the tensioning roller mounting nut ( 27 Nm ) . b - Checking the timing Check that the tensioning roller indexes are correctly positioned before checking the timing setting. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly until it is resting against the pin.

103263

Check that adjustable index (18) is opposite the notch (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 the notch (19) turning the eccentric (20) in a clockwise direction. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) .

11A-18

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

II - PROCEDURE FOR ENGINES FITTED WITH TIMING COVER WITH FLAP 1 - ADJUSTING THE TIMING The first procedure is used when replacing any timing component that does not require one or more camshaft pulleys to be loosened. WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the xed roller.

WARNING Be sure to degrease: - the end of the crankshaft (timing end),


14490

- the timing sprocket bore and contact surfaces, - the contact surfaces of the crankshaft and accessories pulley. This is to avoid timing slippage. This slippage causes engine damage.

Fit the camshaft adjusting tool (Mot. 1496) without forcing (the camshaft grooves must be horizontal and below the centre line). WARNING The timing adjustment and tensioning operation must be repeated if the camshaft setting tool does not engage. Remove the TDC setting pin.

14490

Set the camshaft grooves horizontally and below the centre line by turning the camshafts with the (Mot. 799-01) , if necessary.

11A-19

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

111337

14489

Fit the (Mot. 1496) with the (Mot. 1750) (21) .

108875 111336

Position the TDC setting pin (Mot. 1489) (22) . Check that the crankshaft is in contact with the TDC setting pin (Mot. 1489) (22) (crankshaft groove (23) should be at the top).

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts

11A-20

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 2 - REFITTING 3 - TIMING BELT TENSION

11A

108879

Refit the tensioning roller by positioning the tensioning roller lug in rib (24) . Refit the crankshaft timing sprocket.

103263

Bring the adjustable index (26) opposite the notch (27) , by turning the eccentric (28) clockwise using a 6 mm Allen key. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) .

14487-3

Refit:
109054

- the timing belt, - the timing fixed roller (25) Tighten to torque the fixed roller mounting bolt ( 45 Nm ) using the (Mot. 1368) .

Refit the lower timing cover.

11A-21

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

Rotate the crankshaft twice in a clockwise direction, on the timing end, before aligning the markings (on the camshaft dephaser) already made by the operator. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to rest on the TDC setting pin. Remove the TDC setting pin (Mot. 1489) .

109055

Refit the crankshaft accessories pulley. Tighten to torque and angle the crankshaft accessories pulley mounting bolt ( 40 Nm + 145 15 ) (crankshaft in contact with TDC setting pin).

109052

Remove the cover plate from the lower timing cover. Remove: - the camshaft setting tool (Mot. 1496) , - the TDC setting pin (Mot. 1489) .

11A-22

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

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 (on the camshaft dephaser) already made by the operator. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. Remove the TDC setting pin. Check through the lower timing cover window that the index and the notch of the timing tensioning roller are aligned; if not, readjust the tension by loosening the tensioning roller nut on the eccentric by a single turn.
109051

Align the adjustable index with the notch. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) . b - Checking the timing Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to rest on the TDC setting pin.

103263

Check through the lower timing cover window that the adjustable index (30) is opposite the notch (29) , if not, loosen the timing tensioning roller screw by a single turn while holding the eccentric using a 6 mm Allen key. Gradually move the adjustable index (30) facing the notch (29) turning the eccentric (31) in a clockwise direction. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) . Check that dephaser marking is in alignment with marking already made by the operator.

11A-23

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

REFITTING -PROCEDURE 2
I - ADJUSTING THE TIMING The second procedure is used for the replacement of all components requiring the slackening of one or more of the camshaft pulleys. WARNING If the stud is loosened with the nut (see NT 3887A, Replacing camshaft pulley studs K9 K4, 11A, Top and fr ont of engine, Camshaft ).

WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the xed roller.
14490

WARNING Be sure to degrease: - the end of the crankshaft (timing end), - the timing sprocket bore and contact surfaces,

Fit (without forcing) the camshaft setting tool (Mot. 1496) (the camshaft grooves must be horizontal and offset towards the bottom).

Note: The timing adjustment and tensioning operation must be repeated if the camshaft setting tool does not engage.

- the crankshaft accessories pulley bearing faces, - the camshaft ends (timing end), - the camshaft sprocket bores and contact surfaces. This is to avoid timing slippage. This slippage causes engine damage. Refit the camshaft pulleys and the old nuts, tightening to a torque of 15 Nm .

109052

Refit the lower timing cover plate, checking that the locating pin (32) fits properly in the notch (33) .

11A-24

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

14490

111337

Fit the (Mot. 1496) with the (Mot. 1750) (34) .

103261

Position the camshaft grooves horizontally and offset downwards, by turning the camshafts with the (Mot. 1496) if necessary.

111336

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts Remove the old camshaft pulley nuts and replace them with new ones (without tightening the nuts: 0.5 to 1 mm play between nuts and pulleys).

11A-25

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 II - REFITTING

11A

14489 108879

Refit the tensioning roller by positioning the tensioning roller lug in groove (38) .

14487-1

Check that the crankshaft is in contact with the TDC setting pin (Mot. 1489) (35) (crankshaft groove (36) should be at the top). Position the RENAULT badge (37) etched on the camshaft pulley spokes vertically at the top. Refit: - the timing sprocket (39) ,

14487-3

- the timing belt on the camshaft pulleys (without moving the camshaft pulleys).

11A-26

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 III - BELT TENSION

11A

101876

Fit the camshaft pulley locking tool (Mot. 1490-01) (40) (use the timing cover mountings to mount the tool).

103263

Using a 6 mm Allen key, bring the adjustable index (42) in line with the notch (43) , by turning the eccentric (44) clockwise. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) . Remove camshaft pulley locking tool (Mot. 1490-01) . Note: Check that the camshaft pulley nuts and bolt do not come into contact with their respective pulleys. In addition, from time to time, press the camshaft pulleys against the camshafts. Rotate the timing system through six revolutions with the exhaust camshaft sprocket, using the (Mot. 799-01) .

14487-3

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 tightening the bolt, 2 to 3 mm play between bolt and pulley).

11A-27

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732

11A

103263

14489

Check that adjustable index (45) is opposite the notch (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 the notch (46) turning the eccentric (47) in a clockwise direction. Tighten to torque the tensioning roller mounting nut ( 27 Nm ) .

WARNING Check that the crankshaft is in contact with the TDC setting pin (Mot. 1489) . Tighten to torque and angle: - the accessories pulley mounting bolt ( 40 Nm + 115 15 ) (crankshaft in contact with TDC setting pin) - 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 revolutions (timing end). screw the TDC setting pin (Mot. 1489) into the cylinder block.

14839

Position the camshaft pulley locking tool (Mot. 149001) .

slowly and smoothly position the crankshaft in contact with the TDC setting pin (Mot. 1489) . Remove the TDC setting pin (Mot. 1489) .

11A-28

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4J, and 730 or 732 Check the tensioning roller indexes are aligned; if not readjust the tension by loosening the tensioning roller eccentric by a single turn. Correctly align the adjustable index with the fixed index or the notch (depending on the type of tensioning roller). Tighten to torque the tensioning roller mounting nut ( 27 Nm ) .

11A

REFITTING
Refit the TDC setting pin plug, applying a drop of JOINT 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 and nuts ( 41 Nm ) .

2 - Checking the timing Check that the timing pulley indexes are correctly positioned before checking the timing setting. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly and rest it on the TDC setting pin (Mot. 1489) .

15103-1

Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the accessories belt (see 11A, Top and front of engine, Accessories belt ), - new inlet camshaft sealing plugs (Mot. 1487) , - new exhaust camshaft sealing plugs (Mot. 1488) . Proceed in the reverse order to removal. Note: The timing adjustment and tensioning operation must be repeated if the camshaft setting tool does not engage. Remove the TDC setting pin. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque: - the wheel bolts ( 110 Nm ) - the battery cover mounting bolts ( 4 Nm ) .

14490

Fit the camshaft adjusting tool (Mot. 1496) without forcing (the camshaft grooves must be horizontal and offset downwards).

11A-29

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 TDC locating pin Set of 5 crankshaft and camshaft pulley timing pins

11A

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

Mot. 1453-01

Mot. 1489 Mot. 1430

Tightening torquesm tensioning roller bolt crankshaft accessories pulley M12 mounting bolt crankshaft accessories pulley M14 mounting bolt tensioning roller mounting bolt TDC setting pin plug cylinder head suspended mounting bolts wheel bolts battery cover mounting bolts 25 Nm 60 Nm + 100 10
102450

120 Nm + 95 15 25 Nm 20 Nm 21 Nm 110 Nm 4 Nm

WARNING Never turn the engine in the opposite direction to its normal operation.
102451

Position the (Mot. 1453) and (Mot. 1453-01) with retaining straps.

11A-30

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

1
102115

Remove the lower tie-bar bolts (1) . Remove the lower engine tie-bar.

102114

Mark the position of the suspended engine mounting. Slacken the bolt (2) Remove the suspended engine mounting.

WARNING Do not damage the air conditioning pipe.

11A-31

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19654

Remove the upper timing cover by unclipping the tabs (3) .

11A-32

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19654-1

Remove: - the cylinder marking sensor on the high pressure pump (4) , - the plastic bolt (6) . Unclip the tabs (5) . Remove the lower timing cover.

11A-33

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19654-2

Remove the cylinder head suspended mounting.

Positioning the timing at the adjustment point

8
19702 19650

Remove the TDC setting pin plug.

Rotate the crankshaft clockwise (timing end) to position the hole (8) in the camshaft pulley partially in line with the hole (9) in the cylinder head.

11A-34

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

2 1

19650-1

19655

Screw in the TDC setting pin (1) (Mot. 1489) .

Insert the pin (2) (Mot. 1430) in the camshaft pulley and cylinder head holes. Remove: - the pin (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

14489-1

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes in contact with the TDC setting pin (Mot. 1489) .

11A-35

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19656

Remove the crankshaft accessories pulley, locking the flywheel with a screwdriver.

11A-36

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

10

19656-1

Undo the tensioning roller bolt (10) to slacken the timing belt. Remove: - the timing belt (take care not to drop the crankshaft sprocket), - the timing sprocket, - the tensioning roller.

REFITTING
WARNING It is imperative to replace the timing belt, the tensioning 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 accessories pulley. This is to avoid timing slippage. This slippage causes engine damage.

11A-37

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19710

Refit the crankshaft timing sprocket.

11A-38

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729 I - ADJUSTING THE TIMING

11A

2 13

14

12 11

15

19656-2

Note: Check that the tensioning roller lug (11) is correctly positioned in the groove (12) . Refit the tensioning roller. Insert the pin (2) (Mot. 1430) in the camshaft pulley and cylinder head holes. Screw the TDC setting pin into the cylinder block. Check that the mark (13) on the high pressure pump pulley is in line with the bolt head (14) .

14489

Check that the crankshaft is hard against the TDC setting pin (Mot. 1489) (crankshaft groove (15) facing upwards).

11A-39

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A
16

19657

19658

Fit the new timing belt, aligning the marks on the belt with those on the camshaft sprockets and the high pressure pump. Note: 19 belt tooth spaces between the camshaft sprocket and pump marks.

Position the tensioning roller adjustable index (16) opposite the lug using a 6 mm Allen key, turning it anticlockwise. 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 mounting bolt ( 60 Nm + 100 10 ) , - crankshaft accessories pulley M14 mounting bolt ( 120 Nm + 95 15 ) . Remove: - the TDC setting pin (Mot. 1489) , - the camshaft pulley timing pin (Mot. 1430) .

11A-40

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A
20

19

18

17
19702 19655

Rotate the crankshaft clockwise through two revolutions (timing end). Before the camshaft pulley hole (17) comes in line with the cylinder head hole (18) , screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly into contact with the pin.

Check: - that the timing pin (Mot. 1430) engages properly in the camshaft and cylinder head holes, - that there are 19 belt tooth spaces between the camshaft sprocket mark (19) and the high pressure pump sprocket mark (20) . Remove: - the TDC setting pin (Mot. 1489) , - the camshaft pulley timing pin (Mot. 1430) . After two turns, the tensioning roller indexes may be in two different positions. The rotation of the tensioning roller eccentric depends on the position.

11A-41

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729 First position Second position

11A

21

23

111083

111082

23

24

111081

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index (21) , turning the Allen key anticlockwise, to the middle of the timing window (22) .

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index (23) , turning the key clockwise, to the middle of the timing window (24) .

11A-42

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729 II - REFITTING Tighten to torque the tensioning roller mounting bolt ( 25 Nm ) . Refit the TDC setting pin plug, applying JOINT SILICONE ADHERENT to the thread hole. Tighten to torque the TDC setting pin plug ( 20 Nm ).

11A

19654-2

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 Nm ) .

11A-43

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19654-1

25

26
19659

Refit the lower timing cover, positioning the tab (25) in the lower timing cover aperture (26) .

11A-44

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 722 or 728 or 729

11A

19654

Refit: - the upper timing cover, - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). . Tighten to torque: - the wheel bolts ( 110 Nm ) , - the battery cover mounting bolts ( 4 Nm ) .

11A-45

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 TDC setting pin Tool for pretensioning timing belt

11A

Mot. 1453-01

Mot. 1054 Mot. 1543

102450

Mot. 1705 Mot. 1505 Mot. 1715

Adapter for timing belt pretensioning tool Belt tension setting tool (frequency meter) Belt tension setting tool (frequency meter)

Tightening torquesm TDC setting pin plug tensioning roller mounting nut crankshaft accessories pulley mounting bolt wheel bolts battery cover bolts 20 Nm 45 Nm 40 Nm + 110 10 110 Nm 4 Nm
102451

Position the (Mot. 1453) and (Mot. 1453-01) with retaining straps. WARNING Never turn the engine in the opposite direction to its normal operation.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the engine undertray, - the accessories belt (see 11A, Cylinder head, Accessories belt: Removal - Refitting ).

11A-46

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808

11A

102420

15102

Remove: - the upper engine tie-bar. - the lower engine tie-bar. Mark the position of the suspended engine mounting in relation to the body. Slacken the bolt (1) Remove the suspended engine mounting. WARNING Do not damage the air conditioning pipes (if tted to the vehicle).

Remove: - the TDC setting pin plug. - the flywheel guard cover plate.

104739

Remove: - the crankshaft accessories pulley, locking the flywheel with a screwdriver, - the timing cover mounting bolts (2) , - the timing cover.

11A-47

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808 ADJUSTING THE TIMING

11A

104326 104329

Rotate the crankshaft clockwise (timing end); bring the camshaft pulley mark to half a tooth before the mark on the guard.

Undo the tensioning roller mounting nut (3) to slacken the tensioning roller. Remove the timing belt.

REFITTING
WARNING Replace the timing belt, the tensioning roller, the crankshaft accessories pulley and bolt.

104330

When the mark on the camshaft pulley is half a tooth before the mark on the guard, press in the TDC setting pin (Mot. 1054) until the crankshaft is timed.

11A-48

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808

11A

104336

104327

Refit the tensioning roller, taking care to position it correctly on the locating pin (4) .

Fit the new timing belt, aligning the marks on the belt with those on the crankshaft, camshaft and high pressure pump sprockets (count 28 belt tooth spaces between the mark on the camshaft sprocket and the mark on the high pressure pump sprocket). Press the tensioning roller against the belt by tightening the bolt (8) on the tensioning roller mounting. Note:

5 7

The bolt (8) is manufactured locally . Remove the TDC setting pin (Mot. 1054) . Position the crankshaft accessories pulley bolt.

16187

Check that the TDC setting pin (Mot. 1054) is in place.

Note: The crankshaft groove (5) must be in the middle of the two ribs (6) on the crankshaft guard plate. The crankshaft timing sprocket mark (7) should be offset one tooth to the left of the vertical axis of the engine.

11A-49

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808

11A

16563

104332

Pretension the timing belt between the crankshaft timing sprocket and the tensioning roller using the (Mot. 1543) and a torque wrench set to a torque of (11 Nm) .

104331

Mount the timing belt pretensioning tool (Mot. 1543) fitted with the cover (Mot. 1705) (9) on the crankshaft accessories pulley bolt.

11A-50

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F9Q, and 800 or 804 or 808

11A

10

104333

105435

Position the sensor of the (Mot. 1505) o r (Mot. 1715) between the crankshaft sprocket and the tensioning roller. Tension the belt to obtain the recommended value 90 3 Hz by turning the bolt (10) . Tighten to torque the tensioning roller mounting nut (10 Nm) . Turn the crankshaft through two revolutions. Reposition the TDC setting pin (Mot. 1054) . Position the timing at its setting point (start pressing on the pin half a tooth before alignment of the camshaft pulley mark and the cover plate mark, to avoid going into a camshaft balancing hole). Remove the TDC setting pin (Mot. 1054) . Refit the TDC setting pin plug, applying a drop of RHODORSEAL 5661 onto the thread. Tighten to torque the TDC setting pin plug ( 20 Nm ). Apply a pretensioning force between the crankshaft timing sprocket and the tensioning roller using the (Mot. 1543) and a torque wrench set to a torque of 11 Nm . Place the sensor of the (Mot. 1505) between the crankshaft sprocket and the tensioning roller. Check that the tension value is 80 5 Hz ; if not, readjust. Tighten to torque the tensioning roller mounting nut ( 45 Nm ) . Remove the (Mot. 1543) .

Remove the crankshaft accessories pulley bolt. Refit the crankshaft accessories pulley, without separating its two component parts. Tighten to torque and angle the crankshaft accessories pulley mounting bolt ( 40 Nm + 110 10 ) . Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended mounting ), - the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ), - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

To refit, proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque: - the wheel bolts ( 110 Nm ) , - the battery cover bolts ( 4 Nm ) .

11A-51

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Lower engine support TDC setting pin Camshaft locking tool sprocket

11A
Tightening torquesm 80 Nm 80 Nm 28 Nm 80 Nm (30 Nm) (30 Nm)

toothed sprocket nuts toothed sprocket nuts tensioning roller nut toothed sprocket nuts inlet camshaft dephaser mounting bolt exhaust camshaft pulley nut inlet camshaft dephaser mounting bolt camshaft pulley dephaser blanking cover exhaust camshaft pulley nut toothed sprocket nuts inlet and exhaust camshaft pulley nuts nuts inlet and exhaust camshaft pulley nuts crankshaft accessories pulley bolt

Mot. 1453-01

Mot. 1672 Mot. 1054 Mot. 1509 Mot. 1509-01 Mot. 799-01 Mot. 1496 Mot. 1487

100 Nm 25 Nm 86 6 80 Nm 86 6 80 Nm 30 Nm + 86 6 40 Nm + 110 10 80 Nm 20 Nm 18 Nm 38 Nm 110 Nm 4 Nm

Conversion kit for Mot. 1509 Timing gear wheel immobiliser Camshaft setting tool Tool for retting camshaft covers (57 mm diameter) Remote operation clip pliers for cooling system hose clips

Mot. 1448

Tightening torquesm toothed sprocket nuts toothed sprocket nuts xed roller mounting bolt tensioning roller nut toothed sprocket nuts old inlet camshaft dephaser mounting bolt old exhaust camshaft pulley nut toothed sprocket nuts old inlet and exhaust camshaft pulley nuts 80 Nm 80 Nm 50 Nm 7 Nm (80 Nm) (30 Nm)

M6 lower timing cover bolts M8 lower timing cover bolts M8 upper timing cover bolts M10 upper timing cover bolts wheel bolts

30 Nm (80 Nm) (30 Nm)

battery cover mounting bolts

Note The timing belt procedure is the same for engines with or without camshaft dephasers.

11A-52

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

WARNING Never turn the engine in the opposite direction to its normal operation.

WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley.

WARNING On the F4R engine, it is essential to t the crankshaft sprocket with the integral key.

102450

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 replace the tensioning roller and the xed roller.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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.

102451

Position the (Mot. 1453) and (Mot. 1453-01) with retaining straps.

11A-53

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

102365

Remove: - the front end panel mounting bolts (6) , - the front end panel,
106077

Remove: - the radiator cross member right-hand side reinforcement (1) , - the lower engine tie-bar. F4R, and 776

- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ).

3 2
Position the (Mot. 1672) with retaining straps.
105432

102504

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.

11A-54

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

- the connector on the lifting bracket.

F4R, and 776

102742

Mark the suspended engine mounting in relation to the body. Remove the suspended mounting assembly.

9
106278

Note: Be careful not to bend the air conditioning pipe. Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). F4R, and 770 or 771

Remove the fuel vapour recirculation solenoid valve (9) .

101807

Remove: - the air filter outlet duct (7) , - the throttle valve (8) ,

11A-55

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

10 11

106632

15105

Loosen the nut (10) . Pull the mounting bracket away from the electric coolant pump. Move the electric coolant pump (11) to one side. Remove the wiring harness mounting bracket.

Remove the camshaft sealing plugs. I - ADJUSTING THE TIMING

15106

Rotate the engine clockwise (timing end) so that the camshaft grooves are offset below the centre line and almost horizontal, as shown in the drawing.

12
15102

Insert the TDC setting pin (Mot. 1054) so that it is between the balancing hole and the crankshaft setting groove.

Remove the TDC setting pin plug (12) .

11A-56

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 Correct position

11A

15163-2

15163-1

Turn the engine slightly in the same direction, pushing in the TDC setting pin (Mot. 1054) until the setting point is reached.

Incorrect position

15163 15106-1

Remove the TDC setting pin (Mot. 1054) .

At the setting point, the camshaft grooves must be horizontal and offset below the centre line, as shown in the drawing.

11A-57

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

106519

15303

Remove: - the flywheel guard, - the crankshaft pulley, locking the flywheel with a screwdriver. Refit the TDC setting pin (Mot. 1054) .

11A-58

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 770 or 771

13

14

18433

Remove: - the upper timing cover (13) , - the lower timing cover (14) .

11A-59

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 776

15

106338

16

17

104719

Remove: - the heat shield (15) ,

- the upper timing cover (16) ,

11A-60

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 - the lower timing cover (17) .

11A

18

19

18433-2

Slacken the timing belt by loosening the tensioning roller nut (18) . Remove: - the fixed roller (19) , - the timing belt, - the crankshaft timing sprocket. WARNING When replacing the timing belt, it is imperative to replace the tensioning roller and the xed roller.

WARNING Never turn the engine in the opposite direction to its normal operation.

WARNING A belt which has been removed MUST be replaced.

11A-61

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 II - ADJUSTING THE TIMING

11A

20

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 accessories pulley, This is to prevent slippage between the timing gear and the crankshaft. This slippage causes engine damage.

WARNING Never turn the engine in the opposite direction to its normal operation.

WARNING In this case, the old camshaft pulley nuts must be removed in order to correctly set the belt tension.

11A-62

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 770 or 771

15815-3

Check that the camshaft dephaser wheel is correctly locked (no rotation of the wheel to the left or to the right).

11A-63

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

26

25

22

27 21
16019 16019-3

Position the (Mot. 1509) with sprocket (Mot. 150901) . Position the spacer (21) of the (Mot. 1509-01) on the stud (22) .

Tighten the bolt and the shouldered nut (25) . Bring the toothed sprockets of the (Mot. 1509) into contact 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) ,

24

23

- the camshaft pulleys. Loosen the stud with the nut (see NT 3884A, Replacing F4 camshaft pulley studs, Top and front of engine, Camshaft ).

16019-1

Fit the upper bolt (23) , positioning the spacer (24) (Mot. 1509-01) between the tool and the rocker cover (do not tighten the bolt).

11A-64

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 776

Refit the degreased camshaft pulleys with the old mountings. Tighten to torque the old mountings (15 Nm max.) using the (Mot. 799-01) . WARNING When removing the timing belt, it is essential to replace:

28

- the crankshaft accessories pulley, - the tensioning roller and xed roller, - the accessories and timing belts.

29

104711

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 the camshaft 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, Replacing F4 camshaft pulley studs, Top and front of engine, Camshaft ).
15106-1

Position the grooves offset horizontally below the centre-line as shown above by turning the camshafts using the (Mot. 799-01) .

11A-65

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A
31

30

15104

15114

Position the (Mot. 1496) , attaching it to the end of the camshafts. F4R, and 770 or 771 Loosen: - the exhaust camshaft pulley nut, - the inlet camshaft dephaser pulley bolt,

Correct position

F4R, and 776 Loosen the camshaft pulley nuts.

15163-1

WARNING Check that the crankshaft is correctly centered. The crankshaft groove (30) must be between the two ribs (31) .

11A-66

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

33

32

15201

Refit the tensioning roller, correctly positioning the (32) of the tensioning roller in the groove (33) .

34

15815-1

Refit: - the timing sprocket, - the timing belt, - the fixed roller (34) . Tighten to torque the fixed roller mounting bolt ( 50 Nm ) .

11A-67

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 III - ADJUSTING THE TENSION F4R, and 770 or 771

11A

37

35

38 39

36

15256 104728

Note: Do not rotate the tensioning roller anticlockwise. Align the marks (35) and (36) on the tensioning roller using 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 the camshaft 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. 150901) .

11A-68

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A
42

F4R, and 776

40 41

21877

104711

Make a pencil mark (42) between the camshaft pulleys 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 revolutions (timing end).

Position the (Mot. 1509) for locking the camshaft pulley. Tighten the bolt and the shouldered nut (40) . Bring the toothed sprocket nuts into contact with the camshaft 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. 150901) .

11A-69

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 IV - CHECKING THE TIMING AND THE TENSION 1 - Checking the tension

11A

15104

Position the camshaft adjustment tool (Mot. 1496) .


15163-2

Before the end of the second revolution (i.e. half a tooth before alignment of the marks made previously by the operator), insert the crankshaft TDC setting pin (Mot. 1054) (so that it is between the balancing hole and the timing hole).

15163-1

Bring the timing to its adjustment point.

11A-70

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 770 or 771

F4R, and 776

43 44

45 46

104728

104711

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 camshaft pulleys. Tighten the toothed sprocket nuts ( 80 Nm ) (44) . Loosen: - the old inlet camshaft dephaser pulley mounting bolt, - 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 camshaft pulley. Tighten the bolt and the shouldered nut (45) . Offer up the toothed sprocket nuts against the camshaft 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 camshaft pulley.

11A-71

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

49

47

48

15256

Align mark (47) with mark (48) by loosening the tensioning roller nut by up to one turn, while holding it in position with a 6 mm (49) Allen key. Final tighten the tensioning roller nut ( 28 Nm ) .

11A-72

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 Remove the following tools: F4R, and 770 or 771 - TDC setting pin (Mot. 1054) ,

11A

- camshaft pulley locking tool (Mot. 1509) with toothed sprockets (Mot. 1509-01) . Rotate the crankshaft clockwise through two revolutions (timing end).

50 51

104728

Position the (Mot. 1509) with toothed sprockets to lock the camshaft pulleys. Tighten the bolt and the shouldered nut (50) . Bring the toothed sprockets into contact with the camshaft 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 ( (30 Nm) ) , - the exhaust camshaft pulley nut ( (30 Nm) ) . Remove the camshaft adjustment tool (Mot. 1496) . Tighten to torque: - the inlet camshaft dephaser mounting bolt ( 100 Nm ) , - the camshaft pulley dephaser blanking cover ( 25 Nm ) Tighten to angle the exhaust camshaft pulley nut ( 86 6 ) .

11A-73

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

F4R, and 776

54 55 52 53

104711

104711

Position the camshaft locking tool (Mot. 1509) , torque tightening the nuts ( 80 Nm ) (54) . Tighten the bolt and the shouldered nut (55) . Remove the old camshaft pulley nuts and replace them with new ones. Tighten to torque and angle the inlet and exhaust camshaft 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 revolutions.

Position the (Mot. 1509) for locking the camshaft pulley. Tighten the bolt and the shouldered nut (52) . Bring the toothed sprocket nuts into contact with the camshaft 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 camshaft pulley. Tighten to torque the inlet and exhaust camshaft pulley nuts 30 Nm . Remove the camshaft adjustment tool (Mot. 1496) . Tighten to angle the inlet and exhaust camshaft pulley nuts ( 86 6 ) . Remove the following tools: - TDC setting pin (Mot. 1054) , - camshaft pulley locking tool (Mot. 1509) . Rotate the crankshaft clockwise through two revolutions (timing end).

11A-74

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776 2 - Checking the timing

11A

56

57
15649

15104

Before the end of the second revolution (i.e. half a tooth before alignment of the marks made previously by the operator), insert the crankshaft TDC setting pin ( (Mot. 1054) so that it is between the balancing hole and the timing hole). Check that mark (56) is aligned with mark (57) on the tensioning roller before checking the timing adjustment.

Position the camshaft setting tool (Mot. 1496) without forcing it. If the tool does not engage, repeat the timing and tensioning procedure.

REFITTING
Refit: - the lower timing cover, - the upper timing cover. WARNING It is imperative to replace the crankshaft accessories pulley and bolt.

58

15106-1

The offset grooves (58) should be horizontal and below the centre line.

11A-75

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


F4R, and 770 or 771 or 776

11A

15303

15103-1

Lock the flywheel using a large screwdriver. Tighten to torque and angle the crankshaft accessories pulley bolt ( 40 Nm + 110 10 ) . WARNING T avoid damaging the crankshaft accessories o pulley, do not start the engine without the accessories belt. Refit: - the crankshaft accessories belt (see 11A, Top and front of engine, Accessories belt ), - the TDC setting pin plug, applying a drop of RHODORSEAL 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, Engine mounting, Suspended mounting ) in accordance 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: Removal - Refitting ).

11A-76

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 TDC locating pin Tool for tightening tensioner bolt. 8 mm Torx wrench 12.7 mm square Timing gear wheel immobiliser Camshaft setting tool Adapter for camshaft setting tool Mot. 1496 Locking and adjusting camshaft pulleys Tool for retting camshaft covers (57 mm diameter) Tool for retting camshaft covers (43 mm diameter) wheel bolts battery cover mounting bolts

11A
Tightening torquesm 110 Nm 4 Nm

Mot. 1453-01

WARNING Never turn the engine in the opposite direction to its normal operation.

Mot. 1489 Mot. 1368

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the engine undertray, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

Mot. 799-01 Mot. 1496 Mot. 1750 Mot. 1490-01 Mot. 1487

Mot. 1488

Tightening torquesm crankshaft accessories pulley bolt timing tensioning roller nut pulley mounting bolt exhaust camshaft pulley nut inlet camshaft pulley dephaser bolt TDC pin plug upper timing cover nuts and bolts 40 Nm + 145 15 27 Nm 45 Nm 30 Nm + 84 4 75 Nm 20 Nm 41 Nm

11A-77

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

102450

101866

Mark the suspended engine mounting in relation to the body. Remove: - the engine/suspended engine mounting assembly, - the lower engine tie-bar. WARNING Do not damage the air conditioning pipe.

102451

Fit the (Mot. 1453) and the (Mot. 1453-01) and the retaining straps.

2 1

101807

Remove: - the air filter outlet duct (1) , - the throttle valve (2) , - the connector from the lifting bracket, - the lifting eye (flywheel end).

11A-78

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 ADJUSTING THE TIMING

11A

14491

Pierce the centre of the plugs on the end of the camshaft using a screwdriver. Remove: - the sealing plugs at the camshaft end with a screwdriver, - the TDC setting pin plug (3) .

14491-1

Position the camshaft grooves (5) almost horizontally and offset towards the bottom while turning the crankshaft in its operating direction (clockwise timing end). Screw in the TDC setting pin (4) (Mot. 1489) .

14489

Turn the crankshaft in its operating direction (timing end clockwise), until the crankshaft comes into contact with TDC setting pin.

11A-79

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

10 9

14490

101872

Check that the camshaft grooves are horizontal and offset downwards.

Undo the tensioning roller bolt (9) to slacken the timing belt. Remove: - the pulley (10) using the (Mot. 1368) , - the timing belt, taking care not to drop the crankshaft sprocket,

- the timing sprocket, - the tensioning roller.

14487

Remove: - the crankshaft accessories pulley (6) , locking the flywheel with a screwdriver, - the upper timing cover (7) , - the lower timing cover (8) .

11A-80

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

REFITTING - 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 timing component that does not require one or more camshaft pulleys to be loosened. WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the pulley.

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 surfaces. This is to avoid slippage between: - the timing, - the crankshaft, - the camshaft sprockets. This slippage causes engine damage. Position the camshaft grooves horizontally and below the centre line by turning the camshafts using the (Mot. 799-01) if necessary. Fit the (Mot. 1496) with (Mot. 1750) (11) .
111337

111336

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts

11A-81

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

103269

Check that the mark (12) on the dephaser is vertical and pointing upwards. Make a mark (13) with a pencil between the dephaser wheel and the rocker cover.

11A-82

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

14489

14487-3

Check: - that the crankshaft is correctly in contact with the TDC setting pin (Mot. 1489) (15) with the crankshaft groove (14) facing upwards, - that the inlet camshaft dephaser wheel is correctly locked (wheel does not rotate right or left). . 2 - REFITTING

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

103263 108879

Refit the tensioning roller by positioning the tensioning roller lug in the groove (16) .

Using a 6 mm Allen key, bring the adjustable index marker (19) opposite the notch (20) , by turning the eccentric (21) clockwise.

11A-83

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 Tighten to torque the tensioning roller mounting nut (7 Nm) Refit the crankshaft accessories pulley. Tighten to torque and angle the crankshaft accessories pulley bolt ( 40 Nm + 145 15 ) (crankshaft 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 revolutions (timing end) before aligning the marks (on the camshaft dephaser). Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. Remove the TDC setting pin (Mot. 1489) .

11A

103263

Check that the adjustable index marker (22) is opposite 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) in a clockwise direction.

11A-84

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

103267

Tighten to torque the timing tensioning roller nut (27 Nm) (25) . Check that the dephaser mark (26) is aligned with the mark (27) . 4 - CHECKING THE TIMING AND TENSION a - Checking the tension Rotate the crankshaft through two clockwise revolutions (timing end) before aligning the marks (on the camshaft dephaser). Screw in the TDC setting pin (Mot. 1489) . Move the crankshaft slowly and smoothly to rest on the 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 correctly positioned before checking the timing setting. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly until it is resting against the pin. Fit the camshaft adjusting the (Mot. 1496) without forcing (the camshaft grooves must be horizontal and below the centre line). WARNING If the tool cannot be engaged, readjust the timing and the tension.

11A-85

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 II - PROCEDURE FOR AN ENGINE FITTED WITH A TIMING COVER WITH A FLAP 1 - ADJUSTING THE TIMING The first procedure is used when replacing any timing component that does not require one or more camshaft pulleys to be loosened. WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the pulley.

11A

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 surfaces. This is to avoid slippage between: - the timing, - the crankshaft, - the camshaft sprockets. This slippage causes engine damage. Set the camshaft grooves horizontally and below the centre line by turning the camshafts using the (Mot. 799-01) if necessary. Fit the (Mot. 1496) with (Mot. 1750) (28) .
111337

111336

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts

11A-86

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

103269

Check that the mark (29) on the dephaser is vertical and pointing upwards. Make a mark (30) with a pencil between the dephaser wheel and the rocker cover.

11A-87

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

14489

14487-3

Check: - that the crankshaft is correctly in contact with the TDC setting pin (Mot. 1489) (32) with the crankshaft groove (48) facing upwards, - that the inlet camshaft dephaser wheel is correctly locked (wheel does not rotate right or left). . 2 - REFITTING

Refit: - the timing sprocket (35) , - the timing belt, - the pulley (34) .

14487-2

Tighten to torque the pulley mounting bolt (45 Nm) using (Mot. 1368) .

108879

Refit the tensioning roller by positioning the tensioning roller lug in the groove (33) .

11A-88

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 3 - BELT TENSION

11A

109055 103263

Refit the crankshaft accessories pulley. Tighten to torque and angle the crankshaft accessories pulley bolt (40 Nm + 145 15) .

Move the adjustable index marker (36) opposite the notch (37) , by turning the eccentric (38) clockwise using a 6 mm Allen key.

109054

Refit the lower timing cover.

11A-89

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

109052

109051

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 (on the camshaft dephaser) already made by the operator. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. Remove the TDC setting pin (Mot. 1489) .

103263

Using the lower timing cover window, check that the adjustable index marker (40) is opposite the notch (39) . Loosen the timing tensioning roller nut by up to one turn while holding the eccentric with a 6 mm Allen key. Gradually move the adjustable indexing marker (40) opposite the notch (39) turning the eccentric (41) in a clockwise direction. Tighten to torque the timing tensioning roller nut (27 Nm) .

11A-90

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 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 (on the camshaft dephaser) already made by the operator. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. Remove the TDC setting pin. Using the lower timing cover window, check that the index marker and the timing tensioning roller notch are aligned. Reset the tension by loosening the tensioning roller eccentric 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 tensioning roller notch are correctly positioned before checking the timing. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly to press against the TDC setting pin. WARNING

11A

14490

Position (without forcing) the camshaft timing tool (Mot. 1496) (the camshaft end grooves must be horizontal and offset towards the bottom).

The timing adjustment and tensioning operation must be repeated if the camshaft setting tool does not engage.

109052

Refit the lower timing cover flap, checking that the pin (42) fits into the notch properly (43) .

11A-91

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

REFITTING -PROCEDURE 2
I - ADJUSTING THE TIMING The second procedure is used for the replacement of all components requiring the loosening of one or more of the camshaft pulleys. WARNING If the stud is loosened with the nut (see T echnical Note 3887A, Replacement of K9 -K4 camshaft pulley studs, 11A, Top and front of engine, Camshaft ).

WARNING Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the pulley.
14490

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 surfaces. This is to avoid timing slippage. This slippage causes engine damage. Refit the camshaft pulleys and the old nuts, tightening them to a torque of 15 Nm .

103261

Position the camshaft grooves horizontally and offset downwards, by turning the camshafts using the (Mot. 1496) if necessary.

11A-92

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

111337

Fit the (Mot. 1496) with (Mot. 1750) (44) .

111336

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the end of the camshafts

11A-93

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

14489

103269

Check that the crankshaft is in contact with the TDC setting pin (Mot. 1489) (45) (crankshaft groove (46) should be at the top).

11A-94

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

111338

111340

Fit the camshaft dephaser into a vice with jaws.

Check that the dephaser hub is mechanically secured correctly using a tubular hexagon box spanner (the hub must not be able to rotate towards the left or right). 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 camshaft pulley spokes vertically at the top, - the dephaser marking (48) vertically and at the top. Make a mark (49) with a pencil between the dephaser wheel and the rocker cover.

111339

Fit a bolt in the dephaser hub.

11A-95

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 II - REFITTING

11A

103265 108879

When refitting the tensioning roller, ensure that the tensioning roller lug fits correctly into the groove (50) .

Fit the camshaft pulley locking tool (Mot. 1490-01) (52) (use the timing cover mountings to fit the tool).

14487-3

Refit the pulley (53) .


14487-3

Refit: - the timing sprocket (51) , - the timing belt on the camshaft pulleys (without moving the camshaft pulleys).

Tighten to torque the pulley mounting bolt ( 45 Nm ) using the (Mot. 1368) . Refit the crankshaft accessories pulley (without tightening the bolt, leaving 2 to 3 mm play between bolt and pulley).

11A-96

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 III - BELT TENSION

11A

103263 103263

Using a 6 mm Allen key, bring the adjustable index marker (54) opposite the notch (55) , by turning the eccentric (56) clockwise. Tighten to torque the tensioning roller mounting nut (7 Nm). Remove the camshaft pulley immobilising tool (Mot. 1490-01) . Note: Check that the camshaft pulley nuts and bolt do not come into contact with their respective pulleys. In addition, from time to time, press the camshaft pulleys against the camshafts. Rotate the timing system through six revolutions with the exhaust camshaft pulley, using the (Mot. 799-01) .

Check that the adjustable index marker (57) is aligned 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) in a clockwise direction.

11A-97

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

103268

Tighten to torque the tensioning roller mounting nut (27 Nm) . Check that: - the RENAULT logo (60) engraved on the camshaft pulley spokes is positioned vertically at the top, - the dephaser mark (61) is aligned with the mark (62) already made by the operator.

14839

Fit the camshaft pulley immobilising tool (Mot. 149001) .

11A-98

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732

11A

14489

103265

WARNING Check that the crankshaft is pressing against the TDC setting pin (Mot. 1489) (63) . Tighten to torque and angle the crankshaft accessories pulley bolt (40 Nm + 145 15) (crankshaft in contact with the TDC setting pin).

Tighten to torque and angle the exhaust camshaft pulley nut ( 30 Nm + 84 4 ) . Tighten to torque the inlet camshaft pulley dephaser bolt ( 75 Nm ) . Refit the new inlet camshaft dephaser blanking cover (64) . Remove: - (Mot. 1496) , - the camshaft pulley immobilising tool (Mot. 149001) , - the TDC setting pin (Mot. 1489) . IV - CHECKING THE TIMING AND TENSION

1 - Checking the tension Rotate the crankshaft clockwise through two revolutions (timing end). Screw the TDC setting pin (Mot. 1489) into the cylinder block. Slowly and smoothly position the crankshaft so that is in contact with TDC setting pin (Mot. 1489) . Remove the TDC setting pin (Mot. 1489) . Check that the pulley indexes are aligned, otherwise continue with the tensioning process.

11A-99

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K4M, and 730 or 732 2 - Checking the timing Check that the tensioning roller indexes are correctly positioned before checking the timing setting. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Move the crankshaft slowly and smoothly into position against the pin.

11A

15103-1

Refit: - the suspended engine mounting (see 19D, Engine mounting, Suspended engine mounting ), - the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting ), - the accessories belt (see 11A, Top and front of engine, Accessories belt ),
14490

- 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 terminal.

Fit the camshaft adjusting tool (Mot. 1496) without forcing (the camshaft grooves must be horizontal and offset downwards).

WARNING If the tool cannot be engaged, readjust the timing and the tension. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque: - the wheel bolts ( 110 Nm ) Refit the TDC pin plug, applying a drop of SILICONE ADHESIVE 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 and bolts ( 41 Nm ) . - the battery cover mounting bolts ( 4 Nm ) .

REFITTING

11A-100

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 TDC locating pin Set of 5 crankshaft and camshaft pulley timing pins I - PRECAUTIONS FOR REPAIR

11A

IMPORTANT Wear protective gloves during all operations.

Mot. 1453-01

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operation. Do not run the engine without the accessories belt so as not to break the crankshaft accessories pulley. When replacing the belt, be sure to replace the tensioning rollers and pulleys.

Mot. 1489 Mot. 1430

Tightening torquesm camshaft pulley wheel bolts tensioning roller bolt camshaft pulley wheel bolts crankshaft pulley M14 bolt TDC pin plug cap cylinder head suspended mounting bolts ball joint bracket mounting bolts with their springs wheel bolts 14 Nm

II - PARTS AND CONSUMABLES FOR THE REPAIR 27 Nm 14 Nm 120 Nm + 95 15 20 Nm 21 Nm 21 Nm 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, 110 Nm - female torx socket ( 14 ), - Allen key ( 6 mm ), - Offset spanner ( 18 mm ), - bolt tightening gauge, - Torque wrench.

11A-101

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732 IV - REMOVAL 1 - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, Accessories belt ).

11A

102450

102451

Fit the (Mot. 1453) and the (Mot. 1453-01) with the retaining straps. Remove: - the exhaust ball joint bracket mounting bolts, - the lower engine tie-bar mounting bolts. Detach the manual priming pump. WARNING Be careful not to damage the air conditioning pipes.

11A-102

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

112998

113927

Remove the right-hand suspended mounting (1) and (2) (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ).

112989

Undo the cylinder head suspended mounting bolts. Twist the timing belt slightly (to remove the cylinder head suspended mounting). Remove the cylinder head suspended mounting (6) .

112990

Unclip the tabs (3) . Remove: - the upper timing cover, - the plastic bolt (4) . Unclip the tabs (5) . Remove the lower timing cover.

11A-103

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

19650

19650-1

Remove the TDC pin plug (7) using a torx socket (14). 2 - OPERATION FOR REMOVAL OF PART CONCERNED

Screw in the TDC setting pin (10) (Mot. 1489) .

14489

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft is pressed against the TDC setting pin.
107270

Turn the crankshaft to position the hole (8) of the camshaft pulley almost opposite the hole (9) in the cylinder head.

11A-104

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

109049

109046

Engage the pin (11) (Mot. 1430) in the camshaft pulley and cylinder head holes. Remove: - the timing pin from the camshaft pulley (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

Undo the tensioning roller bolt (12) to slacken the timing belt. Remove: - the timing belt, - the timing tensioning roller.

107260

Remove the crankshaft accessories pulley, locking the engine flywheel using a screwdriver passing it through orifice under the starter motor.

11A-105

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732 V - REFITTING 1 - REFITTING PART CONCERNED

11A

- the mark on the high-pressure pump (16) is offset by 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).

109042 14489

109043

Refit the timing tensioning roller. Place the tensioning roller lug (13) in the cylinder head groove (14) . Engage the pin (15) (Mot. 1430) in the holes of the camshaft pulley and cylinder head, turning the camshaft using an 18 mm offset spanner if necessary. Check that:

109042

Remove one bolt from the camshaft pulley wheel. Loosen the two other camshaft pulley wheel bolts (19) by one turn.

11A-106

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

109044

Fit the timing belt, starting with the crankshaft sprocket, aligning the marks on the belt with those on the crankshaft sprockets, the camshaft and the highpressure pump. There should be 19 tooth spaces between the sprocket marks and 51 tooth spaces between the crankshaft sprockets and the high pressure pump.

11A-107

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

19658

Position the tensioning roller adjustable index marker (20) opposite the lug (21) using a 6 mm Allen key, turning it anti-clockwise. Tighten to torque the tensioning roller bolt (27 Nm) .

109047

Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.

11A-108

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

109045

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) ,

107272

Tighten the old crankshaft accessories pulley bolt fitted with a spacer (23) (which does not cover the timing sprocket mark) onto the crankshaft.

11A-109

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

107270

109048

Rotate the crankshaft twice in a clockwise direction (timing end) before the camshaft pulley hole (24) is opposite the cylinder head hole (25) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

If the (Mot. 1430) does not engage: loosen the camshaft pulley wheel bolts by one turn, Turn the camshaft pulley hub using an offset spanner to facilitate setting of the camshaft pulley hub. Do not retighten the camshaft pulley wheel bolts.

109049

Set the camshaft pulley using the (Mot. 1430) .

11A-110

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

109045

Check that the crankshaft timing sprocket collet (26) is positioned vertically facing upwards. Note: After two turns, the tensioning roller markers may be in two different positions. The rotation of the tensioning roller eccentric depends on the position.

11A-111

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732 a - First position b - Second position

11A

111083

111082

111081

Loosen the tensioning roller bolt by a maximum of one turn, holding the tensioning roller using a 6 MM Allen key. Gradually align the adjustable index marker (27) to the middle of the timing window (28) , turning the key anti-clockwise.

111081

Loosen the tensioning roller bolt by a maximum of one turn, holding the tensioning roller using a 6 MM Allen key. Gradually align the adjustable index marker (29) to the middle of the timing window (30) , turning the key clockwise. Tighten to torque: - the tensioning roller bolt ( 27 Nm ) , - the camshaft pulley wheel bolts ( 14 Nm ) .

11A-112

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732 Remove: - 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 opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

11A

107260

Refit the accessories crankshaft pulley with a new bolt. Tighten to torque and angle (crankshaft in contact with the TDC setting pin) the crankshaft pulley M14 bolt ( 120 Nm + 95 15 ) Remove the following tools: - TDC setting pin (Mot. 1489) , - timing pin from camshaft pulley (Mot. 1430) .
109049

2 - FINAL OPERATION Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEAL . Tighten to torque the TDC pin plug cap ( 20 Nm ) .

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the operation for refitting the timing belt.

11A-113

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

112989

112990

Refit the cylinder head suspended mounting (31) . Tighten to torque the cylinder head suspended mounting bolts ( 21 Nm )

19659

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) .

11A-114

TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting


K9K, and 732

11A

112990

113927

Refit the upper timing cover (36)

Refit the right-hand suspended mounting support (see 19D, Engine mounting, Right-hand suspended 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 engine mounting: Removal - Refitting ). - the exhaust ball joint bracket mounting bolts Tighten to torque the ball joint bracket mounting bolts with their springs ( 21 Nm ) Refit: - the accessories belt (see 11A, Top and front of engine, 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 ).

11A-115

TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting


M9R, and 700

11A

REMOVAL
Removing the timing chain requires the engine and gearbox assembly to be removed (see 10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ). To remove the timing chain (see Technical Note 6017A, M9R diesel engine ).

REFITTING
To refit the timing chain (see Technical Note 6017A, M9R diesel engine ). Refit the engine and gearbox assembly (see 10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ).

11A-116

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 Special tooling required Mot. 1672 Mot. 1453 Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Locking and adjusting camshaft pulleys Cylinder head support Cylinder head gning tool aliplugs coil mounting bolts (if the holes are already threaded) coil mounting bolts (if the holes are not threaded) inlet manifold mounting bolts battery cover bolts Mot. 1573 Mot. 104 Ele. 1382

11A
25 to 30 Nm 12 Nm

Tightening torquesm

15 Nm

Mot. 1453-01

9 Nm

Mot. 1490-01

4 Nm

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the engine covers,

Spark plug spanner toolkit 16 & 21 mm torque 1.75 & 28 Nm + square adapter 9-9.52 for spanner Ele. 1086 Camshaft oil seal tting tool Tool for tting the camshaft seal Tool for retting camshaft covers (57 mm diameter) Tool for retting camshaft covers (43 mm diameter) Equipment required

Mot. 1491 Mot. 1632 Mot. 1487

- the engine undertray, - the accessories belt (see 11A, Top and front of engine, 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 ).

Mot. 1488

cylinder head testing tool

Tightening torquesm rocker cover mounting bolts 22, 23, 20, 13 oil separator mounting bolts (new) in the nonthreaded housings (new or original) oil separa t o r mounting bolts in the pre-threaded housings 12 Nm 15 Nm

10 Nm

11A-117

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 Move the fuel supply pipe aside.

11A

1 3

105432

Set up the engine stand (1) (Mot. 1672) Remove the (Mot. 1453) and (Mot. 1453-01) .

2
18699

101876

Remove the camshaft pulleys using camshaft pulley locking tool (2) (Mot. 1490-01) . IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union. Loosen the stud with the nut if necessary (see Technical Note 3887A, Replacement of K9 - K4 camshaft pulley studs, 11A, Top and front of engine, Camshaft ). Remove: - the injection rail protector, - the fuel supply pipe from the injection rail.

2
14889

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 manifold. - the connector (4) from the coolant temperature sensor, - the water unit hoses,

11A-118

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 Move the bracket/wiring harness assembly aside.

11A

5 9 6 5 10

104240 18666

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 filter unit: Removal - Refitting ). - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting ).

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 sensor connector.

11A-119

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

12

15

11

18706

18431

Remove: - the lifting bracket (11) , - the inlet manifold mounting bolts (12) - the inlet manifold.

Remove: - the oil separator mounting bolts (15) , - the oil separator.

13

16 16 14

103256 101793

Remove: - the rocker cover mounting bolts, - detach the rocker cover vertically, tapping the lugs (16) with a copper hammer. WARNING Do not damage the aluminium surfaces.

Remove: - the catalytic converter/gearbox stay mounting bolts (13) , - the catalytic converter/gearbox stay - the exhaust pipe mounting nuts (14) . Detach the exhaust pipe.

11A-120

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

14498

Remove the inlet and exhaust camshafts.

11A-121

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

17

Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula.

WARNING

18

Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return pipes. Failure to follow this guideline could lead to blockage of the oilways, resulting in rapid and serious damage to the engine. II - CHECKING THE GASKET FACE Use a ruler and feeler gauge to check that there is no gasket face bow.
14499

Maximum bow: 0.05 mm WARNING No regrinding of the cylinder head is permitted. Test the cylinder head to detect any possible cracks using the cylinder head testing tool . For the cylinder head stripping procedure (see Technical Note 3784A, K4 4-cylinder petrol engine, 10A, Engine and peripherals, Rebuilding the cylinder head) . Position the pistons at mid-stroke to prevent any contact with the valves when refitting the camshafts. Be sure to degrease: - the cylinder head combustion face, - the cylinder block combustion face.

Remove: - the valve rockers (17) , - the hydraulic tappets (18) . Note: T prevent any risk of unpriming the hydraulic o tappets make sure that they are vertical. Remove: - the cylinder head mounting bolts, - the cylinder head. Mount the cylinder head on the cylinder head mounting (Mot. 1573) . Remove the cylinder head gasket from the cylinder block. I - CLEANING THE CYLINDER HEAD

IMPORTANT Do not scratch the aluminium gasket faces. During the operation, wear: - goggles, - gloves. Clean the gasket faces with DCAPJOINT to dissolve any parts of the seal still attached to the lower cover and the cylinder block.

11A-122

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

20

19 21

14689

14499

Check that the centring dowel is present (19) on the cylinder block. Fit the (Mot. 104) (20) onto the cylinder block.

Reprime the hydraulic tappets (hydraulic tappets may empty after a long down time). To check if repriming is necessary, press the top of the tappet (21) with your thumb. If the tappet piston depresses: - immerse the tappets in a container full of diesel fuel, - refit the hydraulic tappets. Refit: - the valve rockers, - the camshafts, oiling the bearings.

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 front of engine, Tightening the cylinder head ).

11A-123

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 I - CAMSHAFT MARKINGS Inlet camshaft

11A

101880

Position the groove (22) on the end of the camshaft horizontally (groove below the centre line of the camshaft). The cams (23) for cylinder 1 must be located to the right of the vertical axis (24) , flywheel end view.

11A-124

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 Exhaust camshaft

11A

101881

Position groove (25) horizontally on the end of the camshaft (groove below the centre line of the camshaft). The cams (26) for cylinder 1 must be located to the left of the vertical axis (27) , flywheel end view.

11A-125

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

28

15106-1

14517

Position the camshaft grooves horizontally and offset downwards. WARNING The sealing faces must be clean, dry and free of grease.

Using a stipple roller, apply LOCTITE 518 to the camshaft rocker cover gasket face until it turns reddish. Using a cloth, remove the LOCTITE 518 from (28) the six camshaft rocker cover bearings. Refit the rocker cover.

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator).

WARNING Do not apply oil to the rocker cover gasket faces.

11A-126

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 II - TIGHTENING PROCEDURE

11A

14497

Tighten to torque and in order: - rocker cover mounting bolts 22, 23, 20, 13 , 8 Nm , - 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 mounting bolts 22, 23, 20, 13 ( 12 Nm ) .

11A-127

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A
3

2 6

4 5 7
101869 18431

Refit the oil separator. WARNING the gasket faces must be clean, dry and free of grease. Torque tighten in order - the oil separator mounting bolts (new) in the non-threaded housings ( 15 Nm ) - the (new or original) oil separator mounting bolts in the pre-threaded housings ( 10 Nm )

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator). Using a stipple roller, apply LOCTITE 518 to the gasket face until it is reddish in colour.

11A-128

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

29

106443

On the four ignition coils, apply a bead (2 9) of FLUORINATED GREASE 82 00168 855 2 mm in diameter to the inner circumference of the high-tension cap. Refit the plugs. Tighten to torque the plugs ( 25 to 30 Nm ) using the plug spanner set (Ele. 1382) . Refit the coils. Tighten to torque: - the coil mounting bolts (if the holes are already threaded) ( 12 Nm ) , - the coil mounting bolts (if the holes are not threaded) ( 15 Nm ) , Always replace all the inlet manifold seals.

11A-129

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

14497-1

Tighten to torque and in order the inlet manifold mounting bolts ( 9 Nm ) . Refit: - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting ). - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting ). III - REPLACING THE CAMSHAFT SEALS There are two types of elastomer camshaft seal which are easy to identify.

30

31

20256

The first type of elastomer seal is fitted with a spring (30) with a lip seal (31) in the shape of a V

11A-130

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

1 - Fitting the first seal type to the inlet camshaft

34

32

33

35

20257

The second type of elastomer seal is fitted with a flat lip seal (32) and a protector (33) (which also assists in fitting the seal to the engine). Note: Both seal versions can be tted on the same engine. They are not interchangeable. It is essential to use the same version when replacing an old seal, except when one or more camshafts are replaced.

14892

Fit the seals using the (Mot. 1491) (34) and the old nuts (35) .

11A-131

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732 2 - Fitting the seal to the exhaust camshaft

11A
38

36

37

105531

18687

WARNING It is very important to hold the protector (3 6) when handling the seal, as this type of seal is very fragile. It is strictly forbidden to touch the elastomer seal (37) in order to prevent any oil leaks once the seal is tted to the engine.

38

21687

Screw the stud of (38) the (Mot. 1632) onto the camshaft.

11A-132

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

21687-1

21687-3

Fit the protector, with a seal, to the camshaft.

Screw in the collar nut until the cover comes into contact with the cylinder head. Remove the nut, cover, protector and threaded rod. IV - REFITTING Refit the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ). WARNING Follow the second procedure in the timing belt retting procedure.

39 40

21687-2

Fit cover (39) and the collar nut (40) of the (Mot. 1632) .

11A-133

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4J, and 730 or 732

11A

15103-1

Refit: - the accessories belt (see 11A, 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, Cooling circuit: Draining-refilling ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 16A, Cooling, Cooling circuit: Bleeding ). Tighten to torque the battery cover bolts ( 4 Nm ) .

11A-134

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Car. 1363 Mot. 1672 Mot. 1453 Trim removal lever Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required diagnostic tool cylinder head testing tool angular tightening wrench IMPORTANT Before any operation: - connect the diagnostic tool ,

11A

- 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 circuit plug kit.

Mot. 1453-01

Mot. 1202-01

WARNING Procedure for removing the air inlet duct (K9K 728 and 729): - make a mark on the inlet duct between the stainless steel pipe and the hose, - detach the hose, using the (Car. 1363) , - do not use a degreaser, brake cleaning product, or any other product, - clean the stainless steel pipe and the hose with a dry, lint-free cloth, - ret the clip in the same recess in the event that the hoses are not replaced, - rotate the clip around its axis to make torque tightening easier,

Mot. 1202-02 Mot. 1448

Tightening torquesm rocker cover mounting bolts turbocharger oil return pipe intercooler hose clip battery cover bolts 10 Nm 9 Nm 5.5 Nm 4 Nm

- it is essential to replace the hose and/or the stainless steel pipe in the event of damage. There is a risk of leaks or dislodging if this procedure is not followed.

11A-135

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729

11A
3

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, 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 ).
102081

K9K, and 722

5 2

Disconnect: - the air temperature and pressure sensor connector (1) , - the exhaust gas recirculation valve control connector (2) , - the air hoses (3) , - the air hose (4) , - the turbocharging pressure regulation valve rubber pipe, - the air sleeve from the air filter unit,
105432

Fit the engine stand (Mot. 1672) . Remove the (Mot. 1453) and (Mot. 1453-01) .

- the oil vapour rebreathing pipe from the rocker cover. Remove the air resonator unit mounting stay (5) .

11A-136

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729

11A

K9K, and 728 or 729

6 9

110325

Pull out the clip.


110326

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 pressure control valve.

11

12 10

110322

Make a mark on the inlet duct between the stainless steel pipe and the hose (10) . Undo the bolt (11) . Remove the air duct (12) .

11A-137

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729

11A

18 13

17 16

14

15

102086

102263

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 vacuum pump side, - the coolant temperature sensor connector on the water unit. - the radiator top hose from the cylinder head water outlet 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 ).

11A-138

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729

11A

21 19

104175

19711

Disconnect the turbocharger oil return pipe (19) .

Remove: - the rocker cover mounting bolts (21) , - the rocker cover.

22

20 22

19712

Remove:
19710

- the cylinder head mounting bolts (22) , - the cylinder head.

Remove the inner timing cover (20) .

11A-139

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729 I - CLEANING Clean the cylinder head. IMPORTANT Do not scratch the aluminium gasket faces. During the operation, wear: - goggles, - gloves. Clean the gasket faces with DCAPJOINT to dissolve the section of the gasket which is still attached. Apply the product to the section to be cleaned; wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING Please make sure, during this operation, that no foreign bodies enter the oilways (galleries in both the cylinder block and the cylinder head). WARNING

11A

Bring the pistons to mid-stroke position to prevent any risk of contact with the valves when tightening the cylinder head. WARNING The sealing surfaces must be clean, dry and free from grease (avoid nger marks). Refit the cylinder head. Tighten the cylinder head (see 11A, Top and front of engine, Tightening the cylinder head ) using the angular tightening wrench . WARNING The sealing surfaces must be clean, dry and free from grease (avoid nger marks).

Applying excess sealant could cause it to be squeezed out when parts are tightened. The product-uid mix may damage some components (engine, radiator).

WARNING Protect the oilway to prevent any foreign bodies from entering the cylinder head oil supply galleries. Failure to follow this advice could lead to the pipe blocking, quickly damaging the camshaft.

23

23
II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a feeler gauge. The maximum bow is 0.05 mm . WARNING No regrinding of the cylinder head is permitted. Test the cylinder head to detect any possible cracks using the cylinder head testing tool . For the cylinder head stripping procedure (see Technical Note 6006A, 4 cast iron cylinder High Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder head ). Fit the new rocker cover gasket. Apply beads (23) of SILICONE ADHESIVE SEAL 2 mm in diameter.

23

19712-1

REFITTING
Proceed in the reverse order to removal. Fit the new cylinder head gasket, centred by two dowels.

11A-140

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 722 or 728 or 729

11A

Tighten to torque the intercooler hose clip ( 5.5 Nm ) .

5 6 2

1 3

Refit: - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).

7 4 8

- the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). Fill the cooling circuit (see 19D, Cooling, Cooling circuit: Draining-refilling ). Reprime the diesel circuit (see 13B, Fuel supply, Diesel fuel supply circuit ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).
19711

Tighten to torque the battery cover bolts ( 4 Nm ) .

Refit the rocker cover. Tighten to torque and in order the rocker cover mounting bolts ( 10 Nm ) . Reconnect the turbocharger oil return pipe, fitted with new seals. Tighten to torque the turbocharger oil return pipe ( 9 Nm ) .

19709

Reconnect: - the oil vapour rebreather pipe, - the new turbocharger air sleeves. K9K, and 728 or 729 Reconnect the air duct by aligning the marks.

11A-141

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 800 or 808 Special tooling required Mot. 1672 Mot. 1453 Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required diagnostic tool cylinder head testing tool angular tightening wrench WARNING Fit plugs in the openings.

11A

Be sure to follow the safety instructions. Refer to (see 13B, Diesel injection, Cleanliness guidelines ).

Mot. 1453-01

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, Accessories belt: Removal - Refitting ). - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).

Mot. 1202-01

Mot. 1202-02 Mot. 1448

Tightening torquesm oil supply pipe bolt on the turbocharger oil supply pipe bolt on the cylinder block oil return pipe bolts battery cover bolts 22.5 Nm 22.5 Nm 12 Nm 4 Nm

- the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ). Drain the engine cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ).

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 circuit plug kit.
105432

Fit the engine stand (Mot. 1672) . Remove the (Mot. 1453) and (Mot. 1453-01) .

11A-142

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 800 or 808

11A
9 8

3 4 2
18983

Remove the vacuum tank mounting bolts (7) . Disconnect: - the turbocharger pressure regulation solenoid valve pipes, - the engine damping device solenoid valve connector (8) , - the camshaft sensor connector (9) . Remove the vacuum tank.

105511

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) .

11A-143

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 800 or 808

11A

10 11 11 12 13 12 16 14 15 17 18

105512

104323

Disconnect: - the exhaust gas recirculation solenoid valve connector (10) , - the injector connectors (11) , - the heater plug connectors (12) , - the rail pressure sensor connector (13) , - the high-pressure pump pressure regulator connector (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 temperature sensor.

19

102348

Remove the three high-pressure pump support mounting bolts (19) .

11A-144

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 800 or 808

11A

21

23 22

20
18997 16189

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 turbocharger.

Remove the cylinder head mounting bolts (23) . WARNING When removing the cylinder head, take care not to cause any damage to its gasket face as it passes the turbocharger above it. Remove the cylinder head. This operation requires two people. I - CLEANING Clean the cylinder head. IMPORTANT Do not scratch the aluminium gasket faces. During the operation, wear: - goggles, - gloves. Clean the gasket faces with DCAPJOINT to dissolve the section of the gasket which is still attached.

11A-145

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 800 or 808 Apply the product to the section to be cleaned; wait approximately ten minutes, then remove the residue using a wooden spatula. WARNING T prevent any foreign bodies from entering the o oil pipes (pipes in both the cylinder block and cylinder head). Tighten to torque:

11A

- 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, Catalytic converter: Removal - Refitting ).

WARNING Protect the oilway to prevent any foreign bodies from entering the cylinder head oil supply galleries. Failure to follow this advice could block the oil supply pipes, causing rapid camshaft damage.

- the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ). - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). Fill the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ). Reprime the diesel circuit (see 13A, Fuel supply, Diesel fuel supply circuit ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).

WARNING The cylinder head bolts must be replaced each time they are removed and must not be oiled before being tted.

II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a feeler gauge. The maximum bow is 0.05 mm .

Tighten to torque the battery cover bolts ( 4 Nm ) .

WARNING No regrinding of the cylinder head is permitted. Test the cylinder head to detect any possible cracks using the cylinder head testing tool . For the cylinder head stripping procedure (see Technical Note 3652A, 4-cylinder Cast Iron High Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder head ).

REFITTING
Bring the pistons to mid-stroke position to prevent any risk of contact with the valves when tightening the cylinder head. Fit the cylinder head gasket. Refit the cylinder head. Tighten the cylinder head (see 11A, Top and front of engine, Tightening the cylinder head ) using a angular tightening wrench .

11A-146

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771 Special tooling required Mot. 1672 Mot. 1509 Lower engine support Camshaft locking tool sprocket plugs coils (if holes already threaded) coils (if holes not threaded) inlet manifold battery cover mounting bolts

11A
25 to 30 Nm 12 Nm

Tightening torquesm

Mot. 1509-01 Mot. 1202-01

Conversion kit for Mot. 1509 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Cylinder head support Camshaft seal tting tool Camshaft oil seal tting tool (28 x 47) Tool for retting camshaft covers (57 mm diameter) Tool for retting camshaft covers (43 mm diameter) Equipment required

15 Nm 9 Nm 4 Nm

Mot. 1202-02 Mot. 1448

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the engine covers,

Mot. 1573 Mot. 1517 Mot. 1512 Mot. 1487

- 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 of engine, 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 ).

Mot. 1488

cylinder head testing tool angular tightening wrench

Tightening torquesm rocker cover bolts 22, 23, 20, 13 rocker cover bolts 1 to 12, 14 to 19, 21 to 24 new or original oil separator mounting bolts (in threaded holes) new oil separator mounting bolts (in nonthreaded holes) (8 Nm) (12 Nm) 10 Nm

15 Nm
105432

Fit the engine stand (Mot. 1672) .

11A-147

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

3 2

16019-4

16019-4

Fit the (Mot. 1509) with the gear (Mot. 1509-01) . Tighten the collar nut (1) and the bolt (2) , then bring the gears of (Mot. 1509) into contact with the camshaft pulleys while torque tightening the nuts (80 Nm) (3) . Remove the inlet camshaft dephaser blanking cover using a 14 mm Allen key.

Remove: - the exhaust camshaft pulley nut, - the inlet camshaft dephaser mounting bolt, Loosen the nut stud if necessary (see Technical Note 3887A, Replacement of F4 camshaft pulley studs, 11A, Top and front of engine, Camshaft ).

4
18699

Remove the bracket mounting bolts (4) . Move the bracket to one side.

11A-148

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A
8 9

5 8

12 6
14889

11 10

18666

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,
102735

- the dephaser solenoid valve.

Remove the wiring harness bracket mounting bolts (5) . Disconnect: - the connector (6) from the coolant temperature sensor, - 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 manifold side. Move the bracket/wiring harness assembly aside.

11A-149

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A
18

17 13 14

102939

102940

Remove: - the lifting bracket (13) at the timing end, - the inlet manifold mounting bolts (14) , - the inlet manifold.

Remove: - the oil separator mounting bolts. - the oil separator (17) , - the lifting bracket at the flywheel end (18) .

15

16

101793

Remove: - the catalytic converter/gearbox stay mounting bolts (15) , - the catalytic converter/gearbox stay, - the exhaust pipe mounting nuts (16) .

11A-150

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

19

19

102941

Remove the rocker cover bolts. Remove the rocker cover vertically, tapping the lugs (19) with a copper hammer. WARNING Do not damage the aluminium surfaces. Remove the camshaft seals.

11A-151

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

20

15151

Remove the inlet and exhaust camshafts (20)

11A-152

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

21

22

14499

Remove: - the valve rockers (21) , - the hydraulic tappets (22) . Note: T prevent any risk of unpriming the hydraulic o tappets make sure that they are vertical.

11A-153

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

15153

Remove: - the cylinder head bolts, - the cylinder head. Mount the cylinder head on the cylinder head mounting (Mot. 1573) . Remove the cylinder head gasket from the cylinder block I - CLEANING WARNING To prevent any foreign bodies from entering the oil pipes (pipes in the cylinder block and cylinder head).

II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a feeler gauge. Maximum bow: 0.05 mm

IMPORTANT Do not scratch the aluminium gasket faces. During the operation, wear: - goggles, - gloves. Clean the gasket faces with DCAPJOINT to dissolve any sections where the seal is still attached. Apply the product to the section to be cleaned; Wait for approximately ten minutes, then remove it using a wooden spatula. WARNING No regrinding of the cylinder head is permitted. Test the cylinder head to detect any cracks using the cylinder head testing tool (see Technical Note 3783A, F4 4-cylinder petrol engine, 10A, Engine and peripherals, Rebuilding the cylinder head) for the cylinder head stripping procedure. Position the pistons at mid-stroke to prevent any contact with the valves when the camshafts are being refitted.

11A-154

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771 Be sure to degrease: - The combustion face of the cylinder head, - the combustion face of the cylinder block.

11A

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 front of engine, Tightening the cylinder head ) using a angular tightening wrench .

24 23

25
15152

The camshafts are identified by the pulley mountings. Detailed view of the pulley mountings: - (24) : exhaust camshaft, - (25) : inlet camshaft.

14499

Re-prime the hydraulic tappets (hydraulic tappets may empty if they have been removed for some time). To check or reprime them, press the top of the tappet at (23) with your thumb. If the tappet piston depresses: - immerse the tappets in a container full of diesel fuel, - refit the hydraulic tappets. Refit: - the valve rockers, - the camshafts, oiling the bearings.

11A-155

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

26

15106-1

14517

Position the camshaft grooves as shown in the diagram. WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

Using a stipple roller, apply LOCTITE 518 to the camshaft rocker cover gasket face until it is reddish in colour. Note: Using a cloth, remove the LOCTITE 518 from (26) the camshaft rocker cover bearings. Refit the rocker cover.

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator, etc.).

WARNING Do not apply oil to the sealing face of the camshaft bearing cap cover.

11A-156

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

14497

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) .

11A-157

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

102738

102729

Refit the oil separator. WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks). 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 nonthreaded holes) ( 15 Nm ) .

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator, etc.). Using a stipple roller, apply LOCTITE 518 to the joint face of the oil separator until it is reddish in colour.

11A-158

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

27

106443

On the four ignition coils, apply a bead (2 7) of FLUORINATED GREASE 82 00 169 855 2 mm in diameter to the lower circumference of the high-tension cap.

11A-159

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 770 or 771

11A

102939

15103-1

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 ( 9 Nm ) . Refit the camshaft offset timer solenoid valve, with a new 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 procedure (see 11A, Top and front of engine, Timing belt: Removal - Refitting ). - the accessories belt (see 11A, Top and front of engine, 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 (see 19D, Engine mounting, Suspended engine mounting ). Proceed in the reverse order to removal. Fill the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

11A-160

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761 Special tooling required Mot. 1672 Mot. 1453 Lower engine support Multiple-adjusting engine mounting support with retaining straps Fitting cam follower tappet Additional winder nut on engine lift support Mot. 1453 Locking and adjusting camshaft pulleys Cylinder head support Cylinder head gning tool ali-

11A
10 Nm 25 to 30 Nm 12 Nm 15 Nm 10 Nm

Tightening torquesm camshaft dephaser solenoid valve bolt plugs coil mounting bolts (if holes already threaded) coil mounting bolts (if holes not threaded) camshaft position sensor mounting bolt inlet manifold mounting bolts battery cover bolts

Mot. 1669 Mot. 1453-01

Mot. 1490-01 Mot. 1573 Mot. 104 Mot. 1513

9 Nm 4 Nm

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, 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 ).

Tool for retting camshaft dephaser solenoid valve lip seal Spark plug spanner toolkit 16 & 21 mm torque 1.75 & 28 Nm + square adapter 9-9.52 for spanner Ele. 1086 Tool for tting the camshaft seal Tool for retting camshaft covers (57 mm diameter) Tool for retting camshaft covers (43 mm diameter) Equipment required

Ele. 1382

Mot. 1632 Mot. 1487

Mot. 1488

cylinder head testing tool

Tightening torquesm rocker cover mounting bolts 22, 23, 20, 13 oil separator mounting bolts 12 Nm 15 Nm

11A-161

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

1 2

105432

Set up the engine stand (1) (Mot. 1672) . Remove the (Mot. 1453) and (Mot. 1669) .

1
14889

102735

Remove the wiring harness support mounting bolt (1) . Disconnect: - the connector (2) from the coolant temperature sensor, - 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 manifold side. Move the bracket/wiring harness assembly aside.

11A-162

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

- the catalytic converter upstream oxygen sensor connector.

4 5 10 4 11

7 8

18666

Disconnect:
104240

- 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 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.

101809

Disconnect: - the camshaft position sensor connector (9) ,

11A-163

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

12 14

13

15

103272

101793

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. 149001) .

11A-164

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

16 18 17 18

103255

103256

Remove: WARNING Do not remove the bolt (16) as it acts as a stop for the squared cam tappet. Remove: - the oil separator mounting bolts (17) , - the oil separator. WARNING Do not damage the aluminium surfaces. - the rocker cover mounting bolts, - detach the rocker cover vertically, tapping the lugs (18) with a copper hammer.

103258

Remove the inlet and exhaust camshafts.

11A-165

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

19

Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula.

WARNING

20

Do not allow this product to drip onto the paintwork. Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return pipes. Failure to follow this guideline could lead to blockage of the oilways, resulting in rapid and serious damage to the engine. II - CHECKING THE GASKET FACE Use a ruler and feeler gauge to check that there is no gasket face bow.
14499

Maximum bow: 0.05 mm WARNING No regrinding of the cylinder head is permitted. Test the cylinder head to detect any possible cracks using the cylinder head testing tool . For the cylinder head stripping procedure (see Technical Note 3784A, K4 4-cylinder petrol engine, 10A, Engine and peripherals, Rebuilding the cylinder head) . Position the pistons at mid-stroke to prevent any contact with the valves when refitting the camshafts. Be sure to degrease: - the cylinder head combustion face, - the cylinder block combustion face.

Remove: - the valve rockers (19) , - the hydraulic tappets (20) . Note: T prevent any risk of unpriming the hydraulic o tappets make sure that they are vertical. Remove: - the cylinder head mounting bolts, - the cylinder head. Mount the cylinder head on the cylinder head mounting (Mot. 1573) . Remove the cylinder head gasket from the cylinder block. I - CLEANING THE CYLINDER HEAD

IMPORTANT Do not scratch the aluminium gasket faces. During the operation, wear: - goggles, - gloves. Clean the gasket faces with DECAPJOINT to dissolve any parts of the seal still attached to the lower cover and the cylinder block.

11A-166

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

22

21

23

14689

14499

Check that the centring dowel is present (21) on the cylinder block. Fit the (Mot. 104) (22) on the cylinder block.

Reprime the hydraulic tappets (hydraulic tappets may empty after a long down time). To check if repriming is necessary, press the top of the tappet (23) with your thumb. If the tappet piston depresses: - immerse the tappets in a container full of diesel fuel, - refit the hydraulic tappets. Refit: - the valve rockers, - the camshafts, oiling the bearings.

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 front of engine, Tightening the cylinder head ).

11A-167

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761 I - CAMSHAFT MARKINGS Inlet camshaft

11A
26 27

24

28

29

103685

102507

Position the pin (26) of the (Mot. 1669) against the bottom of the groove by loosening bolt (27) . Mount the (Mot. 1669) on the rocker cover, correctly positioning the pin (28) in the rocker cover hole (29) .

(24)

The inlet camshaft is tted with the camshaft sensor target.

Exhaust camshaft

25 30

103684

102506

Fit the rocker cover tool (Mot. 1669) using the bolts (30) .

(25)

The exhaust camshaft is tted with the square cam.

11A-168

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

32

35

31

34

103687

103686

Tighten the bolt (31) until the pin (32) is hard up against the bottom of the groove.

Turn the bolt (34) until the pin (35) is hard up against the bottom of the groove. Remove the (Mot. 1669) from the rocker cover.

33

103688

Position the bolt of the (Mot. 1669) in place of the original bolt at (33) to hold the tappet in the compressed position.

11A-169

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

36

15106-1

14517

Position the camshaft grooves horizontally and offset downwards. WARNING The sealing faces must be clean, dry and free of grease. (do not leave any nger marks).

Using a stipple roller, apply LOCTITE 518 to the camshaft rocker cover gasket face until it turns reddish. Using a cloth, remove the LOCTITE 518 from (36) on the six camshaft rocker cover bearings. Refit the camshaft rocker cover.

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator).

11A-170

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761 II - TIGHTENING PROCEDURE

11A

14497

Tighten to torque and in order: - rocker cover mounting bolts 22, 23, 20, 13 (8 Nm) , - 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 mounting bolts 22, 23, 20, 13 ( 12 Nm ) .

11A-171

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A
1 9 4 5

10 8

7 3 6
Refit the oil separator. Tighten to torque and in order the oil separator mounting bolts ( 15 Nm ) .
102073

2
101820

Remove the bolt (10) of the (Mot. 1669) to release the tappet. Refit the original bolt, applying a drop of LOCTITE FRENETANCH .

WARNING the sealing surfaces must be clean, dry and free from grease (avoid nger marks).

WARNING Excess sealant could be squeezed out when the parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator). Using a stipple roller, apply LOCTITE 518 to the gasket face until it is reddish in colour.

37

16016

Refit: - the camshaft dephaser solenoid valve seal using the (Mot. 1513) (37) , - the camshaft dephaser solenoid valve. Tighten to torque the camshaft dephaser solenoid valve bolt ( 10 Nm ) .

11A-172

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

38

106443

On the four ignition coils, apply a bead (3 8) of FLUORINATED GREASE 82 00168 855 2 mm in diameter to the inner circumference of the high-tension cap.

11A-173

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A
8

4 3 1 2 5 39 7

6
103257 103272

Refit the plugs. Tighten to torque the plugs ( 25 to 30 Nm ) using the plug spanner set (Ele. 1382) . Refit the coils. Tighten to torque - the coil mounting bolts (if holes already threaded) ( 12 Nm ) , - the coil mounting bolts (if holes not threaded) ( 15 Nm ) . Refit the cylinder reference sensor (39) with a new seal. Tighten to torque the camshaft position sensor mounting bolt ( 10 Nm ) . Always replace all the inlet manifold seals.

Tighten to torque and in order the inlet manifold mounting bolts ( 9 Nm ) . III - REPLACING THE CAMSHAFT SEALS

41 40

20257

The elastomer seal on these engines is fitted with a flat lip seal (40) and a protector (41) (also assists in fitting the seal to the engine).

11A-174

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761 1 - Fitting the seal to the exhaust camshaft

11A
44

42

43

105531

18687

WARNING It is very important to hold the protector (4 2) when handling the seal, as this type of seal is very fragile. It is strictly forbidden to touch the elastomer seal (43) in order to prevent any oil leaks once the seal is tted to the engine.

44

21687

Screw the stud (44) of the (Mot. 1632) onto the camshaft.

11A-175

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

21687-1

21687-3

Fit the protector, with a seal, to the camshaft.

Screw in the collar nut until the cover comes into contact with the cylinder head. Remove the nut, cover, protector and threaded rod. 2 - Fitting the inlet camshaft seal

45 46

WARNING It is very important to hold the protector when handling the seal, as this type of seal is very fragile. In order to prevent any oil leaks once the seal is tted to the engine, it is strictly forbidden to touch the elastomer seal.

21687-2

Fit the cover (45) and the collar nut (46) of the (Mot. 1632) .

11A-176

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

47

48

105531

105532

Fit the protector (47) , with a seal, to the camshaft. Push the centre of the protector to force the seal into its housing.

48

105534

Screw the stud (48) of the (Mot. 1632) onto the camshaft.

105533

Remove the seal protector, taking care not to drop the seal.

11A-177

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K4M, and 760 or 761

11A

49

50

105535

15103-1

Fit the cover (49) and the collar nut (50) of the (Mot. 1632) . Screw in the collar nut until the cover comes into contact with the cylinder head. Remove the nut, cover, protector and threaded rod. IV - REFITTING Refit the timing belt (see 11A, Top and front of engine, Timing belt: Removal and Refitting ) WARNING Follow the second procedure in the timing belt retting procedure.

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, Cooling circuit: Draining - refilling ). Connect the battery (see 80A, Battery, Battery: Removal - refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ). Tighten to torque the battery cover bolts ( 4 Nm ) .

11A-178

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F4R, and 776

11A

WARNING Removing and retting the turbocharger requires careful application of the repair procedures to ensure the system is properly sealed. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY HAVE SERIOUS SAFETY-RELATED CONSEQUENCES FOR THE DRIVER. Removing the cylinder head gasket requires the engine and transmission assembly to be removed (see 10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ). To remove the cylinder head gasket (see Technical Note 3784A, F4 4-Cylinder Petrol Engine, 10A, Engine and peripherals, Cylinder head: Stripping - Refitting .

11A-179

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Equipment required cylinder head testing equipment angular tightening wrench

11A

Disconnect the battery, starting with the negative terminal. Drain the cooling circuit through the cooling radiator using (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) . WARNING Plug the orices. Make sure that you follow all the safety instructions. Refer to 13B, Diesel injection, Cleanliness instructions). Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle Panel Grille ). Remove:

Mot. 1202-02 Mot. 1448

Mot. 1672 Mot. 1453

Mot. 1453-01

- 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,

Tightening torquesm battery cover mounting bolts. 4 Nm .

- the lower engine tie-bar. Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ). Remove: - the timing belt (see 11A, Top and front of engine: Timing belt ). - the accessories belt (see 11A, Top and front of engine, Accessories belt ) ,

REMOVING - REFITTING
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 circuit plug kit. Position the vehicle on a two-post lift. Remove: - the engine covers, - the engine undertray.

11A-180

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

105432

Fit the engine support with (Mot. 1672) . Remove (Mot. 1453) and (Mot. 1453-01) .

111887

111888

Disconnect: - the oil vapour rebreathing pipe (4) - the air inlet duct (see 12A, Fuel mixture, Air intake: Removal - Refitting ) (5) . - the turbocharging pressure connector (7) , - the throttle valve connector (8) , - the turbocharging pressure solenoid valve connector (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 injection, Injector rail protector ).

11A-181

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

111889

Disconnect: - the diesel return temperature sensor connector, - the high-pressure pump pressure regulator connector, - 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 cylinder head outlet.

111886

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) .

111965

Disconnect: - the camshaft sensor connector (19) , - the injector connectors (20) , Insert the blanking plugs. Move the wiring harness to one side.

11A-182

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

111861

102348

Remove: - the high-pressure pump rear mounting bolts (23) , - the windscreen wiper mounting, - the bonnet, - the cylinder head mounting bolts.

WARNING When removing the cylinder head, take care not to cause any damage to its gasket face as it passes the turbocharger above it. Remove the cylinder head.
111863

Remove exhaust gas recirculation pipe mounting bolts (24) . Remove the exhaust gas recirculation pipe mounting clip. Remove the cylinder head mounting bolts. Remove the cylinder head.

11A-183

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804 I - CLEANING Clean the cylinder head. IMPORTANT Do not scratch the aluminium gasket faces. Wear protective goggles. Wear gloves during the operation. Clean the gasket faces with DECAPJOINT cleaning product to dissolve the part of the gasket which is stuck to the sump and cylinder cover. Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula.

11A

Refit the cylinder head with a new cylinder head gasket. Refit new cylinder head bolts. Tighten the cylinder head (see 11A, Top and front of engine, tightening the cylinder head) using a angular tightening wrench . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Refit the timing belt (see 11A, Top and front of engine, Timing belt ). Refit the accessories belt (see 11A, Top and front of 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 terminal. WARNING

WARNING T prevent any foreign bodies from entering the o oil pipes (pipes in both the cylinder block and cylinder head).

WARNING Protect the oilway to prevent any foreign bodies from entering the cylinder head oil supply pipes. Failure to follow this instruction could lead to the pipes becoming blocked, causing rapid camshaft damage.

carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts. ( 4 Nm . )

II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a set of shims. The maximum deformation is 0.05 mm . WARNING No regrinding is permitted. Test the cylinder head to detect any possible cracks using a cylinder head testing equipment . (see TN 3652A, 4-cylinder Cast Iron High Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder head) for the cylinder head stripping procedure.

REFITTING
Bring the pistons to mid-stroke position to prevent any risk of contact with the valves when tightening the cylinder head. Degrease the gasket faces.

11A-184

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804 Special tooling required Mot. 1672 Mot. 1453 Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Equipment required diagnostic tool cylinder head testing equipment angular tightening wrench WARNING Fit plugs in the openings.

11A

Drain the engine cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ).

Mot. 1453-01

Always respect the repair precautions (see 13B, Diesel injection, Diesel injection: Precautions during repair ). Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the engine covers, - the battery tray, - the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ). Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ).

Tightening torquesm battery cover mounting bolts 4 Nm

Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting) ,

REMOVING - REFITTING
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 circuit plug kit. Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the engine covers, - the engine undertray. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

- the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).

105432

Fit the engine support using the (Mot. 1672) . Remove the (Mot. 1453) and (Mot. 1453-01) .

11A-185

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

13

11

1 3

4 5

15 12 14

111887

111886

Disconnect:

10

- 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) .

9
111888

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 connector (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 injection, Injection rail protector ).

16

17

111965

Disconnect: - the camshaft sensor connector (16) , - the injector connectors (17) . Insert the blanking plugs. Move the electric wiring harness to one side.

11A-186

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

18

19

20
111889

Disconnect: - the diesel return temperature sensor connector, - the high-pressure pump pressure regulator connector, - 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, Turbocharger: Removal - Refitting ). - the water hoses. Disconnect the cylinder head outlet water unit hoses. Remove: - the high pressure pump rear mounting bolts (20) , - the windscreen wiper mounting, - the bonnet, - the cylinder head mounting bolts.

102348

WARNING When removing the cylinder head, take care not to cause any damage to its gasket face as it passes the turbocharger above it.

11A-187

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804 I - CLEANING Clean the cylinder head.

11A

IMPORTANT Do not scratch the aluminium sealing surfaces. During the operation, wear:

21

- goggles, - gloves. Clean the gasket faces with DECAPJOINT to dissolve any part of the gasket which is attached to the lower cover and cylinder block. Apply the product to the section to be cleaned; wait approximately 10 minutes, then remove residue using a wooden spatula.

111861

21

WARNING To prevent any foreign bodies from entering the oil pipes (pipes in both the cylinder block and cylinder head).

WARNING Protect the oilway to prevent any foreign bodies from entering the cylinder head oil supply galleries. Failure to follow this instruction could lead to the pipes becoming blocked, causing rapid camshaft damage.
111863

Remove the mounting bolts (21) from the exhaust gas recirculation pipe. Remove the mounting clip from the exhaust gas recirculation pipe. Remove the cylinder head mounting bolts. Remove the cylinder head.

II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a feeler gauge. The maximum bow is 0.05 mm .

WARNING No regrinding is permitted. Test the cylinder head to detect any possible cracks using a cylinder head testing equipment . For the cylinder head stripping procedure (see Technical Note 3652A, 4-cylinder Cast Iron High Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder head) .

11A-188

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


F9Q, and 804

11A

REFITTING
Bring the pistons to mid-stroke position to prevent any risk of contact with the valves when tightening the cylinder head. Degrease the gasket faces. Refit the cylinder head with a new cylinder head gasket. Refit new cylinder head bolts. Tighten the cylinder head (see 11A, Top and front of engine, Tightening the cylinder head) using a angular 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 engine, Timing belt: Removal - Refitting ). Refit the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). Fill the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ). Reprime the diesel circuit (see 13B, Fuel supply, Diesel fuel supply circuit ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

11A-189

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732 Special tooling required Car. 1363 Ele. 1552 Trim removal lever Tool for removing rear screen wiper arm Lower engine support Multiple-adjusting engine mounting support with retaining straps Additional winder nut on engine lift support Mot. 1453 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Equipment required diagnostic tool hydraulic crane load positioner cylinder head testing tool angular tightening wrench WARNING

11A

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) .

Mot. 1672 Mot. 1453

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system (see 13B, Diesel injection, Cleanliness guidelines).

Mot. 1453-01

Mot. 1202-01

Mot. 1202-02 Mot. 1448

WARNING Procedure for removing the air inlet duct (risk of leaking and dislodging if this procedure is not respected): - detach the hose using the (Car. 1363) , - do not use degreaser, brake cleaning agents, or any other products, - clean the bearing face on the intercooler with a dry, lint-free cloth, - always replace the clip with a new one,

Tightening torquesm rocker cover mounting bolts alternator mounting bolts hose clip on the stainless steel pipe turbocharger oil return pipe battery cover bolts 10 Nm 21 Nm

- place the clip in the same position if the hose is not replaced, - it is essential to replace the hose and/or the rigid pipe in the event of damage.

REMOVAL
5.5 Nm I - REMOVAL PREPARATION OPERATION 9 Nm 4 Nm Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine covers. Disconnect the battery (see 80A, Battery: Removal - Refitting ).

11A-190

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732 Remove the engine undertray.

11A

- the front bumper (see MR365, Bodywork, 55A, Exterior protection, Front bumper ). - the catalytic converter (see 19B, Exhaust, Catalytic converter ).

102101

104175

Remove the turbocharger oil return pipe (5) . Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ).

102100

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 of engine, Accessories belt ), - the timing belt (see 11A, Top and front of engine, Timing belt ), Remove: - the alternator upper mounting bolt (26) , - the alternator lower mounting bolt (27) ,
102267

11A-191

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732

11A

112815

19710

Remove: - the inner timing cover mounting bolts (6) , - the inner timing cover.

102473

Disconnect the air inlet pressure sensor connector (7) . Loosen the clips (8) and (9) .
19626

Fit the engine stand (Mot. 1672) . Remove the (Mot. 1453) fitted with the (Mot. 145301) .

Remove the air inlet duct (10) .

11A-192

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732

11A

112811

112992

Pull out the clip.

Unclip the injection rail protector cover (14) . Remove: - the injection rail protector cover, - the injection rail protector cover mounting bolt and mounting nut (15) , - the dipstick, - the dipstick guide tube mounting bolts (16) . Remove the dipstick guide tube.

112991

Make a mark (11) on the air inlet duct between the stainless steel pipe and the hose using an indelible pen. Detach the hose from the stainless steel pipe. Remove: - the mounting bolt (12) from the stainless steel pipe, - the stainless steel pipe (13) .
112993

Disconnect: - the heater plug connectors (17) ,

11A-193

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732 - the injector connectors (18) ,

11A

112656 112994

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 (see 13A, Diesel injection, Repair precautions ).

WARNING Do not blast compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use wipes if necessary.

Note: Make preparations for fuel outow. Clean with new wipes. Disconnect: - the fuel supply pipe (28) , - the fuel return pipe (29) . Fit plugs.

11A-194

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732

11A

112996

Disconnect the oil vapour rebreathing pipe on the rocker cover side (31) . Remove the air inlet duct (32) .
113475

Remove: - the retaining bracket mounting bolts from the exhaust gas recirculation cooler, - the bracket from the exhaust gas recirculation cooler.

112997

Disconnect: - the exhaust gas recirculation solenoid valve connector, - the scuttle panel hoses (33) using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) ,
111748

- the brake servo vacuum pipe (34) on the vacuum pump side, - the temperature sensor connector from the scuttle panel, - the radiator top hose from the cylinder head outlet water unit (35) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , - the turbocharging pressure regulation solenoid valve hose on the vacuum pump side, - the turbocharging pressure regulation solenoid valve hose on the pressure regulation valve side.

Remove the injection rail protector cover support mounting bolt and mounting nuts (30) . Unclip the drain pipe from the injection rail protector cover support. Remove: - the injection rail protector cover support, - the damper valve (see 12A, Damper valve: Removal - Refitting .

11A-195

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732

11A

REFITTING
I - CLEANING Clean the cylinder head.

IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation. Clean the gasket faces with DECAPJOINT to dissolve any parts of the seal still attached. Apply the product to the part to be cleaned. Wait approximately ten minutes, then remove the residue using a wooden spatula.
113476

Remove: - the rocker cover mounting bolts (36) , - the rocker cover. II - OPERATION FOR REMOVAL OF PART CONCERNED WARNING Protect the oil duct to prevent any foreign bodies from entering the cylinder head oil supply pipes. Failure to follow this procedure could lead to the oil supply pipes becoming blocked, quickly damaging the camshaft. WARNING Please make sure, during this operation, that no foreign bodies enter the oil pipes (pipes in both the cylinder block and the cylinder head).

II - CHECKING THE GASKET FACE Check for gasket face bow using a ruler and a feeler gauge.
19712

The maximum bow is 0.05 mm .

Remove: - the cylinder head mounting bolts (37) , - the cylinder head using a hydraulic crane fitted with a load positioner . WARNING No regrinding of the cylinder head is permitted. For the cylinder head stripping procedure see Technical Note 6006A, 4-cylinder cast iron High Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder head . . Test the cylinder head to detect any possible cracks using the cylinder head testing tool .

11A-196

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732 III - REFITTING OPERATION FOR PART CONCERNED

11A

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks). Bring the pistons to mid-stroke position to prevent any risk of contact with the valves when tightening the cylinder head. Fit the new cylinder head gasket, centred by two dowels. Refit the cylinder head using the hydraulic crane fitted with the load positioner . Tighten the cylinder head (see 11A, Top and front of engine, Tightening the cylinder head ) using angular tightening wrench .
113476

IV - FINAL OPERATION Fit the new rocker cover gasket.

Refit the rocker cover. Tighten to torque and in order the rocker cover mounting bolts ( 10 Nm ) . Connect: - the turbocharging pressure regulation solenoid valve hose on the pressure regulation valve side. - the turbocharging pressure regulation solenoid valve hose on the vacuum pump side, - the radiator top hose from the cylinder head water outlet unit using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) , - the temperature sensor connector to the scuttle panel, - the brake servo vacuum pipe on the vacuum pump side,
19712-1

- 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 outlet and the turbocharger inlet, - the oil vapour rebreathing pipe;

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and uid could damage certain components (engine, radiator, etc.) Apply beads (38) of SILICONE ADHESIVE SEAL 2 mm in diameter.

- the damper valve (see 12A, Damper valve: Removal - Refitting ). - the injection rail protector cover support, - the injection rail protector cover support mounting bolt and mounting nuts. Clip the drain pipe onto the injection rail protector cover support.

11A-197

TOP AND FRONT OF ENGINE Cylinder head gasket : Removal - Refitting


K9K, and 732 Refit: - the injection rail protector cover mounting bracket, - the injection rail protector cover retaining bracket mounting bolts, Remove the blanking plugs. Connect: - the fuel supply pipe, - the fuel return pipe. Torque tighten the alternator mounting bolts ( 21 Nm ) . 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 injection 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. Connect: - the air pressure sensor,

11A

- the exhaust gas recirculation solenoid valve connector. 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, Catalytic converter ), - the timing belt (see 11A, Top and front of engine, Timing belt ), - the accessories belt (see 11A, Top and front of engine, 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 ) .

Refit: - the clip to the stainless steel pipe, - the stainless steel pipe between the intercooler hose and the turbocharger, aligning the marks, - the pipe between the intercooler and the damper valve. Tighten to torque the hose clip on the stainless steel pipe ( 5.5 Nm ) Clip the stainless steel pipe to the turbocharger. Refit the air duct between the damper valve and the intercooler Tighten the clips.

11A-198

TOP AND FRONT OF ENGINE Tightening the cylinder head


K4J, and 730 or 732 K4M, and 760 or 761

11A

CYLINDER HEAD TIGHTENING PROCEDURE Tightening torquesm cylinder head mounting bolts cylinder head mounting bolts 20 Nm 240 6

14500

WARNING Reuse the bolts if the length under the head does not exceed 117.7 mm (otherwise replace all the bolts with new ones). In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes. Do not oil the new bolts. The bolts must be oiled if reused.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks). Tighten to torque and in order the cylinder head mounting bolts ( 20 Nm ) . Check that all of the cylinder head mounting bolts are tightened to the correct torque of 20 Nm . Angle-tighten in order the cylinder head mounting bolts ( 240 6 ) . WARNING Do not retighten the cylinder head bolts after applying this procedure.

11A-199

TOP AND FRONT OF ENGINE Tightening the cylinder head


K9K, and 722 or 728 or 729

11A

Tightening torquesm cylinder head mounting bolts cylinder head mounting bolts 25 Nm 255 10

CYLINDER HEAD TIGHTENING PROCEDURE

10
19712

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Always replace all of the cylinder head bolts with new ones after removal. In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil that may be in the cylinder head mounting holes. Do not oil the new bolts. Tighten to torque and in order the cylinder head mounting bolts ( 25 Nm ) . Check that all of the cylinder head mounting bolts are tightened to the correct torque (25 Nm) . Angle-tighten in order the cylinder head mounting bolts ( 255 10 ) . WARNING Do not retighten the cylinder head bolts after applying this procedure.

11A-200

TOP AND FRONT OF ENGINE Tightening the cylinder head


F9Q, and 800 or 804 or 808

11A

CYLINDER HEAD TIGHTENING PROCEDURE Tightening torquesm cylinder head mounting bolts cylinder head mounting bolts 30 Nm 230 +/- 6

10

16189

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Systematically replace all cylinder head bolts after removal. To ensure correct tightening, use a syringe to remove any oil that may be in the cylinder head mounting holes. Do not oil the new bolts. Tighten to torque and in order the cylinder head mounting bolts ( 30 Nm ) . Check that all of the cylinder head mounting bolts are tightened to the correct torque (30 Nm) . Angle-tighten in order the cylinder head mounting bolts ( 230 +/- 6 ) . WARNING Do not retighten the cylinder head bolts after applying this procedure.

11A-201

TOP AND FRONT OF ENGINE Tightening the cylinder head


F4R, and 770 or 771 or 776

11A

CYLINDER HEAD TIGHTENING PROCEDURE Tightening torquesm cylinder head mounting bolts cylinder head mounting bolts cylinder head mounting bolts 20 Nm 100 6 100 6

9 5 1 4 8 3 7 2 6 10

15153

WARNING Always replace all of the cylinder head bolts with new ones after removal. In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil that may be in the cylinder head mounting holes. Do not oil the new bolts.

Tighten to torque and in order the cylinder head mounting bolts ( 20 Nm ) . Check that all of the cylinder head bolts are tightened to the correct torque (20 Nm) . Step 1 Angle-tighten in order the cylinder head mounting bolts ( 100 6 )

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

11A-202

TOP AND FRONT OF ENGINE Tightening the cylinder head


F4R, and 770 or 771 or 776 Step 2 Angle-tighten in order the cylinder head mounting bolts ( 100 6 ) WARNING Do not retighten the cylinder head bolts after applying this procedure.

11A

11A-203

TOP AND FRONT OF ENGINE Tightening the cylinder head


K9K, and 732

11A

CYLINDER HEAD TIGHTENING PROCEDURE Equipment required low torque wrench angular tightening wrench

Tightening torquesm cylinder head mounting bolts cylinder head mounting bolts 25 Nm 255 10

19712

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Always replace all of the cylinder head bolts with new ones after removal. In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes. Do not oil the new bolts. Tighten to torque and in order the cylinder head mounting bolts ( 25 Nm ) with the low torque wrench . Check that all of the cylinder head mounting bolts are tightened to the correct torque (25 Nm) . Angle-tighten in order the cylinder head mounting bolts ( 255 10 ) using the angular tightening wrench . WARNING Do not retighten the cylinder head bolts after applying this procedure.

11A-204

TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting


M9R, and 700

11A

REMOVAL
Removing the cylinder head requires the engine and gearbox assembly to be removed (see 10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ). To remove the cylinder head (see Technical Note 6017A, M9R Diesel engine ).

REFITTING
To refit the cylinder head (see Technical Note 6017A, M9R Diesel engine ). Refit the engine and gearbox assembly (see 10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ).

11A-205

FUEL MIXTURE Specifications


F4R, and 770 or 771 or 776

12A

Equipment required diagnostic tool Engine Vehicle Gearbox Type Sufx Bore (mm) 770 9.8/1 DP0 XN0W ND0 F4R 771 776 82.7 93 1,998 9.5 0.3 Stroke (mm) Cubic capacity (cc) ND0 XM0U Compression ratio

Test carried out at idle speed(1) Engine Pollutant Type Sufx Idling speed (rpm) F4R 770 771 776 / / 750 50 0.5 maximum 14.5 maximum 100 maximum 0.97< <1.03 CO (%)(4) emissions(3) HC (ppm) Lambda ()

Fuel (2) (minimum octane rating) Super unleaded (Octane rating 95)

CO2 (%)

a coolant temperature above 80C and after the engine speed has stabilised at 2,500 rpm for approximately 30 seconds .
(2)octane

(1)for

(3)for (4)at

the legal values, see specifications by country

2,000 rpm CO should be a maximum of 0.3 %

rating 91 unleaded compatible - 10 10,454 to 8,623 13,588 t o 11, 332 25 2,174 to 1,928 2,364 to 2,140 50 857 to 763 850 to 772 80 326 to 292 290 to 275 110 143 127 117 to 111 120 112 to 98 90 to 86

Temperatures in C 1 Negative temperature coefcient air temperature sensor (resistance in ) Negative temperature coefcient coolant temperature sensor (resistance in )

12A-1

FUEL MIXTURE Specifications


F4R, and 770 or 771 or 776

12A

Description Injection computer

Brand-Type SAGEM 3000

Special notes 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 - lter assembly incorporating the pressure regulator Pressure: 3.5 0.06 bar Minimum ow: 80 to 120 l/h

Ignition coils

SAGEM

Four coils Primary resistance: tracks 1 and 2 approximately 0.5 Secondary resistance: track 1 and high voltage output: 10.5 +/- 1.5 k 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 0.5 Secondary resistance: track 1 and high voltage output: 6.70 +/- 0.7 k 2-track connector: - 1: + 12 V supply - 2: earth control

SIEMENS - DEKA 4

Bi-jet solenoid injector Resistance: 14.5 +/- 0.7 at 20C 2-track connector: - 1: + 12 V supply - 2: earth control

Injectors SIEMENS - DEKA 7 (F4R 776) only Bi-jet solenoid injector Resistance: 12 0.5 at 20C 2-track connector: - 1: + 12 V supply - 2: earth control

12A-2

FUEL MIXTURE Specifications


F4R, and 770 or 771 or 776 Description Brand-Type SIEMENS - MAP03 Special notes Piezoelectric type sensor

12A

Replace the seal each time it is removed. 3-track connector: - A: earth - B: signal - C: + 5 V supply Manifold pressure sensor 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 ywheel end Fault nding Accelerator pedal potentiometer diagnostic tool CTS CLIP only Dual gang potentiometer Resistance values: - circuit 1: tracks 3 and 5: 1,700 900 - gang 2: tracks 2 and 6: 2,850 2,050 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 position sensor SIEMENS Variable reluctance type sensor Resistance: 200 to 270 at 23C Tightening torque: 8 Nm

12A-3

FUEL MIXTURE Specifications


F4R, and 770 or 771 or 776 Description Upstream and downstream oxygen sensors Brand-Type BOSCH - LSF 4.2 Special notes

12A

The sensor heating is interrupted when the exhaust gas temperature rises above 850C . Heating resistor: 9 at 20C 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 solenoid valve

SAGEM

Resistance: 26 4 to 23C 2-track connector: - 1: + 12 V supply - 2: earth control

Air temperature sensor Coolant temperature sensor

JAEGER JAEGER ELTH or SILEA

Negative temperature coefcient thermistor (see previous table) Negative temperature coefcient thermistor (see previous table) 3-track connector: - A: earth - B: + 5 V supply - C: signal

Refrigerant sensor

TEXAS INSTRUMENTS

12A-4

FUEL MIXTURE Specifications


F4R, and 770 or 771 or 776 Description Brand-Type VDO EGAS 5 Diameter 60 mm (F4R 770 and 771) Special notes 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

12A

Engine resistance: approximately 2.3 at 23C Potentiometer resistance: tracks 2 and 6: 1000 250 Throttle valve VDO EGAS - T Diameter 40 mm (F4R 776) 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 to 23C Potentiometer resistance: tracks 1 and 5: 1,000 250 Camshaft dephaser solenoid valve AISIN (F4R 770 and 771) It is controlled by the opening cyclic ratio. Resistance: 7.2 0.5 to 20C 2-track connector: - 1: + 12 V supply - 2: earth CHAMPION RC 87 YCL (F4R 770 and 771 Spark plug NGK PFR6G - 9 (F4R 776) only Single electrode spark plugs Gap: 0.90 0.05 mm Torque: 25 to 30 Nm Single electrode spark plugs Gap: 0.900 --0.1mm Torque: 25 to 30 Nm Catalytic converter EBERSPCHER C175

12A-5

FUEL MIXTURE Specifications


K4J, and 730 or 732 K4M, and 760 or 761

12A

Equipment required diagnostic tool Engine Vehicle Gearbox Type Sufx Bore (mm) 730 XM0B JH3 JH3 XM0C DP0 K4M 761 K4J 732 10 / 1 760 79.5 80.5 1,598 79.5 70 1390 Stroke (mm) Cubic capacity (cc) Compression ratio

Test carried out at idle speed(1) Engine Pollutant emissions(3) Type Sufx Idling speed (rpm) K4J K4M
(1)for

Fuel (2) (minimum Lambda () octane rating)

CO (%)(4)

CO2 (%)

HC (ppm)

730 732 760 761

/ /

750 50 0.5 700 40 maximum 14.5 maximum 100 maximum 0.97<<1.03

Super unleaded (Octane rating 95)

a coolant temperature above 80C and after the engine speed has stabilised at 2,500 rpm for approximately 30 seconds .
(2)octane

(3)for (4)at

the legal values, see specifications by country

2,000 rpm CO should be a maximum of 0.3 %

rating 91 unleaded compatible - 10 10,454 to 8,623 13,588 t o 11, 332 25 2,174 to 1,928 2,364 to 2,140 50 857 to 763 850 to 772 80 326 to 292 290 to 275 110 143 127 117 to 111 120 112 to 98 90 to 86

Temperatures in C 1 Negative temperature coefcient air temperature sensor (resistance in ) Negative temperature coefcient coolant temperature sensor (resistance in )

12A-6

FUEL MIXTURE Specifications


K4J, and 730 or 732 K4M, and 760 or 761

12A

Description Injection computer

Brand -Type SAGEM 3000

Special notes 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 - lter assembly incorporating the pressure regulator Pressure: 3.5 0.06 bar Minimum ow: 80 to 120 l/h

Ignition coils

SAGEM

Four coils Primary resistance: tracks 1 and 2 approximately 0.5 Secondary resistance: track 1 and high voltage output: 10.5 +/- 1.5 k 2-track connector: - 1: + 12 V supply - 2: earth control

Injectors

SIEMENS - DEKA 4

Bi-jet solenoid injector Resistance: 14.5 +/- 0.7 at 20C 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 ywheel end

Fault nding

diagnostic tool

CLIP only

12A-7

FUEL MIXTURE Specifications


K4J, and 730 or 732 K4M, and 760 or 761 Description Accelerator pedal potentiometer Brand -Type CTS Special notes Dual gang potentiometer Resistance values:

12A

- gang 1: tracks 3 and 5: 1,700 900 - gang 2: tracks 2 and 6: 3,875 1,025 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 position sensor SIEMENS Variable reluctance type sensor Resistance: 200 to 270 at 23C Tightening torque: 8 Nm Upstream and downstream oxygen sensors BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaust gas temperature rises above 850C . Heating resistor: 9 at 20C 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 solenoid valve SAGEM Resistance: 26 4 to 23C 2-track connector: - 1: + 12 V supply - 2: earth control Air temperature sensor JAEGER Negative temperature coefcient thermistor (see previous table)

12A-8

FUEL MIXTURE Specifications


K4J, and 730 or 732 K4M, and 760 or 761 Description Coolant temperature sensor Brand -Type JAEGER ELTH or SILEA Refrigerant sensor TEXAS INSTRUMENTS Special notes

12A

Negative temperature coefcient thermistor (see previous table) 3-track connector: - A: earth - B: + 5 V supply - C: signal

K4J

Description Throttle valve

Brand-Type VDO EGAS T 60 mm diameter

Special notes 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 1.6 to 23C Potentiometer resistance; tracks 1 and 5: 1,000 250

K4M

Description Throttle valve

Brand-Type VDO EGAS 5 57 mm diameter

Special notes 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

12A-9

FUEL MIXTURE Specifications


K4J, and 730 or 732 K4M, and 760 or 761

12A
Special notes It is controlled by the opening cyclic ratio. Resistance: 7.2 0.5 to 20C 2-track connector: - 1: + 12 V supply - 2: earth

K4M

Description Camshaft dephaser solenoid valve

Brand-Type DELPHI

Camshaft position sensor

SAGEM

Hall effect sensor 3-track connector: - 1: earth - 2: signal - 3: + 12 V supply

Description Spark plug

Brand-Type EYQUEM RFN 58 LZ or CHAMPION RC 87 YCL

Special notes Single electrode spark plugs Gap: 0.95 0.05 mm Torque: 25 to 30 Nm

Catalytic converter

EBERSPCHER

C150

12A-10

FUEL MIXTURE Air inlet


K4J, and 730 or 732 Diagram of the air inlet circuit

12A

102071

(1) (2) (3) (4) (5) (6) (7) (8)

Air inlet sleeve Air resonator Air lter unit Air unit Throttle valve Inlet manifold Injector holder plate Air inlet

12A-11

FUEL MIXTURE Air inlet


K4M, and 760 or 761 Diagram of the air intake circuit

12A
4

6 2 3 7

2
101190

(1) (2) (3) (4) (5) (6) (7)

Air intake sleeve Air resonators Air lter unit Throttle valve Inlet manifold Injector holder shim Air inlet

12A-12

FUEL MIXTURE Air inlet


K9K, and 722 Diagram of the air intake circuit

12A
4 3 7

2 8 1

102070

(1) (2) (3) (4) (5) (6) (7) (8)

Air intake sleeve Air lter unit Exhaust gas recirculation unit Air resonator Metal air intake tube Intercooler Turbocharger Air inlet

12A-13

FUEL MIXTURE Air inlet


F9Q, and 800 Air intake circuit diagram

12A
1 7

102482

(1) (2) (3) (4) (5) (6) (7)

Air inlet Air lter Flowmeter Turbocharger Inlet manifold Engine shut-off ap Air-to-air intercooler

12A-14

FUEL MIXTURE Air inlet


F4R, and 770 or 771 Air intake circuit diagram

12A
4

6 3 2 7

2
102744

(1) (2) (3) (4) (5) (6) (7)

Air intake trunking Resonators Air lter unit Throttle body Intake manifold Injector mounting plate Air intake

12A-15

FUEL MIXTURE Air inlet


F4R, and 776

12A
3

4 6

2 5 1
107841

(1) (2) (3) (4) (5) (6)

Air intake Air resonator Air lter unit Turbocharger Intercooler Inlet manifold

12A-16

FUEL MIXTURE Air inlet


K9K, and 728 or 729

12A
3 7

4 5

8 2 1

6
110316

(1) (2) (3) (4) (5) (6) (7) (8)

Air inlet sleeve Air lter unit Exhaust gas recirculation unit Air resonator Metal air inlet tube Intercooler Turbocharger Air inlet

12A-17

FUEL MIXTURE Air inlet


F9Q, and 804 Diagram of the air inlet circuit

12A

112269

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Air inlet Air lter unit Flowmeter Turbocharger Inlet manifold Throttle valve Intercooler Air lter EGR unit

12A-18

FUEL MIXTURE Air inlet


K9K, and 732

12A
6

4 1

112302

(1) (2) (3) (4) (5) (6) (7) (8)

Air inlet Air lter unit Flowmeter Turbocharger Damper ap Air lter Intercooler Air resonator

12A-19

FUEL MIXTURE Air inlet


F9Q, and 808 Diagram of the air inlet circuit

12A

114617

(1) (2) (3) (4) (5) (6) (7)

Air inlet Air lter Flowmeter Turbocharger Inlet manifold Engine stop ap Intercooler

12A-20

FUEL MIXTURE Air inlet


M9R, and 700 Diagram of the air inlet circuit

12A

114472

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Air inlet scoop Noise-reducing air duct Air resonator Air lter unit Air lter Air owmeter Turbocharger Intercooler Damper ap EGR solenoid valve

12A-21

FUEL MIXTURE Air resonator: Removal - Refitting


M9R, and 700

12A

REMOVAL
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 ).

II - OPERATION FOR REMOVAL OF PART CONCERNED

114659 115726

Remove the air resonator (3) starting with the end piece 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 piece side of the duct that is upstream of the air filter. II - FINAL OPERATION Refit the left-hand headlight. Tighten:
115725

- 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: Removal - Refitting ).

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.

12A-22

FUEL MIXTURE Air filter: Replacement


K4J, and 730 or 732 REPLACING THE FILTER ELEMENT

12A

2 1

101104 101103

Remove: - the air resonator mounting bolt (1) , - the air resonator housing.

Disconnect brake servo vacuum pipe (2) from the inlet manifold. WARNING Do not damage the vacuum outlet on the inlet manifold. If it is broken the inlet manifold will need to be replaced. Remove: - the two air filter cover mounting bolts (3) , - the filter element.

12A-23

FUEL MIXTURE Air filter: Replacement

12A

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 or 732

Tightening torquesm battery cover mounting bolts 4 Nm

REPLACING THE FILTER ELEMENT

1
Remove: - the cover (2) , - the filter element. .

106276

106277

REFITTING
Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

Remove the mounting bolts (1) from the air filter cover.

12A-24

FUEL MIXTURE Air filter: Removal - Refitting


F4R or F9Q or K4M or K9K or M9R

12A

REMOVAL
I - REMOVAL PREPARATION OPERATION

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

Remove the mounting bolts (1) from the air filter cover. II - OPERATION FOR REMOVAL OF PART CONCERNED

106276

Remove: - the cover (2) , - the air filter.

12A-25

FUEL MIXTURE Air filter unit: Removal - Refitting


K4J, and 730 or 732 Special tooling required Ele. 1294-01 Windscreen wiper arm removing tool

12A

Tightening torquesm air lter unit mounting bolts battery cover mounting bolts 9 Nm 4 Nm

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.
102101

2 1

Unclip the trim (3) .

102100

Remove: - the seal (1) , - the plastic rivets (2) . Remove the scuttle panel grille.
102105

Remove wiper arms (4) using tool (Ele. 1294-01) .

12A-26

FUEL MIXTURE Air filter unit: Removal - Refitting


K4J, and 730 or 732

12A

5 5

101487

101104

Remove: - the bulkhead soundproofing mountings (5) , - the bulkhead soundproofing material.

Disconnect brake servo vacuum pipe (7) from the inlet manifold. WARNING Do not damage the vacuum outlet on the inlet manifold. If it is damaged, the inlet manifold will need to be replaced. Remove: - air filter cover mounting bolts (8) , - the filter element.

101103

Remove: - the air resonator mounting bolt (6) , - the air resonator.

12A-27

FUEL MIXTURE Air filter unit: Removal - Refitting


K4J, and 730 or 732

12A

REFITTING
Replace: - the throttle valve seal each time it is removed using grease to make fitting easier, - the plastic rivets and clips every time they are removed. Proceed in the reverse order to removal. Torque tighten the air filter unit mounting bolts ( 9 Nm ) . Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

10

101494

Disconnect the oxygen sensor connector. (9) Remove the retaining bracket (10) .

11

101488

Remove: - air filter mounting bolts (11) , - the air filter unit.

12A-28

FUEL MIXTURE Air filter unit: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1608 Torque screwdriver

12A

Tightening torquesm air owmeter mounting bolts air duct clip mounting bolt between the air lter unit and the turbocharger front end panel lower mounting bolts front end panel upper mounting bolts battery tray mounting bolts wiring harness mounting nut 4 Nm 5.5 Nm

44 Nm 21 Nm 21 Nm 8 Nm Remove: - the Protection and Switching Unit cover mounting bolts (1) , - the Protection and Switching Unit cover.
112658

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 ).

102504

Disconnect the connectors (2) . Unpick the bonnet opening cable (3) . Remove: - the clips (4) , - the front end panel upper mounting bolts (5) .

12A-29

FUEL MIXTURE Air filter unit: Removal - Refitting


M9R, and 700

12A

112659

104555

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 and the turbocharger.

114933

Unclip the air inlet scoop (11) .

12A-30

FUEL MIXTURE Air filter unit: Removal - Refitting


M9R, and 700

12A

II - OPERATION FOR REMOVAL OF PART CONCERNED

102365

Remove: - the lower front end panel mounting bolts (12) . - the front end panel.

115019

Remove the air inlet duct (14) .

114659

Remove the air resonator (13) .

115020

Remove the air filter unit (15)

12A-31

FUEL MIXTURE Air filter unit: Removal - Refitting


M9R, and 700 II - FINAL OPERATION Refit: - the air inlet duct, - the air resonator,

12A

- 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 air filter unit and the turbocharger ( 5.5 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) , - the front end panel upper mounting bolts ( 21 Nm ) . Clip on: - the air inlet scoop to the front end panel, - the bonnet opening cable Fit the turbocharger regulation solenoid valve onto the 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 Unit box. 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

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.

12A-32

FUEL MIXTURE Air filter unit: Removal - Refitting


K4M, and 760 or 761 F4R, and 770 or 771 or 776

12A

Tightening torquesm battery tray mounting bolts battery cover mounting bolts 21 Nm 4 Nm

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the battery (see 80A, Battery: Removal Refitting ).

101811

Remove the injection computer (4) and its mounting.

2 1

101822

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 air inlet sleeve (5) , - the air ducts (6) , - the air filter unit.
101737

12A-33

FUEL MIXTURE Air filter unit: Removal - Refitting


K4M, and 760 or 761 F4R, and 770 or 771 or 776

12A

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-34

FUEL MIXTURE Air filter unit: Removal - Refitting


K9K, and 722 or 728 or 729

12A

Tightening torquesm battery tray mounting bolts battery cover mounting bolts 21 Nm 4 Nm

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the battery (see 80A, Battery: Removal Refitting ).

101811

Remove the injection computer (4) and its mounting.

101822

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.
101737

Remove: - the air inlet sleeve (5) , - the air ducts (6) , - the air filter unit.

12A-35

FUEL MIXTURE Air filter unit: Removal - Refitting


K9K, and 722 or 728 or 729

12A

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-36

FUEL MIXTURE Air filter unit: Removal - Refitting


F9Q, and 800 or 804 or 808 K9K, and 732

12A

Tightening torquesm battery tray mounting bolts battery cover mounting bolts 21 Nm 4 Nm

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the battery (see 80A, Battery: Removal Refitting ).

101811

Remove the injection computer (4) and its mounting.

101822

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.
101737

Remove: - the air inlet sleeve (5) , - the air ducts (6) , - the air filter unit.

12A-37

FUEL MIXTURE Air filter unit: Removal - Refitting


F9Q, and 800 or 804 or 808 K9K, and 732

12A

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-38

FUEL MIXTURE Air flowmeter: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1608 Torque screwdriver

12A

Tightening torquesm air owmeter mounting bolts on the air lter unit air inlet duct clip on the air lter unit side air inlet duct clip on the turbocharger side 4 Nm 5.5 Nm 5.5 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). 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
114990

114846

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 turbocharger - air filter unit air inlet duct. Unpick the turbocharger regulation solenoid valve on the air filter unit.
114993

Disconnect the air flowmeter connector. Move the turbocharger regulation solenoid valve and air flowmeter connector aside.

Remove: - the air flowmeter mounting bolts (4) from the air filter unit,

12A-39

FUEL MIXTURE Air flowmeter: Removal - Refitting


M9R, and 700 - the air flowmeter (5) .

12A

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED Refit: - the air flowmeter, - the bolts securing the air flowmeter. Note: Be sure not to damage the air owmeter seal. Replace the seal if necessary. Tighten to torque the air flowmeter mounting bolts on 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 hose onto the air filter unit - turbocharger air inlet duct, Refit the turbocharger regulation solenoid valve onto the air filter unit. Connect: - the air flowmeter connector, - the battery (see 80A, Battery, Battery: Removal Refitting ).

12A-40

FUEL MIXTURE Air inlet flap: Removal - Refitting


K9K, and 732

12A

II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm damper ap mounting nuts 12 Nm

REMOVAL
I - REFITTING PREPARATION OPERATION Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

112810

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.
112815

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 ).

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip and (2) and move the air inlet duct (3) to one side.

12A-41

FUEL MIXTURE Air inlet flap: Removal - Refitting


K9K, and 732 Refit the engine covers.

12A

12A-42

FUEL MIXTURE Air inlet flap: Removal - Refitting


F9Q, and 804

12A

REFITTING
Tightening torquesm damper ap mounting bolts battery cover mounting bolts 8 Nm 4 Nm 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

111887

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.

12A-43

FUEL MIXTURE Air inlet flap: Removal - Refitting


M9R, and 700

12A

Tightening torquesm damper ap retaining strut mounting bolts on the inlet manifold damper ap retaining strut mounting bolts on the exhaust gas recirculation solenoid valve downstream intercooler duct clip on the intercooler downstream intercooler duct clip on the damper ap front end panel upper mounting bolts front end panel lower mounting bolts battery tray mounting bolts wiring harness mounting nut on the battery tray 12 Nm

12 Nm

5.5 Nm

5.5 Nm

21 Nm
112658

44 Nm 21 Nm 8 Nm

Remove: - the Protection and Switching Unit cover mounting bolts (1) , - the Protection and Switching Unit cover.

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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 ).

115585

Disconnect the Protection and Switching Unit connectors (2) . Unfasten the bonnet opening cable (3) . Remove: - the clips (4) , - the upper front end panel mounting bolts (5) , Disconnect the screen washer pipes.

12A-44

FUEL MIXTURE Air inlet flap: Removal - Refitting


M9R, and 700

12A

112659

115701

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.

Disconnect the turbocharger pressure sensor connector (11) . Remove the turbocharger pressure sensor mounting nut (12) on the damper flap strut.

102365

Remove: - the lower front end panel mounting bolts (13) . - the front end panel.

114933

Unclip the air inlet scoop (10) .

12A-45

FUEL MIXTURE Air inlet flap: Removal - Refitting


M9R, and 700

12A

II - OPERATION FOR REMOVAL OF PART CONCERNED

114649 114406

Disconnect the damper flap connector (17) . Remove: - the mounting bolts (18) from the damper flap retaining strut on the inlet manifold, - the mounting bolts (19) from the damper flap retaining strut on the exhaust gas recirculation solenoid valve, - the damper flap, - the seal between the damper flap and the exhaust gas recirculation solenoid valve

REFITTING
I - REFITTING PREPARATION OPERATION
115702

Remove the mounting bolt (14) from the intercooler duct (downstream) on the cooling radiator. Loosen: - the downstream intercooler duct clip (15) on the intercooler, - the downstream intercooler duct clip (16) on the damper flap. Remove the downstream intercooler duct.

Replace the seal between the damper flap and the exhaust gas recirculation solenoid valve.

12A-46

FUEL MIXTURE Air inlet flap: Removal - Refitting


M9R, and 700 II - REFITTING OPERATION FOR PART CONCERNED Finger tighten until contact: - the damper flap retaining strut mounting bolts on the inlet manifold, - the damper flap retaining strut mounting bolts on the exhaust gas recirculation solenoid valve, Tighten to torque: - the damper flap retaining strut mounting bolts on the inlet manifold ( 12 Nm ) , - the damper flap retaining strut mounting bolts on the exhaust gas recirculation solenoid valve ( 12 Nm ) .

12A

12A-47

FUEL MIXTURE Air inlet flap: Removal - Refitting


M9R, and 700 III - FINAL OPERATION Refit: - the downstream intercooler duct clip onto the intercooler and the damper flap, - the downstream intercooler duct mounting bolt onto the cooling radiator. Tighten to torque: - the downstream intercooler duct clip on the intercooler ( 5.5 Nm ) , - the downstream intercooler duct clip on the damper flap ( 5.5 Nm ) . Refit: - the front end panel, - front end panel mounting bolts. Tighten to torque: - the front end panel upper mounting bolts ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) , 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 battery tray. Tighten to torque: - the battery tray mounting bolts ( 21 Nm ) , - the wiring harness mounting nut on the battery tray ( 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 mounting bolts, - the front bumper (see MR365, Bodywork, 55A, Exterior protection, Front bumper ), - the engine undertray, - the engine protectors,

12A

- the battery (see 80A, Battery, Battery: Removal Refitting ). Carry out programming by following command scenario SC036 if replacing or removing - refitting the damper flap (see MR 366 Fault finding, 13B, Fault finding - Interpretation of commands ) and (see MR 366 Fault finding, 13B, Fault finding - Replacement of components ).

12A-48

FUEL MIXTURE Air inlet duct: Removal - Refitting


F9Q, and 800 or 808

12A

Tightening torquesm inlet duct mounting bolts inlet duct nut battery cover mounting bolt 8 Nm 21 Nm 4 Nm

3 2

REMOVAL

101892

Loosen the clip (2) . Disconnect the air inlet hose. Separate the air inlet hose. Disconnect the vacuum hose from the (3) diaphragm.

1 4
101893

Disconnect: - the battery, starting with the negative terminal, - the turbocharging pressure sensor (1) .

101884

Remove: - inlet duct mounting bolts (4) , - the air inlet duct mounting nut (5) , - the air inlet duct.

12A-49

FUEL MIXTURE Air inlet duct: Removal - Refitting


F9Q, and 800 or 808

12A

REFITTING

8 7

101884

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 terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolt ( 4 Nm ) .

12A-50

FUEL MIXTURE Air inlet duct: Removal - Refitting


F9Q, and 804

12A

REFITTING
Tightening torquesm inlet duct mounting bolts inlet duct mounting nut battery cover mounting bolts 25 Nm 21 Nm 4 Nm 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 terminal.

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

111887

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.

12A-51

FUEL MIXTURE Inlet manifold: Removal - Refitting


K4J, and 730 or 732

12A

Tightening torquesm plenum chamber mounting bolts throttle valve bolts air unit bolts battery cover mounting bolts 9 Nm 13 Nm 9 Nm 4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the air filter unit (see 12A, Fuel mixture, Air filter unit ), - the throttle valve (see 12A, Fuel mixture, Throttle valve ).
101794

Remove: - the plenum chamber mounting bolts, - the plenum chamber.

REFITTING
Always replace all of the seals. Proceed in the reverse order to removal.

3
101100

Disconnect: - the manifold pressure sensor (1) , - the ignition coils (2) , - the air temperature sensor (3) . Move the wiring harness to one side.

12A-52

FUEL MIXTURE Inlet manifold: Removal - Refitting


K4J, and 730 or 732

12A

7 5 1 2

3
101794

Tighten to torque and in order the plenum chamber mounting 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-53

FUEL MIXTURE Inlet manifold: Removal - Refitting


F4R, and 770 or 771 K4M, and 760 or 761

12A
3

Tightening torquesm inlet manifold bolts motorised throttle valve bolts battery cover mounting bolts 9 Nm 13 Nm 4 Nm

REMOVAL
4 2 1

102735

Disconnect: - throttle valve connector (2) , - brake servo vacuum pipe (3) to the inlet manifold. Note: Do not damage the vacuum outlet on the inlet manifold. If it is damaged, the inlet manifold will need to be replaced. Disconnect fuel vapour recirculation pipe (4) to the throttle valve.

101807

Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - air duct (1) .

12A-54

FUEL MIXTURE Inlet manifold: Removal - Refitting


F4R, and 770 or 771 K4M, and 760 or 761 ON THE WORKBENCH Remove the throttle valve.

12A

REFITTING
Always replace all of the seals with new ones. Proceed in the reverse order to removal.

7 6

5 6 5
Disconnect electrical wiring harness (5) . Pull the electric wiring harness to one side. Disconnect fuel inlet pipe (6) from the injector rail. IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail. Unclip fuel vapour recirculation pipe (7) from the inlet manifold.
102726

8 5
101795

2 1 3

Tighten to torque and in order the inlet manifold bolts ( 9 Nm ) . Tighten to torque the motorised throttle valve bolts ( 13 Nm ) , tightening each bolt evenly. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

102726

Remove the inlet manifold bolts.

12A-55

FUEL MIXTURE Inlet manifold: Removal - Refitting


F4R, and 776

12A

Tightening torquesm inlet manifold mounting bolts motorised throttle valve mounting bolts battery cover mounting bolts 21 Nm 21 Nm 4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the engine covers.

106633

Remove: - motorised throttle valve mounting bolts (4) ,

- the motorised throttle valve.

1 5
106270

Remove air duct (1) . Remove petrol vapour rebreathing pipe (2) . Disconnect the motorised throttle valve connector.

106787

Disconnect: - turbocharging pressure sensor connector (5) , - vacuum pipe (6) from the brake servo, - oil vapour recirculation pipe (7) .

106272

Remove air pipe (3) between the turbocharger and the intercooler.

12A-56

FUEL MIXTURE Inlet manifold: Removal - Refitting


F4R, and 776

12A

106271

106337

Disconnect: - injection rail petrol supply pipe (8) , - the injector connectors.

Tighten to torque and in order the inlet manifold mounting bolts ( 21 Nm ) . Tighten to torque the motorised throttle valve mounting bolts ( 21 Nm ) . Connect the battery, starting with the positive terminal.

WARNING Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail. Pull the electric wiring harness to one side. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

106337

Remove the inlet manifold bolts.

REFITTING

WARNING Be sure to replace all the sealing joints with new ones when they are removed. Proceed in the reverse order to removal.

12A-57

FUEL MIXTURE Injector holder shim: Removal - Refitting


K4J, and 730 or 732

12A

Tightening torquesm injector holder shim mounting bolts 11 and 12 injector holder shim mounting bolts 13 to 20 upper timing cover bolt suspended mounting bolt battery cover mounting bolts 25 Nm

21 Nm

2
44 Nm 44 Nm

3 3 4

4 Nm Disconnect: - fuel supply union (2) ,

101802

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the inlet manifold (see 12A, Fuel mixture, Inlet manifold ).

- injectors (3) , - pinking sensor (4) .

IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail.

WARNING Protect the alternator against fuel spills from the rail or supply duct.

7 5

6
101493

Remove the two injection rail bolts (5) Pull the injection rail gently towards yourself to remove it.

Remove: - nut (6) securing the electrical wiring harness, - oil gauge well (7) .
101801

Remove injector rail protector mounting nuts (1) . Move the wiring harness to one side.

12A-58

FUEL MIXTURE Injector holder shim: Removal - Refitting


K4J, and 730 or 732

12A
10

REFITTING

19 20

15

11

12

16

101792

18 14

13

17
101792

Remove the injector holder shim mounting bolts.

The injector holder shim seal must always be replaced. Insert all the mounting bolts. Secure: - the injector holder shim against the upper timing cover, by tightening bolt (8) by hand, - the injector holder shim against the engine suspended mounting by tightening bolt (9) by hand. Position the injector mounting plate against the cross 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, Inlet manifold ). Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

12A-59

FUEL MIXTURE Injector holder shim: Removal - Refitting


K4M, and 760 or 761

12A

Tightening torquesm bolts 5 and 6 on the injector holder shim bolts 7 to 14 on the injector holder shim suspended mounting bolt upper timing cover bolt battery cover mounting bolts 25 Nm 21 Nm

1
44 Nm 44 Nm 4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the inlet manifold (see 12A, Fuel mixture, Inlet manifold ). IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail. Disconnect injectors (1) . Move the wiring harness to one side. Remove: - injector rail mounting bolts (2) , - the injector rail, pulling it carefully towards you.
101810

WARNING Protect the alternator against fuel spills from the rail or supply duct.

102303

Remove injector mounting plate mounting bolts (3) .

12A-60

FUEL MIXTURE Injector holder shim: Removal - Refitting


K4M, and 760 or 761

12A

REFITTING

4 Nm ) .

13 14 12 3

6 10

11

102303

The injector holder shim seal must always be replaced. Insert all the mounting bolts. Secure: - the injector holder shim against the upper timing cover, by tightening bolt (3) by hand, - the injector holder shim against the engine suspended mounting by tightening bolt (4) by hand. Tighten to torque in order: - bolts 5 and 6 on the injector holder shim ( 25 Nm ) , - 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, Inlet manifold ). Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts (

12A-61

FUEL MIXTURE Injector holder shim: Removal - Refitting


F4R, and 770 or 771

12A
3

Tightening torquesm bolts 7 and 8 of the injector holder shim bolts 9 to 16 on the injector holder shim suspended mounting bolt 6 upper timing cover bolt 5 battery cover mounting bolts 25 Nm 21 Nm

2
44 Nm 44 Nm

4 Nm Disconnect: - fuel supply union (2) ,

102728

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the inlet manifold (see 12A, Fuel mixture, Inlet manifold ).

- injection wiring harness (3) .

IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail.

WARNING Protect the alternator against fuel spills from the rail or supply duct.

102730

Remove: - injector rail mounting bolts (4) , - the injector rail, pulling it carefully towards you.

101801

Remove injector rail protector mounting nuts (1) . Move the wiring harness to one side.

12A-62

FUEL MIXTURE Injector holder shim: Removal - Refitting


F4R, and 770 or 771

12A

REFITTING

6 7 8 13
101792

12

15 16
101792

11 10

14

Remove the injector holder shim mounting bolts.

The injector holder shim seal must always be replaced. Insert all the mounting bolts. Secure: - the injector holder shim against the upper timing cover, by tightening bolt (5) by hand - the injector holder shim against the suspended engine mounting by tightening bolt (6) by hand. Tighten to torque in order: - bolts 7 and 8 of the injector holder shim ( 25 Nm ) , - 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, Inlet manifold ). Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

12A-63

FUEL MIXTURE Manifolds: Removal - Refitting


F9Q, and 800 or 808

12A
8

Tightening torquesm Manifold mounting stud manifold mounting nuts, exhaust gas recirculation valve mounting bolt engine cover mounting bolts 8 Nm 28 Nm 8 Nm 4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the inlet duct (see 12A, Fuel mixture, Inlet duct ), - the turbocharger (See 12B, Turbocharging, Turbocharger ).
102478

Disconnect the exhaust gas recirculation solenoid valve. Remove: - the exhaust gas recirculation solenoid valve (6) , - the exhaust gas recirculation pipe (7)

4 3

- the engine lifting bracket (8) - the manifold mounting nuts, - the manifolds.

REFITTING
2 5
Proceed in the reverse order to removal. Replace the gaskets: - on the manifolds,
102486

- 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 mounting bolt ( 8 Nm ) .

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) .

WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the engine cover mounting bolts ( 4 Nm ) .

12A-64

FUEL MIXTURE Manifolds: Removal - Refitting


F9Q, and 804

12A

Tightening torquesm manifold studs mounting 8 Nm 28 Nm 4 Nm

manifold mounting nuts battery cover mounting bolts

REMOVAL
Disconnect the battery, starting with the negative terminal. Position the vehicle on a lift. Remove: - the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ). - the inlet duct (see 12A, Fuel mixture, Inlet duct ), - the exhaust gas recirculation unit (see 14A, Emission control, Exhaust gas recirculation unit ), - the exhaust gas recirculation pipe, - the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting ). - the starter motor (see 16A, Starting-charging, Starter motor: Removal - Refitting ). - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ).

111872

Disconnect the exhaust gas temperature before turbocharger sensor (1) . Remove: - the manifold mounting nuts - the exhaust manifold (2) .

111873

Remove the inlet manifold (3) .

12A-65

FUEL MIXTURE Manifolds: Removal - Refitting


F9Q, and 804

12A

REFITTING
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 (see 14A, Emission control, Exhaust gas recirculation unit ), - the turbocharger (see 12B, Turbocharging, Turbocharger ). Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Refit the engine lifting bracket. Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-66

FUEL MIXTURE Exhaust manifold: Removal - Refitting


M9R, and 700

12A

Tightening torquesm exhaust manifold studs exhaust manifold mounting nuts EGR duct mounting bolts on the EGR cooler EGR duct mounting bolts on the exhaust manifold EGR duct mounting bolt on the cylinder head EGR duct heat shield mounting bolt on the cylinder head EGR duct heat shield mounting bolt on the exhaust manifold lower mounting bolts of the front end panel upper mounting bolts of the front end panel air inlet duct clip battery tray mounting bolts 9 Nm 30 Nm 30 Nm 30 Nm

10 Nm

10 Nm
112659

10 Nm

Disconnect: - the injection computer connectors (1) , - the air flowmeter connector,

44 Nm 21 Nm 5.5 Nm 21 Nm

- the turbocharger regulation solenoid valve connector. Unclip: - the battery negative terminal wiring harness (2) , - the injection computer connector wiring harness, - the turbocharger regulation solenoid valve wiring harness. Remove:

IMPORTANT Wear protective gloves during all operations.

- the battery tray mounting bolts (3) , - the wiring harness mounting nut (4) . Unpick the wiring harness from the injection computer connectors.

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ).

Remove the battery tray with the injection computer mounting.

12A-67

FUEL MIXTURE Exhaust manifold: Removal - Refitting


M9R, and 700

12A

114990

112658

Loosen the air inlet duct clip (5) on the air flowmeter side. Remove: - the air inlet duct on the air flowmeter side, - the front bumper (see MR 365, Bodywork, 55A, Exterior protection, Front bumper ).

Remove: - the Protection and Switching Unit cover mounting bolts (7) , - the Protection and Switching Unit cover.

102504

Disconnect the Protection and Switching Unit connectors (8) . Unfasten the bonnet opening cable (9) .
114933

Remove: - the clips (10) , - the upper mounting bolts (11) . Disconnect the screen washer pipes.

Unclip the air inlet scoop (6) .

12A-68

FUEL MIXTURE Exhaust manifold: Removal - Refitting


M9R, and 700

12A

- the EGR duct heat shield mounting bolt (14) on the cylinder head, - the EGR duct mounting bolts (15) on the cylinder head. Move the EGR duct heat shield to one side.

102365

Remove: - the front end panel mounting bolts (12) , - the front end panel.

113311

Remove the EGR duct mounting bolts (16) on the EGR cooler.

113280

113281

Remove the EGR duct mounting bolts (17) on the exhaust manifold. Move the EGR duct to one side. Remove:
113295

Remove: - the EGR duct heat shield mounting bolt (13) on the exhaust manifold,

- the gasket between the EGR cooler and the EGR duct, - the gasket between the EGR duct and the exhaust manifold.

12A-69

FUEL MIXTURE Exhaust manifold: Removal - Refitting


M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

12A

113279 113279

Remove: - the exhaust manifold mounting nuts, - the exhaust manifold spacers, - the exhaust manifold, - the exhaust manifold gasket.

Note: Check that the manifold gasket is positioned correctly. The tab must be positioned as (18) . 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 are in contact with the exhaust manifold.

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 correctly torque tightened (9 Nm) ; if not, replace any loose exhaust manifold studs. Tighten to torque the exhaust manifold studs ( 9 Nm ) .

113279

Tighten to torque and in order the exhaust manifold mounting nuts (18 Nm) . Tighten to torque and in order the exhaust manifold mounting nuts ( 30 Nm ) .

12A-70

FUEL MIXTURE Exhaust manifold: Removal - Refitting


M9R, and 700 III - FINAL OPERATION Refit: - the new gasket between the EGR duct and the exhaust manifold, - the new gasket between the EGR cooler and the EGR duct. Finger tighten until contact: - the EGR duct mounting bolts on the exhaust manifold, - 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 exhaust manifold ( 30 Nm ) , - the EGR duct mounting bolt on the cylinder head ( 10 Nm ) . Fit the heat shield. Refit: - the EGR duct heat shield mounting bolt to the cylinder head, - the EGR duct heat shield mounting bolt to the exhaust manifold. Tighten to torque: - the EGR duct heat shield mounting bolt on the cylinder head ( 10 Nm ) , - the EGR duct heat shield mounting bolt on the exhaust 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.

12A

Connect the Protection and Switching Unit connectors. Refit: - the Protection and Switching Unit cover, - the Protection and Switching Unit cover mounting bolts, - 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 computer mounting. 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 wiring harness, - the battery negative terminal connector wiring harness, - the injection computer connector wiring harness. Connect: - the turbocharger regulation solenoid valve connector, - the air flowmeter connector, - the injection computer connectors. Refit: - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ). - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the battery (see 80A, Battery, Battery: Removal Refitting ).

12A-71

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Mot. 1567 Remote operation pliers for EGR clips - the exhaust gas recirculation unit, - the manifold mounting nuts (5) , - the manifold.

12A

Tightening torquesm exhaust manifold studs exhaust manifold mounting nuts exhaust gas recirculation unit mounting bolts air inlet metal tube mounting bolts lifting eye battery cover mounting bolts 9 Nm 26 Nm 21 Nm 21 Nm 21 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.

4 5

3 1 5
102074

Remove: - the lifting eye (2) , - the air inlet metal tube (3) , - the turbocharger (see 12B, Turbocharging, Turbocharger ), - the exhaust gas recirculation metal tube (1) , - the exhaust gas recirculation unit mounting bolts (4) ,

12A-72

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 722 or 728 or 729

12A

REFITTING

8 4 2 6 1 5 3 7

20848-1

Replace the manifold gasket. Tighten to torque the exhaust manifold studs ( 9 Nm ) . Refit the manifold. Tighten to torque and in order the exhaust manifold mounting nuts ( 26 Nm ) . Fit: - the exhaust gas recirculation unit, - the new exhaust gas recirculation unit tube, - the new clips on the new exhaust gas recirculation unit tube. Tighten the new clips using the (Mot. 1567) . Tighten to torque: - the exhaust gas recirculation unit mounting bolts ( 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-73

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

12A

Tightening torquesm manifold nuts. heat shield bolts oxygen sensors mounting bolts for the exhaust pipe brackets to the body bolt on the inlet manifold strut exhaust bracket nuts battery cover mounting bolts 23 3 Nm 10 Nm 45 Nm 21 Nm

8 Nm
101501

20 Nm Disconnect downstream oxygen sensor (1) . 4 Nm

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. K4J Remove the air filter unit (see 12A, Fuel mixture, Air filter unit ).

3 2

K4M Remove the inlet manifold (see 12A, Fuel mixture, Inlet manifold ). Remove: - exhaust bracket mounting nuts (2) , - exhaust manifold strut (3) .

101793

Note: Mark with a pen the position of the exhaust silentbloc supports on the vehicle body.

12A-74

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

12A
7

7
102116 101798

Remove mounting bolt (4) from the exhaust pipe silentbloc supports on the body.

Remove oxygen sensor (6) using tool (Mot. 149501) . Remove upper heat shield (7) from the exhaust manifold.

102117

Remove mounting bolt (5) from the silencer silentbloc bracket on the body. Withdraw the exhaust pipe towards the rear of the vehicle. Remove: - the nine exhaust manifold securing nuts, - the exhaust manifold.

101797

12A-75

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761 ON THE WORKBENCH

12A
3 2 8

5 9 7 4 6 1

101797 101502

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 brackets 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

Remove the lower heat shield.

REFITTING
Always replace: - the manifold gaskets, - the exhaust bracket gaskets, - the manifold nuts.

12A-76

FUEL MIXTURE Exhaust manifold: Removal - Refitting


F4R, and 770 or 771 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

12A

Tightening torquesm manifold nuts heat shield bolts oxygen sensors mounting bolts for the exhaust pipe brackets to the body bolt on the exhaust manifold strut on the gearbox exhaust bracket nuts battery cover mounting bolts 18 Nm

2
10 Nm 45 Nm 21 Nm

21 Nm
101793

20 Nm 4 Nm

Remove: - exhaust bracket mounting nuts (2) , - the exhaust manifold strut (3) .

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.

Note: Mark with a pen the position of the exhaust silentbloc supports on the vehicle body.

1 4

102116 101501

Disconnect downstream oxygen sensor (1) .

Remove mounting bolt (4) from the exhaust pipe silentbloc supports on the body.

12A-77

FUEL MIXTURE Exhaust manifold: Removal - Refitting


F4R, and 770 or 771

12A

102117

101797

Remove mounting bolt (5) from the silencer silentbloc bracket on the body. Withdraw the exhaust pipe towards the rear of the vehicle.

Remove: - the exhaust manifold mounting nuts, - the exhaust manifold. ON THE WORKBENCH

7
101798

Remove oxygen sensor (6) using tool (Mot. 149501) . Remove upper heat shield (7) from the exhaust manifold. Remove the lower heat shield.

101502

REFITTING
Always replace: - the manifold gaskets,

12A-78

FUEL MIXTURE Exhaust manifold: Removal - Refitting


F4R, and 770 or 771 - the exhaust bracket gaskets, - the manifold nuts.

12A

8 5 3 2 9 7 4 6 1

101797

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 brackets to the body ( 21 Nm ) , - the bolt on the exhaust manifold strut on the gearbox ( 21 Nm ) , - the exhaust bracket nuts ( 20 Nm ) . Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-79

FUEL MIXTURE Exhaust manifold: Removal - Refitting


F4R, and 776

12A

REFITTING
Tightening torquesm exhaust manifold mounting nuts the battery cover mounting bolts 20 Nm 4 Nm Proceed in the reverse order to removal. WARNING Always replace: - the exhaust manifold sealing ring, - the exhaust manifold mounting nuts.

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the engine and transmission assembly (see 10A, Engine and peripherals, Engine - gearbox ), - the turbocharger (see 12B, Turbocharging, Turbocharger ).

21936

Remove: - the exhaust manifold mounting nuts, - the exhaust manifold.

12A-80

FUEL MIXTURE Exhaust manifold: Removal - Refitting


F4R, and 776

12A

2 6 5 1

4
21936

Tighten to torque and in order the exhaust manifold mounting nuts ( 20 Nm ) . Refit: - the turbocharger (see 12B, Turbocharging, Turbocharger ). - the engine and transmission assembly (see 10A, Engine and peripherals, Engine - gearbox ), Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . WARNING Strict adherence to the repair procedures is required for the removal and retting of the turbocharger in order to seal the system FAILURE TO COMPL WITH THESE INSTRUCTIONS MAY Y HAVE SERIOUS SAFETY-RELATED CONSEQUENCES .

12A-81

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1567 Remote operation pliers for EGR clips

12A

Tightening torquesm exhaust manifold mounting studs exhaust manifold mounting nuts exhaust gas recirculation unit mounting bolts exhaust gas recirculation rigid pipe mounting bolts 9 Nm 26 Nm

25 Nm 35 Nm

112815

REMOVAL
I - REMOVAL PREPARATION OPERATION Put the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery: Removal - Refitting ).
112810

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip (2) . Move aside the air inlet duct between the intercooler and the damper valve on the damper valve. Remove the mounting bolt (3) from the damper valve. Remove: - the engine undertray, - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ). - the lifting eye mounting bolts on the timing end, - the lifting eye on the timing end.

12A-82

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 732

12A

113558

Loosen the mounting bolts (7) on the EGR unit by a few turns. Move the EGR unit to one side without removing it.
113475

II - REMOVAL OF PART CONCERNED

Remove the mounting bolts (4) from the injection rail cover mounting bracket.

113561 113842

Remove: - the mounting nuts (8) from the exhaust manifold, - the exhaust manifold.

Remove: - the clip (5) from the EGR rigid pipe using the (Mot. 1567) , - the mounting bolts (6) from the exhaust gas recirculation pipe, - the exhaust gas inlet pipe .

REFITTING
I - REFITTING PREPARATION OPERATION Always clean the joint faces thoroughly.

12A-83

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 732 II - REFITTING OPERATION FOR PART CONCERNED

12A

20848-1

Tighten to torque and in order the exhaust manifold mounting studs ( 9 Nm ) . Position the new exhaust manifold gasket. Refit: - the exhaust manifold, - the exhaust manifold mounting nuts. Tighten to torque the exhaust manifold mounting nuts ( 26 Nm ) . III - FINAL OPERATION Fit the exhaust gas recirculation unit. Torque tighten the exhaust gas recirculation unit mounting bolts ( 25 Nm ) . Refit: - the new exhaust gas recirculation rigid pipe with a new seal, - the mounting bolts on the exhaust gas recirculation pipe,

Fit the new snap-on clip. WARNING Ensure that you do not constrain the exhaust gas recirculation rigid pipe before tting the snap-on clip. Tighten the bolts of the exhaust gas recirculation rigid pipe on the manifold until they make contact. Adjust the exhaust gas recirculation rigid pipe in relation to the cooler support. Lock the snap-on clip of the exhaust gas recirculation rigid pipe using the (Mot. 1567) . Tighten to torque the exhaust gas recirculation rigid 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 bracket mounting bolts,

12A-84

FUEL MIXTURE Exhaust manifold: Removal - Refitting


K9K, and 732 - the inlet throttle valve mounting bolt, - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ). - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the engine undertray. Connect the damper valve connector. Refit the air inlet duct between the intercooler and the 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

12A-85

FUEL MIXTURE Throttle valve: Removal - Refitting


K4J, and 730 or 732

12A

Equipment required diagnostic tool

Tightening torquesm throttle valve bolts air lter unit bolts battery cover mounting bolts 13 Nm 9 Nm 4 Nm

REMOVAL

1
101800

Remove:

- mounting bolts (4) , - the throttle valve.

101489

Disconnect the battery, starting with the negative terminal. 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 solenoid valve.

12A-86

FUEL MIXTURE Throttle valve: Removal - Refitting


K4J, and 730 or 732

12A

REFITTING
Proceed in the reverse order to removal. Replace the throttle valve seal each time it is removed (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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . In the event of a throttle valve replacement, use the diagnostic tool CLIP to reinitialise the stop programming using command RZ005 Programming . When the ignition is switched on, the throttle valve should go through a cycle of programming the MIN and MAX throttle stop positions. Using the diagnostic tool CLIP , check that the programming has been performed correctly ET051 Throttle stop programming .

12A-87

FUEL MIXTURE Throttle valve: Removal - Refitting


F9Q, and 800 or 808

12A

Tightening torquesm throttle valve mounting bolts battery cover mounting bolts 8 Nm 4 Nm

REMOVAL
2 4

101892

Unscrew air inlet hose clip (2) . Disconnect the air inlet hose. Separate the air inlet hose. Disconnect vacuum hose (3) from the diaphragm.

1
101893

Remove: - the three mounting bolts (4) , - the throttle valve / diaphragm assembly.

Disconnect: - the battery, starting with the negative terminal, - turbocharging pressure sensor (1) .

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 terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12A-88

FUEL MIXTURE Throttle valve: Removal - Refitting


K4M, and 760 or 761

12A

Equipment required diagnostic tool

Tightening torquesm throttle valve mounting bolts battery cover mounting bolts 13 Nm

3
4 Nm

REMOVAL

102735

Disconnect:

- throttle valve connector (2) , - fuel vapour recirculation pipe (3) on the control solenoid valve. Remove: - the four throttle valve mounting bolts (4) ,

101807

- the throttle valve.

Disconnect the battery, starting with the negative terminal. Remove air duct (1) .

12A-89

FUEL MIXTURE Throttle valve: Removal - Refitting


K4M, and 760 or 761

12A

REFITTING
Replace the throttle valve seal with a new one each time 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . In the event of a throttle valve replacement, use the diagnostic tool CLIP to reinitialise the stop programming using command RZ005 Programming . When the ignition is switched on, the throttle valve should go through a cycle of programming the MIN and MAX throttle stop positions. Check using the diagnostic tool CLIP that the programming has been performed correctly ET051 Throttle stop programming .

12A-90

FUEL MIXTURE Throttle valve: Removal - Refitting


F4R, and 770 or 771 or 776

12A

Equipment required diagnostic tool

Tightening torquesm throttle valve mounting bolts (F4R 776) throttle valve mounting bolts battery cover mounting bolts 10 Nm 13 Nm

4 Nm

REMOVAL
F4R, and 776 Remove: - motorised throttle valve mounting bolts (3) , - the motorised throttle valve.
106633

1
106270

Remove the engine covers. Remove air duct (1) . Remove fuel vapour recirculation pipe (2) . Disconnect the motorised throttle valve connector.
101807

Disconnect the battery, starting with the negative terminal. Remove air duct (4) .

12A-91

FUEL MIXTURE Throttle valve: Removal - Refitting


F4R, and 770 or 771 or 776

12A

REFITTING
7
Replace the throttle valve seal each time it is removed. 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 terminal. WARNING

7 5

Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .
102735

Disconnect: - throttle valve connector (5) , - fuel vapour recirculation pipe (6) on the control solenoid valve. Remove: - the four throttle valve mounting bolts (7) , - the throttle valve.

In the event of a throttle valve replacement, use the diagnostic tool CLIP to reinitialise the stop programming using command RZ005 Programming . When the ignition is switched on, the throttle valve should go through a cycle of programming the MIN and MAX throttle stop positions. Using the diagnostic tool CLIP , check that the programming has been performed correctly ET051 Throttle stop programming .

12A-92

FUEL MIXTURE Throttle valve: Removal - Refitting


F9Q, and 804

12A

REFITTING
Tightening torquesm throttle valve mounting bolts battery cover mounting bolts 8 Nm 4 Nm 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

3 2 1

111887

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.

12A-93

FUEL MIXTURE Throttle valve: Cleaning


F4R or K4J or K4M

12A

Equipment required diagnostic tool

WARNING Wear protective goggles and gloves during the operation. Be sure to work in a clean environment so as not to allow any contamination of the throttle valve. Remove the throttle valve (see 12A, Fuel mixture, Throttle valve ).

106901

Hold the throttle valve flap open manually. Spray the cleaning product onto the inside of the valve until all traces of clogging disappear.

WARNING Do not apply cleaning agent, part number 77 11 171 437 , to the outside of the valve, in the spring housing or on the connector.

106899

Remove the external O-ring seals from the throttle valve. Note: The Renault carburettor cleaning agent, part number 77 11 171 437 can damage the seals.

106900

Remove the cleaning product residue and the dirt residue using a cloth, part number 77 11 211 707

12A-94

FUEL MIXTURE Throttle valve: Cleaning


F4R or K4J or K4M

12A

106902

Use a nozzle to direct compressed air at the edges and outside of the throttle valve.

WARNING It is essential to replace the throttle valve O-ring seals.

Note: If the throttle valve is dropped or receives any other impact, it will need to be replaced. Refit the throttle valve (see 12A, Fuel mixture, Throttle valve ). Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Using tool diagnostic tool , reinitialise the programming of the throttle stops via the delete command RZ005 Programming . When the ignition is switched on, the throttle valve should go through a cycle of programming the MIN and MAX throttle stop positions. Check, using the diagnostic tool , that this programming has been carried out using the command ET051 Throttle stop programming .

12A-95

FUEL MIXTURE Engine stop device


F9Q, and 800 or 808 I - OBJECTIVE The system is intended to stop the engine quickly after the ignition is switched off. II - DESCRIPTION

12A
4

3 2
102486

The system consists of: - a diaphragm (1) acting on the throttle, - a throttle (2) , - a solenoid valve (3) ,

- a vacuum (4) . III - OPERATING PRINCIPLE


101892

When the ignition is switched off, the solenoid valve connects the vacuum and the diaphragm. The diaphragm is submitted to the vacuum; this closes the air inlet flap.

The engine can no longer take in air and stops running immediately.

101894

12A-96

TURBOCHARGING Turbocharging: Precautions for repair


F9Q Instructions that must be followed when turbochargers are replaced due to mechanical damage: - damage to the bearing system, - broken shaft, - compressor wheel rubbing against the turbocharger casing, - broken compressor wheel. Damage of the kind listed above can lead to impurities entering the circuits to which the turbocharger is connected. FOR THE AIR CIRCUIT: - Consequences: swarf and metal objects in the ducts upstream and downstream of the turbocharger, large volumes of oil in the air circuit (collected in the intercooler). - Risks (after replacing the turbocharger): metal objects found in the compressor wheel (destruction 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 (destruction of turbocharger). Diagram of the air circuit

12B

- Replace the turbocharger upstream duct (see diagram) - Clean the turbocharger ducts - Drain the engine oil - Replace the oil filter - Replace the oil return and supply pipes and their seals I - INSTRUCTIONS FOR THE AIR CIRCUIT

5 4 C 3

112666

WARNING Metal objects may enter the oil and air circuits as a result of a broken turbocharger. Failure to follow the INSTRUCTIONS listed will lead to the turbocharger breaking again. 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

(1) (2) (3) (4) (5) (6)

air lter compressor wheel intercooler turbocharger pressure sensor inlet manifold turbine wheel

Remove intercooler (3) if the vehicle is fitted with one (refer to the Workshop Repair Manual of the vehicle affected 12B, Turbocharging, Intercooler ).

WARNING Always replace the intercooler.

12B-1

TURBOCHARGING Turbocharging: Precautions for repair


F9Q

12B

11

110738

112772

Damage to the compressor wheel results in metal objects entering the air duct (A) between the air filter and the turbocharger. Replace the air duct (A) between the air filter and the turbocharger. Check that there are no metal objects inside the flowmeter (7) . Clean the ducts Remove: - the air circuit duct (between the turbocharger and the intercooler) for section (B) , - the air circuit duct (between the intercooler and the inlet manifold) for section (C) . Remove the turbocharger pressure sensor (4) for section (C) , if the duct is fitted with one.

For ducts comprising several components: - mark the duct (11) so that you can identify where each component should be positioned when refitting, - separate all the duct components.

112770

Clean the removed ducts one by one using a cleaning spray: - brush as much of the duct interior as possible (only use brushes with plastic bristles), - wash the duct with plenty of cleaning liquid, - let the cleaned duct drain by standing it up vertically and then start cleaning the next duct.

12B-2

TURBOCHARGING Turbocharging: Precautions for repair


F9Q

12B

112771

102480

Dry the ducts one by one using a compressed air spray gun. For ducts comprising several components: - assemble the components in the correct order using the 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 the intercooler) for section (B) , - the air circuit duct (between the intercooler and the inlet manifold) for section (C) , Refit the new intercooler (3) , if the vehicle is fitted with one (refer to the Workshop Repair Manual of the vehicle affected 12B, Turbocharging, Intercooler ,). II - INSTRUCTIONS FOR THE LUBRICATION CIRCUIT Drain the engine oil. Replace the oil filter.

111870

Replace: - the turbocharger oil supply pipe, - the turbocharger oil return pipe(s).

WARNING Always replace all seals that have been removed.

12B-3

TURBOCHARGING Turbocharging: Precautions for repair


F9Q

12B

WARNING When starting the engine: - let the engine run at idle speed for 1 minute so that the oil circuit pressure can reach the required level, - accelerate several times under no load.

12B-4

TURBOCHARGING Turbocharging: Precautions for repair


M9R, and 700

12B

WARNING With a marker, mark the position of the exhaust rubber mounting bush supports on the bodywork.

WARNING - Ensure that no foreign bodies enter the turbine or compressor during the retting operation. - Check that the turbocharger oil return pipe is not completely or partially blocked by scale. Check that it is not leaking; if it is, replace it.

12B-5

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 722 or 728 or 729

12B
3 1

Equipment required diagnostic tool

K9K, and 722

6
Tightening torquesm turbocharger mounting studs on the turbocharger turbocharger mounting studs on the exhaust manifold turbocharger mounting nuts on the exhaust manifold turbocharger oil inlet pipe union on the cylinder head turbocharger oil inlet duct socketed bolt on the turbocharger turbocharger oil return pipe mounting bolts on the turbocharger exhaust gas recirculation solenoid valve heat shield mounting bolts battery cover mounting bolts 7 Nm

2
7 Nm

26 Nm

4
22.5 Nm

22.5 Nm Disconnect air duct (1) . Remove air duct (2) from the turbocharger. 12 Nm Disconnect: - the turbocharger pressure sensor (3) , 12 Nm

102081

- the exhaust gas recirculation solenoid valve (4) , - the turbocharging duct (5) on the turbocharger,

4 Nm

- the pipe (6) from the turbocharging pressure regulation valve on the air duct.

REMOVAL
Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the engine undertray.

12B-6

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 722 or 728 or 729

12B

K9K, and 728 or 729

10

11
110326

Disconnect:
110325

- the turbocharging pressure sensor connector (9) , - the exhaust gas recirculation solenoid valve manifold (10) , - the turbocharging duct (11) on the turbocharger,

Pull out the clip.

8 7

- the pipe from the turbocharging pressure regulation valve on the turbocharging pressure regulation solenoid valve.

110323

Undo bolt (7) . Remove the air duct (8) .

12B-7

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 722 or 728 or 729

12B
14

12

13

102076

102116

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) . Note: Mark the position of the exhaust rubber mounting bush supports on the vehicle body with a pen.

Remove mounting bolt (14) from the exhaust pipe rubber mounting bush support on the body.

15

102117

Remove mounting bolt (15) from the silencer rubber mounting bush support on the body. Withdraw the exhaust pipe towards the rear of the vehicle.

12B-8

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 722 or 728 or 729

12B

22 20 17

21 16
102077 102079

Remove: - the catalytic converter stay (16) , - the four mounting nuts (17) securing the catalytic converter to the turbocharger, - the catalytic converter.

Remove: - the oil supply pipe (20) , - the oil return pipe (21) , - the two upper mounting nuts (22) from the turbocharger, - the lower mounting nut from below, - the turbocharger.

19

18

102119

Remove: - the bracket (18) , - the exhaust gas recirculation solenoid valve heat shield (19) .

12B-9

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 722 or 728 or 729

12B

REFITTING

Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). Proceed in the reverse order to removal.

WARNING Ensure that no impurities enter the turbine or compressor during the retting operation. Check that the turbocharger oil return pipe is not completely or partially blocked by scale. Also check that the sealing is perfect; if not, replace it.

Tighten to torque the exhaust gas recirculation solenoid valve heat shield mounting bolts ( 12 Nm ) . Connect the battery, starting with the positive terminal. WARNING

WARNING Check that the intercooler is not full of oil. If this is the case, remove it, rinse with a cleaning agent and then let it dry.

Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Before starting, disconnect the 4 injectors (starting the engine is prohibited). Run the starter motor until the oil pressure warning light 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 several times with no load. Switch off the ignition.

WARNING Always replace: - all the O-rings and both copper seals on the turbocharger oil inlet duct, - the exhaust ange seal. - any damaged heat shield. Tighten to torque: - the turbocharger mounting studs on the turbocharger ( 7 Nm ) , - the turbocharger mounting studs on the exhaust manifold ( 7 Nm ) . Position the turbocharger on the exhaust manifold. Tighten to torque the turbocharger mounting nuts on the exhaust manifold ( 26 Nm ) . Apply LOCTITE FRENTANCH to the threads of the turbocharger oil inlet pipe union on the cylinder head. Position the turbocharger oil supply pipe on the turbocharger and on the cylinder head, applying new seals in the process. Tighten to torque: - the turbocharger oil inlet pipe union on the cylinder head ( 22.5 Nm ) , - the turbocharger oil inlet duct socketed bolt on the turbocharger ( 22.5 Nm ) . Position the turbocharger oil return pipe on the turbocharger and on the cylinder block, applying new seals in the process. Torque tighten the turbocharger oil return pipe mounting bolts on the turbocharger ( 12 Nm )

Make sure that there are no oil leaks. Connect the diagnostic tool and clear the stored faults. Make sure that all the exhaust pipe heat shields are in place and properly secured. Make sure that there is no contact with the underbody. Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12B-10

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 800

12B

Tightening torquesm turbocharger mounting studs turbocharger union end piece turbocharger mounting nuts oil supply pipe mounting nuts oil supply pipe mounting bolt on the cylinder block turbocharger oil return pipe mounting bolts battery cover mounting bolts 8 Nm 26 Nm 26 Nm 22.5 Nm

12 Nm

12 Nm 4 Nm
102481

Disconnect the turbocharger air inlet and outlet pipes.

REMOVAL
Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).

102480

Disconnect the tube (1) from the turbocharging pressure regulation valve control diaphragm. Remove: - the turbocharger oil supply pipe (2) , - the turbocharger oil return pipe (3) , - the turbocharger mounting nuts (4) , - the turbocharger.

12B-11

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 800

12B

REFITTING

WARNING Ensure that no impurities enter the turbine or compressor during the retting operation. Check that the turbocharger oil return pipe is not completely or partially blocked by scale. check that the sealing is perfect; if not, replace it. 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,

12B-12

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 800 made previously.

12B

Make sure that there is no contact with the underbody. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Check that there are no leaks: - start the engine, - check that the oil pressure warning light has gone out, - 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

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 ) , if the 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 pipe nuts, - screw on (without tightening) the oil supply pipe mounting 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 cylinder block ( 12 Nm ) , - the turbocharger oil return pipe mounting bolts ( 12 Nm ) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). Proceed in the reverse order to removal. Make sure that all the exhaust pipe heat shields are in place and properly secured. Refit the exhaust pipe, aligning it with the marks

12B-13

TURBOCHARGING Turbocharger: Removal - Refitting


F4R, and 776

12B

Equipment required diagnostic tool

Tightening torquesm bolts of the oil return pipe towards the cylinder block turbocharger cooling duct bolts (initial torque) turbocharger cooling duct bolts turbocharger mountings oil supply pipe hollow mounting bolt oil supply pipe union oil return pipe mounting bolts mounting bolts of the oil return and supply pipes 12 Nm

12 Nm

4
21927

27 Nm Disconnect: 15 Nm + 75 45 Nm 25 Nm 8 Nm 21 Nm

- 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) .

REMOVAL
Note: T loosen the turbocharger mounting nuts on the o exhaust manifold, spray some releasing agent onto the nuts while they are still warm, just before removal. Disconnect the battery, starting with the negative terminal. Removal of the turbocharger requires the engine to be removed (see 10A, Engine and peripherals, Engine - Gearbox ). Remove the catalytic converter (see 19B, Exhaust, Catalytic converter ).

21928

Fit hose clamps and remove the turbocharger cooling hoses (5) .

12B-14

TURBOCHARGING Turbocharger: Removal - Refitting


F4R, and 776

12B

21929

21931

Remove: - the heat shield bolt (6) , - the engine cover mounting and the turbocharger strut (7) , - the turbocharger - intercooler air pipe.

Remove: - the turbocharger oil return pipe mounting bolts (8) , - the turbocharger oil return pipe (10) , - the turbocharger oil supply pipe (9) .

21930

Remove the starter motor heat shield. Remove:

21933

- the nuts (11) securing the turbocharger to the manifold, - the turbocharger.

12B-15

TURBOCHARGING Turbocharger: Removal - Refitting


F4R, and 776

12B

REFITTING
The turbocharger mounting nuts and studs must be replaced along with the seals.

WARNING Ensure that no impurities enter the turbine or compressor during the retting operation. If there has been a fault in the turbocharger, check that the intercooler is not full of oil. If this is the case, remove it, rinse with a cleaning agent and then let it dry. Check that the turbocharger oil return pipe is not partially or completely blocked by scale. Also check that it is perfectly sealed. If not, replace it.

15
21931

Fit and finger tighten:

13 14

- the turbocharger mountings on the exhaust manifold, - the oil supply pipe mountings on the turbocharger, - the return pipe to the cylinder block, - the turbocharger - intercooler air pipe, - the turbocharger strut mounting.

16
22809

On the workbench, refit and tighten to torque: - the two bolts of the oil return pipe towards the cylinder 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 duct bolts ( 27 Nm ) .
106273

17

Tighten: - the clip (16) from the intercooler - turbocharger pipe to position the turbocharger, - the turbocharger strut (17) .

12B-16

TURBOCHARGING Turbocharger: Removal - Refitting


F4R, and 776

12B

18

All removed seals must be replaced including those on the cooling pipe as well as the intercooler - turbocharger air pipe. Fill and bleed the cooling circuit (see 19A, Cooling, Filling - Bleeding ). Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

18

WARNING - Before starting the engine, connect the diagnostic tool and lock the injection system. - Run the starter motor until the oil pressure warning light goes out (wait a few seconds) then unlock the injection system. - Start the engine then accelerate with no load several times. - Switch off the ignition and check that there are no oil leaks. - Run the engine at idle speed until the engine cooling fan starts up: - Accelerate several times with no load then perform a road test. - Clear the faults using the diagnostic tool . - Switch off the ignition and check that there are no oil leaks.

21933

21931

Tighten to torque: - the turbocharger mountings ( 15 Nm + 75 ) (18) , - the oil supply pipe hollow mounting bolt ( 45 Nm ) (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 supply pipes ( 21 Nm ) (22) . Proceed in the reverse order to removal.

12B-17

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 804 Special tooling required Mot. 1448 Remote operation clip pliers for cooling system hose clips Equipment required diagnostic tool

12B

Tightening torquesm turbocharger mounting nuts turbocharger oil supply pipe hollow mounting bolts oil supply pipe hollow mounting bolt on the housing oil supply pipe mounting bolt on the housing turbocharger oil return pipe battery cover mounting bolts 37 Nm 22.5 Nm

44 Nm
112659

Remove: 25 Nm 12 Nm 4 Nm - the battery tray mounting bolts (1) , - the nut (2) , - the battery tray. Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - filling ). Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ).

REMOVAL
Put the vehicle on a two-post lift. Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the battery.

12B-18

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 804

12B

111866

111869

Remove, using the (Mot. 1448) : - the hose - rigid pipe assembly (3) . between the EGR cooler (4) and the water outlet unit, - the hose - rigid pipe assembly (5) between the EGR coolant and the heater matrix hose. Disconnect the upper cooling hose on the turbocharger.

Remove the duct between the turbocharger and the air filter. Disconnect the turbocharger (7) vacuum pipe.

111860

Remove the air duct (6) from the turbocharger. Remove the turbocharger oil return pipe (8) .

111865

12B-19

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 804

12B

111868

111870

Remove the starter motor (see 16A, Starting-Charging, Starter motor: Removal - Refitting ).

Remove the turbocharger oil supply pipe (10) .

111871 111867

Remove the turbocharger mounting nuts (11) .

Remove the heat shield (9) .

12B-20

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 804

12B

REFITTING

WARNING Ensure that no impurities enter the turbine or compressor during the retting operation. Check that the turbocharger oil return pipe is not completely or partially blocked by scale. Also check that it is perfectly sealed. If not, replace it. 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 exhaust manifold,
112457

Note: Pay attention to the direction of tting of the manifold - turbocharger seal. The seal tab must be on the turbocharger side. Tighten to torque: - the turbocharger mounting nuts ( 37 Nm ) , - the turbocharger oil supply pipe hollow mounting bolts ( 22.5 Nm ) , - the oil supply pipe hollow mounting bolt on the housing ( 44 Nm ) , - the oil supply pipe mounting bolt on the housing ( 25 Nm ) , - the turbocharger oil return pipe ( 12 Nm ) . Refit:
112458

- the starter motor (see 16A, Starting-charging, Starter motor: Removal - Refitting ). - the catalytic pre-converter (see 19B, Catalytic pre-converter: Removal - Refitting ).

Remove the turbocharger (12) .

12B-21

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 804 Make sure that all the exhaust pipe heat shields are in place and properly secured. Make sure that there is no contact with the underbody. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Check that there are no leaks: - start the engine, - check that the oil pressure warning light has gone out, - 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 stored faults. Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Fill the cooling circuit (see 19A, Cooling, Cooling circuit: Draining - filling ). Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).

12B

12B-22

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 732

12B

Tightening torquesm turbocharger mounting studs turbocharger mounting nuts bolts mounting the oil inlet pipe on the turbocharger bolts mounting the oil inlet pipe on the cylinder head bolts mounting the oil return pipe on the turbocharger 9 Nm 26 Nm 22.5 Nm

22.5 Nm

12 Nm

112991

REMOVAL
I - REMOVAL PREPARATION OPERATION Put the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the engine covers. Disconnect the battery (see 80A, Battery: Removal - Refitting ). Remove the engine undertray.

Loosen the mounting bolt (1) on the air inlet rigid duct. Move the air inlet rigid duct to one side (see (2) .

112816

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


112811

Pull out the clip.

Disconnect the turbocharging pressure regulation valve hose on the regulation valve side.

12B-23

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 732

12B

REFITTING
I - REFITTING PREPARATION OPERATION Always clean the joint faces thoroughly. WARNING Ensure that no foreign bodies enter the turbine or compressor during the retting operation. Check that the turbocharger oil return pipe is not completely or partially blocked by scale. Check that there are no leaks. If there are, replace the part.

WARNING Check that the intercooler is not full of oil. If it is, remove and rinse it with the cleaning agent, then let it drip dry.
102079

Remove: - the bolt (6) mounting the oil inlet pipe on the turbocharger, - the bolt mounting the oil inlet pipe on the cylinder head, - 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.

WARNING Replace any damaged heat shield.

12B-24

TURBOCHARGING Turbocharger: Removal - Refitting


K9K, and 732 II - REFITTING OPERATION FOR PART CONCERNED Tighten to torque the turbocharger mounting studs ( 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 cylinder head. Tighten to torque: - the bolts mounting the oil inlet pipe on the turbocharger ( 22.5 Nm ) , - the bolts mounting the oil inlet pipe on the cylinder 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 return pipe on the turbocharger ( 12 Nm ) . Connect the vacuum pipe to the pressure regulation solenoid valve on the turbocharger. Refit: - the oil inlet pipe on the turbocharger, - the turbocharger oil inlet pipe union on the turbocharger, 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 cover side.

12B

Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). Note: Make sure there is no contact between the catalytic converter and the turbocharger oil return pipe. 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.

12B-25

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 808 Special tooling required Mot. 1566 Wrench for removing high-pressure pipes

12B

Disconnect the battery, starting with the negative terminal.

Tightening torquesm turbocharger mounting studs turbocharger mounting nuts hollow mounting bolt on the turbocharger oil supply pipe nut mounting the oil supply pipe on the cylinder block bolt mounting the oil supply pipe on the cylinder block turbocharger oil return pipe mounting bolts turbocharger mounting studs turbocharger union end piece turbocharger mounting nuts oil supply pipe mounting nut on the turbocharger side oil supply pipe mounting nut on the cylinder block turbocharger oil return pipe mounting bolts battery cover mounting bolts 8 Nm 26 Nm

22.5 Nm

22.5 Nm

25 Nm
104424

Disconnect: 12 Nm 8 Nm 26 Nm 26 Nm 22.5 Nm - the oil vapour rebreathing pipe (1) , - the turbocharging pressure regulation valve (2) pipe.

22.5 Nm

12 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Remove the engine covers.

12B-26

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 808

12B

I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE)

104421

Disconnect the turbocharger air inlet and outlet pipes (3) . Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). Note: During factory tting, 2 types of oil supply pipe can be tted to the turbocharger. The way in which a turbocharger is removed depends on the type of pipe. Remove:

114207

- the mounting bolt (4) from the oil supply pipe, - the hollow mounting bolt (5) from the oil supply pipe union on the turbocharger. Loosen the union (6) on the cylinder block. Remove the oil supply pipe by passing it through the turbocharger wheels. Remove: - the oil return pipe mounting bolts, - the oil return pipe, - the turbocharger bracket mounting nuts, - the turbocharger.

12B-27

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 808 II - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)

12B

114467

In the event that the oil supply pipe is replaced:


104417

Remove the bolt (7) mounting the oil supply pipe to the 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.

- remove the oil supply union end piece (9) . This step prepares the turbocharger for the supply pipe to be refitted with the hollow bolt union.

REFITTING
Note: During factory tting, 2 types of oil supply pipe can be tted to the turbocharger. The way in which a turbocharger is retted depends on the type of pipe.

WARNING Note: There is only one supply pipe part number available as a replacement part. Only the oil supply pipe with a hollow bolt union is available. Ensure that no impurities enter the turbine or compressor during the retting operation. Check that the turbocharger oil return pipe is not completely or partially blocked by scale. Also check that it is perfectly sealed. If not, replace it. Proceed in the reverse order to removal. Always replace: - the oil supply pipe with hollow bolt union on the turbocharger side (depending on version), - the oil supply pipe seals with nut unions on the turbocharger side (depending on version), - the seals on the turbocharger oil return pipe,

12B-28

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 808 - the turbocharger seals. I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE) Tighten to torque the turbocharger mounting studs ( 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 union mounting nut on the cylinder block, - screw on (without tightening) the supply pipe hollow mounting bolt, - screw on (without tightening) the oil supply pipe mounting bolt on the cylinder block. Refit the oil return pipe. Tighten to torque: - the hollow mounting bolt on the turbocharger oil supply pipe ( 22.5 Nm ) , - the nut mounting the oil supply pipe on the cylinder block ( 22.5 Nm ) , - the bolt mounting the oil supply pipe on the cylinder block ( 25 Nm ) - the turbocharger oil return pipe mounting bolts ( 12 Nm ) .

12B

II - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)

114467

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 it has 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 pipe mounting nuts, - screw on (without tightening) the oil supply pipe mounting bolt on the cylinder block. Refit the oil return pipe. Tighten to torque: - using the tool, the oil supply pipe mounting nut on the turbocharger side ( 22.5 Nm ) , - the oil supply pipe mounting nut on the cylinder block ( 22.5 Nm ) , - the turbocharger oil return pipe mounting bolts ( 12 Nm ) III - CONTINUATION OF REFITTING PROCEDURE Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).

12B-29

TURBOCHARGING Turbocharger: Removal - Refitting


F9Q, and 808 To refit, proceed in the reverse order to removal. Make sure that all the exhaust pipe heat shields are in place and properly secured. Refit the exhaust pipe, aligning it with the marks made previously. Make sure that there is no contact with the underbody. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Check that there are no leaks: - start the engine, - check that the oil pressure warning light has gone out, - 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

12B-30

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700

12B

REMOVAL
Equipment required roller-type stud removal tool tweezers diagnostic tool I - REMOVAL PREPARATION OPERATION Put the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). 9 Nm

Tightening torquesm stud on the exhaust manifold studs on the turbocharger turbocharger strut mounting bolt on the ywheel end lower mounting nuts on the turbocharger upper mounting nut on the turbocharger turbocharger transverse mounting bolt turbocharger strut mounting bolt on the timing side air inlet duct mounting bolts air inlet duct clip on the turbocharger side bolts mounting the oil pipe on the turbocharger hollow bolt securing the oil pipe on the cylinder block bolt mounting the oil pipe on the cylinder block

14.5 Nm 25 Nm

28 Nm 28 Nm 25 Nm 25 Nm
114982

8 Nm 5.5 Nm 10 Nm

Remove: - the bolts (1) mounting the oil pipe on the turbocharger, - the oil pipe mounting bolts (2) on the cylinder block, - the hollow bolt (3) securing the turbocharger oil pipe to the cylinder block, - the turbocharger oil pipe.

16 Nm

25 Nm

IMPORTANT Wear protective gloves during the operation.

12B-31

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700

12B

113282

Rotate the air duct retaining clip (7) on the turbocharger.

113277

Remove the lower mounting nuts (4) from the turbocharger.

114846

113155

Disconnect: - the hose (5) from the turbocharging pressure regulator on the control diaphragm, - the oil vapour rebreathing hose (6) on the oil separator. Loosen the air duct clip on the turbocharger side. Disconnect the air inlet duct on the turbocharger side.

Remove the mounting bolts (8) for the air duct on the inlet manifold. Move to one side the air duct towards the intercooler.

12B-32

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED - the turbocharger strut.

12B

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 a roller-type stud removal tool . Refit a new stud to the exhaust manifold using a roller-type stud removal tool . Tighten to torque the stud on the exhaust manifold ( 9 Nm ) . Remove the turbocharger studs in the event that the turbocharger is reused. Refit the new studs on the turbocharger in the event that the turbocharger is reused.
113277

Remove: - the turbocharger upper mounting nut (9) on the exhaust manifold, - the turbocharger mounting bolt (10) , - the turbocharger. - the gasket between the turbocharger and the exhaust manifold.

Tighten to torque the studs on the turbocharger ( 14.5 Nm ) .

115068

Remove the air inlet duct seal at the turbocharger outlet using a tweezers .

114471

Remove: - the mounting bolts (11) from the turbocharger strut,

12B-33

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700

12B

115069

Refit the new seal to the turbocharger air inlet duct. Note: Check that the turbocharger air inlet duct seal (12) is tted in the correct direction.

12B-34

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700 II - REFITTING OPERATION FOR PART CONCERNED

12B

- 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 timing end (13) . Tighten to torque: - the turbocharger transverse mounting bolt ( 25 Nm ) , - the turbocharger strut mounting bolt on the timing side ( 25 Nm ) (13) . III - FINAL OPERATION Rotate the retaining clip of the air inlet duct to refit the retaining clip in its recess.
114471

Clip the air inlet duct on to the turbocharger. Refit the air inlet duct mounting bolts on the inlet manifold. 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 turbocharger side ( 5.5 Nm ) . Connect the turbocharging pressure regulator on the control diaphragm.

Fit the new turbocharger strut. Finger tighten the mounting bolts (13) and (14) of the turbocharger strut. WARNING The turbocharger strut must move freely. Fit the turbocharger without its seal and hold the turbocharger flat against the exhaust manifold. Move the turbocharger strut until it is against the turbocharger at the flywheel end. Gently tighten the turbocharger strut mounting bolt on the timing end (13) . WARNING Do not tighten the bolt too quickly to prevent the turbocharger strut from rotating. Move the turbocharger to one side. Tighten to torque the turbocharger strut mounting bolt on the flywheel end ( 25 Nm ) (14) . Fit a new seal between the turbocharger and the exhaust manifold. Refit the turbocharger. Finger tighten the new turbocharger transverse mounting bolt by a few turns. Tighten until contact is made:

12B-35

TURBOCHARGING Turbocharger: Removal - Refitting


M9R, and 700

12B

- the hollow bolt securing the oil pipe on the cylinder block ( 16 Nm ) (16) , - the bolt mounting the oil pipe on the cylinder block ( 25 Nm ) (17) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). WARNING Disconnect the injection rail pressure regulator connector (disables engine starting). Run the starter motor until the oil pressure warning light goes out (do this for a few seconds). Switch off the ignition. Connect the injection rail pressure regulator connector.
114982

Start the engine. Let the engine idle then depress the accelerator several times under no load. Switch off the ignition. Make sure that there are no oil leaks. Connect the diagnostic tool and clear the stored faults.

Lubricate the new turbocharger oil pipe O-ring on the cylinder block side. WARNING Check for the gasket between the turbocharger and the turbocharger oil pipe. Remove the protective plug from the oil supply union on the cylinder block side. Fit the turbocharger oil pipe, first positioning it in the cylinder block (14) . WARNING Do not rotate the turbocharger oil pipe O-ring on the cylinder block side when inserting. After tting, check that the turbocharger oil pipe O-ring, on the cylinder block side, has not come out of its housing. Check for two copper seals on the oil supply union on the cylinder block side. Finger tighten: - the bolts (15) mounting the oil pipe on the turbocharger, - the oil pipe hollow bolt (16) on the cylinder block, - the bolts (17) mounting the oil pipe on the cylinder block. Tighten to torque: - the bolts mounting the oil pipe on the turbocharger ( 10 Nm ) (15) ,

12B-36

TURBOCHARGING Pressure regulator: Checking


K9K, and 722 or 724 or 728 or 729 or 732

12B

WARNING It is strictly prohibited to adjust the turbocharging pressure regulation valve rod in the turbocharger.

K9K, and 724 3 - Check

TURBOCHARGING PRESSURE REGULATION VALVE K9K, and 722 1 - Check

21869

Remove the turbocharger (see 12B, Turbocharging, Turbocharger ). Note: The check cannot be carried out with the turbocharger in place.
21869

Remove the turbocharger (see 12B, Turbocharging, Turbocharger ). Note: The check cannot be carried out with the turbocharger in place. Use a magnetic holder fitted with a dial gauge located at the end of the regulation valve rod (as far as possible on the rod shaft). Gradually apply pressure to the regulation valve using the pressure and vacuum pump. 2 - Value For a pressure value of 1.4 bar , the rod movement must be 4.3 mm .

Use a magnetic holder fitted with a dial gauge located at the end of the regulation valve rod (as far as possible on the rod shaft). Gradually apply pressure to the regulation valve using the pressure and vacuum pump. 4 - Value For a vacuum value of 0.6 bar , the rod movement must be 7 mm 0.5 .

12B-37

TURBOCHARGING Pressure regulator: Checking


K9K, and 722 or 724 or 728 or 729 or 732

12B

K9K, and 728 or 729 or 732 5 - Check

110748

Remove the turbocharger (see 12B, Turbocharging, Turbocharger ). Note: The check cannot be carried out with the turbocharger in place. Use a feeler gauge between the regulation valve rod and the stop (as far as possible into the rod shaft). Gradually apply pressure to the regulation valve using the pressure and vacuum pump. 6 - Value For a vacuum value of 0.5 bar , the rod movement must be 1.7 mm .

12B-38

TURBOCHARGING Pressure regulator: Checking


F9Q, and 800 or 808

12B

WARNING Adjusting the turbocharger pressure regulation valve rod is strictly prohibited.

TURBOCHARGING PRESSURE CONTROL VALVE

1 - CHECKING

21869

Remove the turbocharger (See 12B, Turbocharging, Turbocharger ).

Note: The turbocharger cannot be tested in situ. Use a magnetic holder fitted with a dial gauge placed on the end of the control valve stem (as far as possible in the axis of the stem). Gradually apply pressure to the regulation valve using a vacuum/pressure pump.

2 - Value For a pressure value of 265 mbar , the stem movement must be between 0.5 and 3.5 mm . For a vacuum value greater than 600 mbar , the stem is at the stop.

12B-39

TURBOCHARGING Pressure regulator: Checking


F4R, and 776

12B

WARNING Adjusting the turbocharger pressure regulation valve rod is strictly prohibited.

TURBOCHARGING PRESSURE CONTROL VALVE

1 - CHECKING

22807

Remove the turbocharger (See 12B, Turbocharging, Turbocharger ).

Note: The turbocharger cannot be tested in situ. Use a magnetic holder fitted with a dial gauge placed on the end of the control valve stem (as far as possible in the axis of the stem). Gradually apply pressure to the regulation valve using a vacuum/pressure pump.

2 - Value For a pressure value of 331 mbar , the stem movement should be 1 mm . For a pressure value of 544 mbar , the stem movement must be 5 mm .

12B-40

TURBOCHARGING Pressure regulator: Checking


F9Q, and 804

12B

WARNING It is strictly prohibited to adjust the turbocharging pressure regulation valve rod in the turbocharger.

TURBOCHARGING PRESSURE CONTROL VALVE 1 - Checking

21869

Remove the turbocharger (see 12B, Turbocharging, Turbocharger ). Note: The check cannot be carried out with the turbocharger in place. Connect a pressure and vacuum pump (1) to the pressure regulator (2) . Use a magnetic holder fitted with a dial gauge located at the end of the regulation valve rod (as far as possible on the rod shaft). Gradually apply a vacuum to the pressure regulator using the pressure and vacuum pump. 2 - Value Test points: - For a pressure value of 200 mbar , the rod movement should be between 2 and 4 mm . - for a pressure value of 550 mbar , the rod movement should be between 8 and 11 mm. .

12B-41

TURBOCHARGING Pressure regulator: Checking


M9R, and 700

12B

WARNING The turbocharging pressure regulator rod must not be adjusted.

TURBOCHARGING PRESSURE REGULATOR 1 - Check

21869

Remove the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ). Note: The check cannot be carried out with the turbocharger in place. Connect a pressure-vacuum pump (1) to the pressure regulator (2) . Use a magnetic holder fitted with a dial gauge located at the end of the regulation valve rod (as far as possible on the rod shaft). Gradually apply a vacuum to the pressure regulator using the pressure-vacuum pump. 2 - Value Test points: - For a vacuum value of 250 mbar , the rod movement should be between 3 and 6 mm . - for a vacuum value greater than 600 mbar , the rod should not move.

12B-42

TURBOCHARGING Turbocharging pressure regulation valve


F9Q, and 800 or 808

12B

WARNING If the turbocharger solenoid valve is removed, it is essential to mark the supply and return pipes on the solenoid valve.

The turbocharging pressure regulation valve is open in the rest position. The engine operates as normally aspirated. The solenoid valve, closed in the rest position, is supplied after the engine is started following a delay which varies according to the coolant temperature.

103128

Shaft X
102480

Description Time in seconds Coolant temperature in C

101889

The turbocharging pressure regulation valve diaphragm (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 of the engine operating ranges, which allows the turbocharging pressure to be regulated.

12B-43

TURBOCHARGING Turbocharging pressure regulation valve


F4R, and 776

12B

2
21927

Pressure regulation valve diaphragm (1) is controlled by a solenoid valve (2) , which is in turn controlled by the injection computer. The pressure adjustment valve is closed at rest position. Solenoid valve (2) is open in the rest position. In the open position, solenoid valve (2) compares the turbocharger outlet (turbocharging pressure) and diaphragm (1) . Because of this, the turbocharging pressure acts directly on the diaphragm and the pressure adjustment valve opens. When solenoid valve (2) is controlled, the turbocharging pressure signal (taken at the turbocharger outlet) is diverted to the turbocharger inlet. Consequently, the diaphragm is not submitted to turbocharging pressure, the pressure adjustment valve closes. The solenoid valve is open at rest and is energised when the engine is started. However, during a timed period which depends on coolant temperature, the turbocharging pressure is limited and the engine speed cannot exceed 2500 rpm. This ensures that the oil has sufficient time to reach the turbocharger bearings. Shaft X Y Description Time in seconds Coolant temperature in C
107010

12B-44

TURBOCHARGING Turbocharging pressure regulation valve


K9K, and 728 or 732

12B

The turbocharging pressure regulation solenoid valve is closed in the rest position; it is powered once the engine is started and a delay according to the coolant temperature.

WARNING When removing the turbocharging pressure regulation solenoid valve, it is essential to mark the supply and return pipes on the solenoid valve.

114184

114185

The turbocharging pressure regulation valve diaphragm (1) is controlled by a turbocharging pressure regulator solenoid valve (2) attached to a bracket fixed onto the air filter unit. This solenoid valve is controlled by the injection computer. This solenoid valve may, according to engine operating ranges, vary the vacuum pressure used to regulate the turbocharging pressure delivered by a variable geometry turbocharger. The pressure regulation valve is open in the rest position; the engine is therefore naturally aspirated.

12B-45

TURBOCHARGING Intercooler: Removal - Refitting


REMOVAL

12B

K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 F4R, and 776 M9R, and 700 Special tooling required Car. 1363 Trim removal lever

I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).

Tightening torquesm intercooler downstream duct clip on the intercooler intercooler upstream hose clip intercooler downstream duct clip on the damper valve front end panel upper mounting bolts front end panel lower mounting bolts battery tray mounting bolts wiring harness mounting nut on the battery tray 5.5 Nm

Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the engine protectors,

5.5 Nm

- the engine undertray, - the front bumper (see MR 365, Bodywork, 55A, Exterior protection, Front bumper ). F9Q, and 804 K9K, and 732 M9R, and 700

5.5 Nm

21 Nm 44 Nm 21 Nm 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 or any other product, - clean the intercooler bearing face and the hose using a dry, lint-free cloth, - replace the clip in the same position if the hose is not replaced, - always replace the clip with a new one, - always replace the hose and/or the intercooler if they have been damaged. There is a danger of leakage and dislocation if this procedure is not followed.
112658

Remove the Protection and Switching Unit cover mounting bolts (1) .

12B-46

TURBOCHARGING Intercooler: Removal - Refitting

12B

K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 F4R, and 776 M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

102504

Remove the Protection and Switching Unit cover. Disconnect the Protection and Switching Unit connectors (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. M9R, and 700
102473

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.

114933

Unclip the air inlet scoop (6) .

12B-47

TURBOCHARGING Intercooler: Removal - Refitting

12B

K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 F4R, and 776 M9R, and 700

M9R, and 700

102474

114649

Loosen the intercooler downstream duct clip (11) on the intercooler. Move the intercooler downstream duct away from the intercooler. Remove the intercooler.

Remove the intercooler downstream duct mounting bolt (9) on the cooling radiator. Loosen: - the intercooler downstream duct clip (10) on the intercooler, - the intercooler downstream duct clip on the damper valve.

REFITTING
I - REFITTING PREPARATION OPERATION

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-48

TURBOCHARGING Intercooler: Removal - Refitting


II - REFITTING OPERATION FOR PART CONCERNED Connect: - the intercooler upstream hose, - the intercooler downstream duct onto the intercooler. Tighten to torque: - the intercooler downstream duct clip on the intercooler ( 5.5 Nm ) , - the intercooler upstream hose clip ( 5.5 Nm ) . M9R, and 700 Refit the intercooler downstream duct mounting bolt onto the cooling radiator. Tighten to torque the intercooler downstream duct clip on the damper valve ( 5.5 Nm ) . Clip on the bonnet opening cable. Refit: - the battery tray, - the battery tray mounting bolts,

12B

K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 F4R, and 776 M9R, and 700

- 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 battery tray ( 8 Nm ) Clip on the battery terminal wiring harness. Connect: - the screen washer pipes, - the Protection and Switching Unit connectors, - the injection computer connectors.

III - FINAL OPERATION Refit: - the front end panel, - the front end panel mounting bolts. Tighten to torque: - the front end panel upper mounting bolts ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) , Refit: M9R, and 700 Clip on the air inlet scoop. - 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 ). M9R, and 700 Refit the Protection and Switching Unit cover mounting bolts. Refit the Protection and Switching Unit cover.

Note: You must initialise the xenon bulb system (if tted to the vehicle). Adjust the headlights (see 80B, Headlights, Halogen headlights: Adjustment ).

12B-49

TURBOCHARGING Intercooler: Removal - Refitting


B84 or C84, and F4R, and 774

12B

Tightening torquesm battery cover mounting bolts 4 Nm

REMOVAL
Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: - the front bumper, - the headlights.

102474

102476

Remove the air deflectors (1) .

102473

Disconnect the inlet (2) and outlet (3) ducts from the intercooler.

12B-50

TURBOCHARGING Intercooler: Removal - Refitting


B84 or C84, and F4R, and 774

12B

102475

Lift the intercooler upwards to release it from the mounting brackets (4) .

REFITTING
Check that the intercooler is not full of oil. If it is, it must be rinsed with a cleaning agent and then left to drain properly. Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

12B-51

FUEL SUPPLY Petrol supply circuit


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 Operating diagram of the fuel supply circuit

13A
1

5 2 3 4

19310

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 a supply 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 fuel filter (5) (all located in the reservoir), - a fuel vapour recirculation tank (6) .

13A-1

FUEL SUPPLY Diesel fuel supply circuit


C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732 Operating diagram of the diesel fuel supply circuit

13A

102847

The circuit comprises: - a gauge (1) , - a manual priming pump (2) , - a fuel filter (3) that may be fitted with a water detection sensor, - a high-pressure pump (4) with a built-in mechanical low-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. WARNING It is not permitted to remove the pressure sensor from the fuel rail (because this may cause circuit contamination problems). If the pressure sensor fails, the pressure sensor, the rail and the ve highpressure pipes must be replaced.

K9K, and 722 or 728 or 729

WARNING Dismantling the interior of the high-pressure pump and the injectors is prohibited. DELPHI Only the ow actuator, the diesel fuel temperature sensor and the Venturi tube can be replaced.

IMPORTANT Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

13A-2

FUEL SUPPLY Diesel 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 ow regulator solenoid valve and the pressure regulating solenoid valve from the highpressure pump is prohibited. SIEMENS .

13A-3

FUEL SUPPLY Diesel fuel supply circuit


F9Q, and 800 Operating diagram of the fuel supply circuit

13A
5 7 6

100821

The circuit comprises: - a priming bulb (1) (located in the engine compartment), - a fuel filter (2) that may be fitted with a water detection sensor, - a high-pressure regulator (3) mounted on the pump, - a high-pressure pump (4) , - an injection rail (5) fitted with a diesel pressure sensor and a pressure limiter (6) , - four solenoid injectors (7) , - various sensors, - an injection computer. WARNING Dismantling the interior of a high-pressure pump or the injectors is prohibited.

IMPORTANT It is strictly forbidden to uncouple a high-pressure pipe union when the engine is running.

13A-4

FUEL SUPPLY Diesel fuel supply circuit


F9Q, and 800 or 804 or 808 Operating diagram of the diesel fuel supply circuit

13A

102307

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 version, - 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 return circuit, - an injection computer. WARNING Dismantling the interior of the high-pressure pump and the injectors is prohibited. Outside the warranty period for the pump, only the pump pressure regulator can be replaced. During the pump warranty period, the high-pressure pump should be completely replaced if the pressure regulator fails.

IMPORTANT Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

13A-5

FUEL SUPPLY Petrol filter: General information


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

13A

102299

The fuel filter is located in the fuel tank; it is built into the pump-sender-filter assembly and cannot be removed.

WARNING The pump-sender-lter assembly must be replaced if one of the components is faulty. The filter is intended to have a long service life. Checking the fuel supply pressure and the pump delivery rate is the equivalent of running fault finding on the pump-sender-filter assembly.

13A-6

FUEL SUPPLY Diesel filter: Removal - Refitting


K9K, and 722 or 728 or 729

13A

Tightening torquesm wheel bolts 110 Nm

WARNING Follow the cleanliness instructions closely (see 13B, Diesel injection, Cleanliness guidelines ). The cartridge assembly must be replaced (the diesel lter is contained in a non-removable cartridge). Order a set of blanking plugs, part number 77 01 206 804 .

REMOVAL
Disconnect the battery, starting with the negative terminal.
101539

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 it upwards. Disconnect all the filter pipe unions. Place blanking plugs over the open fuel supply pipes.

WARNING Keep the pipe unions away from contaminated areas. 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.

13A-7

FUEL SUPPLY Diesel filter: Removal - Refitting


K9K, and 722 or 728 or 729

13A

102124

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Regularly bleed out the water in the diesel lter via the bleed plug (4) . Some vehicles have a sensor for detecting water in the diesel fuel (5) , located on the lter. If water is detected in the circuit, the injection fault warning light on the instrument panel comes on.
21749

13A-8

FUEL SUPPLY Diesel filter: Removal - Refitting


F9Q, and 800 or 804 or 808

13A

Tightening torquesm battery cover mounting bolts wheel bolts 4 Nm 110 Nm

IMPORTANT Before any operation: - watch out for diesel fuel splashing when disconnecting the supply union, - order the special high pressure injection circuit plug kit.

WARNING - Protect sensitive areas from fuel leakage. - Strictly observe the cleanliness guidelines. The diesel filter is located behind the right-hand headlight. It is contained in a removable cartridge. This cartridge has a built-in diesel fuel heater, comprising a resistor and temperature switch. Remove: - the front right-hand wheel, - the wheel arch liner mounting bolts (1) ,

101539

- the wheel arch liner clips using an unclipping tool, - the wheel arch liner (2) .

Note: Remove the diesel lter assembly to remove the cartridge.

REMOVAL
Disconnect the battery, starting with the negative terminal.

104560

Unclip the diesel filter from its mounting by pushing it upwards.

13A-9

FUEL SUPPLY Diesel filter: Removal - Refitting


F9Q, and 800 or 804 or 808

13A

102477

19317

Disconnect the diesel heater connector (3) from the diesel heater. WARNING Keep the pipe unions away from contaminated areas. 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 relation to the bowl (6) . Remove the mounting bolt (7) from the cover on the bowl. 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.

WARNING Align the marking on the cover, tted with blanking plugs, with the marking on the bowl. Tighten the mounting bolt on the cover over the bowl. Clip the diesel filter onto the mounting. Reconnect to the diesel filter: - the fuel supply pipes, - the diesel fuel heater connector,

13A-10

FUEL SUPPLY Diesel filter: Removal - Refitting


F9Q, and 800 or 804 or 808

13A

Note: Regularly bleed out water that has accumulated in the diesel lter through the bleed plug. Some vehicles have a sensor for detecting water in the diesel fuel, located in the diesel lter. If water is detected in the circuit, the injection fault warning light on the instrument panel comes on. Tighten to torque the wheel bolts ( 110 Nm )

19317

102124

Reprime the supply circuit: - Turn the air bleed screw (8) 360 degrees, - operate the manual priming pump (9) until the fuel runs 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13A-11

FUEL SUPPLY Diesel filter: Removal - Refitting


K9K, and 724 or 732 M9R, and 700

13A

- the front right-hand wheel arch liner (1) . Tightening torquesm wheel bolts 110 Nm II - OPERATION FOR REMOVAL OF PART CONCERNED

WARNING During this operation: - refrain from smoking or bringing red hot objects close to the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.

Note: Make sure you have a new diesel lter before opening the fuel circuit.

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

114559

Remove the diesel filter from its mounting on the body by pushing the filter - metal strap assembly upwards. Disconnect all the fuel pipe unions on the diesel filter. Note: Make preparations for the fuel outow.

WARNING Prevent the hose unions from coming into contact with a polluted environment. Remove the diesel filter from the vehicle. Note: Only use wipes part number 77 11 211 707 to clean the lter and pipes once the fuel circuit is opened.

REFITTING
104544

Remove: - the front right-hand wheel,

I - REFITTING OPERATION FOR PART CONCERNED Connect the fuel pipes onto the new diesel filter.

13A-12

FUEL SUPPLY Diesel filter: Removal - Refitting


K9K, and 724 or 732 M9R, and 700 Refit the filter - metal strap assembly on its mounting on the body.

13A

Note: Check that the lter is correctly positioned and secure in its mounting by shaking it: the lter must not move. If necessary, remove the lter and gently squeeze the metal strap retaining bracket on its mounting.

II - FINAL OPERATION

102124

Prime the fuel circuit using the manual priming pump (2) (automatic degassing). Check there are no leaks from the unions on the filter. 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: Removal - Refitting ).

Note: Regularly bleed out water that has accumulated in the diesel lter through the bleed plug. Some vehicles have a sensor for detecting water in the diesel fuel, located at the bottom of the lter. If water is detected in the circuit, a f ult wara ning light on the instrument panel comes on.

13A-13

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


K4M, and 760 or 761

13A

Tightening torquesm injector rail mounting bolts battery cover mounting bolts 9 Nm 4 Nm

The injectors are secured to the injector rail by clips. The fuel circulates constantly around the circumference of the injector body. This sweeping by the fuel prevents the formation of petrol vapour bubbles and helps warm starting.

1 2

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the inlet manifold (see 12A, Fuel mixture, Inlet manifold ). IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail. Disconnect injector electrical harness (1) . Remove: - the two injector rail mounting bolts (2) , - the injector rail, pulling it carefully towards you. ON THE WORKBENCH
101810

WARNING Protect the alternator against fuel spills from the rail or supply duct.

101816

Remove: - injector clips (3) , - injectors (4) .

13A-14

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


K4M, and 760 or 761

13A

REFITTING

WARNING The O-rings and the injector mounting clips must always be replaced with new ones. Fit the injector rail. Torque tighten the injector rail mounting bolts ( 9 Nm ) . Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

13A-15

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


B84 or C84 or G84, and K4J, and 730 or 732

13A

Tightening torquesm injector rail mounting bolts battery cover mounting bolts 9 Nm 4 Nm

The injectors are secured to the injector rail by clips. The fuel circulates constantly around the circumference of the injector body. This sweeping by the fuel prevents the formation of petrol vapour bubbles and helps warm starting.

101802

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the engine covers.

Disconnect: - fuel supply pipe (2) - injector and pinking sensor electrical harness (3) . IMPORTANT Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail.

WARNING Protect the alternator against fuel spills from the rail or supply duct.

101801

Remove mounting nuts (1) from the injection rail protector. Move the wiring harness to one side.

101493

Remove: - the two injector rail mounting bolts (4) , - the injector rail, pulling it carefully towards you.

13A-16

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


B84 or C84 or G84, and K4J, and 730 or 732 ON THE WORKBENCH

13A

101492

Remove: - injector clips (5) , - injectors (6) .

REFITTING
WARNING The O-rings and the injector mounting clips must always be replaced with new ones. Fit the injector rail. Torque tighten the injector rail mounting bolts ( 9 Nm ) . Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

13A-17

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


F4R, and 770 or 771 or 776

13A
3

Tightening torquesm injector rail mounting bolts battery cover mounting bolts 9 Nm 4 Nm

The injectors are secured to the injector rail by clips. The fuel circulates constantly around the circumference of the injector body. This sweeping by the fuel prevents the formation of petrol vapour bubbles and helps warm starting.

102728

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the engine covers. F4R, and 770 or 771

Disconnect: - fuel supply pipe (2) , - injector and pinking sensor electrical harness (3) .

F4R, and 776

4 6 1

5
101801

Remove the two injection rail guard mounting nuts (1) . Move the wiring harness to one side.

106787

Disconnect: - turbocharging pressure sensor connector (4) - the vacuum pipe from brake servo (5) , - oil vapour recirculation pipe (6) .

13A-18

FUEL SUPPLY Injector rail - Injectors: Removal - Refitting


F4R, and 770 or 771 or 776 ON THE WORKBENCH

13A

106271

10 9

Disconnect fuel supply pipe (7) from the injector rail.

102737

IMPORTANT Be careful of petrol splashing out when disconnecting the fuel supply union.

Remove: - injector clips (9) , - injectors (10) .

WARNING Protect sensitive areas from fuel spillage.

REFITTING
WARNING The O-rings and the injector mounting clips must always be replaced with new ones. Fit the injector rail. Torque tighten the injector rail mounting bolts ( 9 Nm ) . Proceed in the reverse order to removal.

Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Torque tighten the battery cover mounting bolts ( 4 Nm )
102730

Remove: - the two injector rail mounting bolts (8) , - the injector rail, pulling it carefully towards you.

13A-19

FUEL SUPPLY Electric fuel: Checking


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776 Special tooling required K4M, and 760 or 761 Mot. 1311-01 Mot. 1311-08 Fuel pressure test kit Union for measuring fuel pressure

13A

IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects close to the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.

2 3

K4J, and 730 or 732 F4R, and 770 or 771 or 776


101803

Disconnect the petrol inlet pipe from the injection rail.

Connect: - pipe (1) fitted with a pressure gauge and located in test 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. IMPORTANT


101496

This procedure must be carried out with the ignition off. Remove the Protection and Switching Unit cover.

Disconnect the petrol inlet pipe from the injection rail.

13A-20

FUEL SUPPLY Electric fuel: Checking


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776

13A

4
5

1 12

102502

102501

Place the electrical connector (4) to one side without disconnecting it.

Connect terminal (5) of the brown connector to the battery positive feed Note: The ow reading should be between 80 and 120 l/h .

102503

Disconnect the brown connector (5) from the Protection and Switching Unit.

13A-21

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729

13B

Equipment required diagnostic tool Engine Vehicle type Type Sufx Idling speed 805 50 Engine speed (rpm) Maximum unladen 5000 150 Maximum laden 4800 100 Smoke opacity Homologation value (m-1) Legal maximum (m -1) 3

XM0F XM0T XM1F K9K XM02 XM13 XM02

722

724 728

800 50

4900 150

4900 150 1.5

805 50 729

4950 150

4800 100

Description High pressure pump Low pressure pump Injection computer Diesel rail pressure sensor

Make - type DELPHI DELPHI DELPHI DELPHI

Special notes Pressure from 0 to 1,400 bar Integrated in the high pressure pump 112-track computer (A 32, B 48, C 32) Integrated in the rail Resistance not measurable Supply voltage: + 5 V 3-track connector: - 1: signal - 2: diesel rail pressure sensor earth - 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-1

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729 Description Diesel ow actuator Make - type DELPHI Special notes

13B
Located on the high pressure pump Resistance: 5.3 0.5 at 20C Supply voltage: + 5 V 2-track connector: - 1: + battery feed via Protection and Switching Unit - 2: actuator control

Engine speed and position sensor

MGI

Var iable reluctance sensor Resistance: 760 (K9K 722) Resistance: 680 (K9K 724, 728, 729) 2-track connector - A: + signal - B: - signal

Pre-postheating unit

NAGARES BED 7-12

Pre-postheating function managed 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 nding

Heater plugs

CHAMPION or BERU

Resistance: 0.6

13B-2

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729 Description Accelerator pedal potentiometer Make - type CTS Special notes

13B
Dual gang potentiometer Resistance - gang 1: tracks 3 and 5: 1700 900 - gang 2: tracks 2 and 6: 3875 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

Cylinder reference sensor

SAGEM

Hall effect sensor 3-track connector: - 1: cylinder reference sensor earth - 2: signal - 3: + battery feed via Protection and Switching Unit

Diesel temperature sensor

DELPHI

Located on the high pressure pump Negative temperature coefcient thermistor Resistance: 2.2 k at 25C 2-track connector: - 1: signal - 2: diesel temperature sensor earth

Accelerometer

SAGEM

Resistance not measurable 2-track connector: - 1: signal - 2: accelerometer earth

13B-3

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729 Description Engine coolant temperature sensor Make - type ELTH Special notes

13B
Negative temperature coefcient thermistor Resistance: - 75780 7000 at - 40C - 12460 1128 at - 10C - 2252 112 at 25C - 811 38 at 50C - 282 8 at 80C - 115 3 at 110C - 88 2 at 120C 4-track connector: - 3: signal - 4: engine coolant temperature sensor earth

Turbocharging air temperature and pressure sensor

BOSCH / LDF6T 20-250

Pressure sensor with a negative temperature coefcient thermistor Supply voltage: + 5 V Resistance: - 20376 1110.5 at - 25C - 15614 829 at - 20C - 9426 475 at - 10C - 5887 281.5 at 0C - 3791 172.5 at 10C - 2511 109 at 20C - 1715.5 71 at 30C - 1200 47 at 40C - 851 32 at 50C - 612 22 at 60C - 446 15 at 70C - 330 11 at 80C 4-track connector: - 1: earth - 2: air temperature sensor signal - 3: + 5 V supply - 4: pressure sensor signal

Exhaust gas recirculation solenoid valve (K9K 722, 728 and 729)

PIERBURG

Supply voltage: + 13.5 V Resistance: tracks 1 and 5: 8 0.5 at 20C

13B-4

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729 Description Exhaust gas recirculation solenoid valve (K9K 724) Make - type PIERBURG Special notes

13B
Supply voltage: 13.5 V Resistance: tracks 2 and 6: 2.3 at 20C

Exhaust gas recirculation solenoid valve position potentiometer (K9K 724)

PIERBURG

Integrated in the exhaust gas recirculation 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 solenoid valve position potentiometer (K9K 722 728 and 729)

PIERBURG

Integrated in the exhaust gas recirculation solenoid valve Supply voltage: + 5 V Resistance: - tracks 2 and 4: 4 1.6 k at 20C 6-track connector: - 1: solenoid valve + battery feed via 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

13B-5

DIESEL INJECTION Specifications


K9K, and 722 or 728 or 729 Description Fault nding Turbocharging pressure regulation solenoid valve (K9K 724, 728 and 729) Make - type BITRON Special notes

13B
diagnostic tool : CLIP only Proportional solenoid valve Supply voltage: 13.5 V Resistance: 16.5 1.6 at 23C 2-track connector: - 1: signal - 2: supply

13B-6

DIESEL INJECTION Specifications


F9Q, and 800 or 808

13B

Equipment required diagnostic tool Engine Vehicles Gearbox Type Sufx 800 ND0 F9Q 808 80 93 1870 19:1 Bore (mm) Stroke (mm) Cubic capacity (cc) Compression ratio

XM0G XM1G XM00

Engine speed (rpm) Idling speed 800 50 Maximum unladen 4850 150 Maximum laden 4500 100

Smoke opacity Homologation value (m-1) Legal maximum (m -1) 3 (70%)

1.9 (54%)

Description High pressure pump Diesel fuel pressure sensor Injectors

Make - Type BOSCH CP3 BOSCH BOSCH

Special notes Pressure from 250 to 1,350 bar Bolted onto the rail Solenoid injector Operating pressure up to: 1300 bar

Pressure regulator

BOSCH

Bolted onto the high pressure pump Resistance: 3 0.1 at 20C

Injection computer Pre-postheating unit (located behind the front left-hand wheel arch liner) Heater plugs Engine speed sensor Camshaft sensor Accelerator potentiometer

BOSCH EDC 16 NAGARES BED/7-12

112-track computer With pre-postheating function managed by computer Resistance: 0.6 connector disconnected Resistance: 720 at 880 at 20C Dual gang potentiometer Resistance: - gang 1: 1700 900 - gang 2: 3875 1025

BERU ou CHAMPION MGI ELECTRIFIL CTS

13B-7

DIESEL INJECTION Specifications


F9Q, and 800 or 808 Description Air inlet temperature sensor Diesel fuel temperature sensor Engine coolant temperature sensor Air owmeter Make - Type SIEMENS ELTH ELTH SIEMENS Special notes

13B
Integrated in the air owmeter Resistance: 2,050 at 25C Resistance: 2252 112 at 25C Air owmeter with integrated air temperature sensor - track 1: air temperature - track 2: earth - track 3: 5 V reference feed - track 4: + 12 V after injection relay feed - track 5: air ow signal - track 6: earth

T urbocharger pressure sensor

BOSCH

Output voltage with ignition on and engine stopped (between tracks 2 and 3): - = 1.6 V for an atmospheric pressure of 1,013 mbar - > 1.6 V for an atmospheric pressure > 1,013 mbar - < 1.6 V for an atmospheric pressure < 1,013 mbar Replace the seal each time it is removed

Atmospheric pressure sensor Exhaust gas recirculation solenoid valve

PIERBURG

Integrated in the computer Gang resistance: 8 0.5 at 20C (tracks 1 and 5) Sensor resistance: 4 k at 20C (tracks 2 and 4)

Damper valve solenoid valve (engine stop solenoid valve) T urbocharging pressure regulation solenoid valve Fault nding

BITRON ou EATON PIERBURG

Resistance: 46 3 at 25C Resistance: 15.4 0.7 at 20C diagnostic tool : CLIP only

13B-8

DIESEL INJECTION Specifications


F9Q, and 804

13B

Equipment required diagnostic tool Engine Vehicle type Type Sufx Idling speed 800 50 Engine speed (rpm) Maximum unladen 4850 150 Maximum laden 4500 100 Smoke opacity Homologation value (m -1) 1.9 (54%) Legal maximum (m -1) 3 (70%)

XM0L XM1D XM17 XM14

F9Q

804

Description High pressure pump Diesel fuel pressure sensor

Make - Type BOSCH CP3.2 BOSCH

Special notes Pressure 1600 bar Max 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 pressure pump Resistance: 3 0.1 at 20C

Injection computer Pre-postheating unit (located behind the front left-hand wheel arch liner) Heater plugs Engine speed and TDC sensor Camshaft sensor Accelerator potentiometer

BOSCH EDC 16 NAGARES BED/7-12

112-track computer With pre-postheating function managed by computer Resistance: 0.6 connector disconnected Resistance: 800 at 20C Hall effect type Dual gang potentiometer Resistance: - gang 1: 1700 900 - gang 2: 2850 2050

BERU ou CHAMPION MGI ELECTRIFIL CTS

Air inlet temperature sensor Engine coolant temperature sensor

SIEMENS ELTH

Integrated in the air owmeter Resistance: 2252 112 at 25C

13B-9

DIESEL INJECTION Specifications


F9Q, and 804 Description Air owmeter Make - Type SIEMENS Special notes

13B
Air owmeter with integrated air temperature sensor - track 1: air temperature - track 2: earth - track 3: 5 V reference feed - track 4: + 12 V after injection relay feed - track 5: air ow signal - track 6: earth

Turbocharger pressure sensor

BOSCH

Output voltage with ignition on and engine stopped (between tracks 2 and 3): - = 1.6 V for an atmospheric pressure of 1,013 mbar - > 1.6V for an atmospheric pressure > 1013 mbar - < 1.6 V for an atmospheric pressure < 1013 mbar Replace the seal each time it is removed

Atmospheric pressure sensor Exhaust gas recirculation solenoid valve

SIEMENS

Integrated in the computer Gang resistance: 2.96 10 % at 20C (tracks 1 and 5) Sensor resistance: 6.5 k 40% at 20C (tracks 2 and 4)

Turbocharging pressure regulation solenoid valve Turbocharger

PIERBURG GARRET

Resistance: 15.4 0.7 at 20C Calibration - For an underpressure 265 mbar , the rod should have a stroke of between 0.5 and 3.5 mm - for a vacuum greater than 600 mbar the rod should be at the stop

Fault nding

diagnostic tool : CLIP only

13B-10

DIESEL INJECTION Diesel injection: Specifications


K9K, and 732

13B

Equipment required diagnostic tool Engine Vehicle type Type Sufx Idling speed Engine speed (rpm) Maximum unladen Maximum laden Smoke opacity Homologation value 1.5 m
-1

Legal maximum
-1

Depol lution standard Euro IV

X84

K9K

732

800 50

5000 150

5000 150

2m

Description High pressure pump Low pressure pump Injection computer Diesel rail pressure sensor

Make - type SIEMENS VDO SIEMENS VDO SIEMENS VDO SIEMENS VDO

Special notes Pressure from 0 to 1600 bar Integrated in the high pressure pump 128-track computer (A 32, B 48, C 48) Integrated in the rail Resistance not measurable Supply voltage: + 5 V 3-track connector: - 1: signal - 2: diesel rail pressure sensor earth - 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 pressure pump Cannot be removed Supply voltage: + 12 V

13B-11

DIESEL INJECTION Diesel injection: Specifications


K9K, and 732 Description Pressure regulation solenoid valve Make - type SIEMENS VDO Special notes

13B
Integrated in the high pressure pump Cannot be removed Supply voltage: + 12 V

Engine speed and position sensor

SIEMENS VDO

Variable reluctance sensor Resistance: 680 6.8 at 20C 2-track connector - 1: + signal - 2: - signal

Pre-postheating unit

NAGARES

With pre-postheating function controlled by the injection computer 8-track connector - 1: heater plug no. 3 supply - 2: spark plug no. 1 supply - 3: fault nding - 4: + batter y supply - 6: spark plug no. 4 supply - 7: heater plug no. 2 supply - 8: injection computer control

Heater plugs Accelerator pedal potentiometer

CHAMPION ou BERU CTS

Resistance: 0.6 Dual gang potentiometer Resistance - gang 1: tracks 3 and 5: 1700 900 - gang 2: tracks 2 and 6: 3875 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

13B-12

DIESEL INJECTION Diesel injection: Specifications


K9K, and 732 Description Cylinder reference sensor Make - type JCAE Special notes Hall effect sensor 3-track connector: - 1: earth - 2: signal - 3: supply Diesel temperature sensor ELTH

13B

Located on the diesel return rail on the high pressure pump outlet 2-track connector: - 1: signal - 2: earth

Atmospheric pressure sensor Air temperature sensor

SIEMENS VDO SIEMENS VDO

Integrated in the computer Integrated in owmeter Negative temperature coefcient thermistor Resistance: - 44373 3118 at - 40C - 15141 871 at - 20C - 9202 486 at 10C - 5774 276 at 0C - 3714 161 at 10C - 2448 95 at 20C - 1671 58 at 30C - 1150 36 at 40C - 817 22 at 50C - 583 14 at 60C - 316 6 at 80C - 183 2 at 100C

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 potentiometer built into the damper valve Solenoid valve supply voltage: + 13.5V Potentiometer supply voltage: + 5V

13B-13

DIESEL INJECTION Diesel injection: Specifications


K9K, and 732 Description Engine coolant temperature sensor Make - type ELTH Special notes

13B
Negative temperature coefcient thermistor Resistance: - 75780 7000 at - 40C - 12460 1128 at - 10C - 2,252 112 at 25C - 811 38 at 50C - 282 8 at 80C - 115 3 at 110C - 88 2 at 120C 4-track connector: - 1: not used - 2: engine coolant temperature sensor signal - 3: engine coolant temperature sensor earth - 4: not used

Exhaust gas recirculation solenoid valve Exhaust gas recirculation solenoid valve position potentiometer

PIERBURG

Supply voltage: + 13.5 V Resistance: tracks 2 and 6: 2.3

PIERBURG

Integrated in the exhaust gas recirculation 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

13B-14

DIESEL INJECTION Diesel injection: Specifications


K9K, and 732 Description Water in diesel sensor Make - type PRESSAC Special notes

13B
Located on the diesel lter 3-track connector: - 1: supply - 2: signal - 3: earth

Air inlet owmeter

SIEMENS VDO

Air owmeter with integrated air temperature sensor 6-track connector: - 1: air temperature signal - 2: earth - 3: Not used - 4: + 12 V supply - 5: supply: + 5 V - 6: air ow signal

Turbocharging pressure regulation solenoid valve

BIRTON

Proportional solenoid valve supply voltage + 12 V 2-track connector: - 1: computer output - 2: supply

Fault nding

diagnostic tool : CLIP only

13B-15

DIESEL INJECTION Diesel 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 I - RISKS LINKED TO CONTAMINATION The high pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are: - damage to or destruction of the high pressure injection system, - a component seizing, - a component not being properly sealed. All After-Sales operations must be performed under very clean conditions. Having carried out an operation in good conditions means that no impurities (particles a few microns in size) have penetrated the system during dismantling. The cleanliness principle must be applied from the filter to 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. 4 - Cleaning products Two cleaning products can be used: 3 - Protective bags 2 - Blanking plugs

13B

The blanking plugs are used to cap the fuel circuit once it is opened and to therefore prevent contaminants from entering. A set of blanking plugs should be used once only and used plugs must be discarded after use: once used, the plugs are soiled and cleaning them is not sufficient to make them reusable. Unused plugs must also be discarded and not used again 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

Use hermetically-resealable plastic bags, using adhesive tape, for example, to store components which will be refitted and reused. Stored parts will therefore be less subject to the risk of contamination. These bags must be used once only: once they have been used, they are to be discarded.

- an injector cleaner (part number 77 11 224 188 ), - an aerosol spray brake cleaner (part number 77 11 226 128 ). To use the injector cleaner, be sure to have a clean brush in good condition (the brush must not lose any bristles) as well as a clean container which has no impurities in it.

WARNING Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection faults.

Note: Use a new injector cleaner each time work is carried out (a used cleaning agent will contain impurities).

1 - Cleaning cloths Use lint free cleaning cloths (part number 77 11 211 707 ). The use of rags or ordinary paper towels is prohibited: these produce lint and lose fibres, which then contaminate the fuel circuit. Each cloth must only be used once.

II - ADVICE TO BE FOLLOWED BEFORE ANY OPERATION 1) Carry out the work in a clean working area and take care to protect removed components from dust using plastic bags which are hermetically-resealable, for example.

13B-16

DIESEL INJECTION Diesel 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 2) Always order the following from the Parts Department before carrying out work: - une collection de bouchons de propret neuve , specific to the engine, - a sufficient number of lint-free lingettes de nettoyage . - one of the two produits de nettoyage for the fuel pipe unions, - les pices remplacer systmatiquement after each removal and which are mentioned in the work procedures specific to each vehicle (see the relevant Workshop Repair Manual). 3) Wear safety goggles fitted with side shields to prevent the cleaning product from splashing the eyes. 4) Wear latex safety gloves to avoid prolonged contact with the skin.

13B

When replacing a component with a new one or when refitting it after storing it in a plastic bag, do not unpack it until it is time to fit it on the vehicle. IV - CLEANING There are currently two procedures for cleaning the fuel circuit before opening it in order to carry out work in the workshop. These procedures enable the fuel circuit to be cleaned to prevent contamination: they both have the same end result and neither is preferred over the other. 1 - Using the injector cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks.

Note: If wearing leather protective gloves, cover these with latex protective gloves.

Pour the injector cleaning agent into a container which is free from impurities.

IMPORTANT 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 electrical connectors), - the flywheel face. III - INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION Wash your hands before and while carrying out the work. Change the latex safety gloves if they become soiled or damaged. All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been capped. Reseal the bag hermetically using adhesive tape, for example, even if the bag must be opened shortly afterwards: ambient atmosphere can be a source of pollution. After opening the fuel circuit, the use of brushes, cleaning agents, air blow guns, rifle-type brushes or standard cloths is strictly prohibited: These items are likely to allow impurities to enter the system. Wear latex safety gloves when using the cleaning agent. Dip a clean brush, which is not shedding bristles, into the container of injector cleaning agent.

IMPORTANT Wear safety goggles tted with side shields during this operation. Clean the unions carefully using the brush and the injector cleaning agent. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Wipe the sections that were cleaned with fresh cleaning cloths. Open the circuit at the unions and immediately fit the relevant blanking plugs.

WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only if necessar y. ,

13B-17

DIESEL INJECTION Diesel 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 2 - Using the brake cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks.

13B

IMPORTANT Wear latex safety gloves when using the cleaning agent.

IMPORTANT Wear safety goggles tted with side shields during this operation. Spray the brake cleaning agent onto the unions to be opened. Clean the unions carefully using fresh cleaning cloths. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Open the circuit at the unions and immediately fit the relevant blanking plugs.

WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only if necessar y. ,

13B-18

DIESEL INJECTION Diesel 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 V - INSTRUCTIONS FOR FITTING THE PLUGS K9K, and 722 or 724 or 728

13B

13B-19

DIESEL INJECTION Diesel 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 part no. 77 01 206 804

13B

13B-20

DIESEL INJECTION Diesel 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
20977

13B-21

DIESEL INJECTION Diesel 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-22

DIESEL INJECTION Diesel 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 part no. 77 01 476 857

13B

13B-23

DIESEL INJECTION Diesel 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
113430

13B-24

DIESEL INJECTION Diesel 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-25

DIESEL INJECTION Diesel 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 part no. 77 01 208 229

13B

13B-26

DIESEL INJECTION Diesel 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
104561

13B-27

DIESEL INJECTION Diesel 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-28

DIESEL INJECTION Diesel 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 part no. 77 01 209 062

13B

13B-29

DIESEL INJECTION Diesel 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
113737

13B-30

DIESEL INJECTION Description


F9Q, and 800 or 808 The high pressure direct injection system is intended to deliver a specific volume of diesel fuel to the engine at a 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 sensor and a pressure limiter, - four solenoid injectors, - various sensors, - an injection computer.

13B

13B-31

DIESEL INJECTION Description


K9K, and 722 or 728 or 729 The high pressure direct injection system is intended to deliver a specific volume of diesel fuel to the engine at a specific time. The system comprises: - a priming pump on the low pressure circuit, - a diesel filter, - a high pressure pump combined with a low pressure pump (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

13B-32

DIESEL INJECTION Operation


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

13B

Equipment required diagnostic tool

- the needle stroke (determined by a constant for an injector type), - the nominal hydraulic flow of the injector (specific to each injector), - the high pressure rail pressure regulated by the computer. The computer manages:

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 the safety and cleanliness advice specied in this document. Loosening a high pressure pipe union when the engine is running is strictly prohibited. The common rail high pressure injection system operates in sequential mode (based on the multipoint injection 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 particles, - a high engine torque at low engine speeds. The high pressure pump generates the high pressure transmitted to the injection rail. The actuator on the high pressure pump controls the volume of diesel fuel supplied according to the demand determined by the injection computer. The rail supplies each injector through a steel pipe. The computer: - determines the injection pressure value necessary for the engine to operate correctly and then operates the fuel flow actuator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor located on the rail, - determines the injection time necessary to deliver the right volume of diesel fuel and the moment when injection should be started, - electrically actuates each injector individually after determining these two values. The flow injected into the engine is determined according to: - the duration of injector actuation, - the injector opening and closing speed,

- 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: centralised 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 by a mechanical low pressure pump (transfer pump). The high pressure pump supplies the rail which is pressure-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 to supply the exact volume of diesel fuel required to maintain the pressure in the rail. This feature allows heat generation to be minimised and engine output to be improved. To discharge the rail, the injection valves are controlled by small electrical pulses: - short enough not to open the injector (passing through the return circuit from the injectors), - long enough to open the valves and discharge the rail. The injection computer actuates the fan assembly and the coolant temperature warning light on the instrument panel (function: centralised coolant temperature management). The various vehicle computers communicate via multiplex links. The fault warning lights on the instrument panel are therefore activated via the multiplex network. In the event of an impact, the function that cuts off the diesel fuel supply circuit is managed by the airbag computer. It gives the command via the multiplex network to the injection computer to lock the injection locking relay control.

13B-33

DIESEL INJECTION Operation


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 Unlocking is only enabled after the ignition is switched off for 10 seconds . This operation causes the fault warning light to come on for longer than usual when switching on the ignition. The warning light will not return to normal operation until the fault has been cleared using the diagnostic tool . The vehicle speed signal is transmitted to the instrument panel by the ABS computer or the gearbox (vehicle without ABS system) via the multiplex network. Some vehicles have a sensor for detecting water in the diesel fuel, which is located in the filter. If there is water present in the diesel fuel, the orange injection warning light comes on. Automatic configuration for cruise control - speed limiter operation and for air conditioning operation. Injection computer actuating the air conditioning compressor clutch via the UPC. A new electronics casing called the UPC has been added 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 near the battery. It contributes to the protection of certain electrical 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 the diagnostic tool (see 87G, Motor exchange unit, UPC: Configuration ). The injection computer receives a continuous signal via the multiplex network regarding the electrical power available from the alternator. This therefore prevents the vehicle's electrical consumption from being in excess of the alternator's capacity. The aim is to give priority to charging the battery. Note:

13B

WARNING - The engine must not be run with diesel fuel containing more than 10% diester or petrol, even in minute quantities. - Dismantling the interior of the high pressure pump and the injectors is prohibited. Only the fuel ow actuator, the diesel fuel temperature sensor and the Venturi tube can be replaced. - It is prohibited to remove the pressure sensor from the injection rail as this could cause contamination of the circuit. If the pressure sensor is faulty, replace the assembly consisting of the pressure sensor, rail, and the ve high pressure pipes. - It is strictly prohibited to remove any injection pump pulley bearing the number 070 575. If the pump is being replaced also replace the pulley. - Supplying any system component directly with the + 12 V is prohibited. - Ultrasonic decarbonisation and cleaning are prohibited. - Never start the engine unless the battery is properly connected. - Never turn the engine against its operating direction. Reprime the circuit using the priming pump.

IMPORTANT The engine should not be run with diesel fuel containing more than 10% diester.

After any operation, check that there is no diesel fuel leakage. Let the engine idle until the engine cooling fan starts up, then accelerate several times at no load. The system can inject the diesel fuel into the engine up to a pressure of 1350 bar . Before each operation check 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.

13B-34

DIESEL INJECTION Operation


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 When the high pressure pump, injectors and high pressure supply, outlet and return unions are removed or repaired, all apertures should be capped with suitable new blanking covers to prevent contamination.

13B

WARNING Any pipe removed must be replaced. When replacing a high pressure pipe, follow the procedure below: - remove the high pressure pipe, holding the filter rod on 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 Dismantling the interior of the pump is prohibited. The fuel return pipe tted to the injectors must be replaced when removed. The diesel fuel temperature sensor cannot be removed. It is part of the fuel return rail. Loosening a high pressure pipe union when the engine is running is prohibited.

13B-35

DIESEL INJECTION Location of components


K9K, and 722

13B

102072

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Pr iming pump Cylinder reference sensor Turbocharger Exhaust gas recirculation solenoid valve Injector Turbocharging air temperature and pressure sensor Injection computer Air lter unit Protection and Switching Unit Coolant temperature sensor Engine speed and position sensor Rail pressure sensor Spherical injection rail Accelerometer Diesel temperature sensor Diesel ow actuator High pressure pump (18) Injection computer
101811

13B-36

DIESEL INJECTION Location of components


K9K, and 722

13B

101105

102084

(19)

Protection and Switching Unit

(21) (22) (23) (24) (25) (26) (27)

Venturi Flow actuator Diesel temperature sensor Rail pressure sensor Spherical injection rail Accelerometer Injector

102085

(20)

High pressure pump

102082

13B-37

DIESEL INJECTION Location of components


K9K, and 722 (29) (28) Turbocharging air temperature and pressure sensor (30)

13B
Exhaust gas recirculation solenoid valve Wastegate valve

19654-1

(31)

Cylinder reference sensor

13B-38

DIESEL INJECTION Location of components


K9K, and 722

13B

20796

102125

(32) (33)

Coolant temperature sensor Engine speed and position sensor

(35)

Pre-postheating unit

102121

102204

(36)

Diesel lter

(34)

Accelerator pedal potentiometer

13B-39

DIESEL INJECTION Location of components


K9K, and 722

13B

102124

(37)

Pr iming pump

102077

(39) (40)

Turbocharger Catalytic converter

102128

(38)

Refrigerant pressure sensor

13B-40

DIESEL INJECTION Location of components


F9Q, and 800 or 808

13B

101883

(16) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) Diesel lter Manual priming pump Cylinder reference sensor Rail pressure sensor Solenoid injectors Engine stop system vacuum reserve Engine stop system solenoid valve Exhaust gas recirculation solenoid valve (F9Q 800) Turbocharger regulation solenoid valve Flowmeter with air temperature sensor Injection computer Protection and Switching Unit Engine stop valve diaphragm Engine stop valve Pressure limiter (on injection rail) (18) (19) (17)

Turbocharging pressure sensor Diesel temperature sensor (fuel return) High pressure pump Diesel pressure regulator

13B-41

DIESEL INJECTION Location of components


F9Q, and 800 or 808

13B

18297-1

(20) (21) (22) (23) (24) (25) (26)

High pressure pump Injection rail Injector Pressure regulator Pressure sensor Coolant temperature sensor Pressure limiter

27

102485

(27)

TDC sensor

13B-42

DIESEL INJECTION Location of components


F9Q, and 800 or 808

13B

28

31

16181

101891

(28)

Cylinder reference sensor

(31)

Preheating unit

29

32

30

102479

101889

(29) (30)

Turbocharger Catalytic converter

(32)

Turbocharging pressure regulation solenoid valve

13B-43

DIESEL INJECTION Location of components


F9Q, and 800 or 808

13B

33

38

34

101892

101886

(33) (34)

Engine stop valve Engine stop diaphragm valve control

(38)

Manual priming pump

35 37

36

39
102486

(35) (36) (37)

Engine stop valve reserve

vacuum
102121

Engine stop valve solenoid valve Exhaust gas recirculation solenoid valve (F9Q 800) (39) Diesel lter

13B-44

DIESEL INJECTION Location of components


F9Q, and 800 or 808

13B

40

102352

(40)

Turbocharging pressure sensor

102204

(41)

Accelerator pedal potentiometer

13B-45

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

106343

(17) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) Pr iming pump Cylinder reference sensor Turbocharger Exhaust gas recirculation solenoid valve Injector Turbocharging air temperature and pressure sensor Injection computer Air lter unit UPC Coolant temperature sensor Engine speed and position sensor Rail pressure sensor Spherical injection rail Accelerometer Diesel fuel temperature sensor Diesel fuel ow actuator (19) (18)

High pressure pump Turbocharging pressure solenoid valve

101811

Injection computer

13B-46

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

101105

102084

(20)

UPC

(22) (23) (24) (25) (26) (27) (28)

Venturi Fuel ow actuator Diesel fuel temperature sensor Rail pressure sensor Spherical injection rail Accelerometer Injector

102085

(21)

High pressure pump

110327

13B-47

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

110319

(29) (30) (31) (32)

Turbocharging air temperature and pressure sensor Exhaust gas recirculation solenoid valve Engine speed and position sensor Turbocharging pressure regulation valve

101889

(33)

Turbocharging pressure regulation solenoid valve

13B-48

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

19654-1

(34)

Cylinder reference sensor

102204

20796

(36)

Accelerator pedal potentiometer

(35)

Coolant temperature sensor

13B-49

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

102124

(39)

Priming pump

102125

(37)

Pre-postheating unit

102128

(40)

Refrigerant pressure sensor

104954

(38)

Diesel lter

13B-50

DIESEL INJECTION Location of components


K9K, and 728 or 729

13B

102077

(41) (42)

Turbocharger Catalytic converter

13B-51

DIESEL INJECTION Location of components


F9Q, and 804

13B

101883

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

Diesel lter Pr iming pump Cylinder reference sensor Rail pressure sensor Solenoid injectors Exhaust gas recirculation solenoid valve unit Turbocharger regulation solenoid valve Flowmeter with air temperature sensor Injection computer UPC Pressure limiter Turbocharging pressure sensor Diesel fuel temperature sensor High pressure pump Diesel pressure regulator

13B-52

DIESEL INJECTION Location of components


F9Q, and 804

13B

18297-1

(16) (17) (18) (19) (20) (21) (22)

High pressure pump Injection common rail Injectors Pressure regulator Pressure sensor Coolant temperature sensor Pressure limiter

102485

(23)

TDC sensor

13B-53

DIESEL INJECTION Location of components


F9Q, and 804

13B

16181

101891

(24)

Cylinder reference sensor

(27)

Preheating unit

111864

101889

(25) (26)

Turbocharger Catalytic converter

(28)

Turbocharging pressure regulation solenoid valve

13B-54

DIESEL INJECTION Location of components


F9Q, and 804

13B

111856

102121

(29) (30)

Throttle valve. Exhaust gas recirculation solenoid valve unit.

(32)

Diesel lter

102204

101886

(33)

Accelerator pedal potentiometer

(31)

Pr iming pump

13B-55

DIESEL INJECTION Location of components


K9K, and 732

13B

114186

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Manual priming pump High pressure pump Exhaust gas recirculation solenoid valve Turbocharger Injectors Cylinder reference sensor Turbocharging air pressure sensor Air owmeter Air lter unit Protection and Switching Unit Injection computer Turbocharging pressure regulation solenoid valve Coolant temperature sensor Injection rail Injection rail pressure sensor Diesel fuel temperature sensor Diesel lter (18) Injection computer
101811

13B-56

DIESEL INJECTION Location of components


K9K, and 732

13B

101105

112994

(19)

Protection and Switching Unit

(21) (22) (24) (23)

Cylinder reference sensor Air inlet valve Pressure regulation solenoid valve Flow regulation solenoid valve

111748

(20)

High pressure pump

13B-57

DIESEL INJECTION Location of components


K9K, and 732

13B

114348

(25) (26) (27) (28) (29) (30) (31) (32) (33)

Diesel injector fuel return rail Diesel temperature sensor High pressure pipe between the rail and injector High pressure pipe between the pump and rail High pressure rail Rail pressure sensor Diesel injector Injector bracket Spacer between the cylinder head and injector bracket

102204

(34)

Accelerator pedal potentiometer

13B-58

DIESEL INJECTION Location of components


K9K, and 732

13B

102124

(37)

Priming pump

102125

(35)

Pre-postheating unit

113840

(38) (39)
114559

Catalytic converter Turbocharger

(36)

Diesel lter

13B-59

DIESEL INJECTION Location of components


K9K, and 732

13B

114185

(40)

Turbocharging pressure regulation solenoid valve

13B-60

DIESEL INJECTION Immobiliser function


K9K, and 722 or 728 or 729 F9Q, and 800 or 804 or 808 These vehicles are fitted with an engine immobiliser system, controlled by a RENAULT card random rolling code recognition system, which requires a special procedure for replacing the computer.

13B

REPLACEMENT
For the removal/refitting procedure, (see 13B, Diesel injection, Diesel injection computer ). For the engine immobiliser functions (see 82A, Engine immobiliser, Operation ). Injection computers are supplied without a code, but they can all be programmed with one. When replacing the computer, program it with the vehicle code, then check that the engine immobiliser function is operational. Switch on the ignition for a few seconds without starting the engine. Switch off the ignition. Note: The immobiliser function operates after roughly 10 seconds (the red immobiliser warning light blinks on the instrument panel).

WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - Running tests with computers borrowed from the Parts Department or from another vehicle which must then be returned is prohibited. - These computers are permanently coded.

13B-61

DIESEL INJECTION Injection warning light


K9K, and 722 or 728 or 729 or 732

13B

Note: For vehicles tted with K9K 732 engines (see MR 370 Mechanics, Scnic II ). Vehicles fitted with the Delphi DDCR high-pressure diesel fuel system use fault warning symbols and text warning messages, depending on the level of severity of the faults detected, to inform the customer and determine the correct fault finding procedure. The injection computer controls the illumination of warning lights and message displays on the instrument panel. 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 panel via the multiplex network. WARNING LIGHT ACTIVATION PRINCIPLE. During the starting phase (press the Start button, the orange preheating symbol is lit during the preheating phase, then goes out) (see 13C, Preheating, Prepostheating 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 reduced 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 position sensor, - the accelerator pedal potentiometer (gangs 1 and 2), - the accelerator pedal potentiometer supply, - the turbocharging pressure sensor (in the event of overpressure), - water in the diesel fuel or a water detection sensor fault (if fitted on vehicle.

If there is a serious injection fault (level 2), the red engine symbol and the word Stop appears (only on information display), with the message Injection faulty , followed by the Stop warning light and buzzer. The faults relate to: - with delayed stop: the fuel flow actuator (loop discrepancy 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 fault symbol appears with the message Engine overheating (only on information display) followed by the 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 (not operational).

13B-62

DIESEL INJECTION Injection warning light


F9Q, and 800 or 804 or 808 Vehicles fitted with the Bosch EDC16 high pressure diesel fuel system use fault warning symbols and text warning messages, depending on the level of severity of the faults detected, to inform the customer and determine the correct fault finding procedure. The injection computer controls the illumination of warning lights and message displays on the instrument panel. 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 panel via the multiplex network. WARNING LIGHT PRINCIPLE During the starting phase (press on the Start button, the orange preheating symbol is lit during the preheating 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 reduced 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 solenoid valve, - a fault in the main relay of the Protection and Switching 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 engine symbol and the word Stop appears (only on information display), with the message Injection faulty , followed by the Stop warning light and buzzer. These faults are associated with: - an internal computer fault, - an injector fault, - a rail pressure sensor fault, - a rail pressure regulator fault.

13B

If the engine overheats, the engine coolant temperature fault symbol appears with the message Engine overheating (only on information display) followed by the Stop warning light and buzzer. In this case the vehicle must be stopped immediately. On Board Diagnostic excess pollution orange warning light The orange engine symbol comes on when the ignition is switched on for around 5 seconds then goes out. It is never displayed when the engine is running (not operational).

13B-63

DIESEL INJECTION Injection / air conditioning programming


K9K, and 722 or 728 or 729

13B

Note: For vehicles tted with engine concerned (see MR 370 Mechanics, Scnic II ). The air conditioning management is shared between several computers that communicate via the multiplex network. It is of the cold loop type. The injection computer is responsible for: - managing the cooling request according to passenger compartment commands and the circuit pressure value, - calculating the power absorbed by the compressor from the circuit pressure value, - authorising engine cooling fan control in accordance with vehicle speed and circuit pressure, - authorising or inhibiting engagement of the compressor clutch. When the air conditioning is switched on, the air conditioning control panel requests authorisation to engage the compressor clutch. The injection computer authorises or inhibits compressor clutch engagement, controls the fan assembly via the UPC and imposes an increased idle speed. This engine speed is 900 rpm depending on how much power is absorbed by the compressor. The injection computer authorises operation of the air conditioning compressor and the fan unit (both supplied by the UPC), according to the following conditions: - 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.

Note: The value of parameter ( PR044 ) power absorbed by the air conditioning compressor is never 0, whatever the status of the air conditioning compressor. The minimum reading is approximately 250 W . The air conditioning compressor is of the variable displacement type.

I - COMPRESSOR OPERATION PROGRAMMING During certain operating phases, the injection computer disables the operation of the compressor.

1 - Engine starting programming The operation of the air conditioning compressor is inhibited for 1 second after the engine has started.

2 - Thermal protection programming The air conditioning compressor is not engaged if the engine temperature is above 115C or above 110C at high engine speeds, 4500 rpm for more than 10 seconds .

3 - Fan unit control programming With the engine idling or when driving, with the air conditioning on, the fan unit is activated at high or low speed, according to the refrigerant pressure and the vehicle speed.

4 - Recovery of performance If the accelerator pedal is depressed firmly (more than 75 % of its travel), the compressor is disengaged for 5 seconds .

5 - Recovery of power when moving off To assist the vehicle moving away, the air conditioning compressor is disengaged if the accelerator pedal travel is greater than 30 % and the engine speed is less than 1250 rpm .

6 - Anti-stalling function The air conditioning compressor is disengaged if the engine speed is less than 740 rpm .

13B-64

DIESEL INJECTION Injection / air conditioning programming


K9K, and 722 or 728 or 729 7 - Engine overspeed timed protection programming The air conditioning compressor is disengaged if the engine speed is above 4500 rpm for more than 3 seconds . Output conditions: - engine speed above 3500 rpm ,

13B

- and vehicle speed greater than 90 mph (150 km/h) (by way of information). 3 - Performance return programming for hill starts

Note: There is always a delay of more than 10 seconds after the air conditioning compressor is disengaged before it can be disengaged again.

To assist hill starts, the heating resistors are temporarily 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 , operation of passenger compartment heating resistors is interrupted. When engine speed rises above 750 rpm , the passenger compartment heating resistors are reenabled.

II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING To reduce the heating time, fit air heating resistors known as passenger compartment heating resistors in the passenger compartment heating circuit. The UCH determines the need to actuate the heating resistors, according to the user's request. The injection computer determines: - the number of heating resistors supplied (power control limitation) depending on the alternator charge, - whether resistor operation should be disabled, according 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 becomes 900 rpm . III - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING During certain operating phases, the injection computer disables the passenger compartment heating resistors. 1 - Engine start programming Operation of passenger compartment heating resistors is 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 resistors are temporarily disabled. Input conditions: - engine speed less than 3000 rpm , - and vehicle speed less than 78 mph (130 km/h) .

13B-65

DIESEL INJECTION Injection / air conditioning programming


F9Q, and 800 or 804 or 808 The air conditioning management is shared between several computers that communicate via the multiplex network. When the air conditioning is switched on, the air conditioning control panel requests authorisation to engage the compressor clutch. The injection computer authorises or inhibits the compressor clutch, and controls the fan assembly via the UPC. When the air conditioning function is selected, the idling 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 computer disables the compressor. 1 - Engine start programming Air conditioning compressor operation is inhibited for 2 seconds after the engine has started. 2 - Thermal protection programming The air conditioning compressor is not engaged if the engine coolant temperature is above 115 C , it is reengaged if the engine coolant temperature falls below 115 C . This vehicle is equipped with heating resistors located in the air conditioning unit. These heating resistors are designed to heat up the air which is then directed to the passenger compartment. When the heating resistors are activated, the injection computer adopts a fast idling speed. This engine speed is 900 rpm . 3 - Recovery of power when moving off To help the vehicle start moving, the air conditioning compressor is engaged if the accelerator pedal position is above 25 % , the engine speed is below 1350 rpm and the vehicle speed is below 3 mph (5 km/h) . 4 - Anti-stalling function The air conditioning compressor is disengaged if the engine speed is below 750 rpm . Engine coolant temperature (C +/- 1) - 30 - 20 - 10 0 10 20 30 30 25 15 15 15 15 10 Delay (s)

13B

It is re-engaged if the engine speed exceeds 780 rpm . II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING During certain operating phases, the injection computer disables the heating resistors. 1 - Engine start programming The heating resistors are disabled while the heater plugs are in operation. When the engine starts, the heating resistor supply is authorised after a delay that depends on the engine coolant temperature.

2 - Stalling prevention programming When the engine speed falls below 800 rpm , operation of the heating resistors is interrupted. When the engine speed falls below 875 rpm , operation of the heating resistors is authorised.

13B-66

DIESEL INJECTION Idling speed


K9K, and 722 or 728 or 729 or 732

13B

Note: For vehicles tted with K9K 732 engines (see MR 370 Mechanics, Scnic II ). The injection computer calculates the idling speed needed to maintain it at the recommended level and to compensate for any variation in the mechanical or electrical 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.

II - IDLE SPEED CORRECTION IN THE EVENT OF AN ACCELERATOR PEDAL POTENTIOMETER FAULT - If one of the two accelerator pedal potentiometer tracks is faulty, the injection computer forces an idle speed of 1300 rpm . This defect mode limits performance. The Check injection message lights up, followed by the Service warning light. - If the accelerator pedal potentiometer is jammed, no longer supplied, or is no longer sending an output signal, the injection computer imposes an idle speed of 1300 rpm . This defect mode limits performance. The Check injection message lights up, followed by the Service warning light. - If there is inconsistency between the accelerator pedal potentiometer signal and the brake switch signal, the injection computer imposes an idle speed of 1300 rpm . III - IDLE SPEED CORRECTION IN THE EVENT OF AN INJECTOR C2I CODING ERROR In the event of an injector C2I coding error (individual adjustment of the injector flow), the injection computer forces an idle speed of 1300 rpm . This defect mode limits performance. The Check injection message lights 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 2 ndgear, the speed is 875 rpm , - in 3rdand 4 thgear, the speed is 900 rpm , - in 5thgear, the speed is 950 rpm .

Note: At normal engine operating temperature, without major electrical consumers, the engine idling speed is 805 50 rpm .

I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

103122

X: Engine idle speed (rpm) Y: Engine coolant temperature (C)

13B-67

DIESEL INJECTION Idling speed


B84 or C84 or S84, and F9Q, and 800 or 804 I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE In all cases, this engine idling speed correction is deactivated 10 minutes after engine start and adopts a value of 800 rpm .

13B

103129

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 are defective, the injection computer sets the idling speed at 1400 rpm . By pressing on the brake pedal, the idling speed falls back to 1000 rpm . If there is inconsistency between the accelerator pedal potentiometer signals and the brake switch, the idling speed increases to 1400 rpm .

III - ENGINE IDLE SPEED CORRECTION WHEN THE VEHICLE IS BEING DRIVEN The engine idling speed when the vehicle is being driven is: - 870 rpm when the 1stor the 2 ndgear is engaged, - 900 rpm when a higher gear than 2ndis engaged.

13B-68

DIESEL INJECTION Centralised coolant temperature management


K9K, and 722 or 728 or 729 or 732

13B

Note: For vehicles tted with K9K 732 engines (see MR 370 Mechanics, Scnic II ). The coolant temperature sensor (injection and coolant temperature indicator on the instrument panel) is a 3track sensor: - 2 tracks for the coolant temperature signal to the computer (tracks B H2 and B H3), - 1 track for instrument panel indicators. This system allows the engine cooling fan to be controlled by the injection computer. It consists of a single temperature sensor serving injection, the engine cooling fan, the temperature indicator and the instrument panel engine coolant temperature warning light. The request to operate the engine cooling fan is made by the injection computer through the multiplex network.

I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING The fan assembly is controlled: - at low speed if the engine coolant temperature exceeds 99 C or in the event of a coolant temperature sensor fault and stops when the temperature falls below 96 C , - at high speed if the engine coolant temperature exceeds 102 C or if the low speed is faulty and stops when the temperature falls below 99 C . The fan assembly low and high speeds are controlled when the air conditioning function is selected on the instrument panel. The fan will operate at high speed under the low speed operating conditions if low speed is faulty.

II - OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT The warning light is actuated by the injection computer via the multiplex network. The warning light is continuously lit if the coolant temperature exceeds 118C . It goes out when the temperature drops below 115 C .

13B-69

DIESEL INJECTION Centralised coolant temperature management


F9Q, and 800 or 804 or 808 The coolant temperature sensor (injection and coolant temperature indicator on the instrument panel) is a 3track sensor: - 2 tracks for the coolant temperature signal to the computer (tracks B E1 and B K3), - 1 track for instrument panel indicators. This system allows the engine cooling fan to be controlled by the injection computer. It consists of a single temperature sensor serving injection, the engine cooling fan, the temperature indicator and the instrument panel engine coolant temperature warning light. The request to operate the engine cooling fan is made by the injection computer through the multiplex network. I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING The fan assembly is controlled: - at low speed if the engine coolant temperature exceeds 99C and stops when the temperature drops below 96C , - at high speed if the engine coolant temperature exceeds 102C and stops when the temperature drops below 99C , - The fan assembly low and high speeds are controlled when the air conditioning function is selected on the instrument panel. II - ENGINE COOLANT TEMPERATURE WARNING LIGHT The warning light is actuated by the injection computer via the multiplex network. The warning light is lit continuously if the coolant temperature exceeds 120C . It goes out if the temperature falls below 115C .

13B

13B-70

DIESEL INJECTION Computer configuration


K9K, and 722 or 728 or 729 or 732

13B

Equipment required diagnostic tool The system can be programmed and reprogrammed via 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 following 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 computer) and wait for 30 seconds , - switch on the ignition again. - Use the diagnostic tool : use command SC001 Write saved data t o restore the C2I and engine adaptives, enter the VIN using command VP010 Write VIN , rectify any faults in computers indicated by the diagnostic tool , clear the computer memory, carry out a road test, carry out a new check using the 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 duration of computer (re)programming, the engine cooling fan is automatically engaged). - Comply with the engine coolant temperature values given in the diagnostic tool before carrying out any (re)programming.

WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - Running tests with computers borrowed from the Parts Department or from another vehicle which must then be returned is prohibited. - The computers are permanently coded.

Note: If commands SC001 and SC003 are not run or cannot be run following programming, reprogramming or replacement of the computer, the C2I of each injector must be written manually, reading the C2Is on the injectors (see 13B, Diesel Injection, Injectors: Conguration ).

13B-71

DIESEL INJECTION Computer configuration


F9Q, and 800 or 808

13B

Equipment required diagnostic tool The system can be programmed and reprogrammed via the diagnostic socket using the diagnostic tool (refer to Technical Note 3585A ).

using the diagnostic tool , ensure that the computer has not detected any faults relating to the injector codes and that the instrument panel warning light is off.

WARNING - Connect the diagnostic tool (to the mains or the cigarette lighter). - Check the condition of the battery. - Connect a battery charger (the engine cooling fans are automatically activated for the entire duration of the computer (re)programming ). - Keep to the engine coolant temperature guidelines supplied in the diagnostic tool before carrying out any (re)programming.

PROGRAMMING, REPROGRAMMING OR REPLACING THE COMPUTER When a computer is reprogrammed or replaced, it is necessary to reprogram it with the IMA (Injector Flow 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 the diagnostic tool , replace the computer, transfer the data from the diagnostic tool to the new computer, using the diagnostic tool , ensure that the computer has not detected any faults relating to the injector codes and that the instrument panel warning 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 diagnostic tool , reconfigure the computer for the equipment (air conditioning),

13B-72

DIESEL INJECTION High pressure pipe: Checking


K9K, and 722 or 728 or 729

13B

Equipment required diagnostic tool

WARNING After any operation, check that there are is no diesel fuel leakage. Reprime the diesel circuit using the manual priming pump. Remove the engine covers. Note: The diagnostic tool can be used for testing the high pressure circuit with the engine running. This command can be used for nding a leak due to an incorrectly tted or tightened union. This command only works if the engine coolant temperature is above 60C . The fault nding procedure will not reveal small leaks due to incorrect tightening. Run command AC029 high pressure circuit sealing test , in the LPG/fuel circuit tab. WARNING Do not leave anything in the engine bay during the test phase (signicant vibration).

Note: The engine automatically runs a cycle of four accelerations and decelerations to lower the rail pressure. Check that there are no leaks in the high pressure circuit. Deal with the causes of any leaks. Refit the engine covers.

13B-73

DIESEL INJECTION High pressure pipe: Checking


K9K, and 732

13B

Equipment required diagnostic tool

WARNING After any operation, check that there are is no diesel fuel leakage. Reprime the diesel circuit using the manual priming pump. Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

112811

Pull out the clip.

112815

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip and (2) move the air inlet duct aside (3) .

112991

Remove the stainless steel pipe mounting bolt (4) . Move the air inlet duct to one side (5) .

13B-74

DIESEL INJECTION High pressure pipe: Checking


K9K, and 732

13B

Run command AC029 high pressure circuit sealing test , in the LPG/fuel circuit tab.

WARNING Do not leave anything in the engine bay during the test phase (signicant vibration).

Note: The engine automatically runs a cycle of four accelerations and decelerations to lower the rail pressure. Check that there are no leaks in the high pressure circuit. Deal with the causes of any leaks. Disconnect:
112992

Unclip the injection rail protector cover (6) . Remove: - the mounting nut and bolt (7) from the injection rail protector cover, - the injection rail protector cover, Refit the clip onto the stainless steel pipe if necessary. 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 ).

- 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 and bolt, Clip the injection rail protector cover. Refit the clip onto the stainless steel pipe if necessary. Clip the stainless steel pipe to the turbocharger. Refit: - the stainless steel pipe mounting bolt,

Note: The diagnostic tool can be used for testing the high pressure circuit with the engine running. This command can be used for nding a leak due to an incorrectly tted or tightened union. This command only works if the engine coolant temperature is above 60C . The fault nding procedure will not reveal small leaks due to incorrect tightening.

- 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.

13B-75

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732 Special tooling required Mot. 1566 Wrench for removing high-pressure pipes Equipment required diagnostic tool pipe socket for tightening the pump-rail high-pressure pipe (19-17 mm Crowfoot spanner) high-pressure pipe wrench (DM19) pipe socket for tightening injector-rail high pressure pipes ("Crowfoot 18-17" wrench) low torque wrench WARNING

13B

- Ensure that you have a special high-pressure injection circuit blanking plugs kit. - Ensure that any high-pressure pipe or high-pressure pipe clips that have been removed are replaced.

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the engine covers. K9K, and 722

Tightening torquesm rail mounting nuts pump-rail highpressure pipe nuts rail-injectors highpressure pipe nuts ller neck nut on the rail battery cover mounting bolts 28 Nm 38 Nm

1
38 Nm 21 Nm 4 Nm
102120

Note: For vehicles tted with K9K 732 engines (see MR 370 Mechanics, Scnic II ).

Disconnect air inlet duct (1) .

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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

13B-76

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732

13B

K9K, and 728 or 729

102362

Remove diesel fuel splash plate (5) .


110325

Pull out clip (2) .

4 3

6 9 8

102361 110323

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) .

Loosen bolt (3) . Move aside the air duct (4) .

13B-77

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732

13B

10

15

14

13

12

11
102360

Carefully disconnect: - the diesel return pipe (10) connecting the injectors to 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 injector rail. WARNING - Be sure to hold the intermediate injector union (18) in place with a spanner when loosening the high-pressure pipes. - Do not damage injector leak return nozzle (19) .

13B-78

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732

13B

Note: Loosen the nuts pipe by pipe. Move the nuts along the tube, keeping the olive in contact with the taper.

17

20

16
20803

19
Remove high-pressure pipes (20) one by one. Fit blanking plugs into the openings.

20803

18

19724

Loosen mounting nuts (16) on the spherical injector rail by several turns. Remove clips (17) connecting the high-pressure pipes. Loosen: - the high-pressure pipe nut at the injector end using tool (Mot. 1566) , - the high-pressure pipe nut at the injector rail end using tool (Mot. 1566) .

13B-79

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732

13B

REFITTING

II - REFITTING THE RAIL - INJECTORS HIGHPRESSURE PIPES Remove the plugs. Insert the high-pressure pipe olive in the injector high-pressure inlet taper. Insert the high-pressure pipe olive in the rail highpressure outlet taper. Tighten the high-pressure pipe nuts by hand, starting with the nut at the injector end. Slightly pretighten the high-pressure pipe nuts. WARNING When tightening the high-pressure pipes, it is essential to support the injector central union (18) .

Note:
20960

The order of tting the injector rail pipes is not impor tant.

WARNING - Before tting a new high-pressure pipe, lightly lubricate the nut threads with the oil from the applicator provided in the new parts kit. - Be careful not to allow oil into the high-pressure pipe. - Do not lubricate high-pressure pipes supplied without an applicator, as these high-pressure pipes are self-lubricating.

WARNING Do not remove the caps from each component until the last moment.

I - REFITTING THE PUMP - RAIL HIGH PRESSURE PIPE


19723

Remove the plugs. Insert the high-pressure pipe olive in the high-pressure pump high-pressure outlet taper. Insert the high-pressure pipe olive in the spherical injector rail inlet taper. Finger tighten the high-pressure pipe nuts, starting with the one at the rail 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. Note: Follow the direction of tting (the lugs only engage in one position).

13B-80

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732 III - 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 the spanner when tightening. - Be sure to hold the injector central union in place with a spanner when tightening.

13B

13B-81

DIESEL INJECTION High pressure pipe: Replacement


K9K, and 722 or 728 or 729 or 732

13B

WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . WARNING Conrm that there is no diesel fuel leak: - check the sealing after repair (see 13B, Diesel injection, High-pressure pipe: Sealing check , - let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load,
110404

- carry out a road test, - switch off the ignition, - check that there is no diesel fuel escaping.

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-rail high-pressure pipe (19-17 mm Crowfoot spanner) 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-rail high pressure pipes ("Crowfoot 18-17" wrench) or the high-pressure pipe wrench (DM19) .

Note: Tighten each pipe fully before moving on to the next pipe. 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 ( 21 Nm ) using a low torque wrench . Connect the battery, starting with the negative terminal.

13B-82

DIESEL INJECTION Diesel injector: check


K9K, and 722 or 728 or 729 Command AC029 High pressure circuit sealing test in the Fuel/LPG tab also enables the leakage rate of each injector to be checked in order to determine an internal leak in one or several injectors. This test only works when the engine temperature is greater than 60C . Switch off the ignition. Disconnect the return pipes of the four injectors. Connect the four transparent hoses with an internal diameter of 4 mm and a length of 50 cm in the place of the return pipes. Immerse these hoses into four graduated measuring cylinders (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 sealing test in the Fuel/LPG tab. The engine will automatically carry out a cycle of four accelerations / decelerations to increase the pressure in the rail and check whether there are internal leaks on the injectors' return circuit. When the cycle is complete, the test must be run again, to obtain a correct reading of the flow of each injector. After two cycles the flow of each injector should be 35 ml . Replace the faulty injector. IMPORTANT Never leave a tool or other object on the side of the engine housing during the four cycles (signicant vibration).

13B

13B-83

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Mot. 1367-02 Mot. 1367 Engine support Engine support tool for replacing cylinder head High pressure pumppulley retaining tool Extractor for timing gear with tapered hub Adaptor claws for Mot. 1525 Equipment required diagnostic tool IMPORTANT Tightening torquesm high pressure injection pump mounting bolts high pressure injection pump pulley mounting nut rail mounting nuts union at the rail end union at the pump end battery cover mounting bolts 21 Nm 55 Nm WARNING

13B

Tighten to torque 38 Nm the pump-rail and injection rail high pressure pipes with 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 other part numbers, tighten to a torque of 24 Nm .

Mot. 1606 Mot. 1525

Mot. 1525-02

Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high pressure pipe union when the engine is running is strictly prohibited.

28 3 Nm 24 Nm 24 Nm 4 Nm

WARNING - Obtain a set of special high pressure injection circuit plugs. - Always replace any high pressure pipe or high pressure pipe clip removed with a new one.

WARNING Before starting work on the vehicle, obtain: - a new set of blanking plugs (part no.: 77 01 206 804 ), - cleaning cloths (part no.: 77 11 211 707 ), - cleaning product (part no.: 77 11 224 188 ).

WARNING Never turn the engine against its operating direction.

13B-84

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

REMOVAL
I - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING NUMBER 070 575

II - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING A NUMBER OTHER THAN 070 575

21265 21265

Remove the engine covers. K9K, and 722

WARNING Removing any high pressure pump pulley bearing the number 070 575 is strictly prohibited. Replace the pump-pulley assembly, following the removal procedure for the high pressure pump not fitted with a pulley 070 575 . Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt ), - the timing belt (see 11A, Top and front of engine, Timing belt ), - the pump-pulley assembly.

102120

Disconnect: - the battery (see 80A, Battery, Battery: Removal Refitting ). - the air inlet duct (1) .

13B-85

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

K9K, and 728 or 729

5 7 5

6 4
102361

Remove dipstick guide tube (4) .


110325

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) .

Pull out the clip.

110323

Undo the bolt (2) . Remove the air duct (3) .

102362

Remove the diesel fuel splash plate (9) .

13B-86

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

102360

102083

Disconnect: - the fuel return pipe connecting the injectors to the pump (10) , - the rail pressure sensor (11) , - the accelerator (12) , - the oil level sensor (13) , - the cylinder reference sensor (14) on the timing cover. Unclamp the electrical harness and move it to one side. Remove the channel located on the spherical injection 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 the rail end. Slide the nut down the tube, keeping the olive in contact with the taper. Plug the openings on the injection circuit.

19626

Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .

13B-87

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729 - the tie-bar and make a mark.

13B

102114

Remove: - the right-hand suspended mounting support and cover,

19654

Remove the upper timing cover by unclipping both

tabs (17) .

13B-88

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

K9K, and 729, and DP0

102115

Remove the engine tie-bar mounting bolts (18) on the gearbox and sub-frame. Raise the engine a few centimetres for access to the suspended mounting attachments on the cylinder head and the high pressure pump pulley. WARNING Do not dislodge the right-hand driveshaft when lifting the engine.

103749

Remove the mounting bolts securing (19) the engine tie-bar on the gearbox and on the engine sub-frame. Raise the engine a few centimetres for access to the suspended mounting attachments on the cylinder head and the high pressure pump pulley. WARNING Do not dislodge the right-hand driveshaft when lifting the engine.

13B-89

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

19654-1

Remove: - the cylinder reference sensor (20) , - the plastic bolt (21) , Unclip the three tabs (22) . Remove the lower timing cover.

13B-90

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

19654-2

Remove the suspended mounting (23) from the cylinder head.

23167

Position the engine at Top Dead Centre. The camshaft pulley hole (24) should be opposite the cylinder head hole (25) .

13B-91

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

23168

23169

Position the (Mot. 1606) (3) . If necessary, turn the engine slowly to adjust the position 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) . WARNING Ensure that the tool pushrod is correctly oriented and is pressing against the high pressure pump shaft.

13B-92

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

Before fitting the new high pressure pipe, lightly lubricate the union threads with the oil from the applicator provided in the new parts kit. WARNING Some pipes are supplied with applicator and some without. The pipes supplied without applicator are selflubricating pipes.

102085

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

WARNING Do not remove the blanking plugs from each component until the last moment. Ensure that the pulley clamping pin is still in place. Fit the high pressure injection pump. Tighten to torque the high pressure injection pump mounting bolts ( 21 Nm ) . Fit the high pressure injection pump pulley nut. Tighten to torque the high pressure injection pump pulley mounting nut ( 55 Nm ) , holding the pulley with an open-jawed spanner. Remove the (Mot. 1606) . WARNING Always replace all high pressure pipes removed.

13B-93

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 722 or 728 or 729

13B

If replacing the high pressure pump, reprime the diesel circuit using the diagnostic tool .

Note: For VDiag numbers earlier than VDiag 48 , it is essential that the injection computer is reprogrammed. If the reprogramming is not carried out, do not apply the procedure detailed below but prime the fuel circuit using the priming bulb.

WARNING Never start the engine until the pump has been reprimed. Also comply with the operation instructions provided to prevent the high pressure pump from being damaged internally, due to running with no load and no diesel lubrication.

Connect the diagnostic tool to the vehicle.


110404

Establish dialogue with the diesel injection computer. Run command AC212 FILLING NEW PUMP CHAMBER . Follow the instructions on the diagnostic tool until the command is completed. Start the engine.

Refit the high pressure pipe - to do this: - remove the protective plugs, - insert the high pressure pipe olive in the pump outlet taper, - insert the high pressure pipe olive in the rail inlet taper. Finger tighten the high pressure pipe unions, starting with the one located at the rail end. Tighten to torque the rail mounting nuts ( 28 3 Nm ) . 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 priming pump (automatic degassing). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

Note: The star ting phase can last up to 20 seconds .

If the engine does not start or if the start-up sequence is interrupted: - switch off the ignition, - wait for 30 seconds , - restart the engine. Using the diagnostic tool clear any faults stored by the injection computer. Check the high pressure circuit sealing after the repair operation (see 13B, Diesel injection, High pressure pipe: Test ).

WARNING Conrm that there is no diesel fuel leak: - let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load, - switch off the ignition, - check that there is no diesel fuel escaping.

13B-94

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 800 or 808 Special tooling required Mot. 1668 Mot. 1525 Mot. 1525-03 Locking high pressure pump sprocket Extractor for timing gear with tapered hub Adapter claws for Mot. 1525 (for 33-tooth pulley) Offset spanner for tightening high pressure pump pipe Wrench for removing high-pressure pipes Equipment required diagnostic tool WARNING IMPORTANT

13B

Before carrying out any work on the injection system, 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 the engine is running is strictly prohibited.

Mot. 1746

WARNING Ensure that any high-pressure pipe removed is replaced.

Mot. 1566

Dismantling the interior of the high-pressure pump and the injectors is prohibited. It is essential to read the repair precautions (see 13A, Diesel injection, Repair precautions ).

Tightening torquesm high-pressure pump mounting bolts on the pump supports high-pressure pump pulley nut high-pressure pump support mounting bolts on the cylinder head high-pressure pump rear support mounting bolts on the cylinder block injector rail mounting bolts pump-rail high-pressure pipe nut on the pump side pump-rail high-pressure pipe nut on the rail side battery cover mounting bolts 30 Nm

REMOVAL
50 Nm 20 Nm + 80 Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: 44 Nm - the accessories belt (see 11A, Top and front of engine, Accessories belt ), - the timing belt (see 11A, Top and front of engine, Timing belt ). 22 Nm 29 Nm - the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle.

25 Nm 4 Nm

13B-95

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 800 or 808

13B

102352

102353

Disconnect: - the diesel fuel heater from the diesel filter, - the heater plugs, - the pressure regulator (1) , - the pressure sensor (2) (version without injector rail protector).

Remove the pump-rail high-pressure pipe. Plug the openings.

102348

Remove the two mounting bolts (3) from the highpressure pump on the high-pressure pump rear support.

102351

Disconnect the diesel supply and return pipes. Plug the openings. Remove the diesel pipes retaining clip.

13B-96

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 800 or 808

13B

102350

102894

Remove: - the three mounting bolts (4) from the high-pressure pump front support, - the high-pressure pump, with the high-pressure pump support.

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 extractor thrust bolt (6) . Remove (Mot. 1525) , (Mot. 1525-03) and (Mot. 1668) .

102893

Position the (Mot. 1668) (1) .


102345

Remove the nut (5) from the high-pressure pump pulley.

Remove: - the three mounting bolts (7) from the high-pressure pump, - the high-pressure pump.

13B-97

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 800 or 808

13B

REFITTING

II - REFITTING THE PUMP - RAIL HIGH-PRESSURE PIPE Undo the injector rail mounting bolts (the injector rail should be loose ).

WARNING Do not remove the blanking plugs from each component until the last moment.

WARNING Refit the high-pressure pump on the pump support. Tighten to torque: - the high-pressure pump mounting bolts on the pump supports ( 30 Nm ) , - the high-pressure pump pulley nut ( 50 Nm ) by immobilising the pulley with (Mot. 1668) . WARNING Do not remove the plugs from each component until the last moment. Insert the high-pressure pipe olive in the pump outlet taper Insert the high-pressure pipe olive into the injector rail inlet taper. Finger tighten the high-pressure pipe nuts, starting with 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 the pump side ( 29 Nm ) ,
102349

- Be careful not to allow oil into the high-pressure pipe. - Do not lubricate high-pressure pipes supplied without an applicator, as these high-pressure pipes are self-lubricating.

- the pump-rail high-pressure pipe nut on the rail side ( 25 Nm ) . Proceed in the reverse order to removal.

Push the ring (8) back as shown in the diagram. Undo the two mounting bolts (9) on the high-pressure pump rear support on the cylinder block. Refit the high-pressure pump assembly and the pump support. Tighten to torque the high-pressure pump support mounting 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 support against the high-pressure pump and the cylinder block. Tighten to torque the high-pressure pump rear support mounting bolts on the cylinder block ( 44 Nm ) .

13B-98

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 800 or 808 Refit: - the timing belt (see 11A, Top and front of engine, Timing belt ), - the accessories belt (see 11A, Top and front of engine, Accessories belts ). For versions with injector rail protector covers: - Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). Note: Ret the inlet duct without retting the injector rail protector or replacing the duct seal. Prime the diesel circuit using the manual priming pump. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).

13B

WARNING Conrm 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. 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 injection, Injector rail protector: Removal - Refitting ). - Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).

13B-99

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 804 Special tooling required Mot. 1668 Mot. 1525 Mot. 1525-03 Locking high pressure pump sprocket Extractor for timing gear with tapered hub Adapter claws for Mot. 1525 (for 33-tooth pulley) Offset spanner for tightening high pressure pump pipe Wrench for removing high-pressure pipes Equipment required diagnostic tool WARNING IMPORTANT

13B

Before carrying out any work on the injection system, 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 the engine is running is strictly prohibited.

Mot. 1746

WARNING Ensure that any high-pressure pipe removed is replaced.

Mot. 1566

Dismantling the interior of the high-pressure pump and the injectors is prohibited. It is essential to read the repair precautions (see 13A, Diesel injection, Repair precautions ).

Tightening torquesm high-pressure pump mounting bolts on the pump supports high-pressure pump pulley nut high-pressure pump support mounting bolts on the cylinder head high-pressure pump rear support mounting bolts on the cylinder block high-pressure pump mounting bolts on the rear pump support injector rail mounting bolts pump-rail high-pressure pipe nut on the pump side pump-rail high-pressure pipe nut on the rail side battery cover mounting bolts 30 Nm

REMOVAL
50 Nm 20 Nm + 80 Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: 44 Nm - the accessories belt (see 11A, Top and front of engine, Accessories belts ), - the timing belt (see 11A, Top and front of engine, Timing belt ). 30 Nm

25 Nm 29 Nm

25 Nm 4 Nm

13B-100

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 804

13B

111888

Remove the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ). Disconnect: - the diesel fuel heater from the diesel filter, - the heater plugs, - the pressure regulator (1) , Plug the openings.
102353

Remove the pump - rail high-pressure pipe (3) .

102351

102348

Disconnect the diesel supply and return pipes (2) . Plug the openings. Remove the diesel pipes retaining clip.

Remove the bolts mounting the high-pressure pump to the high-pressure pump rear support.

13B-101

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 804

13B

102350

102894

Remove: - the bolts (5) mounting the high-pressure pump front support, - the high-pressure pump, with the high-pressure pump support.

Set the pulley extractor (Mot. 1525) in place; fitted with claws (Mot. 1525-03) (8) for pulleys with thirtythree teeth. Remove the pulley by tightening the pulley extractor thrust bolt (9) . Remove (Mot. 1525) , (Mot. 1525-03) and (Mot. 1668) .

102893

Position the (Mot. 1668) (6) . Remove the nut (7) from the high-pressure pump pulley.
102345

Remove: - the high-pressure pump mounting bolts (10) , - the high-pressure pump.

13B-102

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 804

13B

REFITTING

- the high-pressure pump mounting bolts on the rear pump support ( 30 Nm ) . II - REFITTING THE PUMP-RAIL HIGH-PRESSURE PUMP Undo the injector rail mounting bolts (the injector rail should be loose ). 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 blanking plugs from each component until the last moment. Refit the high-pressure pump on the pump support. Tighten to torque: - the high-pressure pump mounting bolts on the pump supports ( 30 Nm ) , - the high-pressure pump pulley nut ( 50 Nm ) by immobilising the pulley with (Mot. 1668) .

WARNING Do not remove the plugs from each component until the last moment. Refit a new pump-rail high-pressure pipe. Finger tighten the high-pressure pipe nuts, starting with 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 the pump side ( 29 Nm ) , - the pump-rail high-pressure pipe nut on the rail side ( 25 Nm ) . Proceed in the reverse order to removal.
102349

Push the ring (11) back as shown in the diagram. Undo the two mounting bolts on the high-pressure pump rear support on the cylinder block. Refit the high-pressure pump - pump support assembly. Tighten to torque the high-pressure pump support mounting bolts on the cylinder head ( 20 Nm + 80 ) . I - REFITTING THE HIGH-PRESSURE PUMP REAR SUPPORT Finger tighten the mounting bolts to press the support against the high-pressure pump and the cylinder block. Tighten to torque: - the high-pressure pump rear support mounting bolts on the cylinder block ( 44 Nm ) ,

13B-103

DIESEL INJECTION High pressure pump: Removal - Refitting


F9Q, and 804 Refit: - the timing belt (see 11A, Top and front of engine, Timing belt ), - the accessories belt (see 11A, Top and front of engine, Accessories belts ), - the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). Note: Ret the inlet duct without retting the injector rail protector or replacing the duct seal. Prime the diesel circuit using the manual priming pump. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).

13B

WARNING Conrm 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. Remove the air inlet duct. Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ). Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13B-104

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 732 Special tooling required Mot. 855 Mot. 1768 Timing gear locking strap. SIEMENS injection pump pulley extractor claws Offset spanner for tightening high pressure pump pipe Wrench for removing high-pressure pipes Equipment required diagnostic tool IMPORTANT

13B

Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).

Mot. 1746

Mot. 1566

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Switch off the ignition and wait 30 seconds before starting work on the injection system. Remove the engine covers.

Tightening torquesm high-pressure pump pulley mounting bolt high-pressure pump mounting bolts high-pressure pipe nuts 55 Nm 21 Nm 24 Nm

Disconnect the battery (see 80A, Battery: Removal - Refitting .

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-pressure pump and the injector rail.
112811

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 and the turbocharger,

13B-105

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 732 - 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 precautions ): - the fuel return pipe connecting the injectors, - the fuel inlet pipe. Disconnect: - the fuel return pipe connecting the injectors to the high-pressure pump, - the fuel inlet pipe. Note: Make preparations for the fuel outow, Clean with new wipes. Remove:

13B

111748

- the mounting bolts (3) from the dipstick guide on the mounting of the diesel anti-splash device. - the bolt (4) and mounting nuts (5) from the injector rail protector cover support. Move the wiring harness to one side. Unpick the drain pipe on the injector rail protector cover support. Clean the high-pressure pipe between the highpressure pump and injector rail (see 13B, Diesel injection, Repair precautions ). Remove: - the injector rail protector cover support, - the high-pressure pipe between the high-pressure pump and rail.

WARNING - Strictly observe the cleanliness guidelines. - Beware of diesel fuel splashing when disconnecting the supply unions. Fit blanking plugs into the openings (see 13B, Diesel injection, Cleanliness guidelines ). Remove: - the accessories belt (see section 10A, Accessories belt: Removal - Refitting ). - the timing belt (see section 10A, Timing belt: Removal - Refitting ).

Note: Make preparations for fuel outow, Clean with new wipes.

WARNING When loosening the union of the high-pressure pipe on the high-pressure pump, the intermediate nut must be secured on the high-pressure pump using a lock wrench. Fit the correct blanking plugs on: - the high-pressure pump, - the injector rail.

13B-106

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 732 II - OPERATION FOR REMOVAL OF PART CONCERNED

13B

REMOVAL OF THE HIGH-PRESSURE PUMP Remove: - the high-pressure pump mounting bolts, - the high-pressure pump.

WARNING If the high-pressure pump is to be reused, keep it in a sealed plastic bag all the time it is disconnected.

REMOVAL OF THE HIGH-PRESSURE PUMP PULLEY

111744

WARNING When replacing a high-pressure pump, retain the high-pressure pump pulley and ret on the new pump. Hold the high-pressure pump in a vice, using the lower securing point on the pulley side.

Note: The high-pressure pump pulley can also be immobilised using the (Mot. 855) . Fit (Mot. 1768) on the high-pressure pump pulley then extract the pulley. WARNING Ensure that you do not mark the high-pressure pulley when extracting it using the tool. You must replace any damaged high-pressure pump pulleys.

REFITTING
WARNING - Remove the blanking plugs only before reconnecting the fuel circuit pipes - The plugs are single-use. Do not reuse them and throw away the complete kit after opening.

111743

Hold the high-pressure pump pulley with a 32 mm offset wrench then remove the mounting nut from the pulley.

13B-107

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 732 I - REFITTING OPERATION FOR PART CONCERNED 1 - REFITTING THE HIGH-PRESSURE PULLEY Take the high-pressure pump out of its plastic bag. WARNING When replacing an injector rail, only remove it from its packaging just before it is retted. Finger tighten the mounting nut of the high-pressure pump pulley. Lock the high-pressure pump pulley with the tools used previously. Tighten to torque the high-pressure pump pulley mounting bolt ( 55 Nm ) . 2 - REFITTING THE HIGH-PRESSURE PUMP Position the high-pressure pump on the cylinder head. Tighten to torque the high-pressure pump mounting bolts ( 21 Nm ) Remove: the blanking plugs from the injector rail and high-pressure pump. Fit a new high-pressure pipe between the injector rail and the high-pressure pump. Note: If the new parts kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes). Hand-tighten the nut on the high-pressure pipe on the pump end, then the one on the rail end. Tighten to torque the high-pressure pipe nuts ( 24 Nm ) using (Mot. 1746) or (Mot. 1566) and starting with the high-pressure pump side.

13B

13B-108

DIESEL INJECTION High pressure pump: Removal - Refitting


K9K, and 732 II - FINAL OPERATION Refit: - the injector rail protector cover support, - the injector rail protector cover support mounting nuts and bolt, - the dipstick guide, - the dipstick guide mounting bolts. WARNING

13B

Conrm that there are no diesel fuel leaks: - Check the tightness after repair (see 13B, Diesel 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

Note: Ensure that the injector rail protector support mounting bolt does not fall under the high-pressure pump. Connect: - the drain pipe to the injector rail protector cover support - 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 the high-pressure pump, - the fuel supply pipe, - the fuel temperature sensor connector. Reposition the wiring harness. Refit: - the mounting nut to the wiring harness retaining clip, - the timing belt (see section 10A, Timing belt: Removal - Refitting ), - the accessories belt (see section 10A, Accessories 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 - Refitting ). Reprime the fuel circuit using the priming pump. Using the diagnostic tool , clear any faults stored by the injection computer, before restarting the engine.

Using diagnostic tool , check that there are no stored faults. Clear them if necessary.

13B-109

DIESEL INJECTION High pressure pump: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool

13B

REMOVAL
I - REMOVAL PREPARATION OPERATION It is essential to respect the safety and cleanliness advice whenever work is carried out on this system (see 13B, Diesel injection, Repair precautions).

IMPORTANT Before carrying out any work on the injection system, check using the diagnostic tool : - that the injector rail is not under pressure, - that the fuel temperature is not too high. 25 Nm 32 Nm WARNING 32 Nm 10 Nm Obtain a set of special high-pressure injection circuit plugs. Ensure that any high-pressure pipe removed is replaced. Position the vehicle on the two-post lift (see 02A, Lifting equipment, Underbody lift ). 5.5 Nm Remove: - the engine protector, 8 Nm - the battery (see 80A, Battery, Battery: Removal Refitting ). Remove the high-pressure pipe between the highpressure pump and the injector rail (see 13B, Diesel injection, High-pressure pipe: Replacing ). Disconnect the fuel inlet quick-release union on the high-pressure pump. Plug the openings. Disconnect the fuel return union. Plug the openings. Disconnect the pressure regulator connector on the high-pressure pump. II - OPERATION FOR REMOVAL OF PART CONCERNED Remove: - the high-pressure pump mounting bolts, - the high-pressure pump.

Tightening torquesm high-pressure pump mounting bolts high-pressure pipe union on the high-pressure pump high-pressure pipe union on the injector rail high-pressure pipe retaining bracket mounting bolts on the bearing cap casing clips on the air lter duct at the turbocharger inlet bolts securing the turbocharger outlet air duct on the inlet manifold

Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

13B-110

DIESEL INJECTION High pressure pump: Removal - Refitting


M9R, and 700

13B

REFITTING
I - REFITTING PREPARATION OPERATION Always replace: - the high-pressure pump O-ring seal, - the high-pressure pump mounting bolt. WARNING Do not remove the blanking plugs from each component until the last moment. Lubricate the new high-pressure pump seal with engine oil. II - REFITTING OPERATION FOR PART CONCERNED

Fit the high-pressure pump. WARNING Do not apply pressure to the high-pressure pump gear teeth.

WARNING Check that the high-pressure pump is in contact with the cylinder head before positioning the bolts. Finger tighten the high-pressure pump mounting bolts as far as possible. Tighten to torque and in order the high-pressure pump mounting bolts ( 25 Nm ) (1-2-3-4).

13B-111

DIESEL INJECTION High pressure pump: Removal - Refitting


M9R, and 700 III - FINAL OPERATION Proceed in the reverse order to removal. Remove the wiring harness and fuel pipe assembly. WARNING

13B

Conrm that there is no diesel fuel leak: - run the engine at idle speed, - accelerate several times at no load,

WARNING Do not lubricate high-pressure pipes supplied without an applicator, as these high-pressure pipes are self-lubricating. Do not allow oil into the high-pressure pipe. Check that the seal is correctly positioned on the high-pressure pipe. Finger tighten as far as possible and in order: - the high-pressure pipe union on the high-pressure pump, - the high-pressure pipe union on the injector rail, - the bolt mounting the high-pressure pipe retaining bracket on the bearing cap casing. Tighten to torque and in order: - the high-pressure pipe union on the high-pressure 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 mounting bolts on the bearing cap casing ( 10 Nm ) . Tighten to torque: - the clips on the air filter duct at the turbocharger inlet ( 5.5 Nm ) , - the bolts securing the turbocharger outlet air duct on the inlet manifold ( 8 Nm ) . Proceed in the reverse order to removal. Prime the diesel circuit using the manual priming pump. Connect the battery, starting with the positive terminal.

- carry out a road test, - switch off the ignition, - check that there is no diesel fuel escaping.

WARNING Carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).

13B-112

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 722 or 728 or 729

13B

Equipment required diagnostic tool

WARNING Before starting work on the vehicle, have to hand: - a new set of blanking plugs (part no.: 77 01 206 804 ), 28 Nm 28 Nm 24 Nm - cleaning cloths (part no.: 77 11 211 707 ), - cleaning product (part no.: 77 11 224 188 ).

Tightening torquesm injector mounting bracket rail mounting nuts high-pressure pipe nuts of the pump-rail high-pressure pipe nuts of the injector rail of the neck on the rail

REMOVAL
I - REMOVAL PREPARATION OPERATION

24 Nm 21 Nm

Remove the engine undertray. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Disconnect:

IMPORTANT Before any operation on the injection circuit, use the diagnostic tool to check that the injector rail is no longer under pressure, and that the fuel temperature is not too high. It is essential to respect the safety and cleanliness advice specied in this document whenever work is carried out on this system. Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

- the heater plugs, - the connectors to injectors no. 3 and no. 4. - injector connectors no. 1 and no. 2.

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 . It is essential to read the repair precautions whenever work is carried out (see 13B, Diesel injection, Diesel injection: Precautions during repair ).
102362

Remove the diesel fuel splash plate (1) .

13B-113

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 722 or 728 or 729

13B

109463

109467

Disconnect the injector diesel return pipe (2) . Fit plugs into the openings.

Disconnect the high-pressure pump electrical connectors (3) . Remove the mounting bolts from the neck (4) fixed to the spherical injector rail. Pull the electric wiring harness to one side with the neck on the side. Loosen the injector rail mounting nuts by several turns. Remove the clips connecting the high-pressure pipes. Clean the high-pressure pipe (see 13B, Diesel injection, Diesel injection: Precautions during repair ). Remove the injector-rail high-pressure pipe concerned.

13B-114

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 722 or 728 or 729 II - OPERATION FOR REMOVAL OF PART CONCERNED

13B

II - REFITTING OPERATION FOR PART CONCERNED

WARNING Do not remove the plugs from each component until the last moment. If removing the four injectors, loosen the mounting nuts of the injector rail by a few turns (the rail should be loose).

109462

Undo the injector bracket (5) . Remove the injector (6) . If an injector is reused, always mark a removed injector in relation to its cylinder.

Note: an injector corresponds to a cylinder. Pull off the compression washer.

19724

Using cloths (part no.: 77 11 211 707 ) soaked in fresh solvent, clean: - the injector wells, - the injector bodies, - the injector brackets.

REFITTING
I - CLEANING THE INJECTORS

Use a new cloth to dry components that have been cleaned. Replace the compression washer with a new one.

WARNING Position the injector. It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner. Soak the injectors in degreaser. Wipe with new cloths (part no.: 77 11 211 707 ). Tighten to torque the injector mounting bracket ( 28 Nm ) . Note: If one or more injectors are replaced, note the alphanumeric code (C2I) (7) and the cylinder on which it is tted.

13B-115

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 722 or 728 or 729 III - FINAL OPERATION

13B

If removing the four injectors, torque tighten the rail mounting 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.

Note: Tighten a pipe fully before moving on to the next pipe.


20960

Refit the neck on the injector rail. WARNING Before tting a new high-pressure pipe, lightly lubricate the nut threads with oil from the applicator provided with the new part. Be careful not to allow oil into the high-pressure pipe. Do not lubricate high-pressure pipes supplied without an applicator; these pipes are self-lubricating. Torque tighten the nuts of the neck on the rail ( 21 Nm ) 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. WARNING Do not remove the blanking plugs from each component until the last moment. Insert the high-pressure pipe olive in the injector high-pressure inlet taper. Insert the high-pressure pipe olive into the rail highpressure conical outlet. Finger tighten the high-pressure pipe nuts, starting with the nut at the injector end. Slightly pretighten the high-pressure pipe nuts. Note: The assembly order of the injector-rail highpressure pipes is not important. Fit the new clip provided with the new high-pressure pipe. WARNING Conrm 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. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Refit the engine undertray. Program the alphanumeric code (C2I) for the replaced injector(s) using diagnostic tool (see 13B, Diesel injection, Injectors: configuration ).

13B-116

DIESEL INJECTION Diesel injector: Removal - Refitting


F9Q, and 800 or 804 or 808 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool

13B

For versions without injector rail protectors: - remove the inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ), if necessary.

Tightening torquesm injector bracket bolt nut on the injector side nut on the rail side battery cover mounting bolts 25 Nm 25 Nm 29 Nm 4 Nm

IMPORTANT Before carrying out any work on the injection system, 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 the engine is running is strictly prohibited. It is essential to read the repair precautions whenever work is carried out (see 13B, Diesel injection, Diesel injection: Precautions during repair ).

WARNING Opening the injectors is prohibited. Injectors may be replaced individually. Only remove the high-pressure pipe concerned.

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle.

13B-117

DIESEL INJECTION Diesel injector: Removal - Refitting


F9Q, and 800 or 804 or 808

13B

18297-1

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.

13B-118

DIESEL INJECTION Diesel injector: Removal - Refitting


F9Q, and 800 or 804 or 808

13B

REFITTING
I - CLEANING INJECTORS (IF THEY ARE TO BE REUSED)

WARNING It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner. Clean, using new cloths soaked in cleaning product (see 13B, Diesel injection, Diesel injection: Repair precautions ) clean: - the injector wells, - the injector bodies,
1327

Remove the injector-rail high-pressure pipe using (Mot. 1566) or (Mot. 1746) . WARNING The injector lter rod must not be removed.

- the injector brackets. Use a new cloth to dry components that have been cleaned. II - REFITTING THE INJECTOR

WARNING When loosening the injector pipe unions (2) on the injectors, be sure to hold the lter rod retaining nuts (3) with a lock wrench. Fit blanking plugs into the openings. If an injector is reused, always mark a removed injector in relation to its cylinder. Note: an injector corresponds to a cylinder. Remove: - the injector bracket mounting bolt, - the injector and its bracket, - the compressor washer.

WARNING Do not remove the protective caps from each component until the last moment.

13B-119

DIESEL INJECTION Diesel injector: Removal - Refitting


F9Q, and 800 or 804 or 808

13B

1326

Replace the heat shield washer (4) with a new one.

Note: If one or more injectors have been replaced, note down the alphanumeric code (IMA) that is written on the new injector and the cylinder it is tted on. Refit the injector with its bracket. Tighten to torque the injector bracket bolt ( 25 Nm ). WARNING Do not t high-pressure pipes without mountings.

WARNING Always replace any high-pressure pipe removed with a new one. Screw, by hand, the high-pressure pipe nuts on the rail and injector.

WARNING Always hold the lter rod mounting nuts on the injector holder with a lock wrench when tightening. 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 ) ,

13B-120

DIESEL INJECTION Diesel injector: Removal - Refitting


F9Q, and 800 or 804 or 808

13B

18297-1

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 the operation. To refit, proceed in the reverse order to removal. Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ), if removed. Note: For versions with injector rail protector covers: - Ret the inlet duct without retting the injector rail protector or replacing the duct seal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

Program the alphanumeric code (IMA) for the injector(s) replaced using the diagnostic tool (see MR 366 Fault finding, 13B, Diesel injection, Fault finding - Replacement of components ). WARNING Conrm 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. 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 injection, Injector rail protector: Removal - Refitting ). - Refit the inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).

13B-121

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool IMPORTANT

13B

Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).

Tightening torquesm injector bracket mounting bolt injector rail mounting nuts high-pressure pipe nuts air inlet duct clip 30 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION 28 Nm 24 Nm 5.5 Nm Switch off the ignition and wait 30 seconds before starting work on the injection system. Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

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 removed. - any injector that has been opened, contrary to instructions, - Any damaged mounting clips for the fuel return pipe on the injector must be replaced. - the compressor washer.
112815

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip and (2) move the air inlet duct aside (3) .

13B-122

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732

13B

112811

112992

Pull out the clip.

Unclip injector rail protector cover (6) . Remove: - the mounting nut and bolt (7) from the injector rail protector 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 rail and the injectors, - the fuel return connectors of the injectors.

112991

Remove the stainless steel pipe mounting bolt (4) . Move the air inlet duct to one side (5) .

13B-123

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732

13B

- the nut of the high-pressure pipe between the injector rail and the injector on the injector end, Remove the high-pressure pipe in question and discard it.

Note: Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

114075

Disconnect the injector connector (9) .

111749

Using a fine, flat-blade screwdriver, push the lower section of the clip (12) holding the fuel return connector on the injector towards the rocker cover.

WARNING Ensure that the clip is not fully removed from its housing to prevent it from being twisted when touching the rocker cover.

1327

WARNING When the high-pressure pipe unions (10) on the injector holder are loosened, it is imperative to hold the lter rod retaining nut (11) with a lock wrench. Remove: - the nut of the high-pressure pipe between the injector rail and the injector on the rail end,
111751

Extract the fuel return connector from the injector while pushing the lower bracket of the retaining clip downwards.

13B-124

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732 Fit the correct blanking plug. Remove the fuel return pipe from the injector. II - OPERATION FOR REMOVAL OF PART CONCERNED

13B

114010

Note: If the injector is jammed in its well and does not come out, turn the injector at the at support surfaces of the injector bracket using a 13 mm open end wrench. Fit the appropriate blanking plug on the injector's nose. WARNING If it is to be reused, keep the injector(s) in a sealed plastic bag until required.

111746

Remove: - the injector bracket mounting bolt (13) , - the injector bracket, - the spacer between the cylinder head and the injector bracket, - the injector, - the compression washer located at the bottom of the injector well in the cylinder head.

WARNING Ensure that no impurities enter into the cylinder via the injector well in the cylinder head: plug the orice using a clean cloth. Remove four injectors

Note: This procedure only applies if removing all the injectors and, after having removed them all, in preparation for retting them.

13B-125

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732

13B

112993

112994

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.

13B-126

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732 - the injector rail protector support.

13B

Undo the injector rail mounting nuts by a few turns (the injector rail should be loose).

REFITTING
I - REFITTING PREPARATION OPERATION Cleaning the injectors

WARNING It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner.
112656

Clean the fuel supply and return pipe unions (see 13B, Repair Precautions ). Disconnect: - the fuel supply pipe (23) , - the fuel return pipe (24) . Note: Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

Leave the injectors to soak in cleaner fluid. Clean using new wipes. WARNING Only remove the blanking plugs immediately before connecting the fuel circuit pipes. The plugs are single-use. Do not reuse them; dispose of the whole set after use. Remove the injector from its plastic bag. WARNING If replacing the injector, do not remove it (them) from its (their) packaging until just before you ret it (them). Remove the blanking plugs on the nose of the injector. II - REFITTING OPERATION FOR PART CONCERNED Refit: - a new compression washer at the bottom of the injector well in the cylinder head,

111748

- the injector, - the spacer between the cylinder head and the injector bracket, - the injector bracket, - the injector bracket mounting bolt.

Unclip the diesel evacuation pipe. Remove: - the injector rail protector support bolt and mounting nuts (25) ,

13B-127

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732 Tighten to torque the injector bracket mounting bolt ( 30 Nm ) . Remove the blanking plugs. Fit the new high-pressure pipe(s) between the injector rail and the injector. Note: If the new pipes kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes). Finger tighten the high-pressure pipe nuts, starting with 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 protector 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 solenoid valve, - 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 ( 24 Nm ) using (Mot. 1566) or (Mot. 1746) and starting at the injector rail end. WARNING Remove the blanking plugs.

13B

Push the retaining clip of the fuel return connector on the injector to the front of the vehicle in order to place it in its initial position. Clip on the fuel return connector of the injector.

Check the condition of the seal on the fuel return connector of the injector. Change the diesel return rail if one of its components is damaged.

III - FINAL OPERATION Refit: - the dipstick tube mounting bolts. - the dipstick, - the injector rail protector cover mounting nut and bolt, Clip injector rail protector cover. Refit: - the clip on the stainless steel pipe if necessary, - the stainless steel pipe on the hose, aligning the markings, - the air inlet duct clip between the turbocharger 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 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 priming pump. Refit the engine covers.

13B-128

DIESEL INJECTION Diesel injector: Removal - Refitting


K9K, and 732 Using the diagnostic tool , clear any faults stored by the injection computer, before restarting the engine. WARNING Conrm that there is no diesel fuel leak: - Check the tightness after repair (see 13B, Diesel 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 outow. Using diagnostic tool , check that there are no stored faults; clear if necessary.

13B

13B-129

DIESEL INJECTION Injectors: Configuration


K9K, and 722 or 728 or 729 or 732 REPLACING THE INJECTORS

13B

Note: The C2I (individual injector correction) parameters are a factory calibration carried out on each injector to adjust the ow of each injector precisely taking , into account differences in manufacture. The correction values are written on a label affixed to each injector then entered in the computer which can then control each injector by taking account of their differences in manufacture. The system can be configured at the diagnostic socket using the RENAULT CLIP diagnostic tools. The C2I parameters must be renewed after an injector is replaced. To do this, the C2I parameters must be reentered into the computer using the following commands: - 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 cylinder), cylinder 2 injector, command: control VP002 , cylinder injector 3: control VP003 , cylinder injector 4: control VP004 . By using the relevant command, the technician can reenter the new C2I parameters for the injector replaced and delete the old C2I parameters.

Note: Only after replacing all four injectors at once, reset the injector programming adaptives using the RZ004 Pressure regulation adaptives .

13B-130

DIESEL INJECTION Injectors: Configuration


F9Q, and 800 or 808

13B

Equipment required diagnostic tool

reconfigure the computer for the equipment (air conditioning), make sure, using the diagnostic tool CLIP, that the computer has not detected any faults relating to the injector codes and that the instrument panel warning light is off.

INJECTORS A 6-character alphanumeric code known as the IMA (Injector Flow Correction) is marked on the injectors. This code is specific to each injector, and takes into account manufacturing dispersion and specifies the flow of the injector. When one or more injectors is replaced, the code of the new injector(s) must be programmed into the computer. If this operation is not carried out then the engine speed 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 diagnostic tool CLIP, make sure, using the diagnostic tool CLIP, that the computer has not detected any faults relating to the injector codes and that the instrument panel warning light is off. - When a computer is reprogrammed or replaced, it is necessary to program the codes of the four injectors into 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 the diagnostic tool CLIP, replace the computer, transfer the data from the diagnostic tool CLIP to the new computer, make sure, using the diagnostic tool CLIP, that the computer has not detected any faults relating to the injector codes and that the instrument panel warning light 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 diagnostic tool CLIP,

13B-131

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool

13B

REMOVAL
I - REMOVAL PREPARATION OPERATION Switch off the ignition and wait 30 seconds before starting work on the injection system. Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm injector rail mounting nuts high-pressure pipe nuts 28 Nm 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) .
112815

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip (2) and move the air inlet duct aside (3) .

WARNING Parts always to be replaced: - all the high-pressure pipes which have been removed.

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).

112811

Pull out the clip.

13B-132

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732 Move the dipstick pipe to one side.

13B

Protect the alternator from fuel outflow. Clean the high-pressure pipe unions between the injector rail and injectors (see 13B, Repair precautions ). II - OPERATION FOR REMOVAL OF PART CONCERNED

112991

Remove: - the stainless steel pipe mounting bolt (4) , - the stainless steel pipe (5) .

1327

WARNING When the high-pressure pipe unions (9) on the injector holder are loosened, it is imperative to hold the lter rod retaining nut (10) with a lock wrench. Remove: - the nut of the high-pressure pipe between the injector rail and the injector on the rail end, - the nut of the high-pressure pipe between the injector rail and the injector on the injector end, Remove the high-pressure pipe in question and discard it.

112992

Unclip the injector rail protector cover (6) . Remove: - the mounting nut and bolt (7) from the injector rail protector cover, - the injector rail protector cover, - the dipstick, - the dipstick pipe mounting bolts (8) .

Note: Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

13B-133

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732 Removing the four high-pressure pipes

13B

Note: This procedure only applies if removing all the high-pressure pipes and, after having removed them all, in preparation for retting them.

112994

Disconnect: - the connector (13) from the damper valve, - the cylinder marking sensor connector (14) , - the pressure regulation solenoid valve connector (15) ,
112993

- 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.

Disconnect: - the injector connector (11) , - the heater plugs connector (12) .

13B-134

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732

13B

111748

Unclip the diesel evacuation pipe. Remove: - the injector rail protector support bolt and mounting nuts (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 pump and injector rail, - on the high-pressure pipe between the high-pressure pump and the injector rail,

112656

Protect the alternator from fuel outflow. Clean the fuel supply and return pipes unions (see 13B, Repair Precautions ). Disconnect: - the fuel inlet pipe (20) , - the fuel return pipe (21) . Note: Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

REFITTING
I - REFITTING PREPARATION OPERATION

WARNING Only remove the blanking plugs immediately before connecting the fuel circuit pipes. The plugs are single-use. Do not reuse them; dispose of the whole set after use. Take the new high-pressure pipe out of its plastic bag. Remove the blanking plugs.

13B-135

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732 II - REFITTING OPERATION FOR PART CONCERNED Fit the new high-pressure pipe between the injector rail and the injector. Note: If the new pipes kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes). Finger tighten the high-pressure pipe nuts, starting with 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 protector 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 place. 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 solenoid valve, - 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 ( 24 Nm ) using (Mot. 1566) or (Mot. 1746) and starting with the injector rail side. WARNING Connect: III - FINAL OPERATION Refit: - the dipstick tube mounting bolts. - the dipstick, - the injector rail protector cover,

13B

- the injector rail protector cover mounting nut and bolt, Clip injector rail protector cover. Refit the clip onto the stainless steel pipe if necessary. 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.

- the connector of the air inlet pressure sensor, - the battery (see 80A, Battery, Battery: Removal Refitting ). Reprime the fuel circuit with the manual priming pump. Refit the engine covers. Using the diagnostic tool , clear any faults stored by the injection computer, before restarting the engine.

Conrm that there is no diesel fuel leak: - Check the tightness after repair (see 13B, Diesel 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 outow. Use diagnostic tool to check for stored faults. Clear them if necessary.

13B-136

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729

13B

Equipment required diagnostic tool

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 , 28 Nm 24 Nm

Tightening torquesm injector rail mounting nuts pump-rail highpressure pipe nuts high-pressure pipe nuts of the injector rail nuts of the neck on the rail

- 77 01 207 026 , - 77 01 207 027 , - 77 01 207 028 ,

24 Nm 21 Nm

- 77 01 207 029 . For high-pressure pipes with different part numbers, tighten to torque 24 Nm .

REMOVAL
I - REMOVAL PREPARATION OPERATION IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice whenever work is carr ied out on this system. Loosening a high-pressure pipe union when the engine is running is prohibited. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

WARNING Before starting work on the vehicle, have to hand: - a new set of blanking plugs (part no.: 77 01 206 804 ), - cleaning cloths (part no.: 77 11 211 707 ), - cleaning product (part no.: 77 11 224 188 ).
112331

Remove the turbocharging duct retaining pin (1) from the turbocharger. Remove the duct mounting bolt on the cylinder head. Move the duct to one side. Disconnect the inlet air pressure sensor (2) Loosen the clip (3) and remove the inlet duct (4) .

13B-137

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729

13B

K9K, and 724

K9K, and 722 or 728 or 729

109473

102362

Remove the diesel fuel splash plate (7) .

109470

Remove the dipstick mounting bolts (5) . Place the dipstick to one side. Remove the injector rail protector cover (6) .
109466

Remove the connectors (8) : - the heater plugs, - the injectors.

13B-138

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729

13B

REFITTING
I - REFITTING PREPARATION OPERATION

109467

Disconnect the high-pressure pump electrical connectors (9) . Remove the mounting bolts from the neck (10) fixed to the spherical injector rail. Move the electric wiring harness and neck to the side as shown by the arrow. Loosen the injector rail mounting nuts by several turns. Remove the clips connecting the high-pressure pipes. II - REMOVAL OF PART CONCERNED Clean the pipe(s) to be removed (see 13B, Diesel injection, 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. WARNING Leave removal of the blanking plugs from any component until last. 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 injector high-pressure inlet taper. WARNING Before tting a new high-pressure pipe, lightly lubricate the nut threads with oil from the applicator provided in the new part. Be careful not to allow oil into the high-pressure pipe. Do not lubricate high-pressure pipes supplied without an applicator, as these high-pressure pipes are self-lubricating.
20960

13B-139

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 Insert the high-pressure pipe olive in the rail highpressure outlet taper. Finger tighten the high-pressure pipe nuts, starting with the nut at the injector end. Slightly pretighten the high-pressure pipe nuts. Note: The assembly order of the injector-rail highpressure pipes is not important. Fit the new clip provided with the new high-pressure pipe. If replacing the four high-pressure pipes, torque tighten 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. Note: Tighten a pipe fully before moving on to the next pipe. III - FINAL OPERATION Refit the neck to the injector rail and torque tighten the nuts of the neck on the rail ( 21 Nm ) . Connect the connectors: - on the accelerometer - of the injectors, - of the heater plugs. K9K, and 724 Refit the injector rail protector cover. Insert the dipstick. Refit the dipstick mounting bolts. Fit the turbocharger air duct.

13B

Lock the air duct between the turbocharger and the intercooler air inlet pipe. Tighten the bolt of the air duct on the rocker cover. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Prime the diesel circuit using the priming pump. WARNING Conrm that there is no diesel fuel leak: - check the seal after repair, - let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load, - switch off the ignition, - conrm that there is no diesel fuel leak.

Refit the inlet duct and tighten its clip. Connect the inlet air pressure sensor

13B-140

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
M9R, and 700 Special tooling required Mot. 1566 Wrench for removing high-pressure pipes Equipment required diagnostic tool

13B

- the oil separator (see 13B, Diesel injection, Oil separator: Removal - Refitting ).

Tightening torquesm rail-injector highpressure pipe mounting nuts diesel return pipe mounting bolt on the rocker cover 32 Nm

10 Nm
113142

Remove the bolt mounting the diesel return pipe on the rocker cover. Disconnect the quick-release union from the diesel return pipe. Lift the mobile section of the diesel return pipe on the injectors. Remove the diesel return pipe.

WARNING Before carrying out any work on the injection system, 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 specied in this document must be followed during each operation. Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

WARNING Obtain the special high-pressure injection circuit plug kit. Always replace any high-pressure pipe or highpressure pipe clip removed with a new one.

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 injection, Injector rail protector: Removal - Refitting ).

13B-141

DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
M9R, and 700 II - OPERATION FOR REMOVAL OF PART CONCERNED

13B

II - REFITTING OPERATION FOR PART CONCERNED Fit: - the high-pressure pipe olive in the injector taper, - the high-pressure pipe olive into the injector rail outlet taper. Finger tighten until contact the high-pressure pipe nuts, 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.
113134

III - FINAL OPERATION Refit: - the diesel return pipe, - the bolt mounting the diesel return pipe on the rocker cover Drive the mobile section of the diesel return pipe into the injectors. Tighten to torque the diesel return pipe mounting bolt on the rocker cover ( 10 Nm ) . Connect the quick-release union to the diesel return pipe. Refit: - the oil separator (see 13B, Diesel injection, Oil separator: Removal - Refitting ). - the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ). - the engine protector. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Using (Mot. 1566) , loosen: - the high-pressure nut at the injector end, - the high-pressure pipe nut at the injector rail end.

Note: Loosen the nuts pipe by pipe. Move the nuts along the tube, keeping the olive in contact with the taper. Remove the high-pressure pipes one by one. Plug the openings.

REFITTING
I - REFITTING PREPARATION OPERATION

WARNING Do not lubricate the high-pressure pipes supplied without an applicator, these high-pressure pipes are self-lubricated. Do not allow oil into the high-pressure pipe.

WARNING Do not remove the blanking plugs from each component until the last moment. Remove the blanking plugs.

13B-142

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Mot. 1746 Offset spanner for tightening high pressure pump pipe Wrench for removing high-pressure pipes Equipment required diagnostic tool WARNING

13B

Mot. 1566

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 .

Tightening torquesm injector rail mounting nuts high-pressure pipe nuts between the injector rail and the injectors high-pressure pipe nuts between the injector rail and the high-pressure pump 28 Nm 24 Nm

For high-pressure pipes with different part numbers, tighten to torque 24 Nm .

REMOVAL
I - REMOVAL PREPARATION OPERATION

24 Nm

Position the vehicle on a lift (see 02A, Lifting equipment, Underbody lift ). It is essential to read the repair precautions whenever work is carried out (see 13B, Diesel injection, Diesel injection: Precautions during repair ). Switch off the ignition and wait 30 seconds before starting work on the injection system.

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 Before carrying out any work on the injection system, check using the diagnostic tool : - that the rail is not under pressure, - that the fuel temperature is not too high.

WARNING Parts always to be replaced: - all the high-pressure pipes which have been removed.

Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the engine undertray.

13B-143

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 722 or 728 or 729

13B

109466

109467

Disconnect the injector connectors (1) and the heater plugs (2) .

Disconnect: - the connectors (4) for the flow actuator and the diesel fuel temperature sensor, - the spherical rail pressure sensor (5) . Move the electric wiring harness and channel to the side as shown by the arrow. Remove the mountings from the channel (6) fixed on the spherical rail. Protect the alternator from fuel outflow. Clean the high-pressure pipes (see 13B, Diesel injection, Diesel injection: Precautions during repair ). WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use wipes if necessary.

102362

Remove the diesel fuel splash plate (3) .

13B-144

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 722 or 728 or 729

13B

II - OPERATION FOR REMOVAL OF PART CONCERNED

20803

Remove the clips between the high-pressure pipes. Loosen the nuts securing the high-pressure pipes between the injector rail and the injector. Remove the four high-pressure pipes and discard. Note: Make preparations for fuel outow. Clean with new wipes. Insert the blanking plugs. Remove the high-pressure pipe between the highpressure pump and the injector rail (7) .
20803

Remove: - the injector rail mounting nuts (8) , - the injector rail.

WARNING If the injector rail is to be reused, keep it in a sealed plastic bag all the time it is disconnected.

REFITTING
Note: Make preparations for the fuel outow. Clean with new wipes. Insert the blanking plugs. I - REFITTING PREPARATION OPERATION

WARNING Only remove the blanking plugs immediately before connecting the fuel circuit pipes. The plugs are single-use. Do not reuse them and throw away the complete kit after opening. Take the injector rail out of its plastic bag.

WARNING If an injector rail is being replaced, only remove the new one from its original packaging when it is about to be tted.

13B-145

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 722 or 728 or 729 II - REFITTING OPERATION FOR PART CONCERNED Fit the injector rail. Tighten the injector rail mounting bolts (the injector rail 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 injector rail and the high-pressure pump. Note: If the new pipe kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes). Finger tighten the high-pressure pipe nuts until they make 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 and the injectors. Note: If the new pipe kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes). Finger tighten the high-pressure pipe nuts until they make contact. Tighten to torque: - the injector rail mounting nuts ( 28 Nm ) , - the high-pressure pipe nuts between the injector rail and the injectors ( 24 Nm ) using (Mot. 1746) or (Mot. 1566) starting at the injector end, - the high-pressure pipe nuts between the injector rail and the high-pressure pump ( 24 Nm ) using (Mot. 1746) or (Mot. 1566) starting at the high-pressure pump end. Refit: - the wiring harness with the neck, - the neck mountings. Connect the electrical connectors. Reprime the fuel circuit.

13B

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Confirm that there is no diesel fuel leak: - check the seal after repair (see 13B, Diesel injection, Diesel injection: Repair precautions ), - let the engine run at idle speed until the engine cooling 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. Clear them if necessary.

13B-146

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 800 or 808 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool

13B

Tightening torquesm injector rail mounting bolts nuts on the injector end and the nut on the injection pump end nuts on the rail end battery cover mounting bolts 25 Nm 25 Nm

29 Nm 4 Nm

IMPORTANT Before carrying out any work on the injection system, 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 the engine is running is strictly prohibited. It is essential to read the repair precautions (see 13B, Diesel injection, Repair precautions ).

REMOVAL
Disconnect the battery, starting with the positive terminal. Remove: - the engine covers, - the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). - the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle.

13B-147

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 800 or 808

13B

18297-1

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 sensor side. Fit blanking plugs into the openings. Move the diesel temperature sensor (3) to one side. Note: The diesel temperature sensor is an integral part of the fuel return pipe; these two components are connected and cannot be removed separately. 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.

13B-148

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 800 or 808

13B

REFITTING
Position the injector rail. WARNING

Do not remove the protective caps from each component until the last moment. Always replace any high-pressure pipe removed with a new one. Position the injector rail. Pretighten the injector rail bolts, leaving clearance between the bolt heads and the rail. Refit the injector rail pipes and the rail pump pipe: - screw, by hand, the high-pressure pipe nuts onto the pump and injector side, - screw, by hand, the high-pressure pipe nuts onto the rail side.
1327

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 the injection pump end ( 25 Nm ) , - the nuts on the rail end ( 29 Nm ) WARNING Do not put high-pressure pipes under stress. Always hold the lter rod retaining nuts on the injector holder when tightening.

Remove the high-pressure diesel pipes using (Mot. 1566) or (Mot. 1746) . WARNING When loosening the injector pipe unions (6) on the injectors, be sure to hold the lter rod retaining nuts (7) with a lock wrench. Plug the openings. Remove: - the injector rail bolts, - the injector rail (5) .

13B-149

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 800 or 808

13B

18297-1

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 the operation. Proceed in the reverse order to removal. For versions with injector rail protector covers: - Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). Note: Ret the inlet duct without retting the injector rail protector or retting the duct seal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). WARNING Conrm 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. 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 injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle, - Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).

13B-150

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 804 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool

13B

3
Tightening torquesm injector rail mounting bolts nuts on the injector side and the nut on the injector pump side nuts on the rail side battery cover mounting bolts 25 Nm 25 Nm Disconnect: - the injector connectors (1) , - the cylinder marking sensor connector (2) , - the fuel return pipe. 29 Nm 4 Nm Plug the openings. Do not remove the injector clip. Press the injector clip. Pull the return rail end piece vertically. IMPORTANT Before carrying out any work on the injection system, 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 the engine is running is strictly prohibited. It is essential to read the repair precautions (see 13B, Diesel injection, Repair precautions ). Remove the diesel return pipe (3) . Plug the openings.
111965

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ).

13B-151

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 804

13B

REFITTING
4
Position the injector rail. WARNING Do not remove the protective caps from each component until the last moment. Always replace any high-pressure pipe removed with a new one. Tighten the injector rail bolts, leaving clearance between the bolt heads and the rail. Refit the injector rail pipes and the rail pump pipe: - screw, by hand, the high-pressure pipe nuts onto the pump and injector side, - screw, by hand, the high-pressure pipe nuts onto the rail side. Tighten to torque using (Mot. 1566) or (Mot. 1746) :
1327

- the injector rail mounting bolts ( 25 Nm ) - the nuts on the injector side and the nut on the injector pump side ( 25 Nm ) - the nuts on the rail side ( 29 Nm )

Remove the high-pressure diesel pipes using (Mot. 1566) or (Mot. 1746) .

WARNING When loosening the injector pipe unions (4) on the injectors, be sure to hold the lter rod retaining nuts (5) with a lock wrench. Plug the openings. Remove the oil separator. WARNING Do not put high-pressure pipes under stress. Do not touch the high-pressure pipes with the spanner when tightening them. Always hold the lter rod retaining nuts on the injector holder when tightening.

111859

Remove: - the injector rail bolts (6) , - the injector rail (7) .

13B-152

DIESEL INJECTION Injector rail: Removal - Refitting


F9Q, and 804

13B

Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ). Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).

111965

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 the operation. To refit, proceed in the reverse order to removal. Refit the air inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ). Note: Ret the inlet duct without retting the injector rail protector or replacing the duct seal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ).

WARNING Conrm 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. Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Remove the air inlet duct.

13B-153

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1566 Mot. 1746 Wrench for removing high-pressure pipes Offset spanner for tightening high pressure pump pipe Equipment required diagnostic tool IMPORTANT

13B

Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).

Tightening torquesm injector rail mounting nuts high-pressure pipe nuts between the injector rail and the injectors high-pressure pipe nuts between the injector rail and the high-pressure pump air inlet duct clip 28 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION 24 Nm Switch off the ignition and wait 30 seconds before starting work on the injection system. Remove the engine covers 24 Nm Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

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) .
112815

WARNING Parts always to be replaced: - all the high-pressure pipes which have been removed.

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip and (2) move the air inlet duct aside (3) .

13B-154

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732

13B

112811

112992

Pull out the clip.

Unclip injector rail protector cover (6) . Remove: - the mounting nut and bolt (7) from the injector rail protector cover, - the injector rail protector cover, - the dipstick, - the dipstick tube mounting bolts (8) . Move the dipstick tube to one side.

112991

Remove the stainless steel pipe mounting bolt (4) Move the air inlet duct to one side.

112993

Disconnect: - the injector connector (9) ,

13B-155

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732 - the heater plugs connector (10) .

13B

112656 112994

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) . Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

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.

13B-156

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732

13B

111748

Unclip the diesel evacuation pipe. Remove: - the injector rail protector support mounting bolt and mounting nuts, - the injector rail protector support. Clean (see 13B, Repair precautions ): - the high-pressure pipes between the injector rail and the injectors, - the high-pressure pipes (19) between the highpressure pump and the injector rail. WARNING When loosening the high-pressure pipe unions (21) on the injector holder, it is essential to hold the lter rod mounting nut (22) with a lock wrench. Remove: - the nuts from the four high-pressure pipes between the injector rail and the injector on the rail end, - the nuts from the four high-pressure pipes between the injector rail and the injector on the injector end, Remove the four high-pressure pipes and dispose of them in a bin. Note: Make preparations for the fuel outow. Clean with new wipes. Fit blanking plugs,

1327

13B-157

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732 Remove the high-pressure pipe between the highpressure pump and the injector rail and dispose of it in a bin. WARNING When loosening the connector of the high-pressure pipe, the intermediate nut must be secured on the pump using a lock wrench. WARNING

13B

REFITTING
I - REFITTING PREPARATION OPERATION

Only remove the blanking plugs immediately before connecting the fuel circuit pipes. The plugs are single-use. Do not reuse them; dispose of the whole set after use. Take the injector rail out of its plastic bag.

Note: Make preparations for fuel outow. Clean with new wipes. II - OPERATION FOR REMOVAL OF PART CONCERNED

WARNING If an injector rail is being replaced, only remove the new one from its original packaging when it is about to be tted.

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 injector rail and the high-pressure pump.

Note: If the new pipes kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes).
111745

Remove: - the injector rail mounting nuts (23) , - the injector rail. WARNING If the injector rail is to be reused, keep it in a sealed plastic bag all the time it is disconnected.

Finger tighten the high-pressure pipe nuts, starting with the one at the injector rail side. Remove the blanking plugs. Fit the new high-pressure pipes between the injector rail and the injectors.

Note: If the new pipes kit does not contain an applicator, lubrication of the nut threads will be unnecessar y (as they are self-lubricating pipes). Finger tighten the high-pressure pipe nuts, starting with the one at the injector rail side. Tighten to torque the injector rail mounting nuts ( 28 Nm ) .

13B-158

DIESEL INJECTION Injector rail: Removal - Refitting


K9K, and 732 Tighten to torque: - the high-pressure pipe nuts between the injector rail and the injectors ( 24 Nm ) using (Mot. 1566) or (Mot. 1746) starting with the rail end. - the high-pressure pipe nuts between the injector rail and the high-pressure pump ( 24 Nm ) using (Mot. 1566) or (Mot. 1746) starting with the high-pressure pump end. III - FINAL OPERATION Refit: - the injector rail protector support, - the mounting nuts and bolt of the injector rail protector support. Note: Ensure that the injector rail protector support mounting bolt does not fall under the high-pressure pump. 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 valve, - 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, WARNING Refit the engine covers.

13B

- the injector rail protector cover mounting nut and bolt, Clip injector rail protector cover. Refit: - the clip on the stainless steel pipe if necessary, - the stainless steel pipe on the hose, aligning the markings, - the clamp of the air inlet duct between the turbocharger 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 priming pump.

Using the diagnostic tool , clear any faults stored by the injection computer, before restarting the engine.

Conrm that there is no diesel fuel leak: - Check the tightness after repair (see 13B, Diesel 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 outow. Using diagnostic tool , check that there are no stored faults; clear if necessary.

13B-159

DIESEL INJECTION Rail pressure sensor


K9K, and 722 or 724 or 728 or 729 or 732

13B

1
102086

Pressure sensor (1) cannot be removed from the spherical injector rail. In the event of a pressure sensor fault, the rail pressure sensor and high-pressure pipe assembly must be replaced (see 13B, Diesel injection, Injector rail ).

13B-160

DIESEL INJECTION Rail pressure sensor: Removal - Refitting


F9Q, and 800

13B

Equipment required diagnostic tool

Tightening torquesm pressure sensor to torque battery cover mounting bolts to torque 3.5 daNm +/0.5 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 respect the safety and cleanliness advice given in this document. - It is strictly forbidden to undo a high-pressure pipe union when the engine is running.

WARNING - Obtain a set of special high-pressure injection circuit plugs. - All high-pressure pipes must be replaced and any removed high-pressure pipe clips.

13B-161

DIESEL INJECTION Rail pressure sensor: Removal - Refitting


F9Q, and 800

13B

REMOVAL

18297-5

Disconnect: - the battery, starting with the negative terminal. - the pressure sensor. Unscrew the pressure sensor.

13B-162

DIESEL INJECTION Rail pressure sensor: Removal - Refitting


F9Q, and 800

13B

REFITTING
Replace the seal. Screw in the sensor. Tighten the pressure sensor to torque ( 3.5 daNm +/- 0.5 ) . Connect the connector. WARNING Connect the battery; carry out the necessary programming (see (see 8, Electrical equipment) ). Tighten the battery cover mounting bolts to torque ( 0.4 daNm ) . WARNING Check that there are no diesel leaks: - run the engine at idle speed until the fan starts up, - accelerate several times under no load, - carry out a road test, - switch off the ignition, - check that there is no diesel leak:

13B-163

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 722

13B

Equipment required diagnostic tool low torque wrench

1
Tightening torquesm fuel ow actuator mounting bolts battery cover securing bolts 5.5 0.6 Nm 4 Nm
102120

Disconnect: 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high pressure pipe union when the engine is running is strictly prohibited. - the battery, starting with the negative terminal, - the air intake duct (1) .

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Always replace any high pressure pipe and high pressure pipe clips removed with new ones.

REMOVAL
Remove the engine covers. Remove diesel splash plate (2) .

102362

13B-164

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 722

13B
6

5 4

102514

102315

Disconnect: - the heater plugs, - the injector connectors (3) from cylinders no. 3 and no. 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 small successive turns). WARNING Do not use the electrical connector as a lever ar m.

13B-165

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 722

13B

REFITTING
WARNING WARNING Do not remove the blanking plugs from any component until the last moment. Only unpack the new component when you are ready to fit it. WARNING Do not damage the seal when retting. Conrm that there is no diesel fuel leakage: - check the sealing after repair (see 13B, High pressure pipe: Fuel-tightness check ). - Let the engine run at idle speed until the engine cooling 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. Note: Do not lubricate the seals with grease or used diesel fuel. Use the applicator provided in the kit for the new part. Fit the actuator. Finger-tighten the two mounting bolts. Tighten to torque the two fuel flow actuator mounting bolts ( 5.5 0.6 Nm ) using tool low torque wrench . Refit a new high-pressure pipe to injector no. 4 (see 13B, High pressure pipes: Replacement ) and a new 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 terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover securing bolts ( 4 Nm ) .

13B-166

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 728 or 729

13B

Equipment required diagnostic tool low torque wrench

Tightening torquesm ow actuator mounting bolts battery cover mounting bolts 5.5 0.6 Nm 4 Nm

Note: For vehicles with a K9K 732 engine (see MR 370 Mechanical, Scnic II ).
110325

Pull the clip. IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

2 1

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Always replace any high-pressure pipe or highpressure pipe clip removed with a new one. Undo bolt (1) .

110323

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

Remove air duct (2) .

13B-167

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 728 or 729

13B
7

102362

102315

Remove the diesel splash plate (3) .

Remove the high-pressure pipe (7) from injector no. 4 (see 13B, Diesel injection, High-pressure pipes: Replacing ). Fit plugs into the openings.

Undo bracket bolts (8) . Withdraw the fuel flow actuator (by hand using small successive turns). WARNING Do not use the electrical connector as a lever ar m.

6 5

102514

Disconnect: - the heater plugs, - the injector connectors (6) from cylinders n3 and n4, - the pump electrical connectors (4) , - the supply and return pipes (5) .

13B-168

DIESEL INJECTION Fuel flow actuator: Removal - Refitting


K9K, and 728 or 729

13B

REFITTING
WARNING WARNING Do not remove the blanking plugs from each component until the last moment. Only unpack the new component when you are ready to fit it. WARNING Do not damage the seal when retting. Conrm 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 engine cooling 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. Note: Do not lubricate the seals with grease or used diesel fuel. Use the applicator provided in the kit for the new part. Fit the actuator. Finger tighten the mounting bolts. Tighten to torque the two flow actuator mounting bolts ( 5.5 0.6 Nm ) using low torque wrench . Refit a new high-pressure pipe on injector no. 4 (see 13B, High-pressure pipes: Replacement ) and a new 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 terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13B-169

DIESEL INJECTION Leak flow from injectors: Check


K9K, and 722 or 728 or 729 Special tooling required Mot. 1711 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 pipes. Fit the correct blanking plugs, in particular onto the venturi pipe to prevent depriming the circuit. Insert these hoses in the four graduated measuring cylinders of the (Mot. 1711) . Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). IMPORTANT Do not leave any object (tools or other) on the side of the engine housing during the entire operation. Position the tools so that they do not fall during the engine running phase of the test. Follow the procedures described in the Fault finding MR (see MR 372 Fault finding, 13B, Diesel injection, 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: Removal - Refitting ). Refit the engine covers. Kit for measuring injector leak rate

13B

13B-170

DIESEL INJECTION Leak flow from injectors: Check


K9K, and 732 Special tooling required Mot. 1771 Kit for measuring SIEMENS injector leak rate Kit for measuring injector leak rate

13B

Mot. 1711

Switch off the ignition and wait 30 seconds before starting work on the injection system. Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

112811

Pull out the clip.

112815

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip and (2) move the air inlet duct aside (3) .

112991

Remove the stainless steel pipe mounting bolt (4) . Move the air inlet duct to one side (5) .

13B-171

DIESEL INJECTION Leak flow from injectors: Check


K9K, and 732 Connect:

13B

- the connector of the air inlet pressure sensor, - the battery (see 80A, Battery, Battery: Removal Refitting ). IMPORTANT Do not leave any object (tools or other) on the side of the engine housing during the entire operation. Position the tools so that they do not fall during the engine running phase of the test. Follow the procedures described in the Fault finding MR (see MR 372 Fault finding, 13B, Diesel injection, Fault finding - Tests ). Disconnect:
112992

- 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:

Unclip injector rail protector cover (6) . Remove: - the mounting nut and bolt (7) from the injector rail protector 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 injectors (see 13B, Diesel injector fuel return rail: Removal - Refitting ). Connect the transparent hoses of (Mot. 1771) to the injectors instead of the injector fuel return pipes. Fit the correct blanking plug to the injector fuel return connectors. Insert these hoses in the four graduated measuring cylinders of the (Mot. 1711) . Refit: - the dipstick tube mounting bolts. - the dipstick. Refit the clip onto the stainless steel pipe if necessary. Clip the stainless steel pipe to turbocharger. Refit the air inlet duct on the damper valve. Tighten the clamp.

- the dipstick tube mounting bolts. - the dipstick, - the injector rail protector cover, - the injector rail protector cover mounting nut and bolt, Clip injector rail protector cover. Refit the clip onto the stainless steel pipe if necessary. 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.

13B-172

DIESEL INJECTION Leak flow from injectors: Check


K9K, and 732 Connect: - the connector of the air inlet pressure sensor, - the battery (see 80A, Battery, Battery: Removal Refitting ). Reprime the fuel circuit with the manual priming pump. Refit the engine covers.

13B

13B-173

DIESEL INJECTION Fuel pressure regulator: Removal - Refitting


F9Q, and 800 or 808

13B

Equipment required diagnostic tool low torque wrench

Tightening torquesm regulator bolts battery cover mounting bolt 6 Nm 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high pressure pipe union when the engine is running is strictly prohibited.

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Be sure to replace any high pressure pipe and high pressure pipe clips that have been removed.

13B-174

DIESEL INJECTION Fuel pressure regulator: Removal - Refitting


F9Q, and 800 or 808

13B

REMOVAL

18297-1

Disconnect the battery, starting with the negative terminal. Blow the area with compressed air to clean impurities 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 use any tool for leverage).

13B-175

DIESEL INJECTION Fuel pressure regulator: Removal - Refitting


F9Q, and 800 or 808

13B

REFITTING
Clean the fuel pressure regulator bearing face on the high pressure pump, taking care not to introduce any impurities. Wipe the fuel pressure regulator bearing face on the high pressure pump, taking care not to introduce any impurities. Connect the battery. Rinse the fuel pressure regulator housing in the high pressure pump, with the ignition on for a few seconds. Disconnect the battery. Prepare the new regulator: - remove the protective cap, - check the seal positions, - lubricate the O-rings with clean diesel fuel. WARNING Conrm that there is no diesel fuel leakage: - let the engine run at idle speed until the engine cooling 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.

Note: Lubrication is very important to avoid external leakage. 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.

WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Connect the battery, starting with the positive terminal. Torque tighten the battery cover mounting bolt ( 4 Nm ) . Switch on the ignition. Clear the fault shown in the diagnostic tool CLIP if necessary.

13B-176

DIESEL INJECTION Fuel pressure regulator: Removal - Refitting


F9Q, and 804

13B

REMOVAL
Equipment required diagnostic tool low torque wrench

Tightening torquesm regulator bolts battery cover mounting bolts 6 Nm 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

111887

Disconnect the battery, starting with the negative terminal. Blow compressed air into the area to clean dirt from around the fuel pressure regulator. Disconnect the fuel pressure regulator connector. Clean the area with brake degreaser.

WARNING - Obtain the special high-pressure injection cap kit. - Be sure to replace any high-pressure pipe removed.

Remove: - fuel pressure regulator bolts (1) , - the fuel pressure regulator manually (do not use any tool for leverage).

13B-177

DIESEL INJECTION Fuel pressure regulator: Removal - Refitting


F9Q, and 804

13B

REFITTING
Clean the fuel pressure regulator bearing face on the high-pressure pump, taking care not to introduce any impurities. Wipe the fuel pressure regulator bearing face on the high-pressure pump, taking care not to introduce any impurities. Connect the battery, starting with the positive terminal. Flush the fuel pressure regulator housing in the high-pressure pump, with the ignition on for a few seconds. Disconnect the battery, starting with the negative terminal. Prepare the new regulator: - remove the protective cap, - check the seal positions, - lubricate the O-rings with clean diesel fuel. WARNING Conrm that there is no diesel fuel leak: - let the engine run at idle speed until the engine cooling 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.

Note: Lubrication is very important to avoid external leaks. 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 ) using low torque wrench . Clean the area with cleaning cloths. Fit the fuel pressure regulator connector. Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Switch on the ignition. Clear the fault indicated on the diagnostic tool if necessary.

13B-178

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 722

13B

Equipment required diagnostic tool

WARNING Before starting work on the vehicle, have to hand: - a new set of blanking plugs (part no.: 77 01 206 804 ), 15 Nm 4 Nm - cleaning cloths (part no.: 77 11 211 707 ), - cleaning product (part no.: 77 11 224 188 ).

Tightening torquesm diesel temperature sensor batter cover mounting bolts

REMOVAL
Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the engine covers.

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Always replace any high-pressure pipe and highpressure pipe clips that have been removed.
102120

Disconnect air aspiration hose (1) .

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 .

13B-179

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 722

13B

REFITTING

2 3

WARNING Do not remove the blanking plugs from each component until the last moment. Lubricate the O-ring with the lubricant from the applicator supplied with the new part. WARNING Do not damage the O-ring when retting. Fit the diesel fuel temperature sensor. Tighten to torque the diesel temperature sensor ( 15 Nm ) . Reconnect the electrical connector.
102514

Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Tighten to torque the batter cover mounting bolts ( 4 Nm ) . Check the sealing after repair (see 13B, Diesel injection, High-pressure pipe: Check sealing ). WARNING Conrm that there is no diesel fuel leak:

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) .

- let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load, - switch off the ignition, - check that there is no diesel fuel escaping.

102317

Clean the sensor (see 13B, Diesel injection, Diesel injection: Precautions during repair ). Remove the fuel temperature sensor (4) . Fit plugs into the openings.

13B-180

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 728 or 729

13B

Equipment required diagnostic tool

WARNING Before starting work on the vehicle, have to hand: - a new set of blanking plugs (part no.: 77 01 206 804 ), 15 Nm 4 Nm - cleaning cloths (part no.: 77 11 211 707 ), - cleaning product (part no.: 77 11 224 188 ).

Tightening torquesm diesel temperature sensor battery cover mounting bolts

REMOVAL
Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the engine covers.

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice given in this document whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited.

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Always replace any high-pressure pipe and highpressure pipe clips that have been removed.
110325

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 .

Pull the clip.

13B-181

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 728 or 729

13B
5

2 1

110323

102317

Unscrew bolt (1) Remove the air duct (2) .

Clean the sensor (see 13B, Diesel injection, Diesel injection: Precautions during repair ). Remove the diesel fuel temperature sensor (5) . Fit plugs into the openings.

3 4

REFITTING

WARNING Do not remove the blanking plugs from each component until the last moment. Lubricate the O-ring with the lubricant from the applicator supplied with the new part.

WARNING Do not damage the O-ring when retting.


102514

Disconnect: - the heater plugs from cylinders n 3 and 4, - the injectors (3) on cylinders 3 and 4, - the fuel temperature sensor connector (4) .

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: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13B-182

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 728 or 729 Check the sealing after repair (see 13B, Diesel injection, High-pressure pipe: Check sealing ). WARNING Conrm that there is no diesel fuel leak: - let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load, - switch off the ignition, - check that there is no diesel fuel escaping.

13B

13B-183

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 732

13B

111747

The diesel temperature sensor (1) is attached to the diesel injector fuel return rail. Replace the diesel injector fuel return rail and diesel temperature sensor assembly if there is a diesel temperature sensor fault (see 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refitting ).

13B-184

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 724

13B

REMOVAL
Equipment required diagnostic tool I - REMOVAL PREPARATION OPERATION Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove the engine undertray. 15 Nm

Tightening torquesm diesel temperature sensor

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice whenever work is carr ied out on this system. Loosening a high pressure pipe union when the engine is running is strictly prohibited.
112331

Remove the pin securing the turbocharger pipe on the turbocharger (1) . Remove the bolt mounting the pipe on the cylinder head.

WARNING Tighten to a torque of 38 Nm the pump-rail and rail-injectors high pressure pipes with 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 a torque of 24 Nm .

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) .

WARNING Before starting work on the vehicle, obtain: - a new blanking plug kit ( PART NUMBER 77 01 206 804 ), - cleaning cloths ( PART NUMBER 77 11 211 707 ). During each operation, always read the precautions for repair (see 13B, Diesel injection, Diesel injection: Precautions for repair ).

13B-185

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 724

13B

109470

109465

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 protector, - the injection rail protector (7) .

Remove the high pressure pump protectors (8) and (9)

102514

Clean the pipes (see 13B, Diesel injection, Diesel injection: Precautions for repair ). Disconnect the diesel supply and return pipes (10) .

Note: Make preparations for fuel outow. Clean with new cloths. Fit the correct blanking plugs.

13B-186

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 724

13B

REFITTING
I - REFITTING PREPARATION OPERATION Lubricate the O-ring with lubricant from the applicator supplied with the new part.

Note: Do not lubricate the diesel temperature sensor seals with grease or used diesel. Use the applicator supplied with the kit.

WARNING Do not damage the O-ring when retting. Do not remove the blanking plugs from each component until the last moment.
102514

Disconnect the diesel temperature sensor connector (11) . II - REMOVAL OF PART CONCERNED

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
102317

Fit the turbocharger air duct. Lock the air duct onto the turbocharger and the intercooler 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: Removal - Refitting ).

Clean the diesel temperature sensor (see 13B, Diesel injection, Diesel injection: Precautions for repair ). Remove the diesel temperature sensor (12) .

13B-187

DIESEL INJECTION Diesel temperature sensor: Removal - Refitting


K9K, and 724 Check the sealing after repair (see 13B, Diesel injection, High pressure pipe: check ). WARNING Conrm that there is no diesel fuel leak: - let the engine run at idle speed until the engine cooling fan starts to operate, - accelerate several times at no load, - switch off the ignition, - check that there is no diesel fuel leaking.

13B

13B-188

DIESEL INJECTION Accelerometer: Removal - Refitting


K9K, and 722 or 728 or 729 Special tooling required Emb. 1596 2 4 mm socket for removing/retting clutch master cylinder Equipment required low torque wrench

13B

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 terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). 20 Nm 4 Nm Tighten to torque the battery cover securing bolts ( 4 Nm ) .

Tightening torquesm accelerometer battery cover securing bolts

REMOVAL

102086

Disconnect the accelerometer connector (1) . Remove the accelerometer using tool (Emb. 1596) .

13B-189

DIESEL INJECTION Venturi: Removal - Refitting


K9K, and 722

13B

Equipment required diagnostic tool low torque wrench

1
Tightening torquesm Venturi mounting bolt battery cover securing bolts 5.5 Nm 0.6 4 Nm

102120

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 cleanliness advice whenever work is carried out on this system. - Loosening a high pressure pipe union when the engine is running is strictly prohibited.

Disconnect: - the battery, starting with the negative terminal, - the intake duct (1) .

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Always replace any high pressure pipe and high pressure pipe clips removed with new ones.

REMOVAL
Remove the engine covers.
102514

Disconnect the fuel supply and return pipes (2) .

13B-190

DIESEL INJECTION Venturi: Removal - Refitting


K9K, and 722

13B

REFITTING

WARNING Do not remove the blanking plugs from any component until the last moment. Lubricate the O-ring with the lubricant from the applicator 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 ( 5.5 Nm 0.6 ) using tool low torque wrench . Reconnect the various pipes.

4
WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover securing bolts ( 4 Nm ) WARNING Conrm that there is no diesel fuel leakage: - check the sealing after repair (see 13B, Diesel injection, High pressure pipe: Fuel tightness check ), - let the engine run at idle speed until the engine cooling 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.

102316

Disconnect the return pipe (3) connecting the injector to the pump. Remove: - the Venturi mounting bolt (4) , - the Venturi.

13B-191

DIESEL INJECTION Venturi: Removal - Refitting


K9K, and 728 or 729

13B

Equipment required diagnostic tool low torque wrench

Tightening torquesm Venturi mounting bolt battery cover mounting bolts 5.5 Nm 0.6 4 Nm

IMPORTANT Before carrying out any work on the injection system, 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 cleanliness advice whenever work is carried out on this system. - Loosening a high-pressure pipe union when the engine is running is strictly prohibited. Pull the clip.
110325

2 1

WARNING - Obtain a set of special high-pressure injection circuit plugs. - Be sure to replace any high-pressure pipe and high-pressure pipe clips that have been removed.

REMOVAL
Remove the engine covers.

110323

Undo bolt (1) . Remove the air duct (2) .

13B-192

DIESEL INJECTION Venturi: Removal - Refitting


K9K, and 728 or 729

13B

REFITTING

WARNING Do not remove the blanking plugs from each component until the last moment. Lubricate the O-ring with the lubricant from the applicator 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 ( 5.5 Nm 0.6 ) using tool low torque wrench . Reconnect the various pipes. Connect the battery, starting with the positive terminal WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm )

102514

Disconnect the fuel supply and return pipes (3) .

4
WARNING Conrm that there is no diesel fuel leak: - Check the tightness after repair (see 13B, Diesel injection, High-pressure pipe: Sealing check ), - let the engine run at idle speed until the engine cooling 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.
102316

Disconnect the return pipe (4) connecting the injector to the pump. Remove: - the Venturi mounting bolt (5) , - the Venturi.

13B-193

DIESEL INJECTION
Accelerator pedal potentiometer: General information
F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 The accelerator pedal potentiometer is incorporated in the accelerator pedal. If it is replaced, the accelerator pedal must also be replaced. There are two types of pedal: with or without a kickdown point. Vehicles fitted with cruise control / speed limiter have an accelerator pedal with a kickdown point at the end of their travel ( kick-down ). This kickdown point makes it possible to exit the speed limiter function if the driver has to increase speed.

13B

WARNING A pedal tted with a kickdown point may be tted in place of a pedal without a kickdown point. However, tting a pedal without a kickdown point in place of a pedal with a kickdown point is prohibited.

13B-194

DIESEL INJECTION Accelerator pedal potentiometer: Removal - Refitting


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

13B

REFITTING
Tightening torquesm battery cover mounting bolt 4 Nm Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ).

REMOVAL
Disconnect: - the battery, starting with the negative terminal, - the accelerator pedal connector.

Note: A fault on the accelerator pedal position potentiometer results in changes in the idle speed or engine operation (see 13B, Diesel injection, Idle speed ). Torque tighten the battery cover mounting bolt ( 4 Nm ) .

102204

Remove: - pedal mounting bolts (1) , - the pedal.

13B-195

DIESEL INJECTION Diesel injection computer: Removal - Refitting


K9K, and 722 or 728 or 729 F9Q, and 800 or 808

13B

Equipment required diagnostic tool

Tightening torquesm battery tray mounting bolts battery cover mounting bolts 21 Nm 4 Nm

Note: When programming, reprogramming or replacing a computer, it is necessary to program the C2I parameters (individual injector correction) and the engine parameters into the new computer using the diagnostic tool RENAULT CLIP tool. There are two procedures for doing this (see 13B, Diesel Injection, Injectors: Configuration and programming ): - an automatic procedure which can be used if it is possible to read the information contained in the old computer, - a manual procedure for when it is not possible to read the information contained in the old computer. Remove: - the battery tray mounting bolts (2) , - the wiring harness bracket (3) . Detach the wiring harnesses from the battery tray. Remove the battery tray.

3
101822

Disconnect the injection computer connectors (1) .

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. Remove the battery.

101811

Remove the injection computer and its support (4) .

13B-196

DIESEL INJECTION Diesel injection computer: Removal - Refitting


K9K, and 722 or 728 or 729 F9Q, and 800 or 808

13B

REFITTING
5

101890

Remove: - the computer mounting bolts (5) , - the computer. Proceed in the reverse order to removal.

101887

Tighten to torque the battery tray mounting bolts ( 21 Nm ) . Make sure you refit the battery tray correctly on the computer support. Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Respect the programming instructions for the C2I parameters (individual injector correction) and engine adaptives (see 13B, Diesel injection, Computer configuration ). Switch on the ignition and read the fault codes using the diagnostic tool . If necessary, repair the faults indicated. Clear the faults. Check that the vehicle is operating correctly.

13B-197

DIESEL INJECTION Diesel injection computer: Removal - Refitting


K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700

13B

Tightening torquesm mounting bolt on the computer support 21 Nm

WARNING - The injection computer retains the immobiliser code for life. - The system has no security code. - It is forbidden to perform tests with computers borrowed from the Parts Department or from another vehicle, that must then be returned. These computers are permanently coded. When replacing the computer (see MR 372 Fault finding, Diesel injection, Fault finding - Replacement of components ).
115720

REMOVAL
I - REMOVAL PREPARATION OPERATION Remove the engine covers. Remove the battery (see 80A, Battery, Battery: Removal - Refitting ).

Disconnect the computer connectors (1) . Unclip: - the wiring harness (2) from the battery negative terminal, - the wiring harness. Remove: - the upper mounting bolt (3) from the computer support, - 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.

13B-198

DIESEL INJECTION Diesel injection computer: Removal - Refitting


K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700 II - FINAL OPERATION Refit the mounting bolt to the computer support. Tighten to torque the mounting bolt on the computer support ( 21 Nm ) . Refit the upper mounting bolt to the computer support. 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.

13B

13B-199

PREHEATING Pre/postheating unit: Removal - Refitting


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 M9R, and 700

13C

Tightening torquesm battery cover mounting bolts wheel bolts 4 Nm 110 Nm

Note: It is located behind the front left-hand wheel arch liner.

REMOVAL
Disconnect the battery, starting with the negative terminal.

102125

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque: - the battery cover mounting bolts ( 4 Nm ) , - the wheel bolts ( 110 Nm ) . .

101823

Remove: - the front left-hand wheel, - the front left-hand wheel arch liner.

13C-1

PREHEATING Heater plugs Removal - Refitting


K9K, and 722

13C

Tightening torquesm heater plugs battery cover mounting bolts 15 Nm 4 Nm

The resistance of a heater plug is 0.6 (connector disconnected). The heater plugs are removed without opening the high pressure diesel circuit.

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

15762

Disconnect the electrical connector from the heater plugs. Clean around the outside of the heater plugs with a compressed air gun to prevent contamination of the cylinders. Undo then remove the plugs using a 10 mm diameter long radio socket connected to a universal joint. Use a hose to unscrew the plugs completely. WARNING Ensure that no foreign bodies enter the cylinder during this operation.

REFITTING
102120

Proceed in the reverse order to removal. Tighten to torque the heater plugs ( 15 Nm ) . Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

Disconnect the air duct.

13C-2

PREHEATING Heater plugs Removal - Refitting


K9K, and 728 or 729

13C

Tightening torquesm heater plugs battery cover mounting bolts 15 Nm 4 Nm

2 1

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

110323

Undo the bolt (1) . Move the air duct aside (2) .

110325

Pull the clip.

15762

Disconnect the electrical connector from the heater plugs. Clean around the outside of the heater plugs with a compressed air gun to prevent contamination of the cylinders. Undo then remove the plugs using a 10 mm diameter long radio socket connected to a universal joint. Use a hose to unscrew the plugs completely.

WARNING Ensure that no foreign bodies enter the cylinder during this operation.

13C-3

PREHEATING Heater plugs Removal - Refitting


K9K, and 728 or 729

13C

REFITTING
Proceed in the reverse order to removal. Tighten to torque the heater plugs ( 15 Nm ) . Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13C-4

PREHEATING Heater plugs Removal - Refitting


F9Q, and 800 or 804 or 808

13C

Tightening torquesm heater plugs battery cover mounting bolts 15 Nm 4 Nm

The resistance of a heater plug is 0.6 (connector disconnected). The heater plugs are removed without opening the high pressure diesel circuit.

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal. F9Q, and 804 Remove: - the inlet duct (see 12A, Fuel mixture, Inlet duct: Removal - Refitting ). - the injection rail protector (see 13B, Diesel injection, Injection rail protector: Removal - Refitting )

15762

Disconnect the electrical connector from the heater plugs. Clean around the outside of the heater plugs with a compressed air gun to prevent contamination of the cylinders. Undo then remove the plugs using a 10 mm diameter long radio socket connected to a universal joint. Use a hose to unscrew the plugs completely. WARNING Ensure that no foreign bodies enter the cylinder during this operation.

REFITTING
Proceed in the reverse order to removal. Tighten to torque the heater plugs ( 15 Nm ) . Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

13C-5

PREHEATING Heater plugs Removal - Refitting


F9Q, and 804 UD replaced with 11,05,08,02-01,37-001,016 on 08/ 06/2005

13C

13C-6

PREHEATING Heater plugs Removal - Refitting


K9K, and 732 Special tooling required Car. 1363 Trim removal lever

13C

Tightening torquesm heater plugs 15 Nm

WARNING Procedure for removing the air inlet duct (risk of leaking and slipping if this procedure is not observed): - detach the hose using the (Car. 1363) , - do not use a degreaser, brake cleaning product, or any other product, - clean the bearing face on the intercooler and on the 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 is not replaced, - always replace the hose and/or the intercooler if damaged.

112815

Disconnect the air inlet pressure sensor connector (1) . Loosen the clip (2) and move the air inlet duct aside (3) .

REMOVAL
I - REMOVAL PREPARATION OPERATION Remove the engine covers. Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

112811

Pull out the clip.

13C-7

PREHEATING Heater plugs Removal - Refitting


K9K, and 732 - the injection rail protector cover, - the dipstick,

13C

- the dipstick pipe mounting bolts (9) . Move the dipstick pipe to one side. II - OPERATION FOR REMOVAL OF PART CONCERNED

112991

Make a marking (4) on the air inlet duct between the stainless 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) .
112993

Disconnect the connector from the heater plug. Note: Do not pull on the plug cable. Clean around the outside of the heater plugs with a compressed air gun to prevent contamination of the cylinders. Undo then remove the plugs using a 10 mm diameter long radio socket connected to a universal joint. Use a hose to unscrew the plugs completely. WARNING Ensure that no foreign bodies enter the cylinder during this operation.

112992

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED Refit the heater plugs using the hose.

Unclip the injection rail protector cover (7) . Remove: - the mounting nut and bolt (8) from the injection rail protector cover,

13C-8

PREHEATING Heater plugs Removal - Refitting


K9K, and 732 Tighten 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 mounting 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 the marking, 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

13C-9

PREHEATING Heater plugs Removal - Refitting


M9R, and 700

13C

REFITTING
Equipment required socket wrench for removing/retting preheating plugs I - REFITTING OPERATION FOR PART CONCERNED Refit the heater plugs. Tightening torquesm heater plugs 16.5 Nm WARNING Ensure that no foreign bodies enter the cylinder during this operation. Bring the heater plugs just into contact. Tighten to torque the heater plugs ( 16.5 Nm ) using a socket wrench for removing/refitting preheating plugs or a 1/4-inch square drive long socket 10 mm in diameter connected to a universal joint. WARNING The heater plugs are damaged by being tightened to any torque greater than 19 Nm . II - FINAL OPERATION II - OPERATION FOR REMOVAL OF PART CONCERNED Connect - the heater plug connectors, Unscrew then remove the plugs using a socket wrench for removing/refitting preheating plugs or a 1/4-inch square drive long 10 mm socket with a universal joint. If necessary, use a hose to unscrew the plugs completely. - the battery (see 80A, Battery, Battery: Removal Refitting ). Refit the engine cover.

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 prevent any contamination of the cylinders.

13C-10

PREHEATING Pre-postheating control


F9Q, and 800 or 808 The pre/post heating function is controlled by the injection 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 to the heater plugs depends on the coolant temperature and the battery voltage.

13C

101188

X: Time in seconds Y: Coolant temperature in C

101189

X: Time in seconds Y: Coolant temperature in C In all cases the preheating warning light should light up for more than 12 seconds . b - Fixed preheating After the warning light goes out the plugs remain supplied for a fixed period of 10 seconds . 2 - Starting The plugs continue to be supplied while the starter is being activated. 3 - Engine running postheating During this phase the plugs are supplied continuously according to coolant temperature. At idling speed with no depression of the accelerator pedal.

13C-11

PREHEATING Pre-postheating control


K9K, and 722 or 728 or 729 or 732 The pre-postheating function is controlled by the injection computer. PRE-POSTHEATING OPERATING PRINCIPLE 1 - Ignition on preheating a - Variable preheating The time taken for the warning light to come on and for supply to the heater plugs depends on the coolant temperature and the battery voltage.

13C

At idling speed with no depression of the accelerator pedal.

103124

X: Time in seconds Y: Coolant temperature in C

103123

X: Time in seconds Y: Coolant temperature in C Whatever the situation, the heater plug warning light cannot remain lit for more than 12 seconds (except in the event of a coolant temperature sensor fault). b - Fixed preheating After the warning light goes out, the heater plugs continue to be supplied for a fixed period of 5 seconds . 2 - Starting The plugs remain supplied while the starter motor is being activated. 3 - Engine running postheating During this phase the plugs are supplied continuously according to the coolant temperature.

13C-12

ANTIPOLLUTION Petrol vapour rebreathing: Operation


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 I - OPERATING DIAGRAM OF THE CIRCUIT F4R, and 776

14A

6 5

8 3 4

106679

(1) (2) (3) (4) (5) (6)

Inlet manifold Fuel vapour absorber bleed solenoid valve Fuel vapour absorber Tank Breather Anti-return valve (F4R 776 only) (8)

106278

Fuel vapour absorber bleed solenoid valve

7 10

11 12

102734 102724

(9) (10)

Fuel vapour absorber Fuel vapour recirculation coming from the tank

(7)

Fuel vapour absorber bleed solenoid valve

14A-1

ANTIPOLLUTION Petrol vapour rebreathing: Operation


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 (11) (12) Recirculation of fuel vapours going to the engine Tank breather

14A

WARNING The breather should not be blocked during normal engine operation. II - OPERATING PRINCIPLE The tank is vented by means of the fuel vapour absorber. Fuel vapour is trapped by the active charcoal contained in the absorber as it passes through. Fuel vapour trapped in the absorber is eliminated and burnt by the engine. To do this, connect the fuel vapour absorber and the inlet manifold via the solenoid valve. This solenoid valve is located on the shock absorber cup. The principle behind the solenoid valve is to open a passage of variable size (according to the opening cyclic ratio signal sent by the injection computer). The variation in the passage opened for fuel vapour in the solenoid valve results from the balance between the magnetic field created by the supply to the winding and the return spring force attempting to close the solenoid valve.

14A-2

ANTIPOLLUTION Fuel vapour recirculation circuit: check


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 I - CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED

14A

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 55C , - the air temperature is above 10C , - the engine is not at idle speed, - a given load threshold is reached,

Note: A fault with this system may result in rough idling or the engine stalling.

- the throttle potentiometer is not in the no load position. During on board diagnostic fault finding, fuel vapour absorber bleeding is not authorised.

6 5

The opening cyclic ratio of the fuel vapour absorber bleed solenoid valve can be displayed using the diagnostic tools by referring to parameter PR102: Fuel vapour absorber bleed solenoid valve OCR . The solenoid valve is closed for values below 1.2 % .

3 4

106679

(1) (2) (3) (4) (5) (6)

Inlet manifold Fuel vapour absorber bleed solenoid valve Fuel vapour absorber Tank Breather Anti-return valve (F4R 776 only)

Check the conformity of the circuit (see 14A, Antipollution, Fuel vapour rebreathing Operation ). Check the condition of the pipes to the tank.

14A-3

ANTIPOLLUTION Fuel vapour canister: Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 The absorber is located on the fuel tank under the vehicle.

14A

REMOVAL
2

102734

Disconnect: - pipe (2) bringing the fuel vapour from the tank,
102483

Release absorber (1) from the fuel tank retaining notch by pushing it in the direction of the arrow.

- pipe (3) taking the fuel vapours to the solenoid valve, - breather pipe (4) . Remove the absorber.

REFITTING
Proceed in the reverse order to removal.

14A-4

ANTIPOLLUTION Fuel vapour canister:Checking


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 Special tooling required Mot. 1311-01 Fuel pressure test kit

14A

CHECKING THE FUEL VAPOUR ABSORBER


On the fuel vapour absorber, cap the circuit coming from the tank. Connect a pressure gauge on tool (Mot. 1311-01) to the absorber breather outlet. With the engine at idle speed, check that there is no vacuum at the absorber breather outlet (under the same conditions, the command value read by the diagnostic tool in parameter: Fuel vapour absorber bleed solenoid valve OCR remains minimal ( X lower 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 bleeding conditions ), the vacuum should increase (at the same time the parameter value on the diagnostic tool should also increase).

CHECKING THE FUEL VAPOUR ABSORBER TANK CONNECTION


Check this connection by connecting a vacuum pump to the pipe going to the absorber.

14A-5

ANTIPOLLUTION Oil vapour rebreathing


B84 or C84 or S84, and K4J, and 730 or 732 I - LOCATION OF COMPONENTS

14A

101495

(1)

Oil vapour breather port

(2) (3)

Oil vapour recovery plate located on the cylinder head cover Sized port

3 2

2
101499

101869

14A-6

ANTIPOLLUTION Oil vapour rebreathing


B84 or C84 or S84, and K4J, and 730 or 732 For information on removing oil vapour recovery plate (2) , (see 11A, Top and front of engine, Tightening the cylinder head ). II - OPERATING DIAGRAM A: At low loads, small quantities of oil vapour are sucked back in via sized opening (7). (3) (4) (5) (6) (7) III - CHECKING Air unit

14A
Motorised throttle valve Inlet manifold Air inlet Sized port

To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition.

5 2

1
101956

B: At medium and high loads, large quantities of oil vapour are sucked in by the gas throttle.

5 2

101957

(1) (2)

Engine Oil vapour recovery plate

14A-7

ANTIPOLLUTION Oil vapour rebreathing


K4M, and 760 or 761 I - LOCATION OF COMPONENTS

14A

102305

(1) (2)

Oil vapour breather pipe Sized opening

3 4

101820

(3) (4)

Oil vapour recovery plate on the cylinder head cover Oil vapour breather pipe

102073

For information on removing oil vapour recovery plate (3) , (see 11A, Top and front of engine, Cylinder head gasket ).

14A-8

ANTIPOLLUTION Oil vapour rebreathing


K4M, and 760 or 761 II - OPERATING DIAGRAM A: At low loads, the oil vapours are rebreathed in small quantities through the sized opening (6) (5) (6) III - CHECKING Air inlet Sized opening

14A

3 5

To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition.

102308

B: Under average and heavy loads, the oil vapours are rebreathed in large quantities through the gas throttle valve.

3 5

102309

(1) (2) (3) (4)

Engine Oil vapour recovery plate Motorised throttle Inlet manifold

14A-9

ANTIPOLLUTION Oil vapour rebreathing


K9K, and 722 or 728 or 729 or 732 I - PRESENTATION OF THE CIRCUIT

14A

B : Under medium or high load, the pressure in the air inlet duct pulls the valve diaphragm, the oil vapours are rebreathed in small quantities via a sized opening.

1 2

II - CHECK To ensure the correct operation of the anti-pollution system, the oil vapour rebreathing circuit must be kept clean and in good condition.

20965

1 2

6 4

20965-1

(1) (2) (3) (4) (5) (6)

Cylinder head cover Oil vapour breather pipe Oil vapour rebreathing valve Air inlet duct Turbocharger Atmospheric pressure

A : Under low load, the vacuum in the air inlet duct is below the spring calibration. The oil vapours are rebreathed in large volumes by the vacuum in the air inlet duct.

14A-10

ANTIPOLLUTION Oil vapour rebreathing


F9Q, and 800 or 808 I - CIRCUIT PRESENTATION

14A
1

3 2 4 4 5 2 3 1
100054 100053

(1) (1) (2) (3) (4) (5) (6) II - CHECK To ensure the correct operation of the anti-pollution system, the oil vapour rebreathing circuit must be kept clean and in good condition. Engine Oil separator Air lter unit Air duct Turbocharger Inlet manifold (3) (4) (2)

Oil vapour rebreathing pipe connected to the intake pipes Cylinder block outlet oil vapour rebreathing pipe Separator lter oil return pipe Oil separator

14A-11

ANTIPOLLUTION Oil vapour rebreathing


F4R, and 770 or 771 or 776 I - PRESENTATION OF COMPONENTS

14A

102723

(1) (2)

Oil vapour breather pipe Oil vapour recirculation valve

(3)

Oil vapour recovery plate on the cylinder head cover

102729

14A-12

ANTIPOLLUTION Oil vapour rebreathing


F4R, and 770 or 771 or 776

14A

F4R, and 776

106629

(A)

Circuit upstream of turbocharger, used for medium and high loads. The vapour is sucked back in by the prevailing vacuum pressure in the inlet manifold Circuit downstream of throttle valve, used for low loads. The vapour is sucked back in by the prevailing vacuum pressure between the throttle and engine

(B)

106588

Oil vapour recovery plate located on the rocker cover

14A-13

ANTIPOLLUTION Oil vapour rebreathing


F4R, and 770 or 771 or 776

14A

For removal, (see 11A, Top and front of engine, Cylinder head gasket ). II - OIL VAPOUR RECIRCULATION CIRCUIT

102738

(4)

Throttle upstream oil vapour recirculation aperture

5 8 10

102745

14A-14

ANTIPOLLUTION Oil vapour rebreathing


F4R, and 770 or 771 or 776 (5) (6) (7) (8) (9) (10) III - CHECKING To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition. Air duct Throttle valve Inlet manifold Throttle valve upstream oil vapour rebreathing port Oil vapour recovery plate Oil vapour rebreathing valve

14A

14A-15

ANTIPOLLUTION Oil vapour rebreathing


F9Q, and 804 I - THE CIRCUIT

14A

100054 100053

(1) (1) (2) (3) (4) (5) (6) II - CHECK To ensure the antipollution system works properly, the oil vapour rebreathing circuit must be kept clean and in good condition. Engine Oil separator Air lter unit Air duct Turbocharger Inlet manifold (3) (4) (2)

Oil vapour rebreathing pipe connected to the inlet pipes Cylinder block outlet oil vapour rebreathing pipe Oil separator lter return pipe Oil separator

14A-16

ANTIPOLLUTION Exhaust gas recirculation: Description


K9K, and 722 or 728 or 729 I - THE CIRCUIT

14A

Note: The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation of the quantity of air admitted by the engine. IV - OPERATING CONDITIONS The following parameters determine actuation of the exhaust gas recirculation solenoid valve: - coolant temperature, - air temperature,

4 1

6 8
102364

- 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 actuated if: - the air temperature is between -30C and 67 C , inclusive, - or the coolant temperature is between 0C and 127C inclusive, - the engine speed is above 500 rpm , - the diesel fuel injection flow is between 10 and 31 mg/stroke inclusive, - the atmospheric pressure is above 421 mbar . If so, the diagnostic tool indicates an exhaust gas recirculation solenoid valve position opening cylinder ratio value 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 threshold, - the air conditioning compressor is actuated. The exhaust gas recirculation solenoid valve is not supplied after starting for 2 seconds . The exhaust gas recirculation solenoid valve is no longer supplied if there is a fault on: - the exhaust gas recirculation solenoid valve, - the turbocharging pressure sensor,

(1) (2) (3) (4) (5) (6) (7) (8) (A) (B)

Engine Air lter unit Plenum chamber Exhaust manifold Exhaust gas recirculation unit with solenoid valve Turbocharger Injection computer Intercooler Air inlet Exhaust gas outlet

II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases. The computer regulates the passage of gases by actuating a solenoid valve. III - OPERATING PRINCIPLE The solenoid valve is controlled by an opening cyclic ratio signal issued by the injection computer. The opening cyclic ratio signal modulates the opening of the solenoid valve, and consequently the quantity of exhaust gas directed back to the inlet manifold. The computer runs a constant test to keep track of the position of the exhaust gas recirculation solenoid valve.

14A-17

ANTIPOLLUTION Exhaust gas recirculation: Description


K9K, and 722 or 728 or 729

14A

15761

Track 1 2 3 4 5 6

Description Solenoid supply Position potentiometer supply Not used Position potentiometer earth Solenoid earth control Position potentiometer signal

14A-18

ANTIPOLLUTION Exhaust gas recirculation: Description


F9Q, and 800 or 808 I - THE CIRCUIT

14A

9 4

7 8 6 10

3 11 2 1

23244

III - OPERATING PRINCIPLE (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Engine Injection computer Inlet manifold Exhaust manifold Turbocharger Exhaust gas recirculation solenoid valve Air owmeter Air inlet Exhaust gas outlet Intercooler inlet Intercooler outlet IV - OPERATING CONDITIONS The following parameters determine activation of the exhaust gas recirculation solenoid valve: - coolant temperature, - the air temperature, II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases. The injection computer allows gas to pass by actuating a solenoid valve. - atmospheric pressure, - the injection flow, - the engine speed. Exhaust gas recirculation is cut off if: - the battery voltage is below 9 V , The solenoid valve is controlled by an opening cyclic ratio signal issued by the injection computer. The opening cyclic ratio signal modulates the opening of the solenoid valve, and consequently the quantity of exhaust gas directed back to the inlet manifold. The computer runs a constant test to keep track of the position of the exhaust gas recirculation solenoid valve.

14A-19

ANTIPOLLUTION Exhaust gas recirculation: Description


F9Q, and 800 or 808 - If the engine speed is above 2,950 rpm when the pedal is released (low pedal value),

14A

Note: There is no exhaust gas recirculation at altitude (> 1,200m). - if the mapping (engine speed/load) exceeds a given threshold, - 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 not controlled after engine start-up depending on coolant temperature mapping.
15761

Track 1 2 4 5 6
103127

Description Solenoid supply Sensor feed Sensor earth Solenoid earth Sensor output

X Y

Time in seconds Coolant temperature in C

The exhaust gas recirculation solenoid valve is no longer supplied if there is a fault on: - the coolant temperature sensor, - the air temperature sensor, - the turbocharging pressure sensor, - the atmospheric pressure sensor.

14A-20

ANTIPOLLUTION Exhaust gas recirculation: Description


F9Q, and 804 I - DIAGRAM

14A

114451

(1) (2) (3) (4) (5) (6)

Engine Exhaust gas cooler Exhaust gas recirculation unit Inlet manifold Exhaust manifold Turbocharger

II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM Exhaust gas recirculation is used to reduce the nitrogen oxide (NO X) content of the exhaust gases. The injection computer authorises gas passage by running an electric motor which actuates a valve linking the exhaust manifold and the inlet manifold. III - OPERATING PRINCIPLE The principle of the exhaust gas recirculation consists of reintroducing some of the exhaust fumes into the engine air breathing cycle. The EGR valve is controlled by a direct current motor.

14A-21

ANTIPOLLUTION Exhaust gas recirculation: Description


K9K, and 732 I - THE CIRCUIT Note:

14A

The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation of the quantity of air admitted by the engine. 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) (2) (3) (4) (5) (6) (7) (8) (A) (B)

Engine Air lter unit Plenum chamber Exhaust manifold Exhaust gas recirculation unit with solenoid valve Turbocharger Injection computer Intercooler Air inlet Exhaust gas outlet

II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM Exhaust gas recirculation is used to reduce the concentration of nitrogen oxides (NOx) in exhaust fumes. The computer regulates the passage of gases by actuating a solenoid valve. III - OPERATING PRINCIPLE The solenoid valve is controlled by an opening cyclic ratio signal issued by the injection computer. The opening cyclic ratio signal modulates the opening of the solenoid valve, and consequently the quantity of exhaust gas directed back to the inlet manifold. The computer runs a constant test to keep track of the position of the exhaust gas recirculation solenoid valve.

14A-22

ANTIPOLLUTION Exhaust gas recirculation unit


K9K, and 722 Special tooling required Mot. 1567 Remote operation pliers for EGR clips

14A

Tightening torquesm exhaust gas recirculation unit mounting bolt metal air inlet tube mounting bolt lifting eye (timing end) mounting bolts for the heat shield on the exhaust gas recirculation solenoid valve engine cover mounting bolts 21 Nm 21 Nm

21 Nm 12 Nm Disconnect the wiring harness (2) . Move the wiring harness to one side.

102126

4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal.

7
102119

Disconnect: - turbocharging pressure regulation valve pipe (3) from the air duct, - air inlet pipe (4) on the exhaust gas recirculation unit. Remove:
102120

- bracket (5) , - engine lifting eye (6) , - air intake metal pipe (7) .

Remove: - the engine covers, - the air duct (1) .

14A-23

ANTIPOLLUTION Exhaust gas recirculation unit


K9K, and 722

14A

10

102074

Remove: - exhaust gas recirculation solenoid valve heat shield (8) , - exhaust gas recirculation pipe (9) , - the two exhaust gas recirculation unit mounting bolts (10) , - the exhaust gas recirculation unit.

REFITTING
Replace the exhaust gas recirculation tube complete with 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 mounting bolt ( 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 exhaust gas recirculation solenoid valve ( 12 Nm ) . Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the engine cover mounting bolts ( 4 Nm ) .

14A-24

ANTIPOLLUTION Exhaust gas recirculation unit


K9K, and 728 or 729 or 732 Special tooling required Mot. 1567 Remote operation pliers for EGR clips

14A

2
Tightening torquesm exhaust gas recirculation unit mounting bolts metal inlet air tube mounting bolts lifting eye (timing end) exhaust gas recirculation solenoid valve heat shield mounting bolts front engine cover mounting bolts 21 Nm 21 Nm

21 Nm 12 Nm

4 Nm
110323

Undo bolt (1) . Note: For vehicles tted with the K9K 732 engine (see Workshop Repair Manual 370 Mechanics, Scnic II ). Remove the air duct (2) .

REMOVAL
Disconnect the battery, starting with the negative terminal.

102126

Disconnect the wiring harness (3) . Move the wiring harness to one side.

110325

Pull the clip.

14A-25

ANTIPOLLUTION Exhaust gas recirculation unit


K9K, and 728 or 729 or 732

14A

REFITTING
6 7 4
Replace the exhaust gas recirculation tube complete with 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 mounting bolts ( 21 Nm ) , - the metal inlet air tube mounting bolts ( 21 Nm ) , - the lifting eye (timing end) ( 21 Nm ) ,
102119

Disconnect: - the turbocharging pressure regulation valve pipe (4) from the air duct, - the air inlet pipe (5) on the exhaust gas recirculation unit. Remove: - the bracket (6) , - the engine lifting eye (7) , - the air inlet metal tube (8) .

- the exhaust gas recirculation solenoid valve heat shield mounting bolts ( 12 Nm ) . Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the front engine cover mounting bolts ( 4 Nm ) .

11 9

10

102074

Remove: - the exhaust gas recirculation solenoid valve heat shield (9) , - the exhaust gas recirculation pipe (10) , - the two exhaust gas recirculation unit mounting bolts (11) , - the exhaust gas recirculation unit.

14A-26

ANTIPOLLUTION Exhaust gas recirculation unit


F9Q, and 804

14A

Tightening torquesm exhaust gas recirculation unit mounting bolts exhaust gas recirculation pipe mounting bolts battery cover mounting bolts 25 Nm 18 Nm 4 Nm

REMOVAL
Disconnect the battery, starting with the negative terminal. Remove the battery. Remove the air duct (see 12A, Fuel mixture, Inlet duct: Removal - Refitting ).
111964

111861

Remove the mounting bolts (1) from the exhaust gas recirculation pipe.

113177

Remove the mounting bolts (2) from the exhaust gas recirculation unit.

WARNING Never remove the exhaust gas recirculation solenoid valve from the unit.

REFITTING
Proceed in the reverse order to removal.

14A-27

ANTIPOLLUTION Exhaust gas recirculation unit


F9Q, and 804 Tighten to torque: - the exhaust gas recirculation unit mounting bolts ( 25 Nm ) , - the exhaust gas recirculation pipe mounting bolts ( 18 Nm ) . Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Reconnect the connectors. Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

14A

14A-28

ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
K9K, and 722 or 728 or 729 or 732 Special tooling required Mot. 1729 Pin spanner for removing the EGR valve

14A

Tightening torquesm exhaust gas recirculation solenoid valve mounting bolts 9 Nm

Note: For vehicles tted with the K9K 732 engine (see Workshop Repair Manual 370 Mechanics, Scnic II ). The exhaust gas recirculation solenoid valve is fitted into the exhaust gas recirculation unit.

REMOVAL
Remove: - the heat shield, - the exhaust gas recirculation solenoid valve mounting bolts, - the exhaust gas rebreathing solenoid valve by unscrewing it gradually, - the exhaust gas recirculation solenoid valve by gradually turning it using tool (Mot. 1729) .

REFITTING
WARNING Always replace the exhaust gas recirculation solenoid valve seal with a new one Proceed in the reverse order to removal. Tighten to torque the exhaust gas recirculation solenoid valve mounting bolts ( 9 Nm ) .

14A-29

ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
F9Q, and 800 or 808 Special tooling required Mot. 1729 Pin spanner for removing the EGR valve

14A

Tightening torquesm mounting bolts on the exhaust gas recirculation solenoid valve 9 Nm

The exhaust gas recirculation solenoid valve is fitted into the exhaust gas recirculation unit.

REMOVAL
Remove: - the inlet and exhaust manifolds (see 12A, Fuel mixture, Manifold ), - the bolts securing the exhaust gas recirculation solenoid valve, - the exhaust gas recirculation solenoid valve by gradually turning it using tool (Mot. 1729) .

REFITTING
WARNING Always replace the exhaust gas recirculation solenoid valve gasket with a new one Proceed in the reverse order to removal. Tighten to torque the mounting bolts on the exhaust gas recirculation solenoid valve ( 9 Nm ) .

14A-30

ANTIPOLLUTION Intercooler: Removal - Refitting


K9K, and 732 Special tooling required Ms. 583 Mot. 1567 Hose clamps Remote operation pliers for EGR clips Equipment required diagnostic tool

14A

Tightening torquesm bolts mounting the exhaust gas cooler on its two supports bolt mounting the exhaust gas cooler supports on the cylinder head mounting bolts of the rigid exhaust gas recirculation pipe coolant circulation cover mounting bolts bolts mounting the lifting bracket on the timing end 12 Nm
112816

Remove the oil vapour rebreather pipe (1) . 25 Nm Disconnect the connector (2) from the oil vapour recirculation solenoid valve.

35 Nm

10 Nm 10 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove: - the engine covers, - the engine undertray. Disconnect the battery (see 80A, Battery: Removal - Refitting ). Pull out the clip.
112811

14A-31

ANTIPOLLUTION Intercooler: Removal - Refitting


K9K, and 732

14A

112991

113475

Remove the mounting bolt (3) from the stainless steel pipe. Move the air inlet duct (4) to one side.

Remove the mounting bolts (7) from the injection rail protector cover mounting bracket.

112815

Disconnect the connector (5) from the air inlet pressure sensor. Loosen the clip (6) and move the air inlet duct aside. Remove the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting ).

14A-32

ANTIPOLLUTION Intercooler: Removal - Refitting


K9K, and 732 - the air inlet metal tube (11) ,

14A

- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the mounting bolts from the exhaust gas inlet pipe (12) , - the mounting bolts from the exhaust gas recirculation unit assembly (13) , - the exhaust gas recirculation unit assembly. II - OPERATION FOR REMOVAL OF PART CONCERNED

114341

Position the (Ms. 583) on the exhaust gas cooler inlet and outlet hoses. Remove the mounting bolts (8) from the exhaust gas coolant recirculation cover. Move the exhaust gas coolant recirculation cover to one side. Remove the seals from the cover. At the workbench, remove: - the bolt mounting the exhaust gas cooler on its two supports, Note: Make preparations for coolant outow. - the exhaust gas cooler, - the exhaust gas inlet pipe snap-fit clamp, - the exhaust gas inlet pipe.
112326

112329

Remove: - the lifting bracket mounting bolts (9) from the timing end, - the lifting bracket on the timing end (10) ,

14A-33

ANTIPOLLUTION Intercooler: Removal - Refitting


K9K, and 732

14A

REFITTING
I - REFITTING PREPARATION OPERATION All the bearing faces on each removed part must be carefully cleaned. WARNING T ake care not to damage the bearing faces to prevent 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, its seal and its snap-t clamp, - the cooler seals and its supports, - the seals of the coolant circulation cover within the exhaust gas cooler, - the seal between the downstream duct of the cut-off valve and the exhaust gas cooler support, - the seal between the catalytic converter and the turbocharger. II - REFITTING OPERATION FOR PART CONCERNED Refit the exhaust gas cooler on its two supports fitted with new seals. WARNING Ensure that the seals between the cooler and its two supports are correctly positioned to avoid any coolant leaks. Refit: - the mounting bolts to the cooler, without making contact so that the cooler can move, - the exhaust gas recirculation unit assembly, with its cooler, onto the cylinder head. - the mounting bolts for the two exhaust gas cooler supports. Tighten the bolts mounting the two exhaust gas cooler supports on the cylinder head until they make contact. Adjust the exhaust gas cooler on its two supports so that it is immobilised. Tighten the mounting bolts of the exhaust gas cooler on its two supports until they make contact, in order to immobilise it. Remove the exhaust gas recirculation unit assembly with its cooler. At the workbench, tighten to torque the bolts mounting the exhaust gas cooler on its two supports ( 12 Nm ) .
112326

WARNING Ensure that the seals between the cooler and its two supports are correctly positioned to avoid any coolant leaks. Refit the exhaust gas recirculation unit assembly on the cylinder head with its cooler. Refit the bolts mounting the exhaust gas cooler supports on the cylinder head. Tighten to torque the bolt mounting the exhaust gas cooler supports on the cylinder head ( 25 Nm ) .

14A-34

ANTIPOLLUTION Intercooler: Removal - Refitting


K9K, and 732 Refit: - the new rigid exhaust gas recirculation pipe with a new seal, - the new exhaust gas recirculation pipe mounting bolts, Fit the new snap-fit clamp. Tighten:

14A

- the bolts mounting the rail protector mounting bracket on the exhaust gas cooler assembly, - the nut mounting the rail protector on the mounting bracket. Refit the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting ). Connect the air inlet pressure sensor connector.

WARNING Ensure that you do not squeeze the exhaust gas inlet pipe before tting the snap-t clamp. Tighten the rigid exhaust gas recirculation pipe mounting bolts until they make contact. Adjust the rigid exhaust gas recirculation pipe in relation to the cooler support on the timing end. Lock the snap-fit clamp of the rigid exhaust gas recirculation pipe using the (Mot. 1567) . Tighten to torque the mounting bolts of the rigid exhaust gas recirculation pipe ( 35 Nm ) ). III - FINAL OPERATIONS Refit: - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ). - the coolant circulation cover - the coolant circulation cover mounting bolts

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 valve connector. Refit the oil vapour rebreathing pipe. Connect the battery (see 80A, Battery: Removal Refitting). Bleed the coolant (see 19A, Cooling, Cooling circuit: Bleeding ). Refit: - the engine undertray, - the engine covers. Clear any faults stored by the computer using the diagnostic tool .

WARNING Ensure that the water inlet and outlet hoses of the exhaust gas cooler are correctly aligned so that they do not bend. Tighten to torque the coolant circulation cover mounting bolts ( 10 Nm ) Refit: - the lifting bracket on the timing end, - the bolts mounting the lifting bracket on the timing end. Tighten to torque the bolts mounting the lifting bracket on the timing end ( 10 Nm ) Loosen the nut mounting the rail protector on the mounting bracket. Refit the bolts mounting the rail protector mounting bracket on the exhaust gas cooler assembly.

14A-35

ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting
K9K, and 732 For removing and refitting the supports for the exhaust gas recirculation (see 14A, Emission control, Exhaust gas cooler: Removal - Refitting ).

14A

14A-36

ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting
K9K, and 732 Special tooling required Mot. 1567 Remote operation pliers for EGR clips

14A

REFITTING
I - REFITTING PREPARATION OPERATION All the bearing faces must be carefully cleaned. WARNING 35 Nm Always replace: - the exhaust gas inlet pipe, its seal on the cylinder head and its snap-t clamp, - the seals between the catalytic converter and the turbocharger.

Tightening torquesm mounting bolts of the rigid exhaust gas recirculation pipe on the manifold

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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, Catalytic converter: Removal - refitting ). II - OPERATION FOR REMOVAL OF PART CONCERNED

II - REFITTING OPERATION FOR PART CONCERNED Refit: - the rigid exhaust gas recirculation pipe with a new seal, - the new exhaust gas recirculation pipe mounting bolts, Fit a new snap-fit clamp. WARNING Ensure that you do not squeeze the exhaust gas inlet pipe before tting the snap-t clamp. Tighten the mounting bolts of the rigid exhaust gas recirculation pipe on the manifold until they make contact. Adjust the exhaust gas inlet pipe in relation to the cooler support on the timing end. Lock the snap-fit clamp of the rigid exhaust gas recirculation pipe using the (Mot. 1567) . Tighten to torque the mounting bolts of the rigid exhaust gas recirculation pipe on the manifold ( 35 Nm ) . III - FINAL OPERATION Refit:

113842

Remove: - the mounting bolts (1) from the exhaust gas recirculation pipe, - the snap-fit clamp (2) using the (Mot. 1567) , - the rigid exhaust gas recirculation pipe (3) .

- the catalytic converter (see 19B, Exhaust, Catalytic converter ), - the engine undertray. Connect the battery (see 80A, Battery: Removal Refitting ). Refit the engine covers.

14A-37

STARTING - LOAD Alternator: General information


F4R or F9Q or K4J or K4M or K9K or M9R I - 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 follows: - when the ignition is switched on, the warning light comes on, - when the engine starts, the warning light goes out, - if the warning light comes on while the engine is running, this indicates a charge fault. F9Q II - IDENTIFICATION VALEO : SG15 B098 Engine Alternator VALEO : TG11 C011 K4J and K4M 110 A VALEO : TG11 C027 BOSCH : LIE8 0 124 525 028 VALEO : TG11 C040 110 A VALEO : TG11 C049 F4R VALEO : SG12 B092 125 A VALEO : SG12 B098 Note: VALEO : TG11 C041 110 A VALEO : TG11 C034 BOSCH : LIE8 0 124 525 082 150 A K9K BOSCH : LIE8 0 124 525 081 MELCO : 8GM A004 TJ0 581 210 A MELCO : 8GM A004 TJ0 481 150 A M9R Current strength Engine Alternator VALEO : TG11 C018 VALEO : TG11 C040 VALEO : TG11 C049 VALEO : SG12 B078 VALEO : SG12 B081

16A
Current strength

110 A

125 A VALEO : SG15 B092

BOSCH : LIE8 0 124 525 101 BOSCH : 0 124 525 044 VALEO : SG15 L027 BOSCH : LIE6 0 124 0AC 473B VALEO : TG15 C059 MELCO : 8GM A004 TJ0 281

150 A

155A 120A 150 A 210 A

There is a conguration in the Protection and Switching Unit for the alternator tted to the vehicle (see 87G, Engine compartment connection unit, Protection and Switching Unit ).

16A-1

STARTING - LOAD Alternator: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

16A

Equipment required safety belt

Fit the cooling assembly to the upper cross member using the safety belt .

Tightening torquesm alternator mounting bolts air conditioning compressor mounting bolts free pulley support mounting bolts half sub-frame mounting bolts half sub-frame mounting nuts wheel bolts 21 Nm 21 Nm 21 Nm 105 Nm 21 Nm 110 Nm
101212

REMOVAL
REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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 ).

Remove: - the side stiffener mounting bolts, - the side reinforcements (1) .

102008

Note: When tting the safety strap, take care: - not to crush the cooling hoses, - not to strap up the half sub-frame. Remove: - the half sub-frame mounting nuts and bolts (2) , - the half sub-frame.

16A-2

STARTING - LOAD Alternator: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

16A

CA or CAREG

19703

109537

Note: Take care not to constrain the compressor air conditioning pipes during this operation. Remove the air conditioning compressor mounting bolts (5) . Remove the air conditioning compressor and attach it using a safety belt .

Disconnect: - the pressostat connector (3) , - the air conditioning compressor connector (4) , Move the electric wiring harness to one side.

16A-3

STARTING - LOAD Alternator: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

16A

CHAUFO

OPERATION FOR REMOVAL OF PART CONCERNED

19703 111079

Remove: - the free pulley support mounting bolts (6) , - the idler pulley support. WARNING Do not damage the cooling unit vanes (radiator, condenser, etc.) during handling.

Note: To ease alternator removal, slightly move the cooling system towards the front. Remove: - the alternator mounting bolts (7) , - the alternator.

16A-4

STARTING - LOAD Alternator: Removal - Refitting


K9K, and 722 or 724 or 728 or 729 or 732

16A

REFITTING
CHAUFO I - REFITTING PREPARATION OPERATION Refit: - the free pulley support, - the free pulley support mounting bolts. Tighten to torque the free pulley support mounting bolts ( 21 Nm ) .

Refit the accessories belt (see 11A, Top and front of engine, Accessories belt ). Apply a drop of LOCTITE - FRENEBLOC on the sub-frame mounting bolts. Refit: - the half sub-frame, - the side reinforcements. Tighten to torque: - the half sub-frame mounting bolts ( 105 Nm ) ,
18987

- 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.

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 ( 21 Nm ) . III - FINAL OPERATION CA or CAREG Refit: - The air conditioning compressor, - the air conditioning compressor mounting bolts. Tighten to torque the air conditioning compressor mounting bolts ( 21 Nm ) Connect: - the pressostat connector, - the air conditioning compressor connector.

16A-5

STARTING - LOAD Alternator: Removal - Refitting


F4R, and 770 or 771 or 776

16A

Tightening torquesm alternator mounting bolts battery cover mounting bolts wheel bolts 25 Nm 4 Nm 110 Nm

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.

101212

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 pipes.

16A-6

STARTING - LOAD Alternator: Removal - Refitting


F4R, and 770 or 771 or 776

16A

F4R, and 776

3 2

102504

104342

Remove: - intercooler air duct (7) ,

6
102365

- the accessories belt tension wheel.

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 of engine, Accessories belt ). Disconnect the alternator electrical connections.

16A-7

STARTING - LOAD Alternator: Removal - Refitting


F4R, and 770 or 771 or 776

16A

REFITTING

19703

Remove: - the alternator mounting bolts (8) , - the alternator using a screwdriver. WARNING WARNING Do not force it against the air conditioning hose: there is a risk of refrigerant uid escaping.

18987

Refit the rings (9) using pliers or a vice to facilitate fitting.

When replacing the belt, be sure to replace the tension wheels and idler pulleys. Torque tighten the alternator mounting bolts ( 25 Nm ) .

Note: T facilitate removal of the alternator, shift the o cooling assembly gently forward (be careful not to deform the condenser pipes).

Replace the accessories belt. Tension the accessories belt (see 11A, Top and front of engine, Accessories belt ). Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque: - the battery cover mounting bolts ( 4 Nm ) , - the wheel bolts ( 110 Nm ) .

16A-8

STARTING - LOAD Alternator: Removal - Refitting


F9Q, and 800 or 804 or 808

16A

Tightening torquesm alternator mounting bolts wheel bolts battery cover mounting bolts 25 Nm 110 Nm 4 Nm

3 2

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.

102504

1
102365

Disconnect the connectors (2) . Unclip the bonnet opening cable (3) . Remove: - the clip (4) ,
101212

- the mounting (5) , - the front end panel mounting bolts (6) , - the front end panel, - the accessories belt (see 11A, Top and front of engine, Accessories belt ). Disconnect the alternator electrical connections. Remove the accessories belt tensioning roller.

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, Exterior protection, Front bumper ). Disconnect the screen washer pipes.

16A-9

STARTING - LOAD Alternator: Removal - Refitting


F9Q, and 800 or 804 or 808

16A

REFITTING

19703

Remove: - the alternator mountings (7) , - the alternator using a screwdriver. To facilitate removal of the alternator, shift the cooling assembly forward gently (be careful not to damage the condenser pipes). Refit the alternator.

18987

Refit the rings (8) using a vice to facilitate fitting.

Torque tighten the alternator mounting bolts ( 25 Nm ) . Refit the accessories belt (see 11A, Top and front of 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

16A-10

STARTING - LOAD Alternator: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

16A

Tightening torquesm alternator mounting bolts alternator strut mounting bolts nut securing the strut to the stud on the engine side battery cover mounting bolts wheel bolts 21 Nm 21 Nm 21 Nm

4 Nm 110 Nm

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. 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 pipes.
101212

16A-11

STARTING - LOAD Alternator: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

16A

3 2 5

102504

19703

Remove:

- the alternator mounting bolts (7) , - the alternator using a screwdriver. WARNING Do not force it against the air conditioning hose: there is a risk of refrigerant uid escaping.

102365

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 of engine, Accessories belt ). Disconnect the alternator electrical connections. Remove the alternator retaining strut. Note: To facilitate removal of the alternator, shift the cooling assembly gently forward (be careful not to deform the condenser pipes).

16A-12

STARTING - LOAD Alternator: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

16A

REFITTING

18987

Refit the rings (9) using pliers or a vice to facilitate fitting.

WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. 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 engine side ( 21 Nm ) , Replace the accessories belt. Tension the accessories belt (see 11A, Top and front of engine, Accessories belt ). Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal.

WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque: - the battery cover mounting bolts ( 4 Nm ) , - the wheel bolts ( 110 Nm ) .

16A-13

STARTING - LOAD Alternator: Removal - Refitting


B84 or C84, and F4R, and 774

16A

Tightening torquesm alternator mounting bolts wheel mounting bolts battery cover mounting bolts 25 Nm 130 Nm 4 Nm

- the front bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper: Removal Refitting ).

REMOVAL

Note: The tensioning roller and the inertia reel must be replaced when the accessories belt is replaced. Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).
102504

102365

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 of engine, Accessories belt: Removal - Refitting ).
106077

Disconnect the alternator electrical connections. Remove the accessories belt tensioning roller.

Remove: - the engine covers, - the front right-hand wheel, - the right-hand wheel arch liner, - the side stiffener (1) , - the fog lights connector,

16A-14

STARTING - LOAD Alternator: Removal - Refitting


B84 or C84, and F4R, and 774

16A

19703

18987

Remove: - the alternator mountings (7) , - the alternator using a screwdriver. To ease alternator removal, slightly move the cooling system toward the front (be careful not to bend the condenser pipes).

Refit the rings (8) using pliers or a vice to facilitate fitting. 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 front of engine, Accessories belt: Removal - Refitting ). Tighten to torque the wheel mounting bolts ( 130 Nm ) . Proceed in the reverse order to removal. Connect the battery (see 80A, Battery, Battery: Removal - Refitting . Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

REFITTING
WARNING The belt must be replaced with a new one if it has been removed.

16A-15

STARTING - LOAD Alternator: Removal - Refitting


M9R, and 700

16A

Tightening torquesm alternator mounting bolts positive terminal mounting nut air inlet hose clip on the damper valve air inlet hose clip on the intercooler turbocharger pressure sensor mounting nut front end panel upper mounting bolts front end panel lower mounting bolts 25 Nm 8 Nm 5.5 Nm 5.5 Nm

8 Nm 21 Nm 44 Nm Remove: - the right-hand sub-frame side stiffener (1) , - the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ).

101212

REMOVAL
I - REMOVAL PREPARATION STAGE Position the vehicle on a two-post lift (see 02A, Lifting 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.

114855

Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

16A-16

STARTING - LOAD Alternator: Removal - Refitting


M9R, and 700

16A

102504

Disconnect the connectors (4) from the Protection and Switching Unit. Unfasten the bonnet opening cable (5) .
114933

Remove: - the clip (6) , - the front end panel upper mounting bolt (7) . Disconnect the screen washer tubes.

Unclip the air inlet scoop (2) .

102365

Remove:
112658

- the front end panel lower mounting bolts (8) , - the front end panel. Remove the cooling radiator - condenser intercooler assembly from its housing and push it forwards.

Remove the Protection and Switching Unit cover mounting bolts (3) .

16A-17

STARTING - LOAD Alternator: Removal - Refitting


M9R, and 700

16A

II - OPERATION FOR REMOVAL OF PART CONCERNED

114409

Disconnect the turbocharging pressure sensor connector (9) . Remove the turbocharger pressure sensor mounting nut on the air inlet valve stay. Undo the air inlet hose clip on the damper valve.

114860

Disconnect the alternator's electrical connector (12) . Remove the positive terminal mounting nut (13) .

114859 114649

Remove the alternator mounting bolts (14) . Remove the alternator.

Remove: - the air inlet duct clip (10) from the intercooler, - the air inlet clip mounting bolt (11) from the condenser, - the air inlet duct.

16A-18

STARTING - LOAD Alternator: Removal - Refitting


M9R, and 700

16A

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED

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 ( 5.5 Nm ) , - the air inlet hose clip on the intercooler ( 5.5 Nm ). Tighten the air inlet clip mounting bolt on the condenser. Refit the turbocharger pressure sensor on the damper valve stay. Tighten to torque the turbocharger pressure sensor mounting nut ( 8 Nm ) . Connect the turbocharging pressure sensor connector. Connect the screen washer pipes. Refit:
18987

Refit the rings (15) using pliers or a vice to facilitate fitting. 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.

- the front end panel, - front end panel mounting bolts, Tighten to torque: - the front end panel upper mounting bolts ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) . Clip: - the bonnet opening cable, - the air inlet scoop. Refit clips. Refit: - the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ), - the accessories belt (see 11A, Top and front of engine, 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 ).

16A-19

STARTING - LOAD Alternator pulley: Removal - Refitting


K4J or K4M or K9K, and CA Special tooling required Mot. 1732 Tool for removing and retting the alternator pulley

16A

Tightening torquesm alternator decoupling pulley 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) Hold the alternator in a vice. II - OPERATION FOR REMOVAL OF PART CONCERNED
110266

80 Nm

110276

It is essential to replace an alternator decoupling pulley with a decoupling pulley.

110267

REMOVAL
I - REMOVAL PREPARATION OPERATION Remove the alternator (see 16A, Starting - Charging, Alternator: Removal - Refitting ).

Fit the hexagon socket (1) from the tool box for removing and refitting the alternator pulley (Mot. 1732) into the alternator pulley.

16A-20

STARTING - LOAD Alternator pulley: Removal - Refitting


K4J or K4M or K9K, and CA

16A

110268

110270

Fit the drive (2) from the tool box for removing and refitting the alternator pulley (Mot. 1732) (corresponding to the alternator mark) into the hexagon socket (3) .

Hold the hexagon socket (6) using an open-jawed spanner (7) . Loosen the decoupling pulley (8) using a ratchet (9) (turning the ratchet clockwise). Remove the decoupling pulley.

110269

Position the drive adapter (4) in socket (5) .

16A-21

STARTING - LOAD Alternator pulley: Removal - Refitting


K4J or K4M or K9K, and CA

16A

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED

110269

Fit:
110266

- the hexagon socket (10) in the alternator, - the drive (11) (corresponding to the socket in the alternator rotor), - the drive adapter (12) onto the drive (11) . Note: Check that the torque wrench is capable of tightening in an anticlockwise direction.

Screw the new decoupling pulley onto the alternator rotor.

16A-22

STARTING - LOAD Alternator pulley: Removal - Refitting


K4J or K4M or K9K, and CA

16A

110266

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 ).

16A-23

STARTING - LOAD Starter: Identification

16A

Engine K4J and K4M K9K F9Q and F4R

Starter motor V ALEO : D7E27 MITSUBISHI V ALEO : D7R49

16A-24

STARTING - LOAD Starter: Removal - Refitting


F4R, and 770 or 771

16A

REFITTING
Tightening torquesm starter mounting bolts battery cover mounting bolts 38 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal.

101482

Check that the centring dowel (1) is in place. Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque:
14853

- the starter mounting bolts ( 38 Nm ) , - the battery cover mounting bolts ( 4 Nm ) .

Remove the engine covers. Disconnect: - the oil level sensor connector, - the starter connections, Remove: - the starter motor mounting bolts, - the starter motor.

16A-25

STARTING - LOAD Starter: Removal - Refitting


F9Q, and 800 or 808

16A

Tightening torquesm wheel bolts engine cover mounting bolts 110 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the front right wheel, - the battery, - the battery tray, - the air hose between the air filter and turbocharger duct, Remove: - the bracket (3) , - the catalytic converter (4) mounting plate on the gearbox, - the catalytic converter (5) (see 19B, Exhaust, Catalytic converter ). Disconnect the starter motor electrical connections.
101120

6
102421

Remove: - the air hose (1) and gently separate the hose (2) , - the engine tie-bar.

102427

Remove: - the starter motor mounting bolts (6) , - the starter motor.

16A-26

STARTING - LOAD Starter: Removal - Refitting


F9Q, and 800 or 808

16A

REFITTING
Check that the centring dowel is in place. Proceed in the reverse order to removal. Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque: - the wheel bolts ( 110 Nm ) , - the engine cover mounting bolts ( 4 Nm ) .

16A-27

STARTING - LOAD Starter: Removal - Refitting


K9K, and 722

16A

Tightening torquesm starter mounting bolts wheel bolts battery cover mounting bolts 44 Nm 110 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the front right-hand wheel.

102268

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 ( 44 Nm ) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque: - the wheel bolts ( 110 Nm ) , - the battery cover mounting bolts ( 4 Nm ) .

1
104175

Remove: - the catalytic converter stay (1) , - catalytic converter stay (2) on the gearbox, - the catalytic converter (3) (see 19B, Exhaust, Catalytic converter ). Disconnect the starter motor electrical connections.

16A-28

STARTING - LOAD Starter: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

16A

REFITTING
Tightening torquesm starter mounting bolts battery cover mounting bolts 38 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift.

1
Disconnect the battery, starting with the negative terminal.

101482

Check that the centring dowel (1) is in place. Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removing - retting ). Tighten to torque: - the starter mounting bolts ( 38 Nm ) ,
14853

- the battery cover mounting bolts ( 4 Nm ) .

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.

16A-29

STARTING - LOAD Starter: Removal - Refitting


F4R, and 776

16A

Tightening torquesm starter mounting bolts the catalytic converter downstream strut nut heat shield mounting bolts battery cover mounting bolts 38 Nm 21 Nm 8.5 Nm 4 Nm

REMOVAL
The engine needs to be removed if the starter motor is being replaced (see 10A, Engine and peripherals, Engine - gearbox ). Remove the catalytic converter (see 19B, Exhaust, Catalytic converter ). Remove: - the starter mountings (3) , - the starter motor.
21921

1
106249

Remove: - the heat shield mountings (1) , - the heat shield, - the catalytic converter downstream strut (2) . Disconnect the starter supply.

16A-30

STARTING - LOAD Starter: Removal - Refitting


F4R, and 776

16A

REFITTING

21935

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 strut nut ( 21 Nm ) , - the heat shield mounting bolts ( 8.5 Nm ) . Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

16A-31

STARTING - LOAD Starter: Removal - Refitting


K9K, and 728 or 729

16A

Tightening torquesm starter mounting bolts battery cover mounting bolts 44 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the engine covers. Disconnect the gearbox earth.
106203

106201

Disconnect the oil level sensor.

106205

Disconnect: - the starter electrical connections (1) - the rail pressure sensor (2) .

16A-32

STARTING - LOAD Starter: Removal - Refitting


K9K, and 728 or 729

16A

106191

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 ( 44 Nm ) . Connect the battery, starting with the positive terminal. WARNING carry out the necessary programming (see 80A, Battery: Removal - retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

16A-33

STARTING - LOAD Starter: Removal - Refitting


F9Q, and 804

16A

Tightening torquesm starter motor mounting bolts turbocharger oil return pipe mounting bolts battery cover mounting bolts wheel bolts 44 Nm 12 Nm 4 Nm 110 Nm

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the front right-hand wheel, - the battery, - the battery tray, - the air hose between the air filter and turbocharger duct, Remove the catalytic pre-converter. (see 19B; Exhaust, Catalytic pre-converter: Removal - Refitting ). Remove the turbocharger oil return pipe (2) .
111865

111868

Disconnect the wiring harness from the starter motor.


111860

Remove the starter motor mounting bolts (3) . Remove the starter motor.

Remove the air duct (1) from the turbocharger.

REFITTING
Check that the centring dowel is in place. Tighten to torque the starter motor mounting bolts ( 44 Nm ) .

16A-34

STARTING - LOAD Starter: Removal - Refitting


F9Q, and 804 Proceed in the reverse order to removal. Replace the turbocharger oil return pipe seals. Tighten to torque the turbocharger oil return pipe mounting bolts ( 12 Nm ) . Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ). Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque: - the battery cover mounting bolts ( 4 Nm ) , - the wheel bolts ( 110 Nm ) .

16A

16A-35

STARTING - LOAD Starter: Removal - Refitting


M9R, and 700

16A

Equipment required lling station

Tightening torquesm starter motor mounting bolts starter base mounting nut solenoid excitation mounting nut intercooler downstream duct clip on the intercooler intercooler downstream duct clip on the damper valve front end panel upper mounting bolts front end panel lower mounting bolts battery tray mounting bolts wiring harness mounting nut on the battery tray 44 Nm 8 Nm 5 Nm 5.5 Nm

5.5 Nm Remove: 21 Nm 44 Nm 21 Nm 8 Nm

112658

- the Protection and Switching Unit cover mounting bolts (1) , - the Protection and Switching Unit cover.

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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 ).

102504

Disconnect the connectors (2) from the Protection and 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.

16A-36

STARTING - LOAD Starter: Removal - Refitting


M9R, and 700

16A

102365

Remove: - the front end panel lower mounting bolts (11) . - the front end panel.
112659

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 - terminal. Remove the battery tray.

114649

Remove the intercooler downstream duct mounting bolt (12) on the cooling radiator. Loosen: - the intercooler downstream duct clip (13) on the intercooler, - the intercooler downstream duct clip on the damper valve. Remove the intercooler downstream duct from the intercooler.
114933

Unclip the air inlet scoop (10) .

Remove the cooling assembly from its housing and push the assembly forwards.

16A-37

STARTING - LOAD Starter: Removal - Refitting


M9R, and 700

16A

II - OPERATION FOR REMOVAL OF PART CONCERNED

109537

Remove the air dehydration canister conditioning pipe mounting bolt (14) from the air conditioning compressor. Note: Plugs must be tted to the pipe and the compressor to prevent moisture from entering the system. Remove the air dehydration canister conditioning pipe from the air conditioning compressor.

114628

Remove: - the mounting nut (15) from the starter base, - the mounting nut (16) from the solenoid excitation.

114998

Remove the earth wire mounting bolt (17) on the starter. Move the starter motor wiring harness to one side.

16A-38

STARTING - LOAD Starter: Removal - Refitting


M9R, and 700

16A

113312

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 ) .

16A-39

STARTING - LOAD Starter: Removal - Refitting


M9R, and 700 II - FINAL OPERATION Refit: - the air dehydration canister conditioning pipe onto the air conditioning compressor, - the air dehydration canister conditioning pipe mounting bolt onto the air conditioning compressor (see 62A, Air conditioning, Compressor: Removal - Refitting ). Fit the cooling assembly. Refit: - the intercooler downstream duct onto the intercooler and damper valve, - the intercooler downstream duct mounting bolt onto the cooling radiator. Tighten to torque: - the intercooler downstream duct clip on the intercooler ( 5.5 Nm ) , - the intercooler downstream duct clip on the damper 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 ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) , 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 battery tray. Tighten to torque: - the battery tray mounting bolts ( 21 Nm ) , - the wiring harness mounting nut on the battery tray ( 8 Nm ) Clip the battery - terminal wiring harness. Connect: - the screen washer pipes, - the Protection and Switching Unit connectors,

16A

- the injection computer connectors. Refit: - the clips, - the Protection and Switching Unit cover mounting bolts, - 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 (see 62A, Air conditioning, Maintenance ).

16A-40

STARTING - LOAD Starter: Removal - Refitting


K9K, and 732

16A

Tightening torquesm starter motor mounting bolts 44 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment; underbody lift ). Remove the engine cover. Disconnect the battery (see 80A, Battery: Removal - Refitting ). Remove the engine undertray.

113863

106201

Disconnect: - the oil pressure sensor connector (1) , - the oil level sensor connector (2) . Unclip the diesel fuel drain pipe.

16A-41

STARTING - LOAD Starter: Removal - Refitting


K9K, and 732

16A

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.
106205

Remove the starter electrical connections (3) . Disconnect the injector rail pressure sensor connector. Move the wiring harness against the cylinder block. II - OPERATION FOR REMOVAL OF PART CONCERNED

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.

106191

Remove: - the starter mounting bolts (4) . - the starter motor.

16A-42

STARTING - LOAD Starter: Removal - Refitting


B84 or C84, and F4R, and 774

16A

Tightening torquesm starter mountings catalytic converter downstream stay nut heat shield mountings 38 Nm 44 Nm 8.5 Nm

REMOVAL
Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Removal of the starter requires the engine to be removed (see 10A, Engine and peripherals, Gearbox - motor assembly: Removal - Refitting ). Remove the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).
21921

Remove: - the starter mountings (3) , - the starter motor.

106249

Remove: - the heat shield mountings (1) , - the heat shield, - the catalytic converter downstream strut (2) . Disconnect the starter supply.

16A-43

STARTING - LOAD Starter: Removal - Refitting


B84 or C84, and F4R, and 774

16A

REFITTING

21935

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: Removal - Refitting ).

16A-44

IGNITION Coils Removal - Refitting


F4R, and 770 or 771 K4J, and 730 or 732 K4M, and 760 or 761

17A

REMOVAL
Tightening torquesm ignition coil mounting screws to torque the battery cover mounting bolts to 1.5 daNm 0.4 daNm

The power module is incorporated in the injection computer. The ignition system uses the same sensors as the injection system.

1 2
101490

Remove the engine covers. Disconnect: - the battery starting with the negative terminal.
14851

There are four ignition coils secured directly onto the spark plugs by bolts on the cylinder head cover. The coils are in series in pairs by the injection computer: - track C M4 for cylinders 1 and 4, - track C M3 for cylinders 2 and 3.

- the connectors (1) from the ignition coils. WARNING Damaged connectors must be replaced. 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 torque ( 1.5 daNm ) . WARNING Connect the battery; carry out the necessary programming ( (see 80A, Battery) ). Tighten the battery cover mounting bolts to ( 0.4 daNm ) .

17A-1

IGNITION Coils Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

17A

REMOVAL
Tightening torquesm ignition coil mounting bolts battery cover mounting bolts 15 Nm 4 Nm

The power module is built into the injection computer. The ignition system uses the same sensors as the injection system.

101490

Remove the engine covers. Disconnect: - the battery, starting with the negative terminal,
14851

There are four ignition coils, and they are mounted directly onto the spark plug by a bolt on the rocker cover. The coils are supplied in series two by two by the injection computer: - track C M4 for cylinders 1 and 4, - track C M3 for cylinders 2 and 3.

- the ignition coil connectors (1) . Remove the coil mounting bolts (2) .

17A-2

IGNITION Coils Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

17A

F4R, and 776

106589

Remove the coil mounting bolts (3) .

WARNING Be sure to replace any damaged connectors.

REFITTING
Proceed in the reverse order to removal.

17A-3

IGNITION Coils Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

17A

106443

Apply to the four ignition coils a bead (4) of FLUORINE GREASE (PART NO. 82 00 168 855) , 2 mm in diameter around the inner edge of the high tension cap. If necessary, replace the coil O-rings. Tighten to torque: - the ignition coil mounting bolts ( 15 Nm ) , - the battery cover mounting bolts ( 4 Nm ) .

17A-4

IGNITION Spark plugs


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776

17A

Special tooling required Ele. 1382 Spark plug kit

Tightening torque Spark plugs 25 to 30 Nm Remove: - the ignition coils (see 17A, Ignition, Coils ), - the spark plugs.

Engines K4J and K4M

Brand EYQUEM CHAMPION Flat skirt with seal

Type RFN58LZ RC87YCL

Gap: 0.95 ( 0.05 mm ) F4R 770 / 771 CHAMPION Flat skirt with seal Gap 0.90 ( 0.05 mm ) F4R 776 NGK Flat skirt with seal Gap 0.85 ( 0.05 mm ) PFR6G-9 RC87YCL

17A-5

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B

K4J, and 730 or 732

10

9 8

101099

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Fuel vapour recirculation solenoid valve Manifold pressure sensor Motorised throttle valve Ignition coil Injection computer Protection and Switching Unit Coolant temperature sensor Pinking sensor Air temperature sensor Injector rail and injectors

17B-1

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B

K4M, and 760 or 761

11 12

13

14

15 16

17

18

22

21

20

19

101804

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Fuel vapour recirculation solenoid valve Camshaft dephaser solenoid valve Manifold pressure sensor Ignition coil Camshaft position sensor Motorised throttle valve Injection computer Protection and Switching Unit Coolant temperature sensor Pinking sensor Air temperature sensor Injector rail and injectors

K4J, and 730 or 732

23

102107

(23)

Injection computer

17B-2

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B
27

25 29 25

30 24 28

101493

101101

(24) (25)

Injector rail Injectors

(27) (28)

Fuel vapour recirculation solenoid valve Air temperature sensor Manifold pressure sensor Ignition coils

26

(29) (30)

101800

(26)

Motorised throttle valve

31 32
101498

(31) (32)

Coolant temperature sensor Pinking sensor

17B-3

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B
40

K4M, and 760 or 761

41

34 34 33 39

42

101809

(39)
101810

Pinking sensor Camshaft dephaser solenoid valve Camshaft position sensor Coolant temperature sensor

(40) (41) (42)

(33) (34)

Injector rail Injectors

35

36

43 38 38 37
101796

(35) (36) (37) (38)

Fuel vapour recirculation solenoid valve Manifold pressure sensor Air temperature sensor Ignition coils (43) Injection computer

101811

17B-4

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B

K4M, and 760 or 761

44 46

102144

(46)
102735

Engine speed and position sensor

(44)

Motorised throttle valve

47 45

102204

(47)
101105

Accelerator pedal potentiometer

(45)

Protection and Switching Unit

17B-5

PETROL INJECTION Location of components


K4J, and 730 or 732 K4M, and 760 or 761

17B

48

51

101798

102483

(48)

Upstream oxygen sensor

(51)

Fuel vapour recirculation absorber

49

50

101501

(49) (50)

Downstream oxygen sensor Catalytic converter

17B-6

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B

F4R, and 770 or 771

11

10

102722

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Fuel vapour recirculation solenoid valve Camshaft dephaser solenoid valve Manifold pressure sensor Ignition coil Motorised throttle valve Injection computer Protection and Switching Unit Coolant temperature sensor Pinking sensor Air temperature sensor Injector rail and injectors

17B-7

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B

F4R, and 776

12

23

13

14

15

22

21

20

19

18

17

16
106078

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

Ignition coil Fuel vapour recirculation solenoid valve Injection computer Protection and Switching Unit Air temperature sensor Turbocharging pressure sensor Coolant temperature sensor Motorised throttle valve Injector rail and injectors Pinking sensor Manifold pressure sensor Electric water pump

24

106280

(24)

Injection computer

17B-8

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B
32

F4R, and 770 or 771

26

27

28 25 31

102732

(31)
101809

Pinking sensor Camshaft dephaser solenoid valve

(32)

(25) (26) (27) (28)

Pinking sensor Camshaft dephaser solenoid valve Camshaft position sensor Coolant temperature sensor

33 34

36 36 30 30 35

102724

29

(33) (34) (35)


102730

Fuel recirculation solenoid valve Manifold pressure sensor Air temperature sensor Ignition coil

(36)

(29) (30)

Injector rail Injectors

17B-9

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B

F4R, and 776

37

39
102735

40

(37)

Throttle valve
101809

(39) (40)

Pinking sensor Coolant temperature sensor

42 38 41

106269 102144

(41) (42)

Injector rail Injectors

(38)

Engine speed and position sensor

17B-10

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B
46

43

45
106787

(45) (46)
106633

Manifold pressure sensor Ignition coils

(43)

Motorised throttle valve

48 47 44

106279

(47) (48)
106278

Turbocharging pressure sensor Air temperature sensor

(44)

Fuel vapour recirculation solenoid valve

17B-11

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B

49

51

101105

102483

(49)

Protection and Switching Unit

(51)

Fuel vapour recirculation absorber

F4R, and 770 or 771

50

52

102204

(50)

Accelerator pedal potentiometer


101798

(52)

Upstream oxygen sensor

17B-12

PETROL INJECTION Location of components


F4R, and 770 or 771 or 776

17B
56

53

54

101501

106253

(53) (54)

Downstream oxygen sensor Catalytic converter

(56)

Downstream oxygen sensor

F4R, and 776

55

106244

(55)

Upstream oxygen sensor

17B-13

PETROL INJECTION Oxygen sensors: Removal - Refitting


F4R, and 770 or 771 K4M, and 760 or 761 K4J, and 730 or 732 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

17B

II - DOWNSTREAM OXYGEN SENSOR

2
Tightening torquesm oxygen sensor 45 Nm

REMOVAL
I - UPSTREAM OXYGEN SENSORS

101501

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 sensor and tool (Mot. 1495-01) for the upstream oxygen sensor.

101798

Remove lambda sensor (1) using the tool (Mot. 1495-01) .

17B-14

PETROL INJECTION Oxygen sensors: Removal - Refitting


F4R, and 776 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

17B

II - DOWNSTREAM OXYGEN SENSOR

Tightening torquesm oxygen sensors 34 Nm

REMOVAL
I - UPSTREAM OXYGEN SENSORS

1
21926

Remove: - the engine undertray, - the oxygen sensor (2) using (Mot. 1495-01) .

REFITTING
Proceed in the reverse order to removal.
106244

Remove the front engine cover. Disconnect the oxygen sensor. Remove the oxygen sensor (1) using the tool (Mot. 1495-01) .

Tighten to torque the oxygen sensors ( 34 Nm ) using tool (Mot. 1495-01) .

17B-15

PETROL INJECTION Accelerator pedal potentiometer: Removal - Refitting


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 - the pedal. Tightening torquesm battery cover mounting bolts 4 Nm

17B

REFITTING
Proceed in the reverse order to removal. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - retting ).

The accelerator pedal potentiometer is incorporated in the accelerator pedal. If it is replaced, the accelerator pedal must also be replaced. There are two types of pedal: with or without a resistance point . Vehicles equipped with cruise control/speed limiter have an accelerator pedal with a point of resistance at the end of their travel (kickdown) This kickdown point is used for exiting the speed limiter function if the driver has to increase his speed.

Note: A fault on the accelerator pedal position potentiometer results in changes in the idle speed or engine operation (see 17B, Petrol injection, Idle speed correction ). Torque tighten the battery cover mounting bolts ( 4 Nm ) .

WARNING A pedal tted with a kickdown point may be tted in place of a pedal without a kickdown point. Fitting a pedal without a resistance point in place of a pedal with a resistance point is not permitted.

REMOVAL

102204

Disconnect: - the battery, starting with the negative terminal, - the accelerator pedal connector. Remove: - pedal mounting bolts ,

17B-16

PETROL INJECTION Position and speed sensor


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732

17B

Equipment required diagnostic tool

F4R, and 776

F4R, and 770 K4M, and 760 K4J, and 730 or 732

1
1

102485

Program with the engine flywheel target after replacing speed and position sensor (1) or the engine flywheel
102144

Program the engine flywheel target, after replacing speed and position sensor (1) or the engine flywheel.

In third gear, accelerate twice in succession to 4000 rpm , then decelerate to power take-up speed. Power take-up speed is the moment when, during deceleration under no load with the injection cut out, the computer authorises injection again. Use the diagnostic tool to check that programming has been carried out correctly ET089: Program engine flywheel target . Read the fault codes. Repair if necessary. Clear the fault codes. Check that the vehicle is working correctly.

17B-17

PETROL INJECTION Position and speed sensor


F4R, and 771 K4M, and 761

17B

Equipment required diagnostic tool

102144

Program the engine flywheel target, after replacing speed and position sensor (1) or the engine flywheel. In third gear, accelerate twice in succession to 4000 rpm , then decelerate to power take-up speed. Power take-up speed is the moment when, during deceleration under no load with the injection cut out, the computer authorises injection again. Note: Do not shift the gear lever to D Use the diagnostic tool to check that programming has been carried out correctly ET089: Program engine flywheel target . Read the fault codes. Repair if necessary. Clear the fault codes. Check that the vehicle is operating correctly.

17B-18

PETROL INJECTION Petrol injection computer: Removal - Refitting


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732

17B

Equipment required diagnostic tool

F4R, and 770 or 771 or 776

Tightening torquesm battery tray mounting bolts battery cover mounting bolts 21 Nm 4 Nm

REMOVAL
Remove the engine covers. Disconnect the battery, starting with the negative terminal.

4
K4M, and 760 or 761 K4J, and 730 or 732
101822

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.

102107

Disconnect the injection computer connectors (1) . Remove: - the bolts securing the computer to the mounting, - the computer.

17B-19

PETROL INJECTION Petrol injection computer: Removal - Refitting


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732

17B

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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

Note: When the ignition is switched on, the motorised throttle valve should go through a cycle of programming for its minimum and maximum positions.
101811

Remove the injection computer (5) and its mounting.

Use the diagnostic tool to check that this programming has been completed correctly ET051: Throttle stop programming . Perform flywheel target programming during a road test. In third gear, accelerate twice in succession to 4000 rpm , then decelerate to power take-up speed. Power take-up speed is the moment when, during deceleration under no load with the injection cut out, the computer authorises injection again. Use the diagnostic tool to check that programming has been carried out correctly ET089: Program engine 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 ) .

101890

Remove the four computer mounting bolts.

17B-20

PETROL INJECTION Special notes


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 SPECIAL NOTES FOR MULTIPOINT INJECTION SAGEM S3000 6 - Idle speed (warm engine) Nominal idle speed 1 - 128-track computer It is marked SAGEM and is a type S3000 FLASH EEPROM controlling the injection and ignition. Engine K4J 730 / 732 K4M 760 2 - Multipoint injection functioning in sequential mode. K4M 761 F4R 770 F4R, and 770 or 771 or 776 K4J, and 730 or 732 Without cylinder n1 marking sensor on the camshaft Therefore, engine phasing is carried out by software using the TDC sensor. Starting the engine in semi-sequential mode (for engine phasing) then entering phased sequential mode. F4R 771 F4R 776 750 +/- 50

17B
Engine speed (rpm) 750 +/- 50 700 +/- 30

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 K4J, and 730 or 732 When the coolant temperature is below 60C or for 10 seconds after starting, the cut-off value is 5800 rpm .

K4M, and 760 or 761 With cylinder n1 marking sensor on the camshaft Therefore, engine phasing (cylinder n1 recognition) is carried out using the cylinder marking sensor signal. Starting the engine in semi-sequential mode (for engine phasing) then entering phased sequential mode.

3 - Injection warning light on the instrument panel Installation of a special injection warning light (OBD indicator light On Board Diagnostic ) warning light. It is part of the on board diagnostic OBD fault finding system.

K4M, and 760 or 761 When the coolant temperature is below 75C or for 10 seconds after starting, the cut-off value is 5800 rpm .

4 - Special notes relating to the engine immobiliser Installation of a third generation engine immobiliser, involving a specific computer replacement procedure. F4R, and 770 or 771 or 776 When the coolant temperature is below 75C or for a maximum of 17 minutes after starting, the cut-off value is 5900 rpm .

5 - Fuel circuit without return to the tank. The pressure regulator is located on the pump/sender unit assembly.

17B-21

PETROL INJECTION Special notes


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 b - Engine overspeed protection, warm engine Once the engine is warm, the cut-off returns to its normal value: K4J, and 730 or 732 K4M, and 760 or 761 The cut-off speed is 6500 rpm whichever gear is engaged (manual or automatic gearbox). 11 - Operation of the fuel pump

17B

The request is made by the injection computer. It receives its power supply from the Protection and Switching Unit. 12 - Cruise control / speed limiter The configuration of the cruise control / speed limiter and the air conditioning is automatic. 13 - Oxygen sensor

F4R, and 770 or 771 or 776 The cut-off speed is 6000 rpm whichever gear is engaged (manual gearbox), and 6300 rpm (automatic gearbox).

Use of two oxygen sensors located upstream and downstream of the catalytic converter. 14 - Throttle valve Correction of the air flow and the idle speed is carried out by the motorised throttle valve. 15 - Protection and switching unit

8 - Camshaft dephaser K4M, and 760 or 761 It is continuously varied from 0 to 43 of the crankshaft. It is controlled by a solenoid valve supplied by an opening cyclic ratio signal operated by the injection computer.

It supplies: - the ignition coils, - the fuel pump, - the air conditioning compressor, - the fan assembly, - various injection actuators (injectors, fuel vapour absorber solenoid valve, etc.). The protection and switching unit is located in the engine compartment near the battery. It contributes to the protection of certain electrical components. In this capacity, it comprises: - fuses, - several internal relays including: the + after ignition feed relay,

F4R, and 770 or 771 or 776 It is controlled by a solenoid valve which is supplied by an 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 through the multiplex network (coolant temperature centralised control function). The engine cooling fan is supplied by the Protection and Switching Unit. 10 - Air conditioning compressor operation The request is made by the injection computer through the multiplex network. The request depends on the air conditioning , but also the coolant temperature. The air conditioning compressor is supplied by the Protection and Switching Unit.

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, the signal indicating the electrical power available from the alternator. This is to prevent the vehicle's electrical consumption from exceeding the capacity of the alternator. The aim is to give priority to charging the battery.

17B-22

PETROL INJECTION Special notes


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 17 - Accelerator pedal Replacement of the accelerator pedal poses no particular problems. The computer adopts the value read when the ignition was switched on as the no load position reference value. A twin-track potentiometer is used to inform the computer of the accelerator pedal position. It has two tracks with different resistance values. The first track supplies a voltage of ( 0 to 5 V ) which is double the second track ( 0 to 2.5 V ). The comparison between the two provides a check on the consistency of the signal supplied. 18 - Idle speed It is increased by a maximum of 160 rpm if the battery voltage 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

17B-23

PETROL INJECTION Injection warning light


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 The S 3000 injection system manages the lighting of three warning lights and the display of warning messages according to the severity of the faults detected, with the aim of informing the customer and directing fault finding. The injection computer controls the lighting of warning lights and message displays on the instrument panel. These warning lights are lit during the starting phase, in the event of an injection fault or engine overheating. The signals to light up the warning lights reach the instrument 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 on for approximately 3 seconds , then goes out. 2 - When there is an injection fault (level 1) The check injection message lights up, followed by the service warning light. This means a reduced level of operation and a limited safety level. Repairs should 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 matrix only) lights up with the engine overheating text message followed by the stop warning light and a buzzer. If this happens, the vehicle will stop immediately.

17B

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 cause destruction of the catalytic converter (destructive misfires). If this happens, the vehicle will stop immediately. - continuously in the event that depollution standards have not been adhered to (polluting engine misfires, catalytic converter fault, oxygen sensor fault, inconsistency between the oxygen sensors and fuel vapour absorber fault).

17B-24

PETROL INJECTION Immobiliser function


F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732 This vehicle is equipped with an immobiliser which requires a specific procedure for replacing the computer. REPLACING AN INJECTION COMPUTER To program the immobiliser code (see 82A, Engine immobiliser, Injection computer: Programming: ). WARNING - The injection computer retains its immobiliser code for life. - The system has no security code. - It is forbidden to perform tests with computers borrowed from the Parts Department or from another vehicle which must then be returned. - These computers are permanently coded.

17B

17B-25

PETROL INJECTION Injection - air conditioning programming


F4R, and 770 or 771 or 776 I - 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 passenger compartment controls and the circuit pressure level. - determining the power absorbed by the air conditioning compressor based on the pressure of the circuit, - authorising the fan assembly control according to vehicle speed and circuit pressure. - authorising or disables the compressor clutch. When climate control is activated, the climate control panel requests authorisation for air conditioning compressor 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 is made by the injection computer via the multiplex network. This request depends on the air conditioning but also on the coolant temperature and vehicle speed. The engine cooling fan and the compressor are supplied 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.

17B

II - COMPRESSOR FUNCTION PROGRAMMING In certain operating phases, the injection computer disables the air conditioning compressor. 1 - Performance return programming for hill starts To facilitate starting on a hill, operation of the air conditioning compressor is prevented for 20 seconds . 2 - Maximum engine speed protection programming Operation of the air conditioning compressor is prevented if: - the instantaneous engine speed is above 6300 rpm , - the constant engine speed is above 5760 rpm for more than 10 seconds . 3 - Thermal protection programming Operation of the air conditioning compressor is prevented if the coolant temperature is above 115C at high speed 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 temperature centralised management function.

WARNING The value of parameter PR044: power absorbed by the AC compressor is never 0 , irrespective of the status of the compressor. The minimum value reading is approximately 250 to 300 W .

17B-26

PETROL INJECTION Injection - air conditioning programming


K4J, and 730 or 732 I - 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 passenger compartment controls and the circuit pressure level. - determining the power absorbed by the air conditioning compressor based on the pressure value of the circuit, - authorising the fan assembly control according to vehicle speed and circuit pressure. - authorising or disables the compressor clutch. When climate control is activated, the climate control panel requests authorisation for air conditioning compressor 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 is made by the injection computer via the multiplex network. This request depends on the air conditioning but also on the coolant temperature and vehicle speed. The engine cooling fan and the compressor are supplied 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.

17B

II - COMPRESSOR FUNCTION PROGRAMMING In certain operating phases, the injection computer disables the air conditioning compressor. 1 - Performance return programming for hill starts To facilitate starting on a hill, operation of the air conditioning 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 for more than 10 seconds . 3 - Thermal protection programming The compressor does not work if the coolant temperature is above 119C 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 119C , - and inlet manifold pressure below 1046 mbar . 4 - Performance return programming The compressor is prevented from operating for 5 seconds . 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) .

WARNING The value of parameter PR044: power absorbed by the AC compressor is never 0 , irrespective of the status of the compressor. The minimum value reading is approximately 250 to 300 W . 5 - Performance return programming for hill starts To facilitate hill-starting, under certain load and engine operating conditions, operation of the air conditioning compressor is prevented for 5 seconds .

17B-27

PETROL INJECTION Injection - air conditioning programming


K4J, and 730 or 732 6 - Maximum engine speed protection programming The air conditioning compressor does not work if the engine speed is above 6496 rpm . 7 - Thermal protection programming The air conditioning compressor does not work if the coolant temperature is above 119C at high speed and high load.

17B

17B-28

PETROL INJECTION Injection - air conditioning programming


K4M, and 760 or 761 I - 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 passenger compartment controls and the circuit pressure level. - determining the power absorbed by the air conditioning compressor based on the pressure value of the circuit, - authorising the fan assembly control according to vehicle speed and circuit pressure. - authorising or disables the compressor clutch. When climate control is activated, the climate control panel requests authorisation for air conditioning compressor 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 is made by the injection computer via the multiplex network. This request depends on the air conditioning but also on the coolant temperature and vehicle speed. The engine cooling fan and the compressor are supplied 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. 1 - Engine start programming

17B

II - COMPRESSOR FUNCTION PROGRAMMING In certain operating phases, the injection computer disables the air conditioning compressor.

The compressor is prevented from operating for 10 seconds after engine start. 2 - Performance return programming The compressor is prevented from operating for 5 seconds . 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 engine operating conditions, operation of the air conditioning compressor is prevented for 5 seconds . 4 - Maximum engine speed protection programming The air conditioning compressor does not work if the engine speed is above 6496 rpm . 5 - Thermal protection programming The air conditioning compressor does not work if the coolant temperature is above 119C at high speed and high load.

WARNING The value of parameter PR044: power absorbed by the AC compressor is never 0 , irrespective of the status of the compressor. The minimum value reading is approximately 250 to 300 W .

17B-29

PETROL INJECTION Throttle valve: Operating


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 I - THROTTLE BODY The throttle valve ensures that idle speed regulation and engine air intake modulation are performed correctly. It is composed of an electric motor and two throttle position potentiometers. When the engine is idling, the throttle position is regulated according to the idle speed setpoint. This setpoint takes into account the major power consumers (air conditioning) and operating conditions (air temperature and coolant temperature). When the driver depresses the accelerator pedal, his request is translated into an angle of throttle opening. However, to improve driving pleasure, the throttle opening is not directly proportional to the drivers request. To eliminate misfires, facilitate gear changes and perform the safety functions, the throttle valve modulates the engine torque. II - THROTTLE VALVE DEFECT MODES There are four types of defect mode for the throttle valve. 1 - Reduced performance mode This mode covers electrical faults for which there is a viable backup solution for the injection system (loss of one of the two tracks on the pedal potentiometer or the throttle valve). This mode limits acceleration and restricts maximum throttle opening (maximum speed of 56 mph (90 km/h) (manual gearbox) and 62 mph (100 km/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 signal disappears completely, but the injection computer still controls the intake of air to the engine (automatic throttle control is still operational). In this mode, the injection computer imposes a set accelerator pedal position for each gear ratio and imposes the idle speed when the brake pedal is depressed. In this case the maximum engine speed in neutral is 2500 rpm . 3 - Mechanical limp home mode This mode covers faults resulting in loss of automatic throttle control (ie it is impossible to operate the throttle). In this case, the throttle is returned to its mechanical rest position, the injection computer limits the engine speed by cutting injection and limits torque by cutting out the cylinders (ignition and injection) accor-

17B

ding to the position of the accelerator. Therefore, the maximum engine speed under full load or in neutral is 2500 rpm . 4 - Pedal information mode If the signal from the inlet manifold vacuum is lost, opening of the throttle is directly proportional to pressure on the accelerator pedal.

Note: Each of these modes results in the injection fault warning light on the instrument panel lighting up.

17B-30

PETROL INJECTION Idle speed correction


F4R, and 770 or 771 or 776 I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

17B

Coolant temperature ( C ) - 20 20 40 80 100 120

Engine speed ( rpm ) 1072 976 (1) 896 752 752 848

(1) Except when starting between 15C and 30C . II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE The purpose of this correction is to compensate for the drop in voltage due to a power consumer being switched on when the battery is not sufficiently charged. It starts when the voltage falls below 12.7 V and may increase 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 at 1024 rpm .

Note: If the engine is started when the coolant temperature is between 15C and 30C and, as a result, the engine speed remains at idle speed, the engine speed will decrease progressively. This drop in engine speed is due to an antipollution function when the engine is started (oxygen sensor heating resistors starting).

17B-31

PETROL INJECTION Idle speed correction


K4J, and 730 or 732 I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

17B

Coolant temperature ( C ) - 20 20 40 80 100 120

Engine speed ( rpm ) 1152 1008 (1) 960 752 752 896

(1) Except when starting between 15C and 30C . II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE The purpose of this correction is to compensate for the drop in voltage due to a power consumer being switched on when the battery is not sufficiently charged. It starts when the voltage falls below 12.7 V and may increase 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 speed is set at 896 rpm .

Note: If the engine is started when the coolant temperature is between 15C and 30C and, as a result, the engine speed remains at idle speed, the engine speed will decrease progressively. This drop in engine speed is due to an antipollution function when the engine is started (oxygen sensor heating resistors starting).

17B-32

PETROL INJECTION Idle speed correction


K4M, and 760 or 761 I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

17B

Coolant temperature ( C ) - 20 20 40 80 100 120

Engine speed rpm ) 1150 944 (1) 850 700 700 752

(1) Except when starting between 15C and 30C . II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE The purpose of this correction is to compensate for the drop in voltage due to a power consumer being switched on when the battery is not sufficiently charged. It starts when the voltage falls below 12.7 V and may increase 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 speed is set at 896 rpm .

Note: If the engine is started when the coolant temperature is between 15C and 30C and, as a result, the engine speed remains at idle speed, the engine speed will decrease progressively. This drop in engine speed is due to an antipollution function when the engine is started (oxygen sensor heating resistors starting).

17B-33

PETROL INJECTION Adaptive idle speed correction


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776 I - ADAPTIVE IDLE SPEED CORRECTION WARNING Principle In normal warm-engine operating conditions, the idle speed OCR PR091 varies between a high and low value to obtain the nominal idle speed. It is possible that following variations in the operation of the vehicle (running in, fitting the engine, etc.), that the idle speed opening cyclic ratio could approach to the highest or lowest values. Adaptive correction PR090 on the idle speed OCR enables the engine's air requirement to be varied slowly by bringing the opening cyclic ratio back to an average nominal value. This adjustment only takes effect if the coolant temperature is above 75C and for 1 minute after engine start 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 adjusted throttle stop, etc.), the engine speed increases at idling speed. The idle opening cyclic ratio value decreases to return to nominal idle speed; the idle opening cyclic ratio adaptive correction decreases to recentre the idle opening cyclic ratio. If there is insufficient air (clogging, etc.), the logic is reversed: the idle opening cyclic ratio and the adaptive correction increase, to refocus operation of the idle speed regulation.

17B

After the computer memory has been cleared, it is imperative to start the engine, stop it, then leave it running at idle speed so that the adaptive correction can recalibrate itself correctly.

17B-34

PETROL INJECTION Richness regulation


F4R, and 770 or 771 or 776 K4M, and 760 or 761

17B

III - DOWNSTREAM SENSOR VOLTAGE Equipment required diagnostic tool An engine operating with the S 3000 computer is fitted with two oxygen sensors called the upstream sensor and the downstream sensor after their position on the catalytic 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 which depends 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 which depends on the engine's top dead centre (excluding no load operation) and the coolant temperature. Oxygen sensor heating is stopped if the following conditions 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 the computer by the oxygen sensor located upstream of the catalytic converter. It is expressed in millivolts. With a looped engine (when the engine corrects the richness according to the two sensors, the engine is said to be looped ); the voltage should oscillate quickly between two values: - 100 mV and 450 mV for a lean mixture, - value above 50% : request for increase in richness. - 450 mV and 900 mV for a rich mixture. V - ENTERING RICHNESS REGULATION MODE Note: The smaller the difference between the minimum and maximum values, the poorer the signal from the sensor. If the difference is small, check the sensor heater. 1 - Loop mode Richness regulation starts after a maximum delay of 10 seconds and if the coolant temperature is above 10C (manual gearbox) and 2.5C (automatic gearbox). Reading parameter PR099: downstream oxygen sensor voltage on the diagnostic tool The value read represents the voltage supplied to the computer by the oxygen sensor located upstream of the catalytic converter, expressed in millivolts. The function of this sensor is to locate faults on the catalytic converter and to perform a second, more precise, check on the richness. This second richness check is called the slow regulation loop . This function is activated only after the engine has been operating for a certain time. When the engine is looped (when the computer corrects the richness according to the two sensors, the engine is said to be looped ), the voltage should be in the region of 600 mV (except at idle speed when it may be difficult to stabilise). When the vehicle is decelerating, the voltage should be approximately 100 mV .

Note: Do not take into account the voltage on the diagnostic tool at idle speed.

IV - RICHNESS CORRECTION The richness correction value read on the diagnostic tool i n p a r a m e t e r PR 138: RICHNESS CORRECTION represents the average of the richness corrections applied by the computer depending on the richness of the fuel mixture as determined by the oxygen sensor located upstream of the catalytic converter (the oxygen sensor in fact analyses the oxygen content of the exhaust gas). The centre point of the correction value is 50% and the end value 0 to 100% . - value less than 50% : request for decrease in richness,

17B-35

PETROL INJECTION Richness regulation


F4R, and 770 or 771 or 776 K4M, and 760 or 761 2 - Non-loop mode In mixture regulation mode, the phases of operation during which the computer ignores the value of the voltage 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 regulation, the computer will only enter defect mode if the fault has been recognised as present for 3 minutes . When this happens, parameter PR138: RICHNESS CORRECTION is 45 or 60% . If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters the open loop mode directly.

17B

17B-36

PETROL INJECTION Richness regulation


K4J, and 730 or 732

17B

III - DOWNSTREAM SENSOR VOLTAGE Equipment required diagnostic tool An engine operating with the S 3000 computer is fitted with two oxygen sensors called the upstream sensor and the downstream sensor after their position on the catalytic 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 which depends on a function table of the engine speed, - the speed is below ( 84 mph (135 km/h) , - after a certain mapped engine operating time which depends on the engine's top dead centre (excluding no load operation) and the coolant temperature. Oxygen sensor heating is stopped if the following conditions 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 the computer by the oxygen sensor located upstream of the catalytic converter. It is expressed in millivolts. With a looped engine (when the engine corrects the richness according to the two sensors, the engine is said to be looped ); the voltage should oscillate quickly between two values: - 100 mV and 450 mV for a lean mixture, - 450 mV and 900 mV for a rich mixture. Reading parameter PR099: downstream oxygen sensor voltage on the diagnostic tool The value read represents the voltage supplied to the computer by the oxygen sensor located upstream of the catalytic converter, expressed in millivolts. The function of this sensor is to locate faults on the catalytic converter and to perform a second, more precise, check on the richness. This second richness check is called the slow regulation loop . This function is activated only after the engine has been operating for a certain time. When the engine is looped (when the computer corrects the richness according to the two sensors, the engine is said to be looped ), the voltage should be in the region of 600 mV (except at idle speed when it may be difficult to stabilise). When the vehicle is decelerating, the voltage should be approximately 100 mV .

Note: Do not take into account the voltage on the diagnostic tool at idle speed.

IV - RICHNESS CORRECTION The richness correction value read on the diagnostic tool i n p a r a m e t e r PR 138: RICHNESS CORRECTION represents the average of the richness corrections applied by the computer depending on the richness of the fuel mixture as determined by the oxygen sensor located upstream of the catalytic converter (the oxygen sensor in fact analyses the oxygen content of the exhaust gas). The centre point of the correction value is 50% and the end value 0 to 100% . - value less than 50% : request for decrease in richness, - value above 50% : request for increase in richness. V - ENTERING RICHNESS REGULATION MODE 1 - Loop mode The start of richness regulation is effective following a period which depends on the engine coolant temperature when the engine is started. At 20C , the start of the richness loop is effective after approximately 8 seconds .

Note: The smaller the difference between the minimum and maximum values, the poorer the signal from the sensor. If the difference is small, check the sensor heater.

17B-37

PETROL INJECTION Richness regulation


K4J, and 730 or 732 2 - Non-loop mode In mixture regulation mode, the phases of operation during which the computer ignores the value of the voltage 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 regulation, the computer will only enter defect mode if the fault has been recognised as present for 3 minutes . When this happens, parameter PR138: RICHNESS CORRECTION is 45 or 60% . If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters the open loop mode directly.

17B

17B-38

PETROL INJECTION Adaptive richness correction


K4J, and 730 or 732 K4M, and 760 or 761 I - PRINCIPLE In looping phase, the richness regulation corrects the injection time to obtain fuel dosing as close as possible to a richness of 1. Richness correction value PR138 is close to 50% , with stop values of 0 and 100% . Adaptive richness corrections PR143 and PR144 allow the injection map to be shifted to recentre richness regulation at 50 % . Adaptive corrections take 50% as the average value after reinitialising the computer (clearing the memory), and have end values.

17B

Pressure zones which must be passed through during the test There are five pressure zones to scan during road testing. These zones are defined by the following calibrations:

Range N1 N2 n3 N4 N5

mbar 258 to 458 458 to 536 536 to 614 614 to 692 692 to 813 Average 358 Average 497 Average 575 Average 653 Average 752

Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine If the coolant temperature is above 90C while idling for more than 10 minutes (K4M engine) and 1 minute (K4J engine), the adaptives are fixed until the end of idling. Programming conditions for adaptive richness correction - Warm engine: coolant temperature above 80C , - do not exceed an engine speed of 4640 rpm - disconnect the fuel vapour absorber by the solenoid valve 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 varied 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 readings again, taking care to observe the test conditions strictly.

II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST In the event of a lack of fuel (injectors clogged, pressure and fuel flow too low, etc), the richness regulation increases to obtain a richness as close as possible to 1 and the richness adaptive corrections increase until the richness 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 adaptive gain

25% < or = X < or = 63%

PR144

Richness adaptive offset

25% < or = X < or = 63%

17B-39

PETROL INJECTION Adaptive richness correction


F4R, and 770 or 771 or 776 I - PRINCIPLE In looping phase, the richness regulation corrects the injection time to obtain fuel dosing as close as possible to a richness of 1. Richness correction value PR138 is close to 50% , with stop values of 0 and 100% . Adaptive richness corrections PR143 and PR144 allow the injection map to be shifted to recentre richness regulation at 50 % . Adaptive corrections take 50% as the average value after reinitialising the computer (clearing the memory), and have end values.

17B

Pressure zones which must be passed through during the test There are five pressure zones to scan during road testing. These zones are defined by the following calibrations:

Range N1 N2 n3 N4

mbar 276 to 398 398 to 516 516 to 637 637 to 753 753 to 872 Average 337 Average 457 Average 576 Average 695 Average 812

Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine If the coolant temperature is above 80C while idling for more than 1 minute , the adaptives are fixed until the end of idling.

N5

II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST In the event of a lack of fuel (injectors clogged, pressure and fuel flow too low, etc), the richness regulation increases to obtain a richness as close as possible to 1 and the richness adaptive corrections increase until the richness correction is again fluctuating around 50% . If there is an excess of fuel, the logic is inverted.

Programming conditions for adaptive richness correction - Warm engine: coolant temperature above 80C , - Do not exceed an engine speed of 4512 rpm . - disconnect the fuel vapour absorber by the solenoid valve 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 varied driving over a distance of 3 to 6 miles (5 to 10 km) . After the test, read the adaptive values. They should have changed from their original value of 50 % . If not, take the readings again, taking care to observe the test conditions strictly.

PR138

Richness correction

23% < or = X < or = 74%

PR143

Richness adaptive gain

12.5% < or = X < or = 87.5%

PR144

Richness adaptive offset

32% < or = X < or = 87.5%

17B-40

PETROL INJECTION Central coolant temperature management


The fan assembly is controlled by the injection computer.

17B

I - ANTI-PERCOLATION FUNCTION The anti-percolation function is controlled by the injection computer. The coolant temperature signal used is that from the injection system.

K4J, and 730 or 732 K4M, and 760 or 761 After switching the ignition off, the system enters monitoring mode. If the coolant temperature exceeds the threshold 103C for 5 minutes after the engine has been switched off, the low-speed fan assembly is activated.

F4R, and 770 or 771 or 776 After switching the ignition off, the system enters monitoring mode. If the coolant temperature exceeds 110C for 2 minutes after the engine has been switched off, the low-speed fan assembly is activated.

If the coolant temperature falls below 100C again, the fan assembly relay is cut-out (the fan assembly cannot be activated for more than 10 minutes ).

II - FAN ASSEMBLY OPERATION The fan unit is operated at low speed if the coolant temperature exceeds 98C and stops when the temperature falls below 96C . The fan assembly is operated at high speed if the coolant temperature exceeds 102C and stops when the temperature falls below 99C .

III - OPERATION OF THE TEMPERATURE WARNING LIGHT The temperature warning light comes on if the coolant temperature exceeds 119C and goes out when the temperature falls below 115C .

17B-41

PETROL INJECTION Camshaft dephaser: Description


F4R, and 770 or 771 K4M, and 760 or 761 I - SPECIAL NOTES

17B

F4R, and 770 or 771 K4M, and 760 or 761 Its role is to modify the valve timing. To improve cylinder filling at all speeds, K4M and F4R engines are fitted with an inlet camshaft dephaser (1) .

The supply by a variable opening cyclic ratio signal (amplitude 12 V , frequency 250 Hz ) enables oil to be distributed to the mechanism and the dephaser angle to be adjusted.

15200

The operation of the camshaft dephaser varies continuously. The computer supplies the solenoid valve with a variable opening cyclic ratio proportional to the desired dephasing. Dephasing is varied continuously from 0 to 43 of the crankshaft.
102943

Dephasing at the moment when the inlet valves close optimises filling according to engine speed. Midrange torque and output are improved. Leaving the inlet valves open for longer at high engine speed allows the mixture to be continually admitted owing to its high speed. However, at lower engine speeds the gases do not have a high level of inertia. It is therefore preferable to close the inlet valves earlier to avoid incorrect filling and a loss of torque due to the reflux of fresh gases. The higher the engine speed, the later the inlet valves must be closed.
101814

The camshaft dephaser control solenoid valve is controlled if the following conditions are met: - no speed sensor fault, - no camshaft position sensor fault,

II - OPERATION AND PROGRAMMING

- no injection system faults, - after the engine has started,

K4M, and 760 or 761 The oil is supplied to the dephaser by a solenoid valve (2) located on the cylinder head.

- outside idling speed and no load, - threshold of mapping according to load and engine speed reached,

17B-42

PETROL INJECTION Camshaft dephaser: Description


F4R, and 770 or 771 K4M, and 760 or 761 - coolant temperature between 10 and 120C , - engine oil temperature too high. Defect modes: - dephaser returns to initial position, - zero dephasing. Note:

17B

Up to 1,500 rpm , the solenoid valve is no longer supplied. The mechanism is locked by the piston. As soon as the solenoid valve is supplied, at speeds above 1,500 rpm , the oil pressure pushes the locking piston and releases the mechanism.

WARNING A solenoid valve jammed open causes an unstable idle speed, manifold pressure which is too high at idle speed and signicant engine operating noise.

III - OPERATION AND PROGRAMMING

F4R, and 770 or 771 The dephaser is controlled in an all or nothing system by the injection computer using a solenoid valve (3) located on the rocker cover.

102736

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 30C , - engine speed between 1,500 and 4,300 rpm , - charge > 87% (approximately 900 mbar ).
102732

WARNING A solenoid valve which is blocked open leads to an unstable idle speed and too high a pressure in the manifold at idling speed.

From 1,500 to 4,300 rpm , the computer supplies the solenoid valve. Above 4,300 rpm , the solenoid valve is not supplied. The position of the mechanism improves filling at high speeds. In this position, a locking piston locks the mechanism.

17B-43

PETROL INJECTION
Fault finding warning light activation conditions (when driving)

17B

I - FAULTS CAUSING ACTIVATION OF THE ONBOARD DIAGNOSTIC WARNING LIGHT Note: 1 - Electrical fault Continuous illumination of the light after several consecutive detections of a fault (depending on the component). 2 - Combustion misfiring that could destroy the catalytic converter Immediate illumination and flashing of the warning light. 3 - Catalytic converter or oxygen sensor fault, polluting misfires Continuous illumination of the light after a fault is detected three times consecutively. The fault may not be re-detected: - if the fault is eeting in nature, - due to the driving style of the customer, which may not always cover all of the fault detection conditions.

WARNING The diagnostics of the catalytic converter and upstream oxygen sensor are sequential and are run: - once when driving (they take several seconds per test), - only under certain specic driving conditions. Under certain driving conditions, it may be the case that fault nding for certain functions are not performed (e.g. when in a trafc jam).

II - MANAGEMENT OF THE ONBOARD DIAGNOSTIC (OBD) WARNING LIGHT 1 - Warning light comes on If the same OBD fault is detected during three consecutive journeys or there is an electrical fault. 2 - Warning light flashes If misfires that could destroy the catalytic converter are detected. 3 - Light goes out If the OBD fault does not reappear in three consecutive journeys the warning light goes out, but the fault will be stored in the injection computer. The fault must not be detected for 40 consecutive journeys for the a stored fault to be cleared from the computer without using the fault finding tool.

17B-44

PETROL INJECTION
Conditions for carrying out fault finding (when driving)
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 is not between -7.5C and 119.39C , if the coolant temperature read by the sensor is not between -7.5C and 119.39C , or if the difference between 1046 mbar and the manifold pressure is greater than 273 mbar (altitude of about 2500 metres), OBD is not authorised until the ignition is switched on again. In order for the On Board Diagnostic system to function correctly, there must be no electrical fault in the injection system, even if the OBD warning light does not come on. Fault finding of the oxygen sensor and the catalytic converter can never be performed at the same time. When the catalytic converter and oxygen sensor fault finding procedures are in progress, the fuel vapour absorber bleed is closed and the richness adaptive parameters 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 4000 rpm , then decelerate to power take-up speed.

17B

Power take-up speed is the moment when, during deceleration under no load and the injection cut out, the computer authorises injection again. 2 - Programming of richness adaptive parameters To perform this programming, the vehicle must be driven within the pressure ranges (see 17A, Petrol injection, Adaptive richness correction ).

17B-45

PETROL INJECTION Combustion misfire fault finding


IV - CONDITIONS FOR DETECTION Equipment required diagnostic tool The purpose of detecting misfiring is to detect any malfunctions which could cause hydrocarbon pollutant emissions to exceed the OBD limit, or cause damage to the catalytic converter.

17B

Check that programming has been correctly carried out. Check that the prerequisites for switching on the ignition and for detecting misfiring correspond. Detection is carried out as soon as the coolant temperature is above 7.5C , in three operating ranges between idle speed and 4,500 rpm . The pollutant misfiring test can also be carried out by maintaining the engine at idle speed with all the power consumers on for 10 minutes .

Note: - In comparison to the Sagem 2000 injection, Sagem 3000 has the following functions: injection cut-off to cylinders causing misring, appearance of a fault indicating non-conformity of the ywheel target. - If distortion of the target is too marked, the computer cannot implement an adjustment that is sufcient to detect misring correctly.

WARNING At the end of this test, it is essential that the ignition is not switched off before the result is read on the diagnostic tool. Switching the ignition off will lead to the results being misinterpreted. V - REPAIR CONFIRMATION Using the tool diagnostic tool , check:

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 regulator, 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 instantaneous variations in engine rotation speed. If a drop in torque is detected, this is an indication of misfiring. Misfiring results in a drop in engine torque below a predetermined threshold. This fault finding is practically continuous while the car is being driven. If it is not carried out, or if a fault is detected, all other OBD fault finding (catalytic converter and 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 catalytic converter damage. It causes the injection warning light to flash immediately. - Pollutant misfiring - below 15% - causing the OBD pollution limit to be exceeded. It causes the injection warning light to come on if it is detected during three consecutive journeys.

ET 057 ET 058 ET 059 ET 060

Misring on cylinder 1 Misring on cylinder 2 Misring on cylinder 3 Misring on cylinder 4

No No No No

Following this test, if the diagnostic tool has indicated misfiring faults DF065 , DF059 , DF060 , DF061 , or DF062 , refer to the appropriate fault finding procedure for the symptom concerned.

17B-46

PETROL INJECTION Catalytic converter fault finding


The purpose of catalytic converter fault finding is to detect a fault which could cause hydrocarbon pollutant emissions to exceed the OBD limit. The catalytic converter's capacity to store oxygen is indicative of its condition. As the catalytic converter ages, its capacity to store oxygen reduces along with its ability to treat pollutant gases. I - CONDITIONS FOR STARTING FAULT FINDING Fault finding on the catalytic converter can only be carried 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 since the ignition was switched on, - programming has been carried out, - main loop and double loop active, - coolant temperature higher than 75C , - engine speed read by the diagnostic tool as between 1472 rpm and 3868 rpm . II - FAULT DETECTION Fault finding is carried out when driving under stabilised conditions. When the conditions for starting fault finding are met, richness excitation peaks are applied, which has the effect of sending bursts of oxygen into the catalytic converter. 1 - If the catalytic converter is functioning normally It absorbs oxygen and the voltage of downstream oxygen sensor PR099 remains at an average value. 2 - If it needs replacing It rejects the oxygen and downstream oxygen sensor PR099 starts to pulse. The voltage of the oxygen sensor fluctuates (the OBD warning light comes on after three journeys). III - REPAIR CONFIRMATION

17B

If after the test, the diagnostic tool has detected a catalytic 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 ignition is not switched off before the result is read on the diagnostic tool. Switching off the ignition will lead to the results being misinterpreted.

17B-47

PETROL INJECTION Oxygen sensor fault finding

17B

Equipment required diagnostic tool The purpose of fault finding on the upstream oxygen sensor is to detect faults that would cause emissions of hydrocarbon, carbon monoxide or nitrogen oxide to exceed the OBD limit. It is carried out by measuring and comparing periods of upstream oxygen sensor vibration. I - POSSIBLE CAUSES OF FAULTS There are possible types of fault in the upstream oxygen sensor: - mechanical damage to an electrical component (breakage, cut in wire) which leads to an electrical fault, - chemical damage to the component, which causes the response time of the sensor to slow down, thus increasing its switching period. II - CONDITIONS FOR STARTING FAULT FINDING When test conditions are reached, the computer takes an average of sensor cycle readings PR121 Average upstream oxygen sensor cycle , taking away the effects of interference, which is compared to an 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 minutes , 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 the ignition was switched on, - no misfiring detected, - coolant temperature higher than 75C , - engine speed given by the diagnostic tool as between 1472 rpm and 3868 rpm . - manifold pressure between 292 mbar and 900 mbar . IV - FAULT DETECTION Fault finding is carried out when driving, according to the conditions previously outlined, and prevents fuel vapours bleeding from the absorber.

WARNING At the end of this test, it is essential that the ignition is not switched off before the result is read on the diagnostic tool. Switching off the ignition will lead to the results being misinterpreted. V - REPAIR CONFIRMATION If, after the test, the diagnostic tool has detected an upstream oxygen sensor fault DF092: Upstream oxygen sensor circuit refer to the fault finding procedure for this fault.

17B-48

PETROL INJECTION Speed limiter: Operating principle


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 resistance point), - switch in the off position, - 0 button depressed, - injection computer intervention (fault or overspeed),

17B

Note: If the warning light on the instrument panel ashes, it informs to the driver that the cruising speed cannot be maintained.

17B-49

COOLING SYSTEM General information


When a faulty vehicle arrives, check: IMPORTANT The circuits are designed to be pressurised; take care at high temperatures (risk of serious scalding). Never remove the valve from the expansion bottle while 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 is running.

19A

- the condition and tension of the water pump drive belt, - that the fan, the radiator and the radiator grille are not obstructed by an object which may impede the flow of air. Vehicles in the current range have cooling circuits with the following basic specifications: - Pressurised sealed circuit (expansion bottle valve),

Note: Summary of expansion bottle valve ratings. WARNING The coolant helps to keep the engine running properly (heat exchange). The system does not operate using pure water. Expansion bottle valve with: a yellow hand: 1.4 bar a white hand: 1.6 bar a grey hand: 1.8 bar - circuit using type D coolant only. WARNING Drain with the engine warm. Flushing and relling should be carried out with a warm or cold engine. Never ush a hot engine (risk of serious thermal shock). Note: Ready-to-use coolant or antifreeze must be diluted with distilled water in accordance with the guidelines marked on the container.

WARNING When carrying out a repair that requires a the circuit to be completely drained, it is essential to ush the circuit with clean water, blow compressed air through the circuit to eliminate water, ll and drain the circuit and then measure the effective protection. The criteria to be met are: - Protection down to - 25C 2 for cold and temperate climates, - Protection down to - 40 C 2 for very cold climates

Note: Refer to the vehicle's maintenance service booklet for information on cooling circuit service intervals. For any further information, refer to the Workshop Repair Manual of the vehicle concerned.

19A-1

COOLING SYSTEM Specifications


Grade and quantity of coolant Engine Sufx 730 K4J 732 760 K4M 761 722 728 K9K 729 732 770 F4R 771 6.5 776 800 F9Q 804 808 M9R Thermostat Engine K4J K4M K9K F9Q F4R M9R Start of opening (C) 89 89 89 89 89 89 End of opening (C) 99 2 99 2 99 2 99 2 99 2 99 2 700 7.2 7.6 7.2 7.5 6.8 7.5 6 6.5 5.3 6.5 GLACEOL RX (type D). Only use coolant uid 6 6 Quantity (litres) Grade

19A

19A-2

COOLING SYSTEM Checking


I - RECOMMENDATIONS FOR REPAIR

19A

II - CHECKING THE CIRCUIT SEALING

IMPORTANT The circuits are designed to be pressurised; take care at high temperatures (risk of serious scalding). Never remove the valve from the expansion bottle while the engine is hot. Similarly, tak care when working under the bone net, as the radiator fan(s) may start up unexpectedly. Do not open the bleed valve(s) while the engine is running.

Note: The expansion bottle valve must be replaced if coolant is leaking from the valve. Checking the cooling system and the expansion bottle valve

107138

Check the cooling system and the expansion bottle valve using the cooling system diagnostic and filling tool (mot. 1700) . For guidance on the use of this tool see NT 3857A, How to use the cooling circuit diagnostic and filling tool .

Note: For any further information, refer to the Workshop Repair Manual of the vehicle concerned.

19A-3

COOLING SYSTEM Diagram


K4J, and 730 or 732 K4M, and 760 or 761

19A
9 3 9

5 4

6 7 10

2 8

105003

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Engine Cooling radiator Heating radiator Expansion tank Water pump Thermostat 9 mm choke 16 mm choke Bleed screws Automatic gearbox coolant-oil intercooler (if tted to the vehicle)

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-4

COOLING SYSTEM Diagram


K9K, and 722 or 728 or 729

19A
3 9

5 4

7 8

10 11

110741

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat 11 mm choke (K9K 722) 9 mm by-pass choke (K9K 728 / 729) Bleed screws Coolant-engine oil intercooler Coolant-oil intercooler (K9K 729)

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-5

COOLING SYSTEM Diagram


F9Q, and 800 or 808

19A
9 3 9 7

5 4

6 10

8 2

102269

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat 8 mm choke 9 mm choke Bleed screws Coolant-oil intercooler

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-6

COOLING SYSTEM Diagram


F4R, and 770 or 771

19A
9 3

9 10 4 5 7 6 1

11

102740

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat 8.3 mm choke 16 mm choke Bleed screws Coolant-oil intercooler Automatic gearbox coolant-oil intercooler (if tted to the vehicle)

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-7

COOLING SYSTEM Diagram


F4R, and 776

19A
9 3

12

11

4 6 10

7 2 13
106628

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat 9 mm choke 16 mm choke Bleed screws Water-oil intercooler Thermostat mounting Turbocharger Electric water pump

Note The expansion bottle valve rating is 1.4 bar .

19A-8

COOLING SYSTEM Diagram


F9Q, and 804

19A
3

11

12 9 7

4 6 10 9 13

8 2 14
112266

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat 8 mm choke 16 mm choke Bleed screws Water-oil intercooler Cylinder head coolant outlet unit Turbocharger Exhaust gas cooler Electric water pump

Note The expansion bottle valve rating is 1.4 bar .

19A-9

COOLING SYSTEM Diagram


K9K, and 732

19A
7 3

7 9 5 4 1 7

8 2

112268

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat Bleed screws Water-oil intercooler Exhaust gas cooler

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-10

COOLING SYSTEM Diagram


M9R, and 700

19A

114452

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Engine Cooling radiator Heater radiator Expansion bottle Water pump Thermostat Choke Choke Bleed screws Water-oil heat exchanger Exhaust gas recirculation solenoid valve

Note: The expansion bottle degassing valve rating is 1.4 bar .

19A-11

COOLING SYSTEM Cooling circuit: Draining - Refilling

19A

Special tooling required Car. 1363 Mot. 1202-01 Mot. 1202-02 Mot. 1448 Mot. 1700 Trim removal lever Clip pliers for hose clips (large model) Clip pliers for hose clips (small model) Remote operation pliers for cooling system hose clips Cooling system lling and diagnostic tool

WARNING When carrying out a repair that requires a complete change, it is essential to ush the circuit with clean water, blast compressed air through the circuit to drive out the water, ll and bleed the circuit and then measure the effective protection. The parameters to be observed are: - Protection down to - 25C 2 for cold and temperate climates, - Protection down to - 40 C 2 for very cold climates.

Note: IMPORTANT The circuits are designed to be pressurised; take care at high temperatures (risk of serious burns). Never remove the cap from the expansion bottle while 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 is running. Before carrying out any operation, protect electrical equipment using plastic bags.

Note: The engine must be switched off and the air conditioning system deactivated to prevent the engine cooling fans operating as soon as the engine is started.

WARNING The coolant helps to keep the engine running properly (heat exchange). The system does not operate using pure water.

DRAINING
Use the following tools: - (Car. 1363) , - (Mot. 1202-01) , - (Mot. 1202-02) ,

WARNING Drain the uid with the engine warm. Flushing and relling should be carried out with a warm or cold engine. Never ush a hot engine (risk of serious thermal shock).

- (Mot. 1448) . Remove the expansion bottle cap. Open the cooling system at the cooling radiator bottom hose using the (Car. 1363) . Blast compressed air into the circuit through the expansion bottle cap orifice to remove as much water as possible.

CLEANING
For cleaning (see 19A, Cooling, Cooling system: cleaning).

FILLING
Use GLACEOL RX (TYPE D) coolant.

19A-12

COOLING SYSTEM Cooling circuit: Draining - Refilling


Refill the cooling system using the cooling system diagnostic and filling tool (Mot. 1700) . For guidance on the use of this tool see Technical Note 3857A, Using the cooling system diagnostic and filling tool . Fill up the expansion bottle until the coolant overflows. Refit the expansion bottle cap. Bleed the circuit (see 19A, Cooling system, Cooling circuit: Bleeding, page 19A-15) .

19A

19A-13

COOLING SYSTEM Engine cooling circuit: Cleaning

19A

IMPORTANT The circuits are designed to be pressurised; take care at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while 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 is running.

WARNING Drain the uid with the engine warm. Flushing and relling should be carried out with a warm or cold engine. Never ush a hot engine (risk of serious thermal shock). CLEANING THE COOLING SYSTEM To clean the cooling system, fill with water via the expansion bottle. Note: In some cases it will be necessary to disconnect the radiator top hose to correctly ush the engine cooling radiator. Blast compressed air into the circuit through the expansion bottle cap orifice to remove as much water as possible. Connect the top and bottom hoses.

19A-14

COOLING SYSTEM Cooling circuit: Bleeding


BLEEDING
IMPORTANT Do not open the bleed screw(s) while the engine is running or hot. Do not open the expansion bottle while the engine is running or hot (above 50C ). Adjust the level, if necessary. Retighten the expansion bottle cap while the engine is hot. Using approved equipment, measure the degree of coolant protection. Check for any leaks. Make sure the passenger compartment heating is working properly.

19A

K9K, and 722 or 728 or 729 or 732 Run the engine at 1500 rpm , rapidly varying the engine speed (until you reach maximum speed) 2 to 3 times approximately every 2 minutes until the engine cooling fan starts up for a second time.

F4R, and 770 or 771 or 776 F9Q, and 800 or 804 or 808 K4J, and 730 or 732 K4M, and 760 or 761 Run the engine at 2500 rpm , until the engine cooling fan has run three times (time required for automatic degassing).

19A-15

COOLING SYSTEM Cooling radiator: Removal - Refitting


Special tooling required Car. 1363 Mot. 1202-01 Trim removal lever Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips

19A

Disconnect the battery, starting with the negative terminal. Remove: - the engine covers, - the front wheels, - the engine undertray, - the wheel arch liners. Disconnect:

Mot. 1202-02 Mot. 1448

- the fog lights connector (if fitted to vehicle), - the headlight washer pipes (if fitted). Remove:

Tightening torquesm intercooler hose clip battery cover mounting bolts wheel mounting bolts 5.5 Nm 4 Nm 110 Nm

- the bumper mountings, - the bumper.

REMOVAL
F4R, and 776 F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

1 4 3

WARNING Procedure for removing the air inlet duct on the intercooler: - risk of leaks and of coming loose if this procedure is not adhered to. - detach the hose using tool (Car. 1363) , - do not use degreaser, brake cleaner, or any other product, - clean the bearing face on the intercooler and the hose with a dry, lint-free cloth, - always replace the clip with a new one. - replace the new clip in the same position if the hose is not replaced, - it is essential to replace the hose and/or the intercooler if they are damaged, Disconnect the two connectors (1) . Unclip the bonnet opening cable (2) . Remove: - the clip (3) , - the mounting (4) . Disconnect the windscreen washer pipes.

102504

Put the vehicle on a two-post lift.

19A-16

COOLING SYSTEM Cooling radiator: Removal - Refitting

19A

F4R, and 776 F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

102365

Remove the cross member (5) . Drain the cooling circuit through the radiator bottom hose. Disconnect: - the radiator top hose, - the expansion bottle hoses on the radiator, - the fan unit connector.

102473

7
102474

Disconnect the intercooler inlet ducts (6) and outlet ducts (7) . Remove the intercooler.

19A-17

COOLING SYSTEM Cooling radiator: Removal - Refitting


Separate the condenser from the radiator. WARNING Be careful not to damage the air conditioning piping. Remove the radiator. Separate the fan unit from the radiator. Tighten to torque:

19A

- the battery cover mounting bolts ( 4 Nm ) , - the wheel mounting bolts ( 110 Nm ) . Note Be sure to initialise the xenon bulb system (if tted on vehicle; see 80C, Xenon bulbs, Xenon headlight: Adjustment ).

REFITTING
Proceed in the reverse order to removal. F4R, and 776 F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 Tighten to torque the intercooler hose clip ( 5.5 Nm ) .

For refitting plastic clips, use: - hose clip pliers (Mot. 1202-01) , - hose clip pliers (Mot. 1202-02) - remote operation hose clip pliers (Mot. 1448) . WARNING Ensure that the ns of the cooling unit (radiator, condenser) are not damaged when moved. Perform the following operations: - fill the cooling circuit (see 19A, Cooling, Draining - filling the cooling circuit ), - bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ), Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

19A-18

COOLING SYSTEM Cooling radiator: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips

19A

Mot. 1202-02 Mot. 1448

Tightening torquesm front end panel upper mounting bolts front end panel lower mounting bolts wheel bolts I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting 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 ). Remove: - the front end panel bolts (5) , - the front end panel. 21 Nm 44 Nm 110 Nm

102504

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.

102365

Drain the cooling system via the radiator bottom hose, using tool (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

19A-19

COOLING SYSTEM Cooling radiator: Removal - Refitting


K9K, and 732

19A

102473

109537

102474

112661

Disconnect the ducts (6) and (7) from the intercooler. Remove the intercooler.

Disconnect: - the cooling radiator top hose, - the expansion bottle hoses (8) , - the fan unit resistor connector (9) . - the fan unit connector

19A-20

COOLING SYSTEM Cooling radiator: Removal - Refitting


K9K, and 732 Connect: CA or CAREG Separate the condenser from the cooling radiator. WARNING Be careful not to damage the air conditioning piping.

19A

- 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 ( 21 Nm ) - the front end panel lower mounting bolts ( 44 Nm ) Clip the bonnet opening cable Reconnect:

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 CA or CAREG Reposition the condenser on the cooling radiator. WARNING Be careful not to damage the air conditioning piping.

- 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 ).

19A-21

COOLING SYSTEM Water pump: Removal - Refitting


C84 or G84 or S84, and F9Q, and 800 or 804 or 808

19A

REFITTING
Tightening torquesm water pump mounting bolts front right-hand wheel mounting bolts 9 Nm 110 Nm IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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, Cooling system: Draining - Refilling ). Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).

Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering. Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula. Replace the water pump seal every time the water pump is removed.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

Note: Apply two drops of LOCTITE FRENET ANCH to the water pump mounting bolts. Refit: - the water pump, - the water pump mounting bolts.

102422

Remove: - the water pump mounting bolts (6) , - the water pump.

19A-22

COOLING SYSTEM Water pump: Removal - Refitting


C84 or G84 or S84, and F9Q, and 800 or 804 or 808

19A

102422

Tighten to torque and in order the water pump mounting 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 of engine, 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, Bleeding 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 wheel mounting bolts ( 110 Nm ) .

19A-23

COOLING SYSTEM Water pump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

19A

Tightening torquesm water pump M8 mounting bolt water pump M6 mounting bolts front right-hand wheel mounting bolts 22 Nm 10 Nm 110 Nm

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, 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.
14505

REFITTING

IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation. Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering. Apply the product to the section to be cleaned; wait approximately ten minutes, then remove the residue using a wooden spatula.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. The product-uid mix may cause damage to some components (engine, radiator, etc.).

19A-24

COOLING SYSTEM Water pump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761

19A

10063

Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm to 1 mm wide.

19A-25

COOLING SYSTEM Water pump: Removal - Refitting


K4J, and 730 or 732 K4M, and 760 or 761 Refit:

19A

- 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 ( 110 Nm ) .

8
14505

Note: Apply one to two drops of LOCTITE FRENETANCH to the mounting bolts (1) and (4) of the water pump. Refit: - the water pump, - the water pump mounting bolts. Pretighten the water pump M6 mounting bolts to 8 Nm and the water pump M8 mounting bolts to 8 Nm . 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 of engine, Accessories belt: Removal - Refitting ). Fill the cooling system (see 19A, Cooling, Draining - Filling the cooling system ). Connect the battery (see 80A, Battery, Battery: Removal - Refitting ). Bleed the cooling system (see 19A, Cooling, Bleeding the cooling system ). Refit the front right-hand wheel

19A-26

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19A

Tightening torquesm water pump mounting bolts front right-hand wheel mounting bolts 11 Nm 110 Nm

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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 of engine, Accessories belt: Removal - Refitting ). - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ). Remove the alternator upper mounting (1) . Undo the alternator lower mounting (2) . Tilt the alternator forward.
102267

Disconnect the alternator electrical connections.

102266

Remove: - the inner timing cover mounting bolts (3) , - the inner timing cover.

19A-27

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19A

3 5

102262

102262

Remove: - the water pump mounting bolts (4) , - the water pump. WARNING The sealing surfaces must be clean, dry and free from grease (avoid nger marks).

REFITTING
Note: IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation. Clean the gasket faces using DECAPJOINT to dissolve any sealant still adhering. Apply the product to the section to be cleaned; wait approximately ten minutes, then remove the residue using a wooden spatula. Replace the water pump seal every time the water pump is removed. Apply two drops of LOCTITE FRENET ANCH to the water pump mounting bolts. Refit: - the water pump, - the water pump mounting bolts (1) to (5) . Tighten to torque and in order the water pump mounting bolts ( 11 Nm ) .

19A-28

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19A

102266

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 of engine, 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, Bleeding 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 ( 110 Nm )

19A-29

COOLING SYSTEM Water pump: Removal - Refitting


F4R, and 770 or 771 or 776

19A

REFITTING
Tightening torquesm water pump mounting bolts front right-hand wheel mounting bolts 9 Nm 110 Nm IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation.

REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting 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, Cooling system: Draining-refilling ). Remove: - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ). - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).

Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering. Apply the product to the section to be cleaned; Wait approximately ten minutes, then remove the residue using a wooden spatula. Replace the water pump seal every time the water pump is removed.

WARNING The gasket faces must be clean, dry and free from grease (avoid nger marks).

Note: Apply two drops of LOCTITE FRENET ANCH to the water pump mounting bolts. Refit: - the water pump, - the water pump mounting bolts.

102422

Remove: - the water pump mounting bolts (6) , - the water pump.

19A-30

COOLING SYSTEM Water pump: Removal - Refitting


F4R, and 770 or 771 or 776

19A

5 3 2

102422

Tighten to torque and in order the water pump mounting 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 of engine, 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, Bleeding 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 wheel mounting bolts ( 110 Nm ) .

19A-31

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 732 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips

19A

Mot. 1202-02 Mot. 1448

Tightening torquesm water pump mounting bolts wheel mounting bolts battery cover mounting bolts 11 Nm 130 Nm 4 Nm
102267

Loosen the alternator lower mounting bolt by three turns. Remove the alternator upper mounting bolt. Tilt the alternator against the radiator assembly.

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. 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 of Engine, Accessories belt ). - the timing belt (see 11A, Top and front of engine, Timing belt

102266

Remove: - the inner timing cover mounting bolts, - the timing cover.

19A-32

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 732 II - OPERATION FOR REMOVAL OF PART CONCERNED

19A

REFITTING
I - OPERATION FOR REFITTING PART CONCERNED

WARNING The water pump seal every time the water pump is removed.

Note: Apply one or two drops of LOCTITE FRENETANCH to the water pump mounting bolts.

102262

Remove: - the water pump mounting bolts - the water pump. III - CLEANING

IMPORTANT - Do not scratch the aluminium sealing surfaces. - Wear goggles. - Clean the gasket faces with DECAPJOINT to dissolve the part of the gasket still present. Apply the product to the part to be cleaned, wait approximately 10 minutes, then remove residue using a wooden spatula.
102262

Refit: - the water pump, - the water pump mounting bolts. Tighten to torque and in order the water pump mounting bolts ( 11 Nm ) .

19A-33

COOLING SYSTEM Water pump: Removal - Refitting


K9K, and 732 II - FINAL OPERATION

19A

102266

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 of engine, 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, Bleeding the cooling circuit ), Connect the battery starting with the positive terminal (see 80A Battery: Removal - Refitting ).

WARNING Carry out the necessary programming.

Tighten to torque: - the wheel mounting bolts ( 130 Nm ) - the battery cover mounting bolts ( 4 Nm )

19A-34

COOLING SYSTEM Water pump: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1390 Support for removing and retting the engine and gearbox assembly

19A

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Tightening torquesm water pump mounting bolts water pump pulley mounting bolts front end panel upper mounting bolts front end panel lower mounting bolts 25 Nm 21 Nm 21 Nm 44 Nm WARNING When carrying out a repair that requires a complete change, it is essential to ush the circuit with clean water, blast compressed air through the circuit to drive out the water, ll and bleed the circuit and then measure the effective protection. The parameters to be observed are: - protection down to - 25 C 2 for cold and temperate countries, - protection down to - 40 C 2 for very cold countries.

IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot. When working under the bonnet, be aware that the radiator cooling fan(s) may start without warning. Do not open the bleed screw(s) with the engine running. Remove: - the engine undertray, - the front right-hand wheel, - the front right-hand wheel arch liner, - the engine undertray.

19A-35

COOLING SYSTEM Water pump: Removal - Refitting


M9R, and 700

19A

101212

114933

Remove: - the right-hand side stiffener mounting bolts, - the right-hand side stiffener (1) , - the rear mounting (see 19D, Suspended engine mounting, Rear mounting: Removal - Refitting ). - the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ).

Unclip the air inlet scoop (2) .

112658

Remove the Protection and Switching Unit cover mounting bolts (3) .

114855

Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ).

19A-36

COOLING SYSTEM Water pump: Removal - Refitting


M9R, and 700

19A

102504

102365

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, Cooling 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 it forwards. Fit the (Mot. 1390) on two pads. Undo - the right-hand suspended mounting support mounting bolts, - the upper engine tie-bar mounting bolts. Remove the upper engine tie-bar.

19A-37

COOLING SYSTEM Water pump: Removal - Refitting


M9R, and 700

19A

II - OPERATION FOR REMOVAL OF PART CONCERNED

114858

Remove: - the water pump pulley mounting bolts (11) , - the water pump pulley (12) .
114863

At the same time, turn the (Mot. 1390) forwards, lifting the right-hand suspended engine mounting (9) and bring the compressor pulley (10) level.

19A-38

COOLING SYSTEM Water pump: Removal - Refitting


M9R, and 700

19A

Tighten to torque and in order the water pump mounting bolts ( 25 Nm ) . Tighten to torque the water pump pulley mounting bolts ( 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 (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting ). - the front end panel. - the front end panel mounting bolts, Tighten to torque: - the front end panel upper mounting bolts ( 21 Nm ) , - the front end panel lower mounting bolts ( 44 Nm ) . Clip: - the bonnet opening cable, - the air inlet scoop. Refit the clips.

114863

Remove: - the water pump mounting bolts, - the water pump (13) .

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED The water pump seal must be replaced.

Connect the screen washer pipes. Refit: - the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ), - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting ) - the rear suspended engine mounting (see 19D, Engine mounting, Rear suspended engine mounting: 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 ).

WARNING Clean the pump shaft cooling hole on the cylinder block. Apply soapy water to the seal before refitting the water pump. Refit the water pump. Check that the water pump is supported by the cylinder block before tightening the bolts.

19A-39

COOLING SYSTEM Plenum chamber: Removal - Refitting


M9R, and 700 Special tooling required Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Pliers for small hose clips Remote operation clip pliers for cooling system hose clips Cooling circuit lling and diagnostic tool

19A

REMOVAL
I - REMOVAL PREPARATION OPERATION Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Remove the battery (see 80A, Battery, Battery: Removal - Refitting ).

Mot. 1202-02 Mot. 1448

Mot. 1700

Tightening torquesm coolant outlet unit mounting bolts on the cylinder head battery tray mounting bolts wiring harness mounting nut 11 Nm

21 Nm 8 Nm

WARNING When carrying out a repair that requires a complete change, it is essential to ush the circuit with clean water, blast compressed air through the circuit to drive out the water, ll and bleed the circuit and then measure the effective protection. The parameters to be observed are: - protection down to -25C 2 for cold and temperate countries, - protection up to -40C 2 for countries with extremely cold climates.

112659

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 - terminal. Remove the battery tray. Drain the cooling system via the radiator bottom hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) (see 19A, Cooling, Cooling system: Draining - Filling).

IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot. During an operation under the bonnet, be aware that one (or several) of the radiator cooling fan(s) may operate unexpectedly. Do not open the bleed screw(s) with the engine running.

19A-40

COOLING SYSTEM Plenum chamber: Removal - Refitting


M9R, and 700

19A

114934

113291

Disconnect the coolant temperature sensor connector (5) . II - OPERATION FOR REMOVAL OF PART CONCERNED

Remove: - the coolant outlet unit mounting bolts, - the coolant outlet unit.

REFITTING
I - REFITTING PREPARATION OPERATION replace the seal of the coolant outlet unit. WARNING The seal faces must be clean, dry and free from grease (avoid nger marks). II - REFITTING PART CONCERNED Remove:
113293

- the coolant outlet unit. - the coolant outlet unit mounting bolts,

Remove the cooling hose clips using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) on the coolant outlet unit. Disconnect the cooling hoses from the coolant outlet unit. Unpick the wiring harness on the coolant outlet unit.

19A-41

COOLING SYSTEM Plenum chamber: Removal - Refitting


M9R, and 700

19A

113291

Tighten to torque and in order the coolant outlet unit 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 outlet 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: Removal - Refitting ). Fill the cooling system using the (Mot. 1700) (see 19A, Cooling, Cooling system: Draining - Refilling ).

19A-42

EXHAUST General information


Special tooling required F4R, and 776 Mot. 1199-01 35/50 mm diameter and 50/95 mm diameter exhaust pipe cutting tool. Complete assembly in kit.

19B

The whole exhaust pipe is made of stainless steel. The catalytic converter reaches high temperatures; do not park the vehicle close to flammable materials.

WARNING Any damaged heat shields must be replaced. The sealing between the exhaust manifold and the catalytic converter must be perfect. All seals removed must be replaced. Take care not to damage the catalytic converter during removal and retting. 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 exhaust 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 the area to be cut (see 19B, Exhaust, General information on exhausts ).
109580

109581

Before cutting the pipe between the catalytic converter and the expansion chamber, remove the protective plate.

19B-1

EXHAUST General information


Cut zone 1

19B
D P1 P2

80 mm

101504

100649

Cut zone 2

Before 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

101503 102118

Position the tool on the pipe. Tighten the two bolts on the cutting tool so that it grips the exhaust pipe. Turn the cutting tool with the handle while gripping the pipe. As the cut is made, continue to tighten the two bolts of the tool (do not overtighten the tool against the pipe, to prevent deformation during the cutting operation).

19B-2

EXHAUST General information


4 - Special notes on the replacement part Cut zone 1

19B

60 mm

101960

WARNING When replacing the middle section of the exhaust pipe (pipe on diesel version, expansion chamber on petrol versions), the replacement part needs to be shortened by 60 mm .
101501

Cut zone 2

5 - Fitting the After-Sales sleeve Apply exhaust pipe mastic inside the sleeve. To prevent any exhaust leaks, position the sleeve correctly on both lugs. Place the sleeve on the worn section of the pipe. Adjust the clip diameter by tightening slightly.

101500

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 .
95478

Place the sleeve end on the worn section of the pipe. Adjust the sleeve diameter by tightening gently.

19B-3

EXHAUST General information

19B

WARNING Do not reuse a used bracket.

WARNING Do not reuse an old sleeve. The sleeve tightening nuts and bolts must be positioned so that they cannot come into contact with the underbody. Any damaged heat shields must be replaced. Tighten to torque the nut (1) on the exhaust sleeve (25 Nm) . When tightening to torque, a click indicates that the torque of (25 Nm) has been reached. Check that: - there is no contact with the underbody, - the presence and correct positioning of all the exhaust pipe heat shields.

19B-4

EXHAUST Pipe assembly


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776 (1) K4J, and 730 or 732 (2) Cut zone 1 Cut zone 2

19B

K4M, and 760 or 761

112063

112062

19B-5

EXHAUST Pipe assembly


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776 (1) (2) Cut zone 1 Cut zone 2 (1) (2) Cut zone 1 Cut zone 2

19B

F4R, and 770 or 771 or 776

112061

19B-6

EXHAUST Pipe assembly


K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 (1) K9K, and 722 (2) Cut zone 1 Cut zone 2

19B

K9K, and 728 or 729 or 732

112060

112059

19B-7

EXHAUST Pipe assembly


K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 (1) (2) Cut zone 1 Cut zone 2 (1) (2) Cut zone 1 Cut zone 2

19B

F9Q, and 800 or 808

F9Q, and 804

2 2

112059

112058

19B-8

EXHAUST Pipe assembly


K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 (1) (2) Cut zone 1 Cut zone 2

19B

19B-9

EXHAUST Catalytic pre-converter: Removal - Refitting


F4R, and 776

19B

Tightening torquesm upstream stay mounting bolts (on the engine) catalytic converter mounting bolt (on the upstream stay) upper bracket mounting bolt (on the exhaust manifold) upper bracket mounting bolt (on the catalytic converter) catalytic converter nuts (on the turbocharger) oxygen sensors exhaust ange studs 38 Nm

2
8.5 Nm

6
8.5 Nm

8.5 Nm

3
40 Nm

5
34 Nm 8.5 Nm Disconnect the oxygen sensor connectors (2) . Remove:

4
21926

Remove the engine in order to remove the catalytic pre-converter (see 10A, Engine and peripherals, Engine - gearbox ).

- the upper bracket (3) and upstream stays (4) , - the catalytic converter/gearbox stay mounting (5) , - the catalytic converter mounting nuts, (6) on the turbocharger, - the catalytic converter. Remove the oxygen sensor on the workbench.

REMOVAL

REFITTING
Refit the oxygen sensors. WARNING

Be sure to replace all the exhaust ange and turbocharger sealing joints. Tighten to torque the upstream stay mounting bolts (on the engine) ( 38 Nm ) . Pretighten in order: - the upper bracket mounting bolts, - the nuts securing the catalytic converter to the turbocharger,
106246

- the upstream catalytic converter stay mounting bolt. Tighten to torque and in order: - the catalytic converter mounting bolt (on the upstream stay) ( 8.5 Nm ) ,

Remove: - the heat shield mountings (1) , - the heat shield.

19B-10

EXHAUST Catalytic pre-converter: Removal - Refitting


F4R, and 776 - the upper bracket mounting bolt (on the exhaust manifold) ( 8.5 Nm ) , - the upper bracket mounting bolt (on the catalytic converter) ( 8.5 Nm ) , - the catalytic converter nuts (on the turbocharger) ( 40 Nm ) , - the oxygen sensors ( 34 Nm ) , - the exhaust flange studs ( 8.5 Nm ) . Proceed in the reverse order to removal.

19B

19B-11

EXHAUST Catalytic pre-converter: Removal - Refitting


F9Q, and 804 - the exhaust mounting bolts, Tightening torquesm connector clip between the turbocharger and the catalytic pre-converter catalytic pre-converter upstream stay mounting nuts on the engine catalytic pre-converter upstream stay mounting nuts on the catalytic pre-converter catalytic pre-converter gearbox-side downstream stay mounting bolts on the engine catalytic pre-converter gearbox-side downstream stay mounting bolts on the catalytic pre-converter catalytic pre-converter timing-end downstream stay mounting bolts on the engine catalytic pre-converter timing-end downstream stay mounting nuts on the catalytic pre-converter catalytic pre-converter outlet exhaust ange studs exhaust ange nuts battery cover mounting bolts Remove: - the engine covers, - the battery, starting with the negative terminal, - the upper engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ). Remove: - the engine undertray, 20 Nm

19B

- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal Refitting ). - the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ).

30 Nm

30 Nm

50 Nm

50 Nm

50 Nm
111864

Remove: 30 Nm - the catalytic pre-converter lower stay mounting bolts (1) - the catalytic pre-converter lower stay.

7 Nm

21 Nm 4 Nm

19B-12

EXHAUST Catalytic pre-converter: Removal - Refitting


F9Q, and 804

19B

3 2

111862

Remove: - the catalytic pre-converter upper stay mounting bolts (2) , - the catalytic pre-converter upper stay, - the turbocharger and catalytic pre-converter mounting clip bolt (3) , - the catalytic pre-converter.

19B-13

EXHAUST Catalytic pre-converter: Removal - Refitting


F9Q, and 804

19B

REFITTING

and the catalytic pre-converter ( 20 Nm ) , - the catalytic pre-converter upstream stay mounting nuts on the engine ( 30 Nm ) , - the catalytic pre-converter upstream stay mounting nuts on the catalytic pre-converter ( 30 Nm ) , - the catalytic pre-converter gearbox-side downstream stay mounting bolts on the engine ( 50 Nm ) , - the catalytic pre-converter gearbox-side downstream stay mounting bolts on the catalytic pre-converter ( 50 Nm ) , - the catalytic pre-converter timing-end downstream stay mounting bolts on the engine ( 50 Nm ) , - the catalytic pre-converter timing-end downstream stay mounting nuts on the catalytic preconverter ( 30 Nm ) .

WARNING Always replace: - the catalytic converter seal, - the connector clip between the turbocharger and the catalytic pre-converter. On the workbench, refit the gearbox-side downstream stay to the catalytic pre-converter. Tighten the gearbox-side downstream stay mounting bolts on the catalytic pre-converter so that they make contact. Fit the catalytic pre-converter to the engine. Tighten the gearbox-side downstream stay mounting bolts on the engine so that they make contact. Refit: - the connector clip between the turbocharger and the catalytic pre-converter, - the catalytic pre-converter upstream stay. Pretighten in order: - the catalytic pre-converter upstream stay mounting nuts on the engine, - the catalytic pre-converter upstream stay mounting nuts on the catalytic pre-converter, Loosen then tighten in order and until they make contact: - the catalytic pre-converter gearbox-side downstream stay mounting bolts on the engine, - the catalytic pre-converter gearbox-side downstream stay mounting bolts on the catalytic pre-converter. Refit the catalytic pre-converter downstream stay on the timing end. Pretighten in order: - the catalytic pre-converter timing-end downstream stay mounting bolts on the engine, - the catalytic pre-converter timing-end downstream stay mounting nuts on the catalytic pre-converter, - the connector clip between the turbocharger and the catalytic pre-converter.

Note: Make sure there is no contact between the catalytic pre-converter and the turbocharger oil return pipe. Tighten to torque: - the catalytic pre-converter outlet exhaust flange 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 underbody.

WARNING Any damaged heat shields must be replaced. Connect the battery, starting with the positive terminal.

WARNING carry out the necessary programming (see 80A, Battery: Removal - Retting ).

Tighten to torque: - the connector clip between the turbocharger

tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19B-14

EXHAUST Catalytic converter: Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761 Special tooling required Mot. 1495-01 22 mm socket for removing/retting oxygen sensors

19B

Tightening torquesm oxygen sensor exhaust bracket studs exhaust bracket nuts) battery cover mounting bolts 45 Nm 7 Nm 21 Nm

1
4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the engine undertray. F4R, and 770 or 771 K4J, and 730 or 732 K4M, and 760 or 761 Remove the downstream oxygen sensor. Remove: - the exhaust bracket mounting nuts (1) , - the catalytic converter.
101793

Cut the exhaust pipe (see 19B, Exhausts, General information ).

19B-15

EXHAUST Catalytic converter: Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

19B

REFITTING

WARNING Do not reuse an old sleeve. The sleeve tightening nuts and bolts must be positioned so that they cannot come into contact with the underbody. Any damaged heat shields must be replaced. 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 exhaust bracket studs ( 7 Nm ) . Fit: - the catalytic converter, - the sleeve (see 19B, Exhausts, General information ). Proceed in the reverse order to removal.

WARNING Always replace: - the exhaust bracket seal. - all the disconnected air inlet plastic pipes. Tighten to torque the exhaust bracket nuts) ( 21 Nm ) Tighten the sleeve while easing the exhaust to ensure alignment. Reconnect the oxygen sensor. Make sure that all the exhaust pipe heat shields are in place and properly secured. Refit the engine undertray. Make sure that there is no contact with the underbody. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19B-16

EXHAUST Catalytic converter: Removal - Refitting


F9Q, and 800 or 808

19B

Tightening torquesm nuts mounting the catalytic converter onto the turbocharger catalytic converter stay nut (timing end) catalytic converter stay mounting bolt (timing end) catalytic converter stay mounting nut (ywheel end) exhaust bracket studs (at the catalytic converter outlet) exhaust bracket nuts (at the catalytic converter outlet) exhaust pipe support mounting bolt (on the body) battery cover mounting bolts wheel bolts 30 Nm

30 Nm 44 Nm

21 Nm

7 Nm

101118

21 Nm

Remove the nuts (1) from the exhaust bracket (at the catalytic converter outlet). Note: Mark with a pen the position of the exhaust rubber mounting bush supports on the vehicle body.

21 Nm

4 Nm 110 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: - the front right-hand wheel, - the engine undertray.

102116

Remove the mounting bolt (2) from the exhaust pipe rubber mounting bush on the body.

19B-17

EXHAUST Catalytic converter: Removal - Refitting


F9Q, and 800 or 808

19B

102117

101120

Remove the (3) silencer rubber mounting bush bolt. Withdraw the exhaust pipe towards the rear of the vehicle.

Remove: - the catalytic converter stay mounting bolts (5) (timing end), - the catalytic converter stay (timing end).

102479

Remove the catalytic converter stay mounting bolts (4) (flywheel end).

102313

Remove the engine tie-bar (6) .

19B-18

EXHAUST Catalytic converter: Removal - Refitting


F9Q, and 800 or 808 Refitting the stay at the timing end

19B

101121

101120

Remove: - the engine lifting bracket, - the nuts (7) securing the catalytic converter to the turbocharger, - the catalytic converter from underneath the vehicle.

Tighten to torque and in order: - the catalytic converter stay nut (timing end) ( 30 Nm ) (8) , - the catalytic converter stay mounting bolt (timing end) ( 44 Nm ) (9) .

REFITTING

WARNING Do not reuse an old sleeve. The sleeve tightening nuts and bolts must be positioned so that they cannot come into contact with the underbody. Any damaged heat shields must be replaced. The order for fitting catalytic converter stays must be respected. WARNING The gaskets must always be replaced. Pretighten in order: - the catalytic converter stay mounting bolts (timing end), - the stay mounting bolts (flywheel end), - the catalytic converter nuts on the turbocharger, Tighten to torque the nuts mounting the catalytic converter onto the turbocharger ( 30 Nm ) .

19B-19

EXHAUST Catalytic converter: Removal - Refitting


F9Q, and 800 or 808 Refitting the stay at the timing end Tighten to torque:

19B

- the battery cover mounting bolts ( 4 Nm ) , - the wheel bolts ( 110 Nm ) .

10

102479

Tighten to torque and in order the catalytic converter stay mounting nut (flywheel end) ( 21 Nm ) (10) . Note: Make sure there is no contact between the catalytic conver ter and the turbocharger oil return pipe. Proceed in the reverse order to removal. Tighten to torque: - the exhaust bracket studs (at the catalytic converter outlet) ( 7 Nm ) . - the exhaust bracket nuts (at the catalytic converter outlet) ( 21 Nm ) , - the exhaust pipe support mounting bolt (on the body) ( 21 Nm ) . Refit the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting ). Make sure that all the exhaust pipe heat shields are in place and properly secured. Make sure that there is no contact with the underbody. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

19B-20

EXHAUST Catalytic converter: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19B

Tightening torquesm turbocharger outlet studs catalytic converter mounting nuts on the turbocharger upstream stay mounting bolts on the engine d ownstream stay mounting bolts on the gearbox upstream stay mounting bolt on the catalytic converter d ownstream stay mounting bolt on the catalytic converter bolt securing the exhaust pipe bracket onto the body catalytic converter outlet exhaust bracket studs exhaust bracket nuts ball joint bracket bolts with their springs battery cover mounting bolts 7 Nm 26 Nm

44 Nm 21 Nm

2 3

25 Nm

21 Nm Remove: - the exhaust pipe bracket mounting bolts (1) , 21 Nm

102076

- the catalytic converter stay mounting bolt (2) . Loosen the other stay mountings on the gearbox.

7 Nm

Remove the stay (3) .

21 Nm 21 Nm 4 Nm

REMOVAL
Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the engine undertray.

19B-21

EXHAUST Catalytic converter: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19B

102116

102077

Remove the mounting bolt (4) from the exhaust pipe rubber mounting bush on the body.

Remove: - the catalytic converter upstream stay mounting bolts, - the catalytic converter stay (6) , - the catalytic converter mounting nuts on the turbocharger (7) , - the catalytic converter.

Note: Mark with a pen the position of the exhaust rubber mounting bush supports on the vehicle body.

102117

Remove the mounting bolt (5) from the silencer rubber mounting bush. Withdraw the exhaust pipe towards the rear of the vehicle.

19B-22

EXHAUST Catalytic converter: Removal - Refitting


K9K, and 722 or 728 or 729 or 732

19B

REFITTING

- the exhaust bracket nuts ( 21 Nm ) .

WARNING Always replace: - the catalytic converter seal, - the turbocharger - catalytic converter bracket studs. Tighten to torque the turbocharger outlet studs ( 7 Nm ) . Refit the engine undertray. 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 converter, - the catalytic converter/turbocharger mounting nuts. Tighten to torque and in order - the catalytic converter mounting nuts on the turbocharger ( 26 Nm ) , - the upstream stay mounting bolts on the engine ( 44 Nm ) , - the downstream stay mounting bolts on the gearbox ( 21 Nm ) , - the upstream stay mounting bolt on the catalytic converter ( 25 Nm ) , - the downstream stay mounting bolt on the catalytic converter ( 21 Nm ) , - the bolt securing the exhaust pipe bracket onto the body ( 21 Nm ) , WARNING Any damaged heat shields must be replaced. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) . Make sure that there is no contact with the underbody. K9K, and 732 Tighten to torque the ball joint bracket bolts with their springs ( 21 Nm ) . Proceed in the reverse order to removal.

Note: Make sure there is no contact between the catalytic conver ter and the turbocharger oil return pipe.

K9K, and 722 or 728 or 729 Tighten to torque: - the catalytic converter outlet exhaust bracket studs ( 7 Nm ) ,

19B-23

EXHAUST Catalytic converter: Removal - Refitting


M9R, and 700

19B

REMOVAL
Equipment required roller-type stud removal tool safety belt I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery, Battery: Removal - Refitting ). Remove: studs on the turbocharger catalytic converter mounting clamp mounting bolts on the cylinder block catalytic converter mounting nuts on the turbocharger catalytic converter halfclamp mounting bolts stay mounting bolt on the catalytic converter stay mounting nuts on the cylinder block stay mounting nuts on the catalytic converter bolts of the ball-jointed bracket with springs silencer rubber mounting bush mounting bolt exhaust pipe rubber mounting bush mounting bolt 14.5 Nm 21 Nm - the engine protectors, - the scuttle panel grille (see MR 365 Bodywork, 55A, Exterior protection, Scuttle panel grille ), - the acoustic protection clips on the scuttle panel partition, 21 Nm - the acoustic protection.

Tightening torquesm

21 Nm 8 Nm 21 Nm 21 Nm 21 Nm 21 Nm 21 Nm Remove: - the nuts (1) mounting the catalytic converter to the turbocharger,

114986

IMPORTANT Wear protective gloves during all operations.

- the engine undertray.

19B-24

EXHAUST Catalytic converter: Removal - Refitting


M9R, and 700

19B

114771

114991

Remove: - the lower engine tie-bar (see 19D, Engine mounting, rear suspended engine mounting: Removal - Refitting ). - the catalytic converter stay mounting bolt (2) , - the catalytic converter stay mounting nuts (3) , - the nuts (4) mounting the stay on the cylinder block, - the catalytic converter stay, - the catalytic converter studs using a roller-type stud removal tool .

Remove the bolts from the ball-jointed bracket (5) with springs.

19B-25

EXHAUST Catalytic converter: Removal - Refitting


M9R, and 700

19B

II - OPERATION FOR REMOVAL OF PART CONCERNED

102116 114980

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 the lifting eye on the timing end.

102117

Note: Mark with a pen the position of the exhaust rubber mounting bush supports on the vehicle body. Remove: - the exhaust pipe rubber mounting bush mounting bolt (6) , - The silencer rubber mounting bush mounting bolt (7) . Detach the exhaust pipe.

19B-26

EXHAUST Catalytic converter: Removal - Refitting


M9R, and 700

19B

REFITTING
I - REFITTING PREPARATION OPERATION Remove the seal from the ball-jointed bracket. Remove the turbocharger studs using a roller-type stud 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 a roller-type stud removal tool . Tighten to torque the studs on the turbocharger ( 14.5 Nm ) . Fit the new catalytic converter mounting clamps onto the cylinder block.
114981

Remove: - the catalytic converter mounting clamp mounting bolts (10) , - the catalytic converter mounting clamps. Remove the safety belt . Move the engine towards the front of the vehicle.

Finger tighten the catalytic converter mounting clamp mounting bolts on the cylinder block until contact is made. Tighten to torque the catalytic converter mounting clamp mounting bolts on the cylinder block ( 21 Nm ) .

114843

Remove the catalytic converter.

19B-27

EXHAUST Catalytic converter: Removal - Refitting


M9R, and 700 II - REFITTING OPERATION FOR PART CONCERNED

19B

- the stay mounting bolt on the catalytic converter ( 8 Nm ) , - the stay mounting nuts on the cylinder block ( 21 Nm ) , - the stay mounting nuts on the catalytic converter ( 21 Nm ) . III - FINAL OPERATION Refit the lower engine tie-bar (see 19D, Engine mounting, Rear suspended engine mounting: Removal - Refitting ). Tighten to torque the lower engine tie-bar (see 19D, Engine mounting, Rear suspended engine mounting: Tightening torque ). Refit the new seal to the ball-jointed bracket. Fit the exhaust pipe.
114844

Refit: - the exhaust pipe rubber mounting bush mounting bolt, 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 mounting bolt ( 21 Nm ) , - the exhaust pipe rubber mounting bush mounting bolt ( 21 Nm ) . Refit: - the engine undertray, - the acoustic protection, - the acoustic protection clips on the scuttle panel partition, - the scuttle panel grille (see MR 365 Bodywork, 55A, Exterior protection, Scuttle panel grille ), - the engine protectors. Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Move the engine towards the front of the vehicle. Fit: - the new seal between the turbocharger and the catalytic converter, - the catalytic converter. Refit the catalytic converter onto the turbocharger. Fit: - the new catalytic converter nuts onto the turbocharger, - the new catalytic converter half-clamps. Refit: - the catalytic converter studs using a roller-type stud 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 the turbocharger ( 21 Nm ) , - the catalytic converter half-clamp mounting bolts ( 21 Nm ) ,

19B-28

EXHAUST Expansion chamber: Removal - Refitting


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

19B

REFITTING
Tightening torquesm bolts securing the rubber mounting bush support on the expansion chamber bolts securing the rubber mounting bush support on the body 8 Nm WARNING Cut the new expansion chamber pipe (see 19B, Exhaust, General Vehicle Information ). Fit: 21 Nm - the expansion chamber, - the sleeve (see 19B, Exhausts, General information ). Tighten to torque: - the bolts securing the rubber mounting bush support on the expansion chamber ( 8 Nm ) , - the bolts securing the rubber mounting bush support on the body ( 21 Nm ) . Tighten the sleeves, while easing the exhaust pipe to ensure the correct alignment of the pipe . Make sure that all the exhaust pipe heat shields are in place and properly secured. Make sure that there is no contact with the underbody. WARNING Do not reuse an old sleeve. The sleeve tightening nuts and bolts assembly must be positioned so that it cannot come into contact with the underbody.
101818

REMOVAL
Position the vehicle on a lift. Remove the engine undertray. Cut the exhaust pipe (see 19B, Exhausts, General Vehicle Information ).

Any damaged heat shields must be replaced.

Remove: - the bolts (1) securing the expansion chamber to the rubber mounting bush support, - the expansion chamber. Note: If the rubber mounting bushes are damaged, mark the position of the support on the bodywork, then replace the support / rubber mounting bush assembly .

19B-29

EXHAUST Silencer: Removal - Refitting


REFITTING
Tightening torquesm bolts securing the rubber mounting bush on the silencer bolts securing the rubber mounting bush support on the body 8 Nm Fit: - the silencer,

19B

- the sleeve (see 19B, Exhausts, General information ). 21 Nm Tighten to torque: - the bolts securing the rubber mounting bush on the silencer ( 8 Nm ) , - the bolts securing the rubber mounting bush support on the body ( 21 Nm ) . Tighten the sleeve, while easing in the exhaust pipe to ensure the correct alignment of the pipe. Make sure that all the exhaust pipe heat shields are in place and properly secured. Make sure that there is no contact with the underbody. WARNING Do not reuse an old sleeve. The sleeve tightening nut and bolts assembly must be positioned so that it cannot come into contact with the underbody. Any damaged heat shields must be replaced.

REMOVAL
Position the vehicle on a two-post lift. Cut the exhaust pipe (see 19B, Exhausts, General information ).

101817

Remove: - the silencer mounting bolts (1) on the rubber mounting bush support, - the the silencer. Note: If the rubber mounting bushes are damaged: - mark the position of the mounting on the vehicle body, - replace the support / rubber mounting bush tting assembly .

19B-30

EXHAUST Particle filter: Function


F9Q, and 804

19B

Equipment required diagnostic tool

The extent to which the particle filter is clogged depends on the user's driving style: - during an average trip (combined cycle and motorway of more than 15 minutes ), the particle filter automatically burns the particles without being noticed by the customer (apart from some white smoke): this is spontaneous regeneration , - if the operating temperature is not high enough to trigger spontaneous regeneration, clogging increases until it exceeds 35 g ; an acceleration request to trigger spontaneous regeneration is then sent to the driver via an instrument panel warning light; the same happens if several attempts to regenerate have failed. - if these conditions are still not met and clogging reaches 45 g (min) . Static regeneration , using diagnostic tool must be performed in the workshop ( SERVICE warning light comes on and the CHECK ANTIPOLLUTION message appears: (see 19B, Exhaust, Particle filter: Cleaning ).

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 circuit sealing), - Position the pressure pipes correctly. If the pipes are not positioned correctly, their flexible sections may be twisted which will create low points and this may result in the pipes rupturing when fluid freezes and expands.

IMPORTANT Do not park and run the engine in a place where combustible substances and materials such as grass or leaves can come into contact with the hot exhaust system.

II - OPERATING PRINCIPLE The particle filter, placed underbody on the catalytic pre-convertor outlet, limits the pollutant emissions by accumulating the unburnt particles from the exhaust fumes (loading or filtering phase), then these particles are eliminated by combustion (regeneration phase). Using sensors, the injection computer measures the temperature as well as the pressure of the exhaust fumes upstream and downstream of the particle filter. The injection computer continuously evaluates the level of clogging of the particle filter using the pressure difference upstream and downstream of the particle filter. When it is clogged, the two temperature values inform the injection computer that the temperature conditions are high enough (approximately 600C ) to trigger regeneration. This consists of burning the particles held in the particle filter: to do this, the injection switches to delayed injection mode and the fuel not burned in the combustion chambers burns the residues contained in the particle filter cells.

19B-31

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804

19B

Tightening torquesm rubber mounting bush support mounting nut on the particle lter exhaust bracket nuts between the connection hose and the catalytic pre-converter rubber mounting bush nuts on the sub-frame exhaust sleeve nut downstream pressure measurement tapping on its adapter connection clip bolt between the silencer and the particle lter exhaust ange nuts between the connection hose and the catalytic pre-converter nuts mounting the rubber mounting bush support onto the sub-frame 25 Nm

21 Nm

25 Nm

25 Nm 21 Nm

25 Nm

106673

Remove the downstream pressure pipe (1) from its adapter (2) bolted to the exhaust pipe. 21 Nm WARNING When the pressure measurement tapping is removed, the adapter must be held (2) with a lock wrench.

25 Nm

WARNING

REMOVAL
Position the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove the engine undertray. Cut the exhaust pipe after the particle filter (see 19B, Exhaust : repair precautions ) and (see 19B, Exhaust: General information ).

The pressure measurement circuit must never be opened except at the adapters on the exhaust pipe.

19B-32

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804

19B

111881

111885

Remove the heat shield (3) mounting clip then move it aside slightly Unpick the downstream pressure measurement tapping and also the downstream temperature sensor cabling from the heat shield. Pass the downstream pressure measurement tapping into the engine compartment whilst leaving the pressure sensor complete.

Disconnect the upstream and downstream temperature sensor offset connectors (6) . Unpick the upstream and downstream temperature sensor offset connectors (6) .

111885

Remove:
111882

Disconnect the particle filter pressure sensor connector (4) located in the engine compartment. Remove the retaining clip (5) from the cabling on the particle filter pressure sensor mounting.

- the bolt (7) securing the filter particle pressure sensor mounting located in the engine compartment. - the particle filter pressure sensor assembly (8) and its mounting.

19B-33

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804

19B

107038

Remove: - the nuts (9) on the exhaust flange between the connection 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 sensors from their adapters on the exhaust line (see 19B, Exhaust, Particle filter temperature sensor: Removal - Refitting ). - the upstream pressure measurement tapping at its adapter on the exhaust pipe (see 19B, Exhaust, Particle filter pressure sensor: Removal - Refitting ). - the connection hose (see 19B, Exhaust, Connection hose: Removal - Refitting ).

REFITTING
WARNING Always replace: - the seal between the hose and particle lter, - the seal between the hose and the catalytic preconverter, - any adapter on the exhaust pipe that has been loosened,

WARNING Always clean the bearing surfaces of the connection hose - par ticle lter anges thoroughly. With particle filter removed, refit: - the connection hose and its new seals (see 19B, Exhaust, Connection hose: Removal - Refitting ).

19B-34

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804 - the upstream and downstream temperature sensors on their adapters on the exhaust pipe (see 19B, Exhaust, Particle filter temperature sensors: Removal - Refitting ). - the upstream pressure measurement tapping at its adapter on the exhaust line (see 19B, Exhaust, Particle filter pressure sensor: Removal - Refitting ). - the rubber mounting bush on the particle filter. Torque tighten the rubber mounting bush support mounting nut on the particle filter ( 25 Nm ) . Place the pressure sensor and its mounting in the engine compartment before fitting the particle filter. Tighten to torque: - the exhaust bracket nuts between the connection hose and the catalytic pre-converter ( 21 Nm ) . - the rubber mounting bush nuts on the sub-frame ( 25 Nm ) . Fit the exhaust sleeve (see 19B, Exhaust : General Vehicle Information ) by applying sealing mastic for the exhaust. Tighten to torque the exhaust sleeve nut ( 25 Nm ) at the same time as making sure that the exhaust pipe is correctly aligned. WARNING When tting the particle lter, be sure to pass the downstream pressure measurement tapping behind the heat shield. Coat the downstream pressure measurement tapping threads with ANTI-SEIZE high temperature grease. WARNING Make sure that the grease does not ow beyond the threading. WARNING

19B

106673

All the adapters on the exhaust pipe (12) must be replaced.

19B-35

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804

19B

106672

Fit the rigid part of the downstream pressure measurement tapping then position it so that it is parallel ( 3 ) to the exhaust pipe longitudinal axis. Tighten to torque the downstream pressure measurement 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 silencer and the particle filter ( 25 Nm ) , - the exhaust flange nuts between the connection hose and the catalytic pre-converter ( 21 Nm ) , - the nuts mounting the rubber mounting bush support onto the sub-frame ( 25 Nm ) .

WARNING Make sure, after tightening the pressure measurement tappings, that this pressure measurement tapping has no low points (siphon) susceptible to water accumulation. To do this: - check that the rigid sections of the pressure pipes are correctly positioned in relation to the exhaust pipe longitudinal axis, - at the retaining clips, manipulate the pressure measurement tappings on the heat shield (turn the tapping in the clip so as to avoid the low points).

WARNING Any damaged heat shields must be replaced. Make sure that there is no contact with the underbody.

19B-36

EXHAUST Particle filter: Removal - Refitting


F9Q, and 804

19B

WARNING Connect the battery, starting with the positive terminal. carry out the necessary programming (see 80A, Battery: Removal - Retting ). Use the diagnostic tool to clear any faults which may be stored by the injection computer before restarting the engine. WARNING With the engine running, carry out a leak test and check, using a leak detector for 5 minutes , that there is no leak on the adapters on the exhaust pipe. REINITIALISING THE PARTICLE FILTER PARAMETERS Command RZ008: ADAPTATIVES AFTER REPLACEMENT OF THE PARTICLE FILTER

Note: This command is only carried out after replacing the particle lter. Command SC030 enables the parameters to be reset to 0 depending on the type of operation carried out. - PR391 : distance travelled since the particle filter was last replaced, - PR415 : distance travelled since the last regeneration - PR412 : time since the last regeneration, - PR383 : mass of soot in the particle filter. Once the command has finished, check that the parameters are at 0, so that the computer establishes a new regeneration strategy when driving and can signal the system faults. After repairing: Repeat the conformity check from the start.

19B-37

EXHAUST Particle filter pressure sensor: Removal - Refitting


F9Q, and 804

19B
21 Nm

Tightening torquesm upstream pressure measurement tapping on its union bolted onto the exhaust pipe

C B

107038

(A) Particle filter pressure sensor. (B) Upstream pressure measurement tapping end piece. (C) Downstream pressure measurement tapping end piece.

REMOVAL
Remove the particle filter (see 19B, Exhaust, Particle filter: Removal and Refitting ).

19B-38

EXHAUST Particle filter pressure sensor: Removal - Refitting


F9Q, and 804

19B
5

3 2 6 4

106670

111885

Remove the upstream pressure pipe (1) from its intermediary adapter (2) bolted to the exhaust pipe. WARNING When removing the pressure measurement tapping (1) from its adapter it is essential to open the adapter (2) with a lock wrench.

Remove: - the mounting nut (3) from the particle filter pressure sensor mounting (4) , - the particle filter pressure sensor: WARNING Never separate the pressure measurement tappings (5) from the particle lter pressure sensor (6) ; replace the sensor - pipes - end pieces assembly if necessary, this is supplied assembled by the Parts Department (see Particle lter : repair precautions, Safety instructions ).

WARNING The pressure measurement circuit must never be opened except at the level of the adapters on the exhaust pipe.

19B-39

EXHAUST Particle filter pressure sensor: Removal - Refitting


F9Q, and 804

19B

REFITTING

106673

WARNING Each exhaust pipe intermediary adapter (7) that is removed must be replaced. Coat the upstream pressure measurement tapping threads with ANTI-SEIZE high temperature grease. WARNING Make sure that the grease does not ow beyond the threading.

19B-40

EXHAUST Particle filter pressure sensor: Removal - Refitting


F9Q, and 804

19B

106672

Fit the rigid part of the upstream pressure measurement tapping then position it so that it is parallel ( 3 ) with the exhaust pipe longitudinal axis. Tighten to torque the upstream pressure measurement tapping on its union bolted onto the exhaust pipe ( 21 Nm ) . Refit the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ). WARNING Make sure, after tightening the pressure measurement tappings, that this pressure measurement line assembly has no low points (siphon) susceptible to water accumulation. T do this: o - check that the rigid sections of the pressure pipes are correctly positioned in relation to the exhaust pipe longitudinal axis, - at the retaining clips, manipulate the pressure measurement tappings on the heat shield (turn the tapping in the clip so as to avoid the low points). Use the diagnostic tool to clear any faults which may

be stored by the injection computer before restarting the engine.

19B-41

EXHAUST
Particle filter temperature sensors: Removal - Refitting
F9Q, and 804

19B
44 Nm 30 Nm

Tightening torquesm Equipment required diagnostic tool adapter, if it has been replaced downstream particle lter temperature sensor 44 Nm 30 Nm

Tightening torquesm adapter, if it has been replaced upstream particle lter temperature sensor.

107038

(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, Particle filter: Removal - Refitting ).

19B-42

EXHAUST
Particle filter temperature sensors: Removal - Refitting
F9Q, and 804

19B

- the extent of wear on the wiring harness. Replace the wiring harness if necessary. Refit the particle filter (see 19B, Exhaust, Particle filter: 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 negative terminal. Remove the engine undertray.

106671

Remove the upstream particle filter temperature sensor (1) from its adapter (2) bolted onto the exhaust pipe.

WARNING When the upstream particle lter temperature sensor (1) is removed, the adapter must be held (2) with a lock-wrench.

2 - Refitting

WARNING Always replace any adapter (2) that has been removed from the exhaust pipe. Tighten to torque the adapter, if it has been replaced ( 44 Nm ) . Coat the threads on the upstream particle filter temperature sensor with ANTI-SEIZE high temperature grease.

111882

Disconnect the downstream particle filter temperature sensor offset connector (3) .

WARNING Make sure that the grease does not ow beyond the threading. Tighten to torque the upstream particle filter temperature sensor. ( 30 Nm ) . Check that: - that there is no contact with the wiring harness,

19B-43

EXHAUST
Particle filter temperature sensors: Removal - Refitting
F9Q, and 804 2 - Refitting

19B

WARNING Always replace any adapter (3) that has been removed from the exhaust pipe. Tighten to torque the adapter, if it has been replaced ( 44 Nm ) . Coat the threads on the downstream particle filter temperature sensor with ANTI-SEIZE high temperature grease. WARNING Make sure that the grease does not ow beyond the threading. Tighten to torque the downstream particle filter temperature sensor ( 30 Nm ) .
111885

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 terminal WARNING Carry out the necessary programming (see section 80A, Battery: Removing - Retting ). Before restarting the engine, use the diagnostic tool to clear any faults stored by the injection computer.

Unpick the downstream particle filter temperature sensor offset connector (3) from its mounting.

106671

Remove the downstream particle filter temperature sensor (4) from its adapter (5) bolted onto the exhaust pipe.

WARNING When the downstream particle lter temperature sensor (4) is removed, the adapter must be held (5) with a lock wrench.

19B-44

EXHAUST Connecting hose: Removal - Refitting


F9Q, and 804

19B

Tightening torquesm exhaust ange nuts 21 Nm

- the upstream pressure measurement tapping at its adapter on the exhaust pipe (see 19B, Exhaust, Particle filter pressure sensor: Removal - Refitting ). Tighten to torque the exhaust flange nuts ( 21 Nm ) between the connection hose and the particle filter. Refit the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ).

REMOVAL
Remove: - the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ). - the upstream temperature sensor and its adapter on the exhaust pipe (see 19B, Exhaust, Particle filter temperature sensor: Removal - Refitting ). - the upstream pressure measurement tapping at its adapter on the exhaust pipe (see 19B, Exhaust, Particle filter pressure sensor: Removal - Refitting ). Remove: - the nuts for the exhaust flange between the connection hose and the particle filter, - the connection hose.

REFITTING

WARNING Always replace: - the ange seal between the connection hose and the catalytic pre-converter, - the ange seal between the connection hose and particle lter,

WARNING Always clean the bearing surfaces thoroughly on: - the hose connection anges for the catalytic pre-converter connection, - the ange between the connection hose and the particle lter, Refit: - the connection hose with new seals, - the upstream temperature sensor and its adapter on the exhaust pipe (see 19B, Exhaust, Particle filter temperature sensor: Removal - Refitting ).

19B-45

EXHAUST Particle filter: Cleaning


F9Q, and 804 PROCEDURE FOR FORCED REGENERATION OF THE PARTICLE FILTER USING THE CLIP DIAGNOSTIC TOOL Command SC017: REGENERATION OF THE PARTICLE FILTER Follow this procedure: - run command SC017 or VP040 ,

19B

- during regeneration, the engine speed will be held at 1500 rpm , and the engine noise changes (delayed injection), - the exhaust fumes rise in temperature and burn the soot retained in the particle filter,

Note: Only run this command under the following conditions: - fault DF308 Particle lter clogged , or DF312 Number of regenerations exceeded , or DF383 Particle lter regeneration impossible present, - soot weight in the particle lter greater than 45 g .

- the command lasts for approximately 30 minutes , - when the engine speed returns to idle speed the command has terminated, - check the quantity of soot contained in the particle filter PR383 < 10 . Note: Be prepared for strong odours and thick smoke during particle lter regeneration. Once forced regeneration of the particle filter is complete: - deal with the present faults, - clear the stored faults. Allow the engine to cool down. Drain the engine oil. Replace the oil filter.

IMPORTANT During the forced regeneration of the particle lter, the temperature in the exhaust pipe rises signicantly. T to carry out this procedure outside the worksry hop if possible or use an exhaust gas extractor approved for high temperatures.

WARNING Check the engine oil level before running the command to avoid any engine racing. The level should be between MIN and MAX on the dipstick. To run this command, select the specific commands mode on the Clip tool, and select command SC017 or VP040 . Note: If necessary, regeneration can be stopped by pressing the engine start button twice in succession.

Top up the oil. Note: The level should be between MIN and MAX on the dipstick.

19B-46

EXHAUST Particle filter: Cleaning


F9Q Special tooling required Mot. 1329 Mot. 1018 76 mm diameter oil lter removing tool Sump plug tool. Equipment required diagnostic tool kit for particle lter Note: Tightening torquesm engine drain plug rubber mounting bushes on the body rubber mounting bush on the connector pipe rubber mounting bush on the rear silencer 20 Nm 21 Nm 8 Nm 8 Nm IMPORTANT

19B

For the particle filter forced regeneration procedure, see MR 366 or MR 372 Fault finding, 13B, Diesel injection, Fault finding, Interpretation of commands, Particle filter regeneration . Note: If required, the forced regeneration procedure may be stopped by pressing the engine Start button twice in succession.

Be prepared for strong odours and thick smoke during particle lter forced 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.

Allow the engine to cool before draining the oil. PROCEDURE FOR PARTICLE FILTER FORCED REGENERATION USING THE CLIP DIAGNOSTIC TOOL Connect the diagnostic tool to the vehicle. IMPORTANT During forced regeneration of the particle lter, the temperature in the exhaust pipe rises signicantly. Be sure either to carry out the operation outside the workshop, or to use the kit for particle lter , approved for high temperatures, on the exhaust gas extractors in the workshop. 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 with the 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.

WARNING T prevent engine racing, check the engine oil o level using the dipstick before running the forced regeneration command. The engine oil level must be between the MIN and MAX marks on the dipstick.

19B-47

EXHAUST Particle filter: Cleaning


F9Q Rubber-lipped seal

19B

For the connector pipe and rear silencer rubber mounting bushes, tighten to torque: - the mounting bolt of the rubber mounting bushes on the body ( 21 Nm ) , - the mounting bolts of the rubber mounting bush on the connector pipe ( 8 Nm ) , - the mounting bolts of the rubber mounting bush on the rear silencer ( 8 Nm ) ,

113765

Refit the drain plug with its new seal (no fitting direction). 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. Note: The engine oil level must be between the MIN and MAX marks on the dipstick. After any particle filter forced regeneration operation, always replace: - the particle filter rubber mounting bush on the axle sub-frame (see MR 364 or MR 370, 19B, Exhaust, Particle filter: Removal - Refitting ), - the particle filter pressure sensor with its upstream and downstream pressure measurement tappings (see MR 364 or MR 370, 19B, Exhaust, Particle filter pressure sensor : Removal - Refitting ), - the exhaust connector pipe rubber mounting bush on the body, - the rear silencer rubber mounting bush on the body.

19B-48

RESERVOIR Draining the fuel tank


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776 Special tooling required Mot. 1311-08 Union for measuring fuel pressure DRAINING THE FUEL TANK

19C

K4J, and 730 or 732 F4R, and 770 or 771 or 776

WARNING During this operation, it is essential to: - refrain from smoking or bringing red hot objects close to the work area, - guard against petrol splashes caused by the residual pressure in the pipes, - protect sensitive areas from fuel outow.

2 3

WARNING The ignition must be switched off during this operation.

1
101496

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 container to the T -union outlet.

19C-1

RESERVOIR Draining the fuel tank


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776

19C
4

K4M, and 760 or 761

102502

101803

Place the electrical connector (4) to one side without disconnecting it.

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 container to the T -union outlet.

Remove the protection and switching unit cover.

102503

Disconnect the brown connector (6) from the Protection and Switching Unit.

19C-2

RESERVOIR Draining the fuel tank


K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776

19C

12

102501

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) . Note: It is also possible to use the pneumatic siphoning Pump tool for draining the fuel tank (see catalogue entitled Equipment) , to be adapted on the union at T (Mot. 1311-08) .

19C-3

RESERVOIR Draining 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

Equipment required petrol or diesel tank drain pneumatic siphoning pump

IMPORTANT During this operation: - refrain from smoking or bringing red hot objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow. DRAINING THE FUEL TANK
102460

Remove the carpet retaining clip. Take out the carpet.

99641

Disconnect the battery, starting with the negative terminal. Note: Since diesel vehicles are not tted with an electrical fuel pump, the petrol or diesel tank drain pneumatic siphoning pump tool must be used to drain the tank. Lift up the cushion from the rear bench seat (see Workshop repair Manual 365 Bodywork, 76A, Rear seat mountings and runners, Complete seat base ).

102461

Remove: - the closure panel mounting bolts (1) , - the closure panel, - the inspection flap blanking cover (2) .

19C-4

RESERVOIR Draining 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

102462

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 diesel tank drain pneumatic siphoning pump to the diesel fuel supply quick-release union, and the siphoning pump's backflow pipe to the container (5) . Run the petrol or diesel tank drain pneumatic siphoning 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

19C-5

RESERVOIR Fuel tank: Description


F4R or K4J or K4M

19C
1

11

9 12 2 10

13 5 2 6

102487

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Description Tank Mounting holes Filler neck Neck mounting clips Brake pipe retaining clips Fuel supply pipe Petrol vapour supply pipe Petrol vapour absorber supply pipe (from the tank) Fresh air vent Petrol vapour absorber Overll prevention valve and leak prevention valve in case of vehicle roll-over Anti-backow pipe (degassing - lling) Petrol suction assembly

19C-6

RESERVOIR Fuel tank: Description


F4R or K4J or K4M

19C
5

3 4

2 1

10

13036

No. 1 2

Description Connection to petrol vapour absorber Overll prevention ball

19C-7

RESERVOIR Fuel tank: Description


F4R or K4J or K4M No. 3 4 5 6 7 8 9 10 Description Filling anti-backow pipe Restriction valve Excess pressure/underpressure safety valve Air outlet hole during lling Volume of air allowing fuel expansion Fuel inlet for lling Usable fuel volume Overll prevention valve and vehicle roll-over leak prevention valve

19C

ROLE OF THE FILLER NECK AND VALVES 1 - Overpressure/underpressure safety valves If the petrol vapour recirculation circuit is blocked, this valve prevents the fuel tank being subjected to excess pressure (the tank expands) or underpressure (as fuel is used, the tank collapses). 2 - Restriction valve This valve prevents diesel fuel or leaded petrol pump nozzles 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 ball rests on its seat, retaining a specific volume of air in the tank. When the vehicle is moving, the ball leaves its seat, enabling a connection between the tank and the petrol vapour absorber. When the tank is full, a sufficient volume of air to allow the fuel contained within it to expand must remain in the tank, but not so much as to make the tank burst. The vehicle roll-over leak prevention valve prevents the fuel tank from emptying via the pipe to the petrol vapour 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 petrol vapour release or backflow of petrol), - a leak-tight cap.

19C-8

RESERVOIR Fuel tank: Description


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

19C

2 4

1 2

9 10

7 5 2 6
110881

No. 1 2 3 4 5 6 7 8 9 10

Description Tank Mounting holes Filler neck Neck mounting clips Brake pipe retaining clips Fuel supply pipe Fuel return pipe Drying the reservoir and leak prevention valve in case of vehicle roll-over Anti-backow pipe (degassing - lling) Diesel suction assembly

19C-9

RESERVOIR Fuel tank: Description


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732

19C

2 8 1

13036-1

No. 1 2

Description Fresh air vent Overll prevention ball

19C-10

RESERVOIR Fuel tank: Description


F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 No. 3 4 5 6 7 8 Description Filling anti-backow pipe Air outlet hole during lling Volume of air allowing fuel expansion Fuel inlet for lling Usable fuel volume Drying the reservoir and leak prevention valve in case of vehicle roll-over

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 ball rests on its seat, retaining a specific volume of air in the tank. 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 allow the diesel fuel contained within it to expand must remain in the tank, but not so much as to make the tank explode. The vehicle roll-over leak prevention valve prevents the fuel tank from emptying via the air pipe. 2 - Filler neck The filler neck for unleaded fuel has a leaktight cap.

19C-11

RESERVOIR Fuel tank: Removal - Refitting

19C

Equipment required component jack

F4R or K4J or K4M Remove the petrol vapour absorber (see 14A, Antipollution, Petrol vapour absorber ). Unclip the petrol vapour absorber pipes.

Tightening torquesm wheel bolt fuel tank mounting battery cover mounting bolts 110 Nm 21 Nm 4 Nm

Disconnect the connectors on the Pump-SenderFilter assembly (see 19C, Fuel tank, Pump-Sender-Filter ).

IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red-hot objects near the working area, - watch out for fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.

REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining the fuel tank ). Remove the pump-sender-filter assembly (see 19C, Fuel tank, Pump-sender-filter ) for petrol engines 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 negative terminal. Remove: - the engine undertray, - the nuts mounting the exhaust clamp on the manifold, - the bolt mounting the expansion chamber on the body, - the bolts connecting the silentbloc mounting to the silencer, - the exhaust pipe from the sub-frame and the rear axle. Disconnect the headlight height adjustment sensor wiring (depending on vehicle equipment level). Unclip the headlight height adjustment sensor linkage (depending on vehicle equipment level).

102465

Remove: - the mounting bolts (1) from the fuel tank and the heat shield, - the heat shield mounting clips (2) , - the heat shield (3) .

19C-12

RESERVOIR Fuel tank: Removal - Refitting

19C

102467

102466

Remove mounting clips (4) from the brake and fuel pipes. Unclip: - the fuel pipe unions at the catalytic converter, - the clips from the fuel pipes.

Position the component jack under the tank. Remove the fuel tank mounting bolts (6) . Lower the fuel tank.

5
102468

102459

Remove the tank by turning it around the exhaust pipe. Take care not to damage the brake pipes or the parking brake cable.

Remove fuel tank filler neck hose connection clips (5) . Move the hoses to one side.

19C-13

RESERVOIR Fuel tank: Removal - Refitting


REFITTING
Reshape the heat shield. Take care not to bring the heat shield into contact with the fuel tank. The tank hose securing clips must always be replaced. 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 engines or the sender (see 19C, Fuel tank, Sender ) for diesel engines. Connect the battery, starting with the positive terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19C

19C-14

RESERVOIR Filler neck: Removal - Refitting

19C

Tightening torquesm battery cover mounting bolts 4 Nm

3
IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects near the working area, - watch out for fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow.

REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining the fuel tank ). Put the vehicle on a two-post lift. Disconnect the battery, starting with the negative terminal. Remove: - the rear right-hand wheel, - the rear right-hand wheel arch liner.
102469

Remove the filler neck mounting bolts (3) .

104559

Remove: - the filler neck mounting bolts (4) ,

1
102468

- 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 terminal. WARNING Carry out the necessary programming (see 80A, Battery: Removal - Retting ).

Disconnect the anti-backflow pipe (1) . Remove filler pipe clips (2) .

19C-15

RESERVOIR Filler neck: Removal - Refitting


Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19C

19C-16

RESERVOIR Sender unit: Removal - Refitting


F9Q or K9K or M9R Special tooling required Mot. 1397 Universal spanner for removing fuel sender nut

19C

Tightening torquesm battery cover mounting bolts 4 Nm

IMPORTANT During this operation: - refrain from smoking or bringing red hot objects close to the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow. Remove: - the closure panel mounting bolts (1) ,
102461

REMOVAL
Disconnect the battery, starting with the negative terminal. Lift up the rear bench seat base (see MR 365 Bodywork, 76A, Rear seat runners and frames, Complete seat base ). Remove the carpet retaining clip. Move the carpet to one side.

- the closure panel, - the blanking cover (2) on the inspection flap.

19C-17

RESERVOIR Sender unit: Removal - Refitting


F9Q or K9K or M9R

19C

104546

104547

Disconnect: - electrical connectors (3) , - quick-release union(s) (4) . Prepare for fuel outflow. Fit the correct blanking plugs into the unions (see MR 364 Mgane, 13B, Injection: Cleanliness guidelines ).

Remove the nut from the sender using tool (Mot. 1397) (5) . Remove the sender unit, being careful with the float. WARNING Ret the sender nut as soon as the sender has been removed to prevent any deformation of the fuel tank.

19C-18

RESERVOIR Sender unit: Removal - Refitting


F9Q or K9K or M9R

19C

REFITTING

102470

Replace the O-ring seal. Refit the sender unit by aligning mark (6) on the sender with mark (7) on the tank. Position nut (9) . Tighten the nut (9) until mark (8) on the nut is aligned with mark (7) on the tank and mark (6) on the sender. Proceed in the reverse order to removal. Connect the battery starting with the positive terminal (see MR 364 Mgane, 80A, Battery: Removal Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19C-19

RESERVOIR Pump-sender unit-filter: Removal - Refitting


K4M F4R K4J Special tooling required Mot. 1397 Universal spanner for removing fuel sender nut

19C

Tightening torquesm battery cover mounting bolts 4 Nm

2
IMPORTANT During this operation: - refrain from smoking or bringing red hot objects close to the working area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outow. Remove: - the closure panel mounting bolts (1) ,
102461

REMOVAL
Disconnect the battery, starting with the negative terminal. Lift up the rear bench seat base (see MR 365 Bodywork, 76A, Rear seat runners and frames, Complete seat base ). Remove the carpet retaining clip. Move the carpet to one side.

- the closure panel, - the blanking cover (2) on the inspection flap.

104546

Disconnect: - electrical connectors (3) , - quick-release union(s) (4) . Prepare for fuel outflow.

19C-20

RESERVOIR Pump-sender unit-filter: Removal - Refitting


K4M F4R K4J

19C

REFITTING

104547

Remove the nut from the pump/sender/filter assembly using tool (Mot. 1397) (5) . Remove the pump/sender/filter assembly, being careful not to damage the float. WARNING Ret the pump/sender/lter assembly nut as soon as the pump/sender/lter assembly has been removed to prevent any deformation of the fuel tank.

102470

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 aligned with mark (7) on the tank and mark (6) on the pump/sender/filter assembly. Proceed in the reverse order to removal. Connect the battery starting with the positive terminal (see MR 364 Mechanical systems, 80A, Battery: Removal - Refitting ). Tighten to torque the battery cover mounting bolts ( 4 Nm ) .

19C-21

RESERVOIR Petrol filter: General information


F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761

19C

102299

The fuel filter is located in the fuel tank; it is built into the pump-sender-filter assembly and cannot be removed.

WARNING The pump-sender-lter assembly must be replaced if one of the components is faulty. The filter is intended to have a long service life. Checking the fuel supply pressure and the pump delivery rate is the equivalent of running fault finding on the pump-sender-filter assembly.

19C-22

RESERVOIR Fuel level sensor: Checking


Checking the sender unit Capacity Resistance value between terminals A1 and B2 () 10 20 95 170 245 290 320 Height H (mm) 6mm

19C

Tank full Tank 3/4 full Tank 1/2 full Tank 1/4 full Spare Tank empty MEASURING HEIGHT H

upper stop 150 111 72 40 lower stop

Place the removed sender on a flat surface. H is the height measured between the float pin and the working plane. Note: All these values are given as a guide.

19C-23

ENGINE MOUNTING Suspended engine mounting


K4J, and 730 or 732 K4M, and 760, and JR5

19D
7 6 5

103235

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) 62 105 62 105 62 180 62

19D-1

ENGINE MOUNTING Suspended engine mounting


K9K, and 722 or 728

19D
10 9

4 8 7 6 5 1 2 3 7

103236

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) 62 105 62 105 62 62 21 62 180 62

19D-2

ENGINE MOUNTING Suspended engine mounting


F9Q, and 800 or 804 or 808

19D
12 11 10

5 3 4 8 2

103237

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) (9) 62 105 105 62 62 180 105 62 21 for M8 bolts 62 bolts (10) (11) (12) 62 180 62 for M10

19D-3

ENGINE MOUNTING Suspended engine mounting


K4M, and 761

19D
7 6 9 8

3 1 8 5 2

103274

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) 62 105 62 105 62 180 62 21 for M8 bolts 62 bolts (9) 62 for M10

19D-4

ENGINE MOUNTING Suspended engine mounting


F4R, and 770 or 771 or 776

19D
12 11 9 10

5 3 4 8 1 9

2 1
103275

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) 62 105 105 62 62 180 105 62 21 62 180 62

19D-5

ENGINE MOUNTING Suspended engine mounting


F4R, and 770 or 771 or 776

19D
11 9 12 10

5 3 13 4 8

1
103244

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) 62 105 105 62 62 180 105 62 21 62 180 62

19D-6

ENGINE MOUNTING Suspended engine mounting


K9K, and 729, and DP0

19D
7 9 8

4 5 6

3 1

1
110743

Tightening torques (in Nm) (1) (2) (3) (4) (5) (6) (7) (8) (9) 62 105 62 105 62 62 62 62 62

19D-7

ENGINE MOUNTING Suspended engine mounting


K9K, and 732

19D

113926

Tightening torques (in Nm)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

62 62 105 115 62 180 105 62 105 62 62

19D-8

ENGINE MOUNTING Suspended engine mounting: Tightening torque


K9K, and 732

19D

113926

No.

Description

Tightening torque (Nm)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Bolt mounting the lower engine tie-bar on the sub-frame Bolt mounting the lower engine tie-bar onto its support Bolt mounting the lower engine tie-bar onto its support Bolt mounting the upper engine tie-bar onto the bodywork Bolt mounting the upper engine tie-bar onto the engine Bolt mounting the right-hand suspended mounting support on the body Bolt mounting the right-hand suspended mounting support on the engine Bolt mounting the left-hand suspended mounting support onto the gearbox Bolt mounting the left-hand suspended mounting support on the body Left-hand rubber pad mounting nut on the gearbox mounting Left-hand rubber pad mounting bolts on the body mounting

105 180 62 105 115 62 62 62 62 62 105

19D-9

ENGINE MOUNTING Suspended engine mounting: Tightening torque


M9R, and 700

19D

114630

No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Description Bolt mounting the lower engine tie-bar on the sub-frame Bolt mounting the lower engine tie-bar onto its support Lower engine tie-bar support mounting bolt Bolt mounting the upper engine tie-bar onto the bodywork Bolt mounting the upper engine tie-bar onto the engine Bolt mounting the right-hand suspended mounting support on the body Bolt mounting the right-hand suspended mounting support on the engine Bolt mounting the left-hand suspended mounting support onto the gearbox Bolt mounting the left-hand suspended mounting support on the body Left-hand rubber pad mounting nut on the gearbox mounting Left-hand rubber pad mounting bolts on the body mounting

Tightening torque (Nm) 105 180 62 105 115 62 62 105 62 62 62

19D-10

ENGINE MOUNTING Suspended engine mounting: Tightening torque


B84 or C84, and F4R, and 774

19D

106075

No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Tightening torque (Nm) 62 105 105 62 62 180 105 62 62 21 105 180 62

19D-11

ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting
K9K, and 732 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps

19D

Tightening torquesm left-hand suspended mounting bolts on the gearbox left-hand suspended mounting bolts on the body left-hand rubber pad mounting bolts on the body mounting left-hand rubber pad mounting nut on the gearbox mounting 62 Nm

62 Nm

105 Nm
101822

62 Nm

Disconnect the engine management computer connectors (1) . Unclip:

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, 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 - Refitting ).

- 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.

102450

Position the (Mot. 1453) . Mark the position of the suspended mounting on the body.

19D-12

ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting
K9K, and 732 II - OPERATION FOR REMOVAL OF PART CONCERNED

19D

Tighten to torque the left-hand suspended mounting bolts on the body ( 62 Nm ) . Refit the left-hand rubber pad. Refit the left-hand rubber pad mounting nut onto the gearbox mounting and the left-hand rubber pad mounting bolts onto the body mounting. Tighten to torque: - the left-hand rubber pad mounting bolts on the body mounting ( 105 Nm ) , - the left-hand rubber pad mounting nut on the gearbox mounting ( 62 Nm ) . II - FINAL OPERATION Remove the (Mot. 1453) . Refit: - the battery tray with the engine management computer and its support, - the battery tray mounting bolts.
112655

Clip: - the battery negative terminal wiring harness, - the wiring harness onto the battery tray. Connect the engine management computer connectors. Refit: - the scuttle panel grille (see MR 365, 55A, Exterior protection, Scuttle panel grille ), - the engine undertray, Connect the battery (see 80A, Battery: Removal Refitting ).

Remove: - the left-hand rubber pad mounting nut (3) on the gearbox mounting, - the left-hand rubber pad mounting bolts (4) on the body mounting, - the rubber pad, - the bolts (5) mounting the left-hand suspended mounting on the body, - the left-hand suspended mounting on the body, - the bolts (6) mounting the left-hand suspended mounting 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 suspended mounting on the gearbox. Tighten to torque the left-hand suspended mounting bolts on the gearbox ( 62 Nm ) . Refit the left-hand suspended mounting on the body. Refit the bolts mounting the left-hand suspended mounting on the body,

19D-13

ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting
K9K, and 732 Special tooling required Mot. 1453 Multiple-adjusting engine mounting support with retaining straps

19D

Tightening torquesm bolts mounting the right-hand suspended mounting on the body bolts mounting the right-hand suspended mounting support on the engine upper engine tie-bar mounting bolt on the engine upper engine tie-bar mounting bolt on the body 62 Nm

62 Nm Position the (Mot. 1453) . 115 Nm

102450

Mark the position of the suspended mounting on the body. II - OPERATION FOR REMOVAL OF PART CONCERNED

105 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery: Removal - Refitting ). Remove the scuttle panel grille (see MR 365, Bodywork, 55A, Exterior protection, Scuttle panel grille ).

113927

Remove: - the upper engine tie-bar mounting bolt (2) on the engine, - the upper engine tie-bar mounting bolt (1) on the body, - the upper engine tie-bar. - the bolts (3) mounting the suspended mounting on the body,

19D-14

ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting
K9K, and 732 - the bolts (4) mounting the suspended mounting on the engine, - the suspended mounting.

19D

REFITTING
I - REFITTING OPERATION FOR PART CONCERNED Refit: - the right-hand suspended mounting support, - the bolts mounting the right-hand suspended mounting support on the body, - the bolts mounting the right-hand suspended mounting on the engine, - the upper engine tie-bar. - the upper engine tie-bar mounting bolt onto the body, - the upper engine tie-bar mounting bolt onto the engine, Tighten to torque: - the bolts mounting the right-hand suspended mounting on the body ( 62 Nm ) - the bolts mounting the right-hand suspended mounting support on the engine ( 62 Nm ) - the upper engine tie-bar mounting bolt on the engine ( 115 Nm ) - the upper engine tie-bar mounting bolt on the body ( 105 Nm ) II - FINAL OPERATION Remove the (Mot. 1453) Refit the scuttle panel grille (see MR 365, Bodywork, 55A, Exterior protection, Scuttle panel grille ). Connect the battery (see 80A, Battery: Removal Refitting).

19D-15

ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting
K9K, and 732

19D

REFITTING
Tightening torquesm I - REFITTING PREPARATION OPERATION bolt mounting the engine tie-bar on its support bolt mounting the engine tie-bar on the sub-frame 180 Nm Refit: - the bolt mounting the engine tie-bar on its support 105 Nm - the bolt mounting the engine tie-bar on the sub-frame Tighten to torque: - the bolt mounting the engine tie-bar on its support ( 180 Nm ) , - the bolt mounting the engine tie-bar on the subframe ( 105 Nm ) . I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery: Removal - Refitting ). Remove the engine undertray II - FINAL OPERATION Refit the engine undertray. Connect the battery (see 80A, Battery: Removal Refitting ).

REMOVAL

II - OPERATION FOR REMOVAL OF PART CONCERNED

112653

Remove: - the bolt mounting the engine tie-bar on the sub-frame (1) , - the bolt mounting the engine tie-bar on its support (2) .

19D-16

ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting
M9R, and 700

19D

Tightening torquesm bolt mounting the engine tie-bar on its support bolt mounting the engine tie-bar on the sub-frame 180 Nm

105 Nm

REMOVAL
I - REMOVAL PREPARATION OPERATION Place the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ). Disconnect the battery (see 80A, Battery: Removal - Refitting ). Remove the engine undertray.
114632

Remove the engine tie-bar. - by pushing it back (1) to detach it from its support, - by pivoting it (2) to the right.

II - OPERATION FOR REMOVAL OF PART CONCERNED

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-frame Tighten to torque: - the bolt mounting the engine tie-bar on its support ( 180 Nm ) , - the bolt mounting the engine tie-bar on the subframe ( 105 Nm ) . II - FINAL OPERATION Refit the engine undertray. Connect the battery (see 80A, Battery: Removal Refitting ).
114650

Remove: - the bolt mounting the engine tie-bar on the sub-frame, - the bolt mounting the engine tie-bar on its support.

19D-17

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