Mr364megane1 PDF

1 Engine and peripherals
10A ENGINE AND LOWER ENGINE ASSEMBLY
11A TOP AND FRONT OF ENGINE
12A FUEL MIXTURE
12B TURBOCHARGING
13A FUEL SUPPLY
13B DIESEL INJECTION
13C PREHEATING
14A ANTIPOLLUTION
16A STARTING - LOAD
17A IGNITION
17B PETROL INJECTION

X84, and B84 or C84 or G84 or S84
77 11 318 022 FEBRUARY 2003 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
Renault s.a.s. 2005

19A COOLING SYSTEM
19B EXHAUST
19C RESERVOIR
19D ENGINE MOUNTING
X84, and B84 or C84 or G84 or S84
77 11 318 022 FEBRUARY 2003 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
Renault s.a.s. 2005

Mgane II - Section 1ContentsPage
Mgane II - Section 1
Contents
Page
10A ENGINE AND LOWER ENGINE ASSEMBLY 11A TOP AND FRONT OF ENGINE
Engine identification 10A-1 Timing chain: Removal -

Refitting 11A-116
Engine oil: Draining -
Refilling 10A-2 Cylinder head gasket :
Removal - Refitting 11A-117
Oil consumption Check 10A-3
Tightening the cylinder head 11A-199
Oil filter: Removal - Refitting 10A-4
Cylinder head: Removal -
Exchanger: Removal - Refitting 11A-205
Refitting 10A-10
Oil pressure 10A-16
Oil pressure sensor:

12A FUEL MIXTURE
Oil level sensor: Removal - Specifications 12A-1

Refitting 10A-20
Air inlet 12A-11
Sump: Removal - Refitting 10A-21
Air resonator: Removal -
Oil pump: Removal - Refitting 12A-22
Refitting 10A-42
Air filter: Replacement 12A-23
Multifunction support:
Air filter: Removal - Refitting 12A-25
Air filter unit: Removal -
Engine/gearbox assembly:
Refitting 12A-26
Air flowmeter: Removal -
Engine speed and position
Refitting 12A-39
sensor: Removal - Refitting 10A-131
Air inlet flap: Removal -
Crankshaft seal at timing end
Refitting 12A-41
Air inlet duct: Removal -
Refitting 12A-49
Inlet manifold: Removal -

11A TOP AND FRONT OF ENGINE
Refitting 12A-52
Accessories belt: Removal - Injector holder shim:

Refitting 11A-1 Removal - Refitting 12A-58
Timing belt: Removal - Manifolds: Removal -
Refitting 11A-11 Refitting 12A-64
Contents
12A FUEL MIXTURE 13B DIESEL INJECTION
Exhaust manifold: Removal - Diesel injection: Precautions

Refitting 12A-67 for repair 13B-16
Throttle valve: Removal - Description 13B-31

Refitting 12A-86
Operation 13B-33
Throttle valve: Cleaning 12A-94
Location of components 13B-36
Engine stop device 12A-96
Immobiliser function 13B-61
Injection warning light 13B-62
Injection / air conditioning

12B TURBOCHARGING
programming 13B-64
Turbocharging: Precautions Idling speed 13B-67
for repair 12B-1
Centralised coolant
Turbocharger: Removal - temperature management 13B-69
Refitting 12B-6
Computer configuration 13B-71
Pressure regulator: Checking 12B-37
High pressure pipe:
Turbocharging pressure Checking 13B-73
regulation valve 12B-43
High pressure pipe:
Intercooler: Removal - Replacement 13B-76
Refitting 12B-46
Diesel injector: check 13B-83
High pressure pump:

Removal - Refitting 13B-84
13A FUEL SUPPLY
Diesel injector: Removal -
Petrol supply circuit 13A-1 Refitting 13B-113
Diesel fuel supply circuit 13A-2 Injectors: Configuration 13B-130
Petrol filter: General High-pressure pipe between

information 13A-6 the rail and injector: Removal
- Refitting 13B-132
Diesel filter: Removal -
Refitting 13A-7 Injector rail: Removal -
Refitting 13B-143
Injector rail - Injectors:
Removal - Refitting 13A-14 Rail pressure sensor 13B-160
Electric fuel: Checking 13A-20 Rail pressure sensor:

Fuel flow actuator: Removal -

Refitting 13B-164
13B DIESEL INJECTION
Leak flow from injectors:
Check 13B-170
Specifications 13B-1
Fuel pressure regulator:
Diesel injection:
Specifications 13B-11
Contents
13B DIESEL INJECTION 14A ANTIPOLLUTION
Diesel temperature sensor: Exhaust gas recirculation

Removal - Refitting 13B-179 solenoid valve: Removal -
Refitting 14A-29
Accelerometer: Removal -
Refitting 13B-189 Intercooler: Removal -
Refitting 14A-31
Venturi: Removal - Refitting 13B-190
Exhaust gas recirculation
Accelerator pedal mounting: Removal -
potentiometer: General Refitting 14A-36
information 13B-194
Accelerator pedal rigid pipe: Removal -
potentiometer: Removal - Refitting 14A-37
Refitting 13B-195
Diesel injection computer:

16A STARTING - LOAD
Alternator: General
13C PREHEATING information 16A-1
Alternator: Removal -
Pre/postheating unit: Refitting 16A-2
Removal - Refitting 13C-1
Alternator pulley: Removal -
Heater plugs Removal - Refitting 16A-20
Refitting 13C-2
Starter: Identification 16A-24
Pre-postheating control 13C-11
Starter: Removal - Refitting 16A-25
14A ANTIPOLLUTION
17A IGNITION
Petrol vapour rebreathing:
Operation 14A-1 Coils Removal - Refitting 17A-1
Fuel vapour recirculation Spark plugs 17A-5

circuit: check 14A-3
Fuel vapour canister:

17B PETROL INJECTION
Fuel vapour
canister:Checking 14A-5 Location of components 17B-1
Oil vapour rebreathing 14A-6 Oxygen sensors: Removal -
Refitting 17B-14
Exhaust gas recirculation:
Operating diagram Accelerator pedal
potentiometer: Removal -
Exhaust gas recirculation:
Refitting 17B-16
Description 14A-17
Position and speed sensor 17B-17
unit 14A-23
Contents
17B PETROL INJECTION 19A COOLING SYSTEM
Petrol injection computer: Cooling circuit: Draining -

Removal - Refitting 17B-19 Refilling 19A-12
Special notes 17B-21 Engine cooling circuit:

Cleaning 19A-14
Injection warning light 17B-24
Cooling circuit: Bleeding 19A-15
Immobiliser function 17B-25
Cooling radiator: Removal -
Injection - air conditioning Refitting 19A-16
programming 17B-26
Water pump: Removal -
Throttle valve: Operating 17B-30 Refitting 19A-22
Idle speed correction 17B-31 Plenum chamber: Removal -
Adaptive idle speed Refitting 19A-40
correction 17B-34
Richness regulation 17B-35
Adaptive richness correction 17B-39 19B EXHAUST
Central coolant temperature General information 19B-1

management 17B-41
Pipe assembly 19B-5
Camshaft dephaser:
Description 17B-42 Catalytic pre-converter:
Fault finding warning light
activation conditions (when Catalytic converter: Removal
driving) 17B-44 - Refitting 19B-15
Conditions for carrying out Expansion chamber:

fault finding (when driving) 17B-45 Removal - Refitting 19B-29
Combustion misfire fault Silencer: Removal - Refitting 19B-30

finding 17B-46
Particle filter: Function 19B-31
Catalytic converter fault
Particle filter: Removal -
finding 17B-47
Refitting 19B-32
Oxygen sensor fault finding 17B-48
Particle filter pressure
Speed limiter: Operating sensor: Removal - Refitting 19B-38
principle 17B-49
Particle filter temperature
sensors: Removal - Refitting 19B-42
Connecting hose: Removal -

19A COOLING SYSTEM Refitting 19B-45
Particle filter: Cleaning 19B-46

General information 19A-1
Specifications 19A-2
Checking 19A-3
Diagram 19A-4
Contents
19C RESERVOIR
Draining the fuel tank 19C-1
Fuel tank: Description 19C-6
Fuel tank: Removal -

Refitting 19C-12
Filler neck: Removal -

Refitting 19C-15
Sender unit: Removal -

Refitting 19C-17
Pump-sender unit-filter:
Removal - Refitting 19C-20
Petrol filter: General

information 19C-22
Fuel level sensor: Checking 19C-23
19D ENGINE MOUNTING
Suspended engine mounting 19D-1
Suspended engine
mounting: Tightening torque 19D-9
Left-hand suspended engine

mounting: Removal -
Refitting 19D-12
Right-hand suspended
engine mounting: Removal -
Refitting 19D-14
Rear suspended engine

mounting: Removal -
Refitting 19D-16
ENGINE AND LOWER ENGINE ASSEMBLY
Engine identification 10A
Vehicle type Engine type Engine suf- Cubic capa- Bore (mm) Stroke (mm) Compression
fix city (cc) ratio
XM0B 730
XM0H
K4J 1390 79.5 70 10/1
XM1A
XM08 732
XM0C 760
XM0J K4M 761 1598 79.5 80.5 9.8/1
XM1B
XM05 770
XM0U 771
9.8/1
XM1M F4R 1998 82.7 93
XM1N
XNOW 776 9.5/1
XM0F 722
XM0T
XM02 728 17.9/1

K9K 1461 76 80.5
XM13
XM02 729
XM1E 732 15.3/1
XM0G 800 18.4/1

XM1G
XM0L F9Q 804 1870 80 93 17/1

XM1D
XM00 808 18.4/1
List of engine Workshop Repair Manuals to be consul-

ted depending on the engine type:
- K4J and K4M engine, Technical Note 3784A,
- K9K engine, Technical note 6006A,
- F9Q engine, Technical Note 3652A,
- F4R engine, Technical Note 3783 A.
10A-1
Engine oil: Draining - Refilling 10A
M9R, and 700
Copper seal
Tightening torquesm
drain plug 44 Nm
Average oil capacity

(check and adjust with
dipstick) (l)
Engine Draining Oil change
with oil filter
replace-
ment
M9R 6.4 6.7
I - OIL SERVICE
Remove the oil filler plug and the dipstick.
113764
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ). Refit the new seal on the plug, positioning the groo-
ve (2) towards the plug.
Remove the engine undertray.
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
Oil consumption Check 10A
PROCEDURE FOR MEASURING OIL
CONSUMPTION
1 - Filling to the maximum level
Note:
The operation should be carried out with the
engine warm after the fan unit has started opera-
ting.
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 mi-

les (2,000 km) in the vehicle without letting the oil le-
vel 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 cove-

red since the last top-up to maximum level.
4 - Measurement of the oil consumption
Oil consumption = Quantity of topping up oil (in

litres) / number of kilometres (in thousands).
10A-3
Oil filter: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
III - FINAL OPERATION
Special tooling required
Top up the engine oil.
Mot. 1329 76 mm diameter oil fil-
Wipe any oil run-off with a cloth.
ter removing tool
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-

ting equipment, Underbody lift ).
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
F4R, and 770 or 771 or 776

ter removing tool
Tightening torquesm
air conditioning com- 44 Nm

pressor stay mounting 2
bolts
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
111852
Position the (Mot. 1329) (2) on the oil filter.
REFITTING
Lubricate the oil filter seal with new engine oil.
1 Refit the air conditioning compressor stay.
Tighten to torque the air conditioning compressor
stay mounting bolts ( 44 Nm ) .
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.
10A-5
K4M, and 760 or 761 K4J, and 730 or 732

ter removing tool
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
110385
Position tool (Mot. 1329) (1) on the oil filter.
REFITTING
Apply new engine oil to the oil filter seal.
10A-6
M9R, and 700
Tightening torquesm
cover 25 Nm
REMOVAL

equipment, Underbody lift ).
114779
Remove the filter element - cover assembly.

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
M9R, and 700
REFITTING II - REFITTING OPERATION FOR PART

CONCERNED

Clean the cover.
114780
Refit:
113869
- the new filter element (6) in the cover (7) ,
Position the new O-ring (5) correctly on the cover. - the filter element - cover assembly.
Apply new engine oil to the O-ring. Tighten to torque the cover ( 25 Nm ) .

10A-8
F9Q
REFITTING
Mot. 1329 76 mm diameter oil fil- I - REFITTING PREPARATION OPERATION

ter removing tool
Lubricate the new oil filter seal.
If the AC pipe is significantly deformed when the oil fil-
ter is removed, there may be a refrigerant leak.
II - REFITTING THE OIL FILTER
To reduce the risk of a leak in the MEGANE II and Tighten the oil filter until it makes contact.
SCENIC II equipped with F9Q engine, the ADVICE in
this Technical Note relating to the removal of the oil fil- Tighten the oil filter three-quarters of a turn by hand.
ter from the TOP OF THE ENGINE must be strictly fol-
lowed. III - FINAL OPERATION
Top up the engine oil (see 05A, Draining - Filling-
REMOVAL up ).
Refit:
I - REMOVAL PREPARATION OPERATION - the engine undertray,
Position the vehicle on a two-post lift (see 02A, Lif- - the engine covers.
Remove:
- the engine covers,
- the engine undertray.
Drain the engine oil (see 05A, Draining/Filling-up ).
II - REMOVING THE OIL FILTER
115078
From the top of the engine, position the (Mot. 1329)

on the oil filter using an open-jawed spanner 27 mm
in width.
10A-9
Exchanger: Removal - Refitting 10A
M9R, and 700
REMOVAL
Mot. 1202-01 Clip pliers for cooling I - REMOVAL PREPARATION OPERATION

system hose clips
(large model) Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1202-02 Pliers for small hose Disconnect the battery (see 80A, Battery, Battery:
clips Removal and Refitting )
Mot. 1448 Remote operation clip Remove:
pliers for cooling sys-
- the engine protectors,
tem hose clips
- the engine undertray,
Mot. 1495-01 22 mm socket for
- the oil filter (see 10A, Engine and peripherals, Oil
removing/refitting oxy-
gen sensors filter: Removal - Refitting ).
- the front bumper (see MR365 Bodywork, 55A Ex-
Equipment required terior protection, Front bumper )
Drain the coolant circuit using filling station (see
filling station
62A, Air conditioning, Maintenance ).
Tightening torquesm
oil cooler mounting 25 Nm

bolts
coolant inlet union 24 Nm

mounting bolts
oil pressure sensor 44 Nm
intercooler downs- 5.5 Nm

tream duct clip on the
intercooler

damper valve
intercooler upstream 5.5 Nm

hose clip
front end panel upper 21 Nm 112658

mounting bolts Remove:
front end panel lower 44 Nm - the mounting bolts (1) from the Protection and
Switching Unit,
mounting bolts
- the Protection and Switching Unit cover.
10A-10
M9R, and 700
102504 102365
Disconnect the connectors (2) from the Protection Remove:
and Switching Unit.
- front end panel mounting bolts (7) ,
Unfasten the bonnet opening cable (3) .
- the front end panel,
Remove:
- the air inlet scoop.
- the clips (4) ,
Drain the engine cooling system (see 19A, Cooling,
- the front end panel upper mounting bolts (5) , Engine cooling system: Draining-refilling ).
Disconnect the screen washer tubes.
102473
114933 Loosen the clip (8) from the intercooler upstream ho-
se.
Unclip the air inlet scoop.
Disconnect the intercooler upstream hose.
10A-11
M9R, and 700
114649 112661
Remove the bolt (9) mounting the intercooler downs- Disconnect:
tream duct on the cooling radiator.
- the cooling radiator top and bottom hose using
Loosen: (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the clip (10) on the intercooler downstream duct on - the fan unit resistor connector (11) ,
the intercooler,
- the fan unit connector.
- the intercooler downstream duct clip on the damper
Unclip the wiring harness from the fan unit.
valve.
Move the downstream duct away from the intercoo-
ler.
10A-12
M9R, and 700
109537 114929
Disconnect: Disconnect the hose (15) from the oil cooler coolant
outlet union.
- the hoses from the expansion bottle on the cooling
radiator side (12) , Remove:
- the pressure switch connector on the condenser - the oil pressure sensor using the (Mot. 1495-01) ,
lower air conditioning pipe (13) .
- the mounting bolts (16) from the coolant inlet union,
Unpick the wiring harness from the pressure switch
- the coolant inlet union.
connector on the fan unit.
Disconnect, using the (Mot. 1202-01) or (Mot. 1202-
Remove the air conditioning pipes from the conden-
02) or (Mot. 1448) :
ser (14) .
- the hose (17) from the coolant inlet union on the
union,
Note:
- the hose (18) from the cylinder block coolant inlet
Plugs must be fitted to the hoses and the expan- pipe,
sion valve to prevent moisture from entering the
system. Remove the hose from the coolant inlet union.
Remove the cooling assembly.
10A-13
M9R, and 700
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
I - REFITTING OPERATION FOR PART

CONCERNED
114928
Remove:
- the mounting bolts (19) from the oil cooler, 114928
- 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 ) .
10A-14
M9R, and 700
II - FINAL OPERATION Tighten to torque the intercooler upstream hose
clip ( 5.5 Nm ) .
Connect, using the (Mot. 1202-01) or (Mot. 1202-
02) or (Mot. 1448) :
Refit:
- the coolant inlet union hose on the cylinder block,
- the air inlet scoop,
- the coolant inlet pipe hose on the union,
- the coolant outlet union hose to the oil cooler. - the front end panel,
Refit:
- the clips,
- the coolant inlet union,
- the front end panel mounting bolts.
- the coolant inlet union mounting bolts,
- the oil pressure sensor. Tighten to torque:
Tighten to torque:
- the front end panel upper mounting bolts ( 21
- the coolant inlet union mounting bolts ( 24 Nm ) Nm ) ,
,
- using (Mot. 1495-01) the oil pressure sensor ( 44 - the front end panel lower mounting bolts ( 44
Nm ) . Nm ) .
Refit the cooling assembly. Connect the Protection and Switching Unit connec-
Refit the air conditioning pipes to the condenser. tors.
Attach the pressure switch connector wiring harness
Clip the bonnet opening cable.
to the fan unit.
Connect, using the (Mot. 1202-01) or (Mot. 1202- Disconnect the screen washer tubes.
02) or (Mot. 1448) :
Refit:
- the expansion bottle hoses on the cooling radiator
side, - the Protection and Switching Unit cover,
- the cooling radiator top and bottom hose.
- the Protection and Switching Unit cover mounting
Connect:
bolts,
- the pressure switch connector on the condenser
lower air conditioning pipe, - the oil filter (see 10A, Engine and peripherals, Oil
filter: Removal - Refitting ).
- the fan unit connector,
- the fan unit resistor connector, - the engine undertray.
Clip the fan unit wiring harness into place.
Refit:
Refit:
- the intercooler downstream duct clip to the inter-
cooler,
- the front bumper (see MR365 Bodywork, 55A Ex-
- the intercooler downstream duct clip on the damper terior protection, Front bumper ).
valve.
Tighten to torque: Refill:
- the intercooler downstream duct clip on the in- - the coolant circuit using the filling station (see
tercooler ( 5.5 Nm ) , 62A, Air conditioning, Maintenance ),
- the intercooler downstream duct clip on the
damper valve ( 5.5 Nm ) . - the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
Tighten the bolt mounting the intercooler downs-
tream duct on the cooling radiator. Connect the battery (see 80A, Battery, Battery: Re-
Connect the intercooler upstream hose. moval - Refitting ).
10A-15
Oil pressure 10A
Connect the battery (see 80A, Battery, Battery: Re-
Special tooling required moval - Refitting ).
Mot. 836-05 Oil pressure gauge kit Start the vehicle.
Carry out the check.
I - ADAPTERS FOR USE WITH VARIOUS ENGINES Check the values.
Engine Adapters Minimum pressure

(bar)
K4J E+C+F Engine
Engine
suffix Idle 3000 rpm
K4M E+C+F
speed
F4R B+F
K4J 730 1 3
K9K E+C+F
760
K4M 1 3
F9Q B+F 782
M9R C+F 770
1 3
F4R 771
II - PRECAUTIONS TO TAKE DURING CHECKS
The oil pressure check must be carried out with the en- 776 1.2 3.5
gine warm ( 80C ).
722
III - CHECKING PROCEDURE K9K 728 1.2 3.5
Disconnect the battery (see 80A, Battery, Battery: 732

Removal - Refitting ).
804
Remove the oil pressure sensor (see 10A, Engine and F9Q 1.2 3.5
peripherals, Oil pressure sensor: Removal - Refit- 812
ting ).
M9R 700 0.9 4
Disconnect the battery (see 80A, Battery, Battery:

Remove the (Mot. 836-05) and the adapters.
Refit the oil pressure sensor (see 10A, Engine and pe-
ripherals, Oil pressure sensor: Removal - Refitting
).
moval - Refitting ).
87363
Position the (Mot. 836-05) with the appropriate adap-
ters.
10A-16
Oil pressure sensor: Removal - Refitting 10A
M9R, and 700
- the engine accessories unit cover.

gen sensors
Tightening torquesm
oil pressure sensor 44 Nm
front end panel upper 21 Nm

mounting bolts
front end panel lower 44 Nm

mounting bolts
115585
Disconnect the connectors (2) from the engine ac-
REMOVAL cessories unit.
I - REMOVAL PREPARATION OPERATION Remove:
Position the vehicle on a two-post lift (see 02A, Lif- - the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Remove:
- the front bumper (see MR 365 Bodywork, 55A Ex-
terior protection, Front bumper ).
114933
Unclip the air inlet scoop (6) .
112658
Remove:
- the engine accessories unit cover mounting bolts
(1) ,
10A-17
M9R, and 700
102365
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
115022
CONCERNED
115021
Remove the oil pressure sensor using the (Mot.
114061 1495-01) (1) .
Disconnect the oil pressure sensor connector (8) .
Note:
Be careful not to damage the air conditioning
compressor connector.
10A-18
M9R, and 700
REFITTING

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 upper mounting bolts of the front end panel,
- the lower mounting bolts of the front end panel.
Tighten to torque:
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,
terior protection, Front bumper ),
- the engine protectors.
10A-19
Oil level sensor: Removal - Refitting 10A
M9R, and 700
Tightening torquesm Refit the heat insulating material around the oil level
sensor.
oil level sensor 25 Nm Refit the front right-hand wheel.
front right-hand wheel 110 Nm Tighten to torque the front right-hand wheel ( 110
Nm ) .
REMOVAL

Position the vehicle on a two-post lift (see 02A Lif-
Remove the front right-hand wheel.
Move the heat insulating material away from the oil
level sensor.

CONCERNED
114932
Disconnect the oil level sensor (1) .
Remove the oil level sensor.
REFITTING

CONCERNED
Refit the oil level sensor.
Tighten to torque the oil level sensor ( 25 Nm ) .
Connect the oil level sensor.
10A-20
Sump: Removal - Refitting 10A
K4J, and 730 or 732 K4M, and 760 or 761
Equipment required
safety belt
Tightening torquesm
sump mounting bolts 14 Nm

are tightened to torque
gearbox - sump moun- 44 Nm

ting bolts
1

gearbox - sump moun- 44 Nm 101212

ting bolts
Remove the half sub-frame side reinforcements (1) .
bolt mounting the sump 21 Nm Attach the cooling assembly to the upper cross
on the multifunction member using a safety belt .
support
half sub-frame moun- 105 Nm Note:

ting bolts
When positioning the safety belt , be careful not
half sub-frame moun- 21 Nm to:
ting nuts - pinch the cooling hoses,
wheel bolts 110 Nm - strap the half sub-frame.
battery cover bolts 4 Nm
REMOVAL

Drain the engine oil (see 05A, Draining - Filling,

Engine ).
Remove:
- the dipstick,
- the front wheels,
- the wheel arch liners,
10A-21
K4J, and 730 or 732 K4M, and 760 or 761
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 finger marks).
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
(engine, radiator, etc.).
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 multi-

function support.
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-
solve any seal still adhering.
10A-22
K4J, and 730 or 732 K4M, and 760 or 761
I - FIRST FITTING
20167
20170
Refit the oil splash plate onto the cylinder block.
5
Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positio-
5 ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent deformation of the
clutch housing.
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 cy-
linder block.
10A-23
K4J, and 730 or 732 K4M, and 760 or 761
6 7 8 9 10 11 12 13 14
15
16
5 4 3 2 1 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 tighte-
ning.
Tighten to torque and in order the sump mounting
bolts ( 14 Nm ) .
Check that all the sump mounting bolts are tighte-
ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
bolts ( 44 Nm ) .
10A-24
K4J, and 730 or 732 K4M, and 760 or 761
II - SECOND FITTING bolts ( 44 Nm ) .
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.
6 7 8 9 10 11 12 13 14 Top up the engine oil (see 05A, Draining - Filling,

Engine ).
15
16
5 4 3 2 1 20 19 18 17
20171
Fit:
- the sump mounting bolts without tightening,
ning.
bolts ( 14 Nm ) .
ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
10A-25
F9Q, and 800 or 804 or 808
Equipment required
safety belt
Tightening torquesm
half sub-frame moun- 105 Nm

ting bolts

ting nuts
1
wheel bolts 110 Nm
battery cover mounting 4 Nm

bolts
REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting 101212
equipment, Underbody lift ). Remove the half sub-frame side reinforcements (1) .
Disconnect the battery (see 80A, Battery, Battery: Attach the cooling assembly to the upper cross
Removal - Refitting ). member using a safety belt .
Drain the engine oil (see 05A, Draining - Filling, Note:
Engine ). When positioning the safety belt , be careful not
Remove: to:
- the engine covers, - pinch the cooling hoses,
- the dipstick, - strap the half sub-frame.
- the front wheels,

10A-26
F9Q, and 800 or 804 or 808
WARNING
WARNING
Note:
2
There are two fitting procedures for preparing the
cylinder block gasket face when refitting:
102008
- the first fitting procedure is used if SILICONE
Remove: ADHESIVE SEALANT has been used to seal
the crankshaft closure panel,
- the mounting nuts from the half sub-frame,
- the second fitting is used if a seal is used for the
crankshaft closure panel sealing.
Remove:
- the engine tie-bar,
- the sump mountings,
- the sump.
REFITTING
10A-27
F9Q, and 800 or 804 or 808
I - FIRST FITTING II - SECOND FITTING
A A
B B
15159 15159
Apply a bead of SILICONE ADHESIVE SEALANT : Apply a bead of SILICONE ADHESIVE SEALANT
at (A) , on the joint between the crankshaft closure
- at (A) , both sides of bearing No.1,
panel and the cylinder block.
- at (B) , the joint between the cylinder block and the
crankshaft closure panel.
Note
Refit the sump fitted with a new seal.
Do not cut the two crankshaft closure panel seal
tabs which sit higher than the cylinder block gas-
ket face (B) .
Refit the sump fitted with a new seal.
10A-28
F9Q, and 800 or 804 or 808
III - REFITTING (FOR THE FIRST AND SECOND
FITTINGS)
2 3 4 5 6 7 8 9
10
1
11
22
12
21 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 wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) ,
Top up the engine oil (see 05A, Draining - Filling,

Engine ).

10A-29
K9K, and 722 or 728 or 729 or 732
REMOVAL
Equipment required
safety belt
Tightening torquesm Disconnect the battery (see 80A, Battery, Battery:
sump mounting bolts 14 NM
Remove:
- the dipstick,
sump mounting bolts 14 NM Remove:
sump mounting bolts 14 NM - the front bumper (see MR 365 Bodywork, 55A Ex-
are tightened to torque terior protection, Front bumper ),
sump mounting bolts 44 NM - the front wheels,

- the wheel arch liners.
bolt mounting the sump 21 Nm
on the multifunction Drain the engine oil (see 05A, Draining - Filling,
support Engine ).
catalytic converter ups- 21 Nm

tream stay mounting
bolts

ting bolts

ting nuts
half sub-frame side 21 Nm

reinforcement mounting
bolts
wheel bolts 110 Nm
10A-30
K9K, and 722 or 728 or 729 or 732
101212 102008
Remove the half sub-frame side reinforcements (1) . Remove:
Attach the cooling assembly to the upper cross - the mounting nuts from the half sub-frame,
member using a safety belt .
Note: - the half sub-frame (2) .
to:
K9K, and 732
- pinch the cooling hoses,
Remove:
- strap the half sub-frame.
- the lower engine tie-bar mounting bolts,
K9K, and 732 - the lower engine tie-bar,
Move the diesel drain pipe away from the injection - the lower engine tie-bar support lower mounting
rail protector. bolts.
Loosen the lower engine tie-bar upper bolt.
Remove:
- the bolts mounting the right-hand driveshaft brac-

ket on the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the relay bearing,
- the catalytic converter upstream stay mounting

bolts,
- the catalytic converter upstream stay.
Disconnect the oil level sensor.
10A-31
K9K, and 722 or 728 or 729 or 732
CA or CAREG
Remove the mounting bolt from the sump on the
multifunction support.

CONCERNED
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
3
20167
K9K, and 732

Clean the strainer with a soft, lint-free cloth. 5

5
WARNING
WARNING
4
20166
Apply:
using a wooden spatula. - 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.
10A-32
K9K, and 722 or 728 or 729 or 732
CONCERNED
6 7 8 9 10 11 12 13 14
1 - FIRST FITTING
15
6
16
7
5 4 3 2 1 20 19 18 17
20171
Fit:
20170 - the sump mounting bolts without tightening,

Refit the oil splash plate onto the cylinder block. - the gearbox - sump mounting bolts without tighte-
ning.
Note: Tighten to torque and in order the sump mounting

bolts ( 14 NM ) .
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positioned to torque ( 14 NM ) .
ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel bolts ( 44 NM ) .
end are aligned to prevent deformation of the
clutch housing.
10A-33
K9K, and 722 or 728 or 729 or 732
2 - SECOND FITTING bolts ( 44 NM ) .
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

108881 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 brac-

ket on the relay bearing.
K9K, and 732
Refit the lower engine tie-bar support lower moun-

ting bolts (see 19A, Engine mounting, Suspended
engine mounting ).
Tighten the lower engine tie-bar support lower

20171 mounting bolts (see 19A, Engine mounting, Sus-
Refit the oil sump with a new seal. pended engine mounting ).
Fit: Refit the lower engine tie-bar (see 19A, Engine
- the sump mounting bolts without tightening, mounting, Suspended engine mounting ).

ning.
Note:
Apply a drop of LOCTITE FRENBLOC to the half
bolts ( 14 NM ) .
sub-frame mounting bolts.
ned to torque ( 14 NM ) .
10A-34
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 nuts ( 21 Nm ) .
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 reinfor-

cement mounting bolts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365, Bodywork, 55A,

Exterior protection, Front bumper ),
- the front wheels.
Tighten to torque the wheel bolts ( 110 Nm ) .


Engine ).
Refit:
- the dipstick,
10A-35
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm

ting bolts

ting nuts
wheel bolts (F4R 776) 130 Nm

1
wheel bolts 110 Nm

bolts
101212
REMOVAL
Remove:
equipment, Underbody lift ). - the half sub-frame side reinforcement mounting
bolts,
Removal - Refitting ). - the side reinforcements (1) .
Remove the engine undertray. Attach the cooling assembly to the upper cross
member using the safety belt .
Drain the engine oil (see 05A, Draining - Filling,
Engine ).
Note:
Remove:
to:
- the dipstick,
- pinch the cooling hoses,
- the front wheels,
- strap the half sub-frame.
- the wheel arch liners.
10A-36
F4R, and 770 or 771 or 776
B
2
102008 15159
Remove: Apply a bead of SILICONE ADHESIVE SEALANT

at (A) , at the joint between the crankshaft closure
- the mounting nuts from the half sub-frame, panel and the cylinder block.

Note:
Do not cut the two tabs on the crankshaft closure
Remove: panel seal, which sit higher than the joint face of
the cylinder block (B) .
- the engine tie-bar,
Refit the sump with a new gasket.
- the sump mountings,
- the sump.
REFITTING

WARNING
WARNING
10A-37
F4R, and 770 or 771 or 776
2 3 4 5 6 7 8 9
10
1
11
22
12
21
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 ).
Tighten to torque:
- the wheel bolts (F4R 776) ( 130 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Engine ).
10A-38
M9R, and 700
Mot. 1716 Removes housing with

silicone seals.
Tightening torquesm

ting bolts

ting nuts
the side reinforcement 21 Nm

lower mounting bolts
REMOVAL
102008
Remove:
- the lower mounting bolts (1) from the side reinfor-
Position the vehicle on a lift (see 02A, Lifting equi-
cements,
pment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery :
Removal - Refitting ). Drain the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ).
Remove:
- the dipstick,
- the front wheels,
- the front wheel arch liners,
10A-39
M9R, and 700
II - OPERATION FOR REMOVAL OF PART Check that the base plate is not scratched.
CONCERNED
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 mix-
ture of sealant and fluid could cause damage to
cer tain components (engine, radiator, etc.).
WARNING
The sealing surfaces must be clean, dry and free
114997 II - REFITTING OPERATION FOR PART

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

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 ma-

de.

bolts ( 16 Nm ) .
10A-40
M9R, and 700
Refit:
- the half sub-frame,
- the half sub-frame mounting nuts.
Tighten to torque:
Refit the side reinforcement lower mounting bolts.
Tighten to torque the side reinforcement lower
mounting bolts ( 21 Nm ) .
Refit:
- the front wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery, B attery :
Fill up the engine oil (see 10A, Engine and periphe-
Refit:
- the dipstick,
10A-41
Oil pump: Removal - Refitting 10A
Connect the battery, starting with the positive termi-
nal.
Tightening torquesm
oil pump mounting bolts 25 Nm WARNING

Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
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 periphe-

rals, Sump ).
Example for F9Q engine
23224
Remove:
- the bolt (1) and the oil splash plate,
- the oil pump bolts (2) ,
- the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts ( 25

Nm ) .
Refit the sump (see 10A, Engine and peripherals,

Sump ).
10A-42
M9R, and 700
CONCERNED
Tightening torquesm
oil pump mounting bolts 25 Nm

on the cylinder block
oil pump mounting bolts 10 Nm

on the anti-splash plate
strainer mounting bolts 10 Nm
REMOVAL

Remove the sump (see 10A, Engine and periphe-
rals, Sump: Removal - Refitting ).
113157
Remove:
- the oil pump mounting bolts on the anti-splash pla-

te,
- the oil pump mounting bolts on the cylinder block,
- the oil pump.
REFITTING
If necessary, use a locally-produced hook to fit the

113156 oil pump chain to the oil pump sprocket.
Remove:
- the strainer mounting bolts , II - REFITTING OPERATION FOR PART
CONCERNED
- the strainer.
Finger tighten:
- the oil pump mounting bolts on the anti-splash pla-
te,
- the oil pump mounting bolts on the cylinder block.
Tighten to torque the oil pump mounting bolts 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 ) ,
10A-43
M9R, and 700
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 .
Fill up the engine oil (see 10A, Engine and periphe-
Start the engine and wait until the engine oil warning
light goes out.
Check the engine oil level.
10A-44
Multifunction support: Removal - Refitting 10A
K4J, and 730 or 732 K4M, and 760 or 761
Tightening torquesm CA or CAREG
multifunction support 44 Nm
mounting bolts
mounting bolt on the
sump
REMOVAL
Remove the engine protectors.
Disconnect the battery (see 80A, Battery, Battery :
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray, 102265
Remove:
Exterior protection, Front bumper: Removal - - the multifunction support mounting bolts (1) ,
Refitting ),
- the bolt (2) mounting the multifunction support on
- the accessories belt (see 11A, Top and front of the sump,
engine, Accessories belt: Removal - Refitting ),
- the multifunction support.
- the alternator (see 16A, Starting-Charging, Alter-
nator: Removal - Refitting ).
10A-45
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
CHAUFO
CA or CAREG
111057
Remove: 102265
- the multifunction support mounting bolts (3) , Refit:
- the multifunction support. - the multifunction support,

- the multifunction support mounting bolts.
Tighten to torque and in order:
- the multifunction support mounting bolts ( 44
Nm ) ,
- the multifunction support mounting bolt on the
sump ( 21 Nm ) .
10A-46
K4J, and 730 or 732 K4M, and 760 or 761
CHAUFO
111057
Refit:
- the multifunction support,
Tighten to torque and in order the multifunction

support mounting bolts (44 Nm) .
Refit:

- 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 front wheels.

Refit the engine protectors.
10A-47
K9K, and 722 or 724 or 728 or 729 or 732
CONCERNED
Tightening torquesm
multifunction support 21 Nm CA or CAREG

sump
mounting bolts
REMOVAL

Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
Remove:
- the front wheels,
102265
Remove:
- the multifunction support mounting bolts (1) ,
Refitting ). - the bolt (2) mounting the multifunction support on
the sump,
engine, Accessories belt: Removal - Refitting ). - the multifunction support.
10A-48
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
CONCERNED
CA or CAREG
111057
Remove:
- the multifunction support. 102265
Refit:
- the multifunction support mounting bolt on the
sump ( 21 Nm ) .
Nm ) ,
10A-49
K9K, and 722 or 724 or 728 or 729 or 732
CHAUFO
111057
Refit:
Tighten to torque and in order the multifunction

support mounting bolts (44 Nm) .
Refit:


engine, Accessories belt: Removal - Refitting ).

Refitting ).
- the front wheels.
Connect the battery (see 80A, Battery: Removal -

Refitting ).
Refit the engine covers.
10A-50
F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG
Equipment required
filling station
Tightening torquesm
mounting bolts
air conditioning com- 25 Nm 3

pressor mounting bolts
1
pressor strut mounting
bolts
2
REMOVAL 109537
Place the vehicle on a two-post lift (see 02A, Lifting Disconnect:
- the air conditioning compressor connector,
Drain the coolant circuit using the filling station
- the pressure switch connector (1) .
(see 62A, Air conditioning, Maintenance ).
Remove:
Removal - Refitting ). - the air conditioning compressor pipe (2) ,
Remove the alternator (see 16A, Starting - Char- - the air conditioning pipe between the compressor
ging, Alternator ). and the dehydration canister (3) .
Note:
Plugs must be fitted to the hoses and the expan-
system.
Remove:
- the air conditioning compressor mounting bolts,
- the air conditioning compressor.
10A-51
104337
Remove:
REFITTING
Refit the multifunction support.
Tighten to torque:
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 ).
Fill the coolant circuit using the filling station (62A,
Air conditioning, Maintenance).
10A-52
M9R, and 700
CONCERNED
Tightening torquesm
mounting bolts

REMOVAL


Remove the alternator (see 16A, Starting-Char-

ging, Alternator: Removal - Refitting ).
114862
Remove:
114861
Disconnect the connector (1) from the air conditio-

ning 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
M9R, and 700
REFITTING

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 moun-

ting bolts ( 44 Nm ) in the following tightening order
( (4) - (1) - (2) - (3) - (5) ).
Fit the air conditioning compressor.

mounting bolts ( 25 Nm )
Refit the alternator (see 16A, Starting-Charging,

Alternator: Removal - Refitting ).

10A-54
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
REMOVAL
Mot. 1202-01 Clip pliers for cooling ting equipment, Underbody lift ).
system hose clips
(large model)
IMPORTANT
Mot. 1202-02 Pliers for small hose During this operation, secure the vehicle to the
clips lift with a safety belt , to avoid any imbalance.
tem hose clips - the engine covers,
- the front wheels,
Equipment required
safety belt - the engine undertray.
filling station Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-
hydraulic crane
box ),
load positioner - the engine (see 05A, Draining-Refilling, Engine ).
Tightening torquesm Removal - Refitting ).

CA or CAREG
mounting bolt
Drain the refrigerant circuit using the filling station
front end panel lower 44 Nm (see 62A, Air conditioning, Maintenance ).
mounting bolt
half sub-frame front 105 Nm

mounting bolt
half sub-frame rear 21 Nm

mounting bolt
wheel bolt 110 Nm
101212
Remove:
- the battery (see 80A, Battery, Battery: Removal -
Refitting ),
10A-55
K4M, and 760 or 761
- the half sub-frame side reinforcements (1) ,
Exterior protection, Front bumper ).
2
4 5
7
102504
Disconnect the two connectors (2) .
101795
Unclip the front bonnet opening cable (3) .
Remove: Disconnect:
- the clip (4) ,
- the petrol inlet pipe from the injector rail (7) ,
- the fastening (5) .
- the radiator top hose, using the (Mot. 1202-01) or
Disconnect the screen washer tubes. (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors,
102365 11
Remove:
- the front end panel mounting bolts (6) , 8 9
10
109537
Disconnect the hoses from the expansion bottle on

the cooling radiator side (8) .
10A-56
K4M, and 760 or 761
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 conditio-
ning compressor and the dehydration canister (11)
13
, 14
Note:
system.
101822
Disconnect the computer connectors (13) .
Remove the battery tray mounting bolts (14) .
Remove:
- the battery tray,
- the computer mounting.
12
15
101807
Remove the air filter outlet duct (12) .
104553
Remove the air filter unit (15) .
10A-57
K4M, and 760 or 761
17
101978 101812
Disconnect the wiring harness connectors from the Remove the brake servo pipe (17) .
relay board.
19
18
16
104240
111051 Disconnect:
Disconnect the earth strap on the body.
- the hoses (18) and (19) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
10A-58
K4M, and 760 or 761
K4M, and 760 K4M, and 761
22
B
C
21
A
101743 103409
Remove:
Unclip the lever cables on the gearbox:
- the multifunction switch cable ball joint (21) ,
- grip the gearbox control at (A) ,
- the multifunction switch cable (22) by unlocking the
- pull the pin at (B) , sleeve stop.
- raise the gearbox control at (C) .
20
101699
Remove the gearbox controls (20) .
10A-59
K4M, and 760 or 761
K4M, and 760
24
23
102008
Remove:
101740 - the front left-hand driveshaft (see 29A, Drives-
Pull out clip (23) . hafts, Front left-hand driveshaft ),
Disconnect the hydraulic clutch supply pipes. - the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the exhaust downpipe mountings,
Note:
- the lower engine tie-bar,
Plug the pipes to prevent fluid from escaping.
Position the hydraulic crane fitted with a load posi-
tioner or a chain.
10A-60
K4M, and 760 or 761
K4M, and 761
101866
Mark the suspended engine mounting in relation to
the body.
103273
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
K4M, and 760
Rotate the engine and gearbox assembly in or-

der to remove it.
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 3784A, Petrol engine - 4 cy-
linders - K4, 10A, Engine and peripherals, Nor-
mal replacement ).
Position the engine and gearbox assembly in the

vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine

mounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engi-
ne mounting, Suspended mounting ),
102112 - the lower engine tie-bar (see 19D, Engine moun-

ting, Suspended mounting ),
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-

hafts, Front right-hand driveshaft ).
10A-61
K4M, and 760 or 761
Tighten to torque: Tighten to torque the battery cover bolts ( 4 Nm ) .
- the front end panel upper mounting bolt ( 21 Nm

), Note:
If the vehicle is fitted with xenon lamps, it is
- the front end panel lower mounting bolt ( 44 Nm
essential to initialise the system (see 80C,
),
Xenon bulbs, Xenon headlights: Adjustment
- the half sub-frame front mounting bolt ( 105 Nm ).
),
Adjust the headlights (see 80B, Headlights,
Halogen headlights: Adjustment) .
- the half sub-frame rear mounting bolt ( 21 Nm ) ,
- the wheel bolt ( 110 Nm ) .
Add brake fluid to the brake fluid reservoir.
K4M, and 760
Bleed the clutch system (see 37A, Mechanical

component controls, Bleeding the clutch sys-
tem: ).
Perform the following operations:
- fill up the gearbox oil (see 05A, Draining-Refilling,

Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,

Engine ),
- fill up the cooling system (see 19A, Cooling, Coo-

ling system: Draining-refilling ).
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.

Bleed the cooling circuit (see 19A, Cooling, Coo-

ling circuit: Bleeding ).
10A-62
F9Q, and 800 or 808

WARNING
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler:
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
tem hose clips - refit the clip in the same recess in the event that
the hoses are not replaced,
Equipment required - it is essential to replace the hoses and/or the inter-
cooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak
filling station or come undone.
hydraulic crane
load positioner REMOVAL

Tightening torquesm

IMPORTANT
mounting bolt
During this operation, secure the vehicle to the
front end panel lower 44 Nm lift with a safety belt , to avoid any imbalance.
mounting bolt
Remove:
wheel mounting bolt 110 Nm
mounting bolt - the front wheels,
half sub-frame rear 321 Nm - the right and left-hand wheel arch liners,
mounting bolt
Drain:

box ),
- the engine (see 05A, Draining-Refilling, Engine ).

CA or CAREG

10A-63
F9Q, and 800 or 808
1 102365
Remove:
- the front end panel mounting bolts (6) ,

101212
Remove: Cooling system: Draining-refilling ).
Refitting ).
- the front bumper (see MR 365 Bodywork, 55A, 8

9 7
3
104338
2 Remove:
5 - the fuel supply pipe (7) ,

4
- the fuel return pipe (8) .
102504
WARNING
Disconnect the connectors (2) .
Follow the cleanliness guidelines closely (see
Unclip the bonnet release cable (3) . 13B, Diesel injection, Cleanliness guidelines
).
Remove:
Be aware of the residual pressure and the quan-
- the clip (4) , tity of diesel fuel in the pipes.
- the fastening (5) . Disconnect the electrical connector (9) .
Disconnect the screen washer tubes. Fit plugs into the openings.
10A-64
F9Q, and 800 or 808
CA or CAREG
conditioning pipe from the condenser (12) .
Remove:
.
10 Note:
106275 Plugs must be fitted to the hoses and the expan-

Disconnect:
system.
- the intercooler hose (10) ,
- the cooling radiator top hose using the (Mot. 1202-
01) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors.
14
15
11 12
102473
13 Disconnect the air duct from the intercooler (15) .
109537
Disconnect the hoses from the expansion bottle on
10A-65
F9Q, and 800 or 808
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) . 22
Remove:
- the battery tray mounting bolts (18) ,
- the battery tray,
104340
Remove:
- the earth strap (21) ,
- the pre-postheating unit (22) .
10A-66
F9Q, and 800 or 808
23
24 A
104322 101743
Remove the brake servo pipe (23) from the vacuum Unclip the lever cables on the gearbox:
pump.
- clip the gearbox control at (A) ,
Disconnect the heater radiator top hose (24) on the
- pull the pin at (B) ,
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) . - raise the gearbox control at (C) .
25
101699
Remove the gearbox controls (25) .
10A-67
F9Q, and 800 or 808
26
27
102513 102008
Press the clip (26) . Remove:
Disconnect the supply pipes. - the front right-hand driveshaft (see 29A, Drives-
Remove the clutch hydraulic control at the bulkhead.
Note:
- the upper engine tie-bar.
tioner or a chain.
10A-68
F9Q, and 800 or 808
REFITTING
To replace the engine (see Technical Note 3652A,
High pressure diesel engine - Common Rail 4 cy-
linder cast iron, 10A, Engine and peripherals,
Normal replacement ).
vehicle.
Refit:
mounting, Suspended mounting ) in accordance
with the marks,
- the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting )
- the upper engine tie-bar (see 19D, Engine moun-
102742
hafts, Front left-hand driveshaft ).
Tighten to torque:
),
),
- 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
IMPORTANT
the body.
Remove: Do not twist the brake hose.
- the upper engine tie-bar. - bleed the clutch (see 37A, Mechanical compo-
nent controls): bleed the clutch circuit
- the suspended engine mounting,
- the gearbox suspended mounting, Gearbox ),
Rotate the engine and gearbox assembly in or- - fill up the engine oil (see 05A, Draining-Refilling,
der to remove it. Engine ),
10A-69
F9Q, and 800 or 808
- fill up the coolant (see 19A, Cooling, Cooling sys-
tem: Draining-refilling ).
CA or CAREG

Note:
Always initialise the xenon bulb system (if fitted
to the vehicle; see 80C, Xenon bulbs, Xenon
headlight: Adjustment ).
Bleed the engine cooling circuit (see 19A, Cooling,

Cooling circuit: Bleeding ).
Halogen headlights: Adjustment ).
10A-70
K9K, and 722 or 728

WARNING
tem hose clips - refit the clip in the same recess in the event that
safety belt
hydraulic crane

Tightening torquesm

IMPORTANT
mounting bolt
mounting bolt
Remove:
wheel mounting bolts 110 Nm
mounting bolt - the front wheels,
half sub-frame rear 21 Nm - the right and left-hand wheel arch liners,
mounting bolt
Drain:

box ),

CA or CAREG

10A-71
K9K, and 722 or 728
1 102365
Remove:
101212 Drain the engine cooling system (see 19A, Cooling,
Remove:

Refitting ).
- the side reinforcements (1) from the half sub-frame

cross member,

5
4
102504
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
10A-72
K9K, and 722 or 728
9
106275
7
102514
Remove:
- the fuel supply pipe (7)
WARNING
13B, Diesel injection, Cleanliness guidelines
).
10
tity of diesel fuel in the pipes.
Fit plugs into the openings.

Disconnect: 102473
Remove the intercooler air ducts (9) and (10) .
(Mot. 1202-02) or (Mot. 1448) .
10A-73
K9K, and 722 or 728
16
15
14
11 12
13
109537 101822
Disconnect the hoses from the expansion bottle on Disconnect the computer connectors (15) .
Remove:
CA or CAREG
- the battery tray,
conditioning pipe on the condenser (12) . - the computer mounting.
Remove:
K9K, and 728
- the air conditioning pipes on the condenser (13) ,
Move the turbocharger pressure regulation solenoid
valve to one side.
,
Note: Disconnect:
Plugs must be fitted to the hoses and the expan- - the air filter outlet duct,
- the flow meter connector (if fitted to the vehicle).
system.
Remove the cooling radiator assemblies.
10A-74
K9K, and 722 or 728
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
Disconnect the wiring harness connectors from the
relay board.
102263
Remove the brake servo pipe (20) .
Disconnect the heater radiator hoses from the scutt-
le panel (21) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
10A-75
K9K, and 722 or 728
B
22
A
C
102264 A
Disconnect the heater radiator hoses from the scutt-
le panel (2 2) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
101743
23
101699
Remove the gearbox controls (23) . 24
101701
Remove the clutch hydraulic control (24) .
10A-76
K9K, and 722 or 728
25
102008 101866
Remove:
tioner or a chain.
102112

the body.
Remove:
- the gearbox suspended mounting,

der to remove it.
10A-77
K9K, and 722 or 728
REFITTING
To replace the engine (see Technical Note 6006A, CA or CAREG
High pressure diesel engine Common Rail - 4
cylinder cast iron, 10A, Engine and peripherals, (see 62A Air conditioning, Maintenance ).
vehicle.
Refit:
Note:
to the vehicle; see 80C, Xenon bulbs, Xenon
- the lower engine tie-bar (see 19D, Engine moun- headlight: Adjustment ).
- the front right-hand driveshaft (see 29A, Drives- ling circuit: Bleeding ).
Tighten to torque:
),
),
- the wheel mounting bolts ( 110 Nm ) ,
),
- the half sub-frame rear mounting bolt ( 21 Nm ) .
IMPORTANT
Do not twist the brake hose.

- bleed the clutch system (see 37A, Mechanical
tem: ),
Gearbox ),
Engine ),
ling system: Draining-Refilling .
10A-78
M9R, and 700
Special tooling required Tightening torquesm
Mot. 1202-01 Clip pliers for cooling battery tray bolts 21 Nm

system hose clips
(large model) wiring harness moun- 8 Nm
ting nuts
Mot. 1202-02 Pliers for small hose
clips
REMOVAL
tem hose clips
Mot. 1390 Support for removing ting equipment, Underbody lift ).
and refitting the
engine and gearbox Remove:
assembly - the engine undertrays,
Equipment required Refitting ).
filling station - the front wheels,
- the right-hand and left-hand wheel arch liners,
Tightening torquesm - the engine undertray,
rounded bracket bolts 21 Nm - the front bumper (see MR 365, Bodywork, 55A,
with their spring Exterior protection, Front bumper ),
Drain:
mounting nuts - the gearbox (see 05A, Draining-Refilling, Gear-
box ),
- the refrigerant circuit using the filling station (see
mounting bolts
hose

tream pipe
intercooler downs- 8 Nm
tream pipe on the air
inlet valve
air conditioning pipes 8 Nm

on the condenser
air conditioning pipe 8 Nm

between the air condi-
tioning compressor and
the dehydration canister

mounting bolts

mounting bolts
10A-79
M9R, and 700
112658 112659
Remove: Disconnect the computer connectors (6) .

Remove:
bolts (1) , - the battery tray mounting bolts (7) ,
- the Protection and Switching Unit cover. - 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.
Remove:
- the clips (4) , 114933

- upper mounting bolts from the front end panel (5) ,
- the fuse box,
- the relay box.
10A-80
M9R, and 700
102365
Remove:
- the mounting bolts from the lower front end panel
(10) ,
115019
Remove the air inlet duct (12) .
115020
114659
Remove the air filter unit.
Remove the air resonator (11) .
10A-81
M9R, and 700
102473
Loosen the intercooler upstream hose clip (13) .
Disconnect the intercooler upstream hose.
112661
Disconnect:
- the fan unit resistor connector (14) ,
10A-82
M9R, and 700
Disconnect:
- the fuel supply pipe,
- the fuel return pipe from the diesel filter,
- the fuel return pipe.
WARNING
13B, Diesel injection, Cleanliness guidelines:
Precautions during repair ).
Watch out for diesel fuel splashing when discon-
necting 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) .
104340
radiator side (17) ,
Disconnect:
- the pressostat connector on the condenser lower
air conditioning pipe (18) . - the pre-postheating unit connector (21) ,
Release the wiring harness from the pressostat con- - the earth strap on the body (22) .
nector on the fan unit.
Remove:
.
Note:
system.
10A-83
M9R, and 700
115003 101743
Remove the clutch hydraulic control pipe at the bulk- Unclip the lever cables on the gearbox:
head (23) .
Remove the brake assistance pipe from the vacuum
pump. - pull the pin at (B) ,
Disconnect: - raise the gearbox control at (C) .
- the heater radiator hose from the scuttle panel out-

let,

let using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
102008
Remove:
- the side reinforcement mounting bolts (25) ,
- the side reinforcements,
115001 - the half sub-frame mounting bolts (26) ,

Remove the gearbox controls (24) . - the half sub-frame mounting nuts (27) ,
10A-84
M9R, and 700
114650
Remove:
- the rear mounting (28) (see 19D, Engine moun-
ting, Rear mounting: Removal and Refitting )
114991
Remove the rounded bracket bolts with their springs

(29) .
Remove:
10A-85
M9R, and 700
CONCERNED
114989
Position the (Mot. 1390) . REFITTING
Remove:
- the right-hand suspended mounting (see 19D, En- I - REFITTING OPERATION FOR PART
gine mounting, Right-hand suspended moun- CONCERNED
ting: Removal - Refitting ). Position:
- the mounting nut on the left-hand suspended - the right-hand suspended mounting in its housing,
mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ). - the Engine and gearbox assembly in the vehi-
cle.
der to remove it. Refit:
- the right-hand suspended mounting (see 19D, En-
gine mounting, Right-hand suspended moun-
ting: Removal - Refitting ).
- the mounting nut on the left-hand suspended
mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ).
10A-86
M9R, and 700
II - FINAL OPERATION pe,
Refit: - the intercooler upstream hose,
- the rear mounting (see 19D, Engine mounting, - the intercooler downstream pipe.
Rear mounting: Removal - Refitting ).
Tighten to torque:
- the intercooler upstream hose ( 5.5 Nm ) ,
- the intercooler downstream pipe ( 5.5 Nm ) ,
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ), - the intercooler downstream pipe on the air inlet
valve ( 8 Nm ) .
- the rounded bracket bolts with their spring.
Refit:
Tighten to torque the rounded bracket bolts with
their spring ( 21 Nm ) . - the air conditioning pipes to the condenser.
Refit: - the air conditioning pipe between the air conditio-
- the half sub-frame, ning compressor and the dehydration canister.
Tighten to torque:
- the air conditioning pipes on the condenser ( 8
- the half sub-frame mounting nuts.
Nm ) ,
Tighten to torque:
- the air conditioning pipe between the air condi-
- the half sub-frame rear mounting nuts ( 21 Nm ) tioning compressor and the dehydration canis-
, ter ( 8 Nm ) .
- the half sub-frame front mounting bolts ( 105 Secure the wiring harness to the pressostat connec-
Nm ) . tor on the fan unit.
Refit: Connect
- the gearbox controls, - the hoses from the expansion bottle on the cooling
radiator side,
- the fuse box,
- the relay box,
air conditioning pipe.
- the earth strap on the body,
- the fan unit resistor connector,
Connect:
- the pre-postheating unit connector,
Clip the fan unit wiring harness into place.
- the brake servo pipe from the vacuum pump,
Refit:
- the clutch hydraulic control pipe at the bulkhead,
- the Protection and Switching Unit mounting bolt,
- the air inlet duct,
let,
- the air resonator,
let using the (Mot. 1202-01) or (Mot. 1202-02) or - the front end panel,
(Mot. 1448) ,
- the front end panel lower mounting bolts,
- the front end panel upper mounting bolts,
- the fuel return pipe on the diesel filter,
- the clips.
- the fuel return pipe.
Tighten to torque:
Refit the cooling assembly.
Connect: Nm ) ,
- the cooling radiator top and bottom hoses using the - the front end panel lower mounting bolts ( 44
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , Nm ) .
- the mounting bolt to the intercooler downstream pi- Clip on the air inlet scoop.
10A-87
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 ).

tem: ),

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 side reinforcements,
- the side reinforcement mounting bolts,

- the front wheels,

- the battery (see 80A, Battery, Battery: Removal
and Refitting )
- the engine protector.
10A-88
F4R, and 770 or 771 or 776

WARNING
system hose clips intercooler (F4R 776):
tem hose clips - refit the clip in the same recess if the hoses are
not replaced,
safety belt
hydraulic crane

Tightening torquesm

Note:
mounting bolt
During this operation, strap the vehicle to the lift
front end panel lower 44 Nm using a safety belt , to avoid any imbalance.
mounting bolt
Remove:
wheel bolts 110 Nm
wheel bolt (F4R 776) 130 Nm
- the front wheels,
mounting bolt - the right and left-hand wheel arch liners,
half sub-frame rear 21 Nm - the engine undertray.

mounting bolt
Drain:
bolts - the gearbox (see 05A, Draining-Refilling, Gear-
box ),

CA or CAREG

10A-89
F4R, and 770 or 771 or 776
1
102365
Remove:
Remove:
- the battery (see 80A, Battery, Battery: Removal - F4R, and 770 or 771
Refitting ).

2 7
4 5
102504 101795
Disconnect the connectors (2) . Disconnect the fuel supply pipe (7) from the injector
rail.
Remove:
- the clip (4) ,
10A-90
F4R, and 770 or 771 or 776
F4R, and 776
10
13 11
12
8
106271
Disconnect:
- the injector rail (8) from the fuel supply pipe
109536
Disconnect:
01) or (Mot. 1202-02) or (Mot. 1448) ,
- the fan unit connectors. - the turbocharging pressure sensor connector (10) ,
Unclip the wiring harness from the fan unit. - the air temperature sensor connector (11) ,
Move the air duct (13) to one side.

F4R, and 776
F4R, and 770 or 771
9
106275
Disconnect the intercooler hose (9) . 14
101807
10A-91
F4R, and 770 or 771 or 776
19 20
18
16
15
17
109537 101822
Disconnect the hoses from the cooling radiator ex- Disconnect the computer connectors (19) .
pansion bottle (15) .
CA or CAREG
Remove:
- the air conditioning pipe between the compressor
and the dehydration canister (18) .
Note:
system.
10A-92
F4R, and 770 or 771 or 776
F4R, and 776
25
21
106280
106278
Remove the computer and its mounting (25) .
24
22
23
106632
104553
Move the fuel vapour recirculation solenoid valve to
Remove the air filter unit.
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) .
10A-93
F4R, and 770 or 771 or 776
F4R, and 770 or 771
27
101978
relay board. 101812
Disconnect the downstream oxygen sensor connec-
tor.
F4R, and 776
26
28
111051
Disconnect the earth strap (26) .
106787
10A-94
F4R, and 770 or 771 or 776
29
30
A
104240 101743
Disconnect hoses (29) and (30) using the (Mot. Unclip the two gear lever cables on the gearbox:
1202-01) or (Mot. 1202-02) or (Mot. 1448) .
F4R, and 770 or 776
F4R, and 771
33
31
101699 32
Remove the control cables from the gearbox (31) .
103409
Remove:
10A-95
F4R, and 770 or 771 or 776
- the multifunction switch cable (33) by loosening the
sleeve stop.
F4R, and 770 or 776
34
102008
Remove:
33
101740
Place a cloth under the master cylinder.
Remove the clip (33) from the union on the master
cylinder return. - the upper engine tie-bar.
Disconnect the pipes from the slave cylinder. - the half sub-frame (34) .
Fit plugs into the openings. Position the hydraulic crane fitted with a load posi-
tioner or a chain.
Withdraw the slave cylinder feed pipes.
10A-96
F4R, and 770 or 771 or 776
F4R, and 771
102742
the body.
103273
F4R, and 770 or 776

der to remove it.
REFITTING
linders - F4, 10A, Engine and peripherals, Nor-
mal replacement ).

vehicle.
Refit:

with the marks,

102112
Remove the suspended gearbox mounting. - the lower engine tie-bar (see 19D, Engine moun-


10A-97
F4R, and 770 or 771 or 776
- the front left-hand driveshaft (see 29A, Drives- Tighten to torque the battery cover mounting bolts
hafts, Front left-hand driveshaft ). ( 4 Nm ) .
Tighten to torque: Note:
Be sure to initialise the xenon bulb system (if fit-
ted to the vehicle) see 80C, Xenon bulbs,
),
Xenon headlights: Adjustment ).
), Adjust the headlights (see 80B, Headlights,
- the wheel bolt (F4R 776) ( 130 Nm ) ,

),
- the half sub-frame rear mounting bolt ( 21 Nm ) .
IMPORTANT
Correctly attach the flexible brake pipe and ABS
sensor wiring.
Do not twist the brake hoses.
F4R, and 770 or 776

Bleed the clutch system (see 37A, Mechanical
tem: ).
- fill up the gearbox oil (see 05A, Draining-refilling,

Gearbox ),
- fill up the engine oil (see 05A, Draining-refilling,

Engine ),
CA or CAREG

10A-98
K9K, and 729, and DP0

WARNING
not replaced,
safety belt
hydraulic crane

Tightening torquesm

IMPORTANT
mounting bolt
mounting bolt
Remove:
mounting bolt - the engine covers,
half sub-frame rear 210 Nm - the front wheels,

mounting bolt
wheel bolts 110 Nm
bolts Drain:

box ),

CA or CAREG

10A-99
1
102365
Remove:
Remove:

Refitting ).

4 5
102504
Remove:
- the clip (4) ,
10A-100
106275
7
8
102514
Remove:
- the fuel supply pipe (7) ,
WARNING
10
).
tity of diesel fuel in the pipes.

Disconnect: 102473
Disconnect the intercooler hoses (9) and (10) .
(Mot. 1202-02) or (Mot. 1448) .
10A-101
14
15
11
12
101807
13
109537
Disconnect the hoses from the cooling radiator ex-
CA or CAREG
Disconnect the pressostat connector on the lower air 16
17
Remove:
- the air conditioning hoses from the condenser (13)
,
- the air conditioning hose between the air conditio-
.
101822
Note:
sion valve to prevent moisture from entering the Remove the battery tray mounting bolts (17) .
system.
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).
10A-102
104245 104553
Disconnect: Remove the air filter unit.

- the relay plate harness connectors,
- the relay,
- the fuse box,
- the earth strap from the body,
20
21
18
103409
Remove:
19
- the multifunction switch cable (21) by unlocking the

102263 sleeve stop.
Remove the brake servo pipe from the vacuum Disconnect:

pump (18) .
- the engine speed sensor,
Disconnect the heater radiator hose from the scuttle
panel (19) using the (Mot. 1202-01) or (Mot. 1202- - the connector by releasing the slide from the con-
02) or (Mot. 1448) . nector.
10A-103
22
23
25
26
110681 103749
Disconnect: Remove:
- the pre-postheating unit (22) , - the exhaust mounting nuts (25) ,
- the automatic transmission computer connector - the lower engine tie-bar (26) .
(23) .
24
103413
Open the gearbox computer wiring harness moun-
ting bracket (24) .
10A-104
27
102008 102114
Remove:
tioner .
103273

the body.
Remove:
- the suspended gearbox mounting,

der to remove it.
10A-105
REFITTING
To replace the engine (see Technical Note 6006A, CA or CAREG
cylinder cast iron, 10A, Engine and peripherals, (see 62A Air conditioning, Maintenance ).

vehicle.
Refit: Bleeding the cooling circuit ).
- the suspended engine mounting (see 19D, Engine Connect the battery (see 80A, Battery, Battery: Re-
mounting, Suspended mounting ) in accordance moval - Refitting ).
with the marks,
Tighten to torque the battery cover mounting bolts
- the suspended gearbox mounting (see 19D, Engi- ( 4 Nm ) .
- the lower engine tie-bar (see 19D, Engine moun- Note:

ting, Suspended mounting ).
- the front right-hand driveshaft (see 29A, Drives- to the vehicle; see 80C, Xenon bulbs, Xenon
hafts, Front right-hand driveshaft ), headlights: Adjustment ).
- the front left-hand driveshaft (see 29A, Drives- Adjust the headlights (see 80B, Headlights,
hafts, Front left-hand driveshaft ). Halogen headlights: Adjustment ).
Tighten to torque:

),

),

),
- the half sub-frame rear mounting bolt ( 210 Nm

).
IMPORTANT
sensor wiring.

Gearbox ),

Engine ),
- fill up the coolant circuit (see 19A, Cooling, Blee-
ding the cooling circuit ),
10A-106
K4J, and 730 or 732
REMOVAL
system hose clips
(large model)
IMPORTANT
Mot. 1202-02 Pliers for small hose During this operation, secure the vehicle to the
clips lift with a safety belt , to avoid any imbalance.
tem hose clips - the engine covers,
- the front wheels,
Equipment required
safety belt - the engine undertray.
filling station Drain:
hydraulic crane
box ),
load positioner - the engine (see 05A, Draining-Refilling, Engine ).
Tightening torquesm Removal - Refitting ).

CA or CAREG
mounting bolt
front end panel lower 44 Nm (see 62A, Air conditioning, Maintenance ).
mounting bolt

mounting bolt

mounting bolt
wheel bolt 110 Nm
101212
Remove:
Refitting ).
10A-107
K4J, and 730 or 732
7
2
5
4 101802
Disconnect the fuel supply union (7) .
Disconnect:
102504
01) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors,
Remove:
- the clip (4) ,
11
6
8 9
10
102365
Remove:
109537
- front end panel mounting bolts (6) , Disconnect the hoses from the cooling radiator ex-
- the front end panel. pansion bottle (8) .
10A-108
K4J, and 730 or 732
CA or CAREG
Remove:
- the air conditioning pipe between the compressor
13
and the dehydration canister (11) . 14
Note:
system.

101822
Remove:
- the battery tray,
12
101103
Remove:
- the air resonator mounting bolt (12) ,
- the air resonator.
101978
relay board.
10A-109
K4J, and 730 or 732
17 18
15
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 B
C
101812 A
101743
10A-110
K4J, and 730 or 732
19 21
101699 102008
Remove the gearbox controls (19) . Remove:
Front left-hand driveshaft ),
tioner or a chain.
20
101740
Pull out clip (20) .
Disconnect the hydraulic clutch supply pipes.
Note:
10A-111
K4J, and 730 or 732
REFITTING
linders - K4, 10A, Engine and peripherals, Nor-
mal replacement ).
vehicle.
Refit:
101866 - the front right-hand driveshaft (see 29A, Drives-

Tighten to torque:
),
),
),
tem: ),
102112
Mark the suspended engine mounting in relation to Gearbox ),
the body.
Engine ),
Remove:
- fill up the coolant circuit (see 19A, Cooling, Blee-
- the suspended engine mounting, ding the cooling circuit ).

IMPORTANT
Rotate the engine and gearbox assembly in or- Correctly attach the brake hose and the sensor
der to remove it. wiring for the ABS system.
Remove the engine and gearbox assembly . Do not twist the brake hose.
10A-112
K4J, and 730 or 732
Bleed the cooling circuit (see 19A, Cooling, Blee-
ding the cooling circuit: ).
CA or CAREG
Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the xenon bulb system (see
80C, Xenon bulbs, Xenon headlights: ).
Adjustment ).

Halogen headlights: Adjustment) .
10A-113
F9Q, and 804

WARNING
not replaced,
Mot. 1390 Support for removing
and refitting the - it is essential to replace the hoses and/or the inter-
engine and gearbox cooler if they are damaged.
assembly If this procedure is not followed the hoses may leak
or come undone.
Equipment required
safety belt REMOVAL

filling station Position the vehicle on a two-post lift (see 02A, Lif-
Tightening torquesm
IMPORTANT
front end panel upper 21 Nm During this operation, strap the vehicle to the lift
mounting bolt using a safety belt , to avoid any imbalance.
front end panel lower 44 Nm Remove:

mounting bolt
- the front wheels,
mounting bolt
mounting bolt - the engine undertray.
wheel bolt 130 Nm Drain:

box ),
bolts
CA or CAREG

10A-114
F9Q, and 804
Remove:
- the battery (see 80A, Battery, Battery: Removal - CA or CAREG
Refitting ).
Disconnect the pressostat connector from the lower
- the scuttle panel grille (see MR 371 Bodywork, air conditioning pipe on the condenser.
55A, Exterior protection, Scuttle panel grille ). Remove:
- the two air conditioning pipes from the condenser,
ning compressor and the dehydration canister.
2
Note:
1 Plugs must be fitted to the hoses and the expan-
system.
4
3

102504

Remove:
- the clip (3) ,
6
102365
Remove:
101212
Remove:
10A-115
F9Q, and 804
7
10
104338 106275
Remove: Disconnect.
- the fuel supply pipe (7) , Disconnect:
- the fuel return pipe (8) . - the intercooler hose (10)
WARNING 01) or (Mot. 1202-02) or (Mot. 1448) .
Follow the cleanliness guidelines closely (see - the fan unit connectors,
).
radiator side.
Watch out for diesel fuel splashing when discon-
necting the supply union.
Disconnect the electrical connector (9) .

Insert plugs into the openings.
11
102473
Disconnect the duct (11) .
10A-116
F9Q, and 804
12
13
17
16
102500 104245
Disconnect the connector (12) . Remove:
Remove the air filter outlet duct (13) . - 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
Remove:
- the battery tray,
104340
Remove:
- the earth strap (18) ,
- the pre-postheating unit (19) .
10A-117
F9Q, and 804
20
23
21
104322 101740
Remove the brake servo pipe (20) from the vacuum Pull the clip (23) from the clutch pipes.
pump.
Disconnect the hydraulic clutch supply pipes.
Disconnect the heater radiator hoses (21) from the
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) . Note:
24
22
104085
Remove the gearbox controls (2 2) , using a
102008
screwdriver.
Remove:
10A-118
F9Q, and 804
111879
102742
111880
Position the (Mot. 1390) .
102419

the body.
Remove:

der to remove it.
Remove the engine and gearbox assembly .
10A-119
F9Q, and 804
REFITTING - fill up the coolant circuit (see 19A, Cooling, Blee-

ding the cooling circuit ).
High pressure diesel engine - Common Rail 4 cy-
linder cast iron, 10A, Engine and peripherals, CA or CAREG
Position the engine and gearbox assembly in the (see 62A Air conditioning, Maintenance ).
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine Connect the battery (see 80A, Battery, Battery: Re-
mounting, Suspended mounting ) in accordance moval - Refitting ).
with the marks,
- the suspended gearbox mounting (see 19D, Engi- Bleeding the cooling circuit ).
- the lower engine tie-bar (see 19D, Engine moun- ( 4 Nm ) .
- the upper engine tie-bar (see 19D, Engine moun- Note:
If the vehicle is fitted with xenon bulbs, it is
- the front right-hand driveshaft (see 29A, Drives- essential to initialise the system (see 80C,
hafts, Front right-hand driveshaft ), Xenon bulbs, Xenon headlights: ). Adjust-
ment ).
Proceed in the reverse order to removal. Halogen headlights: Adjustment ).
Tighten to torque:
),
),
),
IMPORTANT
sensor wiring.

tem: ),
Gearbox ),
Engine ),
10A-120
K9K, and 732

WARNING
system hose clips intercooler (there is a danger of leakage and dislo-
(large model) cation if this procedure is not complied with):
- detach the hose using the (Car. 1363) ,
clips - 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,
tem hose clips
- always replace the clip with a new one,
Mot. 1390 Support for removing
and refitting the - replace the new clip in the same position if the
engine and gearbox hose is not replaced,
assembly - it is essential to replace the hose and/or the inter-
cooler if they are damaged,
Equipment required
filling station REMOVAL
Tightening torquesm I - REMOVAL PREPARATION OPERATION
half sub-frame front 105 Nm Position the vehicle on a two-post lift (see 02A, Lif-
mounting bolt ting equipment, Underbody lift ).

mounting bolt IMPORTANT
lift with a strap, to avoid any imbalance.
mounting bolt
Remove:
mounting bolt - the engine covers,
wheel bolts 110 Nm - the front wheels,
Drain:
- the gearbox, if necessary,
- the engine, if necessary.

CA or CAREG
Drain the coolant circuit using the filling station .
10A-121
K9K, and 732
102504
Remove:
- the relay plate cover mounting bolts.
101212
- the relay plate cover.
Remove: Disconnect the connectors (2) from the relay board.

- the battery,
Unclip the bonnet opening cable (3) ,
- the side reinforcements (1) ,
Remove:
- the clip (4) ,
102365
Remove:
Drain the cooling system (see 19A, Cooling, Coo-

10A-122
K9K, and 732
106275
112656
Remove:
WARNING
- Follow the cleanliness guidelines closely.
- Beware of diesel fuel splashing when discon-
necting the supply unions.
Place plugs in the holes (see 13B, Diesel injection,

Cleanliness guidelines ).
112661
Disconnect:
- the hoses from the intercooler (9) ,
(Mot. 1202-02) or (Mot. 1448) .
10A-123
K9K, and 732
109537 101822
Disconnect the hoses from the cooling radiator ex- Disconnect the computer connectors (15) .
Unclip:
- the wiring harness from the battery negative termi-
CA or CAREG nal,
Disconnect the pressostat connector from the lower - the wiring harness.
air conditioning pipe on the condenser. (12)
Remove:
Remove:
- the battery tray with the computer and its support.
ning compressor and the dehydration canister (14) Move the turbocharger pressure solenoid valve to
. one side.
Disconnect:
Note: - the connector from the flowmeter,
Plugs must be fitted to the hoses and the expan- - the air duct between the air filter unit and the turbo-
sion valve to prevent moisture from entering the charger.
system.
Remove the cooling radiator assemblies.
10A-124
K9K, and 732
112657
101978
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
K9K, and 732
112946 101743
Remove the brake servo pipe (21) from the vacuum Remove the gearbox controls.
pump.
Disconnect: WARNING
- the heating radiator hose from the scuttle panel Do not touch the gearbox control slides.
(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) .
101740
Pull clip (24) .
Disconnect the clutch hydraulic control.
Remove:
10A-126
K9K, and 732

CONCERNED
112814
112813
10A-127
K9K, and 732
Rotate the engine and gearbox assembly in order to
remove it.
Remove the engine and gearbox assembly.
REFITTING

cylinder cast iron, 10A, Engine and peripherals,

CONCERNED
Position the engine and gearbox assembly in the ve-
hicle.
Refit:
113927
gine mounting, Right-hand suspended moun-
ting: Removal - Refitting ),
- the left-hand suspended mounting (see 19D, Engi-
ne mounting, Left-hand suspended mounting:
Removal - Refitting ),
- the rear suspended mounting (see 19D, Engine
suspension, Rear suspended mounting: Remo-
val / Refitting ).
Remove the (Mot. 1390) .

Refit:
- the half sub-frame mounting bolts.
Tighten to torque:
112655 - the half sub-frame front mounting bolt ( 105 Nm

),
the body. - the half sub-frame rear mounting bolt ( 21 Nm ) .
Remove: Refit:
- the rear suspended mounting (see 19D, Engine - the front right-hand driveshaft (see 29A, Drives-
suspension, Rear suspended mounting: Remo- hafts, Front right-hand driveshaft ),
val - Refitting ),
- the left-hand suspended mounting (see 19D, Engi- hafts, Front left-hand driveshaft ).
ne mounting, Left-hand suspended mounting:
Removal - Refitting ),
IMPORTANT
gine mounting, Right-hand suspended moun- Correctly attach the flexible brake pipe and ABS
ting: Removal - Refitting ), sensor wiring.
10A-128
K9K, and 732
Connect:
- the clutch hydraulic control. CA or CAREG

- the heater radiator hose using the (Mot. 1202-01) Connect:
or (Mot. 1202-02) or (Mot. 1448) .
- the air conditioning pipes to the condenser.
- the heater radiator hose from the scuttle panel
using the (Mot. 1202-01) or (Mot. 1202-02) or
ning compressor and the dehydration canister.
(Mot. 1448) .
Refit the gearbox controls. air conditioning pipe
Connect:
- the pre-postheating unit connector,
- the earth strap on the body, Refit the fan unit wiring harness.
- the relay plate harness connectors. Refit:

Refit:
- the front end panel mounting bolts,
- the air filter unit,
- the two cooling assembly guide clips.
- the air duct upstream of the air filter.
- the mounting bolts,
Connect:
- the front bonnet opening cable clip.
- the air duct between the air filter unit and the turbo-
charger. Tighten to torque:
- the connector from the flowmeter.
),
Reposition the turbocharging pressure regulating
solenoid valve.
).
Refit:
Connect:
- the battery tray,
- the connectors to the relay board,
- the battery tray bolts, - the screen washer tubes.
Connect the computer connectors. Refit:
Refit: - the front bumper (see Workshop Repair Manual
365 Bodywork, 55A, Exterior protection, Front
- the negative terminal wiring harness,
bumper ),
- the wiring harness. - the side reinforcements,
Connect: - the right-hand and left-hand wheel arch liners,
- the fuel supply pipe, - the front wheels,
- the fuel return pipe. - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Prime the diesel circuit using the priming pump.
Refit the cooling assembly.
- the relay plate cover,
Connect:
- the relay plate cover mounting bolts.
- the cooling radiator hoses,
- the intercooler hoses,
Connect the battery ( 80A, Battery, Battery: Remo-
- the fan unit connectors. val - refitting) .
10A-129
K9K, and 732
CA or CAREG

component controls, Clutch system: Bleeding
),
Gearbox ),
Engine ),
ling circuit: Draining-refilling ).
Adjust the headlights (see, depending on equip-
ment, 80B, Headlights, Halogen headlights: Ad-
justment or 80C, Xenon bulbs, Xenon headlights:
Adjustment ).
You must initialise the xenon bulb system (if fitted

to the vehicle).
10A-130
Engine speed and position sensor: Removal - Refitting 10A
M9R, and 700
IV - FINAL OPERATION
Tightening torquesm Refit:

- the heat insulating material around the engine
engine speed and posi- 10 Nm speed and position sensor,
tion sensor mounting
bolt - the engine undertray.
REMOVAL

Move the heat insulating material to one side.

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
Crankshaft seal at timing end Removal - Refitting 10A
M9R, and 700
CONCERNED
Tightening torquesm
the crankshaft timing 47 Nm

end sealing ring
REMOVAL


Remove:
- the front right-hand wheel,

114853
- the front right-hand wheel arch liner.
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 sub-

frame cross member (1) ,

10A-132
M9R, and 700

CONCERNED
114850
113656
Position the sealing ring notches opposite the not-
ches in the timing cover.
WARNING
114851
Engage the sealing ring notches in the timing cover
notches.
Tighten the sealing ring by hand using the tool sup-
plied in the new gasket spare parts kit.
10A-133
M9R, and 700
114852
Using tool supplied in the new gasket spare parts kit
tighten to torque the crankshaft timing end sea-
ling ring ( 47 Nm ) .

Refit:
- the right-hand side reinforcements on the half sub-
frame,
- the front right-hand wheel arch liner,
- the front right-hand wheel.
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 moun- 40 Nm

ting bolt
wheel bolts 110 Nm
IMPORTANT
Wear protective gloves during every operation.
1
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 accesso-
ries pulley.
REMOVAL
Remove:
101878
Turn the accessories belt auto tensioner clockwise
- the front right-hand wheel arch liner. using a 16 mm spanner.
Remove:
- the accessories belt,
- the tensioning roller.
11A-1
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 five teeth, but the air
conditioning compressor pulley has six grooves.
When fitting 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 accesso-
ries belt correctly.
Tighten to torque:
11A-2
K9K, and 722 or 728 or 729, and CHAUFO K4J, and 730 or 732, and CHAUFO K4M, and 760 or 761, and
CHAUFO
Mot. 1638 Accessories belt ten-
sioning tool
Mot. 1505 Belt tension setting

tool (frequency meter)

Tightening torquesm

ting bolt
wheel bolts 110 Nm

bolts
IMPORTANT 101212
Wear protective gloves during the operation. Remove the side reinforcement (1) .
Loosen the tensioning roller bracket mounting bolts.
Remove:
WARNING
normal operation. - the tensioning roller.
REFITTING
WARNING Use a brush to remove any deposits from the
It is imperative to replace the accessories belt and crankshaft pulley V-grooves.
WARNING
- The two Torx mounting bolts of the tensioning
WARNING roller must be replaced by M8 x 20 bolts (part
number 77 03 002 059 ).
to avoid damaging the crankshaft and the accesso- Refit the accessories belt.
ries pulley.
Refit the tensioning roller fitted with new bolts.
REMOVAL

Remove:
11A-3
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 five teeth, but the pul-
leys have six grooves. It is essential to check that
21861
groove (2) remains free when the belt is fitted.
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 revolu-
tions 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.
bolt ( 35 Nm ) .
Proceed in the reverse order to removal
Tighten to torque:
11A-4
Tightening torquesm

ting bolt
wheel bolts 110 Nm
IMPORTANT
Wear gloves throughout the operation. 1
WARNING
normal operation.
101212
Remove the right-hand side reinforcement (1) .
WARNING
It is imperative to replace the accessories belt and
WARNING
to avoid damaging the crankshaft and the accesso-
ries pulley.
REMOVAL
Remove:
- the engine covers, 104339
- the front right-hand wheel, Turn the accessories belt auto tensioning roller anti-
clockwise using a 16 mm spanner.
Remove:

REFITTING
Use a brush to remove any deposits from the
crankshaft pulley V-grooves.
11A-5
bolt ( 50 Nm ) .
Rotate the crankshaft twice to position the accesso-
ries belt correctly.
Tighten to torque:
11A-6
M9R, and 700
Special tooling required frame cross member (1) .
Mot. 1770 Crankshaft pulley loc-
king tool II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

ting bolt

ting bolt
crankshaft accessories 50 Nm + 85
pulley mounting bolt 6
REMOVAL

Removal - Refitting ). 114854
Remove the engine undertray. 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 arch liner;
11A-7
M9R, and 700
114856 114849
Remove: Remove:
- the tensioning roller mounting bolts (3) , - 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
M9R, and 700

CONCERNED
I - REMOVAL PREPARATION OPERATION Refit the fixed roller.

Use a brush to remove any deposits from the Tighten to torque the tensioning roller mounting
crankshaft pulley V-grooves. bolt ( 44 Nm )
Refit the plastic cover on to the fixed roller mounting
WARNING bolt.
Only use brushes with plastic or non-corrosive

metal (brass) bristles. Note:
The Parts Department supplies the tensioning
roller pin.
WARNING
Do not run the engine without the accessories Refit the tensioning roller.
belt so as not to damage the crankshaft accesso-
.
ries pulley.
bolt ( 25 Nm ) .
WARNING
Refit the crankshaft accessories pulley by inserting it
onto the two crankshaft flat surfaces.
When replacing the accessories belt recommen-
ded by the manufacturer, always replace: Refit the washer inside the crankshaft accessories
pulley by inserting it onto the two crankshaft flat sur-
faces.
- the tensioning roller and fixed roller,
- the crankshaft accessories pulley bolt, WARNING
- the crankshaft accessories pulley. Check that the washer fits properly on the
crankshaft flat surfaces.
Finger tighten the crankshaft accessories pulley

mounting bolt.
Tighten to torque and angle the crankshaft acces-
sories pulley mounting bolt ( 50 Nm + 85 6 )
using the (Mot. 1770) .
Refit the accessories belt.
Remove the tensioning roller pin.
Turn the crankshaft twice.
Check that the accessories belt V-blocks are well
positioned in the V-grooves of all the pulleys.
11A-9
M9R, and 700
Refit:
frame cross member.
- the front right-hand wheel arch liner;
11A-10
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
Mot. 1453 Multiple-adjusting tensioning roller moun- 27 Nm

engine mounting sup- ting nut
port with retaining
straps crankshaft accessories 40 Nm + 145
Mot. 1453-01 Additional winder nut
on engine lift support tensioning roller moun- 27 Nm
Mot. 1453 ting nut
Mot. 1489 TDC locating pin tensioning roller moun- 27 Nm

ting nut
Mot. 1368 Tool for tightening ten-
sioner bolt. 8 mm Torx fixed roller mounting 45 Nm
wrench 12.7 mm bolt
square
Mot. 799-01 Timing gear wheel ting nut
immobiliser
Mot. 1496 Camshaft setting tool ting nut
Mot. 1750 Adapter for camshaft accessories pulley 40 Nm + 115

setting tool Mot. 1496 mounting bolt 15
Mot. 1490-01 Locking and adjusting new camshaft pulley 30 Nm + 84

camshaft pulleys nuts 4
Mot. 1487 Tool for refitting cams- tensioning roller moun- 27 Nm

haft covers (57 mm ting nut
diameter)
TDC setting pin plug 20 Nm
Mot. 1488 Tool for refitting cams-
haft covers (43 mm upper timing cover bolts 41 Nm
diameter) and nuts
wheel bolts 110 Nm
Tightening torquesm battery cover mounting 4 Nm

bolts
fixed roller mounting 45 Nm
bolt
IMPORTANT
Wear protective gloves during every operation.
ting nut

WARNING
tensioning roller moun- 27 Nm Never turn the engine in the opposite direction to its
ting nut normal operation.

ting nut
WARNING
fixed roller mounting 45 Nm
The belt must be replaced with a new one if it has
bolt
been removed.
11A-11
K4J, and 730 or 732
WARNING
When replacing the belt, be sure to replace the ten-
sioning rollers and fixed rollers.
Note:
The timing belt procedure is the same for engines
with or without camshaft dephasers
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif- 102450
Remove:
102451
Position the (Mot. 1453) and the (Mot. 1453-01) with
retaining straps.
11A-12
K4J, and 730 or 732
101866 101103
Mark the suspended engine mounting in relation to Remove:
the body.
- the air resonator mounting,
Remove:
- the engine and suspended engine mounting
assembly,
- the lower engine tie-bar.
WARNING
Do not damage the air conditioning pipe.
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
K4J, and 730 or 732
ADJUSTING THE TIMING
14490
14491-1 Check that the camshaft grooves are horizontal and
Position the camshaft grooves (2) almost horizontal- offset downwards.
ly and offset downwards, turning the crankshaft in its
normal operating direction (timing end clockwise).
Screw in the TDC setting pin (3) (Mot. 1489) .
14487
Remove:
- the crankshaft accessories pulley (4) , locking the
14489 flywheel with a screwdriver,
Turn the crankshaft in its operating direction (timing
- the upper timing cover (5) ,
end clockwise), until the crankshaft comes into con-
tact with TDC setting pin. - the lower timing cover (6) .
11A-14
K4J, and 730 or 732
REFITTING - PROCEDURE 1
I - PROCEDURE FOR ENGINES FITTED WITH A

TIMING COVER WITHOUT FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any timi-

8 ng component that does not require one or more
camshaft pulleys to be loosened.
7 WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the fixed
roller.
WARNING
101872
Undo the nut (7) on the tensioning roller to slacken Be sure to degrease:
the timing belt.
- the end of the crankshaft (timing end),
Remove:
- the timing sprocket bore and contact surfaces,
- the fixed roller (8) using the (Mot. 1368) ,
- the contact surfaces of the crankshaft and
- the timing belt, taking care not to drop the cranks- accessories pulley.
haft sprocket,
This is to avoid timing slippage.
- the timing sprocket,
This slippage causes engine damage.
14490
Set the camshaft grooves horizontally and below the

centre line by turning the camshafts with the (Mot.
799-01) if necessary.
11A-15
K4J, and 730 or 732
111337 14489
Fit the (Mot. 1496) with the (Mot. 1750) (9) .
108875
111336 Position the TDC setting pin (Mot. 1489) (10) .

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the Check that the crankshaft is in contact with the TDC
end of the camshafts. setting pin (Mot. 1489) (10) (crankshaft groove (11)
should be at the top).
11A-16
K4J, and 730 or 732
2 - REFITTING
14487-2
108879 Tighten to torque the fixed roller mounting bolt (
Refit the tensioning roller by positioning the tensio- 45 Nm ) using the (Mot. 1368) .
ning roller lug in rib (12) .
3 - BELT TENSION
14487-3
Refit: 103263
- the crankshaft timing sprocket (13) , Using a 6 mm Allen key, bring the adjustable index
(15) opposite the notch (16) , by turning the eccen-
- the timing belt,
tric (17) clockwise.
11A-17
K4J, and 730 or 732
Tighten to torque the tensioning roller mounting 4 - CHECKING THE TIMING AND TENSION
nut ( 27 Nm ) .
Refit the crankshaft accessories pulley. a - Checking the tension

Rotate the crankshaft clockwise through two revolu-
tions (timing end).
(crankshaft in contact with TDC setting pin) Screw in the TDC setting pin (Mot. 1489) .
Remove: Move the crankshaft slowly and smoothly to rest on

the TDC setting pin (Mot. 1489) .
- the camshaft setting tool (Mot. 1496) , Remove the TDC setting pin.
- the TDC setting pin (Mot. 1489) . Check the tensioning roller indexes are aligned; if
not readjust the tension by loosening the tensioning
Rotate the crankshaft clockwise (timing end) throu-
roller eccentric by a single turn.
gh two revolutions and before completing the se-
cond revolution. Correctly align the adjustable index with the fixed in-
dex or the notch (depending on the type of tensio-
Screw the TDC setting pin (Mot. 1489) into the cylin- ning roller).
der block.
Move the crankshaft slowly and smoothly to press nut ( 27 Nm ) .
against the TDC setting pin.
b - Checking the timing
Remove the TDC setting pin (Mot. 1489) .
Check that the tensioning roller indexes are correctly
positioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
Move the crankshaft slowly and smoothly until it 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.

nut ( 27 Nm ) .
11A-18
K4J, and 730 or 732
II - PROCEDURE FOR ENGINES FITTED WITH
TIMING COVER WITH FLAP

ng component that does not require one or more
WARNING
roller.
WARNING
Be sure to degrease:
14490 - the timing sprocket bore and contact surfaces,
Fit the camshaft adjusting tool (Mot. 1496) without - the contact surfaces of the crankshaft and
forcing (the camshaft grooves must be horizontal accessories pulley.
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
centre line by turning the camshafts with the (Mot.
799-01) , if necessary.
11A-19
K4J, and 730 or 732
111337 14489
108875
111336 Position the TDC setting pin (Mot. 1489) (22) .

Fix the (Mot. 1496) fitted with the (Mot. 1750) on the Check that the crankshaft is in contact with the TDC
end of the camshafts setting pin (Mot. 1489) (22) (crankshaft groove (23)
11A-20
K4J, and 730 or 732
2 - REFITTING 3 - TIMING BELT TENSION
108879
103263
Refit the tensioning roller by positioning the tensio-
ning roller lug in rib (24) . Bring the adjustable index (26) opposite the notch
(27) , by turning the eccentric (28) clockwise using a
Refit the crankshaft timing sprocket. 6 mm Allen key.
nut ( 27 Nm ) .
14487-3
Refit:
109054
- the timing belt, Refit the lower timing cover.
- the timing fixed roller (25)
Tighten to torque the fixed roller mounting bolt (

45 Nm ) using the (Mot. 1368) .
11A-21
K4J, and 730 or 732
Rotate the crankshaft twice in a clockwise direction,
on the timing end, before aligning the markings (on
the camshaft dephaser) already made by the opera-
tor.
der block.
Move the crankshaft slowly and smoothly to rest on
the TDC setting pin.
109055
Refit the crankshaft accessories pulley.

(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
K4J, and 730 or 732
4 - CHECKING THE TIMING AND TENSION
a - Checking the tension

tor.
der block.
Move the crankshaft slowly and smoothly to press
Check through the lower timing cover window that
the index and the notch of the timing tensioning rol-
ler are aligned; if not, readjust the tension by loose-
ning the tensioning roller nut on the eccentric by a
single turn.
Align the adjustable index with the notch.
109051
nut ( 27 Nm ) .

Ensure that the index and the notch on the timing
tensioning roller are in the correct position before
checking the timing.
der block.
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.

notch (29) turning the eccentric (31) in a clockwise
direction.
nut ( 27 Nm ) .
Check that dephaser marking is in alignment with
marking already made by the operator.
11A-23
K4J, and 730 or 732
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 front of engine, Camshaft ).
WARNING
roller.
14490
WARNING
Fit (without forcing) the camshaft setting tool (Mot.
1496) (the camshaft grooves must be horizontal and Be sure to degrease:
offset towards the bottom). - the end of the crankshaft (timing end),
Note: - the crankshaft accessories pulley bearing

faces,
must be repeated if the camshaft setting tool - the camshaft ends (timing end),
does not engage. - the camshaft sprocket bores and contact surfa-
ces.
Refit the camshaft pulleys and the old nuts, tighte-

ning 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
K4J, and 730 or 732
14490 111337
103261
Position the camshaft grooves horizontally and off- 111336
set downwards, by turning the camshafts with the
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
(Mot. 1496) if necessary.
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
K4J, and 730 or 732
II - REFITTING
14489
108879
ning 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). 14487-3
Position the RENAULT badge (37) etched on the Refit:
camshaft pulley spokes vertically at the top.
- the timing sprocket (39) ,
- the timing belt on the camshaft pulleys (without mo-
ving the camshaft pulleys).
11A-26
K4J, and 730 or 732
III - BELT TENSION
101876
Fit the camshaft pulley locking tool (Mot. 1490-01) 103263
(40) (use the timing cover mountings to mount the Using a 6 mm Allen key, bring the adjustable index
tool). (42) in line with the notch (43) , by turning the eccen-
tric (44) clockwise.
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 pul-
leys. 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) .
45 Nm ) using the (Mot. 1368) .
Refit the crankshaft accessories pulley (without tigh-
tening the bolt, 2 to 3 mm play between bolt and pul-
ley).
11A-27
K4J, and 730 or 732
103263 14489
Check that adjustable index (45) is opposite the

notch (46) .
WARNING
Loosen the tensioning roller nut by up to one turn, Check that the crankshaft is in contact with the
holding the adjustable index with a 6 mm Allen key. TDC setting pin (Mot. 1489) .
notch (46) turning the eccentric (47) in a clockwise Tighten to torque and angle:
direction. - the accessories pulley mounting bolt ( 40 Nm +
Tighten to torque the tensioning roller mounting 115 15 ) (crankshaft in contact with TDC setting
nut ( 27 Nm ) . pin)
- the new camshaft pulley nuts ( 30 Nm + 84 4

) starting with the exhaust pulley
Remove:
- the camshaft pulley locking tool (Mot. 1490-01) ,
IV - CHECKING THE TIMING AND TENSION
1 - Checking the tension

tions (timing end).
screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
14839 slowly and smoothly position the crankshaft in con-

tact with the TDC setting pin (Mot. 1489) .
Position the camshaft pulley locking tool (Mot. 1490-
01) . Remove the TDC setting pin (Mot. 1489) .
11A-28
K4J, and 730 or 732
Check the tensioning roller indexes are aligned; if REFITTING
not readjust the tension by loosening the tensioning
roller eccentric by a single turn. Refit the TDC setting pin plug, applying a drop of
JOINT SILICONE ADHERENT onto the thread hole.
Correctly align the adjustable index with the fixed in-
Tighten to torque the TDC setting pin plug ( 20 Nm
dex or the notch (depending on the type of tensio-
).
ning roller).
Refit the lower timing cover.
nut ( 27 Nm ) . 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

der block.
Move the crankshaft slowly and smoothly and rest it

on the TDC setting pin (Mot. 1489) .
15103-1
Refit:



14490 engine, Accessories belt ),
Fit the camshaft adjusting tool (Mot. 1496) without - new inlet camshaft sealing plugs (Mot. 1487) ,
forcing (the camshaft grooves must be horizontal - new exhaust camshaft sealing plugs (Mot. 1488) .
and offset downwards).

Note:
must be repeated if the camshaft setting tool Tighten to torque:
does not engage.
- the wheel bolts ( 110 Nm )
Remove the TDC setting pin. - the battery cover mounting bolts ( 4 Nm ) .
11A-29
K9K, and 722 or 728 or 729
REMOVAL
Mot. 1453 Multiple-adjusting ting equipment, Underbody lift ).
engine mounting sup-
port with retaining Disconnect the battery (see 80A, Battery, Battery:
straps Removal - Refitting ).
Remove the accessories belt (see 11A, Top and
Mot. 1453-01 Additional winder nut front of engine, Accessories belt: Removal - Re-
on engine lift support fitting ).
Mot. 1453
Mot. 1489 TDC locating pin
Mot. 1430 Set of 5 crankshaft

and camshaft pulley
timing pins
Tightening torquesm
tensioning roller bolt 25 Nm

pulley M12 mounting 10
bolt
102450
pulley M14 mounting 15
bolt

ting bolt
cylinder head suspen- 21 Nm

ded mounting bolts
wheel bolts 110 Nm

bolts
WARNING
normal operation.
102451
Position the (Mot. 1453) and (Mot. 1453-01) with re-
taining straps.
11A-30
K9K, and 722 or 728 or 729
102115
Remove the lower tie-bar bolts (1) .
Remove the lower engine tie-bar.
102114
Mark the position of the suspended engine moun-

ting.
Slacken the bolt (2)
WARNING
11A-31
K9K, and 722 or 728 or 729
19654
Remove the upper timing cover by unclipping the
tabs (3) .
11A-32
K9K, and 722 or 728 or 729
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
K9K, and 722 or 728 or 729
19654-2
Remove the cylinder head suspended mounting. Positioning the timing at the adjustment point
7 8
19702
19650
Rotate the crankshaft clockwise (timing end) to posi-
Remove the TDC setting pin plug. tion the hole (8) in the camshaft pulley partially in
line with the hole (9) in the cylinder head.
11A-34
K9K, and 722 or 728 or 729
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) ,
14489-1
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft comes in contact with the TDC
setting pin (Mot. 1489) .
11A-35
K9K, and 722 or 728 or 729
19656
Remove the crankshaft accessories pulley, locking
the flywheel with a screwdriver.
11A-36
K9K, and 722 or 728 or 729
10
19656-1
Undo the tensioning roller bolt (10) to slacken the ti- REFITTING
ming belt.
Remove:
WARNING
- the timing belt (take care not to drop the crankshaft
sprocket), It is imperative to replace the timing belt, the ten-
sioning roller and the accessories pulley bolt.
WARNING
- the contact surfaces of the crankshaft accesso-
ries pulley.
11A-37
K9K, and 722 or 728 or 729
19710
Refit the crankshaft timing sprocket.
11A-38
K9K, and 722 or 728 or 729
2 14
13
12
11
15
19656-2
Note:
Check that the tensioning roller lug (11) is cor-
rectly 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) fa-
cing upwards).
11A-39
K9K, and 722 or 728 or 729
16
19657 19658
Fit the new timing belt, aligning the marks on the belt Position the tensioning roller adjustable index (16)
with those on the camshaft sprockets and the high opposite the lug using a 6 mm Allen key, turning it
pressure pump. anticlockwise.
Tighten to torque the tensioning roller bolt ( 25 Nm
Note: ).
19 belt tooth spaces between the camshaft Refit the crankshaft accessories pulley.
sprocket and pump marks. 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
K9K, and 722 or 728 or 729
19
20
18
17
19702 19655
Rotate the crankshaft clockwise through two revolu- Check:
tions (timing end).
- that the timing pin (Mot. 1430) engages properly in
Before the camshaft pulley hole (17) comes in line the camshaft and cylinder head holes,
with the cylinder head hole (18) , screw the TDC set-
- that there are 19 belt tooth spaces between the
ting pin (Mot. 1489) into the cylinder block.
camshaft sprocket mark (19) and the high pressure
Bring the crankshaft slowly and smoothly into con- pump sprocket mark (20) .
tact with the pin.
Remove:
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
K9K, and 722 or 728 or 729
First position Second position
21
23
111083 111082
23
24
111081 111081
Loosen the tensioning roller bolt by no more than Loosen the tensioning roller bolt by no more than
one turn, holding it with a 6 mm Allen key. one turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index (21) , turning Gradually align the adjustable index (23) , turning
the Allen key anticlockwise, to the middle of the timi- the key clockwise, to the middle of the timing window
ng window (22) . (24) .
11A-42
K9K, and 722 or 728 or 729
II - REFITTING
bolt ( 25 Nm ) .
Refit the TDC setting pin plug, applying JOINT SILI-
CONE ADHERENT to the thread hole.
).
19654-2
Refit the cylinder head suspended mounting.
Tighten to torque the cylinder head suspended
11A-43
K9K, and 722 or 728 or 729
19654-1
25
26
19659
Refit the lower timing cover, positioning the tab (25)
in the lower timing cover aperture (26) .
11A-44
K9K, and 722 or 728 or 729
19654
Refit:
- the upper timing cover,
with the marks,
.
Tighten to torque:
11A-45
F9Q, and 800 or 804 or 808
Mot. 1453 Multiple-adjusting

port with retaining
straps

on engine lift support
Mot. 1453
Mot. 1054 TDC setting pin
Mot. 1543 Tool for pretensioning

timing belt
102450
Mot. 1705 Adapter for timing belt
pretensioning tool


Tightening torquesm

ting nut

wheel bolts 110 Nm
battery cover bolts 4 Nm 102451

Position the (Mot. 1453) and (Mot. 1453-01) with re-
taining straps.
WARNING
normal operation.
REMOVAL

Remove:
- the accessories belt (see 11A, Cylinder head, Ac-
cessories belt: Removal - Refitting ).
11A-46
F9Q, and 800 or 804 or 808
102420 15102
Remove:
Remove:
- the TDC setting pin plug.
Mark the position of the suspended engine mounting - the flywheel guard cover plate.
in relation to the body.
Slacken the bolt (1)
WARNING
Do not damage the air conditioning pipes (if fitted
to the vehicle).
104739
Remove:
- the crankshaft accessories pulley, locking the

flywheel with a screwdriver,
- the timing cover mounting bolts (2) ,
- the timing cover.
11A-47
F9Q, and 800 or 804 or 808
104326
104329 Undo the tensioning roller mounting nut (3) to slac-
Rotate the crankshaft clockwise (timing end); bring ken the tensioning roller.
the camshaft pulley mark to half a tooth before the
Remove the timing belt.
mark on the guard.
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 set-
ting pin (Mot. 1054) until the crankshaft is timed.
11A-48
F9Q, and 800 or 804 or 808
104336 104327
Refit the tensioning roller, taking care to position it Fit the new timing belt, aligning the marks on the belt
correctly on the locating pin (4) . with those on the crankshaft, camshaft and high
pressure pump sprockets (count 28 belt tooth spa-
ces between the mark on the camshaft sprocket and
the mark on the high pressure pump sprocket).
6 6 Press the tensioning roller against the belt by tighte-
ning the bolt (8) on the tensioning roller mounting.
Note:
5 The bolt (8) is manufactured locally.

7
Position the crankshaft accessories pulley bolt.
16187
Check that the TDC setting pin (Mot. 1054) is in pla-

ce.
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
F9Q, and 800 or 804 or 808
16563 104332
Pretension the timing belt between the crankshaft ti-
ming sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of
(11 Nm) .
104331
Mount the timing belt pretensioning tool (Mot. 1543)
fitted with the cover (Mot. 1705) (9) on the cranks-
haft accessories pulley bolt.
11A-50
F9Q, and 800 or 804 or 808
10
104333 105435
Position the sensor of the (Mot. 1505) o r (Mot.
Remove the crankshaft accessories pulley bolt.
1715) between the crankshaft sprocket and the ten-
sioning roller.
Refit the crankshaft accessories pulley, without se-
Tension the belt to obtain the recommended value parating its two component parts.
90 3 Hz by turning the bolt (10) .
nut (10 Nm) .
.
Turn the crankshaft through two revolutions.
Refit:
Reposition the TDC setting pin (Mot. 1054) .
Position the timing at its setting point (start pressing - the suspended engine mounting (see 19D, Engine
on the pin half a tooth before alignment of the cams- mounting, Suspended mounting ),
haft pulley mark and the cover plate mark, to avoid
going into a camshaft balancing hole). - the upper engine tie-bar (see 19D, Engine moun-
Refit the TDC setting pin plug, applying a drop of - the lower engine tie-bar (see 19D, Engine moun-
RHODORSEAL 5661 onto the thread. ting, Suspended mounting ),
). - the accessories belt (see 11A, Top and front of
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 . To refit, proceed in the reverse order to removal.
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, rea-
djust. Tighten to torque:
nut ( 45 Nm ) .
Remove the (Mot. 1543) . - the battery cover bolts ( 4 Nm ) .
11A-51
F4R, and 770 or 771 or 776
Mot. 1453 Multiple-adjusting toothed sprocket nuts 80 Nm

port with retaining toothed sprocket nuts 80 Nm
straps
tensioning roller nut 28 Nm
on engine lift support toothed sprocket nuts 80 Nm
Mot. 1453
inlet camshaft depha- (30 Nm)
Mot. 1672 Lower engine support ser mounting bolt
Mot. 1054 TDC setting pin exhaust camshaft pul- (30 Nm)
ley nut
Mot. 1509 Camshaft sprocket
locking tool inlet camshaft depha- 100 Nm
ser mounting bolt
Mot. 1509-01 Conversion kit for Mot.
1509 camshaft pulley depha- 25 Nm
ser blanking cover
Mot. 799-01 Timing gear wheel
immobiliser exhaust camshaft pul- 86 6
ley nut
Mot. 1496 Camshaft setting tool
toothed sprocket nuts 80 Nm
haft covers (57 mm inlet and exhaust cams- 86 6
diameter) haft pulley nuts
Mot. 1448 Remote operation clip nuts 80 Nm

inlet and exhaust cams- 30 Nm + 86
tem hose clips
haft pulley nuts 6

Tightening torquesm pulley bolt 10
toothed sprocket nuts 80 Nm M6 lower timing cover 80 Nm

bolts
toothed sprocket nuts 80 Nm
M8 lower timing cover 20 Nm
fixed roller mounting 50 Nm bolts
bolt
M8 upper timing cover 18 Nm
tensioning roller nut 7 Nm bolts
toothed sprocket nuts (80 Nm) M10 upper timing cover 38 Nm

bolts
old inlet camshaft (30 Nm)
dephaser mounting bolt wheel bolts 110 Nm
old exhaust camshaft 30 Nm battery cover mounting 4 Nm

pulley nut bolts
toothed sprocket nuts (80 Nm)

Note
old inlet and exhaust (30 Nm)
camshaft pulley nuts The timing belt procedure is the same for engines
with or without camshaft dephasers.
11A-52
F4R, and 770 or 771 or 776
WARNING
normal operation.
WARNING
to avoid damaging the crankshaft accessories pul-
ley.
WARNING 102450
On the F4R engine, it is essential to fit the cranks-
haft sprocket with the integral key.
WARNING
Replace the following parts when they are removed:

- the camshaft pulley nuts,
- the crankshaft accessories pulley,
- the crankshaft accessories pulley bolt.
WARNING
When replacing the belt, it is imperative to replace
the tensioning roller and the fixed roller.
REMOVAL 102451
Position the vehicle on a two-post lift (see 02A, Lif- Position the (Mot. 1453) and (Mot. 1453-01) with re-
ting equipment, Underbody lift ). taining straps.

Remove:
Refitting ).
- the engine covers.
11A-53
F4R, and 770 or 771 or 776
102365
1 Remove:
106077 - the front right-hand driveshaft (see 29A, Drives-
Remove:
- the radiator cross member right-hand side reinfor-
cement (1) ,
F4R, and 776
3
2 105432
Position the (Mot. 1672) with retaining straps.
5
4
102504

Remove:
- the clip (4) ,
- the fastening (5) ,
11A-54
F4R, and 770 or 771 or 776
- the connector on the lifting bracket.
F4R, and 776
102742

the body.
Remove the suspended mounting assembly. 9
106278
Note:
Remove the fuel vapour recirculation solenoid valve
Be careful not to bend the air conditioning pipe. (9) .

front of engine, Accessories belt: Removal - Re-
fitting ).
F4R, and 770 or 771
101807
Remove:
- the air filter outlet duct (7) ,

- the throttle valve (8) ,
11A-55
F4R, and 770 or 771 or 776
10
11
106632 15105
Remove the camshaft sealing plugs.
Loosen the nut (10) .
Pull the mounting bracket away from the electric I - ADJUSTING THE TIMING
coolant pump.
Move the electric coolant pump (11) to one side.
Remove the wiring harness mounting bracket.
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.
Insert the TDC setting pin (Mot. 1054) so that it is
12 between the balancing hole and the crankshaft set-
ting groove.
15102
Remove the TDC setting pin plug (12) .
11A-56
F4R, and 770 or 771 or 776
Correct position
15163-2 15163-1
Turn the engine slightly in the same direction,
pushing in the TDC setting pin (Mot. 1054) until the Incorrect position
setting point is reached.
15163
15106-1
At the setting point, the camshaft grooves must be

horizontal and offset below the centre line, as shown
in the drawing.
11A-57
F4R, and 770 or 771 or 776
106519
15303
Remove:
- the flywheel guard,
- the crankshaft pulley, locking the flywheel with a
screwdriver.
Refit the TDC setting pin (Mot. 1054) .
11A-58
F4R, and 770 or 771 or 776
F4R, and 770 or 771
13
14
18433
Remove:
- the lower timing cover (14) .
11A-59
F4R, and 770 or 771 or 776
F4R, and 776
15
106338
16
17
104719
Remove: - the upper timing cover (16) ,

- the heat shield (15) ,
11A-60
F4R, and 770 or 771 or 776
18
19
18433-2
Slacken the timing belt by loosening the tensioning
roller nut (18) .
WARNING
Remove:
Never turn the engine in the opposite direction to
- the fixed roller (19) , its normal operation.
- the timing belt,
- the crankshaft timing sprocket.
WARNING
When replacing the timing belt, it is imperative to
replace the tensioning roller and the fixed roller.
WARNING
A belt which has been removed MUST be repla-
ced.
11A-61
F4R, and 770 or 771 or 776
II - ADJUSTING THE TIMING
20
104703
WARNING
- the timing sprocket bore and contact surfaces
(20) ,
- the contact surfaces of the crankshaft accesso-
ries pulley,
This is to prevent slippage between the timing
gear and the crankshaft.
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
F4R, and 770 or 771 or 776
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
F4R, and 770 or 771 or 776
26 25
22
27
21
16019 16019-3
Position the (Mot. 1509) with sprocket (Mot. 1509- Tighten the bolt and the shouldered nut (25) .
01) .
Bring the toothed sprockets of the (Mot. 1509) into
Position the spacer (21) of the (Mot. 1509-01) on the contact with the camshaft pulleys.
stud (22) .
Tighten the toothed sprocket nuts ( 80 Nm ) (26) .
Remove:
24
- the inlet camshaft dephaser blanking cover (27) ,
- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
23
- the camshaft pulleys.
Loosen the stud with the nut (see NT 3884A, Repla-
cing 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 co-
ver (do not tighten the bolt).
11A-64
F4R, and 770 or 771 or 776
Refit the degreased camshaft pulleys with the old
mountings.
F4R, and 776
Tighten to torque the old mountings (15 Nm max.)
WARNING
When removing the timing belt, it is essential to

replace:
28 - the crankshaft accessories pulley,
- the tensioning roller and fixed 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.
Remove:
- the camshaft pulley nuts,
- the (Mot. 1509) , 15106-1
- the camshaft pulleys. Position the grooves offset horizontally below the
centre-line as shown above by turning the cams-
Loosen the stud with the nut (see NT 3884A, Repla-
hafts using the (Mot. 799-01) .
cing F4 camshaft pulley studs, Top and front of
engine, Camshaft ).
11A-65
F4R, and 770 or 771 or 776
31
30
15104 15114
Position the (Mot. 1496) , attaching it to the end of
the camshafts. Correct position
F4R, and 770 or 771

Loosen:
- the exhaust camshaft pulley nut,
- the inlet camshaft dephaser pulley bolt,
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
F4R, and 770 or 771 or 776
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 belt,
50 Nm ) .
11A-67
F4R, and 770 or 771 or 776
III - ADJUSTING THE TENSION
F4R, and 770 or 771
37
38
35
39
36
15256
104728
Note: Position the (Mot. 1509) with the toothed sprocket

(Mot. 1509-01) for locking the camshaft pulleys.
Do not rotate the tensioning roller anticlockwise.
Align the marks (35) and (36) on the tensioning roller
Bring the toothed sprocket nuts into contact with the
using an Allen key (6 mm) in (37) .
camshaft pulleys.
Tighten to torque the tensioning roller nut ( 7 Nm )
Tighten to torque:
.
- the toothed sprocket nuts ( (80 Nm) ) (39) ,
- the old inlet camshaft dephaser mounting bolt (
(30 Nm) ) ,
- the old exhaust camshaft pulley nut ( 30 Nm ) .
Remove the (Mot. 1509) fitted with the (Mot. 1509-
01) .
11A-68
F4R, and 770 or 771 or 776
F4R, and 776
42
40
41
21877
Make a pencil mark (42) between the camshaft pul-
104711
leys and the camshaft bearing cap.
Position the (Mot. 1509) for locking the camshaft Remove the following tools:
pulley. - TDC setting pin (Mot. 1054) ,
Tighten the bolt and the shouldered nut (40) . - camshaft setting tool (Mot. 1496) .
Bring the toothed sprocket nuts into contact with the Rotate the crankshaft clockwise through two revolu-
camshaft pulleys. tions (timing end).
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (40) ,
- the old inlet and exhaust camshaft pulley nuts (
(30 Nm) ) (41) ,
01) .
11A-69
F4R, and 770 or 771 or 776
IV - CHECKING THE TIMING AND THE TENSION
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
F4R, and 770 or 771 or 776
F4R, and 770 or 771 F4R, and 776
43 45
44
46
104728 104711
Position the (Mot. 1509) with the toothed sprockets Position the (Mot. 1509) for locking the camshaft
(Mot. 1509-01) for locking the camshaft pulleys. pulley.
Tighten the bolt and the shouldered nut (43) . Tighten the bolt and the shouldered nut (45) .
Offer up the toothed sprocket nuts against the cams- Offer up the toothed sprocket nuts against the cams-
haft pulleys. haft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (44) . Tighten the toothed sprocket nuts ( 80 Nm ) (46) .
Loosen: Loosen:
- the old inlet camshaft dephaser pulley mounting - the old inlet camshaft pulley nut,
bolt,
- the old exhaust camshaft pulley nut.
- the old exhaust camshaft pulley nut.
Remove the (Mot. 1509) for locking the camshaft
Remove the (Mot. 1509) with the sprocket (Mot. pulley.
1509-01) for locking the camshaft pulleys.
11A-71
F4R, and 770 or 771 or 776
49
47
48
15256
Align mark (47) with mark (48) by loosening the ten-
sioning 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
F4R, and 770 or 771 or 776
Remove the following tools:
F4R, and 770 or 771 - TDC setting pin (Mot. 1054) ,

- camshaft pulley locking tool (Mot. 1509) with too-
thed sprockets (Mot. 1509-01) .
tions (timing end).
50
51
104728
Position the (Mot. 1509) with toothed sprockets to

lock the camshaft pulleys.
Bring the toothed sprockets into contact with the
camshaft pulleys.
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
F4R, and 770 or 771 or 776
F4R, and 776
54
55
52
53
104711
Position the camshaft locking tool (Mot. 1509) , tor-
que tightening the nuts ( 80 Nm ) (54) .
104711
Position the (Mot. 1509) for locking the camshaft
pulley. Remove the old camshaft pulley nuts and replace
them with new ones.
Tighten to torque and angle the inlet and exhaust
Bring the toothed sprocket nuts into contact with the camshaft pulley nuts ( 30 Nm + 86 6 ) .
camshaft pulleys.
- (Mot. 1496) ,
Remove:
- camshaft pulley locking tool (Mot. 1509) .
- the old inlet camshaft pulley nut, - the TDC setting pin (Mot. 1054) .
- the old exhaust camshaft pulley nut. Rotate the crankshaft clockwise through two revolu-
tions.
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 ) .
- TDC setting pin (Mot. 1054) ,
- camshaft pulley locking tool (Mot. 1509) .

tions (timing end).
11A-74
F4R, and 770 or 771 or 776
56
57
15104
15649 Position the camshaft setting tool (Mot. 1496) wi-

thout forcing it. If the tool does not engage, repeat
Before the end of the second revolution (i.e. half a the timing and tensioning procedure.
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 REFITTING
hole and the timing hole). Refit:
Check that mark (56) is aligned with mark (57) on - the lower timing cover,
the tensioning roller before checking the timing ad-
- the upper timing cover.
justment.
WARNING
It is imperative to replace the crankshaft acces-
sories pulley and bolt.
58
15106-1
The offset grooves (58) should be horizontal and be-

low the centre line.
11A-75
F4R, and 770 or 771 or 776
15303 15103-1
Lock the flywheel using a large screwdriver. Refit:
Tighten to torque and angle the crankshaft acces- - the new sealing plugs:
sories pulley bolt ( 40 Nm + 110 10 ) .
on the inlet camshaft (Mot. 1487) ,
on the exhaust camshaft (Mot. 1448) ,
WARNING
To avoid damaging the crankshaft accessories
gine mounting, Suspended mounting ) in accor-
pulley, do not start the engine without the acces-
dance with the marks.
sories belt.
Refit:
Tighten to torque:
- the crankshaft accessories belt (see 11A, Top and
front of engine, Accessories belt ), - the M6 lower timing cover bolts ( 80 Nm ) ,
- the TDC setting pin plug, applying a drop of RHO- - the M8 lower timing cover bolts ( 20 Nm ) ,
DORSEAL 5661 to the thread hole. - the M8 upper timing cover bolts ( 18 Nm ) ,
- the M10 upper timing cover bolts ( 38 Nm ) ,
11A-76
K4M, and 730 or 732
Mot. 1453 Multiple-adjusting wheel bolts 110 Nm

port with retaining battery cover mounting 4 Nm
straps bolts

on engine lift support WARNING
Mot. 1453
Mot. 1489 TDC locating pin normal operation.
Mot. 1368 Tool for tightening ten-

sioner bolt. 8 mm Torx REMOVAL
wrench 12.7 mm Position the vehicle on a two-post lift (see 02A, Lif-
square ting equipment, Underbody lift ).
Mot. 799-01 Timing gear wheel Disconnect the battery (see 80A, Battery, Battery:
immobiliser Removal - Refitting ).
Mot. 1496 Camshaft setting tool Remove:

Mot. 1750 Adapter for camshaft
setting tool Mot. 1496 - the accessories belt (see 11A, Top and front of
Mot. 1490-01 Locking and adjusting
camshaft pulleys

haft covers (57 mm
diameter)

haft covers (43 mm
diameter)
Tightening torquesm

pulley bolt 15
timing tensioning roller 27 Nm

nut
pulley mounting bolt 45 Nm
exhaust camshaft pul- 30 Nm + 84

ley nut 4
inlet camshaft pulley 75 Nm

dephaser bolt
TDC pin plug 20 Nm
upper timing cover nuts 41 Nm

and bolts
11A-77
K4M, and 730 or 732
102450
101866
the body.
Remove:
- the engine/suspended engine mounting as-
sembly,
WARNING
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) and the 2
retaining straps.
101807
Remove:
- the throttle valve (2) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
11A-78
K4M, and 730 or 732
4
3
14491
Pierce the centre of the plugs on the end of the 14491-1
camshaft using a screwdriver. Position the camshaft grooves (5) almost horizontal-
ly and offset towards the bottom while turning the
Remove:
crankshaft in its operating direction (clockwise timi-
- the sealing plugs at the camshaft end with a ng end).
screwdriver,
Screw in the TDC setting pin (4) (Mot. 1489) .
- the TDC setting pin plug (3) .
14489
Turn the crankshaft in its operating direction (timing
end clockwise), until the crankshaft comes into con-
tact with TDC setting pin.
11A-79
K4M, and 730 or 732
10
9
14490 101872
Check that the camshaft grooves are horizontal and Undo the tensioning roller bolt (9) to slacken the timi-
offset downwards. ng belt.
Remove:
- the pulley (10) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the cranks-
haft sprocket,
7 - the timing sprocket,
14487
Remove:
- the crankshaft accessories pulley (6) , locking the
flywheel with a screwdriver,
11A-80
K4M, and 730 or 732
REFITTING - PROCEDURE 1
I - PROCEDURE FOR AN ENGINE FITTED WITH A

TIMING COVER WITHOUT A FLAP

WARNING
ries pulley bolt, the tensioning roller and the pul-
ley.
WARNING
Be sure to degrease: 111337

- the end of the crankshaft (timing end), Fit the (Mot. 1496) with (Mot. 1750) (11) .
- the accessories pulley contact surfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-
ces.
This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.
Position the camshaft grooves horizontally and be-

low the centre line by turning the camshafts using
the (Mot. 799-01) if necessary.
111336
11A-81
K4M, and 730 or 732
103269
Check that the mark (12) on the dephaser is vertical
and pointing upwards.
Make a mark (13) with a pencil between the depha-
ser wheel and the rocker cover.
11A-82
K4M, and 730 or 732
14489 14487-3
Check: Refit:
- that the crankshaft is correctly in contact with the - the timing sprocket (18) ,
TDC setting pin (Mot. 1489) (15) with the cranks- - the timing belt,
haft groove (14) facing upwards,
- the pulley (17) .
- that the inlet camshaft dephaser wheel is correctly
locked (wheel does not rotate right or left). Tighten to torque the pulley mounting bolt (45 Nm)
using (Mot. 1368) .
.
3 - BELT TENSION
2 - REFITTING
103263
108879 Using a 6 mm Allen key, bring the adjustable index
Refit the tensioning roller by positioning the tensio- marker (19) opposite the notch (20) , by turning the
ning roller lug in the groove (16) . eccentric (21) clockwise.
11A-83
K4M, and 730 or 732
nut (7 Nm)
Refit the crankshaft accessories pulley.

sories pulley bolt ( 40 Nm + 145 15 ) (cranks-
haft in contact with the TDC setting pin).
Remove:
Rotate the crankshaft through two clockwise revolu-

tions (timing end) before aligning the marks (on the
camshaft dephaser).
der block.

103263
Check that the adjustable index marker (22) is oppo-

site the notch (23) .

Gradually move the adjustable indexing marker (22)

opposite the notch (23) turning the eccentric (24) in
a clockwise direction.
11A-84
K4M, and 730 or 732
103267
Tighten to torque the timing tensioning roller nut Check that the timing pulley index markers are cor-
(27 Nm) (25) . rectly positioned before checking the timing setting.
Check that the dephaser mark (26) is aligned with Screw the TDC setting pin (Mot. 1489) into the cylin-
the mark (27) . der 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
a - Checking the tension and below the centre line).
Rotate the crankshaft through two clockwise revolu-
tions (timing end) before aligning the marks (on the WARNING
camshaft dephaser).
If the tool cannot be engaged, readjust the timing
Screw in the TDC setting pin (Mot. 1489) . and the tension.

the TDC setting pin (Mot. 1489) .
Check that the tensioning roller markers are aligned.

If not, repeat the tensioning procedure.
11A-85
K4M, and 730 or 732
II - PROCEDURE FOR AN ENGINE FITTED WITH A
TIMING COVER WITH A FLAP

WARNING
ley.
WARNING
- the timing sprocket bore and contact surfaces, 111337
- the accessories pulley contact surfaces, Fit the (Mot. 1496) with (Mot. 1750) (28) .

ces.
This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.

centre line by turning the camshafts using the (Mot.
799-01) if necessary.
111336
11A-86
K4M, and 730 or 732
103269
Check that the mark (29) on the dephaser is vertical
and pointing upwards.
11A-87
K4M, and 730 or 732
14489 14487-3
Check: Refit:
- that the crankshaft is correctly in contact with the - the timing sprocket (35) ,
TDC setting pin (Mot. 1489) (32) with the cranks- - the timing belt,
haft groove (48) facing upwards,
- the pulley (34) .
- that the inlet camshaft dephaser wheel is correctly
locked (wheel does not rotate right or left).
.
2 - REFITTING
14487-2
Tighten to torque the pulley mounting bolt (45 Nm)
using (Mot. 1368) .
108879
ning roller lug in the groove (33) .
11A-88
K4M, and 730 or 732
3 - BELT TENSION
109055
103263 Refit the crankshaft accessories pulley.
Move the adjustable index marker (36) opposite the
notch (37) , by turning the eccentric (38) clockwise
sories pulley bolt (40 Nm + 145 15) .
using a 6 mm Allen key.
109054
11A-89
K4M, and 730 or 732
109052 109051
Remove the timing flap from the lower timing cover.
Remove:
tor.
der block.
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
K4M, and 730 or 732
a - Checking the tension

tor.
der block.
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. 14490
Tighten to torque the timing tensioning roller nut ( Position (without forcing) the camshaft timing tool
27 Nm ) .
(Mot. 1496) (the camshaft end grooves must be ho-
rizontal and offset towards the bottom).
Check that the index marker and the timing tensio-
ning roller notch are correctly positioned before WARNING
checking the timing. The timing adjustment and tensioning operation
must be repeated if the camshaft setting tool
does not engage.
der block.
109052
Refit the lower timing cover flap, checking that the

pin (42) fits into the notch properly (43) .
11A-91
K4M, and 730 or 732
REFITTING -PROCEDURE 2

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 Techni-
cal Note 3887A, Replacement of K9 -K4 cams-
haft pulley studs, 11A, Top and front of
engine, Camshaft ).
WARNING
ley.
14490
WARNING
- the accessories pulley contact surfaces,
ces.
Refit the camshaft pulleys and the old nuts, tighte-

ning them to a torque of 15 Nm .
103261
Position the camshaft grooves horizontally and off-
set downwards, by turning the camshafts using the
(Mot. 1496) if necessary.
11A-92
K4M, and 730 or 732
111337
Fit the (Mot. 1496) with (Mot. 1750) (44) .
111336
11A-93
K4M, and 730 or 732
14489
103269
Check that the crankshaft is in contact with the TDC
setting pin (Mot. 1489) (45) (crankshaft groove (46)
11A-94
K4M, and 730 or 732
111338 111340
Fit the camshaft dephaser into a vice with jaws. Check that the dephaser hub is mechanically secu-
red correctly using a tubular hexagon box spanner
(the hub must not be able to rotate towards the left 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.
111339
Fit a bolt in the dephaser hub.
11A-95
K4M, and 730 or 732
II - REFITTING
103265
108879 Fit the camshaft pulley locking tool (Mot. 1490-01)
When refitting the tensioning roller, ensure that the (52) (use the timing cover mountings to fit the tool).
tensioning roller lug fits correctly into the groove (50)
.
14487-3
Refit the pulley (53) .
14487-3
Tighten to torque the pulley mounting bolt ( 45 Nm
Refit:
) using the (Mot. 1368) .
- the timing sprocket (51) ,
Refit the crankshaft accessories pulley (without tigh-
- the timing belt on the camshaft pulleys (without mo- tening the bolt, leaving 2 to 3 mm play between bolt
ving the camshaft pulleys). and pulley).
11A-96
K4M, and 730 or 732
III - BELT TENSION
103263
103263 Check that the adjustable index marker (57) is ali-
Using a 6 mm Allen key, bring the adjustable index gned with the fixed index marker (58) .
marker (54) opposite the notch (55) , by turning the
eccentric (56) clockwise.
Gradually move the adjustable index marker (57)
nut (7 Nm).
opposite the notch (58) , turning the eccentric (59) in
Remove the camshaft pulley immobilising tool (Mot. a clockwise direction.
1490-01) .
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pul-
leys. 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) .
11A-97
K4M, and 730 or 732
103268
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. 1490-
01) .
11A-98
K4M, and 730 or 732
14489 103265
Tighten to torque and angle the exhaust camshaft

pulley nut ( 30 Nm + 84 4 ) .
WARNING
Check that the crankshaft is pressing against the Tighten to torque the inlet camshaft pulley depha-
TDC setting pin (Mot. 1489) (63) . ser bolt ( 75 Nm ) .
Tighten to torque and angle the crankshaft acces- Refit the new inlet camshaft dephaser blanking co-
sories pulley bolt (40 Nm + 145 15) (crankshaft ver (64) .
in contact with the TDC setting pin).
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool (Mot. 1490-

01) ,
IV - CHECKING THE TIMING AND TENSION

tions (timing end).
der block.
Slowly and smoothly position the crankshaft so that

is in contact with TDC setting pin (Mot. 1489) .
Check that the pulley indexes are aligned, otherwise

continue with the tensioning process.
11A-99
K4M, and 730 or 732
Check that the tensioning roller indexes are correctly

der block.
Move the crankshaft slowly and smoothly into posi-

tion against the pin.
15103-1
Refit:
mounting, Suspended engine mounting ),
ting, Suspended engine mounting ),
engine, Accessories belt ),
- the new inlet camshaft sealing plugs (Mot. 1487) ,
14490
- the new exhaust camshaft sealing plugs (Mot.
Fit the camshaft adjusting tool (Mot. 1496) without 1488) .
forcing (the camshaft grooves must be horizontal
and offset downwards).
nal.
WARNING
If the tool cannot be engaged, readjust the timing WARNING
and the tension.
REFITTING 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 upper timing cover.
Tighten to torque the upper timing cover nuts and

bolts ( 41 Nm ) .
11A-100
K9K, and 732
I - PRECAUTIONS FOR REPAIR

engine mounting sup- IMPORTANT
port with retaining Wear protective gloves during all operations.
straps
Mot. 1453-01 Additional winder nut WARNING

The belt must be replaced with a new one if it
Mot. 1453
has been removed.
Mot. 1489 TDC locating pin Never turn the engine in the opposite direction to
its normal operation.
Mot. 1430 Set of 5 crankshaft
and camshaft pulley Do not run the engine without the accessories
timing pins belt so as not to break the crankshaft accesso-
ries pulley.
When replacing the belt, be sure to replace the
Tightening torquesm tensioning rollers and pulleys.
camshaft pulley wheel 14 Nm

bolts II - PARTS AND CONSUMABLES FOR THE REPAIR
Parts always to be replaced:
tensioning roller bolt 27 Nm
- timing belt,
camshaft pulley wheel 14 Nm
bolts - timing belt tensioning roller,
- crankshaft accessories pulley bolts.
crankshaft pulley M14 120 Nm + 95
bolt 15 Consumables:
- Silicone adhesive seal part no. 77 11 227 484 .
TDC pin plug cap 20 Nm
cylinder head suspen- 21 Nm III - ESSENTIAL EQUIPMENT

ded mounting bolts
Equipment:
ball joint bracket moun- 21 Nm - Protective gloves,
ting bolts with their
springs - Large screwdriver,
- female torx socket ( 14 ),
wheel bolts 110 Nm
- Allen key ( 6 mm ),
- Offset spanner ( 18 mm ),
- bolt tightening gauge,
- Torque wrench.
11A-101
K9K, and 732
IV - REMOVAL
1 - REMOVAL PREPARATION OPERATION

- Refitting ).
Remove:
- the scuttle panel grille (see MR 365 Bodywork,
55A, Exterior protection, Scuttle panel grille ),
102450
- the right-hand wheel arch liners,
engine, Accessories belt ).
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
pipes.
11A-102
K9K, and 732
112998
113927
Remove the right-hand suspended mounting (1) and

(2) (see 19D, Engine mounting, Right-hand sus-
pended 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
Remove:
- the upper timing cover,
- the plastic bolt (4) .
11A-103
K9K, and 732
19650 19650-1
Remove the TDC pin plug (7) using a torx socket Screw in the TDC setting pin (10) (Mot. 1489) .
(14).
2 - OPERATION FOR REMOVAL OF PART

CONCERNED
14489
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft is pressed against the TDC set-
ting 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
K9K, and 732
109049 109046
Undo the tensioning roller bolt (12) to slacken the ti-
Engage the pin (11) (Mot. 1430) in the camshaft
ming belt.
pulley and cylinder head holes.
Remove:
Remove:
- the timing belt,
- the timing pin from the camshaft pulley (Mot. 1430) - 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
K9K, and 732
V - REFITTING - the mark on the high-pressure pump (16) is offset
by one tooth to the right of the vertical axis (17) ,
1 - REFITTING PART CONCERNED - 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. 109042
Place the tensioning roller lug (13) in the cylinder Remove one bolt from the camshaft pulley wheel.
head groove (14) . Loosen the two other camshaft pulley wheel bolts
(19) by one turn.
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 necessa-
ry.
Check that:
11A-106
K9K, and 732
109044
Fit the timing belt, starting with the crankshaft sproc-
ket, aligning the marks on the belt with those on the
crankshaft sprockets, the camshaft and the high-
pressure pump. There should be 19 tooth spaces
between the sprocket marks and 51 tooth spaces
between the crankshaft sprockets and the high pres-
sure pump.
11A-107
K9K, and 732
19658
Position the tensioning roller adjustable index mar-
ker (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 ful-
ly up against the camshaft pulley wheel.
11A-108
K9K, and 732
109045
Refit camshaft pulley wheel bolt (22) .
Tighten to torque the camshaft pulley wheel bolts
( 14 Nm ) .
Remove:
- the timing pin from the camshaft pulley (Mot. 1430)
,
107272
Tighten the old crankshaft accessories pulley bolt fit-
ted with a spacer (23) (which does not cover the timi-
ng sprocket mark) onto the crankshaft.
11A-109
K9K, and 732
107270 109048
Rotate the crankshaft twice in a clockwise direction If the (Mot. 1430) does not engage:
(timing end) before the camshaft pulley hole (24) is
loosen the camshaft pulley wheel bolts by one turn,
opposite the cylinder head hole (25) .
Turn the camshaft pulley hub using an offset span-
ner to facilitate setting of the camshaft pulley hub.
der block.
Do not retighten the camshaft pulley wheel bolts.
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
109049
Set the camshaft pulley using the (Mot. 1430) .
11A-110
K9K, and 732
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
K9K, and 732
a - First position b - Second position
111083 111082
111081
111081
Loosen the tensioning roller bolt by a maximum of
one turn, holding the tensioning roller using a 6 MM Loosen the tensioning roller bolt by a maximum of
Allen key. 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 Gradually align the adjustable index marker (29) to
anti-clockwise. 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
K9K, and 732
Remove:
Rotate the crankshaft twice in a clockwise direction
(timing end) before the camshaft pulley hole is oppo-
site the cylinder head hole.
der block.
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
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 )
- TDC setting pin (Mot. 1489) ,
- timing pin from camshaft pulley (Mot. 1430) .
109049 2 - FINAL OPERATION

Set the camshaft pulley using the (Mot. 1430) .
Refit the TDC pin plug, coating the thread with SILI-
If this is not possible, repeat the operation for refit- CONE ADHESIVE SEAL .
ting the timing belt.
Tighten to torque the TDC pin plug cap ( 20 Nm ) .
11A-113
K9K, and 732
112989 112990
Refit the cylinder head suspended mounting (31) .
Tighten to torque the cylinder head suspended
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
K9K, and 732
112990 113927
Refit the upper timing cover (36) Refit the right-hand suspended mounting support
(see 19D, Engine mounting, Right-hand suspen-
ded engine mounting: Removal - Refitting ).
Remove the (Mot. 1453) and the (Mot. 1453-01) .
Refit the manual priming pump
Refit:
- the rear suspended engine mounting (see 19D,

Engine mounting, Right-hand suspended engi-
ne mounting: Removal - Refitting ).
- the exhaust ball joint bracket mounting bolts
Tighten to torque the ball joint bracket mounting

bolts with their springs ( 21 Nm )
Refit:

- the right-hand wheel arch liner,

Tighten to torque the wheel bolts ( 110 Nm )

Refitting ).
11A-115
Timing chain: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removing the timing chain requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
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 as-
sembly: Removal - Refitting ).
11A-116
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Mot. 1672 Lower engine support plugs 25 to 30 Nm
Mot. 1453 Multiple-adjusting coil mounting bolts (if 12 Nm

engine mounting sup- the holes are already
port with retaining threaded)
straps
coil mounting bolts (if 15 Nm
Mot. 1453-01 Additional winder nut the holes are not threa-
on engine lift support ded)
Mot. 1453
inlet manifold mounting 9 Nm
Mot. 1490-01 Locking and adjusting bolts
camshaft pulleys
Mot. 1573 Cylinder head support
Mot. 104 Cylinder head ali- REMOVAL

gning tool
Ele. 1382 Spark plug spanner ting equipment, Underbody lift ).
toolkit 16 & 21 mm tor- Disconnect the battery (see 80A, Battery, Battery:
que 1.75 & 28 Nm + Removal - Refitting ).
square adapter 9-9.52
for spanner Ele. 1086 Remove:
Mot. 1491 Camshaft oil seal fit- Refitting ).
ting tool
Mot. 1632 Tool for fit ting the
camshaft seal
Mot. 1487 Tool for refitting cams- engine, Accessories belt: Removal - Refitting ).
haft covers (57 mm
diameter) - the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
Mot. 1488 Tool for refitting cams- - the front bumper (see MR 365 Bodywork, 55A,
haft covers (43 mm Exterior protection, Front bumper ).
diameter)
Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining-refilling ).
Equipment required
cylinder head testing tool
Tightening torquesm
rocker cover mounting 12 Nm

bolts 22, 23, 20, 13
oil separator mounting 15 Nm

bolts (new) in the non-
threaded housings
(new or original) oil 10 Nm

separa t o r mounting
bolts in the pre-threaded
housings
11A-117
K4J, and 730 or 732
Move the fuel supply pipe aside.
1
3
105432
1
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 2

locking tool (2) (Mot. 1490-01) .
14889
IMPORTANT Remove bracket mounting bolt (1) .

Be careful of petrol splashing out when discon- Move the bracket to one side.
necting the fuel supply union.
Remove the wiring harness bracket mounting bolt
Loosen the stud with the nut if necessary (see Tech- (2) .
nical Note 3887A, Replacement of K9 - K4 cams- Disconnect:
haft pulley studs, 11A, Top and front of engine,
Camshaft ). - the brake servo vacuum pipe (3) from the inlet ma-
nifold.
Remove:
- the connector (4) from the coolant temperature
- the injection rail protector, sensor,
- the fuel supply pipe from the injection rail. - the water unit hoses,
11A-118
K4J, and 730 or 732
Move the bracket/wiring harness assembly aside.
5
9
6
10
7
8
104240
18666 Disconnect the connector (9) from the injectors
Disconnect:
Unfasten the clip (10) .
- the ignition coil connectors (5) ,
- the air temperature sensor connector (6) ,
Remove:
- the inlet manifold pressure sensor connector (7) ,
- the ignition coils,
- the fuel vapour recirculation solenoid valve pipe (8)
- the plugs,
,
- the air filter unit (see 12A, Fuel mixture, Air filter
- the catalytic converter upstream oxygen sensor
unit: Removal - Refitting ).
connector.
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting ).
11A-119
K4J, and 730 or 732
12
15
11
18706 18431
Remove: Remove:
- the lifting bracket (11) , - the oil separator mounting bolts (15) ,
- the inlet manifold mounting bolts (12) - the oil separator.
- the inlet manifold.
13
16
16
14
103256
101793 Remove:
Remove: - the rocker cover mounting bolts,
- the catalytic converter/gearbox stay mounting bolts - detach the rocker cover vertically, tapping the lugs
(13) , (16) with a copper hammer.
- the catalytic converter/gearbox stay
- the exhaust pipe mounting nuts (14) . WARNING
Detach the exhaust pipe. Do not damage the aluminium surfaces.
11A-120
K4J, and 730 or 732
14498
Remove the inlet and exhaust camshafts.
11A-121
K4J, and 730 or 732
Apply the product to the section to be cleaned; Wait
17
WARNING
18 Do not allow this product to drip onto the pain-
twork.
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 bloc-
kage 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
Remove:
- the valve rockers (17) , WARNING

- the hydraulic tappets (18) . No regrinding of the cylinder head is permitted.
Test the cylinder head to detect any possible cracks

Note: using the cylinder head testing tool .
To prevent any risk of unpriming the hydraulic For the cylinder head stripping procedure (see
tappets make sure that they are vertical. Technical Note 3784A, K4 4-cylinder petrol engi-
ne, 10A, Engine and peripherals, Rebuilding the
Remove: cylinder head) .
Position the pistons at mid-stroke to prevent any
- the cylinder head mounting bolts,
contact with the valves when refitting the camshafts.
- the cylinder head. Be sure to degrease:
Mount the cylinder head on the cylinder head moun- - the cylinder head combustion face,
ting (Mot. 1573) .
- the cylinder block combustion face.
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 dissol-

ve any parts of the seal still attached to the lower co-
ver and the cylinder block.
11A-122
K4J, and 730 or 732
20 19
21
14689 14499
Check that the centring dowel is present (19) on the Reprime the hydraulic tappets (hydraulic tappets
cylinder block. may empty after a long down time).
Fit the (Mot. 104) (20) onto the cylinder block. To check if repriming is necessary, press the top of
the tappet (21) with your thumb.
REFITTING If the tappet piston depresses:
Fit the new cylinder head gasket. - immerse the tappets in a container full of diesel
fuel,
Refit the cylinder head.
- refit the hydraulic tappets.
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket: Refit:
Removal - Refitting ). - the valve rockers,
Tighten the cylinder head (see 11A, Top and front - the camshafts, oiling the bearings.
of engine, Tightening the cylinder head ).
11A-123
K4J, and 730 or 732
I - CAMSHAFT MARKINGS
Inlet camshaft
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
K4J, and 730 or 732
Exhaust camshaft
101881
Position groove (25) horizontally on the end of the
camshaft (groove below the centre line of the cams-
haft).
The cams (26) for cylinder 1 must be located to the
left of the vertical axis (27) , flywheel end view.
11A-125
K4J, and 730 or 732
28
15106-1 14517
Position the camshaft grooves horizontally and off- Using a stipple roller, apply LOCTITE 518 to the
set downwards. camshaft rocker cover gasket face until it turns red-
dish.
WARNING Using a cloth, remove the LOCTITE 518 from (28)

the six camshaft rocker cover bearings.
The sealing faces must be clean, dry and free of
grease. Refit the rocker cover.
WARNING
could damage certain components (engine,
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-126
K4J, and 730 or 732
II - TIGHTENING PROCEDURE
14497
- 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 moun-
ting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-127
K4J, and 730 or 732
3
2
6 8
4
5 1
7
101869 18431
Refit the oil separator.
WARNING Torque tighten in order

the gasket faces must be clean, dry and free of - the oil separator mounting bolts (new) in the
grease. non-threaded housings ( 15 Nm )
- the (new or original) oil separator mounting
bolts in the pre-threaded housings ( 10 Nm )
WARNING
radiator).
Using a stipple roller, apply LOCTITE 518 to the

gasket face until it is reddish in colour.
11A-128
K4J, and 730 or 732
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-ten-
sion 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
K4J, and 730 or 732
14497-1
Tighten to torque and in order the inlet manifold
Refit: 30
valve: Removal - Refitting ).
unit: Removal - Refitting ).
III - REPLACING THE CAMSHAFT SEALS

There are two types of elastomer camshaft seal
which are easy to identify.
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
K4J, and 730 or 732
1 - Fitting the first seal type to the inlet camshaft
34
33
32
35
20257
The second type of elastomer seal is fitted with a flat 14892
lip seal (32) and a protector (33) (which also assists Fit the seals using the (Mot. 1491) (34) and the old
in fitting the seal to the engine). nuts (35) .
Note:
Both seal versions can be fitted 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.
11A-131
K4J, and 730 or 732
2 - Fitting the seal to the exhaust camshaft
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 fitted to the engine.
38
21687
Screw the stud of (38) the (Mot. 1632) onto the
camshaft.
11A-132
K4J, and 730 or 732
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 en-
gine, Timing belt: Removal - Refitting ).
39
40 WARNING
Follow the second procedure in the timing belt
refitting procedure.
21687-2
Fit cover (39) and the collar nut (40) of the (Mot.
1632) .
11A-133
K4J, and 730 or 732
15103-1
Refit:
- new inlet camshaft sealing plugs using the (Mot.
1487) ,
- new exhaust camshaft sealing plugs using the
(Mot. 1488) ,
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining-refilling ).
11A-134
K9K, and 722 or 728 or 729

IMPORTANT
Mot. 1672 Lower engine support Before any operation:

- connect the diagnostic tool ,
engine mounting sup- - establish dialogue with the injection computer,
port with retaining - check that the injection rail is depressurised,
straps
- be aware of the fuel temperature,
- order the special high-pressure injection circuit
plug kit.
Mot. 1453
Mot. 1202-01 Clip pliers for cooling

system hose clips WARNING
(large model)
Mot. 1202-02 Pliers for small hose Procedure for removing the air inlet duct (K9K 728
clips and 729):
- make a mark on the inlet duct between the stain-
Mot. 1448 Remote operation clip less steel pipe and the hose,
tem hose clips - detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, or
Equipment required any other product,
diagnostic tool - clean the stainless steel pipe and the hose with a
dry, lint-free cloth,
cylinder head testing tool - refit the clip in the same recess in the event that
angular tightening wrench
- rotate the clip around its axis to make torque tigh-
tening easier,
Tightening torquesm
- it is essential to replace the hose and/or the stain-
rocker cover mounting 10 Nm less steel pipe in the event of damage.
bolts There is a risk of leaks or dislodging if this proce-
dure is not followed.
turbocharger oil return 9 Nm
pipe
intercooler hose clip 5.5 Nm
11A-135
K9K, and 722 or 728 or 729
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif- K9K, and 722
Remove: 4 3
1
Removal - Refitting ). 5
Remove: 2
- the battery,
- the timing belt (see 11A, Top and front of engine,
102081
Disconnect:
- the air temperature and pressure sensor connector
(1) ,
- the exhaust gas recirculation valve control connec-
tor (2) ,
- the air hoses (3) ,
- the air hose (4) ,
- the turbocharging pressure regulation valve rubber
pipe,
- the air sleeve from the air filter unit,
105432 - the oil vapour rebreathing pipe from the rocker co-
ver.
Fit the engine stand (Mot. 1672) .
Remove the air resonator unit mounting stay (5) .
11A-136
K9K, and 722 or 728 or 729
K9K, and 728 or 729
6
9
8
7
110325
Pull out the clip.
110326
Disconnect:
11
- the air temperature and pressure sensor connector
(6) ,
- the exhaust gas regulation valve control connector
(7) ,
12
- the engine speed and position sensor connector
(8) , 10
- the air hose (9) ,
- the rubber hose from the turbocharging pressure
control valve.
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
K9K, and 722 or 728 or 729
17
18
13
16
14
15
102086 102263
Disconnect: Disconnect:
- the injector connectors, - the water unit hoses (16) using the (Mot. 1202-01)
or (Mot. 1202-02) or (Mot. 1448) ,
- the heater plug connectors,
- the brake servo vacuum pipe (17) on the vacuum
- the rail pressure sensor connectors,
pump side,
- the diesel fuel supply pipe from the pump,
- the coolant temperature sensor connector on the
- the diesel return pipe from the pump, water unit.
- the fuel temperature sensor (13) , - the radiator top hose from the cylinder head water
outlet using the (Mot. 1202-01) or (Mot. 1202-02)
- the fuel flow actuator connector (14) .
or (Mot. 1448) .
Remove the wiring and diesel return pipe support
Unclip the heater radiator hose (18) .
(15) .
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
11A-138
K9K, and 722 or 728 or 729
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) ,
Remove the inner timing cover (20) . - the cylinder head.
11A-139
K9K, and 722 or 728 or 729
I - CLEANING Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
Clean the cylinder head.
the cylinder head.
IMPORTANT
WARNING
The sealing surfaces must be clean, dry and free
During the operation, wear: from grease (avoid finger marks).
- goggles, Refit the cylinder head.
- gloves. Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head ) using
the angular tightening wrench .
ve 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 WARNING
using a wooden spatula. The sealing surfaces must be clean, dry and free
WARNING
Please make sure, during this operation, that no WARNING
foreign bodies enter the oilways (galleries in both Applying excess sealant could cause it to be
the cylinder block and the cylinder head). squeezed out when parts are tightened. The pro-
duct-fluid mix may damage some components
(engine, radiator).
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply galle- 23
ries.
Failure to follow this advice could lead to the pipe
blocking, quickly damaging the camshaft.
23
Check for gasket face bow using a ruler and a feeler
gauge.
The maximum bow is 0.05 mm .
23
WARNING 19712-1
No regrinding of the cylinder head is permitted. Fit the new rocker cover gasket.
Test the cylinder head to detect any possible cracks Apply beads (23) of SILICONE ADHESIVE SEAL 2
using the cylinder head testing tool . mm in diameter.
For the cylinder head stripping procedure (see
Technical Note 6006A, 4 cast iron cylinder High
Pressure Common Rail Diesel Engine, 10A, En-
gine and peripherals, Rebuilding the cylinder
head ).
REFITTING
Fit the new cylinder head gasket, centred by two
dowels.
11A-140
K9K, and 722 or 728 or 729
Tighten to torque the intercooler hose clip ( 5.5
Nm ) .
5 1
Refit:
6 3 - the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ).
2 - the timing belt (see 11A, Top and front of engine,
7
4 engine, Accessories belt: Removal - Refitting ).
Fill the cooling circuit (see 19D, Cooling, Cooling
8
Reprime the diesel circuit (see 13B, Fuel supply,
Diesel fuel supply circuit ).
19711
Refit the rocker cover.
Tighten to torque and in order the rocker cover
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
F9Q, and 800 or 808

WARNING
Mot. 1672 Lower engine support
Fit plugs in the openings.
Be sure to follow the safety instructions.
port with retaining Refer to (see 13B, Diesel injection, Cleanliness
straps guidelines ).

on engine lift support REMOVAL
Mot. 1453
system hose clips
(large model) Remove:
Mot. 1202-02 Pliers for small hose - the engine covers,

clips - the engine undertray.
Mot. 1448 Remote operation clip Disconnect the battery (see 80A, Battery, Battery:
pliers for cooling sys- Removal - Refitting ).
tem hose clips
Remove:
Equipment required - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
diagnostic tool
- the battery tray,
angular tightening wrench engine, Accessories belt: Removal - Refitting ).

Tightening torquesm Timing belt: Removal - Refitting ).
oil supply pipe bolt on 22.5 Nm - the front bumper (see MR 365 Bodywork, 55A,
the turbocharger Exterior protection, Front bumper ).

oil supply pipe bolt on 22.5 Nm
the cylinder block
oil return pipe bolts 12 Nm
IMPORTANT
Before any operation:

- connect the diagnostic tool ,
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
105432
plug kit. Fit the engine stand (Mot. 1672) .
11A-142
F9Q, and 800 or 808
1 9 8
5
4
7
18983
Remove the vacuum tank mounting bolts (7) .
6
Disconnect:
- the turbocharger pressure regulation solenoid val-
ve pipes,
105511
- the engine damping device solenoid valve connec-
Disconnect:
tor (8) ,
- the camshaft sensor connector (9) .
- the air duct (2) towards the turbocharger,
Remove the vacuum tank.
- 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
F9Q, and 800 or 808
10
11
11
18
12
13
12
14
16
15 17
105512 104323
- the exhaust gas recirculation solenoid valve con- - the cylinder head outlet water unit hoses using the
nector (10) , (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the injector connectors (11) , - the connector (18) from the coolant temperature
sensor.
- the heater plug connectors (12) ,
- the rail pressure sensor connector (13) ,
- the high-pressure pump pressure regulator con-
nector (14) ,
- the diesel return temperature sensor connector
(15) ,
- the diesel filter connector,
- the diesel fuel supply pipe (16) ,
- the diesel return pipe (17) .
Insert the blanking plugs.
19
Move the wiring harnesses to one side.
102348
Remove the three high-pressure pump support
mounting bolts (19) .
11A-144
F9Q, and 800 or 808
21
23
22
20
18997 16189
Remove: Remove the cylinder head mounting bolts (23) .
- the catalytic converter (20) (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ). WARNING
- the oil supply pipe (21) , When removing the cylinder head, take care not
to cause any damage to its gasket face as it pas-
- the oil return pipe mountings (22) on the turbochar-
ses the turbocharger above it.
ger.
Remove the cylinder head. This operation requires
two people.
I - CLEANING
IMPORTANT
- goggles,
- gloves.

ve the section of the gasket which is still attached.
11A-145
F9Q, and 800 or 808
Apply the product to the section to be cleaned; wait Tighten to torque:
- the oil supply pipe bolt on the turbocharger (
22.5 Nm ) ,
- the oil supply pipe bolt on the cylinder block (
WARNING 22.5 Nm ) ,
To prevent any foreign bodies from entering the - the oil return pipe bolts ( 12 Nm ) .
oil pipes (pipes in both the cylinder block and
cylinder head). Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-
WARNING
Protect the oilway to prevent any foreign bodies Timing belt: Removal - Refitting ).
from entering the cylinder head oil supply galle-
ries. - the accessories belt (see 11A, Top and front of
Failure to follow this advice could block the oil
supply pipes, causing rapid camshaft damage. Fill the cooling circuit (see 19A, Cooling, Cooling
Reprime the diesel circuit (see 13A, Fuel supply,
WARNING Diesel fuel supply circuit ).
The cylinder head bolts must be replaced each Connect the battery (see 80A, Battery, Battery: Re-
time they are removed and must not be oiled moval - Refitting ).
before being fitted.
II - CHECKING THE GASKET FACE Tighten to torque the battery cover bolts ( 4 Nm ) .
gauge.
WARNING
No regrinding of the cylinder head is permitted.

using the cylinder head testing tool .
Technical Note 3652A, 4-cylinder Cast Iron High
head ).
REFITTING
Bring the pistons to mid-stroke position to prevent
the cylinder head.
Fit the cylinder head gasket.

Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head ) using a
angular tightening wrench .
11A-146
F4R, and 770 or 771
Mot. 1672 Lower engine support plugs 25 to 30 Nm
Mot. 1509 Camshaft sprocket coils (if holes already 12 Nm

locking tool threaded)
Mot. 1509-01 Conversion kit for Mot. coils (if holes not threa- 15 Nm
1509 ded)
Mot. 1202-01 Clip pliers for cooling inlet manifold 9 Nm

system hose clips
(large model) battery cover mounting 4 Nm
bolts
clips
REMOVAL
tem hose clips
Remove:
Mot. 1573 Cylinder head support
Mot. 1517 Camshaft seal fitting
tool
Mot. 1512 Camshaft oil seal fit- Removal - Refitting ).
ting tool (28 x 47)
Remove
haft covers (57 mm
Refitting ).
diameter)
Mot. 1488 Tool for refitting cams- engine, Accessories belt: Removal - Refitting ).
haft covers (43 mm
diameter) - the timing belt (see 11A, Top and front of engine,
Equipment required - the front bumper (see MR 365 Bodywork, 55A,
angular tightening wrench Cooling circuit: Draining-refilling ).
Tightening torquesm
rocker cover bolts 22, (8 Nm)

23, 20, 13
rocker cover bolts 1 to (12 Nm)

12, 14 to 19, 21 to 24
new or original oil sepa- 10 Nm

rator mounting bolts (in
threaded holes)
new oil separator 15 Nm

mounting bolts (in non-
105432
threaded holes)
11A-147
F4R, and 770 or 771
16019-4 16019-4
Fit the (Mot. 1509) with the gear (Mot. 1509-01) .
Remove:
Tighten the collar nut (1) and the bolt (2) , then bring
the gears of (Mot. 1509) into contact with the cams- - the exhaust camshaft pulley nut,
haft pulleys while torque tightening the nuts (80
Nm) (3) . - the inlet camshaft dephaser mounting bolt,
Remove the inlet camshaft dephaser blanking cover
Loosen the nut stud if necessary (see Technical
using a 14 mm Allen key.
Note 3887A, Replacement of F4 camshaft pulley
studs, 11A, Top and front of engine, Camshaft ).
18699
Remove the bracket mounting bolts (4) .
Move the bracket to one side.
11A-148
F4R, and 770 or 771
5
8
12 11 10
6
14889 18666
Disconnect:
- the ignition coil connectors (8) ,
7 - the air temperature sensor connector (9) ,
- the camshaft dephaser connector (10) ,
- the fuel vapour recirculation solenoid valve pipe
(12) ,
- the injector connectors,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Remove:
- the plugs,
102735 - the dephaser solenoid valve.
Remove the wiring harness bracket mounting bolts

(5) .
Disconnect:

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 mani-

fold side.
11A-149
F4R, and 770 or 771
17
18
13
14
102939 102940
Remove: Remove:
- the lifting bracket (13) at the timing end, - the oil separator mounting bolts.
- the oil separator (17) ,
- the inlet manifold mounting bolts (14) ,
- 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
F4R, and 770 or 771
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
F4R, and 770 or 771
20
15151
Remove the inlet and exhaust camshafts (20)
11A-152
F4R, and 770 or 771
21
22
14499
Remove:
- the valve rockers (21) ,
- the hydraulic tappets (22) .
Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
11A-153
F4R, and 770 or 771
15153
Remove:
- the cylinder head bolts, WARNING
- the cylinder head. To prevent any foreign bodies from entering the
oil pipes (pipes in the cylinder block and cylinder
Mount the cylinder head on the cylinder head moun-
head).
ting (Mot. 1573) .
block II - CHECKING THE GASKET FACE

I - CLEANING gauge.
Maximum bow: 0.05 mm
IMPORTANT
Do not scratch the aluminium gasket faces. WARNING
During the operation, wear: No regrinding of the cylinder head is permitted.
- goggles, Test the cylinder head to detect any cracks using the
- gloves. cylinder head testing tool (see Technical Note
3783A, F4 4-cylinder petrol engine, 10A, Engine
Clean the gasket faces with DCAPJOINT to dissol- and peripherals, Rebuilding the cylinder head)
ve any sections where the seal is still attached. for the cylinder head stripping procedure.
Apply the product to the section to be cleaned; Wait Position the pistons at mid-stroke to prevent any
for approximately ten minutes, then remove it using contact with the valves when the camshafts are
a wooden spatula. being refitted.
11A-154
F4R, and 770 or 771
- The combustion face of the cylinder head,
- the combustion face of the cylinder block.
REFITTING
Fit the new cylinder head gasket.
Check the bolts (see 11A, Top and front of engine,

Tightening the cylinder head ).

of engine, Tightening the cylinder head ) using a
24 25
23 15152
The camshafts are identified by the pulley moun-
tings.
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 ti-
me).
To check or reprime them, press the top of the tap-

pet at (23) with your thumb.
If the tappet piston depresses:
- immerse the tappets in a container full of diesel

fuel,
Refit:
- the valve rockers,
- the camshafts, oiling the bearings.
11A-155
F4R, and 770 or 771
26
15106-1 14517
Position the camshaft grooves as shown in the dia- Using a stipple roller, apply LOCTITE 518 to the
gram. camshaft rocker cover gasket face until it is reddish
in colour.
WARNING
The gasket faces must be clean, dry and free Note:
from grease (avoid finger marks). Using a cloth, remove the LOCTITE 518 from
(26) the camshaft rocker cover bearings.
WARNING Refit the rocker cover.

ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
WARNING
Do not apply oil to the sealing face of the cams-
haft bearing cap cover.
11A-156
F4R, and 770 or 771
14497
- rocker cover bolts 22, 23, 20, 13 ( (8 Nm) ) ,
- rocker cover bolts 1 to 12, 14 to 19, 21 to 24 (
(12 Nm) ) .
Tighten to torque and in order mounting bolts 22,
23, 20, 13 (12 Nm) .
11A-157
F4R, and 770 or 771
102738 102729
WARNING Tighten to torque and in order:

The gasket faces must be clean, dry and free - the new or original oil separator mounting bolts
from grease (avoid finger marks). (in threaded holes) ( 10 Nm ) ,
- the new oil separator mounting bolts (in non-
threaded holes) ( 15 Nm ) .
WARNING
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
F4R, and 770 or 771
27
106443
FLUORINATED GREASE 82 00 169 855 2 mm in
diameter to the lower circumference of the high-ten-
sion cap.
11A-159
F4R, and 770 or 771
102939 15103-1
Refit the plugs. Refit:
Tighten to torque the plugs ( 25 to 30 Nm ) . - the new sealing plugs:
Refit the coils. on the inlet camshaft (Mot. 1487) ,
Tighten to torque: on the exhaust camshaft (Mot. 1488) ,
- the coils (if holes already threaded) ( 12 Nm ) , - the right-hand suspended engine mounting (see
19D, Engine mounting, Suspended engine
- the coils (if holes not threaded) ( 15 Nm ) .
mounting ).
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. ling circuit: Bleeding ).
- use the (Mot. 1512) for the exhaust camshaft seal. Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
Refit:
- the timing belt (it is essential to follow the procedu-
re (see 11A, Top and front of engine, Timing
belt: Removal - Refitting ).
11A-160
K4M, and 760 or 761
Mot. 1672 Lower engine support camshaft dephaser 10 Nm

solenoid valve bolt
engine mounting sup- plugs 25 to 30 Nm
port with retaining
straps coil mounting bolts (if 12 Nm
holes already threaded)
Mot. 1669 Fitting cam follower
tappet coil mounting bolts (if 15 Nm
holes not threaded)
on engine lift support camshaft position sen- 10 Nm
Mot. 1453 sor mounting bolt
Mot. 1490-01 Locking and adjusting inlet manifold mounting 9 Nm

camshaft pulleys bolts
Mot. 1573 Cylinder head support battery cover bolts 4 Nm
Mot. 104 Cylinder head ali-

gning tool REMOVAL
haft dephaser solenoid
valve lip seal Remove:
Ele. 1382 Spark plug spanner - the engine covers,

toolkit 16 & 21 mm tor- - the engine undertray.
que 1.75 & 28 Nm +
square adapter 9-9.52 Disconnect the battery (see 80A, Battery, Battery:
for spanner Ele. 1086 Removal - Refitting ).
Remove:
Mot. 1632 Tool for fit ting the
camshaft seal - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
haft covers (57 mm
diameter)
Mot. 1488 Tool for refitting cams- Timing belt: Removal - Refitting ).
haft covers (43 mm
diameter) - the front bumper (see MR 365 Bodywork, 55A,
Equipment required Drain the engine cooling circuit (see 19A, Cooling,
Tightening torquesm

bolts 22, 23, 20, 13
oil separator mounting 15 Nm

bolts
11A-161
K4M, and 760 or 761
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:

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 mani-

fold side.
11A-162
K4M, and 760 or 761
- the catalytic converter upstream oxygen sensor
connector.
5
10
4
11
7 6
8
18666
Disconnect:
104240
- the ignition coil connectors (4) , Disconnect the connector (10) from the injectors
- the air temperature sensor connector (5) , Unfasten the clip (11) .
- the camshaft dephaser solenoid valve connector Move the wiring harness to one side.
(6) ,
Remove:
- the fuel vapour recirculation solenoid valve pipe (8)
, - the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
101809
Disconnect:
- the camshaft position sensor connector (9) ,
11A-163
K4M, and 760 or 761
12
14
13
15
103272 101793
Remove: Remove:
- the lifting bracket (12) , - the catalytic converter-gearbox stay mounting bolts
(14) ,
- the inlet manifold mounting bolts (13) ,
- the catalytic converter/gearbox strut,
- the exhaust pipe mounting nuts (15) .
Move the exhaust pipe aside.
Remove the camshaft pulleys using the (Mot. 1490-
01) .
11A-164
K4M, and 760 or 761
16
18
17
18
103255 103256
Remove:
WARNING - the rocker cover mounting bolts,

Do not remove the bolt (16) as it acts as a stop - detach the rocker cover vertically, tapping the lugs
for the squared cam tappet. (18) with a copper hammer.
Remove:
WARNING
- the oil separator mounting bolts (17) ,
Do not damage the aluminium surfaces.
- the oil separator.
103258
Remove the inlet and exhaust camshafts.
11A-165
K4M, and 760 or 761
19
WARNING
Do not allow this product to drip onto the pain-
20
twork.
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 bloc-
kage of the oilways, resulting in rapid and serious
damage to the engine.

Use a ruler and feeler gauge to check that there is
no gasket face bow.
14499 Maximum bow: 0.05 mm
Remove:
- the valve rockers (19) , WARNING

- the hydraulic tappets (20) . No regrinding of the cylinder head is permitted.

Note: using the cylinder head testing tool .
To prevent any risk of unpriming the hydraulic For the cylinder head stripping procedure (see
tappets make sure that they are vertical. Technical Note 3784A, K4 4-cylinder petrol engi-
ne, 10A, Engine and peripherals, Rebuilding the
Remove: cylinder head) .
Position the pistons at mid-stroke to prevent any
- the cylinder head mounting bolts,
contact with the valves when refitting the camshafts.
- the cylinder head. Be sure to degrease:
Mount the cylinder head on the cylinder head moun- - the cylinder head combustion face,
ting (Mot. 1573) .
- the cylinder block combustion face.
block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
- goggles,
- gloves.
Clean the gasket faces with DECAPJOINT to dissol-

ve any parts of the seal still attached to the lower co-
ver and the cylinder block.
11A-166
K4M, and 760 or 761
22 21 23
14689 14499
Check that the centring dowel is present (21) on the Reprime the hydraulic tappets (hydraulic tappets
cylinder block. may empty after a long down time).
Fit the (Mot. 104) (22) on the cylinder block. To check if repriming is necessary, press the top of
the tappet (23) with your thumb.
REFITTING If the tappet piston depresses:
Fit the new cylinder head gasket. - immerse the tappets in a container full of diesel
fuel,
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket: Refit:
Removal - Refitting ). - the valve rockers,
Tighten the cylinder head (see 11A, Top and front - the camshafts, oiling the bearings.
of engine, Tightening the cylinder head ).
11A-167
K4M, and 760 or 761
I - CAMSHAFT MARKINGS
26 27
Inlet camshaft
24
28
29
103685
Position the pin (26) of the (Mot. 1669) against the
102507
bottom of the groove by loosening bolt (27) .
Mount the (Mot. 1669) on the rocker cover, correctly
(24) The inlet camshaft is fitted with positioning the pin (28) in the rocker cover hole (29) .
the camshaft sensor target.
Exhaust camshaft
25
30
103684
Fit the rocker cover tool (Mot. 1669) using the bolts
102506
(30) .
(25) The exhaust camshaft is fitted

with the square cam.
11A-168
K4M, and 760 or 761
32
35
31 34
103687 103686
Tighten the bolt (31) until the pin (32) is hard up Turn the bolt (34) until the pin (35) is hard up against
against the bottom of the groove. 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 com-
pressed position.
11A-169
K4M, and 760 or 761
36
15106-1 14517
Position the camshaft grooves horizontally and off- Using a stipple roller, apply LOCTITE 518 to the
set downwards. camshaft rocker cover gasket face until it turns red-
dish.
WARNING Using a cloth, remove the LOCTITE 518 from (36)

on the six camshaft rocker cover bearings.
The sealing faces must be clean, dry and free of
grease. (do not leave any finger marks). Refit the camshaft rocker cover.
WARNING
radiator).
11A-170
K4M, and 760 or 761
II - TIGHTENING PROCEDURE
14497
- 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) .
Tighten to torque and in order rocker cover moun-
ting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-171
K4M, and 760 or 761
10 1 9
4
5
8
3
2
6
101820
Tighten to torque and in order the oil separator

102073
Remove the bolt (10) of the (Mot. 1669) to release
the tappet.
WARNING Refit the original bolt, applying a drop of LOCTITE
the sealing surfaces must be clean, dry and free FRENETANCH .
WARNING
Excess sealant could be squeezed out when the 37
radiator).
Using a stipple roller, apply LOCTITE 518 to the

gasket face until it is reddish in colour.
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
K4M, and 760 or 761
38
106443

FLUORINATED GREASE 82 00168 855 2 mm in
diameter to the inner circumference of the high-ten-
sion cap.
11A-173
K4M, and 760 or 761
3 8
39 7
103257 103272
Refit the plugs. Tighten to torque and in order the inlet manifold
Tighten to torque the plugs ( 25 to 30 Nm ) using
the plug spanner set (Ele. 1382) .
III - REPLACING THE CAMSHAFT SEALS
Refit the coils.
Tighten to torque
- the coil mounting bolts (if holes already threa-
ded) ( 12 Nm ) ,
- the coil mounting bolts (if holes not threaded) (
15 Nm )
.
Refit the cylinder reference sensor (39) with a new
seal.
Tighten to torque the camshaft position sensor
mounting bolt ( 10 Nm ) . 41
40
Always replace all the inlet manifold seals.
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
K4M, and 760 or 761
1 - Fitting the seal to the exhaust camshaft
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 fitted to the engine.
44
21687
Screw the stud (44) of the (Mot. 1632) onto the
camshaft.
11A-175
K4M, and 760 or 761
21687-1 21687-3
Fit the protector, with a seal, to the camshaft. Screw in the collar nut until the cover comes into
Remove the nut, cover, protector and threaded rod.
2 - Fitting the inlet camshaft seal
45 WARNING
46 It is very important to hold the protector when
handling the seal, as this type of seal is very fra-
gile. In order to prevent any oil leaks once the
seal is fitted 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
K4M, and 760 or 761
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
K4M, and 760 or 761
49
50
105535 15103-1
Fit the cover (49) and the collar nut (50) of the (Mot. Refit:
1632) .
- the accessories belt (see Top and front of engine,
Screw in the collar nut until the cover comes into Accessories belt: Removal - Refitting ).
- new inlet camshaft sealing plugs using the (Mot.
Remove the nut, cover, protector and threaded rod. 1487) ,
- new exhaust camshaft sealing plugs using the
IV - REFITTING (Mot. 1488) ,
Refit the timing belt (see 11A, Top and front of en- Proceed in the reverse order to removal.
gine, Timing belt: Removal and Refitting )
circuit: Draining - refilling ).
WARNING Connect the battery (see 80A, Battery, Battery: Re-
Follow the second procedure in the timing belt moval - refitting ).
refitting procedure.
11A-178
F4R, and 776
WARNING
Removing and refitting the turbocharger requires
careful application of the repair procedures to
ensure the system is properly sealed.
FAILURE TO COMPLY WITH THESE INSTRUC-
TIONS MAY HAVE SERIOUS SAFETY-RELATED
CONSEQUENCES FOR THE DRIVER.
Removing the cylinder head gasket requires the en-

gine and transmission assembly to be removed (see
10A, Engine and peripherals, Engine and gear-
box assembly: Removal - Refitting ).
To remove the cylinder head gasket (see Technical
Note 3784A, F4 4-Cylinder Petrol Engine, 10A,
Engine and peripherals, Cylinder head: Strip-
ping - Refitting .
11A-179
F9Q, and 804
Special tooling required terminal.
Mot. 1202-01 Clip pliers for cooling Drain the cooling circuit through the cooling radiator
system hose clips using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
(large model) 1448) .

clips WARNING
Plug the orifices.
pliers for cooling sys- Make sure that you follow all the safety instruc-
tem hose clips tions.
Refer to 13B, Diesel injection, Cleanliness ins-
tructions).
Remove the scuttle panel grille (see MR 371 Bo-
engine mounting sup- dywork, 55A, Exterior Protection, Scuttle Panel
port with retaining
Grille ).
straps
Remove:
on engine lift support - air filter access panel mounting bolts,
Mot. 1453 - the scuttle panel partition mounting bolt,
- the scuttle panel partition mounting bolts,
Equipment required
- the scuttle panel partition,
cylinder head testing equipment
angular tightening wrench - the battery,
- the battery tray,
Tightening torquesm - the lower engine tie-bar.
battery cover mounting 4 Nm . Remove the catalytic pre-converter (see 19B, Ex-
bolts. haust, Catalytic Pre-converter: Removal - Refit-
ting ).
Remove:
REMOVING - REFITTING
- the timing belt (see 11A, Top and front of engine:
Timing belt ).
IMPORTANT - the accessories belt (see 11A, Top and front of
engine, Accessories belt ) ,
- connect the diagnostic tool (After-Sales),
- check that the injector rail is depressurised,
- watch out for the fuel temperature,
plug kit.

Remove:
11A-180
F9Q, and 804
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 inta-
ke: Removal - Refitting ) (5) .
- the turbocharging pressure connector (7) ,
- the throttle valve connector (8) ,
- the turbocharging pressure solenoid valve connec-
tor (9) ,
- the flowmeter connector (10)
- the rail pressure sensor connector (11) ,
- the diesel pressure regulator connector (12) .
Remove:
- the injector rail protector (13) (see 13B, Diesel in-
jection, Injector rail protector ).
11A-181
F9Q, and 804
111889
Disconnect:
- the diesel return temperature sensor connector,
nector,
111886
Disconnect:
- the diesel return pipe (22) ,
- the vacuum pipe (14) from the vacuum pump,
- the diesel fuel supply pipe.
- the air filter outlet duct (15) , Remove the starter (see 16A, Starting-Charging,
Starter: Removal - Refitting .
- the exhaust gas recirculation connector (16) ,
Remove:
- the coolant temperature sensor (17) ,
- the turbocharger air duct,
- the turbocharger vacuum pipes (18) . - the turbocharger oil return pipe
- the coolant hoses.
- the turbocharger oil supply pipe.
Disconnect the scuttle panel hoses from the cylinder
head outlet.
111965
Disconnect:
- the camshaft sensor connector (19) ,
- the injector connectors (20) ,
11A-182
F9Q, and 804
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
Remove the cylinder head. 111863

Remove exhaust gas recirculation pipe mounting
bolts (24) .
Remove the exhaust gas recirculation pipe moun-
ting clip.
Remove the cylinder head mounting bolts.
Remove the cylinder head.
11A-183
F9Q, and 804
I - CLEANING Refit the cylinder head with a new cylinder head gas-
ket.
Refit new cylinder head bolts.
IMPORTANT
of engine, tightening the cylinder head) using a
Wear protective goggles.
Refit the catalytic converter (see 19B, Exhaust, Ca-
Wear gloves during the operation. talytic converter ).
Clean the gasket faces with DECAPJOINT clea- Refit the timing belt (see 11A, Top and front of en-
ning product to dissolve the part of the gasket gine, Timing belt ).
which is stuck to the sump and cylinder cover. Refit the accessories belt (see 11A, Top and front
Apply the product to the section to be cleaned; of engine, Accessories belt ).
Wait approximately ten minutes, then remove the
Fill and bleed the cooling circuit (see 19A, Cooling,
residue using a wooden spatula. Bleeding the cooling circuit .
WARNING Diesel supply circuit ).
To prevent any foreign bodies from entering the Connect the battery, starting with the positive termi-
oil pipes (pipes in both the cylinder block and nal.
cylinder head).
WARNING
WARNING carry out the necessary programming (see 80A,
from entering the cylinder head oil supply pipes.
Tighten to torque the battery cover mounting
Failure to follow this instruction could lead to the bolts. ( 4 Nm . )
pipes becoming blocked, causing rapid camshaft
damage.

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.

using a cylinder head testing equipment .
(see TN 3652A, 4-cylinder Cast Iron High Pressu-
re Common Rail Diesel Engine, 10A, Engine and
peripherals, Rebuilding the cylinder head) for the
cylinder head stripping procedure.
REFITTING
the cylinder head.
Degrease the gasket faces.
11A-184
F9Q, and 804
Special tooling required Cooling circuit: Draining-refilling ).
WARNING
engine mounting sup- Fit plugs in the openings.
port with retaining
Always respect the repair precautions (see 13B,
straps
Diesel injection, Diesel injection: Precautions
Mot. 1453-01 Additional winder nut during repair ).
on engine lift support Remove:
Mot. 1453
Refitting ).
Equipment required
diagnostic tool
- the battery tray,
cylinder head testing equipment - the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended engine mounting: Removal -
angular tightening wrench Refitting ).
Remove the catalytic pre-converter (see 19B, Ex-
Tightening torquesm haust, Catalytic Pre-converter: Removal - Refit-
ting ).
Remove:
bolts
engine, Accessories belt: Removal - Refitting) ,
REMOVING - REFITTING - the timing belt (see 11A, Top and front of engine,
IMPORTANT

- connect the diagnostic tool (After-Sales),
- check that the injection rail is depressurised,
plug kit.

105432
Remove:
Fit the engine support using the (Mot. 1672) .
11A-185
F9Q, and 804
7 6 13
11
1 4
2 15
5 12
3
14
111887 111886
Disconnect:
10 - the vacuum pipe from the vacuum pump (11) ,
- the exhaust gas recirculation connector (13) ,
- the coolant temperature sensor (14) ,

8
- the turbocharger vacuum pipes (15) .
111888
Disconnect: 16
17
- the air inlet duct (see 12A, Fuel mixture, Air inlet:
Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the turbocharging pressure solenoid valve connec-
tor (6) , 111965
- the air flowmeter sensor connector (7) , Disconnect:

- the rail pressure sensor connector (8) , - the camshaft sensor connector (16) ,
- the diesel pressure regulator connector (9) .
- the injector connectors (17) .
Remove:
- the injection rail protector (10) (see 13B, Diesel in-
jection, Injection rail protector ). Move the electric wiring harness to one side.
11A-186
F9Q, and 804
18
19
20
111889
Disconnect:
- the diesel return temperature sensor connector,
nector,
102348
- the heater plug connectors (18) , Remove:
- the diesel return pipe (19) , - the high pressure pump rear mounting bolts (20) ,
- the diesel fuel supply pipe. - the windscreen wiper mounting,
Remove: - the bonnet,
- the starter motor (see 16A, Starting-charging, - the cylinder head mounting bolts.
Starter motor: Removal - Refitting .
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting ). WARNING
- the water hoses. When removing the cylinder head, take care not
Disconnect the cylinder head outlet water unit ho-
ses.
11A-187
F9Q, and 804
I - CLEANING
IMPORTANT
Do not scratch the aluminium sealing surfaces.
21
- goggles,
- gloves.

ve any part of the gasket which is attached to the
111861 lower cover and cylinder block.

approximately 10 minutes, then remove residue
21 WARNING
To prevent any foreign bodies from entering the
oil pipes (pipes in both the cylinder block and
cylinder head).
WARNING
from entering the cylinder head oil supply galle-
ries.
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. II - CHECKING THE GASKET FACE
Remove the mounting clip from the exhaust gas re- Check for gasket face bow using a ruler and a feeler
circulation pipe. gauge.
Remove the cylinder head mounting bolts.
Remove the cylinder head.
WARNING
No regrinding is permitted.

using a cylinder head testing equipment .

Technical Note 3652A, 4-cylinder Cast Iron High
head) .
11A-188
F9Q, and 804
REFITTING
the cylinder head.
Degrease the gasket faces.
Refit the cylinder head with a new cylinder head gas-
ket.
Refit new cylinder head bolts.
of engine, Tightening the cylinder head) using a
Refit the catalytic pre-converter (see 19B, Exhaust,
Catalytic Pre-converter: Removal - Refitting ).
Refit the timing belt (see 11A, Top and front of en-
gine, Timing belt: Removal - Refitting ).
Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting
).
Diesel fuel supply circuit ).
( 4 Nm ) .
11A-189
K9K, and 732

WARNING
Ele. 1552 Tool for removing rear Before starting work on the vehicle, obtain:
screen wiper arm - a new plug kit ( PART NO. 77 01 476 857) ,
Mot. 1672 Lower engine support - some cleaning cloths ( PART NO. 77 11 211 707) ,
- cleaning product ( PART NO. 77 11 24 188) .
port with retaining
straps
IMPORTANT
on engine lift support Before carrying out any work on the injection sys-
Mot. 1453 tem, check using the diagnostic tool :
- that the injection rail is not under pressure,
system hose clips - that the fuel temperature is not too high.
(large model) 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 injec-
clips
tion, Cleanliness guidelines).
tem hose clips
WARNING
Equipment required Procedure for removing the air inlet duct (risk of
leaking and dislodging if this procedure is not res-
diagnostic tool
pected):
hydraulic crane - detach the hose using the (Car. 1363) ,
load positioner - do not use degreaser, brake cleaning agents, or
any other products,
- clean the bearing face on the intercooler with a
angular tightening wrench dry, lint-free cloth,
Tightening torquesm - place the clip in the same position if the hose is
not replaced,
- it is essential to replace the hose and/or the rigid
bolts
pipe in the event of damage.
alternator mounting 21 Nm
bolts
REMOVAL
hose clip on the stain- 5.5 Nm
less steel pipe
pipe Position the vehicle on a two-post lift (see 02A, Lif-

- Refitting ).
11A-190
K9K, and 732
Remove the engine undertray. - the front bumper (see MR365, Bodywork, 55A,

tic converter ).
102101
104175
Remove the turbocharger oil return pipe (5) .

ling 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:
102267
- the accessories belt (see 11A, Top and front of Remove:
- the alternator upper mounting bolt (26) ,
Timing belt ), - the alternator lower mounting bolt (27) ,
11A-191
K9K, and 732
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
01) .
11A-192
K9K, and 732
112811 112992
Unclip the injection rail protector cover (14) .
Pull out the clip.
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:
112993
- the mounting bolt (12) from the stainless steel pipe,
Disconnect:
- the stainless steel pipe (13) . - the heater plug connectors (17) ,
11A-193
K9K, and 732
112656
112994 Clean the fuel return and supply pipe unions (see
Disconnect: 13A, Diesel injection, Repair precautions ).
- the connector (19) from the damper valve,
- the cylinder reference sensor connector (20) , WARNING
- the pressure regulation solenoid valve connector Do not blast compressed air once the fuel circuit
(21) , is open, otherwise impurities may enter the sys-
tem. Use wipes if necessary.
- the flow regulation solenoid valve connector (22) ,
- the diesel temperature sensor connector (23) ,
Note:
- the rail pressure sensor connector.
Make preparations for fuel outflow. Clean with
Unclip the wiring harness retaining clip (24) .
new wipes.
Remove the wiring harness clip mounting nut (25) .
Disconnect:
Remove the wiring harness.
Tilt the alternator against the radiator assembly.
Fit plugs.
11A-194
K9K, and 732
112996
Disconnect the oil vapour rebreathing pipe on the

rocker cover side (31) .
113475
Remove:
- the retaining bracket mounting bolts from the ex-

haust gas recirculation cooler,
- the bracket from the exhaust gas recirculation coo-

ler.
112997
Disconnect:
- the exhaust gas recirculation solenoid valve con-

nector,
- the scuttle panel hoses (33) using the (Mot. 1202-

01) or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (34) on the vacuum

111748 pump side,
Remove the injection rail protector cover support
- the temperature sensor connector from the scuttle
mounting bolt and mounting nuts (30) .
panel,
Unclip the drain pipe from the injection rail protector - the radiator top hose from the cylinder head outlet
cover support. water unit (35) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) ,
Remove:
- the turbocharging pressure regulation solenoid val-
- the injection rail protector cover support, ve hose on the vacuum pump side,
- the damper valve (see 12A, Damper valve: Re- - the turbocharging pressure regulation solenoid val-
moval - Refitting . ve hose on the pressure regulation valve side.
11A-195
K9K, and 732
REFITTING
I - CLEANING
IMPORTANT
Wear goggles.
Wear gloves during the operation.

ve any parts of the seal still attached.
Apply the product to the part to be cleaned. Wait ap-

proximately ten minutes, then remove the residue
113476
Remove:
WARNING
- the rocker cover mounting bolts (36) ,
Please make sure, during this operation, that no
- the rocker cover. foreign bodies enter the oil pipes (pipes in both
the cylinder block and the cylinder head).
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.

gauge.

19712
Remove:
- the cylinder head mounting bolts (37) , WARNING
- the cylinder head using a hydraulic crane fitted No regrinding of the cylinder head is permitted.
with a load positioner .
For the cylinder head stripping procedure see Tech-
nical Note 6006A, 4-cylinder cast iron High Pres-
sure Common Rail Diesel Engine, 10A, Engine
and peripherals, Rebuilding the cylinder head . .

using the cylinder head testing tool .
11A-196
K9K, and 732
III - REFITTING OPERATION FOR PART
CONCERNED
WARNING

the cylinder head.
Fit the new cylinder head gasket, centred by two

dowels.
Refit the cylinder head using the hydraulic crane fit-

ted with the load positioner .

of engine, Tightening the cylinder head ) using
113476
Refit the rocker cover.
IV - FINAL OPERATION
Tighten to torque and in order the rocker cover
Fit the new rocker cover gasket. mounting bolts ( 10 Nm ) .
Connect:
ve hose on the pressure regulation valve side.
ve hose on the vacuum pump side,
- the radiator top hose from the cylinder head water
outlet unit using the (Mot. 1202-01) or (Mot. 1202-
02) or (Mot. 1448) ,
- the temperature sensor connector to the scuttle pa-
nel,
- the brake servo vacuum pipe on the vacuum pump
side,
19712-1
- the scuttle panel hoses using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
WARNING Refit:
The gasket faces must be clean, dry and free - the air inlet duct between the air filter unit outlet
from grease (avoid finger marks). and the turbocharger inlet,
- the oil vapour rebreathing pipe;
WARNING - the damper valve (see 12A, Damper valve: Re-

squeezed out when parts are tightened. A mix- - the injection rail protector cover support,
- the injection rail protector cover support mounting
components (engine, radiator, etc.)
bolt and mounting nuts.
Apply beads (38) of SILICONE ADHESIVE SEAL 2 Clip the drain pipe onto the injection rail protector co-
mm in diameter. ver support.
11A-197
K9K, and 732
Refit: Connect:
- the injection rail protector cover mounting bracket, - the air pressure sensor,
- the injection rail protector cover retaining bracket - the exhaust gas recirculation solenoid valve con-
mounting bolts, nector.
Remove the blanking plugs. Fit the (Mot. 1453) with the (Mot. 1453-01) .
Connect: Remove the (Mot. 1672) .
- the fuel supply pipe, Refit:
- the fuel return pipe. - the inner timing cover,
Torque tighten the alternator mounting bolts ( 21 - the alternator upper mounting bolt,
Nm ) . - the alternator lower mounting bolt,
Connect:
- the turbocharger oil return pipe.
- the rail pressure sensor connector, Tighten to torque the turbocharger oil return pipe
- the diesel fuel temperature sensor connector. ( 9 Nm ) .
- the flow regulation solenoid valve connector, Refit:
- the pressure regulation solenoid valve connector, - the catalytic converter (see 19B, Exhaust, Cataly-
tic converter ),
- the cylinder reference sensor,
- the connector on the damper valve, Timing belt ),
- the heater plugs connector, - the accessories belt (see 11A, Top and front of
- the injector connectors, engine, Accessories belt ),
Position the wiring harness. - the front bumper (see MR 365, Bodywork, 55A,
Refit the mounting nut of the wiring harness clip.
Clip the retaining clip of the wiring harness.
- the battery,
Refit:
- the dipstick guide tube mounting bolts to the injec- Bleeding the cooling circuit ).
tion rail protector cover support,
Reconnect the battery (see 80A, Battery, Removal
- the diesel anti-splash device cover, - Refitting ).
- the injection rail protector cover bolt and nuts, Refit the engine covers.
Clip on the injection rail protector cover. 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
Tightening the cylinder head 11A
K4J, and 730 or 732 K4M, and 760 or 761
CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
cylinder head moun- 20 Nm

ting bolts
cylinder head moun- 240 6

ting bolts
14500
WARNING WARNING
Reuse the bolts if the length under the head The gasket faces must be clean, dry and free
does not exceed 117.7 mm (otherwise replace from grease (avoid finger marks).
all the bolts with new ones).
Tighten to torque and in order the cylinder head
In order to ensure that the bolts are correctly mounting bolts ( 20 Nm ) .
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes. Check that all of the cylinder head mounting bolts
are tightened to the correct torque of 20 Nm .
Do not oil the new bolts. The bolts must be oiled
if reused. 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
K9K, and 722 or 728 or 729
Tightening torquesm

ting bolts

ting bolts
8 4 1 5 9
7 3 2 6 10
19712
WARNING
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.

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
11A-200
F9Q, and 800 or 804 or 808
Tightening torquesm

ting bolts
cylinder head moun- 230 +/- 6

ting bolts
10 6 2 3 7
9 5 1 4 8
16189
WARNING
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.

bolts ( 230 +/- 6 ) .
WARNING
11A-201
F4R, and 770 or 771 or 776
Tightening torquesm

ting bolts

ting bolts

ting bolts
1 10
6
4
2
8
3
7
15153

WARNING
Check that all of the cylinder head bolts are tighte-
ned to the correct torque (20 Nm) .
In order to ensure that the bolts are correctly Step 1
tightened, use a syringe to remove any oil that Angle-tighten in order the cylinder head mounting
may be in the cylinder head mounting holes. bolts ( 100 6 )
WARNING
11A-202
F4R, and 770 or 771 or 776
Step 2
bolts ( 100 6 )
WARNING
11A-203
K9K, and 732
Equipment required
low torque wrench
angular tightening wrench
Tightening torquesm

ting bolts

ting bolts
19712
WARNING
WARNING
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.

mounting bolts ( 25 Nm ) with the low torque
wrench .
bolts ( 255 10 ) using the angular tightening
wrench .
WARNING
11A-204
Cylinder head: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removing the cylinder head requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
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 as-
sembly: Removal - Refitting ).
11A-205
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Engine
Gear-
Vehicle Type Suffix Bore Stroke Cubic Compression
box capacity
(mm) (mm) ratio
(cc)
ND0 770
XM0U 9.8/1
DP0 F4R 771 82.7 93 1,998
XN0W ND0 776 9.5 0.3
Test carried out at idle speed(1)

Engine Fuel (2)
Pollutant emissions(3) (minimum
Type Suffix Idling CO (%)(4) CO2 (%) HC (ppm) Lambda () octane
speed
rating)
(rpm)
F4R 770 / 750 50 0.5 14.5 100 0.97< <1.03 Super

771 / unleaded
maximum maximum maximum
776 (Octane
rating 95)
(1)for
a coolant temperature above 80C and after the (3)for the legal values, see specifications by country
engine speed has stabilised at 2,500 rpm for approxi-
mately 30 seconds . (4)at 2,000 rpm CO should be a maximum of 0.3 %
(2)octane rating 91 unleaded compatible
Temperatures in C 1 - 10 25 50 80 110 120
Negative temperature coefficient air tem- 10,454 2,174 to 857 to 326 to 143 112 to
perature sensor (resistance in ) to 8,623 1,928 763 292 127 98
Negative temperature coefficient coolant 13,588 2,364 to 850 to 290 to 117 to 90 to 86

temperature sensor (resistance in ) t o 11, 2,140 772 275 111
332
12A-1
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Description Brand-Type Special notes
Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer
128-track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump - It is part of a pump - sender - filter assembly

incorporating the pressure regulator
Pressure: 3.5 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils SAGEM Four coils

Primary resistance: tracks 1 and 2 approximately 0.5

Secondary resistance: track 1 and high voltage out-
put: 10.5 +/- 1.5 k
2-track connector:
- 1: + 12 V supply
- 2: earth control
Ignition coils BERU (F4R 776) only Four coils


put: 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 Bi-jet solenoid injector
(F4R 776) only
Resistance: 12 0.5 at 20C
2-track connector:
- 1: + 12 V supply
- 2: earth control
12A-2
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
SIEMENS - MAP03 Piezoelectric type sensor

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
3-track connector:
- 1: + 5 V supply
- 2: earth
- 3: signal
Injection order - 1-3-4-2

no. 1 flywheel end
Fault finding diagnostic tool CLIP only
Accelerator pedal potentio- CTS Dual gang potentiometer

meter
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
- 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 SIEMENS Variable reluctance type sensor

sensor
Resistance: 200 to 270 at 23C
12A-3
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Upstream and downstream BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaust
oxygen sensors 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 sole- SAGEM Resistance: 26 4 to 23C

noid valve
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-
vious table)
Coolant temperature sensor JAEGER ELTH Negative temperature coefficient thermistor (see pre-
vious table)
or SILEA
Refrigerant sensor TEXAS 3-track connector:

INSTRUMENTS - A: earth
- B: + 5 V supply
- C: signal
12A-4
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
VDO EGAS 5 Direct current geared electric motor.

Diameter 60 mm (F4R 6-track connector:
770 and 771)
- 1: potentiometer gang no. 1 signal
- 2: 5 V potentiometer supply
- 3: + motor
- 5: - motor
- 6: common earth
Engine resistance: approximately 2.3 at 23C
Potentiometer resistance:
tracks 2 and 6: 1000 250
Throttle valve
VDO EGAS - T Direct current geared electric motor.
Diameter 40 mm (F4R 6-track connector:
776) only
- 1: earth
- 3: + motor
- 4: - motor
Engine resistance: approximately 1.57 to 23C
Potentiometer resistance:
tracks 1 and 5: 1,000 250
Camshaft dephaser solenoid AISIN (F4R 770 and It is controlled by the opening cyclic ratio.
valve 771)
Resistance: 7.2 0.5 to 20C
2-track connector:
- 1: + 12 V supply
- 2: earth
CHAMPION Single electrode spark plugs

RC 87 YCL (F4R 770 Gap: 0.90 0.05 mm
and 771
Torque: 25 to 30 Nm
Spark plug
NGK PFR6G - 9 Single electrode spark plugs
(F4R 776) only Gap: 0.900 --0.1mm
Torque: 25 to 30 Nm
Catalytic converter EBERSPCHER C175
12A-5
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 K4M, and 760 or 761
Equipment required
diagnostic tool
Engine
Gear-
Vehicle Type Suffix Bore Stroke Cubic Compression
box capacity
(mm) (mm) ratio
(cc)
730
XM0B JH3 K4J 79.5 70 1390
732
10 / 1
JH3 760
XM0C K4M 79.5 80.5 1,598
DP0 761
Test carried out at idle speed(1)

Engine Fuel (2)
Pollutant emissions(3) (minimum
Type Suffix Idling CO (%)(4) CO2 (%) HC (ppm) Lambda () octane
speed
rating)
(rpm)
K4J 730 / 750 50

Super
732 0.5 14.5 100 unleaded
0.97<<1.03
(Octane
K4M 760 / 700 40 maximum maximum maximum
rating 95)
761
(1)for
a coolant temperature above 80C and after the (3)for the legal values, see specifications by country
engine speed has stabilised at 2,500 rpm for approxi-
mately 30 seconds . (4)at 2,000 rpm CO should be a maximum of 0.3 %
(2)octane rating 91 unleaded compatible
Temperatures in C 1 - 10 25 50 80 110 120
Negative temperature coefficient air tem- 10,454 2,174 to 857 to 326 to 143 112 to
perature sensor (resistance in ) to 8,623 1,928 763 292 127 98
Negative temperature coefficient coolant 13,588 2,364 to 850 to 290 to 117 to 90 to 86

temperature sensor (resistance in ) t o 11, 2,140 772 275 111
332
12A-6
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 K4M, and 760 or 761
Description Brand -Type Special notes
Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer
128-track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump - It is part of a pump - sender - filter assembly

incorporating the pressure regulator
Pressure: 3.5 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils SAGEM Four coils


put: 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

3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Injection order - 1-3-4-2

no. 1 flywheel end
Fault finding diagnostic tool CLIP only
12A-7
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 K4M, and 760 or 761
Accelerator pedal potentio- CTS Dual gang potentiometer

meter
Resistance values:
- 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
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Pinking sensor SAGEM Piezoelectric type sensor

Engine speed and position SIEMENS Variable reluctance type sensor

sensor
Resistance: 200 to 270 at 23C
Upstream and downstream BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaust
oxygen sensors 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 sole- SAGEM Resistance: 26 4 to 23C

noid valve
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-
vious table)
12A-8
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 K4M, and 760 or 761
Coolant temperature sensor JAEGER ELTH Negative temperature coefficient thermistor (see pre-
vious table)
or SILEA
Refrigerant sensor TEXAS 3-track connector:

INSTRUMENTS - A: earth
- B: + 5 V supply
- C: signal
K4J
Throttle valve VDO EGAS T 6-way connector

60 mm diameter - 1: common earth
- 3: - motor
- 4: + motor
Engine resistance: approximately 1.6 to 23C
Potentiometer resistance; tracks 1 and 5: 1,000 250
K4M
Throttle valve VDO EGAS 5 Direct current geared electronic motor

57 mm diameter 6-way connector
- 3: + motor
- 5: - motor
- 6: common earth
Potentiometer resistance; tracks 2 and 6: 1,000 250
12A-9
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 K4M, and 760 or 761
K4M
Camshaft dephaser solenoid valve DELPHI It is controlled by the opening cyclic ratio.
Resistance: 7.2 0.5 to 20C
2-track connector:
- 1: + 12 V supply
- 2: earth
Camshaft position sensor SAGEM Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: + 12 V supply
Spark plug EYQUEM RFN 58 LZ Single electrode spark plugs

or CHAMPION RC 87 YCL Gap: 0.95 0.05 mm
Torque: 25 to 30 Nm
Catalytic converter EBERSPCHER C150
12A-10
FUEL MIXTURE
Air inlet 12A
K4J, and 730 or 732
Diagram of the air inlet circuit
102071
(1) Air inlet sleeve

(2) Air resonator
(3) Air filter unit
(4) Air unit
(5) Throttle valve
(6) Inlet manifold
(7) Injector holder plate
(8) Air inlet
12A-11
FUEL MIXTURE
Air inlet 12A
K4M, and 760 or 761
Diagram of the air intake circuit
5 4
6
2
3
7
2
101190
(1) Air intake sleeve

(2) Air resonators
(3) Air filter unit
(4) Throttle valve
(5) Inlet manifold
(6) Injector holder shim
(7) Air inlet
12A-12
FUEL MIXTURE
Air inlet 12A
K9K, and 722
Diagram of the air intake circuit
4
5
3 7
2
8
102070
(1) Air intake sleeve

(2) Air filter unit
(3) Exhaust gas recirculation unit
(4) Air resonator
(5) Metal air intake tube
(6) Intercooler
(7) Turbocharger
(8) Air inlet
12A-13
FUEL MIXTURE
Air inlet 12A
F9Q, and 800
Air intake circuit diagram
3 5
4
102482
(1) Air inlet

(2) Air filter
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Engine shut-off flap
(7) Air-to-air intercooler
12A-14
FUEL MIXTURE
Air inlet 12A
F4R, and 770 or 771
Air intake circuit diagram
4
5
3
2
2
102744
(1) Air intake trunking

(2) Resonators
(3) Air filter unit
(4) Throttle body
(5) Intake manifold
(6) Injector mounting plate
(7) Air intake
12A-15
FUEL MIXTURE
Air inlet 12A
F4R, and 776
4
6
2
5
1
107841
(1) Air intake

(2) Air resonator
(3) Air filter unit
(4) Turbocharger
(5) Intercooler
(6) Inlet manifold
12A-16
FUEL MIXTURE
Air inlet 12A
K9K, and 728 or 729
4 3 7
5
2
1
110316
(1) Air inlet sleeve

(2) Air filter unit
(4) Air resonator
(5) Metal air inlet tube
(6) Intercooler
(7) Turbocharger
(8) Air inlet
12A-17
FUEL MIXTURE
Air inlet 12A
F9Q, and 804
112269
(1) Air inlet

(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Throttle valve
(7) Intercooler
(8) Air filter
(9) EGR unit
12A-18
FUEL MIXTURE
Air inlet 12A
K9K, and 732
8 5 3
6
4
1
112302
(1) Air inlet

(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Damper flap
(6) Air filter
(7) Intercooler
(8) Air resonator
12A-19
FUEL MIXTURE
Air inlet 12A
F9Q, and 808
114617
(1) Air inlet

(2) Air filter
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Engine stop flap
(7) Intercooler
12A-20
FUEL MIXTURE
Air inlet 12A
M9R, and 700
114472
(1) Air inlet scoop

(2) Noise-reducing air duct
(3) Air resonator
(4) Air filter unit
(5) Air filter
(6) Air flowmeter
(7) Turbocharger
(8) Intercooler
(9) Damper flap
(10) EGR solenoid valve
12A-21
FUEL MIXTURE
Air resonator: Removal - Refitting 12A
M9R, and 700
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED
I - OPERATION FOR REMOVAL OF PART

CONCERNED
Remove the front bumper (see MR 365, Bodywork,
55A, Exterior protection, Front bumper ).
114659
Remove the air resonator (3) starting with the end
115726
piece side of the duct that is upstream of the air filter.
REFITTING

CONCERNED
Refit the air resonator starting with the end piece
side of the duct that is upstream of the air filter.
Refit the left-hand headlight.
Tighten:
115725 - the left-hand headlight upper mounting bolt,
Remove:
- the left-hand headlight lower mounting bolt.
- the left-hand headlight upper mounting bolt (1) ,
Disconnect the left-hand headlight connectors.
- the left-hand headlight lower mounting bolt (2) .
Refit the front bumper (see MR 365, Bodywork,
Disconnect the left-hand headlight connectors. 55A, Exterior protection, Front bumper ).
Remove the left-hand headlight. Connect the battery (see 80A, Battery, Battery: Re-
12A-22
FUEL MIXTURE
Air filter: Replacement 12A
K4J, and 730 or 732
REPLACING THE FILTER ELEMENT
2
1
101104
101103 Disconnect brake servo vacuum pipe (2) from the in-
Remove: let manifold.
- the air resonator housing. 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
2
bolts
REPLACING THE FILTER ELEMENT
106276
1
Remove:
- the cover (2) ,
.
106277 REFITTING
Remove the mounting bolts (1) from the air filter co- Tighten to torque the battery cover mounting bolts
ver. ( 4 Nm ) .
12A-24
FUEL MIXTURE
Air filter: Removal - Refitting 12A
F4R or F9Q or K4M or K9K or M9R
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING OPERATION FOR PART

CONCERNED
Clean the air filter unit.
Refit:
- the air filter,
- the cover.
Tighten the air filter unit mounting bolts.
106277
Remove the mounting bolts (1) from the air filter co-
ver.

CONCERNED
106276
Remove:
- the cover (2) ,
- the air filter.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4J, and 730 or 732
Ele. 1294-01 Windscreen wiper arm

removing tool
Tightening torquesm
air filter unit mounting 9 Nm

bolts

bolts 3
REMOVAL
terminal.
102101
Unclip the trim (3) .
2
1
4
102100
Remove:
- the seal (1) , 102105
Remove wiper arms (4) using tool (Ele. 1294-01) .
- the plastic rivets (2) .
Remove the scuttle panel grille.
12A-26
FUEL MIXTURE
K4J, and 730 or 732
5 8
101487 101104
Remove: Disconnect brake servo vacuum pipe (7) from the in-
let manifold.
- the bulkhead soundproofing mountings (5) ,
- the bulkhead soundproofing material.
WARNING
Do not damage the vacuum outlet on the inlet
manifold. If it is damaged, the inlet manifold will
Remove:
- air filter cover mounting bolts (8) ,
101103
Remove:
- the air resonator.
12A-27
FUEL MIXTURE
K4J, and 730 or 732
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 re-
moved.
9
Torque tighten the air filter unit mounting bolts ( 9
Nm ) .
nal.
10
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Torque tighten the battery cover mounting bolts (

101494 4 Nm ) .
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
M9R, and 700
Mot. 1608 Torque screwdriver
Tightening torquesm
air flowmeter mounting 4 Nm

bolts
air duct clip mounting 5.5 Nm

bolt between the air fil-
ter unit and the turbo-
charger

mounting bolts

mounting bolts
battery tray mounting 21 Nm 112658

bolts
wiring harness moun- 8 Nm Remove:

ting nut - the Protection and Switching Unit cover mounting
bolts (1) ,
REMOVAL - the Protection and Switching Unit cover.

Remove
Refitting ).
Refitting ).
102504
Unpick the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) .
12A-29
FUEL MIXTURE
M9R, and 700
112659 104555
Disconnect the injection computer connectors (6) . Move the turbocharger regulation solenoid valve
(10) to one side.
Remove:
Remove the air duct between the air filter unit and
the turbocharger.
- 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.
114933
12A-30
FUEL MIXTURE
M9R, and 700
CONCERNED
102365
Remove:
- the lower front end panel mounting bolts (12) .
115019
114659
Remove the air resonator (13) .
115020
Remove the air filter unit (15)
12A-31
FUEL MIXTURE
M9R, and 700
Refit:
- the front end panel clips,
Tighten to torque:
- the air duct clip mounting bolt between the air

filter unit and the turbocharger ( 5.5 Nm ) ,

Nm ) ,

Nm ) .
114993
Remove Clip on:
- the air flowmeter mounting bolts (16) , - the air inlet scoop to the front end panel,
- the air flowmeter (17) .
- the bonnet opening cable
Fit the turbocharger regulation solenoid valve onto

REFITTING the air filter unit.
I - REFITTING OPERATION FOR PART Refit the battery tray and the computer.
CONCERNED
Tighten to torque the battery tray mounting bolts (
Refit the air flowmeter onto the air filter unit. 21 Nm ) .
Tighten to torque the air flowmeter mounting bolts Refit the wiring harness mounting nut.
( 4 Nm ) using the (Mot. 1608) .
Tighten to torque the wiring harness mounting nut
Refit the air filter unit.
( 8 Nm ) .
Connect:
- the injection computer connectors,
- the air flowmeter connector,
- the connectors to the Protection and Switching Unit

box.
Refit:

Refitting ).

Refitting ).
12A-32
FUEL MIXTURE
K4M, and 760 or 761 F4R, and 770 or 771 or 776
Tightening torquesm
battery tray mounting 21 Nm

bolts

bolts
4
REMOVAL
terminal.
Remove the battery (see 80A, Battery: Removal -
Refitting ).
101811
Remove the injection computer (4) and its mounting.
2
1
6
3
101822 5
Disconnect the injection computer connectors (1) .
Remove:
101737
- the wiring harness strap (3) .
Remove:
Unclip the wiring harnesses from the battery tray.
- the air inlet sleeve (5) ,
- the air ducts (6) ,
12A-33
FUEL MIXTURE
K4M, and 760 or 761 F4R, and 770 or 771 or 776
REFITTING
21 Nm ) .
nal.
WARNING

( 4 Nm ) .
12A-34
FUEL MIXTURE
K9K, and 722 or 728 or 729
Tightening torquesm

bolts

bolts
REMOVAL
terminal.
Refitting ).
101811
101822
Remove:
101737
Remove:
12A-35
FUEL MIXTURE
K9K, and 722 or 728 or 729
REFITTING
21 Nm ) .
nal.
WARNING

( 4 Nm ) .
12A-36
FUEL MIXTURE
F9Q, and 800 or 804 or 808 K9K, and 732
Tightening torquesm

bolts

bolts
REMOVAL
terminal.
Refitting ).
101811
101822
Remove:
101737
Remove:
12A-37
FUEL MIXTURE
F9Q, and 800 or 804 or 808 K9K, and 732
REFITTING
21 Nm ) .
nal.
WARNING

( 4 Nm ) .
12A-38
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
M9R, and 700
Mot. 1608 Torque screwdriver
Tightening torquesm
air flowmeter mounting 4 Nm

bolts on the air filter unit
air inlet duct clip on the 5.5 Nm

air filter unit side

turbocharger side
REMOVAL
I - REMOVAL PREPARATION OPERATION 114990
Loosen:
Removal - Refitting ). - 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.

CONCERNED
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 turbo-

charger - air filter unit air inlet duct.
Unpick the turbocharger regulation solenoid valve

on the air filter unit.
114993
Disconnect the air flowmeter connector.
Remove:
Move the turbocharger regulation solenoid valve - the air flowmeter mounting bolts (4) from the air fil-
and air flowmeter connector aside. ter unit,
12A-39
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
M9R, and 700
- the air flowmeter (5) .
REFITTING

CONCERNED
Refit:
- the air flowmeter,
- the bolts securing the air flowmeter.
Note:
Be sure not to damage the air flowmeter 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) .
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:
Refitting ).
12A-40
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
K9K, and 732
CONCERNED
Tightening torquesm
damper flap mounting 12 Nm

nuts
REMOVAL

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
(1) .
Loosen the clip and (2) and move the air inlet duct CONCERNED
(3) to one side.
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.
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
Refitting ).
12A-41
FUEL MIXTURE
K9K, and 732
12A-42
FUEL MIXTURE
F9Q, and 804
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
Replace the seal.
damper flap mounting 8 Nm
bolts Tighten to torque the damper flap mounting bolts
( 8 Nm ) .
bolts Connect the battery, starting with the positive termi-
nal.
REMOVAL WARNING
Remove the engine covers. Carry out the necessary programming (see 80A,
Disconnect the battery, starting with the negative Battery: Removal - Refitting ).
terminal.
( 4 Nm ) .
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
M9R, and 700
Tightening torquesm
damper flap retaining 12 Nm

strut mounting bolts on
the inlet manifold
damper flap retaining 12 Nm

strut mounting bolts on
the exhaust gas recircu-
lation solenoid valve
downstream intercoo- 5.5 Nm

ler duct clip on the inter-
cooler
downstream intercoo- 5.5 Nm

ler duct clip on the dam-
per flap

mounting bolts 112658

mounting bolts
battery tray mounting 21 Nm bolts (1) ,
bolts
- the Protection and Switching Unit cover.
wiring harness moun- 8 Nm
ting nut on the battery
tray
REMOVAL

Remove:
Refitting ). 115585
Disconnect the Protection and Switching Unit con-
- the front bumper (see MR365, Bodywork, 55A, nectors (2) .
Remove:
- the clips (4) ,
- the upper front end panel mounting bolts (5) ,
Disconnect the screen washer pipes.
12A-44
FUEL MIXTURE
M9R, and 700
112659 115701
Disconnect the injection computer connectors (6) . Disconnect the turbocharger pressure sensor con-
nector (11) .
Remove:
Remove the turbocharger pressure sensor mounting
- the battery tray mounting bolts (7) , nut (12) on the damper flap strut.
Unpick the battery negative terminal wiring harness

(9) .
102365
Remove:
- the lower front end panel mounting bolts (13) .
114933
12A-45
FUEL MIXTURE
M9R, and 700
CONCERNED
114649
114406
Disconnect the damper flap connector (17) .
Remove:
- the mounting bolts (18) from the damper flap retai-
ning strut on the inlet manifold,
- the mounting bolts (19) from the damper flap retai-
ning strut on the exhaust gas recirculation solenoid
valve,
- the damper flap,
- the seal between the damper flap and the exhaust
gas recirculation solenoid valve
REFITTING
115702 Replace the seal between the damper flap and the
exhaust gas recirculation solenoid valve.
Remove the mounting bolt (14) from the intercooler
duct (downstream) on the cooling radiator.
Loosen:
- the downstream intercooler duct clip (15) on the in-
tercooler,
- the downstream intercooler duct clip (16) on the
damper flap.
Remove the downstream intercooler duct.
12A-46
FUEL MIXTURE
M9R, and 700
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-47
FUEL MIXTURE
M9R, and 700
III - FINAL OPERATION - the engine undertray,
Refit: - the engine protectors,
- the downstream intercooler duct clip onto the inter- - the battery (see 80A, Battery, Battery: Removal -
cooler and the damper flap, Refitting ).
- the downstream intercooler duct mounting bolt Carry out programming by following command sce-
onto the cooling radiator. nario SC036 if replacing or removing - refitting the
damper flap (see MR 366 Fault finding, 13B, Fault
Tighten to torque: finding - Interpretation of commands ) and (see
- the downstream intercooler duct clip on the in- MR 366 Fault finding, 13B, Fault finding - Repla-
tercooler ( 5.5 Nm ) , cement of components ).
- the downstream intercooler duct clip on the

damper flap ( 5.5 Nm ) .
Refit:
- front end panel mounting bolts.
Tighten to torque:
Nm ) ,
Nm ) ,
Clip:
- the bonnet opening cable.
Refit:
- the battery tray,
- 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,
bolts,
- the front bumper (see MR365, Bodywork, 55A,
12A-48
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
F9Q, and 800 or 808
Tightening torquesm
inlet duct mounting 8 Nm

bolts
3
inlet duct nut 21 Nm

2
bolt
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,
5
- 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
F9Q, and 800 or 808
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 ) .
nal.
WARNING
Torque tighten the battery cover mounting bolt ( 4

Nm ) .
12A-50
FUEL MIXTURE
F9Q, and 804
REFITTING
Tightening torquesm Replace the seals.
Refit the inlet duct.
inlet duct mounting 25 Nm
bolts Tighten to torque and in order:
inlet duct mounting nut 21 Nm - the inlet duct mounting bolts ( 25 Nm ) ,

- the inlet duct mounting nut ( 21 Nm ) ,
bolts To refit, proceed in the reverse order to removal.
nal.
REMOVAL
Remove the engine covers. WARNING
terminal.
( 4 Nm ) .
111887
Disconnect:
- 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) ,
12A-51
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
K4J, and 730 or 732
Tightening torquesm
plenum chamber moun- 9 Nm

ting bolts
throttle valve bolts 13 Nm
air unit bolts 9 Nm

bolts
REMOVAL
terminal.
Remove:
101794
unit ), Remove:
- the plenum chamber mounting bolts,
valve ). - the plenum chamber.
REFITTING
Always replace all of the seals.
1 2
101100
Disconnect:
- the manifold pressure sensor (1) ,
- the ignition coils (2) ,
- the air temperature sensor (3) .
12A-52
FUEL MIXTURE
K4J, and 730 or 732
7
5
4
3
101794
Tighten to torque and in order the plenum chamber
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air unit bolts ( 9 Nm ) ,
nal.
WARNING
Battery: Removal - Refitting

( 4 Nm ) .
12A-53
FUEL MIXTURE
F4R, and 770 or 771 K4M, and 760 or 761
Tightening torquesm
inlet manifold bolts 9 Nm 3
motorised throttle valve 13 Nm

bolts

bolts
REMOVAL
4
2
1
102735
Disconnect:
- throttle valve connector (2) ,
- brake servo vacuum pipe (3) to the inlet manifold.
101807
Note:
Disconnect the battery, starting with the negative Do not damage the vacuum outlet on the inlet
terminal. manifold. If it is damaged, the inlet manifold will
Remove:
- the engine covers, Disconnect fuel vapour recirculation pipe (4) to the
throttle valve.
- air duct (1) .
12A-54
FUEL MIXTURE
F4R, and 770 or 771 K4M, and 760 or 761
ON THE WORKBENCH
Remove the throttle valve.
7 REFITTING
Always replace all of the seals with new ones.
7
6
5
8
6
5 2
5
101795 1
Disconnect electrical wiring harness (5) . 3
Pull the electric wiring harness to one side.
Disconnect fuel inlet pipe (6) from the injector rail.

4
IMPORTANT
102726
Be careful of petrol splashing when disconnec-
ting the supply pipe union from the injector rail. Tighten to torque and in order the inlet manifold
bolts ( 9 Nm ) .
Unclip fuel vapour recirculation pipe (7) from the in- Tighten to torque the motorised throttle valve
let manifold. bolts ( 13 Nm ) , tightening each bolt evenly.
nal.
WARNING

( 4 Nm ) .
102726
Remove the inlet manifold bolts.
12A-55
FUEL MIXTURE
F4R, and 776
Tightening torquesm
inlet manifold mounting 21 Nm

bolts
motorised throttle valve 21 Nm

4
mounting bolts

bolts
REMOVAL
terminal.
106633
Remove:
- motorised throttle valve mounting bolts (4) ,
2 - the motorised throttle valve.
1
5
7
106270
Remove air duct (1) .

Remove petrol vapour rebreathing pipe (2) .
6
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
F4R, and 776
106271 106337
Disconnect: Tighten to torque and in order the inlet manifold

- injection rail petrol supply pipe (8) , Tighten to torque the motorised throttle valve
- the injector connectors.
nal.
WARNING
Be careful of petrol splashing when disconnec- WARNING
ting the supply pipe union from the injector rail.
Pull the electric wiring harness to one side.
( 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.
12A-57
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4J, and 730 or 732
Tightening torquesm
injector holder shim 25 Nm

mounting bolts 11 and
12
injector holder shim 21 Nm

mounting bolts 13 to 20 2
3
upper timing cover bolt 44 Nm 3 4
suspended mounting 44 Nm
bolt
battery cover mounting 4 Nm 101802

bolts
Disconnect:
- fuel supply union (2) ,
REMOVAL - injectors (3) ,
- pinking sensor (4) .
terminal.
Remove the inlet manifold (see 12A, Fuel mixture,

Inlet manifold ).
IMPORTANT
WARNING 7
Protect the alternator against fuel spills from the 5
rail or supply duct.
6
101493
Remove the two injection rail bolts (5)
Pull the injection rail gently towards yourself to re-
move it.
Remove:
1
- nut (6) securing the electrical wiring harness,
- oil gauge well (7) .
101801
Remove injector rail protector mounting nuts (1) .
12A-58
FUEL MIXTURE
K4J, and 730 or 732
REFITTING
9 10
12 16
11
8 15
19
13 17
101792 20 18 14
Remove the injector holder shim mounting bolts. 101792
The injector holder shim seal must always be repla-

ced.
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 suspen-

ded mounting by tightening bolt (9) by hand.
Position the injector mounting plate against the

cross pieces (10) on the cylinder head cover.

- 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 ).

nal.
WARNING

4 Nm ) .
12A-59
FUEL MIXTURE
K4M, and 760 or 761
Tightening torquesm
bolts 5 and 6 on the 25 Nm

injector holder shim
bolts 7 to 14 on the 21 Nm
1
bolt
upper timing cover bolt 44 Nm

2
bolts
REMOVAL
terminal.
101810
Remove the inlet manifold (see 12A, Fuel mixture, Disconnect injectors (1) .
Inlet manifold ).
Remove:
IMPORTANT
Be careful of petrol splashing when disconnec- - injector rail mounting bolts (2) ,
ting the supply pipe union from the injector rail. - the injector rail, pulling it carefully towards you.
WARNING
3
Protect the alternator against fuel spills from the
102303
Remove injector mounting plate mounting bolts (3) .
12A-60
FUEL MIXTURE
K4M, and 760 or 761
REFITTING 4 Nm ) .
5 6
13 9
10
14
7 11
12 8
102303
ced.
Secure:
cover, by tightening bolt (3) by hand,
- the injector holder shim against the engine suspen-
ded mounting by tightening bolt (4) by hand.
- 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 ) .
manifold ).
nal.
WARNING
12A-61
FUEL MIXTURE
F4R, and 770 or 771
Tightening torquesm
bolts 7 and 8 of the 25 Nm 3

bolts 9 to 16 on the 21 Nm
injector holder shim 2
bolt 6
upper timing cover bolt 44 Nm

5

bolts
Disconnect:
- fuel supply union (2) ,
REMOVAL - injection wiring harness (3) .

terminal.

Inlet manifold ).
IMPORTANT
Be careful of petrol splashing when disconnec- 4
WARNING
102730
Remove:
- injector rail mounting bolts (4) ,
- the injector rail, pulling it carefully towards you.
101801
Remove injector rail protector mounting nuts (1) .
12A-62
FUEL MIXTURE
F4R, and 770 or 771
REFITTING
8 12
7
11
15
16 13
10 9
101792 5 14
Remove the injector holder shim mounting bolts. 101792

ced.
Secure:

cover, by tightening bolt (5) by hand
- the injector holder shim against the suspended en-

gine mounting by tightening bolt (6) by hand.
- 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 ) .

manifold ).

nal.
WARNING

4 Nm ) .
12A-63
FUEL MIXTURE
Manifolds: Removal - Refitting 12A
F9Q, and 800 or 808
Tightening torquesm 6
8
Manifold mounting stud 8 Nm
manifold mounting nuts, 28 Nm
exhaust gas recircula- 8 Nm 7

tion valve mounting bolt
engine cover mounting 4 Nm

bolts
REMOVAL
102478
terminal. Disconnect the exhaust gas recirculation solenoid
valve.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ), Remove:
- the turbocharger (See 12B, Turbocharging, Tur- - the exhaust gas recirculation solenoid valve (6) ,
bocharger ).
- the exhaust gas recirculation pipe (7)
4 - the engine lifting bracket (8)

1
3 - the manifold mounting nuts,
- the manifolds.
REFITTING
5 Proceed in the reverse order to removal.

2
Replace the gaskets:
- on the manifolds,
102486
- the exhaust gas recirculation solenoid valve,
Disconnect:
- on the air inlet duct.
- the air inlet pipe from the damper (1) ,
- the engine stop solenoid valve (2) connector. Tighten to torque:
Remove: - the Manifold mounting stud ( 8 Nm ) ,

- the pipe mountings (3) , - the manifold mounting nuts, ( 28 Nm ) ,
- the vacuum canister (4) ,
- the exhaust gas recirculation valve mounting
- the engine stop solenoid valve (5) . bolt ( 8 Nm ) .
WARNING
Tighten to torque the engine cover mounting bolts

( 4 Nm ) .
12A-64
FUEL MIXTURE
F9Q, and 804
Tightening torquesm
manifold mounting 8 Nm
studs
manifold mounting nuts 28 Nm

bolts
REMOVAL
terminal.
Position the vehicle on a lift.
Remove:
- the injector rail protector (see 13B, Diesel injec-
tion, Injector rail protector: Removal - Refitting
). 111872
Disconnect the exhaust gas temperature before tur-
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
bocharger sensor (1) .
- the exhaust gas recirculation unit (see 14A, Emis-
Remove:
sion control, Exhaust gas recirculation unit ),
- the manifold mounting nuts
- the exhaust gas recirculation pipe,
- the exhaust manifold (2) .
- the catalytic pre-converter (see 19B, Exhaust, Ca-
talytic pre-converter: Removal - Refitting ).
- the starter motor (see 16A, Starting-charging,
Starter motor: Removal - Refitting ).
bocharger: Removal - Refitting ).
111873
Remove the inlet manifold (3) .
12A-65
FUEL MIXTURE
F9Q, and 804
REFITTING
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 recircula-
tion unit ),
bocharger ).
nal.
WARNING
Refit the engine lifting bracket.

( 4 Nm ) .
12A-66
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
Tightening torquesm
exhaust manifold studs 9 Nm
exhaust manifold 30 Nm
mounting nuts
EGR duct mounting 30 Nm

bolts on the EGR cooler

bolts on the exhaust
manifold

bolt on the cylinder
head
EGR duct heat shield 10 Nm

cylinder head 112659
EGR duct heat shield 10 Nm Disconnect:

mounting bolt on the - the injection computer connectors (1) ,
exhaust manifold
lower mounting bolts of 44 Nm - the turbocharger regulation solenoid valve connec-
the front end panel tor.
upper mounting bolts of 21 Nm Unclip:
the front end panel
- the battery negative terminal wiring harness (2) ,
air inlet duct clip 5.5 Nm - the injection computer connector wiring harness,
battery tray mounting 21 Nm - the turbocharger regulation solenoid valve wiring

bolts harness.
Remove:
IMPORTANT
Wear protective gloves during all operations.
Unpick the wiring harness from the injection compu-
ter connectors.
REMOVAL
Remove the battery tray with the injection computer
mounting.
Remove:
Refitting ).
12A-67
FUEL MIXTURE
M9R, and 700
114990 112658
Loosen the air inlet duct clip (5) on the air flowmeter
Remove:
side.
Remove: - the Protection and Switching Unit cover mounting
bolts (7) ,
- the air inlet duct on the air flowmeter side,
- the front bumper (see MR 365, Bodywork, 55A, - the Protection and Switching Unit cover.
102504

nectors (8) .

114933
Remove:
- the clips (10) ,
- the upper mounting bolts (11) .
12A-68
FUEL MIXTURE
M9R, and 700
- 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:
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
- the gasket between the EGR cooler and the EGR
Remove: duct,
- the EGR duct heat shield mounting bolt (13) on the - the gasket between the EGR duct and the exhaust
exhaust manifold, manifold.
12A-69
FUEL MIXTURE
M9R, and 700
CONCERNED
113279
113279
Remove: Note:
- the exhaust manifold mounting nuts, Check that the manifold gasket is positioned cor-
rectly.
- the exhaust manifold spacers,
The tab must be positioned as (18) .
- the exhaust manifold,
- the exhaust manifold gasket. Refit the new seal on the exhaust manifold.

CONCERNED
I - REFITTING PREPARATION OPERATION Refit:
Clean and degrease the bearing faces: - the exhaust manifold,
- the exhaust manifold in case of reuse,
- the spacers.
- the cylinder head face,
Finger tighten the new mounting nuts until they are
- the EGR duct, in contact with the exhaust manifold.
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) .

mounting nuts ( 30 Nm ) .
12A-70
FUEL MIXTURE
M9R, and 700
III - FINAL OPERATION Connect the Protection and Switching Unit connec-
tors.
Refit:
- the new gasket between the EGR duct and the ex- Refit:
haust manifold,
- the Protection and Switching Unit cover,
- the new gasket between the EGR cooler and the
EGR duct. - the Protection and Switching Unit cover mounting
bolts,
Finger tighten until contact:
- the EGR duct mounting bolts on the exhaust mani-
fold,
- the EGR duct mounting bolts on the EGR cooler, - the air inlet duct to the air flowmeter,
- the EGR duct mounting bolts on the cylinder head. - the air inlet duct clip on the air flowmeter side.
Tighten to torque:
Tighten to torque the air inlet duct clip ( 5.5 Nm ) .
- the EGR duct mounting bolts on the EGR cooler
( 30 Nm ) , Refit the battery tray with the injection computer
mounting.
- the EGR duct mounting bolts on the exhaust
manifold ( 30 Nm ) , Fit the computer connector wiring harness.
- the EGR duct mounting bolt on the cylinder Refit:
head ( 10 Nm ) .
Fit the heat shield. - the wiring harness mounting nut,
Refit: - the battery tray mounting bolts.
- the EGR duct heat shield mounting bolt to the cylin- Tighten to torque the battery tray mounting bolts (
der head, 21 Nm ) .
- the EGR duct heat shield mounting bolt to the ex-
Fit:
haust manifold.
Tighten to torque: - the turbocharger regulation solenoid valve wiring
harness,
- the EGR duct heat shield mounting bolt on the
cylinder head ( 10 Nm ) , - the battery negative terminal connector wiring har-
ness,
- the EGR duct heat shield mounting bolt on the
exhaust manifold ( 10 Nm ) . - the injection computer connector wiring harness.
Refit:
Connect:
- the turbocharger regulation solenoid valve connec-
- the upper mounting bolts of the front end panel, tor,
Tighten to torque:
- the lower mounting bolts of the front end panel
( 44 Nm ) , Refit:
- the upper mounting bolts of the front end panel
( 21 Nm ) .
Clip on the air inlet scoop.
Connect the screen washer pipes. tic converter: Removal - Refitting ).
Refit the clips.
Fit the bonnet opening cable. Refitting ).
12A-71
FUEL MIXTURE
K9K, and 722 or 728 or 729
- the exhaust gas recirculation unit,
- the manifold mounting nuts (5) ,
Mot. 1567 Remote operation
- the manifold.
pliers for EGR clips
Tightening torquesm
exhaust manifold studs 9 Nm
mounting nuts
exhaust gas recircula- 21 Nm

tion unit mounting bolts
air inlet metal tube 21 Nm

mounting bolts
lifting eye 21 Nm

bolts
REMOVAL
Put the vehicle on a two-post lift.

terminal.
4 2
3
1
5
102074
Remove:
- the lifting eye (2) ,
- the air inlet metal tube (3) ,

bocharger ),
- the exhaust gas recirculation metal tube (1) ,
- the exhaust gas recirculation unit mounting bolts
(4) ,
12A-72
FUEL MIXTURE
K9K, and 722 or 728 or 729
REFITTING
8
4
2
6 7
3
1
5
20848-1
Replace the manifold gasket. Refit the turbocharger (see 12B, Turbocharging,
Turbocharger ).
Tighten to torque the exhaust manifold studs ( 9
Nm ) . Connect the battery, starting with the positive termi-
nal.
Refit the manifold.
mounting nuts ( 26 Nm ) . WARNING
Fit:
- the exhaust gas recirculation unit,
- the new exhaust gas recirculation unit tube, ( 4 Nm ) .
- 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 ) .
12A-73
FUEL MIXTURE
K4J, and 730 or 732 K4M, and 760 or 761

gen sensors 1
Tightening torquesm
manifold nuts. 23 3 Nm
heat shield bolts 10 Nm
oxygen sensors 45 Nm
mounting bolts for the 21 Nm

exhaust pipe brackets to
the body
bolt on the inlet mani- 8 Nm

fold strut
101501
exhaust bracket nuts 20 Nm
Disconnect downstream oxygen sensor (1) .
bolts
REMOVAL
terminal.
K4J
Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit ). 3
2
K4M
Inlet manifold ).
101793
Remove:
- exhaust bracket mounting nuts (2) ,
- exhaust manifold strut (3) .
Note:
Mark with a pen the position of the exhaust
silentbloc supports on the vehicle body.
12A-74
FUEL MIXTURE
K4J, and 730 or 732 K4M, and 760 or 761
7
4
7
102116 101798
Remove mounting bolt (4) from the exhaust pipe si- Remove oxygen sensor (6) using tool (Mot. 1495-
lentbloc supports on the body. 01) .
Remove upper heat shield (7) from the exhaust ma-
nifold.
102117
Remove mounting bolt (5) from the silencer silent-
bloc bracket on the body. 101797
Withdraw the exhaust pipe towards the rear of the Remove:
vehicle.
- the nine exhaust manifold securing nuts,
- the exhaust manifold.
12A-75
FUEL MIXTURE
K4J, and 730 or 732 K4M, and 760 or 761
ON THE WORKBENCH
8
2
3
5
9
7
1
4
6
101797
Remove the lower heat shield.
- the manifold nuts. ( 23 3 Nm ) ,
REFITTING
- the heat shield bolts ( 10 Nm ) ,
Always replace:
- the oxygen sensors ( 45 Nm ) ,
- the manifold gaskets,
- the mounting bolts for the exhaust pipe brac-
- the exhaust bracket gaskets, kets to the body ( 21 Nm ) ,
- the manifold nuts. - the bolt on the inlet manifold strut ( 8 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
nal.
WARNING

( 4 Nm ) .
12A-76
FUEL MIXTURE
F4R, and 770 or 771

gen sensors
Tightening torquesm
manifold nuts 18 Nm
2
heat shield bolts 10 Nm
3
mounting bolts for the 21 Nm

exhaust pipe brackets to
the body
bolt on the exhaust 21 Nm

manifold strut on the
gearbox 101793
exhaust bracket nuts 20 Nm Remove:
battery cover mounting 4 Nm - exhaust bracket mounting nuts (2) ,

bolts
- the exhaust manifold strut (3) .
REMOVAL Note:
Position the vehicle on a two-post lift. Mark with a pen the position of the exhaust
silentbloc supports on the vehicle body.
terminal.
1
4
102116
101501
Remove mounting bolt (4) from the exhaust pipe si-
Disconnect downstream oxygen sensor (1) . lentbloc supports on the body.
12A-77
FUEL MIXTURE
F4R, and 770 or 771
102117 101797
Remove mounting bolt (5) from the silencer silent- Remove:
bloc bracket on the body.
- the exhaust manifold mounting nuts,
Withdraw the exhaust pipe towards the rear of the
vehicle.
ON THE WORKBENCH
7
101798
Remove oxygen sensor (6) using tool (Mot. 1495-
01) . 101502
Remove upper heat shield (7) from the exhaust ma- Remove the lower heat shield.
nifold.
REFITTING
Always replace:
- the manifold gaskets,
12A-78
FUEL MIXTURE
F4R, and 770 or 771
- the exhaust bracket gaskets,
- the manifold nuts.
8
2
3
5
9
7
1
4
6
101797
- the manifold nuts ( 18 Nm ) ,
- the heat shield bolts ( 10 Nm ) ,
- the mounting bolts for the exhaust pipe brac-
kets to the body ( 21 Nm ) ,
- the bolt on the exhaust manifold strut on the
gearbox ( 21 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
nal.
WARNING

( 4 Nm ) .
12A-79
FUEL MIXTURE
F4R, and 776
REFITTING
mounting nuts WARNING
the battery cover moun- 4 Nm Always replace:

ting bolts
- the exhaust manifold sealing ring,
- the exhaust manifold mounting nuts.
REMOVAL
terminal.
Remove:
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
bocharger ).
21936
Remove:
- the exhaust manifold mounting nuts,
12A-80
FUEL MIXTURE
F4R, and 776
2
6
5
1
3 7 8
4
21936
Refit:
bocharger ).
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
nal.
WARNING
Tighten to torque the battery cover mounting

bolts ( 4 Nm ) .
WARNING
Strict adherence to the repair procedures is
required for the removal and refitting of the turbo-
charger in order to seal the system FAILURE TO
COMPLY WITH THESE INSTRUCTIONS MAY
HAVE SERIOUS SAFETY-RELATED CONSE-
QUENCES .
12A-81
FUEL MIXTURE
K9K, and 732

Tightening torquesm
mounting studs
mounting nuts

112815

tion rigid pipe mounting
bolts
REMOVAL

Put the vehicle on a two-post lift (see 02A, Lifting
- Refitting ).
112810
(1) .
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 val-
ve.
Remove:
- the lifting eye mounting bolts on the timing end,
- the lifting eye on the timing end.
12A-82
FUEL MIXTURE
K9K, and 732
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
Remove:
113842
Remove: - the mounting nuts (8) from the exhaust manifold,
- the clip (5) from the EGR rigid pipe using the (Mot. - the exhaust manifold.
1567) ,
- the mounting bolts (6) from the exhaust gas recir- REFITTING
culation pipe,
- the exhaust gas inlet pipe . I - REFITTING PREPARATION OPERATION
Always clean the joint faces thoroughly.
12A-83
FUEL MIXTURE
K9K, and 732
CONCERNED
20848-1
Tighten to torque and in order the exhaust manifold Fit the new snap-on clip.
mounting studs ( 9 Nm ) .
Position the new exhaust manifold gasket. WARNING
Refit: Ensure that you do not constrain the exhaust gas
recirculation rigid pipe before fitting the snap-on
- the exhaust manifold, clip.
- the exhaust manifold mounting nuts.
Tighten the bolts of the exhaust gas recirculation ri-
Tighten to torque the exhaust manifold mounting gid pipe on the manifold until they make contact.
nuts ( 26 Nm ) .
Adjust the exhaust gas recirculation rigid pipe in re-
lation to the cooler support.
III - FINAL OPERATION Lock the snap-on clip of the exhaust gas recircula-
Fit the exhaust gas recirculation unit. tion rigid pipe using the (Mot. 1567) .
Torque tighten the exhaust gas recirculation unit Tighten to torque the exhaust gas recirculation ri-
mounting bolts ( 25 Nm ) . gid pipe mounting bolts ( 35 Nm ) .
Refit: Refit:
- the lifting eye mounting bolts on the timing end,
- the new exhaust gas recirculation rigid pipe with a
new seal, - the timing end lifting eye,
- the mounting bolts on the exhaust gas recirculation - the injection rail protector cover retaining bracket
pipe, mounting bolts,
12A-84
FUEL MIXTURE
K9K, and 732
- the inlet throttle valve mounting bolt,
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.
Refitting ).
12A-85
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4J, and 730 or 732
Equipment required
diagnostic tool
Tightening torquesm
throttle valve bolts 13 Nm
air filter unit bolts 9 Nm

bolts
4
REMOVAL
1
101800
Remove:
2 - mounting bolts (4) ,
- the throttle valve.
101489
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 so-
lenoid valve.
12A-86
FUEL MIXTURE
K4J, and 730 or 732
REFITTING
Replace the throttle valve seal each time it is remo-
ved (use grease to make it easier to fit).
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air filter unit bolts ( 9 Nm ) .
nal.
WARNING

( 4 Nm ) .
In the event of a throttle valve replacement, use the
diagnostic tool CLIP to reinitialise the stop pro-
gramming 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
F9Q, and 800 or 808
Tightening torquesm
throttle valve mounting 8 Nm

bolts

3
bolts
REMOVAL
2
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 Remove:
101893 - the three mounting bolts (4) ,

Disconnect:
- the throttle valve / diaphragm assembly.
- turbocharging pressure sensor (1) .
REFITTING
Replace the seal.
Tighten to torque the throttle valve mounting bolts

( 8 Nm ) .

nal.
WARNING

( 4 Nm ) .
12A-88
FUEL MIXTURE
K4M, and 760 or 761
Equipment required
diagnostic tool 4
Tightening torquesm

bolts 3
bolts
REMOVAL 2
4
102735
Disconnect:
1 - throttle valve connector (2) ,
- fuel vapour recirculation pipe (3) on the control so-
lenoid valve.
Remove:
- the four throttle valve mounting bolts (4) ,
- the throttle valve.
101807
terminal.
12A-89
FUEL MIXTURE
K4M, and 760 or 761
REFITTING
Replace the throttle valve seal with a new one each
time it is removed.
( 13 Nm ) , tightening them evenly.
nal.
WARNING

( 4 Nm ) .
In the event of a throttle valve replacement, use the
diagnostic tool CLIP to reinitialise the stop pro-
Programming .
Check using the diagnostic tool CLIP that the
Throttle stop programming .
12A-90
FUEL MIXTURE
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Tightening torquesm

bolts (F4R 776)

bolts

bolts
3
REMOVAL
F4R, and 776 106633

Remove:
- motorised throttle valve mounting bolts (3) ,
- the motorised throttle valve.
2 4
1
106270
Remove fuel vapour recirculation pipe (2) . 101807
Disconnect the motorised throttle valve connector. Disconnect the battery, starting with the negative
terminal.
12A-91
FUEL MIXTURE
F4R, and 770 or 771 or 776
REFITTING
Replace the throttle valve seal each time it is remo-
ved.
7
(F4R 776) ( 10 Nm ) , tightening them evenly.
6 ( 13 Nm ) , tightening them evenly.
nal.
WARNING
7 Carry out the necessary programming (see 80A,
5 Battery: Removal - refitting ).

( 4 Nm ) .
102735 In the event of a throttle valve replacement, use the
Disconnect: diagnostic tool CLIP to reinitialise the stop pro-
- throttle valve connector (5) , Programming .
- fuel vapour recirculation pipe (6) on the control so- When the ignition is switched on, the throttle valve
lenoid valve. should go through a cycle of programming the MIN
Remove: and MAX throttle stop positions.
- the four throttle valve mounting bolts (7) , Using the diagnostic tool CLIP , check that the
- the throttle valve. Throttle stop programming .
12A-92
FUEL MIXTURE
F9Q, and 804
REFITTING
Replace the seal.
bolts Torque tighten the throttle valve mounting bolts (
8 Nm ) .
bolts Connect the battery, starting with the positive termi-
nal.
REMOVAL WARNING
Remove the engine covers. Carry out the necessary programming (see 80A,
terminal.
( 4 Nm ) .
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 turbocharging pressure sensor connector (3) .
Remove the throttle valve.
12A-93
FUEL MIXTURE
Throttle valve: Cleaning 12A
F4R or K4J or K4M
Equipment required
diagnostic tool
WARNING
Wear protective goggles and gloves during the ope-
ration. 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 val-

ve 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 re-

sidue using a cloth, part number 77 11 211 707
12A-94
FUEL MIXTURE
Throttle valve: Cleaning 12A
F4R or K4J or K4M
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 ).

nal.
WARNING
Using tool diagnostic tool , reinitialise the program-

ming of the throttle stops via the delete command
RZ005 Programming .

Check, using the diagnostic tool , that this pro-

gramming has been carried out using the command
ET051 Throttle stop programming .
12A-95
FUEL MIXTURE
Engine stop device 12A
F9Q, and 800 or 808
I - OBJECTIVE
The system is intended to stop the engine quickly after
the ignition is switched off. 4
II - DESCRIPTION
102486
The system consists of:
- a diaphragm (1) acting on the throttle,
- a throttle (2) ,
- a solenoid valve (3) ,
- a vacuum (4) .
1
III - OPERATING PRINCIPLE
When the ignition is switched off, the solenoid valve
101892
connects the vacuum and the diaphragm.
The diaphragm is submitted to the vacuum; this closes
the air inlet flap.
2 The engine can no longer take in air and stops running
immediately.
101894
12A-96
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F9Q
Instructions that must be followed when turbochargers - Replace the turbocharger upstream duct (see dia-
are replaced due to mechanical damage: gram)
- damage to the bearing system, - Clean the turbocharger ducts
- broken shaft,
- Drain the engine oil
- compressor wheel rubbing against the turbocharger
casing, - Replace the oil filter
- broken compressor wheel. - Replace the oil return and supply pipes and their
Damage of the kind listed above can lead to impurities seals
entering the circuits to which the turbocharger is con-
nected.
I - INSTRUCTIONS FOR THE AIR CIRCUIT
FOR THE AIR CIRCUIT:
- Consequences:
Diagram of the air circuit
swarf and metal objects in the ducts upstream and
downstream of the turbocharger, 6 2
A
large volumes of oil in the air circuit (collected in the
intercooler).
- Risks (after replacing the turbocharger):
metal objects found in the compressor wheel (des- 7
truction of turbocharger),
engine racing (oil sucked up in the intercooler).
FOR THE LUBRICATION CIRCUIT:
5
- Consequences: B
1
swarf found in the engine oil circuit, 4
circulation of swarf within the circuit. C
3
- Risks (after replacing the turbocharger):
premature wear on the bearing system (destruction
of turbocharger).
112666
WARNING (1) air filter

Metal objects may enter the oil and air circuits as a
(2) compressor wheel
result of a broken turbocharger.
(3) intercooler
Failure to follow the INSTRUCTIONS listed will lead
(4) turbocharger pressure sensor
to the turbocharger breaking again.
(5) inlet manifold
The following must be replaced: (6) turbine wheel
- intercooler,
- turbocharger upstream air duct,
- engine oil,
Remove intercooler (3) if the vehicle is fitted with one
- oil filter, (refer to the Workshop Repair Manual of the vehicle af-
fected 12B, Turbocharging, Intercooler ).
- turbocharger oil supply and return pipes,
- all seals that have been removed.
DESCRIPTION OF OPERATION WARNING
- Replace the intercooler Always replace the intercooler.
12B-1
TURBOCHARGING
F9Q
11
110738 112772
Damage to the compressor wheel results in metal ob- For ducts comprising several components:
jects entering the air duct (A) between the air filter and
- mark the duct (11) so that you can identify where
the turbocharger.
each component should be positioned when refitting,
Replace the air duct (A) between the air filter and the
- separate all the duct components.
turbocharger.
Check that there are no metal objects inside the flow-
meter (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 in-
let manifold) for section (C) .
Remove the turbocharger pressure sensor (4) for sec-
tion (C) , if the duct is fitted with one.
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
F9Q
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 in-
let manifold) for section (C) ,
Refit the new intercooler (3) , if the vehicle is fitted with
one (refer to the Workshop Repair Manual of the vehi-
cle affected 12B, Turbocharging, Intercooler ,).
II - INSTRUCTIONS FOR THE LUBRICATION

111870
CIRCUIT
Replace:
Drain the engine oil.
- the turbocharger oil supply pipe,
Replace the oil filter.
- the turbocharger oil return pipe(s).
WARNING
Always replace all seals that have been removed.
12B-3
TURBOCHARGING
F9Q
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
M9R, and 700
WARNING
With a marker, mark the position of the exhaust rub-
ber mounting bush supports on the bodywork.
WARNING
- Ensure that no foreign bodies enter the turbine or
compressor during the refitting 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 12B
K9K, and 722 or 728 or 729
Equipment required K9K, and 722
diagnostic tool
6 3
1
Tightening torquesm
turbocharger mounting 7 Nm
studs on the turbochar-
ger 2
studs on the exhaust
manifold
nuts on the exhaust
manifold 4
5
turbocharger oil inlet 22.5 Nm
pipe union on the cylin-
der head
turbocharger oil inlet 22.5 Nm 102081

duct socketed bolt on Disconnect air duct (1) .
the turbocharger
Remove air duct (2) from the turbocharger.
Disconnect:
pipe mounting bolts on
the turbocharger - the turbocharger pressure sensor (3) ,
exhaust gas recircula- 12 Nm - the exhaust gas recirculation solenoid valve (4) ,
tion solenoid valve heat - the turbocharging duct (5) on the turbocharger,
shield mounting bolts
- the pipe (6) from the turbocharging pressure regu-
battery cover mounting 4 Nm lation valve on the air duct.
bolts
REMOVAL
terminal.
12B-6
TURBOCHARGING
K9K, and 722 or 728 or 729
K9K, and 728 or 729

9
10
11
110326
Disconnect:
110325 - the turbocharging pressure sensor connector (9) ,
Pull out the clip. - the exhaust gas recirculation solenoid valve mani-
fold (10) ,
- the turbocharging duct (11) on the turbocharger,
- the pipe from the turbocharging pressure regula-
8 tion valve on the turbocharging pressure regulation
solenoid valve.
110323
Undo bolt (7) .
12B-7
TURBOCHARGING
K9K, and 722 or 728 or 729
14
12
13
102076 102116
Remove: Remove mounting bolt (14) from the exhaust pipe
rubber mounting bush support on the body.
- the exhaust flange mountings (12) ,
- the stay mounting (13) on the catalytic converter.
Loosen the other stay mountings on the gearbox.
Remove stay (13) . 15
Note:
Mark the position of the exhaust rubber mounting
bush supports on the vehicle body with a pen.
102117
Remove mounting bolt (15) from the silencer rubber
mounting bush support on the body.
vehicle.
12B-8
TURBOCHARGING
K9K, and 722 or 728 or 729
22
20
17
21
16
102077 102079
Remove: Remove:
- the catalytic converter stay (16) , - the oil supply pipe (20) ,
- the four mounting nuts (17) securing the catalytic - the oil return pipe (21) ,
converter to the turbocharger,
- the two upper mounting nuts (22) from the turbo-
- the catalytic converter. charger,
- 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
K9K, and 722 or 728 or 729
REFITTING Refit the catalytic converter (see 19B, Exhaust, Ca-

talytic converter: Removal - Refitting ).
WARNING
Tighten to torque the exhaust gas recirculation
Ensure that no impurities enter the turbine or solenoid valve heat shield mounting bolts ( 12
compressor during the refitting operation. Nm ) .
Check that the turbocharger oil return pipe is not Connect the battery, starting with the positive termi-
completely or partially blocked by scale. Also nal.
check that the sealing is perfect; if not, replace it.
WARNING
WARNING Carry out the necessary programming (see 80A,
Check that the intercooler is not full of oil. If this Battery: Removal - Refitting ).
is the case, remove it, rinse with a cleaning agent
and then let it dry. Before starting, disconnect the 4 injectors (starting
the engine is prohibited).
Run the starter motor until the oil pressure warning
WARNING light goes out (wait for a few seconds).
Switch off the ignition.
Always replace:
Reconnect the 4 injector connectors.
- all the O-rings and both copper seals on the tur-
bocharger oil inlet duct, Start the engine.
- the exhaust flange seal. Let the engine idle then depress the accelerator se-
veral times with no load.
- any damaged heat shield.
Tighten to torque:
Make sure that there are no oil leaks.
- the turbocharger mounting studs on the turbo-
charger ( 7 Nm ) , Connect the diagnostic tool and clear the stored
faults.
- the turbocharger mounting studs on the ex-
Make sure that all the exhaust pipe heat shields are
haust manifold ( 7 Nm ) .
in place and properly secured.
Position the turbocharger on the exhaust manifold.
Make sure that there is no contact with the underbo-
Tighten to torque the turbocharger mounting nuts dy.
on the exhaust manifold ( 26 Nm ) .
Apply LOCTITE FRENTANCH to the threads of the ( 4 Nm ) .
turbocharger oil inlet pipe union on the cylinder
head.
Position the turbocharger oil supply pipe on the tur-
bocharger and on the cylinder head, applying new
seals in the process.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cy-
linder head ( 22.5 Nm ) ,
- the turbocharger oil inlet duct socketed bolt on
the turbocharger ( 22.5 Nm ) .
Position the turbocharger oil return pipe on the tur-
bocharger 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 )
12B-10
TURBOCHARGING
F9Q, and 800
Tightening torquesm
studs
turbocharger union end 26 Nm

piece
nuts
oil supply pipe moun- 22.5 Nm

ting nuts
oil supply pipe moun- 12 Nm

ting bolt on the cylinder
block

pipe mounting bolts
102481
bolts Disconnect the turbocharger air inlet and outlet pi-
pes.
REMOVAL
terminal.
102480
Disconnect the tube (1) from the turbocharging pres-

sure regulation valve control diaphragm.
Remove:
- the turbocharger oil supply pipe (2) ,
- the turbocharger oil return pipe (3) ,
- the turbocharger mounting nuts (4) ,
- the turbocharger.
12B-11
TURBOCHARGING
F9Q, and 800
REFITTING
WARNING
Ensure that no impurities enter the turbine or
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.

Be sure to replace the seals:
- on the turbocharger oil supply pipe,
- on the turbocharger oil return pipe,
- the turbocharger,
12B-12
TURBOCHARGING
F9Q, and 800
made previously.
dy.
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.
( 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,
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 cylin-
der block ( 12 Nm ) ,
- the turbocharger oil return pipe mounting bolts
( 12 Nm ) .
Refit the exhaust pipe, aligning it with the marks
12B-13
TURBOCHARGING
F4R, and 776
Equipment required
1
diagnostic tool
Tightening torquesm
bolts of the oil return 12 Nm

pipe towards the cylin-
der block
turbocharger cooling 12 Nm 3
2 4
duct bolts (initial torque)
turbocharger cooling 27 Nm 21927

duct bolts
Disconnect:
turbocharger mountings 15 Nm + 75 - the wastegate control solenoid valve pipe (1) ,
oil supply pipe hollow 45 Nm - the solenoid valve - turbocharger pipe (2) ,
mounting bolt - the braking solenoid valve pipe (3) .
oil supply pipe union 25 Nm Remove the air filter - turbocharger pipe (4) .
oil return pipe mounting 8 Nm

bolts
mounting bolts of the oil 21 Nm

return and supply pipes 5
REMOVAL
Note:
To loosen the turbocharger mounting nuts on the
exhaust manifold, spray some releasing agent
onto the nuts while they are still warm, just
21928
before removal.
Fit hose clamps and remove the turbocharger coo-
Disconnect the battery, starting with the negative ling hoses (5) .
terminal.
Removal of the turbocharger requires the engine to
be removed (see 10A, Engine and peripherals,
Engine - Gearbox ).
Catalytic converter ).
12B-14
TURBOCHARGING
F4R, and 776
21929 21931
Remove:
Remove:
- the heat shield bolt (6) ,
- the turbocharger oil return pipe mounting bolts (8) ,
- the engine cover mounting and the turbocharger
strut (7) , - the turbocharger oil return pipe (10) ,
- the turbocharger - intercooler air pipe.
- the turbocharger oil supply pipe (9) .
21930
21933
Remove the starter motor heat shield.
Remove:
- the nuts (11) securing the turbocharger to the ma-

nifold,
- the turbocharger.
12B-15
TURBOCHARGING
F4R, and 776
REFITTING
The turbocharger mounting nuts and studs must be
replaced along with the seals.
WARNING
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.
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
15
21931
Fit and finger tighten:
- the turbocharger mountings on the exhaust mani-

13 fold,
14
- 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) .
17
Pre-tighten the turbocharger cooling duct bolts
(initial torque) ( 12 Nm ) (15) ,
Tighten to torque the turbocharger cooling duct
bolts ( 27 Nm ) .
106273
Tighten:
- the clip (16) from the intercooler - turbocharger

pipe to position the turbocharger,
- the turbocharger strut (17) .
12B-16
TURBOCHARGING
F4R, and 776
All removed seals must be replaced including those
on the cooling pipe as well as the intercooler - turbo-
18 charger air pipe.
Filling - Bleeding ).
nal.
WARNING
18 Battery: Removal - Refitting ).
WARNING
- Before starting the engine, connect the dia-
gnostic tool and lock the injection system.
- Run the starter motor until the oil pressure war-
ning light goes out (wait a few seconds) then
21933 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 per-
form a road test.
- Clear the faults using the diagnostic tool .
- Switch off the ignition and check that there are
no oil leaks.
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) .
12B-17
TURBOCHARGING
F9Q, and 804

tem hose clips
Equipment required
diagnostic tool
Tightening torquesm
nuts
turbocharger oil supply 22.5 Nm

pipe hollow mounting
bolts
oil supply pipe hollow 44 Nm

mounting bolt on the 112659
housing Remove:
oil supply pipe moun- 25 Nm - the battery tray mounting bolts (1) ,
ting bolt on the housing - the nut (2) ,
turbocharger oil return 12 Nm - the battery tray.
pipe
Bleed the cooling system (see 19A, Cooling, Coo-
battery cover mounting 4 Nm ling system: Draining - filling ).
bolts Remove the catalytic pre-converter (see 19B, Ex-
haust, Catalytic Pre-converter: Removal - Refit-
ting ).
REMOVAL
terminal.
Remove the battery.
12B-18
TURBOCHARGING
F9Q, and 804
111866 111869
Remove, using the (Mot. 1448) : Remove the duct between the turbocharger and the
air filter.
- the hose - rigid pipe assembly (3) . between
the EGR cooler (4) and the water outlet unit, Disconnect the turbocharger (7) vacuum pipe.
- the hose - rigid pipe assembly (5) between the
EGR coolant and the heater matrix hose.
Disconnect the upper cooling hose on the turbochar-
ger.
111860
111865
Remove the air duct (6) from the turbocharger.
Remove the turbocharger oil return pipe (8) .
12B-19
TURBOCHARGING
F9Q, and 804
111868 111870
Remove the starter motor (see 16A, Starting-Char- Remove the turbocharger oil supply pipe (10) .
ging, Starter motor: Removal - Refitting ).
111871
111867 Remove the turbocharger mounting nuts (11) .
Remove the heat shield (9) .
12B-20
TURBOCHARGING
F9Q, and 804
REFITTING
WARNING
completely or partially blocked by scale. Also
check that it is perfectly sealed. If not, replace it.

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 fitting 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 moun-
ting bolts ( 22.5 Nm ) ,
- the oil supply pipe hollow mounting bolt on the
housing ( 44 Nm ) ,
- the oil supply pipe mounting bolt on the hou-
sing ( 25 Nm ) ,
- the turbocharger oil return pipe ( 12 Nm ) .
Refit:
- the starter motor (see 16A, Starting-charging,
112458 Starter motor: Removal - Refitting ).
Remove the turbocharger (12) . - the catalytic pre-converter (see 19B, Catalytic
pre-converter: Removal - Refitting ).
12B-21
TURBOCHARGING
F9Q, and 804
dy.
nal.
WARNING

- start the engine,
out,
Connect the diagnostic tool and clear the stored
faults.
( 4 Nm ) .
circuit: Draining - filling ).
12B-22
TURBOCHARGING
K9K, and 732
Tightening torquesm
studs
nuts
bolts mounting the oil 22.5 Nm

inlet pipe on the turbo-
charger
bolts mounting the oil 22.5 Nm

inlet pipe on the cylinder
head
bolts mounting the oil 12 Nm

return pipe on the turbo-
charger
112991
REMOVAL
Loosen the mounting bolt (1) on the air inlet rigid
duct.
Move the air inlet rigid duct to one side (see (2) .

- Refitting ).
112816
Disconnect:
- the air inlet duct (4) on the turbocharger,

Catalytic converter ).

CONCERNED
112811
Disconnect the turbocharging pressure regulation
Pull out the clip. valve hose on the regulation valve side.
12B-23
TURBOCHARGING
K9K, and 732
REFITTING

Always clean the joint faces thoroughly.
WARNING
Ensure that no foreign bodies enter the turbine or
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:
WARNING
- the bolt (6) mounting the oil inlet pipe on the turbo-
Replace any damaged heat shield.
charger,
- 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.
12B-24
TURBOCHARGING
K9K, and 732
II - REFITTING OPERATION FOR PART Refit the catalytic converter (see 19B, Exhaust, Ca-
CONCERNED talytic converter: Removal - Refitting ).
Tighten to torque the turbocharger mounting

studs ( 9 Nm ) Note:
Fit the new turbocharger seal. Make sure there is no contact between the cata-
lytic converter and the turbocharger oil return
Refit: pipe.
- the turbocharger. Refit the clip on the air inlet duct if necessary.
- the turbocharger mounting nuts. Clip the air inlet rigid pipe on the turbocharger.
Tighten to torque the turbocharger mounting nuts Refit the air inlet rigid duct mounting bolt.
( 26 Nm ) . Connect:
Refit: - the air inlet duct on the turbocharger,
- the new oil inlet pipe, - the oil vapour rebreathing pipe.
- the oil inlet pipe mounting bolt on the turbocharger Refit the engine undertray.
- the bolt mounting the oil inlet pipe on the cylinder
Refitting ).
head.
Tighten to torque:
- the bolts mounting the oil inlet pipe on the tur-

bocharger ( 22.5 Nm ) ,
- the bolts mounting the oil inlet pipe on the cy-

linder head ( 22.5 Nm )
Fit new seals on the oil return pipe.
Refit:
- the oil return pipe,
- the oil return pipe mounting bolts.
Tighten to torque the bolts mounting the oil 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 turbo-

charger,
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-25
TURBOCHARGING
F9Q, and 808
Mot. 1566 Wrench for removing
high-pressure pipes
Tightening torquesm
studs
nuts
hollow mounting bolt on 22.5 Nm

the turbocharger oil sup-
ply pipe
nut mounting the oil 22.5 Nm

supply pipe on the cylin-
der block
bolt mounting the oil 25 Nm

supply pipe on the cylin- 104424
der block Disconnect:
turbocharger oil return 12 Nm - the oil vapour rebreathing pipe (1) ,

pipe mounting bolts - the turbocharging pressure regulation valve (2) pi-
pe.
studs
turbocharger union end 26 Nm

piece
nuts

ting nut on the turbo-
charger side

ting nut on the cylinder
block

pipe mounting bolts

bolts
REMOVAL
12B-26
TURBOCHARGING
F9Q, and 808
I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION
(TURBOCHARGER SIDE)
104421
Disconnect the turbocharger air inlet and outlet pi-
pes (3) . 114207
Remove:
Catalytic converter: Removal - Refitting ). - the mounting bolt (4) from the oil supply pipe,
- the hollow mounting bolt (5) from the oil supply pipe
Note: union on the turbocharger.
During factory fitting, 2 types of oil supply pipe Loosen the union (6) on the cylinder block.
can be fitted to the turbocharger. Remove the oil supply pipe by passing it through the
The way in which a turbocharger is removed turbocharger wheels.
depends on the type of pipe. Remove:
- the oil return pipe mounting bolts,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger.
12B-27
TURBOCHARGING
F9Q, and 808
II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
114467
In the event that the oil supply pipe is replaced:
104417
- remove the oil supply union end piece (9) . This
Remove the bolt (7) mounting the oil supply pipe to
step prepares the turbocharger for the supply pipe
the cylinder block.
to be refitted with the hollow bolt union.
Undo the oil supply pipe unions on:
- the cylinder block, REFITTING
- the turbocharger (8) using the (Mot. 1566) .
Remove the turbocharger oil supply pipe.
Note:
Remove:
During factory fitting, 2 types of oil supply pipe
- the oil return pipe mounting bolts, can be fitted to the turbocharger.
- the oil return pipe, The way in which a turbocharger is refitted
depends on the type of pipe.
- the turbocharger bracket mounting nuts,
- the turbocharger.
WARNING
Note:
There is only one supply pipe part number
available as a replacement part. Only the oil sup-
completely or partially blocked by scale.
ply pipe with a hollow bolt union is available.
Also check that it is perfectly sealed. If not,
replace it.

Always replace:
- the oil supply pipe with hollow bolt union on the tur-
bocharger side (depending on version),
- the oil supply pipe seals with nut unions on the tur-
bocharger side (depending on version),
- the seals on the turbocharger oil return pipe,
12B-28
TURBOCHARGING
F9Q, and 808
- the turbocharger seals. II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT
UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mounting
studs ( 8 Nm ) .
( 26 Nm ) .
- screw on (without tightening) the oil supply union
mounting nut on the cylinder block,
- screw on (without tightening) the supply pipe hol-
low mounting bolt,
Tighten to torque:
114467
- the hollow mounting bolt on the turbocharger
oil supply pipe ( 22.5 Nm ) , Always replace the end piece seal on the union (10)
, if the end piece has been removed.
- the nut mounting the oil supply pipe on the cy-
linder block ( 22.5 Nm ) , Tighten to torque:
- the bolt mounting the oil supply pipe on the cy- - the turbocharger mounting studs ( 8 Nm ) ,
linder block ( 25 Nm ) - the turbocharger union end piece ( 26 Nm ) , if it
- the turbocharger oil return pipe mounting bolts has been removed.
( 12 Nm ) . Refit the turbocharger.
( 26 Nm ) .
mounting nuts,
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

12B-29
TURBOCHARGING
F9Q, and 808
To refit, proceed in the reverse order to removal.
Refit the exhaust pipe, aligning it with the marks
made previously.
dy.
- start the engine,
out,
( 4 Nm ) .
12B-30
TURBOCHARGING
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool
tweezers equipment, Underbody lift ).
diagnostic tool Disconnect the battery (see 80A, Battery, Battery:

Tightening torquesm Catalytic converter: Removal - Refitting ).
stud on the exhaust 9 Nm

manifold
studs on the turbochar- 14.5 Nm

ger
turbocharger strut 25 Nm
flywheel end
lower mounting nuts on 28 Nm

the turbocharger
upper mounting nut on 28 Nm

the turbocharger
turbocharger transverse 25 Nm
mounting bolt
turbocharger strut 25 Nm
timing side 114982
air inlet duct mounting 8 Nm Remove:

bolts - the bolts (1) mounting the oil pipe on the turbochar-
ger,
turbocharger side - the oil pipe mounting bolts (2) on the cylinder block,
- the hollow bolt (3) securing the turbocharger oil
bolts mounting the oil 10 Nm
pipe to the cylinder block,
pipe on the turbochar-
ger - the turbocharger oil pipe.
hollow bolt securing the 16 Nm

oil pipe on the cylinder
block
bolt mounting the oil 25 Nm

pipe on the cylinder
block
IMPORTANT
Wear protective gloves during the operation.
12B-31
TURBOCHARGING
M9R, and 700
113282
Rotate the air duct retaining clip (7) on the turbo-
charger.
113277
Remove the lower mounting nuts (4) from the turbo-
charger.
114846 113155
Disconnect: Remove the mounting bolts (8) for the air duct on the
inlet manifold.
- the hose (5) from the turbocharging pressure regu-
lator on the control diaphragm, Move to one side the air duct towards the intercoo-
ler.
- the oil vapour rebreathing hose (6) on the oil sepa-
rator.
Loosen the air duct clip on the turbocharger side.
Disconnect the air inlet duct on the turbocharger si-
de.
12B-32
TURBOCHARGING
M9R, and 700
II - OPERATION FOR REMOVAL OF PART - the turbocharger strut.
CONCERNED
REFITTING

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 rol-
ler-type stud removal tool .
Tighten to torque the stud on the exhaust mani-
fold ( 9 Nm ) .
Remove the turbocharger studs in the event that the
turbocharger is reused.
Refit the new studs on the turbocharger in the event
that the turbocharger is reused.
113277
Tighten to torque the studs on the turbocharger (
Remove: 14.5 Nm ) .
- the turbocharger upper mounting nut (9) on the ex-
haust manifold,
- the turbocharger mounting bolt (10) ,
- the turbocharger.
- the gasket between the turbocharger and the ex-
haust manifold.
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
M9R, and 700
115069
Refit the new seal to the turbocharger air inlet duct.
Note:
Check that the turbocharger air inlet duct seal
(12) is fitted in the correct direction.
12B-34
TURBOCHARGING
M9R, and 700
II - REFITTING OPERATION FOR PART - the new upper mounting nut on the turbocharger,
CONCERNED
- the new lower mounting nuts on the turbocharger.
Tighten to torque:
- the lower mounting nuts on the turbocharger (
28 Nm ) ,
- the upper mounting nut on the turbocharger (
28 Nm ) .
Undo the turbocharger strut mounting bolt on the ti-
ming end (13) .
Tighten to torque:
- the turbocharger transverse mounting bolt ( 25
Nm ) ,
- the turbocharger strut mounting bolt on the ti-
ming side ( 25 Nm ) (13) .

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.
Fit the new turbocharger strut.
Refit the air inlet duct mounting bolts on the inlet ma-
Finger tighten the mounting bolts (13) and (14) of the nifold.
turbocharger strut. Tighten to torque the air inlet duct mounting bolts
( 8 Nm ) .
WARNING Connect:
The turbocharger strut must move freely. - the air inlet duct to the turbocharger,
Fit the turbocharger without its seal and hold the tur- - the oil vapour rebreathing hose to the oil separator.
bocharger flat against the exhaust manifold. Tighten to torque the air inlet duct clip on the tur-
Move the turbocharger strut until it is against the turbocharger side ( 5.5 Nm ) .
bocharger at the flywheel end. Connect the turbocharging pressure regulator on the
Gently tighten the turbocharger strut mounting bolt control diaphragm.
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 ex-
haust manifold.
Finger tighten the new turbocharger transverse
mounting bolt by a few turns.
Tighten until contact is made:
12B-35
TURBOCHARGING
M9R, and 700
- the hollow bolt securing the oil pipe on the cy-
linder block ( 16 Nm ) (16) ,
- the bolt mounting the oil pipe on the cylinder
block ( 25 Nm ) (17) .
WARNING
Disconnect the injection rail pressure regulator
connector (disables engine starting).
Run the starter motor until the oil pressure war-
ning light goes out (do this for a few seconds).
Connect the injection rail pressure regulator con-
nector.
114982
Start the engine.
Lubricate the new turbocharger oil pipe O-ring on
the cylinder block side. Let the engine idle then depress the accelerator
several times under no load.
WARNING
Check for the gasket between the turbocharger Make sure that there are no oil leaks.
and the turbocharger oil pipe. Connect the diagnostic tool and clear the sto-
red faults.
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 fitting, 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 turbo-
charger,
- 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 turbo-
charger ( 10 Nm ) (15) ,
12B-36
TURBOCHARGING
Pressure regulator: Checking 12B
K9K, and 722 or 724 or 728 or 729 or 732
WARNING K9K, and 724

It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger. 3 - Check
TURBOCHARGING PRESSURE REGULATION

VALVE
K9K, and 722
1 - Check
21869
Remove the turbocharger (see 12B, Turbochar-
ging, Turbocharger ).
Note:
The check cannot be carried out with the turbo-
charger in place.
21869 Use a magnetic holder fitted with a dial gauge loca-
Remove the turbocharger (see 12B, Turbochar- ted at the end of the regulation valve rod (as far as
ging, Turbocharger ). possible on the rod shaft).
Gradually apply pressure to the regulation valve
using the pressure and vacuum pump.
Note:
4 - Value
charger in place.
For a vacuum value of 0.6 bar , the rod movement
Use a magnetic holder fitted with a dial gauge loca- must be 7 mm 0.5 .
ted at the end of the regulation valve rod (as far as
possible on the rod shaft).
2 - Value
For a pressure value of 1.4 bar , the rod movement
must be 4.3 mm .
12B-37
TURBOCHARGING
K9K, and 722 or 724 or 728 or 729 or 732
K9K, and 728 or 729 or 732
5 - Check
110748
Note:
charger in place.
Use a feeler gauge between the regulation valve rod

and the stop (as far as possible into the rod shaft).
6 - Value
For a vacuum value of 0.5 bar , the rod movement
must be 1.7 mm .
12B-38
TURBOCHARGING
F9Q, and 800 or 808
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
TURBOCHARGING PRESSURE CONTROL VALVE
1 - CHECKING
21869
Remove the turbocharger (See 12B, Turbochar-

Note:
The turbocharger cannot be tested in situ.
Use a magnetic holder fitted with a dial gauge pla-

ced on the end of the control valve stem (as far as
possible in the axis of the stem).

using a vacuum/pressure pump.
2 - Value
For a pressure value of 265 mbar , the stem move-

ment must be between 0.5 and 3.5 mm .
For a vacuum value greater than 600 mbar , the

stem is at the stop.
12B-39
TURBOCHARGING
F4R, and 776
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
1 - CHECKING
22807
Remove the turbocharger (See 12B, Turbochar-

Note:
The turbocharger cannot be tested in situ.
Use a magnetic holder fitted with a dial gauge pla-

ced on the end of the control valve stem (as far as
possible in the axis of the stem).

using a vacuum/pressure pump.
2 - Value

ment should be 1 mm .

ment must be 5 mm .
12B-40
TURBOCHARGING
F9Q, and 804
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.
1 - Checking
21869
Note:
charger in place.
Connect a pressure and vacuum pump (1) to the

pressure regulator (2) .
Use a magnetic holder fitted with a dial gauge loca-
Gradually apply a vacuum to the pressure regulator
2 - Value
Test points:
- For a pressure value of 200 mbar , the rod move-
ment should be between 2 and 4 mm .
- for a pressure value of 550 mbar , the rod move-
ment should be between 8 and 11 mm. .
12B-41
TURBOCHARGING
M9R, and 700
WARNING
The turbocharging pressure regulator rod must not
be adjusted.
TURBOCHARGING PRESSURE REGULATOR
1 - Check
21869
ging, Turbocharger: Removal - Refitting ).
Note:
charger in place.
Connect a pressure-vacuum pump (1) to the pressu-

re regulator (2) .
Use a magnetic holder fitted with a dial gauge loca-
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 move-
ment 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 12B
F9Q, and 800 or 808
The turbocharging pressure regulation valve is open in
the rest position. The engine operates as normally as-
WARNING pirated.
If the turbocharger solenoid valve is removed, it is The solenoid valve, closed in the rest position, is sup-
essential to mark the supply and return pipes on plied after the engine is started following a delay which
the solenoid valve. varies according to the coolant temperature.
103128
Shaft Description
X Time in seconds
102480
Y 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 turbo-
charging pressure to be regulated.
12B-43
TURBOCHARGING
F4R, and 776
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 posi-
tion. 107010
Solenoid valve (2) is open in the rest position.

In the open position, solenoid valve (2) compares the Shaft Description
turbocharger outlet (turbocharging pressure) and
diaphragm (1) . X Time in seconds
Because of this, the turbocharging pressure acts di- Y Coolant temperature in C

rectly on the diaphragm and the pressure adjustment
valve opens.
When solenoid valve (2) is controlled, the turbochar-
ging 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 tur-
bocharging pressure is limited and the engine speed
cannot exceed 2500 rpm.
This ensures that the oil has sufficient time to reach the
turbocharger bearings.
12B-44
TURBOCHARGING
K9K, and 728 or 732
The turbocharging pressure regulation solenoid valve
is closed in the rest position; it is powered once the en-
gine is started and a delay according to the coolant
temperature.
WARNING
When removing the turbocharging pressure regula-
tion 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 pressu-
re regulator solenoid valve (2) attached to a bracket
fixed onto the air filter unit. This solenoid valve is con-
trolled 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 geo-
metry turbocharger.
The pressure regulation valve is open in the rest posi-
tion; the engine is therefore naturally aspirated.
12B-45
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
REMOVAL
Car. 1363 Trim removal lever I - REMOVAL PREPARATION OPERATION

Tightening torquesm
intercooler downs- 5.5 Nm Removal - Refitting ).
tream duct clip on the Remove:
intercooler
hose clip
intercooler downs- 5.5 Nm Exterior protection, Front bumper ).
damper valve
F9Q, and 804 K9K, and 732 M9R, and 700
mounting bolts

mounting bolts

bolts

tray
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, 112658
- clean the intercooler bearing face and the hose Remove the Protection and Switching Unit cover
using a dry, lint-free cloth, mounting bolts (1) .
- replace the clip in the same position if the hose is
not replaced,
- 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.
12B-46
TURBOCHARGING
CONCERNED
102504
Remove the Protection and Switching Unit cover.

nectors (2) .
Remove:
102473
- the clips (4) ,
Remove:
- the upper mounting bolts (5) of the front end panel,
Undo the hose clip (8) upstream of the intercooler.
Disconnect the hose upstream of the intercooler.
M9R, and 700
114933
12B-47
TURBOCHARGING
M9R, and 700
102474
Loosen the intercooler downstream duct clip (11) on
114649
the intercooler.
Remove the intercooler downstream duct mounting Move the intercooler downstream duct away from
bolt (9) on the cooling radiator. the intercooler.
Loosen: Remove the intercooler.
- the intercooler downstream duct clip (10) on the in-

tercooler, REFITTING
valve. 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
II - REFITTING OPERATION FOR PART Clip on the bonnet opening cable.
CONCERNED
Refit:
Connect:
- the intercooler upstream hose, - the battery tray,
- the intercooler downstream duct onto the intercoo- - the battery tray mounting bolts,
ler.
Tighten to torque: - the wiring harness mounting nut on the battery tray.
- the intercooler downstream duct clip on the in- Tighten to torque:

tercooler ( 5.5 Nm ) ,
- the intercooler upstream hose clip ( 5.5 Nm ) .
M9R, and 700 tray ( 8 Nm )
Refit the intercooler downstream duct mounting bolt Clip on the battery terminal wiring harness.
onto the cooling radiator.
Connect:
Tighten to torque the intercooler downstream duct
clip on the damper valve ( 5.5 Nm ) .

Refit the Protection and Switching Unit cover.
Refit:
M9R, and 700
Tighten to torque: Refit the Protection and Switching Unit cover moun-
ting bolts.
Nm ) ,
Nm ) ,
Refit:
M9R, and 700 - the clips,

Clip on the air inlet scoop.

Refitting ).
Note:
You must initialise the xenon bulb system (if fitted
to the vehicle).

12B-49
TURBOCHARGING
B84 or C84, and F4R, and 774
Tightening torquesm

bolts
REMOVAL
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
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.
( 4 Nm ) .
12B-51
FUEL SUPPLY
Petrol supply circuit 13A
F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761
Operating diagram of the fuel supply circuit
5
2
4
3
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 13A
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
Operating diagram of the diesel fuel supply circuit
102847
- a gauge (1) , WARNING

- a manual priming pump (2) , It is not permitted to remove the pressure sensor
from the fuel rail (because this may cause circuit
- a fuel filter (3) that may be fitted with a water detection contamination problems). If the pressure sensor
sensor, fails, the pressure sensor, the rail and the five high-
pressure pipes must be replaced.
- a high-pressure pump (4) with a built-in mechanical
low-pressure pump (transfer pump),
- a fuel flow actuator (5) , K9K, and 722 or 728 or 729

- an injector rail (6) fitted with a diesel pressure sensor
(7) ,
WARNING
- four solenoid injectors (8) fitted with discharge valves, Dismantling the interior of the high-pressure pump
and the injectors is prohibited. DELPHI Only the
- a Venturi tube (9) , flow actuator, the diesel fuel temperature sensor
and the Venturi tube can be replaced.
- various sensors,
- an injection computer.
IMPORTANT
Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
13A-2
FUEL SUPPLY
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
K9K, and 732
WARNING
Removing the flow regulator solenoid valve and the
pressure regulating solenoid valve from the high-
pressure pump is prohibited. SIEMENS .
13A-3
FUEL SUPPLY
F9Q, and 800
Operating diagram of the fuel supply circuit
1 2 3 4 5 7 6
100821
- a priming bulb (1) (located in the engine compart-
WARNING
ment),
Dismantling the interior of a high-pressure pump or
- a fuel filter (2) that may be fitted with a water detection the injectors is prohibited.
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,
IMPORTANT
It is strictly forbidden to uncouple a high-pressure
pipe union when the engine is running.
13A-4
FUEL SUPPLY
F9Q, and 800 or 804 or 808
Operating diagram of the diesel fuel supply circuit
102307

- a gauge (1)
WARNING
- a manual priming pump, (2) Dismantling the interior of the high-pressure pump
- a diesel filter (3) consisting of: and the injectors is prohibited.
a fuel heater, Outside the warranty period for the pump, only the
pump pressure regulator can be replaced.
a water detection sensor (4) , depending on the ver-
sion, During the pump warranty period, the high-pressure
pump should be completely replaced if the pressure
- a high-pressure pump (5) consisting of: regulator fails.
a mechanical low-pressure pump,
a pressure regulator, (6)
- an injector rail (7) fitted with a pressure regulator (8) ,
- four solenoid injectors (9) ,
- a diesel fuel temperature sensor (10) for the diesel re-
turn circuit,
IMPORTANT
13A-5
FUEL SUPPLY
Petrol filter: General information 13A
102299
The fuel filter is located in the fuel tank; it is built into
the pump-sender-filter assembly and cannot be re-
moved.
WARNING
The pump-sender-filter assembly must be repla-
ced 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 deli-
very rate is the equivalent of running fault finding on the
pump-sender-filter assembly.
13A-6
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 722 or 728 or 729
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 die-
sel filter is contained in a non-removable cartridge).
Order a set of blanking plugs, part number 77 01 206

804 .
REMOVAL
terminal.
101539
Remove:
- 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 pi-

pes.
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
K9K, and 722 or 728 or 729
102124
Prime the fuel system with the priming pump (3)
(automatic degassing).
21749
nal.
Regularly bleed out the water in the diesel filter
via the bleed plug (4) .
WARNING
Carry out the necessary programming (see 80A, Some vehicles have a sensor for detecting water
Battery: Removal - Refitting ). in the diesel fuel (5) , located on the filter. If water
is detected in the circuit, the injection fault war-
ning light on the instrument panel comes on.
13A-8
FUEL SUPPLY
F9Q, and 800 or 804 or 808
Tightening torquesm

bolts
wheel bolts 110 Nm
IMPORTANT

- watch out for diesel fuel splashing when discon-
necting the supply union,
- order the special high pressure injection circuit
plug kit.
WARNING 101539
- Protect sensitive areas from fuel leakage.
Remove:
- Strictly observe the cleanliness guidelines.
The diesel filter is located behind the right-hand headli- - the wheel arch liner mounting bolts (1) ,
ght. It is contained in a removable cartridge. This car-
tridge has a built-in diesel fuel heater, comprising a - the wheel arch liner clips using an unclipping tool,
resistor and temperature switch. - the wheel arch liner (2) .
Note:
Remove the diesel filter assembly to remove the
cartridge.
REMOVAL
terminal.
104560
Unclip the diesel filter from its mounting by pushing it
upwards.
13A-9
FUEL SUPPLY
F9Q, and 800 or 804 or 808
102477 19317
Disconnect the diesel heater connector (3) from the
Mark the position of the diesel filter cover in relation
diesel heater.
to the bowl (6) .
WARNING Remove the mounting bolt (7) from the cover on the
Keep the pipe unions away from contaminated bowl.
areas.
Open the diesel filter and replace:
Disconnect from the diesel filter:
- the filter element,
- the pipe (4) coming from the tank,
- the engine supply pipe (5) . - the seal,
fit plugs to the pipes and filter.

Remove the diesel filter. REFITTING
Always replace the filter element O-ring.
Refit the cover over the bowl.
WARNING
Align the marking on the cover, fitted with blan-
king 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
F9Q, and 800 or 804 or 808
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting water
in the diesel fuel, located in the diesel filter. If
water is detected in the circuit, the injection fault
warning light on the instrument panel comes on.
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.
nal.
WARNING

( 4 Nm ) .
13A-11
FUEL SUPPLY
K9K, and 724 or 732 M9R, and 700
- the front right-hand wheel arch liner (1) .
Tightening torquesm
wheel bolts 110 Nm 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 outflow.
Note:
Make sure you have a new diesel filter before ope-
ning the fuel circuit.
REMOVAL
114559
Remove the diesel filter from its mounting on the
body by pushing the filter - metal strap assembly
Place the vehicle on a two-post lift (see 02A, Lifting upwards.
Disconnect all the fuel pipe unions on the diesel fil-
Disconnect the battery (see 80A, Battery, Battery: ter.
Note:
Make preparations for the fuel outflow.
WARNING
Prevent the hose unions from coming into con-
tact with a polluted environment.
Remove the diesel filter from the vehicle.
Note:
Only use wipes part number 77 11 211 707 to
clean the filter and pipes once the fuel circuit is
opened.
REFITTING
104544 I - REFITTING OPERATION FOR PART

Remove: CONCERNED
- the front right-hand wheel, Connect the fuel pipes onto the new diesel filter.
13A-12
FUEL SUPPLY
K9K, and 724 or 732 M9R, and 700
Refit the filter - metal strap assembly on its
mounting on the body.
Note:
Check that the filter is correctly positioned and
secure in its mounting by shaking it: the filter
must not move.
If necessary, remove the filter and gently
squeeze the metal strap retaining bracket on its
mounting.
102124
Prime the fuel circuit using the manual priming pump

(2) (automatic degassing).
Check there are no leaks from the unions on the fil-

ter.
Refit:

Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting water
in the diesel fuel, located at the bottom of the fil-
ter. If water is detected in the circuit, a fault war-
ning light on the instrument panel comes on.
13A-13
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
K4M, and 760 or 761
Tightening torquesm
injector rail mounting 9 Nm

bolts

bolts
The injectors are secured to the injector rail by clips.

The fuel circulates constantly around the circumferen- 1
ce of the injector body. This sweeping by the fuel pre-
vents the formation of petrol vapour bubbles and helps 2
warm starting.
REMOVAL
terminal.
Remove:
101810
- the engine covers, Disconnect injector electrical harness (1) .
- the inlet manifold (see 12A, Fuel mixture, Inlet Remove:
manifold ).
- the two injector rail mounting bolts (2) ,
IMPORTANT
ting the supply pipe union from the injector rail. ON THE WORKBENCH
WARNING
4 3
101816
Remove:
- injector clips (3) ,
- injectors (4) .
13A-14
FUEL SUPPLY
K4M, and 760 or 761
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 ) .
nal.
WARNING

4 Nm ) .
13A-15
FUEL SUPPLY
B84 or C84 or G84, and K4J, and 730 or 732
Tightening torquesm

bolts

bolts

The fuel circulates constantly around the circumferen- 2
ce of the injector body. This sweeping by the fuel pre- 3
vents the formation of petrol vapour bubbles and helps
warm starting.
101802
REMOVAL Disconnect:
Disconnect the battery, starting with the negative - fuel supply pipe (2)
terminal.
- injector and pinking sensor electrical harness (3) .
IMPORTANT
WARNING
101801
Remove mounting nuts (1) from the injection rail pro-
tector.
101493
Remove:
13A-16
FUEL SUPPLY
B84 or C84 or G84, and K4J, and 730 or 732
ON THE WORKBENCH
6
5
101492
Remove:
- injector clips (5) ,
- injectors (6) .
REFITTING
WARNING

Nm ) .
nal.
WARNING

4 Nm ) .
13A-17
FUEL SUPPLY
F4R, and 770 or 771 or 776
bolts

bolts

2
The fuel circulates constantly around the circumferen-
ce of the injector body. This sweeping by the fuel pre-
vents the formation of petrol vapour bubbles and helps
warm starting.
102728
REMOVAL Disconnect:
Disconnect the battery, starting with the negative - fuel supply pipe (2) ,
terminal. - injector and pinking sensor electrical harness (3) .
F4R, and 770 or 771

F4R, and 776
4
6
1
5
101801
Remove the two injection rail guard mounting nuts 106787
(1) .
Disconnect:
- turbocharging pressure sensor connector (4)
- the vacuum pipe from brake servo (5) ,
- oil vapour recirculation pipe (6) .
13A-18
FUEL SUPPLY
F4R, and 770 or 771 or 776
ON THE WORKBENCH
106271
10
Disconnect fuel supply pipe (7) from the injector rail. 9
102737
IMPORTANT
Remove:
Be careful of petrol splashing out when discon-
necting the fuel supply union. - injector clips (9) ,
- injectors (10) .
WARNING
REFITTING
Protect sensitive areas from fuel spillage.
WARNING

Nm ) .
8 Connect the battery, starting with the positive termi-

nal.
WARNING

4 Nm )
102730
Remove:
13A-19
FUEL SUPPLY
Electric fuel: Checking 13A
K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776

K4M, and 760 or 761
Mot. 1311-01 Fuel pressure test kit
Mot. 1311-08 Union for measuring

fuel pressure
1
IMPORTANT
During this operation, be sure to:

2
- refrain from smoking or bringing hot objects close
to the working area,
3
union,
K4J, and 730 or 732 F4R, and 770 or 771 or 776
101803
Disconnect the petrol inlet pipe from the injection
rail.
1 Connect:
2 - 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.
3 Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the igni-
101496 tion off.
Disconnect the petrol inlet pipe from the injection
rail. Remove the Protection and Switching Unit cover.
13A-20
FUEL SUPPLY
Electric fuel: Checking 13A
4
5
1
12
102502 102501
Place the electrical connector (4) to one side without Connect terminal (5) of the brown connector to the
disconnecting it. battery positive feed
Note:
The flow reading should be between 80 and 120
l/h .
102503
Disconnect the brown connector (5) from the Protec-
tion and Switching Unit.
13A-21
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
Engine Engine speed (rpm) Smoke opacity
Vehicle type Type Suffix Idling Maximum Maximum Homologa- Legal maxi-
speed unladen laden tion value mum (m -1)
(m-1)
XM0F 722 805 50 5000 150 4800 100 3

XM0T
XM1F 724 800 50 4900 150 4900 150 2

K9K 1.5
XM02 728
XM13 805 50 4950 150 4800 100 3
XM02 729
Description Make - type Special notes
High pressure pump DELPHI Pressure from 0 to 1,400 bar
Low pressure pump DELPHI Integrated in the high pressure

pump
Injection computer DELPHI 112-track computer (A 32, B 48, C

32)
Diesel rail pressure sensor DELPHI Integrated in the rail

Resistance not measurable
Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel rail pressure sensor
earth
- 3: + 5 V supply
Injectors DELPHI / MNS HP Solenoid injector

Maximum pressure 1,600 bar
2-track connector:
- 1: injector + control
- 2: injector - control
13B-1
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Diesel flow actuator DELPHI Located on the high pressure

pump
Resistance: 5.3 0.5 at 20C
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 mana-

ged by the computer
9-track connector
- 1: heater plug no. 3 supply
- 3: + battery supply
- 8: injection computer control
- 9: fault finding
Heater plugs CHAMPION or BERU Resistance: 0.6
13B-2
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance
- gang 1: tracks 3 and 5: 1700
900
1025
6-track connector:
- 1: gang 2 signal
- 2: gang 2 + 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 coefficient
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 13B
K9K, and 722 or 728 or 729
Engine coolant temperature sen- ELTH Negative temperature coefficient

sor 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 BOSCH / LDF6T 20-250 Pressure sensor with a negative
and pressure sensor temperature coefficient thermistor
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 sole- PIERBURG Supply voltage: + 13.5 V

noid valve (K9K 722, 728 and
Resistance: tracks 1 and 5: 8
729)
0.5 at 20C
13B-4
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Exhaust gas recirculation sole- PIERBURG Supply voltage: 13.5 V

noid valve (K9K 724)
Resistance: tracks 2 and 6: 2.3
at 20C
Exhaust gas recirculation sole- PIERBURG Integrated in the exhaust gas

noid valve position potentiometer recirculation solenoid valve
(K9K 724)
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: not used
- 5: potentiometer signal
- 6: solenoid valve earth
Exhaust gas recirculation sole- PIERBURG Integrated in the exhaust gas

noid valve position potentiometer recirculation solenoid valve
(K9K 722 728 and 729)
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
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 13B
K9K, and 722 or 728 or 729
Fault finding - diagnostic tool : CLIP only
Turbocharging pressure regula- BITRON Proportional solenoid valve

tion solenoid valve (K9K 724, 728
Supply voltage: 13.5 V
and 729)
Resistance: 16.5 1.6 at 23C
2-track connector:
- 1: signal
- 2: supply
13B-6
DIESEL INJECTION
Specifications 13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
Engine
Vehicles Gearbox
Type Suffix Bore Stroke Cubic capa- Compres-
(mm) (mm) city (cc) sion ratio
XM0G 800
XM1G ND0 F9Q 80 93 1870 19:1
XM00 808
Engine speed (rpm) Smoke opacity
Idling speed Maximum unladen Maximum laden Homologation Legal maximum

value (m-1) (m -1)
800 50 4850 150 4500 100 1.9 (54%) 3 (70%)
Description Make - Type Special notes
High pressure pump BOSCH CP3 Pressure from 250 to 1,350 bar
Diesel fuel pressure sensor BOSCH Bolted onto the rail
Injectors BOSCH Solenoid injector

Operating pressure up to: 1300
bar
Pressure regulator BOSCH Bolted onto the high pressure

pump
Injection computer BOSCH EDC 16 112-track computer
Pre-postheating unit (located NAGARES BED/7-12 With pre-postheating function

behind the front left-hand wheel managed by computer
arch liner)
Heater plugs BERU ou CHAMPION Resistance: 0.6 connector dis-

connected
Engine speed sensor MGI Resistance: 720 at 880 at 20C
Camshaft sensor ELECTRIFIL -
Accelerator potentiometer CTS Dual gang potentiometer

Resistance:
- gang 1: 1700 900
- gang 2: 3875 1025
13B-7
DIESEL INJECTION
Specifications 13B
F9Q, and 800 or 808
Air inlet temperature sensor SIEMENS Integrated in the air flowmeter
Diesel fuel temperature sensor ELTH Resistance: 2,050 at 25C
Engine coolant temperature sen- ELTH Resistance: 2252 112 at 25C

sor
Air flowmeter SIEMENS Air flowmeter 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 flow 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 pres-
sure of 1,013 mbar
- > 1.6 V for an atmospheric pres-
sure > 1,013 mbar
- < 1.6 V for an atmospheric pres-
sure < 1,013 mbar
Replace the seal each time it is
removed
Atmospheric pressure sensor - Integrated in the computer
Exhaust gas recirculation solenoid PIERBURG Gang resistance: 8 0.5 at

valve 20C (tracks 1 and 5)
Sensor resistance: 4 k at 20C
(tracks 2 and 4)
Damper valve solenoid valve BITRON ou EATON Resistance: 46 3 at 25C

(engine stop solenoid valve)
Turbocharging pressure regulation PIERBURG Resistance: 15.4 0.7 at 20C

solenoid valve
Fault finding diagnostic tool : CLIP only
13B-8
DIESEL INJECTION
Specifications 13B
F9Q, and 804
Equipment required
diagnostic tool
Vehicle type Type Suffix Idling Maximum Maximum Homologa- Legal maxi-
speed unladen laden tion value mum (m -1)
(m -1)
XM0L F9Q 804 800 50 4850 4500 1.9 (54%) 3 (70%)

150 100
XM1D
XM17
XM14
High pressure pump BOSCH CP3.2 Pressure 1600 bar Max
Diesel fuel pressure sensor BOSCH Bolted onto the rail

Tightening torque: 3.5 5 Nm
Injectors BOSCH Solenoid injector

Operating pressure up to: 1600 bar
Pressure regulator BOSCH Screwed onto the high pressure

pump
Injection computer BOSCH EDC 16 112-track computer
Pre-postheating unit (located NAGARES BED/7-12 With pre-postheating function

behind the front left-hand wheel managed by computer
arch liner)
Heater plugs BERU ou CHAMPION Resistance: 0.6 connector dis-

connected
Engine speed and TDC sensor MGI Resistance: 800 at 20C
Camshaft sensor ELECTRIFIL Hall effect type
Accelerator potentiometer CTS Dual gang potentiometer

Resistance:
- gang 1: 1700 900
- gang 2: 2850 2050
Air inlet temperature sensor SIEMENS Integrated in the air flowmeter
Engine coolant temperature sensor ELTH Resistance: 2252 112 at 25C
13B-9
DIESEL INJECTION
Specifications 13B
F9Q, and 804
Air flowmeter SIEMENS Air flowmeter 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 flow 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 pres-
sure of 1,013 mbar
- > 1.6V for an atmospheric pres-
sure > 1013 mbar
- < 1.6 V for an atmospheric pres-
sure < 1013 mbar
Replace the seal each time it is
removed
Atmospheric pressure sensor - Integrated in the computer
Exhaust gas recirculation solenoid SIEMENS Gang resistance: 2.96 10 % at

valve 20C (tracks 1 and 5)
Sensor resistance: 6.5 k 40% at
20C (tracks 2 and 4)
Turbocharging pressure regulation PIERBURG Resistance: 15.4 0.7 at 20C

solenoid valve
Turbocharger GARRET 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 finding diagnostic tool : CLIP only
13B-10
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
Equipment required
diagnostic tool

Depol
Vehicle Type Suffix Idling Maximum Maximum Homo- Legal lution
type speed unladen laden loga- maxi- stan-
tion mum dard
value
X84 K9K 732 800 50 5000 5000 1.5 m -1 2m -1 Euro

150 150 IV
High pressure pump SIEMENS VDO Pressure from 0 to 1600 bar
Low pressure pump SIEMENS VDO Integrated in the high pressure

pump
Injection computer SIEMENS VDO 128-track computer (A 32, B 48, C

48)
Diesel rail pressure sensor SIEMENS VDO Integrated in the rail

3-track connector:
- 1: signal
- 2: diesel rail pressure sensor
earth
- 3: supply +
Injectors SIEMENS VDO 6-hole piezoelectric injector

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
13B-11
DIESEL INJECTION
K9K, and 732
Pressure regulation solenoid valve SIEMENS VDO Integrated in the high pressure
pump
Cannot be removed
Engine speed and position sensor SIEMENS VDO Variable reluctance sensor
2-track connector
- 1: + signal
- 2: - signal
Pre-postheating unit NAGARES With pre-postheating function con-

trolled by the injection computer
8-track connector
- 2: spark plug no. 1 supply
- 3: fault finding
- 4: + batter y supply
- 6: spark plug no. 4 supply
- 8: injection computer control
Heater plugs CHAMPION ou BERU Resistance: 0.6
Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance
900
1025
6-track connector:
- 1: gang 2 signal
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
13B-12
DIESEL INJECTION
K9K, and 732
Cylinder reference sensor JCAE Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: supply
Diesel temperature sensor ELTH Located on the diesel return rail on

the high pressure pump outlet
2-track connector:
- 1: signal
- 2: earth
Atmospheric pressure sensor SIEMENS VDO Integrated in the computer
Air temperature sensor SIEMENS VDO Integrated in flowmeter

Negative temperature coefficient
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 potentiome-

ter built into the damper valve
Solenoid valve supply voltage: +
13.5V
Potentiometer supply voltage: + 5V
13B-13
DIESEL INJECTION
K9K, and 732
Engine coolant temperature sensor ELTH Negative temperature coefficient

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
sensor signal
sensor earth
- 4: not used
Exhaust gas recirculation solenoid PIERBURG Supply voltage: + 13.5 V

valve
Resistance: tracks 2 and 6: 2.3
Exhaust gas recirculation solenoid PIERBURG Integrated in the exhaust gas recir-
valve position potentiometer culation solenoid valve
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 4: not used
Refrigerant pressure sensor TEXAS INSTRUMENT Supply voltage: + 5 V

BIRTON 3-track connector:
- A: earth
- B: supply
- C: signal
13B-14
DIESEL INJECTION
K9K, and 732
Water in diesel sensor PRESSAC Located on the diesel filter

3-track connector:
- 1: supply
- 2: signal
- 3: earth
Air inlet flowmeter SIEMENS VDO Air flowmeter with integrated 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 flow signal
Turbocharging pressure regulation BIRTON Proportional solenoid valve

solenoid valve
supply voltage + 12 V
2-track connector:
- 1: computer output
- 2: supply
Fault finding - diagnostic tool : CLIP only
13B-15
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
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 2 - Blanking plugs
The high pressure direct injection system is highly sen- The blanking plugs are used to cap the fuel circuit once
sitive to contamination. The risks caused by contami- it is opened and to therefore prevent contaminants
nation are: from entering.
- damage to or destruction of the high pressure injec- A set of blanking plugs should be used once only and
tion system, used plugs must be discarded after use: once used,
the plugs are soiled and cleaning them is not sufficient
- a component seizing, to make them reusable.
- a component not being properly sealed. Unused plugs must also be discarded and not used
again for any other operation on an injection system.
All After-Sales operations must be performed under
very clean conditions. Having carried out an operation Blanking plug set part number:
in good conditions means that no impurities (particles a
few microns in size) have penetrated the system during - F9Q: 77 01 208 229
dismantling. - K9K ( DELPHI injection): 77 01 206 804
The cleanliness principle must be applied from the filter - K9K ( SIEMENS injection): 77 01 476 857
to the injectors.
- M9R: 77 01 209 062
What are the sources of contamination?
- metal or plastic chips, 3 - Protective bags
- paint, Use hermetically-resealable plastic bags, using adhe-

sive tape, for example, to store components which will
- fibres from: be refitted and reused. Stored parts will therefore be
less subject to the risk of contamination.
cardboard,
These bags must be used once only: once they have
brushes,
been used, they are to be discarded.
paper,
clothing, 4 - Cleaning products

Two cleaning products can be used:
cloth,
- an injector cleaner (part number 77 11 224 188 ),
- foreign bodies such as hair,
- an aerosol spray brake cleaner (part number 77 11
- ambient atmosphere,
226 128 ).
- etc. 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 im-
WARNING purities in it.
Cleaning the engine using a high pressure washer
is prohibited because of the risk of damaging con-
nections. In addition, moisture may collect in the Note:
connectors and create electrical connection faults.
Use a new injector cleaner each time work is car-
ried out (a used cleaning agent will contain impuri-
ties).
1 - Cleaning cloths
Use lint free cleaning cloths (part number 77 11 211

707 ). II - ADVICE TO BE FOLLOWED BEFORE ANY
OPERATION
The use of rags or ordinary paper towels is prohibited:
these produce lint and lose fibres, which then contami- 1) Carry out the work in a clean working area and take
nate the fuel circuit. care to protect removed components from dust using
plastic bags which are hermetically-resealable, for
Each cloth must only be used once. example.
13B-16
DIESEL INJECTION
2) Always order the following from the Parts Depart- When replacing a component with a new one or when
ment before carrying out work: refitting it after storing it in a plastic bag, do not unpack
it until it is time to fit it on the vehicle.
- une collection de bouchons de propret neuve ,
specific to the engine,
IV - CLEANING
- a sufficient number of lint-free lingettes de nettoya-
ge . There are currently two procedures for cleaning the
fuel circuit before opening it in order to carry out work in
- one of the two produits de nettoyage for the fuel the workshop.
pipe unions,
These procedures enable the fuel circuit to be cleaned
- les pices remplacer systmatiquement after to prevent contamination: they both have the same end
each removal and which are mentioned in the work result and neither is preferred over the other.
procedures specific to each vehicle (see the relevant
Workshop Repair Manual).
1 - Using the injector cleaning agent
3) Wear safety goggles fitted with side shields to pre-
vent the cleaning product from splashing the eyes. Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
4) Wear latex safety gloves to avoid prolonged contact the relevant Workshop Repair Manual).
with the skin.
Protect sections which are sensitive to fuel leaks.
Pour the injector cleaning agent into a container which

Note: is free from impurities.
If wearing leather protective gloves, cover these
with latex protective gloves.
IMPORTANT
5) Before any operation on the injection system protect Wear latex safety gloves when using the cleaning
(using plastic bags or clean cloths for example): agent.
- the accessories and timing belts,
Dip a clean brush, which is not shedding bristles, into
- the electrical accessories (starter motor, alternator, the container of injector cleaning agent.
power-assisted steering pump, sensors and electrical
connectors),
IMPORTANT
- the flywheel face. Wear safety goggles fitted with side shields during
this operation.
III - INSTRUCTIONS TO BE FOLLOWED DURING
THE OPERATION Clean the unions carefully using the brush and the in-
jector cleaning agent.
Wash your hands before and while carrying out the
work. Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
Change the latex safety gloves if they become soiled or unions and around the injection system). Make sure
damaged. there are no brush bristles remaining and that the area
is clean.
All components removed from the injection system
must be stored in a hermetically sealed plastic bag Wipe the sections that were cleaned with fresh clea-
once they have been capped. ning cloths.
Reseal the bag hermetically using adhesive tape, for Open the circuit at the unions and immediately fit the
example, even if the bag must be opened shortly afte- relevant blanking plugs.
rwards: ambient atmosphere can be a source of pollu-
tion.
WARNING
After opening the fuel circuit, the use of brushes, clea-
ning agents, air blow guns, rifle-type brushes or stan- Do not blast with compressed air once the fuel cir-
dard cloths is strictly prohibited: These items are likely cuit is open, otherwise impurities may enter the sys-
to allow impurities to enter the system. tem. Use cleaning cloths only, if necessar y.
13B-17
DIESEL INJECTION
2 - Using the brake cleaning agent
Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
IMPORTANT
Wear latex safety gloves when using the cleaning
agent.
IMPORTANT
Wear safety goggles fitted 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 cir-
cuit is open, otherwise impurities may enter the sys-
tem. Use cleaning cloths only, if necessar y.
13B-18
DIESEL INJECTION
V - INSTRUCTIONS FOR FITTING THE PLUGS
K9K, and 722 or 724 or 728
13B-19
DIESEL INJECTION
part no. 77 01 206 804
13B-20
DIESEL INJECTION
20977
13B-21
DIESEL INJECTION
K9K, and 732
13B-22
DIESEL INJECTION
part no. 77 01 476 857
13B-23
DIESEL INJECTION
113430
13B-24
DIESEL INJECTION
F9Q, and 804
13B-25
DIESEL INJECTION
part no. 77 01 208 229
13B-26
DIESEL INJECTION
104561
13B-27
DIESEL INJECTION
M9R, and 700
13B-28
DIESEL INJECTION
part no. 77 01 209 062
13B-29
DIESEL INJECTION
113737
13B-30
DIESEL INJECTION
Description 13B
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 sen-
sor and a pressure limiter,
- four solenoid injectors,
- various sensors,
13B-31
DIESEL INJECTION
Description 13B
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,
13B-32
DIESEL INJECTION
Operation 13B
F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
- the needle stroke (determined by a constant for an in-
jector type),
Equipment required
- the nominal hydraulic flow of the injector (specific to
diagnostic tool each injector),
- the high pressure rail pressure regulated by the com-
puter.
IMPORTANT
The computer manages:
Before carrying out any work on the injection circuit,
- idle speed regulation,
check using the diagnostic tool :
- that the rail is not pressurised, - the exhaust gas flow reinjected into the inlet,
- that the fuel temperature is not too high. - the fuel supply (timing, flow and rail pressure),
Every time work is carried out, be sure to follow the - the fan assembly actuation request (function: centra-
safety and cleanliness advice specified in this docu- lised coolant temperature management),
ment.
- the air conditioning,
Loosening a high pressure pipe union when the
- the cruise control-speed limiter function,
- the pre/postheating actuation.
The common rail high pressure injection system
operates in sequential mode (based on the multipoint The high pressure pump is supplied at low pressure by
injection principle for petrol engines). a mechanical low pressure pump (transfer pump).
Through its pre-injection process, this injection system The high pressure pump supplies the rail which is pres-
can provide: sure-controlled:
- reduced operating noise, - for loading by the fuel flow actuator,
- a reduction in the amount of pollutant gases and par- - for discharge by the injector valves.
ticles,
Drops in pressure may also be compensated for.
- a high engine torque at low engine speeds. The fuel flow actuator allows the high pressure pump to
The high pressure pump generates the high pressure supply the exact volume of diesel fuel required to main-
transmitted to the injection rail. The actuator on the tain the pressure in the rail. This feature allows heat
high pressure pump controls the volume of diesel fuel generation to be minimised and engine output to be im-
supplied according to the demand determined by the proved.
injection computer. The rail supplies each injector To discharge the rail, the injection valves are controlled
through a steel pipe. by small electrical pulses:
The computer: - short enough not to open the injector (passing throu-
- determines the injection pressure value necessary for gh the return circuit from the injectors),
the engine to operate correctly and then operates the - long enough to open the valves and discharge the
fuel flow actuator. It checks that the pressure value is rail.
correct by analysing the value transmitted by the
pressure sensor located on the rail, The injection computer actuates the fan assembly and
the coolant temperature warning light on the instru-
- determines the injection time necessary to deliver the ment panel (function: centralised coolant temperature
right volume of diesel fuel and the moment when in- management).
jection should be started,
The various vehicle computers communicate via multi-
- electrically actuates each injector individually after plex links. The fault warning lights on the instrument
determining these two values. panel are therefore activated via the multiplex network.
The flow injected into the engine is determined accor- In the event of an impact, the function that cuts off the
ding to: diesel fuel supply circuit is managed by the airbag
- the duration of injector actuation, computer. It gives the command via the multiplex
network to the injection computer to lock the injection
- the injector opening and closing speed, locking relay control.
13B-33
DIESEL INJECTION
Operation 13B
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 WARNING
switching on the ignition. The warning light will not re- - The engine must not be run with diesel fuel contai-
turn to normal operation until the fault has been cleared ning more than 10% diester or petrol, even in
using the diagnostic tool . minute quantities.
The vehicle speed signal is transmitted to the instru- - Dismantling the interior of the high pressure pump
ment panel by the ABS computer or the gearbox (vehi- and the injectors is prohibited. Only the fuel flow
cle without ABS system) via the multiplex network. actuator, the diesel fuel temperature sensor and
the Venturi tube can be replaced.
Some vehicles have a sensor for detecting water in the
- It is prohibited to remove the pressure sensor from
diesel fuel, which is located in the filter. If there is water
the injection rail as this could cause contamination
present in the diesel fuel, the orange injection warning
of the circuit. If the pressure sensor is faulty,
light comes on.
replace the assembly consisting of the pressure
Automatic configuration for cruise control - speed limi- sensor, rail, and the five high pressure pipes.
ter operation and for air conditioning operation. - It is strictly prohibited to remove any injection
pump pulley bearing the number 070 575. If the
Injection computer actuating the air conditioning com- pump is being replaced also replace the pulley.
pressor clutch via the UPC.
- Supplying any system component directly with the
A new electronics casing called the UPC has been + 12 V is prohibited.
added to the vehicles wiring diagram.
- Ultrasonic decarbonisation and cleaning are prohi-
bited.
The UPC supplies the following with power:
- Never start the engine unless the battery is pro-
- the air conditioning compressor, perly connected.
- the fan assembly, - Never turn the engine against its operating direc-
tion.
- the electrical heating resistors.
Reprime the circuit using the priming pump.
The UPC is located in the engine compartment near
the battery. It contributes to the protection of certain
electrical components.
IMPORTANT
In this capacity, it comprises: The engine should not be run with diesel fuel con-
taining more than 10% diester.
- fuses,
- several internal relays including:
the + after ignition feed relay, Note:

After any operation, check that there is no diesel
the fan assembly control relays,
fuel leakage. Let the engine idle until the engine
the air conditioning compressor relay. cooling fan starts up, then accelerate several times
at no load.
These relays cannot be removed.
The system can inject the diesel fuel into the engine up
If the UPC is replaced, it must be configured using the to a pressure of 1350 bar . Before each operation
diagnostic tool (see 87G, Motor exchange unit, check that the injection rail is no longer pressurised.
UPC: Configuration ).
Be sure to observe the tightening torque:
The injection computer receives a continuous signal
via the multiplex network regarding the electrical power - for the high pressure pipes,
available from the alternator. This therefore prevents
the vehicle's electrical consumption from being in ex- - for the injector on the cylinder head,
cess of the alternator's capacity. The aim is to give
priority to charging the battery. - for the pressure sensor and pressure regulator.
13B-34
DIESEL INJECTION
Operation 13B
When the high pressure pump, injectors and high pres-
sure supply, outlet and return unions are removed or
repaired, all apertures should be capped with suitable
new blanking covers to prevent contamination.
WARNING
Any pipe removed must be replaced.
When replacing a high pressure pipe, follow the proce-

dure 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 fitted to the injectors must be
replaced when removed.
The diesel fuel temperature sensor cannot be
removed. It is part of the fuel return rail.
engine is running is prohibited.
13B-35
DIESEL INJECTION
Location of components 13B
K9K, and 722
102072
(1) Pr iming pump

(2) Cylinder reference sensor
(3) Turbocharger
(4) Exhaust gas recirculation sole-
noid valve
(5) Injector
(6) Turbocharging air temperature
and pressure sensor
(7) Injection computer
(8) Air filter unit
(9) Protection and Switching Unit
(10) Coolant temperature sensor
(11) Engine speed and position sen-
sor
(12) Rail pressure sensor
(13) Spherical injection rail
101811
(14) Accelerometer
(15) Diesel temperature sensor (18) Injection computer
(16) Diesel flow actuator
(17) High pressure pump
13B-36
DIESEL INJECTION
K9K, and 722
101105 102084
(19) Protection and Switching Unit (21) Venturi

(22) Flow actuator
(23) Diesel temperature sensor
(26) Accelerometer
(27) Injector
102085
102082
13B-37
DIESEL INJECTION
K9K, and 722

(28) Turbocharging air temperature noid valve
and pressure sensor
(30) Wastegate valve
19654-1
13B-38
DIESEL INJECTION
K9K, and 722
20796 102125
(32) Coolant temperature sensor (35) Pre-postheating unit

sor
102121
102204
(36) Diesel filter
(34) Accelerator pedal potentiometer
13B-39
DIESEL INJECTION
K9K, and 722
102124
(37) Pr iming pump
102077
(39) Turbocharger
(40) Catalytic converter
102128
(38) Refrigerant pressure sensor
13B-40
DIESEL INJECTION
F9Q, and 800 or 808
101883
(16) Turbocharging pressure sensor
(1) Diesel filter
(17) Diesel temperature sensor (fuel
(2) Manual priming pump return)
(3) Cylinder reference sensor (18) High pressure pump
(4) Rail pressure sensor (19) Diesel pressure regulator
(5) Solenoid injectors
(6) Engine stop system vacuum
reserve
(7) Engine stop system solenoid
valve
noid valve (F9Q 800)
(9) Turbocharger regulation sole-
noid valve
(10) Flowmeter with air temperature
sensor
(13) Engine stop valve diaphragm
(14) Engine stop valve
(15) Pressure limiter (on injection
rail)
13B-41
DIESEL INJECTION
F9Q, and 800 or 808
18297-1

(21) Injection rail
(22) Injector
(23) Pressure regulator
(24) Pressure sensor
(26) Pressure limiter
27
102485
(27) TDC sensor
13B-42
DIESEL INJECTION
F9Q, and 800 or 808
28
31
16181 101891
(28) Cylinder reference sensor (31) Preheating unit
29
32
30
102479 101889
(29) Turbocharger (32) Turbocharging pressure regula-

(30) Catalytic converter tion solenoid valve
13B-43
DIESEL INJECTION
F9Q, and 800 or 808
33 38
34
101892 101886
(33) Engine stop valve (38) Manual priming pump

(34) Engine stop valve control
diaphragm
35
37
36
39
102486
(35) Engine stop valve vacuum

reserve
102121
(36) Engine stop valve solenoid valve
(37) Exhaust gas recirculation sole- (39) Diesel filter
noid valve (F9Q 800)
13B-44
DIESEL INJECTION
F9Q, and 800 or 808
40
102352
102204
13B-45
DIESEL INJECTION
K9K, and 728 or 729
106343
(1) Pr iming pump
(18) Turbocharging pressure sole-
(2) Cylinder reference sensor noid valve
(3) Turbocharger
noid valve
(5) Injector
and pressure sensor
(8) Air filter unit
(9) UPC
sor
(14) Accelerometer
(15) Diesel fuel temperature sensor
(16) Diesel fuel flow actuator
101811
13B-46
DIESEL INJECTION
K9K, and 728 or 729
101105 102084
(20) UPC (22) Venturi

(23) Fuel flow actuator
(27) Accelerometer
(28) Injector
102085
110327
13B-47
DIESEL INJECTION
K9K, and 728 or 729
110319

and pressure sensor
noid valve
sor
(32) Turbocharging pressure regula-
tion valve
101889

tion solenoid valve
13B-48
DIESEL INJECTION
K9K, and 728 or 729
19654-1
102204
20796
13B-49
DIESEL INJECTION
K9K, and 728 or 729
102124
(39) Priming pump
102125
(37) Pre-postheating unit
102128
(40) Refrigerant pressure sensor
104954
(38) Diesel filter
13B-50
DIESEL INJECTION
K9K, and 728 or 729
102077
(41) Turbocharger
13B-51
DIESEL INJECTION
F9Q, and 804
101883
(1) Diesel filter

(2) Pr iming pump
(5) Solenoid injectors
noid valve unit
(7) Turbocharger regulation sole-
noid valve
(8) Flowmeter with air temperature
sensor
(10) UPC
(15) Diesel pressure regulator
13B-52
DIESEL INJECTION
F9Q, and 804
18297-1

(17) Injection common rail
(18) Injectors
(19) Pressure regulator
(20) Pressure sensor
102485
(23) TDC sensor
13B-53
DIESEL INJECTION
F9Q, and 804
16181 101891
(24) Cylinder reference sensor (27) Preheating unit
111864 101889
(25) Turbocharger (28) Turbocharging pressure regula-

(26) Catalytic converter tion solenoid valve
13B-54
DIESEL INJECTION
F9Q, and 804
111856 102121
(29) Throttle valve. (32) Diesel filter

noid valve unit.
102204
101886
(31) Pr iming pump
13B-55
DIESEL INJECTION
K9K, and 732
114186
(1) Manual priming pump

noid valve
(4) Turbocharger
(5) Injectors
(7) Turbocharging air pressure sen-
sor
(8) Air flowmeter
(9) Air filter unit
tion solenoid valve
101811
(14) Injection rail
(15) Injection rail pressure sensor (18) Injection computer
(17) Diesel filter
13B-56
DIESEL INJECTION
K9K, and 732
101105 112994
(19) Protection and Switching Unit (21) Cylinder reference sensor

(22) Air inlet valve
(24) Pressure regulation solenoid
valve
(23) Flow regulation solenoid valve
111748
13B-57
DIESEL INJECTION
K9K, and 732
114348
(25) Diesel injector fuel return rail

(26) Diesel temperature sensor
(27) High pressure pipe between the
rail and injector
(28) High pressure pipe between the
pump and rail
(29) High pressure rail
(31) Diesel injector
(32) Injector bracket
(33) Spacer between the cylinder
head and injector bracket
102204
13B-58
DIESEL INJECTION
K9K, and 732
102124
(37) Priming pump
102125
(35) Pre-postheating unit
113840

(39) Turbocharger
114559
(36) Diesel filter
13B-59
DIESEL INJECTION
K9K, and 732
114185

tion solenoid valve
13B-60
DIESEL INJECTION
Immobiliser function 13B
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 pro-
cedure for replacing the computer.
REPLACEMENT
For the removal/refitting procedure, (see 13B, Die-
sel injection, Diesel injection computer ).
For the engine immobiliser functions (see 82A, En-
gine immobiliser, Operation ).
Injection computers are supplied without a code, 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 star-
ting the engine.
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 13B
K9K, and 722 or 728 or 729 or 732
If there is a serious injection fault (level 2), the red en-
gine symbol and the word Stop appears (only on in-
Note: formation display), with the message Injection
faulty , followed by the Stop warning light and
For vehicles fitted with K9K 732 engines (see MR
buzzer.
370 Mechanics, Scnic II ).
The faults relate to:
Vehicles fitted with the Delphi DDCR high-pressure
diesel fuel system use fault warning symbols and text - with delayed stop: the fuel flow actuator (loop discre-
warning messages, depending on the level of severity pancy and overpressure),
of the faults detected, to inform the customer and de- - with immediate stop:
termine the correct fault finding procedure.
the engine speed sensor,
The injection computer controls the illumination of war-
the diesel flow actuator,
ning lights and message displays on the instrument pa-
nel. The fault warning lights come on: the rail pressure sensor,
- during the preheating phase, the supply to all the injectors,
- if there is an injection fault, the sensor supply voltage,
- if the engine is overheating. an internal computer fault.
The warning signals are sent to the instrument panel If the engine overheats, the engine temperature fault
via the multiplex network. symbol appears with the message Engine
overheating (only on information display) followed by
the Stop warning light and buzzer. If this happens,
WARNING LIGHT ACTIVATION PRINCIPLE.
the vehicle will stop immediately.
During the starting phase (press the Start button,
the orange preheating symbol is lit during the prehea- On Board Diagnostic excess pollution orange
ting phase, then goes out) (see 13C, Preheating, Pre- warning light
postheating control ).
The orange warning light, represented by an engine,
In the event of an injection fault (level 1), the message comes on for approximately 5 seconds then goes out.
Check injection is displayed and then the It is never displayed when the engine is running (not
Service warning light comes on. This means a re- operational).
duced level of operation and a limited safety level.
Repairs should be carried out as soon as possible.
These faults are associated with:
- the engine immobiliser,
- a C2l (individual injector correction) coding error,
- an injector,
- the injector controls,
- the diesel fuel supply (injector leak, etc.),
- an engine speed sensor target fault,
- the injection locking relay,
- the exhaust gas recirculation solenoid valve or posi-
tion sensor,
- the accelerator pedal potentiometer (gangs 1 and 2),
- the accelerator pedal potentiometer supply,
- the turbocharging pressure sensor (in the event of
overpressure),
- water in the diesel fuel or a water detection sensor
fault (if fitted on vehicle.
13B-62
DIESEL INJECTION
F9Q, and 800 or 804 or 808
Vehicles fitted with the Bosch EDC16 high pressure - an injector fault,
diesel fuel system use fault warning symbols and text
- a rail pressure sensor fault,
warning messages, depending on the level of severity
of the faults detected, to inform the customer and de- - a rail pressure regulator fault.
termine the correct fault finding procedure.
If the engine overheats, the engine coolant temperatu-
The injection computer controls the illumination of war- re fault symbol appears with the message Engine
ning lights and message displays on the instrument pa- overheating (only on information display) followed by
nel. The fault warning lights and error messages are the Stop warning light and buzzer. In this case the
visible: vehicle must be stopped immediately.
- during the preheating phase,
On Board Diagnostic excess pollution orange
- if there is an injection fault, warning light
- if the engine is overheating. The orange engine symbol comes on when the ignition
The warning signals are sent to the instrument panel is switched on for around 5 seconds then goes out. It
via the multiplex network. is never displayed when the engine is running (not ope-
rational).
WARNING LIGHT PRINCIPLE
During the starting phase (press on the Start but-
ton, the orange preheating symbol is lit during the pre-
heating phase then it goes out) (see 13C, Preheating,
Pre-postheating control ).
In the event of an injection fault (level 1), the message
Check injection is displayed and then the
Service warning light comes on. This means a re-
duced level of operation and a limited safety level.
- an internal computer fault,
- an immobiliser system fault,
- a speed synchronisation fault,
- an accelerator pedal potentiometer fault,
- an air flowmeter fault,
- a speed sensor fault (see ABS system),
- an EGR solenoid valve fault,
- a fault in the turbocharging pressure regulation sole-
noid valve,
- a fault in the main relay of the Protection and Swit-
ching Unit,
- an injector fault,
- an injector flow correction fault (IMA),
- a sensor power feed fault.
If there is a serious injection fault (level 2), the red en-
gine symbol and the word Stop appears (only on in-
formation display), with the message Injection
faulty , followed by the Stop warning light and
buzzer.
- an internal computer fault,
13B-63
DIESEL INJECTION
Injection / air conditioning programming 13B
K9K, and 722 or 728 or 729
Note: Note:
For vehicles fitted with engine concerned (see MR The value of parameter ( PR044 ) power absor-
370 Mechanics, Scnic II ). bed by the air conditioning compressor is never 0,
whatever the status of the air conditioning compres-
The air conditioning management is shared between sor. The minimum reading is approximately 250 W .
several computers that communicate via the multiplex
The air conditioning compressor is of the variable
network.
displacement type.
It is of the cold loop type.
The injection computer is responsible for: I - COMPRESSOR OPERATION PROGRAMMING

- managing the cooling request according to passenger
compartment commands and the circuit pressure va- During certain operating phases, the injection compu-
lue, ter disables the operation of the compressor.
- calculating the power absorbed by the compressor

from the circuit pressure value, 1 - Engine starting programming
- authorising engine cooling fan control in accordance The operation of the air conditioning compressor is in-
with vehicle speed and circuit pressure, hibited for 1 second after the engine has started.
- authorising or inhibiting engagement of the compres-

sor clutch. 2 - Thermal protection programming
When the air conditioning is switched on, the air condi-
The air conditioning compressor is not engaged if the
tioning control panel requests authorisation to engage
engine temperature is above 115C or above 110C at
the compressor clutch.
high engine speeds, 4500 rpm for more than 10 se-
The injection computer authorises or inhibits compres- conds .
sor clutch engagement, controls the fan assembly via
the UPC and imposes an increased idle speed.
3 - Fan unit control programming
This engine speed is 900 rpm depending on how much
power is absorbed by the compressor. With the engine idling or when driving, with the air con-
ditioning on, the fan unit is activated at high or low
The injection computer authorises operation of the air speed, according to the refrigerant pressure and the
conditioning compressor and the fan unit (both sup- vehicle speed.
plied by the UPC), according to the following condi-
tions:
- engine coolant temperature, 4 - Recovery of performance
- vehicle speed, If the accelerator pedal is depressed firmly (more than

75 % of its travel), the compressor is disengaged for 5
- climate control. seconds .
The signals used for the air conditioning function are
transmitted via: 5 - Recovery of power when moving off
- track A A4 CAN HIGH multiplex connection,
To assist the vehicle moving away, the air conditioning
- track A A3 CAN LOW multiplex connection. compressor is disengaged if the accelerator pedal tra-
vel is greater than 30 % and the engine speed is less
The connections between the injection computer and than 1250 rpm .
the refrigerant pressure sensor are:
- C C3 refrigerant pressure sensor signal,

6 - Anti-stalling function
- C C4 refrigerant pressure sensor supply,
The air conditioning compressor is disengaged if the
- C G3 refrigerant pressure sensor earth. engine speed is less than 740 rpm .
13B-64
DIESEL INJECTION
K9K, and 722 or 728 or 729
7 - Engine overspeed timed protection Output conditions:
programming
- engine speed above 3500 rpm ,
- and vehicle speed greater than 90 mph (150 km/h)
engine speed is above 4500 rpm for more than 3 se- (by way of information).
conds .
3 - Performance return programming for hill starts

Note: To assist hill starts, the heating resistors are tempora-
There is always a delay of more than 10 seconds rily disabled.
after the air conditioning compressor is disengaged Input conditions:
before it can be disengaged again.
- engine speed less than 900 rpm ,
- and vehicle speed less than 2.4 mph (4 km/h) ,
II - PASSENGER COMPARTMENT HEATING
RESISTORS OPERATION PROGRAMMING - and gearbox in neutral.
To reduce the heating time, fit air heating resistors Output conditions:
known as passenger compartment heating - engine speed greater than 2500 rpm ,
resistors in the passenger compartment heating cir-
cuit. - or vehicle speed greater than 3.6 mph (6 km/h)
- or a gear is engaged.
The UCH determines the need to actuate the heating
resistors, according to the user's request.
4 - Stalling prevention programming
The injection computer determines:
When the engine speed falls below 760 rpm , opera-
- the number of heating resistors supplied (power con- tion of passenger compartment heating resistors is in-
trol limitation) depending on the alternator charge, terrupted. When engine speed rises above 750 rpm ,
- whether resistor operation should be disabled, accor- the passenger compartment heating resistors are re-
ding to engine speed, load and vehicle speed. enabled.
The heating resistors are supplied by the UPC.
At the request of the resistors, the fast idle speed beco-

mes 900 rpm .
III - PASSENGER COMPARTMENT HEATING

RESISTORS OPERATION PROGRAMMING
During certain operating phases, the injection compu-
ter disables the passenger compartment heating resis-
tors.
1 - Engine start programming

Operation of passenger compartment heating 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 re-
sistors 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
F9Q, and 800 or 804 or 808
The air conditioning management is shared between It is re-engaged if the engine speed exceeds 780 rpm .
several computers that communicate via the multiplex
network.
II - PASSENGER COMPARTMENT HEATING
When the air conditioning is switched on, the air condi- RESISTORS OPERATION PROGRAMMING
tioning control panel requests authorisation to engage
During certain operating phases, the injection compu-
the compressor clutch.
ter disables the heating resistors.
The injection computer authorises or inhibits the com-
pressor clutch, and controls the fan assembly via the
UPC.
The heating resistors are disabled while the heater
When the air conditioning function is selected, the plugs are in operation.
idling speed is not altered.
When the engine starts, the heating resistor supply is
The signals used for the air conditioning function are authorised after a delay that depends on the engine
transmitted via:
coolant temperature.
- track A A4 CAN HIGH multiplex connection,
- track A A3 CAN LOW multiplex connection. Engine coolant tem- Delay
This compressor is the variable output type. perature
(s)
(C +/- 1)
I - AIR CONDITIONING COMPRESSOR OPERATION
PROGRAMMING - 30 30
During certain operating phases, the injection compu- - 20 25

ter disables the compressor.
- 10 15
1 - Engine start programming 0 15
Air conditioning compressor operation is inhibited for 2
10 15
seconds after the engine has started.
20 15
2 - Thermal protection programming
30 10
The air conditioning compressor is not engaged if the
engine coolant temperature is above 115 C , it is re-
engaged if the engine coolant temperature falls below 2 - Stalling prevention programming
115 C .
When the engine speed falls below 800 rpm , opera-
This vehicle is equipped with heating resistors located tion of the heating resistors is interrupted. When the
in the air conditioning unit. engine speed falls below 875 rpm , operation of the
heating resistors is authorised.
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 posi-
tion 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
engine speed is below 750 rpm .
13B-66
DIESEL INJECTION
Idling speed 13B
K9K, and 722 or 728 or 729 or 732
II - IDLE SPEED CORRECTION IN THE EVENT OF
AN ACCELERATOR PEDAL POTENTIOMETER
Note: FAULT
For vehicles fitted with K9K 732 engines (see MR - If one of the two accelerator pedal potentiometer
370 Mechanics, Scnic II ). tracks is faulty, the injection computer forces an idle
speed of 1300 rpm . This defect mode limits perfor-
The injection computer calculates the idling speed nee- mance. The Check injection message lights up,
ded to maintain it at the recommended level and to followed by the Service warning light.
compensate for any variation in the mechanical or - If the accelerator pedal potentiometer is jammed, no
electrical torque as a function of: longer supplied, or is no longer sending an output si-
gnal, the injection computer imposes an idle speed of
- the coolant temperature,
1300 rpm . This defect mode limits performance. The
- the battery voltage, Check injection message lights up, followed by
the Service warning light.
- the gear selected,
- If there is inconsistency between the accelerator pe-
- the electrical consumers (climate control, fan unit, dal potentiometer signal and the brake switch signal,
passenger compartment heating electrical resistors, the injection computer imposes an idle speed of 1300
etc.), rpm .
- any faults found.

III - IDLE SPEED CORRECTION IN THE EVENT OF
AN INJECTOR C2I CODING ERROR
In the event of an injector C2I coding error (individual
Note:
adjustment of the injector flow), the injection computer
At normal engine operating temperature, without forces an idle speed of 1300 rpm . This defect mode li-
major electrical consumers, the engine idling speed mits performance. The Check injection message li-
is 805 50 rpm . ghts up, followed by the Service warning light.
IV - IDLE SPEED CORRECTION WHEN THE

I - IDLE SPEED CORRECTION ACCORDING TO
VEHICLE IS BEING DRIVEN
COOLANT TEMPERATURE
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 .
103122
X: Engine idle speed (rpm)
Y: Engine coolant temperature (C)
13B-67
DIESEL INJECTION
Idling speed 13B
B84 or C84 or S84, and F9Q, and 800 or 804
COOLANT TEMPERATURE
In all cases, this engine idling speed correction is deac-

tivated 10 minutes after engine start and adopts a va-
lue of 800 rpm .
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 dri-

ven 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 13B
K9K, and 722 or 728 or 729 or 732
Note:
The coolant temperature sensor (injection and coolant

temperature indicator on the instrument panel) is a 3-
track sensor:
- 2 tracks for the coolant temperature signal to the com-

puter (tracks B H2 and B H3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be con-

trolled by the injection computer. It consists of a single
temperature sensor serving injection, the engine coo-
ling 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 ex-

ceeds 99 C or in the event of a coolant temperature
sensor fault and stops when the temperature falls be-
low 96 C ,
- at high speed if the engine coolant temperature ex-

ceeds 102 C or if the low speed is faulty and 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 tem-

perature exceeds 118C . It goes out when the tempe-
rature drops below 115 C .
13B-69
DIESEL INJECTION
Centralised coolant temperature management 13B
F9Q, and 800 or 804 or 808
The coolant temperature sensor (injection and coolant
temperature indicator on the instrument panel) is a 3-
track sensor:
- 2 tracks for the coolant temperature signal to the com-
puter (tracks B E1 and B K3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be con-
trolled by the injection computer. It consists of a single
temperature sensor serving injection, the engine coo-
ling 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 ex-
ceeds 99C and stops when the temperature drops
below 96C ,
- at high speed if the engine coolant temperature ex-
ceeds 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 tem-
perature exceeds 120C . It goes out if the temperature
falls below 115C .
13B-70
DIESEL INJECTION
Computer configuration 13B
K9K, and 722 or 728 or 729 or 732
PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
Equipment required
Before programming, reprogramming or replacing
diagnostic tool
the computer, save to the diagnostic tool the fol-
The system can be programmed and reprogrammed lowing data:
via the diagnostic socket using the diagnostic tool .
- the C2I parameters (individual injector correction),
- the engine adaptives using command SC003

WARNING Save computer data .
- Connect (to the mains or the cigarette lighter) the
diagnostic tool . After programming, reprogramming or replacing the
computer:
- Check the condition of the battery.
- Connect a battery charger (throughout the dura- - switch off the ignition,
tion of computer (re)programming, the engine coo-
ling fan is automatically engaged). - start and then stop the engine (to initialise the com-
puter) and wait for 30 seconds ,
- Comply with the engine coolant temperature
values given in the diagnostic tool before - switch on the ignition again.
carrying out any (re)programming.
- 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
code for life.
- 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, repro-
gramming or replacement of the computer, the
C2I of each injector must be written manually,
reading the C2Is on the injectors (see 13B, Die-
sel Injection, Injectors: Configuration ).
13B-71
DIESEL INJECTION
Computer configuration 13B
F9Q, and 800 or 808
using the diagnostic tool , ensure that the com-
puter has not detected any faults relating to the in-
Equipment required
jector codes and that the instrument panel
diagnostic tool warning light is off.
The system can be programmed and reprogrammed

via the diagnostic socket using the diagnostic tool (re-
fer to Technical Note 3585A ).
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 com-

puter has not detected any faults relating to the in-
jector codes and that the instrument panel
warning light is off.
- If it is not possible to enter into dialogue with 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 13B
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-
sel fuel leakage.
Reprime the diesel circuit using the manual priming

pump.
Note:
The diagnostic tool can be used for testing the
high pressure circuit with the engine running.
This command can be used for finding a leak due
to an incorrectly fitted or tightened union. This
command only works if the engine coolant tem-
perature is above 60C . The fault finding proce-
dure will not reveal small leaks due to incorrect
tightening.
Run command AC029 high pressure circuit sea-

ling test , in the LPG/fuel circuit tab.
WARNING
Do not leave anything in the engine bay during
the test phase (significant 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.
13B-73
DIESEL INJECTION
K9K, and 732
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-
sel fuel leakage.
Reprime the diesel circuit using the manual priming

pump.
112811
Pull out the clip.
112815
(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
K9K, and 732
Run command AC029 high pressure circuit sea-
ling test , in the LPG/fuel circuit tab.
WARNING
Do not leave anything in the engine bay during
the test phase (significant 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) . Refitting ).
Remove: - the air inlet pressure sensor connector.
Loosen the clip and move the air inlet duct aside.
- the mounting nut and bolt (7) from the injection rail
protector cover, Pull out the stainless steel pipe clip.
- the injection rail protector cover, Remove the air inlet duct.
Refit the clip onto the stainless steel pipe if necessa- Refit:
ry.
Clip the stainless steel pipe to turbocharger.
- the injection rail protector cover mounting nut and
Refit the air inlet duct on the damper valve. bolt,
Tighten the clip. Clip the injection rail protector cover.
Refit the clip onto the stainless steel pipe if necessa-

Connect:
ry.
- the connector of the air inlet pressure sensor, Clip the stainless steel pipe to the turbocharger.
- the battery (see 80A, Battery, Battery: Removal - Refit:
Refitting ).
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.

Note:
The diagnostic tool can be used for testing the Tighten the clip.
high pressure circuit with the engine running.
Connect:
This command can be used for finding a leak due
to an incorrectly fitted or tightened union. This - the connector of the air inlet pressure sensor,
command only works if the engine coolant tem-
perature is above 60C . The fault finding proce- - the battery (see 80A, Battery, Battery: Removal -
dure will not reveal small leaks due to incorrect Refitting ).
tightening. - the engine covers.
13B-75
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732

WARNING
high-pressure pipes - Ensure that you have a special high-pressure
injection circuit blanking plugs kit.
Equipment required - Ensure that any high-pressure pipe or high-pres-

sure pipe clips that have been removed are repla-
diagnostic tool ced.
pipe socket for tightening the pump-rail high-pres-

sure pipe (19-17 mm Crowfoot spanner) REMOVAL
high-pressure pipe wrench (DM19) Disconnect the battery, starting with the negative
terminal.
pipe socket for tightening injector-rail high pressure
pipes ("Crowfoot 18-17" wrench)
low torque wrench

K9K, and 722
Tightening torquesm
rail mounting nuts 28 Nm
pump-rail high- 38 Nm
pressure pipe nuts
1
rail-injectors high- 38 Nm
pressure pipe nuts
filler neck nut on the rail 21 Nm

bolts
102120
Disconnect air inlet duct (1) .
Note:
IMPORTANT

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
carried out on this system.
- Loosening a high-pressure pipe union when the
13B-76
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
K9K, and 728 or 729

5
102362
Remove diesel fuel splash plate (5) .

110325
Pull out clip (2) .
4 7
6
9 8
102361
Remove dipstick guide tube (6) .

110323
Loosen bolt (3) . Fit blanking plugs into the openings.
Move aside the air duct (4) . Carefully disconnect:
- the heater plugs (7) ,
- the injectors,
- the high-pressure pump electrical connectors (8) ,
- the diesel supply and return pipes (9) .
13B-77
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
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 in-
jector 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
K9K, and 722 or 728 or 729 or 732
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 20803
Remove high-pressure pipes (20) one by one.
Fit blanking plugs into the openings.
18
19724
Loosen mounting nuts (16) on the spherical injector

rail by several turns.
Remove clips (17) connecting the high-pressure pi-

pes.
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
K9K, and 722 or 728 or 729 or 732
REFITTING II - REFITTING THE RAIL - INJECTORS HIGH-

PRESSURE 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 high-
pressure outlet taper.
Tighten the high-pressure pipe nuts by hand, star-
ting with the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts.
WARNING
When tightening the high-pressure pipes, it is
essential to support the injector central union
(18) .
Note:
20960 The order of fitting the injector rail pipes is not
impor tant.
WARNING
- Before fitting 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.
Fit a new clip provided with the new high-pressure
Insert the high-pressure pipe olive in the high-pres- pipe:
sure pump high-pressure outlet taper. - insert the first half-shell using adjustable pliers,
Insert the high-pressure pipe olive in the spherical - insert the second half-shell using adjustable pliers.
injector rail inlet taper.
Finger tighten the high-pressure pipe nuts, starting Note:

with the one at the rail end.
Follow the direction of fitting (the lugs only
Slightly pretighten the high-pressure pipe nuts. engage in one position).
13B-80
DIESEL INJECTION
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-81
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
WARNING

( 4 Nm ) .
WARNING
Confirm 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,
- carry out a road test,
110404
Tighten to torque and in order the pump-rail
high-pressure pipe nuts ( 38 Nm ) : - check that there is no diesel fuel escaping.
- pump end,
- rail end.
Use the pipe socket for tightening the pump-rail

high-pressure pipe (19-17 mm Crowfoot span-
ner) or the high-pressure pipe wrench (DM19) .
Tighten to torque and in order the rail-injectors

high-pressure pipe nuts ( 38 Nm ) :
- injectors end,
- rail end.
Use the pipe socket for tightening injector-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.
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 termi-

nal.
13B-82
DIESEL INJECTION
Diesel injector: check 13B
K9K, and 722 or 728 or 729
Command AC029 High pressure circuit sealing
test in the Fuel/LPG tab also enables the lea-
kage rate of each injector to be checked in order to
determine an internal leak in one or several injec-
tors. This test only works when the engine tempera-
ture is greater than 60C .
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 sea-
ling 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 injec-
tors' 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 (signifi-
cant vibration).
13B-83
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729

WARNING
Mot. 1367-02 Engine support
Mot. 1367 Engine support tool for Tighten to torque 38 Nm the pump-rail and
replacing cylinder injection rail high pressure pipes with the fol-
head lowing part numbers:
- 77 01 207 025 ,
Mot. 1606 High pressure pump-
pulley retaining tool - 77 01 207 026 ,
- 77 01 207 027 ,
Mot. 1525 Extractor for timing
gear with tapered hub - 77 01 207 028 ,
- 77 01 207 029 .
Mot. 1525-02 Adaptor claws for Mot.
1525 for high pressure pipes with other part numbers,
tighten to a torque of 24 Nm .
Equipment required
diagnostic tool
IMPORTANT
Tightening torquesm Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
high pressure injection 21 Nm that the injection rail is not under pressure,
pump mounting bolts
high pressure injection 55 Nm
pump pulley mounting
nut
rail mounting nuts 28 3 Nm - Loosening a high pressure pipe union when the
union at the rail end 24 Nm
union at the pump end 24 Nm

WARNING
bolts - Obtain a set of special high pressure injection cir-
cuit plugs.
- Always replace any high pressure pipe or high
WARNING pressure pipe clip removed with a new one.
Before starting work on the vehicle, obtain:

- a new set of blanking plugs (part no.: 77 01 206 WARNING
804 ),
Never turn the engine against its operating direc-
- cleaning cloths (part no.: 77 11 211 707 ), tion.
- cleaning product (part no.: 77 11 224 188 ).
13B-84
DIESEL INJECTION
K9K, and 722 or 728 or 729
REMOVAL II - PROCEDURE FOR HIGH PRESSURE PUMPS

WITH A PULLEY BEARING A NUMBER OTHER
THAN 070 575
I - PROCEDURE FOR HIGH PRESSURE PUMPS
WITH A PULLEY BEARING NUMBER 070 575
21265
21265
K9K, and 722

WARNING
Removing any high pressure pump pulley bea-
ring 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:
Timing belt ),
- the pump-pulley assembly.
102120
Disconnect:
Refitting ).
- the air inlet duct (1) .
13B-85
DIESEL INJECTION
K9K, and 722 or 728 or 729
K9K, and 728 or 729
5
7 5
8 6
4
102361
Remove dipstick guide tube (4) .

110325 Plug the opening on the engine block.
Pull out the clip.
Carefully disconnect:
- the injectors,
- the fuel flow actuator electrical connectors (6) ,

- the supply and return pipes (8) .
110323
Undo the bolt (2) .
102362
Remove the diesel fuel splash plate (9) .
13B-86
DIESEL INJECTION
K9K, and 722 or 728 or 729
102360 102083
Disconnect: Remove the (16) pump-rail high pressure pipe
(see 13B, Diesel injection, High pressure pipe:
- the fuel return pipe connecting the injectors to the
Replacing ).
pump (10) ,
Slacken the rail mounting nuts (15) by a few turns.
- the rail pressure sensor (11) ,
Loosen the nut at the pump end, then the nut at the
- the accelerator (12) ,
rail end.
- the oil level sensor (13) ,
Slide the nut down the tube, keeping the olive in con-
- the cylinder reference sensor (14) on the timing co- tact with the taper.
ver.
Plug the openings on the injection circuit.
Unclamp the electrical harness and move it to one
side.
Remove the channel located on the spherical injec-
tion rail.
19626
Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .
13B-87
DIESEL INJECTION
K9K, and 722 or 728 or 729
- the tie-bar and make a mark.
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
K9K, and 722 or 728 or 729
102115
Remove the engine tie-bar mounting bolts (18) on
the gearbox and sub-frame. 103749
Raise the engine a few centimetres for access to the Remove the mounting bolts securing (19) the engine
suspended mounting attachments on the cylinder tie-bar on the gearbox and on the engine sub-frame.
head and the high pressure pump pulley.
Raise the engine a few centimetres for access to the
suspended mounting attachments on the cylinder
WARNING head and the high pressure pump pulley.
Do not dislodge the right-hand driveshaft when
lifting the engine. WARNING
Do not dislodge the right-hand driveshaft when
lifting the engine.
13B-89
DIESEL INJECTION
K9K, and 722 or 728 or 729
19654-1
Remove:
- the cylinder reference sensor (20) ,
- the plastic bolt (21) ,
Unclip the three tabs (22) .
13B-90
DIESEL INJECTION
K9K, and 722 or 728 or 729
19654-2
Remove the suspended mounting (23) from the cy-

linder head.
23167
Position the engine at Top Dead Centre. The cams-
haft pulley hole (24) should be opposite the cylinder
head hole (25) .
13B-91
DIESEL INJECTION
K9K, and 722 or 728 or 729
23168 23169
Position the (Mot. 1606) (3) . Fit the (Mot. 1525) (4) fitted with the (Mot. 1525-02)
.
If necessary, turn the engine slowly to adjust the po-
sition of the locking tool on the pump pulley teeth.
Remove the high pressure pump pulley nut (26) , WARNING
holding the pulley with an open-jawed spanner. Ensure that the tool pushrod is correctly oriented
and is pressing against the high pressure pump
shaft.
13B-92
DIESEL INJECTION
K9K, and 722 or 728 or 729
Before fitting the new high pressure pipe, lightly lu-
bricate the union threads with the oil from the appli-
cator provided in the new parts kit.
WARNING
Some pipes are supplied with applicator and
some without.
The pipes supplied without applicator are self-
lubricating 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.
WARNING
Always replace all high pressure pipes removed.
13B-93
DIESEL INJECTION
K9K, and 722 or 728 or 729
If replacing the high pressure pump, reprime the die-
sel 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 lubri-
cation.
Connect the diagnostic tool to the vehicle.

Establish dialogue with the diesel injection compu-
110404
ter.
Refit the high pressure pipe - to do this:
Run command AC212 FILLING NEW PUMP
- remove the protective plugs, CHAMBER .
- insert the high pressure pipe olive in the pump out- Follow the instructions on the diagnostic tool until
let taper, the command is completed.
- insert the high pressure pipe olive in the rail inlet ta-
Start the engine.
per.
Finger tighten the high pressure pipe unions, star-
ting with the one located at the rail end. Note:
The star ting phase can last up to 20 seconds .
Tighten to torque the rail mounting nuts ( 28 3
Nm ) . If the engine does not start or if the start-up sequen-
Tighten to torque and in order: ce is interrupted:
- the union at the rail end ( 24 Nm ) , - switch off the ignition,
- the union at the pump end ( 24 Nm ) . - wait for 30 seconds ,
Proceed in the reverse order to removal. - restart the engine.
Prime the diesel fuel supply circuit with the priming Using the diagnostic tool clear any faults stored by
pump (automatic degassing). the injection computer.
Connect the battery (see 80A, Battery, Battery: Re- Check the high pressure circuit sealing after the re-
moval - Refitting ). pair operation (see 13B, Diesel injection, High
Tighten to torque the battery cover mounting bolts pressure pipe: Test ).
( 4 Nm ) .
WARNING

- let the engine run at idle speed until the engine cooling
fan starts to operate,
- check that there is no diesel fuel escaping.
13B-94
DIESEL INJECTION
F9Q, and 800 or 808

IMPORTANT
Mot. 1668 Locking high pressure
pump sprocket
Before carrying out any work on the injection sys-
Mot. 1525 Extractor for timing tem, check using the diagnostic tool :
gear with tapered hub - that the injector rail is not under pressure,
Mot. 1525-03 Adapter claws for Mot. - that the fuel temperature is not too high.
1525 (for 33-tooth pul- Loosening a high-pressure pipe union when the
ley) engine is running is strictly prohibited.
Mot. 1746 Offset spanner for
tightening high pres-
sure pump pipe WARNING
Mot. 1566 Wrench for removing Ensure that any high-pressure pipe removed is
high-pressure pipes replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high-pressure pump
and the injectors is prohibited.
Tightening torquesm
It is essential to read the repair precautions (see 13A,
high-pressure pump 30 Nm Diesel injection, Repair precautions ).
mounting bolts on the
pump supports REMOVAL
high-pressure pump 50 Nm Put the vehicle on a two-post lift.
pulley nut
high-pressure pump 20 Nm + 80 terminal.
support mounting bolts Remove:
on the cylinder head
high-pressure pump 44 Nm engine, Accessories belt ),
rear support mounting - the timing belt (see 11A, Top and front of engine,
bolts on the cylinder Timing belt ).
block
injector rail mounting 22 Nm tion, Injector rail protector: Removal - Refitting
bolts ), if fitted to the vehicle.
pump-rail high-pressure 29 Nm
pipe nut on the pump
side
pipe nut on the rail side

bolts
13B-95
DIESEL INJECTION
F9Q, and 800 or 808
102352 102353
Disconnect: Remove the pump-rail high-pressure pipe.
- the diesel fuel heater from the diesel filter, Plug the openings.
- the heater plugs,
- the pressure regulator (1) ,
- the pressure sensor (2) (version without injector rail

protector).
102348
Remove the two mounting bolts (3) from the high-
pressure pump on the high-pressure pump rear sup-
port.
102351
Disconnect the diesel supply and return pipes.
Plug the openings.
Remove the diesel pipes retaining clip.
13B-96
DIESEL INJECTION
F9Q, and 800 or 808
102350 102894
Remove: Fit the pulley extractor (Mot. 1525) (2) with claws
- the three mounting bolts (4) from the high-pressure (Mot. 1525-03) for pulleys with thirty-three teeth.
pump front support, Remove the pulley by tightening the pulley extractor
- the high-pressure pump, with the high-pressure thrust bolt (6) .
pump support.
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
Remove:
pulley.
- the three mounting bolts (7) from the high-pressure
pump,
- the high-pressure pump.
13B-97
DIESEL INJECTION
F9Q, and 800 or 808
REFITTING II - REFITTING THE PUMP - RAIL HIGH-PRESSURE

PIPE
Undo the injector rail mounting bolts (the injector rail
WARNING should be loose ).
WARNING
Refit the high-pressure pump on the pump support.
- Be careful not to allow oil into the high-pressure
Tighten to torque: pipe.
- the high-pressure pump mounting bolts on the - Do not lubricate high-pressure pipes supplied
pump supports ( 30 Nm ) , without an applicator, as these high-pressure
pipes are self-lubricating.
- the high-pressure pump pulley nut ( 50 Nm ) by
immobilising the pulley with (Mot. 1668) .
WARNING
Do not remove the plugs from each component
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
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 ) ,
- the pump-rail high-pressure pipe nut on the rail
102349 side ( 25 Nm ) .
Push the ring (8) back as shown in the diagram. Proceed in the reverse order to removal.
Undo the two mounting bolts (9) on the high-pressu-

re pump rear support on the cylinder block.
Refit the high-pressure pump assembly and 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 sup-
port against the high-pressure pump and the cylin-
der block.
Tighten to torque the high-pressure pump rear
support mounting bolts on the cylinder block (
44 Nm ) .
13B-98
DIESEL INJECTION
F9Q, and 800 or 808
Refit:
Timing belt ),
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:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
Prime the diesel circuit using the manual priming

pump.
nal.
WARNING
Battery, Battery: Removal - Refitting ).
WARNING

- Run the engine at idle speed,
- accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.

( 4 Nm ) .
- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel in-
jection, Injector rail protector: Removal - Refit-
ting ).
- Refit the air inlet duct (see 12A, Fuel mixture, Air
13B-99
DIESEL INJECTION
F9Q, and 804

IMPORTANT
Mot. 1668 Locking high pressure
pump sprocket
Mot. 1525 Extractor for timing tem, check using the diagnostic tool :
gear with tapered hub - that the injector rail is not under pressure,
Mot. 1525-03 Adapter claws for Mot. - that the fuel temperature is not too high.
1525 (for 33-tooth pul- Loosening a high-pressure pipe union when the
ley) engine is running is strictly prohibited.
sure pump pipe WARNING
Mot. 1566 Wrench for removing Ensure that any high-pressure pipe removed is
high-pressure pipes replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high-pressure pump
and the injectors is prohibited.
Tightening torquesm
It is essential to read the repair precautions (see 13A,
high-pressure pump 30 Nm Diesel injection, Repair precautions ).
pump supports REMOVAL
high-pressure pump 50 Nm Put the vehicle on a two-post lift.
pulley nut
high-pressure pump 20 Nm + 80 terminal.
support mounting bolts Remove:
on the cylinder head
high-pressure pump 44 Nm engine, Accessories belts ),
rear support mounting - the timing belt (see 11A, Top and front of engine,
bolts on the cylinder Timing belt ).
block
high-pressure pump 30 Nm
rear pump support

bolts
pipe nut on the pump
side
pipe nut on the rail side

bolts
13B-100
DIESEL INJECTION
F9Q, and 804
111888
Remove the injector rail protector (see 13B, Diesel
injection, Injector rail protector: Removal - Refit-
ting ).
Disconnect:
102353
- the diesel fuel heater from the diesel filter,
Remove the pump - rail high-pressure pipe (3) .
- the heater plugs,
Plug the openings.
- the pressure regulator (1) ,
102348
102351
Remove the bolts mounting the high-pressure pump
Disconnect the diesel supply and return pipes (2) .
to the high-pressure pump rear support.
Plug the openings.
Remove the diesel pipes retaining clip.
13B-101
DIESEL INJECTION
F9Q, and 804
102350 102894
Remove: Set the pulley extractor (Mot. 1525) in place; fitted
- the bolts (5) mounting the high-pressure pump with claws (Mot. 1525-03) (8) for pulleys with thirty-
front support, three teeth.
- the high-pressure pump, with the high-pressure Remove the pulley by tightening the pulley extractor
pump support. 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 102345
pulley.
Remove:
- the high-pressure pump mounting bolts (10) ,
13B-102
DIESEL INJECTION
F9Q, and 804
REFITTING - the high-pressure pump mounting bolts on the

rear pump support ( 30 Nm ) .
WARNING II - REFITTING THE PUMP-RAIL HIGH-PRESSURE

Do not remove the blanking plugs from each PUMP
component until the last moment. Undo the injector rail mounting bolts (the injector rail
should be loose ).
Refit the high-pressure pump on the pump support.
Tighten to torque:
WARNING
- the high-pressure pump mounting bolts on the - Be careful not to allow oil into the high-pressure
pump supports ( 30 Nm ) , pipe.
- the high-pressure pump pulley nut ( 50 Nm ) by - Do not put high-pressure pipes under stress.
immobilising the pulley with (Mot. 1668) .
WARNING
Refit a new pump-rail high-pressure pipe.

Tighten to torque the injector rail mounting bolts (
25 Nm ) .
- 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 ) .
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 as-
sembly.
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 sup-
port against the high-pressure pump and the cylin-
der block.
Tighten to torque:
- the high-pressure pump rear support mounting
bolts on the cylinder block ( 44 Nm ) ,
13B-103
DIESEL INJECTION
F9Q, and 804
Refit:
Timing belt ),
engine, Accessories belts ),
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ).
Note:

pump.
nal.
WARNING
WARNING

- Run the engine at idle speed,
- Switch off the ignition,
Remove the air inlet duct.

Refit the injector rail protector (see 13B, Diesel in-
ting ).
Refit the air inlet duct (see 12A, Fuel mixture, Air
( 4 Nm ) .
13B-104
DIESEL INJECTION
K9K, and 732

IMPORTANT
Mot. 855 Timing gear locking
strap. Before carrying out any work on the injection sys-
Mot. 1768 SIEMENS injection
- that the injector rail is not under pressure,
pump pulley extractor
claws - that the fuel temperature is not too high.
It is essential to respect the safety and cleanliness
tightening high pres- advice given in this document whenever work is
sure pump pipe
tion, cleanliness guidelines ).
high-pressure pipes
REMOVAL
Equipment required
diagnostic tool
Tightening torquesm Switch off the ignition and wait 30 seconds before
starting work on the injection system.
pulley mounting bolt Remove the engine covers.
high-pressure pump 21 Nm Disconnect the battery (see 80A, Battery: Removal

mounting bolts - Refitting .
high-pressure pipe nuts 24 Nm
WARNING
Before starting work on the vehicle, have to hand:

- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING

- 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
K9K, and 732
- the injector rail protector cover
Disconnect:
- the rail pressure sensor connector,
- the fuel flow actuator connector,
- the fuel temperature sensor connector.
Clean (see 13B, Diesel injection, Repair precau-
tions ):
- the fuel return pipe connecting the injectors,
- the fuel inlet pipe.
111748
Disconnect:
Remove:
high-pressure pump, - the mounting bolts (3) from the dipstick guide on
the mounting of the diesel anti-splash device.
- the fuel inlet pipe.
- the bolt (4) and mounting nuts (5) from the injector
Note: rail protector cover support.
Make preparations for the fuel outflow, Move the wiring harness to one side.
Clean with new wipes. Unpick the drain pipe on the injector rail protector
cover support.
WARNING Clean the high-pressure pipe between the high-

- Strictly observe the cleanliness guidelines. pressure pump and injector rail (see 13B, Diesel in-
jection, Repair precautions ).
- Beware of diesel fuel splashing when discon-
necting the supply unions. Remove:
Fit blanking plugs into the openings (see 13B, Die- - the injector rail protector cover support,
sel injection, Cleanliness guidelines ).
Remove: - the high-pressure pipe between the high-pressure
pump and rail.
- the accessories belt (see section 10A, Accesso-
ries belt: Removal - Refitting ).
- the timing belt (see section 10A, Timing belt: Re- Note:
moval - Refitting ). Make preparations for fuel outflow,
Clean with new wipes.
WARNING
When loosening the union of the high-pressure
pipe on the high-pressure pump, the interme-
diate 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
K9K, and 732
CONCERNED
REMOVAL OF THE HIGH-PRESSURE PUMP
Remove:
- the high-pressure pump mounting bolts,
WARNING
If the high-pressure pump is to be reused, keep it
in a sealed plastic bag all the time it is discon-
nected.
REMOVAL OF THE HIGH-PRESSURE PUMP

PULLEY 111744
WARNING Note:
When replacing a high-pressure pump, retain the The high-pressure pump pulley can also be
high-pressure pump pulley and refit on the new immobilised using the (Mot. 855) .
pump.
Fit (Mot. 1768) on the high-pressure pump pulley
then extract the pulley.
Hold the high-pressure pump in a vice, using the
lower securing point on the pulley side.
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 recon-
necting 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
K9K, and 732
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 refitted.
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 moun-
ting 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 applica-
tor, lubrication of the pipe threads will be unne-
cessary (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-108
DIESEL INJECTION
K9K, and 732
Refit: WARNING
- the injector rail protector cover support,
Confirm that there are no diesel fuel leaks:
- the injector rail protector cover support mounting - Check the tightness after repair (see 13B, Die-
nuts and bolt, sel injection, High-pressure pipe: test ),
- the dipstick guide, - run the engine at idle speed,
- the dipstick guide mounting bolts. - accelerate several times at no load,
- Check that there are no diesel fuel leaks
Note: Using diagnostic tool , check that there are no sto-
Ensure that the injector rail protector support red faults. Clear them if necessary.
mounting bolt does not fall under the high-pres-
sure pump.
Connect:
- the drain pipe to the injector rail protector cover
support
- the fuel flow actuator connector,

high-pressure pump,

- 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: Re-

moval - Refitting ),
- the accessories belt (see section 10A, Accesso-
ries belt: Removal - Refitting ).
- the injector rail protector cover,
Clip the air inlet duct onto the turbocharger.
Refit the inlet duct mounting bolt.
Refit the battery (see 80A, Battery: Removal - Re-

fitting ).
Reprime the fuel circuit using the priming pump.

Using the diagnostic tool , clear any faults stored
by the injection computer, before restarting the engi-
ne.
13B-109
DIESEL INJECTION
M9R, and 700
REMOVAL
Mot. 1566 Wrench for removing I - REMOVAL PREPARATION OPERATION

high-pressure pipes
Mot. 1746 Offset spanner for advice whenever work is carried out on this system
tightening high pres- (see 13B, Diesel injection, Repair precautions).
sure pump pipe
Equipment required IMPORTANT
diagnostic tool Before carrying out any work on the injection sys-
Tightening torquesm
- that the fuel temperature is not too high.
mounting bolts Loosening a high-pressure pipe union when the
high-pressure pipe 32 Nm
union on the high-pres-
sure pump WARNING
Obtain a set of special high-pressure injection
high-pressure pipe 32 Nm circuit plugs.
union on the injector rail
Ensure that any high-pressure pipe removed is
high-pressure pipe 10 Nm replaced.
retaining bracket moun-
ting bolts on the bea- Position the vehicle on the two-post lift (see 02A,
ring cap casing Lifting equipment, Underbody lift ).
clips on the air filter 5.5 Nm Remove:

duct at the turbochar-
- the engine protector,
ger inlet
bolts securing the tur- 8 Nm Refitting ).
bocharger outlet air duct
on the inlet manifold Remove the high-pressure pipe between the high-
pressure 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.

CONCERNED
Remove:
- the high-pressure pump mounting bolts,

13B-110
DIESEL INJECTION
M9R, and 700
REFITTING

Always replace:
- the high-pressure pump O-ring seal,
- the high-pressure pump mounting bolt.
WARNING
Lubricate the new high-pressure pump seal with en-

gine oil.

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
M9R, and 700
Proceed in the reverse order to removal. WARNING
Remove the wiring harness and fuel pipe as- Confirm that there is no diesel fuel leak:
sembly.
- run the engine at idle speed,
WARNING - carry out a road test,
Do not lubricate high-pressure pipes supplied
pipes are self-lubricating. - check that there is no diesel fuel escaping.
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.
- the high-pressure pipe union on the high-pres-

sure pump ( 32 Nm ) , using (Mot. 1566) ,
- the high-pressure pipe union on the injector rail

( 32 Nm ) , using (Mot. 1746) ,
- the high-pressure pipe retaining bracket moun-

ting bolts on the bearing cap casing ( 10 Nm ) .
Tighten to torque:
- the clips on the air filter duct at the turbochar-

ger inlet ( 5.5 Nm ) ,
- the bolts securing the turbocharger outlet air

duct on the inlet manifold ( 8 Nm ) .

pump.

nal.
WARNING
13B-112
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728 or 729
Equipment required
WARNING
diagnostic tool
- a new set of blanking plugs (part no.: 77 01 206
Tightening torquesm 804 ),
injector mounting brac- 28 Nm - cleaning cloths (part no.: 77 11 211 707 ),

ket - cleaning product (part no.: 77 11 224 188 ).
rail mounting nuts 28 Nm

REMOVAL
of the pump-rail
of the injector rail Remove the engine undertray.
of the neck on the rail 21 Nm Removal - Refitting ).
Disconnect:
IMPORTANT - the heater plugs,
Before any operation on the injection circuit, use the - the connectors to injectors no. 3 and no. 4.
diagnostic tool to check that the injector rail is no
longer under pressure, and that the fuel tempera- - injector connectors no. 1 and no. 2.
ture is not too high.
advice specified in this document whenever work is
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 ,
102362
- 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 ).
13B-113
DIESEL INJECTION
K9K, and 722 or 728 or 729
109463 109467
Disconnect the injector diesel return pipe (2) . Disconnect the high-pressure pump electrical con-
nectors (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 pi-
pes.
Clean the high-pressure pipe (see 13B, Diesel in-
jection, Diesel injection: Precautions during re-
pair ).
Remove the injector-rail high-pressure pipe con-
cerned.
13B-114
DIESEL INJECTION
K9K, and 722 or 728 or 729
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
WARNING
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 in-

jector in relation to its cylinder.
Note: 19724
an injector corresponds to a cylinder. Using cloths (part no.: 77 11 211 707 ) soaked in
fresh solvent, clean:
Pull off the compression washer.
- the injector wells,
- the injector bodies,

REFITTING
- the injector brackets.
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,
Note:
- an emery cloth,
If one or more injectors are replaced, note the
- an ultrasonic cleaner. alphanumeric code (C2I) (7) and the cylinder on
which it is fitted.
Soak the injectors in degreaser.
Tighten to torque the injector mounting bracket (
Wipe with new cloths (part no.: 77 11 211 707 ). 28 Nm ) .
13B-115
DIESEL INJECTION
K9K, and 722 or 728 or 729
III - FINAL OPERATION If removing the four injectors, torque tighten the rail

pipe nuts of the pump-rail ( 24 Nm ) :
- high-pressure pump end,
- rail end.

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 Torque tighten the nuts of the neck on the rail ( 21

Before fitting a new high-pressure pipe, lightly Nm )
lubricate the nut threads with oil from the applica-
tor provided with the new part. Connect:
Be careful not to allow oil into the high-pressure
- the injector diesel fuel return pipe,
pipe.
Do not lubricate high-pressure pipes supplied - the connectors to injectors no. 1 and no. 2,
without an applicator; these pipes are self-lubri-
cating. - the connectors to injectors no. 3 and no. 4.
- the heater plugs.

WARNING
Do not remove the blanking plugs from each Connect the battery (see 80A, Battery, Battery: Re-
component until the last moment. moval - Refitting ).
Insert the high-pressure pipe olive in the injector Refit the engine undertray.
Program the alphanumeric code (C2I) for the repla-
Insert the high-pressure pipe olive into the rail high-
ced injector(s) using diagnostic tool (see 13B, Die-
pressure conical outlet.
sel injection, Injectors: configuration ).
with the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts. WARNING

Note:
- Run the engine until the fan starts up.
The assembly order of the injector-rail high-
- Accelerate several times at no load.
pressure pipes is not important.
- Switch off the ignition.
Fit the new clip provided with the new high-pressure
pipe. - Check that there is no diesel fuel escaping.
13B-116
DIESEL INJECTION
F9Q, and 800 or 804 or 808
For versions without injector rail protectors:
- remove the inlet duct (see 12A, Fuel mixture, Air
Mot. 1566 Wrench for removing inlet duct: Removal - Refitting ), if necessary.
high-pressure pipes

sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector bracket bolt 25 Nm
nut on the injector side 25 Nm
nut on the rail side 29 Nm

bolts
IMPORTANT

It is essential to read the repair precautions whenever

work is carried out (see 13B, Diesel injection, Diesel
WARNING
Opening the injectors is prohibited.
Injectors may be replaced individually. Only remove

the high-pressure pipe concerned.
REMOVAL

terminal.
Remove the injector rail protector (see 13B, Diesel

injection, Injector rail protector: Removal - Refit-
ting ), if fitted to the vehicle.
13B-117
DIESEL INJECTION
F9Q, and 800 or 804 or 808
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.
13B-118
DIESEL INJECTION
F9Q, and 800 or 804 or 808
REFITTING
I - CLEANING INJECTORS (IF THEY ARE TO BE

REUSED)
WARNING

- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
Clean, using new cloths soaked in cleaning product

(see 13B, Diesel injection, Diesel injection: Re-
pair precautions ) clean:
- the injector wells,
- the injector bodies,
1327
- the injector brackets.
Remove the injector-rail high-pressure pipe
using (Mot. 1566) or (Mot. 1746) . Use a new cloth to dry components that have been
cleaned.
WARNING
II - REFITTING THE INJECTOR
The injector filter rod must not be removed.
WARNING
WARNING
Do not remove the protective caps from each
When loosening the injector pipe unions (2) on
the injectors, be sure to hold the filter rod retai-
ning nuts (3) with a lock wrench.

If an injector is reused, always mark a removed in-
jector 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.
13B-119
DIESEL INJECTION
F9Q, and 800 or 804 or 808
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 fitted on.
Refit the injector with its bracket.

Tighten to torque the injector bracket bolt ( 25 Nm
).
WARNING
Do not fit 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 filter rod mounting nuts on the
injector holder with a lock wrench when tighte-
ning.

- the nut on the injector side ( 25 Nm ) ,
- the nut on the rail side ( 29 Nm ) ,
13B-120
DIESEL INJECTION
F9Q, and 800 or 804 or 808
18297-1
Refit the return rail (5) . Program the alphanumeric code (IMA) for the injec-
tor(s) replaced using the diagnostic tool (see MR
366 Fault finding, 13B, Diesel injection, Fault fin-
Press the injector clip. ding - Replacement of components ).
Push the return rail end piece vertically.
Throw away the plug set upon completion of the WARNING
operation.
- Run the engine at idle speed.
inlet duct: Removal - Refitting ), if removed. - Accelerate several times at no load.
Note: - Check that there is no diesel fuel escaping.
For versions with injector rail protector covers: Tighten to torque the battery cover mounting bolts
- Refit the inlet duct without refitting the injector ( 4 Nm ) .
rail protector or replacing the duct seal.
Connect the battery, starting with the positive termi- - Remove the air inlet duct,
nal.
- Refit the injector rail protector (see 13B, Diesel in-
WARNING ting ).
Carry out the necessary programming (see 80A, - Refit the inlet duct (see 12A, Fuel mixture, Air in-
Battery: Removal - Refitting ). let duct: Removal - Refitting ).
13B-121
DIESEL INJECTION
K9K, and 732

IMPORTANT
high-pressure pipes Before carrying out any work on the injection sys-
Mot. 1746 Offset spanner for - that the injector rail is not under pressure,
sure pump pipe - that the fuel temperature is not too high.
Equipment required advice given in this document whenever work is
diagnostic tool tion, cleanliness guidelines ).
Tightening torquesm REMOVAL

injector bracket moun- 30 Nm
ting bolt I - REMOVAL PREPARATION OPERATION
Switch off the ignition and wait 30 seconds before
nuts
air inlet duct clip 5.5 Nm Removal - Refitting ).
WARNING

WARNING
Parts always to be replaced: 112815

- all the high-pressure pipes which have been remo- Disconnect the air inlet pressure sensor connector
ved. (1) .
- any injector that has been opened, contrary to ins- Loosen the clip and (2) move the air inlet duct aside
tructions, (3) .
- Any damaged mounting clips for the fuel return
pipe on the injector must be replaced.
- the compressor washer.
13B-122
DIESEL INJECTION
K9K, and 732
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
13B-123
DIESEL INJECTION
K9K, and 732
- the nut of the high-pressure pipe between the injec-
tor rail and the injector on the injector end,
Remove the high-pressure pipe in question and dis-

card it.
Note:
Make preparations for the fuel outflow. 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 con-
nector 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 filter rod retaining nut (11) with a lock
wrench.
111751
Remove:
Extract the fuel return connector from the injector
- the nut of the high-pressure pipe between the injec- while pushing the lower bracket of the retaining clip
tor rail and the injector on the rail end, downwards.
13B-124
DIESEL INJECTION
K9K, and 732
Fit the correct blanking plug.
Remove the fuel return pipe from the injector.

CONCERNED
114010
Note:
If the injector is jammed in its well and does not
come out, turn the injector at the flat support sur-
111746
faces of the injector bracket using a 13 mm open
Remove: end wrench.
- the injector bracket mounting bolt (13) ,
Fit the appropriate blanking plug on the injector's no-
- the injector bracket, se.
- the spacer between the cylinder head and the in-
jector bracket, WARNING
- the injector, If it is to be reused, keep the injector(s) in a sea-
- the compression washer located at the bottom of led plastic bag until required.
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
orifice 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 refitting them.
13B-125
DIESEL INJECTION
K9K, and 732
112993 112994
- the injector connector (14) , - the connector (16) from the damper valve,
- the heater plugs connector (15) . - the cylinder marking sensor connector (17) ,
- the pressure regulation solenoid valve connector
(18) ,
13B-126
DIESEL INJECTION
K9K, and 732
- the injector rail protector support.
Undo the injector rail mounting nuts by a few turns
(the injector rail should be loose).
REFITTING
Cleaning the injectors
WARNING

- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
112656
Clean the fuel supply and return pipe unions (see Leave the injectors to soak in cleaner fluid.
13B, Repair Precautions ). Clean using new wipes.
Disconnect:
- the fuel supply pipe (23) , WARNING
- the fuel return pipe (24) . Only remove the blanking plugs immediately
before connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;
Note: dispose of the whole set after use.
Make preparations for the fuel outflo w. Clean with
new wipes. Remove the injector from its plastic bag.
Fit blanking plugs,

WARNING
If replacing the injector, do not remove it (them)
from its (their) packaging until just before you refit
it (them).
Remove the blanking plugs on the nose of the injec-

tor.

CONCERNED
Refit:
- a new compression washer at the bottom of the in-
jector well in the cylinder head,
111748 - the injector,

Unclip the diesel evacuation pipe. - the spacer between the cylinder head and the in-
jector bracket,
Remove:
- the injector bracket,
- the injector rail protector support bolt and mounting
nuts (25) , - the injector bracket mounting bolt.
13B-127
DIESEL INJECTION
K9K, and 732
Tighten to torque the injector bracket mounting Remove the blanking plugs.
bolt ( 30 Nm ) .
Push the retaining clip of the fuel return connector
Remove the blanking plugs. on the injector to the front of the vehicle in order to
Fit the new high-pressure pipe(s) between the injec- place it in its initial position.
tor rail and the injector.
Clip on the fuel return connector of the injector.
Note:
WARNING
If the new pipes kit does not contain an applica-
tor, lubrication of the pipe threads will be unne- Check the condition of the seal on the fuel return
cessary (as they are self-lubricating pipes). connector of the injector.
Change the diesel return rail if one of its compo-
Finger tighten the high-pressure pipe nuts, starting nents is damaged.
with the one at the injector rail side.
1 - Refit the four high-pressure pipes III - FINAL OPERATION
Tighten to torque the injector rail mounting nuts ( Refit:

28 Nm ) .
- the dipstick tube mounting bolts.
Refit:
- the injector rail protector support, - the dipstick,
- the mounting nuts and bolt of the injector rail pro- - the injector rail protector cover mounting nut and
tector support. bolt,
Clip the diesel evacuation pipe. Clip injector rail protector cover.
Remove the blanking plugs.
Refit:
Connect:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning the
- fuel return pipe.
markings,
Fit the wiring harness.
- the air inlet duct clip between the turbocharger and
Refit the mounting nut of the wiring harness clip. the intercooler.
Clip on the retaining clip of the wiring harness.
Tighten the air inlet duct clip ( 5.5 Nm ) .
Connect:
- the diesel fuel temperature sensor connector, Refit:
- the connector of the flow regulation solenoid valve, - the stainless steel pipe mounting bolt,
- the connector of the pressure regulation solenoid - the air inlet duct on the damper valve.
valve,
- the cylinder marking sensor connector, Tighten the clip.
- the connector on the damper valve, Connect:
- the heater plugs connector, - the connector of the air inlet pressure sensor,
- the injectors' connector.
Refitting ).
2 - All types
Reprime the fuel circuit with the manual priming
Tighten to torque the high-pressure pipe nuts ( 24 pump.
Nm ) using (Mot. 1566) or (Mot. 1746) and starting
at the injector rail end. Refit the engine covers.
13B-128
DIESEL INJECTION
K9K, and 732
ne.
WARNING
- Check the tightness after repair (see 13B, Die-
sel injection, High-pressure pipe: Check ),
- check for leaks and for diesel fuel outflow.
Using diagnostic tool , check that there are no sto-

red faults; clear if necessary.
13B-129
DIESEL INJECTION
Injectors: Configuration 13B
K9K, and 722 or 728 or 729 or 732
REPLACING THE INJECTORS
Note:
The C2I (individual injector correction) parameters
are a factory calibration carried out on each injector
to adjust the flow 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 dif-
ferences 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 re-
entered into the computer using the following com-
mands:
- To enter the four C2Is when replacing the computer,
run the SC002 Enter injector codes .
- To enter an individual C2I parameter, when replacing
one or more injectors, enter the following commands:
cylinder 1 injector: control VP001 (flywheel end cy-
linder),
cylinder 2 injector, command: control VP002 ,
cylinder injector 3: control VP003 ,
cylinder injector 4: control VP004 .
By using the relevant command, the technician can re-
enter the new C2I parameters for the injector 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 13B
F9Q, and 800 or 808
reconfigure the computer for the equipment (air con-
ditioning),
Equipment required
make sure, using the diagnostic tool CLIP, that the
diagnostic tool 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 injec-
tors. 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 compu-
ter. 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,
computer has not detected any faults relating to the
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,
transfer the data from the diagnostic tool CLIP to
the new computer,

computer has not detected any faults relating to the
light is off.
- if it is not possible to establish dialogue with 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 13B
K9K, and 732
REMOVAL

high-pressure pipes
Mot. 1746 Offset spanner for Switch off the ignition and wait 30 seconds before
tightening high pres- starting work on the injection system.
sure pump pipe
Equipment required Disconnect the battery (see 80A, Battery, Battery:

diagnostic tool
Tightening torquesm

nuts
WARNING

- some cleaning cloths (part no. 77 11 211 707) , 112815
- cleaning product (part no. 77 11 224 188) . Disconnect the air inlet pressure sensor connector
(1) .
Loosen the clip (2) and move the air inlet duct aside
WARNING (3) .

- all the high-pressure pipes which have been remo-
ved.
IMPORTANT
tion, cleanliness guidelines ).
112811
Pull out the clip.
13B-132
DIESEL INJECTION
K9K, and 732
Move the dipstick pipe to one side.
Clean the high-pressure pipe unions between the in-

jector rail and injectors (see 13B, Repair precau-
tions ).

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 filter rod retaining nut (10) with a lock
wrench.
Remove:

tor rail and the injector on the rail end,

tor rail and the injector on the injector end,
112992
Unclip the injector rail protector cover (6) . Remove the high-pressure pipe in question and dis-
card it.
Remove:
protector cover, Note:
- the injector rail protector cover, Make preparations for the fuel outflow. Clean with
new wipes.
- the dipstick,
- the dipstick pipe mounting bolts (8) . Fit blanking plugs,
13B-133
DIESEL INJECTION
K9K, and 732
Removing the four high-pressure pipes
Note:
This procedure only applies if removing all the
high-pressure pipes and, after having removed
them all, in preparation for refitting them.
112994
Disconnect:
- the cylinder marking sensor connector (14) ,
(15) ,
112993 - the flow regulation solenoid valve connector (16) ,
Disconnect:
- the injector connector (11) ,
- the heater plugs connector (12) .
13B-134
DIESEL INJECTION
K9K, and 732
111748
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support bolt and mounting
nuts (22) ,
112656
- the injector rail protector support,
- the fuel supply and return pipes.
Clean the fuel supply and return pipes unions (see
13B, Repair Precautions ). Clean the unions (see 13B, Repair precautions ):
Disconnect: - of the fuel return pipe on the high-pressure pump
and injector rail,
- the fuel inlet pipe (20) ,
- on the high-pressure pipe between the high-pres-
sure pump and the injector rail,
Note:
REFITTING
Make preparations for the fuel outflo w. Clean with
new wipes.
Fit blanking plugs,
WARNING
Only remove the blanking plugs immediately
dispose of the whole set after use.
Take the new high-pressure pipe out of its plastic

bag.
13B-135
DIESEL INJECTION
K9K, and 732
II - REFITTING OPERATION FOR PART III - FINAL OPERATION
CONCERNED
Refit:
Fit the new high-pressure pipe between the injector
rail and the injector. - the dipstick tube mounting bolts.
Note: - the dipstick,
If the new pipes kit does not contain an applica- - the injector rail protector cover,
cessary (as they are self-lubricating pipes). - the injector rail protector cover mounting nut and
bolt,
with the one at the injector rail side. Clip injector rail protector cover.

1 - Refit the four high-pressure pipes ry.
Tighten to torque the injector rail mounting nuts (
28 Nm ) . Clip the stainless steel pipe to turbocharger.
Refit: Refit:
- the mounting nuts and bolt of the injector rail pro-
tector support. - the air inlet duct on the damper valve.
Clip the diesel evacuation pipe.
Tighten the clamp.
Connect:
Connect:
- the fuel supply pipe, - the connector of the air inlet pressure sensor,
- fuel return pipe. - the battery (see 80A, Battery, Battery: Removal -
Fit the wiring harness. Refitting ).
Refit the mounting nut of the wiring harness clip. Reprime the fuel circuit with the manual priming
Clip the retaining clip of the wiring harness into pla- pump.
ce.
Connect:
- the diesel fuel temperature sensor connector, ne.
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoid WARNING
valve, Confirm that there is no diesel fuel leak:
- the cylinder marking sensor connector, - Check the tightness after repair (see 13B, Die-
- the connector on the damper valve, sel injection, High-pressure pipe: Check ),
- the heater plugs connector, - run the engine at idle speed,
- the injectors' connector. - accelerate several times at no load,

2 - All types - check for leaks and for diesel fuel outflow.
Tighten to torque the high-pressure pipe nuts ( 24
Nm ) using (Mot. 1566) or (Mot. 1746) and starting Use diagnostic tool to check for stored faults. Clear
with the injector rail side. them if necessary.
13B-136
DIESEL INJECTION
K9K, and 722 or 724 or 728 or 729
Equipment required
WARNING
diagnostic tool
Tightening torquesm
- 77 01 207 025 ,
nuts - 77 01 207 026 ,
- 77 01 207 027 ,
pump-rail high- 24 Nm
pressure pipe nuts - 77 01 207 028 ,
- 77 01 207 029 .
of the injector rail For high-pressure pipes with different part numbers,
nuts of the neck on the 21 Nm
rail
REMOVAL

IMPORTANT Disconnect the battery (see 80A, Battery, Battery:
advice whenever work is carr ied out on this system.
engine is running is prohibited.
WARNING

112331
- a new set of blanking plugs (part no.: 77 01 206 Remove the turbocharging duct retaining pin (1)
804 ), from the turbocharger.
- cleaning cloths (part no.: 77 11 211 707 ), Remove the duct mounting bolt on the cylinder
- cleaning product (part no.: 77 11 224 188 ). 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
K9K, and 722 or 724 or 728 or 729
K9K, and 724 K9K, and 722 or 728 or 729
109473
102362
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
K9K, and 722 or 724 or 728 or 729
REFITTING
109467
Disconnect the high-pressure pump electrical con-
nectors (9) .
Remove the mounting bolts from the neck (10) fixed 20960
to the spherical injector rail.
Move the electric wiring harness and neck to the
side as shown by the arrow. WARNING
Before fitting a new high-pressure pipe, lightly
Loosen the injector rail mounting nuts by several
turns. lubricate the nut threads with oil from the applica-
tor provided in the new part.
Remove the clips connecting the high-pressure pi-
pes. Be careful not to allow oil into the high-pressure
pipe.
II - REMOVAL OF PART CONCERNED Do not lubricate high-pressure pipes supplied

Clean the pipe(s) to be removed (see 13B, Diesel pipes are self-lubricating.
injection, Diesel injection: Repair precautions .
Loosen:
WARNING
- the high-pressure nut at the injector end,
Leave removal of the blanking plugs from any
- the high-pressure pipe nut at the injector rail end. component until last.
If replacing the four high-pressure pipes:
Throw away the pipe.
- remove the anti-splash cover mounting,
- Undo the injector rail mounting nuts by a few turns

(the injector rail should be loose).

CONCERNED

Insert the high-pressure pipe olive in the injector
13B-139
DIESEL INJECTION
K9K, and 722 or 724 or 728 or 729
Insert the high-pressure pipe olive in the rail high- Fit the turbocharger air duct.
pressure outlet taper.
Lock the air duct between the turbocharger and the
Finger tighten the high-pressure pipe nuts, starting intercooler air inlet pipe.
with the nut at the injector end.
Tighten the bolt of the air duct on the rocker cover.
Note: Prime the diesel circuit using the priming pump.
The assembly order of the injector-rail high-
pressure pipes is not important. WARNING
Fit the new clip provided with the new high-pressure
pipe.
- check the seal after repair,
If replacing the four high-pressure pipes, torque tigh-
ten the injector rail mounting nuts ( 28 Nm ) . - let the engine run at idle speed until the engine
Tighten to torque and in order the pump-rail
high-pressure pipe nuts ( 24 Nm ) : - accelerate several times at no load,
- pump end, - switch off the ignition,
- rail end. - confirm that there is no diesel fuel leak.

pipe nuts of the injector rail ( 24 Nm ) .
- injectors end,
- rail end.
Note:
Tighten a pipe fully before moving on to the next
pipe.

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.
Refit the inlet duct and tighten its clip.

Connect the inlet air pressure sensor
13B-140
DIESEL INJECTION
M9R, and 700
- the oil separator (see 13B, Diesel injection, Oil
Special tooling required separator: Removal - Refitting ).
high-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
rail-injector high- 32 Nm
pressure pipe mounting
nuts
diesel return pipe 10 Nm

mounting bolt on the 113142
rocker cover Remove the bolt mounting the diesel return pipe on
the rocker cover.
Disconnect the quick-release union from the diesel
WARNING return pipe.
Lift the mobile section of the diesel return pipe on the
injectors.
tem, use the diagnostic tool to check that:
Remove the diesel return pipe.
- the rail is not under pressure,
The cleanliness and safety advice specified in this
document must be followed during each operation.
WARNING
Obtain the special high-pressure injection circuit
plug kit.
Always replace any high-pressure pipe or high-
pressure pipe clip removed with a new one.
REMOVAL

Remove:

).
13B-141
DIESEL INJECTION
M9R, and 700
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED 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
Using (Mot. 1566) , loosen: Refit:
- the high-pressure nut at the injector end, - the diesel return pipe,
- the bolt mounting the diesel return pipe on the roc-
- the high-pressure pipe nut at the injector rail end.
ker cover
Drive the mobile section of the diesel return pipe into
Note: the injectors.
Loosen the nuts pipe by pipe. Tighten to torque the diesel return pipe mounting
bolt on the rocker cover ( 10 Nm ) .
Move the nuts along the tube, keeping the olive in Connect the quick-release union to the diesel return
contact with the taper. pipe.
Remove the high-pressure pipes one by one. Refit:

- the oil separator (see 13B, Diesel injection, Oil
Plug the openings. separator: Removal - Refitting ).
REFITTING tion, Injector rail protector: Removal - Refitting
).
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
13B-142
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728 or 729

WARNING
sure pump pipe
Mot. 1566 Wrench for removing following part numbers:
high-pressure pipes - 77 01 207 025 ,
- 77 01 207 026 ,
Equipment required
- 77 01 207 027 ,
diagnostic tool
- 77 01 207 028 ,
- 77 01 207 029 .
Tightening torquesm
injector rail mounting 28 Nm tighten to torque 24 Nm .
nuts
high-pressure pipe nuts 24 Nm REMOVAL

between the injector rail
and the injectors I - REMOVAL PREPARATION OPERATION
high-pressure pipe nuts 24 Nm Position the vehicle on a lift (see 02A, Lifting equi-
between the injector rail pment, Underbody lift ).
and the high-pressure
It is essential to read the repair precautions whene-
pump
ver work is carried out (see 13B, Diesel injection,
Diesel injection: Precautions during repair ).
WARNING Switch off the ignition and wait 30 seconds before

Before starting work on the vehicle, make sure you
have:
- a new blanking plug kit ( PART NO. 77 01 206 804
WARNING
),
- some wipes ( PART NO. 77 11 211 707 ), Before carrying out any work on the injection sys-
- cleaning product ( PART NO. 77 11 224 188 ).
- that the rail is not under pressure,
WARNING Disconnect the battery (see 80A, Battery, Battery:
- all the high-pressure pipes which have been remo-
ved.
13B-143
DIESEL INJECTION
K9K, and 722 or 728 or 729
109466 109467
Disconnect the injector connectors (1) and the hea- Disconnect:
ter plugs (2) .
- the connectors (4) for the flow actuator and the die-
sel fuel temperature sensor,
- the spherical rail pressure sensor (5) .
Move the electric wiring harness and channel to the
side as shown by the arrow.
Remove the mountings from the channel (6) fixed on
the spherical rail.
Clean the high-pressure pipes (see 13B, Diesel in-
jection, Diesel injection: Precautions during re-
pair ).
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Use wipes if necessary.
102362
13B-144
DIESEL INJECTION
K9K, and 722 or 728 or 729
CONCERNED
20803
Remove the clips between the high-pressure pipes.
20803
Loosen the nuts securing the high-pressure pipes
between the injector rail and the injector. Remove:
Remove the four high-pressure pipes and discard.
- the injector rail mounting nuts (8) ,
- the injector rail.

Note:
new wipes. WARNING
If the injector rail is to be reused, keep it in a sea-
led plastic bag all the time it is disconnected.
Remove the high-pressure pipe between the high-
pressure pump and the injector rail (7) .
REFITTING
Note:
Make preparations for the fuel outflo w. Clean with I - REFITTING PREPARATION OPERATION
new wipes.

WARNING
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 fitted.
13B-145
DIESEL INJECTION
K9K, and 722 or 728 or 729
II - REFITTING OPERATION FOR PART Reprime the fuel circuit.
CONCERNED
Fit the injector rail. moval - Refitting ).
Tighten the injector rail mounting bolts (the injector Confirm that there is no diesel fuel leak:
rail should be loose).
- check the seal after repair (see 13B, Diesel injec-
tion, Diesel injection: Repair precautions ),
Remove the blanking plugs from: cooling fan starts to operate,
- the high-pressure pump, - accelerate several times at no load,
- the injector rail fuel inlet opening. - check for leaks and for diesel fuel outflow.
Fit a new high-pressure pipe between the injector Use diagnostic tool to check for stored faults. Clear
rail and the high-pressure pump. them if necessary.
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unneces-
sary (as they are self-lubricating pipes).
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 unneces-
sary (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 injec-
tor rail and the injectors ( 24 Nm ) using (Mot.
1746) or (Mot. 1566) starting at the injector end,
tor 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.
13B-146
DIESEL INJECTION
F9Q, and 800 or 808

high-pressure pipes

sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm

bolts
nuts on the injector end 25 Nm

and the nut on the injec-
tion pump end
nuts on the rail end 29 Nm

bolts
IMPORTANT

It is essential to read the repair precautions (see 13B,

Diesel injection, Repair precautions ).
REMOVAL
Disconnect the battery, starting with the positive ter-
minal.
Remove:
- the air inlet duct (see 12A, Fuel mixture, Air inlet

), if fitted to the vehicle.
13B-147
DIESEL INJECTION
F9Q, and 800 or 808
18297-1
Disconnect: Plug the openings.

- the pressure sensor connector (1) ,
- the fuel temperature sensor connector,
- the cylinder marking sensor connector,
- the fuel return pipe on the injection pump side,
- the fuel return pipe on the diesel temperature sen-
sor side.
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.

Remove the diesel return pipe (4) .
13B-148
DIESEL INJECTION
F9Q, and 800 or 808
REFITTING
Position the injector rail.
WARNING
6 component until the last moment.
7
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,
the rail side.
1327
Remove the high-pressure diesel pipes 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 ) ,
WARNING
When loosening the injector pipe unions (6) on - the nuts on the rail end ( 29 Nm )
the injectors, be sure to hold the filter rod retai-
WARNING
Plug the openings. Do not put high-pressure pipes under stress.
Remove: Always hold the filter rod retaining nuts on the

injector holder when tightening.
- the injector rail bolts,
- the injector rail (5) .
13B-149
DIESEL INJECTION
F9Q, and 800 or 808
18297-1
Refit the return rail (4) :

- do not remove the clip from the injector, WARNING
- press the injector clip,
- push the return rail end piece vertically.
Throw away the plug set upon completion of the
operation. - accelerate several times at no load,
Proceed in the reverse order to removal. - switch off the ignition,
For versions with injector rail protector covers: - check that there is no diesel fuel escaping.
- Refit the air inlet duct (see 12A, Fuel mixture, Air Tighten to torque the battery cover mounting bolts
inlet duct: Removal - Refitting ). ( 4 Nm ) .
Note: - Remove the air inlet duct,
Refit the inlet duct without refitting the injector rail - Refit the injector rail protector (see 13B, Diesel in-
protector or refitting the duct seal. jection, Injector rail protector: Removal - Refit-
ting ), if fitted to the vehicle,
nal. - Refit the air inlet duct (see 12A, Fuel mixture, Air
WARNING
13B-150
DIESEL INJECTION
F9Q, and 804

high-pressure pipes
Mot. 1746 Offset spanner for 1

tightening high pres- 2
sure pump pipe
Equipment required
diagnostic tool
3
Tightening torquesm
111965
injector rail mounting 25 Nm Disconnect:
bolts
nuts on the injector side 25 Nm - the cylinder marking sensor connector (2) ,
and the nut on the injec-
tor pump side - the fuel return pipe.
Plug the openings.
nuts on the rail side 29 Nm
bolts
Remove the diesel return pipe (3) .
IMPORTANT
Plug the openings.
It is essential to read the repair precautions (see 13B,

Diesel injection, Repair precautions ).
REMOVAL
terminal.
Remove:
).
13B-151
DIESEL INJECTION
F9Q, and 804
REFITTING
4 Position the injector rail.
WARNING
with a new one.
5
Tighten the injector rail bolts, leaving clearance
between the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
the pump and injector side,
the rail side.
1327
- the injector rail mounting bolts ( 25 Nm )
Remove the high-pressure diesel pipes using (Mot. - the nuts on the injector side and the nut on the
1566) or (Mot. 1746) . injector pump side ( 25 Nm )
- the nuts on the rail side ( 29 Nm )
WARNING
When loosening the injector pipe unions (4) on WARNING
the injectors, be sure to hold the filter rod retai- Do not put high-pressure pipes under stress.
Do not touch the high-pressure pipes with the
spanner when tightening them.
Plug the openings.
Always hold the filter rod retaining nuts on the
Remove the oil separator. injector holder when tightening.
111859
Remove:
- the injector rail bolts (6) ,
- the injector rail (7) .
13B-152
DIESEL INJECTION
F9Q, and 804
Refit the injector rail protector (see 13B, Diesel in-
ting ).
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.
Note:

nal.
WARNING
WARNING


( 4 Nm ) .
Remove the air inlet duct.
13B-153
DIESEL INJECTION
K9K, and 732

IMPORTANT
high-pressure pipes Before carrying out any work on the injection sys-
Mot. 1746 Offset spanner for - that the injector rail is not under pressure,
sure pump pipe - that the fuel temperature is not too high.
Equipment required advice given in this document whenever work is
diagnostic tool tion, cleanliness guidelines ).
Tightening torquesm REMOVAL

nuts I - REMOVAL PREPARATION OPERATION
between the injector rail
and the injectors Remove the engine covers
high-pressure pipe nuts 24 Nm Disconnect the battery (see 80A, Battery, Battery:
between the injector rail Removal - Refitting ).
and the high-pressure
pump
air inlet duct clip 5.5 Nm
WARNING

112815
WARNING Disconnect the air inlet pressure sensor connector

(1) .
Parts always to be replaced: Loosen the clip and (2) move the air inlet duct aside
- all the high-pressure pipes which have been remo- (3) .
ved.
13B-154
DIESEL INJECTION
K9K, and 732
112811 112992
Pull out the clip. Unclip injector rail protector cover (6) .
Remove:
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)
112993
Disconnect:
- the injector connector (9) ,
13B-155
DIESEL INJECTION
K9K, and 732
- the heater plugs connector (10) .
112656
112994 Protect the alternator from fuel outflow.
Disconnect:
Clean (see 13B, Repair precautions ):
- the cylinder marking sensor connector (12) ,
Disconnect:
(13) ,
Unclip the wiring harness retaining clip (16) . new wipes.
Fit blanking plugs,
13B-156
DIESEL INJECTION
K9K, and 732
111748
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support mounting bolt and
mounting nuts,
1327
- the injector rail protector support.
Clean (see 13B, Repair precautions ):
WARNING
- the high-pressure pipes between the injector rail
When loosening the high-pressure pipe unions
and the injectors,
(21) on the injector holder, it is essential to hold
- the high-pressure pipes (19) between the high- the filter rod mounting nut (22) with a lock
pressure pump and the injector rail. 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:
new wipes.
Fit blanking plugs,
13B-157
DIESEL INJECTION
K9K, and 732
Remove the high-pressure pipe between the high- REFITTING
pressure pump and the injector rail and dispose of it
in a bin.
WARNING
When loosening the connector of the high-pres- WARNING
sure pipe, the intermediate nut must be secured
on the pump using a lock wrench.
Note: dispose of the whole set after use.
Take the injector rail out of its plastic bag.
new wipes.
II - OPERATION FOR REMOVAL OF PART WARNING

CONCERNED If an injector rail is being replaced, only remove
the new one from its original packaging when it is
about to be fitted.

CONCERNED
Finger tighten the injector rail mounting bolts.
Fit the new high-pressure pipe between the injector

rail and the high-pressure pump.
Note:
cessary (as they are self-lubricating pipes).
111745 Finger tighten the high-pressure pipe nuts, starting

Remove: with the one at the injector rail side.
- the injector rail mounting nuts (23) , Remove the blanking plugs.
- the injector rail. Fit the new high-pressure pipes between the injector
rail and the injectors.
WARNING
If the injector rail is to be reused, keep it in a sea- Note:
led plastic bag all the time it is disconnected.
tor, lubrication of the nut threads will be unneces-
sar y (as they are self-lubricating pipes).

with the one at the injector rail side.
Tighten to torque the injector rail mounting nuts (

28 Nm ) .
13B-158
DIESEL INJECTION
K9K, and 732
Tighten to torque: - the injector rail protector cover mounting nut and
bolt,
tor rail and the injectors ( 24 Nm ) using (Mot.
Clip injector rail protector cover.
1566) or (Mot. 1746) starting with the rail end.
- the high-pressure pipe nuts between the injec- Refit:
tor rail and the high-pressure pump ( 24 Nm )
using (Mot. 1566) or (Mot. 1746) starting with the - the clip on the stainless steel pipe if necessary,
high-pressure pump end.
markings,
Refit: - the clamp of the air inlet duct between the turbo-
charger and the intercooler.
Tighten the air inlet duct clip ( 5.5 Nm ) .
- the mounting nuts and bolt of the injector rail pro-
tector support.
Refit:
Note:
Ensure that the injector rail protector support - the stainless steel pipe mounting bolt,
mounting bolt does not fall under the high-pres-
sure pump. - the air inlet duct on the damper valve.
Clip the diesel evacuation pipe. Tighten the clamp.

Connect:
Connect:
- the connector to the air inlet pressure sensor,
- fuel return pipe. - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Fit the wiring harness.
Refit the mounting nut of the wiring harness clip. Reprime the fuel circuit with the manual priming
pump.
Clip the retaining clip of the wiring harness.
Connect: Refit the engine covers.
- the rail pressure sensor connector, Using the diagnostic tool , clear any faults stored
- the diesel fuel temperature sensor connector,
ne.
- the connector of the flow control solenoid valve,
- the connector of the pressure control solenoid val-
WARNING
ve,
- the cylinder marking sensor connector,
- the connector on the damper valve, sel injection, High-pressure pipe: Check ),
- the heater plugs connector, - run the engine at idle speed,
- the injectors' connector. - accelerate several times at no load,
Refit: - switch off the ignition,
- the dipstick tube mounting bolts. - check for leaks and for diesel fuel outflow.
- the dipstick,
Using diagnostic tool , check that there are no sto-
- the injector rail protector cover, red faults; clear if necessary.
13B-159
DIESEL INJECTION
Rail pressure sensor 13B
K9K, and 722 or 724 or 728 or 729 or 732
102086
Pressure sensor (1) cannot be removed from the sphe-
rical injector rail.
In the event of a pressure sensor fault, the rail pres-
sure sensor and high-pressure pipe assembly must
be replaced (see 13B, Diesel injection, Injector rail ).
13B-160
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
F9Q, and 800
Equipment required
diagnostic tool
Tightening torquesm
pressure sensor to tor- 3.5 daNm +/-

que 0.5
battery cover mounting 0.4 daNm

bolts to torque
IMPORTANT
Before starting any work on the injection circuit, use

the diagnostic tool to check that:
the injection rail is no longer pressurised,
the fuel temperature is not too high.
- Whenever work is carried out, it is essential to res-
pect the safety and cleanliness advice given in 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 cir-
cuit plugs.
- All high-pressure pipes must be replaced and any
removed high-pressure pipe clips.
13B-161
DIESEL INJECTION
F9Q, and 800
REMOVAL
18297-5
Disconnect:
- the battery, starting with the negative terminal.
- the pressure sensor.
Unscrew the pressure sensor.
13B-162
DIESEL INJECTION
F9Q, and 800
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 pro-
gramming (see (see 8, Electrical equipment) ).
Tighten the battery cover mounting bolts to tor-

que ( 0.4 daNm ) .
WARNING
Check that there are no diesel leaks:

- run the engine at idle speed until the fan starts
up,
- check that there is no diesel leak:
13B-163
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench
1
Tightening torquesm
fuel flow actuator 5.5 0.6 Nm

mounting bolts
battery cover securing 4 Nm

bolts
102120
Disconnect:
IMPORTANT
Before carrying out any work on the injection circuit, - the air intake duct (1) .
check using the diagnostic tool CLIP:
that the injection rail is no longer under pressure,
- Loosening a high pressure pipe union when the
2
WARNING
cuit plugs.
- Always replace any high pressure pipe and high
pressure pipe clips removed with new ones.
REMOVAL
102362
Remove diesel splash plate (2) .
13B-164
DIESEL INJECTION
K9K, and 722
5 7
4
102514 102315
Disconnect: Remove the high-pressure pipe (6) on injector no. 4
(see 13B, Diesel injection, High pressure pipes:
- the heater plugs,
Replacement ).
- the injector connectors (3) from cylinders no. 3 and
Cap the openings.
no. 4,
Undo bracket bolts (7) .
- the pump electrical connectors (4) ,
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
K9K, and 722
REFITTING
WARNING
WARNING Confirm that there is no diesel fuel leakage:

Do not remove the blanking plugs from any com-
- check the sealing after repair (see 13B, High
ponent until the last moment.
pressure pipe: Fuel-tightness check ).
Only unpack the new component when you are rea- - Let the engine run at idle speed until the engine
dy to fit it. cooling fan starts up.
- Accelerate several times under no load.
WARNING
- Carry out a road test.
Do not damage the seal when refitting.
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 moun-
ting 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.
nal.
WARNING
Tighten to torque the battery cover securing bolts

( 4 Nm ) .
13B-166
DIESEL INJECTION
K9K, and 728 or 729
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
flow actuator mounting 5.5 0.6 Nm

bolts

bolts
Note:
For vehicles with a K9K 732 engine (see MR 370
Mechanical, Scnic II ).
110325
Pull the clip.
IMPORTANT

tem, check using the CLIP diagnostic tool :
that the injector rail is not under pressure, 2
- It is essential to respect the safety and cleanliness 1
WARNING
cuit plugs.
- Always replace any high-pressure pipe or high-
pressure pipe clip removed with a new one. 110323
Undo bolt (1) .
REMOVAL Remove air duct (2) .
terminal.
13B-167
DIESEL INJECTION
K9K, and 728 or 729
102362 102315
Remove the diesel splash plate (3) . Remove the high-pressure pipe (7) from injector no.
4 (see 13B, Diesel injection, High-pressure pi-
pes: Replacing ).
Undo bracket bolts (8) .
4
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) ,
13B-168
DIESEL INJECTION
K9K, and 728 or 729
REFITTING
WARNING
WARNING Confirm that there is no diesel fuel leak:

component until the last moment. - Check the tightness after repair (see 13B,
High-pressure pipe: Sealing check ).
Only unpack the new component when you are rea- - Let the engine run at idle speed until the engine
dy to fit it. cooling fan starts to operate.
- Accelerate several times at no load.
WARNING
- Carry out a road test.
Do not damage the seal when refitting.
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.
nal.
WARNING

( 4 Nm ) .
13B-169
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 722 or 728 or 729
Mot. 1711 Kit for measuring

injector leak rate

Connect the four transparent hoses of (Mot. 1711)
to the injectors instead of the injector fuel return pi-
pes.
Fit the correct blanking plugs, in particular onto the
venturi pipe to prevent depriming the circuit.
Insert these hoses in the four graduated measuring
cylinders of the (Mot. 1711) .
IMPORTANT
Do not leave any object (tools or other) on the
side of the engine housing during the entire ope-
ration.
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 injec-
tion, Fault finding - Tests ).
Disconnect:
Refitting ).
- the four transparent hoses of (Mot. 1711) .
Refit the injector fuel return pipes.
13B-170
DIESEL INJECTION
K9K, and 732
Mot. 1771 Kit for measuring SIE-

MENS injector leak
rate
Mot. 1711 Kit for measuring

injector leak rate

112811
Pull out the clip.
112815
(1) .
Loosen the clip and (2) move the air inlet duct aside
(3) .
112991
13B-171
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
IMPORTANT
Do not leave any object (tools or other) on the
side of the engine housing during the entire ope-
ration.
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 injec-
tion, Fault finding - Tests ).
Disconnect:
112992 Refitting ).
Unclip injector rail protector cover (6) . - the air inlet pressure sensor connector.
Remove: Loosen the clip and move the air inlet duct aside.
- the mounting nut and bolt (7) from the injector rail Pull out the clip from the stainless steel pipe.
protector cover,
- the injector rail protector cover, Remove:
- the dipstick, - the dipstick,
- the dipstick tube mounting bolts (8) . - the dipstick tube mounting bolts.
Move the dipstick tube to one side. Move the dipstick tube to one side.
Disconnect the four fuel return pipes of the four in- Disconnect the four transparent pipes from (Mot.
jectors (see 13B, Diesel injector fuel return rail: 1771) .
Refit:
Connect the transparent hoses of (Mot. 1771) to the
injectors instead of the injector fuel return pipes. - the dipstick tube mounting bolts.
Fit the correct blanking plug to the injector fuel return - the dipstick,
connectors. - the injector rail protector cover,
Insert these hoses in the four graduated measuring - the injector rail protector cover mounting nut and
cylinders of the (Mot. 1711) . bolt,
Refit: Clip injector rail protector cover.
- the dipstick tube mounting bolts. Refit the clip onto the stainless steel pipe if necessa-
- the dipstick. ry.
ry. Refit:
Clip the stainless steel pipe to turbocharger. - the stainless steel pipe mounting bolt,
Refit the air inlet duct on the damper valve. - the air inlet duct on the damper valve.
Tighten the clamp. Tighten the clamp.
13B-172
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
Reprime the fuel circuit with the manual priming
pump.
13B-173
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts 6 Nm

bolt
IMPORTANT

check using the diagnostic tool CLIP:
that the injection rail is not under pressure,
- Loosening a high pressure pipe union when the
WARNING
cuit plugs.
- Be sure to replace any high pressure pipe and
high pressure pipe clips that have been removed.
13B-174
DIESEL INJECTION
F9Q, and 800 or 808
REMOVAL
18297-1
terminal.
Blow the area with compressed air to clean impuri-
ties away from the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
- fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not use
any tool for leverage).
13B-175
DIESEL INJECTION
F9Q, and 800 or 808
REFITTING
Clean the fuel pressure regulator bearing face on WARNING
the high pressure pump, taking care not to introduce
any impurities. Confirm that there is no diesel fuel leakage:
Wipe the fuel pressure regulator bearing face on the
cooling fan starts up,
high pressure pump, taking care not to introduce any
impurities. - accelerate several times at no load,
Connect the battery. - carry out a road test,

Rinse the fuel pressure regulator housing in the high
pressure pump, with the ignition on for a few se- - check that there is no diesel fuel escaping.
conds.
Disconnect the battery.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- lubricate the O-rings with clean diesel fuel.
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

nal.

Nm ) .
Switch on the ignition.
Clear the fault shown in the diagnostic tool CLIP if

necessary.
13B-176
DIESEL INJECTION
F9Q, and 804
REMOVAL
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts 6 Nm

bolts
IMPORTANT
1
that the fuel temperature is not too high. 111887
- It is essential to respect the safety and cleanliness Disconnect the battery, starting with the negative
advice given in this document whenever work is terminal.
carried out on this system. Blow compressed air into the area to clean dirt from
- Loosening a high-pressure pipe union when the around the fuel pressure regulator.
engine is running is strictly prohibited. Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
WARNING
- Obtain the special high-pressure injection cap kit. - fuel pressure regulator bolts (1) ,
- Be sure to replace any high-pressure pipe remo- - the fuel pressure regulator manually (do not use
ved. any tool for leverage).
13B-177
DIESEL INJECTION
F9Q, and 804
REFITTING
Clean the fuel pressure regulator bearing face on WARNING
the high-pressure pump, taking care not to introduce
any impurities. Confirm that there is no diesel fuel leak:
Wipe the fuel pressure regulator bearing face on the
high-pressure pump, taking care not to introduce
any impurities. - accelerate several times at no load,
Connect the battery, starting with the positive termi- - carry out a road test,
nal. - switch off the ignition,
Flush the fuel pressure regulator housing in the - check that there is no diesel fuel escaping.
high-pressure pump, with the ignition on for a few
seconds.

terminal.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- lubricate the O-rings with clean diesel fuel.
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.

nal.
WARNING

( 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 13B
K9K, and 722
Equipment required
WARNING
diagnostic tool
diesel temperature sen- 15 Nm - cleaning cloths (part no.: 77 11 211 707 ),

sor - cleaning product (part no.: 77 11 224 188 ).
batter cover mounting 4 Nm
bolts REMOVAL
IMPORTANT
carried out on this system. 1
WARNING
- Obtain a set of special high-pressure injection cir- 102120
cuit plugs.
Disconnect air aspiration hose (1) .
- Always replace any high-pressure pipe and high-
pressure pipe clips that have been removed.
WARNING

injector rail high-pressure pipes with one of the
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
13B-179
DIESEL INJECTION
K9K, and 722
REFITTING
2 WARNING
3
Lubricate the O-ring with the lubricant from the appli-
cator supplied with the new part.
WARNING
Do not damage the O-ring when refitting.
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: Re-

Disconnect:
Tighten to torque the batter cover mounting bolts
- the heater plugs from cylinders n 3 and 4, ( 4 Nm ) .
Check the sealing after repair (see 13B, Diesel in-
- the injectors (2) on cylinders 3 and 4, jection, High-pressure pipe: Check sealing ).
- the diesel fuel temperature sensor connector (3) .
WARNING

4 cooling fan starts to operate,
102317
Clean the sensor (see 13B, Diesel injection, Diesel

Remove the fuel temperature sensor (4) .
13B-180
DIESEL INJECTION
K9K, and 728 or 729
Equipment required
WARNING
diagnostic tool
diesel temperature sen- 15 Nm - cleaning cloths (part no.: 77 11 211 707 ),

sor - cleaning product (part no.: 77 11 224 188 ).
bolts REMOVAL
IMPORTANT
WARNING
cuit plugs.
- Always replace any high-pressure pipe and high-
pressure pipe clips that have been removed.
110325
WARNING Pull the clip.

injector rail high-pressure pipes with one of the
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
13B-181
DIESEL INJECTION
K9K, and 728 or 729
2 5
110323 102317
Unscrew bolt (1) Clean the sensor (see 13B, Diesel injection, Diesel
Remove the air duct (2) . injection: Precautions during repair ).
Remove the diesel fuel temperature sensor (5) .
3 REFITTING
4
WARNING

cator supplied with the new part.
WARNING
102514
Disconnect: Fit the diesel fuel temperature sensor.
- the heater plugs from cylinders n 3 and 4, Tighten to torque the diesel temperature sensor (
- the injectors (3) on cylinders 3 and 4, 15 Nm ) .
- the fuel temperature sensor connector (4) . Reconnect the electrical connector.


( 4 Nm ) .
13B-182
DIESEL INJECTION
K9K, and 728 or 729
jection, High-pressure pipe: Check sealing ).
WARNING

13B-183
DIESEL INJECTION
K9K, and 732
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 tem-
perature sensor fault (see 13B, Diesel injection, Die-
sel injector fuel return rail: Removal - Refitting ).
13B-184
DIESEL INJECTION
K9K, and 724
REMOVAL
Equipment required
diagnostic tool
Tightening torquesm Remove the engine undertray.
diesel temperature sen- 15 Nm

sor
IMPORTANT

- that the injection rail is not under pressure,
advice whenever work is carr ied out on this system.
112331
engine is running is strictly prohibited. Remove the pin securing the turbocharger pipe on
the turbocharger (1) .
Remove the bolt mounting the pipe on the cylinder
head.
WARNING
Move the pipe to one side.
Tighten to a torque of 38 Nm the pump-rail and Disconnect the inlet air pressure sensor (2)
rail-injectors high pressure pipes with the fol-
lowing part numbers:
Move the inlet air duct to one side (4) .
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 ,
For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
WARNING
Before starting work on the vehicle, obtain:

- a new blanking plug kit ( PART NUMBER 77 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
K9K, and 724
109470 109465
Remove: Remove the high pressure pump protectors (8) and
- the dipstick, (9)
- the dipstick pipe mounting bolts.

Unclip the clips (5) from the injection rail protector.
Remove:
- the mounting bolts (6) from the injection rail protec-
tor,
- the injection rail protector (7) .
102514
Clean the pipes (see 13B, Diesel injection, Diesel

injection: Precautions for repair ).
Disconnect the diesel supply and return pipes (10) .
Note:
new cloths.
Fit the correct blanking plugs.
13B-186
DIESEL INJECTION
K9K, and 724
REFITTING
Lubricate the O-ring with lubricant from the applica-

tor supplied with the new part.
Note:
Do not lubricate the diesel temperature sensor
seals with grease or used diesel. Use the appli-
cator supplied with the kit.
WARNING
102514
Disconnect the diesel temperature sensor connector
(11) . II - REFITTING PART CONCERNED
Refit the diesel temperature sensor.

II - REMOVAL OF PART CONCERNED
Tighten to torque the diesel temperature sensor (
15 Nm ) .
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.

Clean the diesel temperature sensor (see 13B, Die-
Lock the air duct onto the turbocharger and the inter-
sel injection, Diesel injection: Precautions for re-
cooler inlet air pipe.
pair ).
Remove the diesel temperature sensor (12) . Tighten the bolt of the air duct on the rocker cover.

13B-187
DIESEL INJECTION
K9K, and 724
jection, High pressure pipe: check ).
WARNING

- check that there is no diesel fuel leaking.
13B-188
DIESEL INJECTION
Accelerometer: Removal - Refitting 13B
K9K, and 722 or 728 or 729
REFITTING
Emb. 1596 2 4 mm socket for
removing/refitting Tighten to torque the accelerometer ( 20 Nm )
clutch master cylinder using tool low torque wrench .
Equipment required nal.
low torque wrench

WARNING
Tightening torquesm Battery: Removal - refitting ).
accelerometer 20 Nm Tighten to torque the battery cover securing bolts

( 4 Nm ) .
bolts
REMOVAL
102086
Disconnect the accelerometer connector (1) .
Remove the accelerometer using tool (Emb. 1596) .
13B-189
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench

1
Tightening torquesm
Venturi mounting bolt 5.5 Nm 0.6

bolts
102120
IMPORTANT Disconnect:
check using the diagnostic tool CLIP: - the intake duct (1) .
that the injection rail is not under pressure,
advice whenever work is carried out on this sys-
tem.
- Loosening a high pressure pipe union when the 2
WARNING
cuit 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
K9K, and 722
REFITTING
WARNING
Do not remove the blanking plugs from any com-
3 ponent until the last moment.

cator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5
Nm 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
4
WARNING
102316
Disconnect the return pipe (3) connecting the injec- Tighten to torque the battery cover securing bolts
tor to the pump. ( 4 Nm )
Remove:
- the Venturi mounting bolt (4) , WARNING
- the Venturi. Confirm that there is no diesel fuel leakage:

- check the sealing after repair (see 13B, Diesel
injection, High pressure pipe: Fuel tightness
check ),
cooling fan starts up,
13B-191
DIESEL INJECTION
K9K, and 728 or 729
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
Venturi mounting bolt 5.5 Nm 0.6

bolts
IMPORTANT

110325
that the fuel temperature is not too high. Pull the clip.
advice whenever work is carried out on this sys-
tem.
engine is running is strictly prohibited. 2
1
WARNING
cuit plugs.
- Be sure to replace any high-pressure pipe and
high-pressure pipe clips that have been removed.
REMOVAL
110323
Undo bolt (1) .
13B-192
DIESEL INJECTION
K9K, and 728 or 729
REFITTING
WARNING
3 component until the last moment.

cator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5
Nm 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
nal
102514 WARNING
Disconnect the fuel supply and return pipes (3) . Carry out the necessary programming (see 80A,

( 4 Nm )
4
WARNING

sel injection, High-pressure pipe: Sealing
check ),
5 - carry out a road test,
102316
Disconnect the return pipe (4) connecting the injec-
tor to the pump.
Remove:
- the Venturi mounting bolt (5) ,
- the Venturi.
13B-193
DIESEL INJECTION
Accelerator pedal potentiometer: General information 13B
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 kic-
kdown 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.
WARNING
A pedal fitted with a kickdown point may be fitted in
place of a pedal without a kickdown point. However,
fitting 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 13B
REFITTING
nal.
bolt
WARNING
REMOVAL
Disconnect: Battery: Removal - refitting ).
- the accelerator pedal connector.
Note:
A fault on the accelerator pedal position potentio-
meter results in changes in the idle speed or
engine operation (see 13B, Diesel injection,
Idle speed ).

Nm ) .
102204
Remove:
- pedal mounting bolts (1) ,
- the pedal.
13B-195
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 722 or 728 or 729 F9Q, and 800 or 808
Equipment required
diagnostic tool
Tightening torquesm
1
battery tray mounting 21 Nm 2
bolts

bolts
Note:
When programming, reprogramming or replacing a
computer, it is necessary to program the C2I para- 3
meters (individual injector correction) and the
engine parameters into the new computer using the
diagnostic tool RENAULT CLIP tool. 101822
There are two procedures for doing this (see 13B, Die-
sel Injection, Injectors: Configuration and pro- Remove:
gramming ):
- an automatic procedure which can be used if it is pos-
- the wiring harness bracket (3) .
sible to read the information contained in the old com-
puter, Detach the wiring harnesses from the battery tray.
- a manual procedure for when it is not possible to read Remove the battery tray.
the information contained in the old computer.
REMOVAL
terminal.
Remove the battery.
101811
Remove the injection computer and its support (4) .
13B-196
DIESEL INJECTION
K9K, and 722 or 728 or 729 F9Q, and 800 or 808
REFITTING
101890
Remove: 101887
- the computer mounting bolts (5) ,
- the computer.
21 Nm ) .
Make sure you refit the battery tray correctly on the

computer support.

nal.
WARNING

( 4 Nm ) .
Respect the programming instructions for the C2I

parameters (individual injector correction) and engi-
ne 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
K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700
Tightening torquesm
mounting bolt on the 21 Nm

computer support
WARNING
code for life.
- It is forbidden to perform tests with computers bor-
rowed from the Parts Department or from another
vehicle, that must then be returned. These compu-
ters are permanently coded.
When replacing the computer (see MR 372 Fault fin-

ding, Diesel injection, Fault finding - Replacement
of components ).
115720
REMOVAL Disconnect the computer connectors (1) .
Unclip:
I - REMOVAL PREPARATION OPERATION - the wiring harness (2) from the battery negative ter-
Remove the engine covers. minal,
Remove the battery (see 80A, Battery, Battery: Re- - the wiring harness.
Remove:
- the upper mounting bolt (3) from the computer sup-

port,
- the mounting bolt (4) from the computer support

- the mounting nut (6) from the wiring harness,
- the computer (5) and its support.

CONCERNED
Remove:
- the computer mounting nuts,
- the computer from its support.
REFITTING

CONCERNED
Refit:
- the computer on its support,
- the computer mounting nuts.
13B-198
DIESEL INJECTION
K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700
Refit the mounting bolt to the computer support.
Tighten to torque the mounting bolt on the compu-
ter support ( 21 Nm ) .
Refit the upper mounting bolt to the computer sup-
port.
Clip on:
- the wiring harness to the battery negative terminal,
- the wiring harness.
Connect the computer connectors.
Refit:
Refitting ).
13B-199
PREHEATING
Pre/postheating unit: Removal - Refitting 13C
F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 M9R, and 700
Tightening torquesm

bolts
wheel bolts 110 Nm
Note:
It is located behind the front left-hand wheel arch
liner.
REMOVAL
terminal.
102125
Disconnect the pre-postheating unit connector.
Remove:
- the pre-postheating unit mounting bolt,
- the pre-postheating unit.
REFITTING
nal.
WARNING
101823 Battery: Removal - Refitting ).
Remove:
Tighten to torque:
- the front left-hand wheel,
- the front left-hand wheel arch liner.
.
13C-1
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 722
Tightening torquesm
heater plugs 15 Nm

bolts
The resistance of a heater plug is 0.6 (connector dis-

connected).
The heater plugs are removed without opening the
high pressure diesel circuit.
REMOVAL
15762
Disconnect the electrical connector from the heater
Disconnect the battery, starting with the negative plugs.
terminal. 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 diame-
ter 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
Disconnect the air duct. Tighten to torque the heater plugs ( 15 Nm ) .
nal.
WARNING

( 4 Nm ) .
13C-2
PREHEATING
K9K, and 728 or 729
Tightening torquesm
heater plugs 15 Nm

bolts
1
REMOVAL
terminal.
110323
Undo the bolt (1) .
Move the air duct aside (2) .
110325
Pull the clip.
15762

plugs.
Clean around the outside of the heater plugs with a

cylinders.

WARNING
13C-3
PREHEATING
K9K, and 728 or 729
REFITTING
Tighten to torque the heater plugs ( 15 Nm ) .
nal.
WARNING

( 4 Nm ) .
13C-4
PREHEATING
F9Q, and 800 or 804 or 808
Tightening torquesm
heater plugs 15 Nm

bolts
The resistance of a heater plug is 0.6 (connector dis-

connected).
The heater plugs are removed without opening the
high pressure diesel circuit.
REMOVAL
15762
Disconnect the battery, starting with the negative plugs.
terminal.
F9Q, and 804 cylinders.
Remove: Undo then remove the plugs using a 10 mm diame-

- the inlet duct (see 12A, Fuel mixture, Inlet duct:
Removal - Refitting ). Use a hose to unscrew the plugs completely.
- the injection rail protector (see 13B, Diesel injec-

tion, Injection rail protector: Removal - Refitting WARNING
) Ensure that no foreign bodies enter the cylinder
REFITTING
nal.
WARNING

( 4 Nm ) .
13C-5
PREHEATING
F9Q, and 804
UD replaced with 11,05,08,02-01,37-001,016 on 08/
06/2005
13C-6
PREHEATING
K9K, and 732
Tightening torquesm
heater plugs 15 Nm
WARNING
Procedure for removing the air inlet duct (risk of

leaking and slipping if this procedure is not obser-
ved): 112815
- detach the hose using the (Car. 1363) , Disconnect the air inlet pressure sensor connector
(1) .
- do not use a degreaser, brake cleaning product, or
any other product, Loosen the clip (2) and move the air inlet duct aside
(3) .
- clean the bearing face on the intercooler and on
- place the clip in the same position if the hose is
not replaced,
- always replace the hose and/or the intercooler if
damaged.
REMOVAL

112811
Pull out the clip.
13C-7
PREHEATING
K9K, and 732
- the dipstick,
- the dipstick pipe mounting bolts (9) .

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.

cylinders.
WARNING
112992
REFITTING
Unclip the injection rail protector cover (7) .
Remove: I - REFITTING OPERATION FOR PART
CONCERNED
- the mounting nut and bolt (8) from the injection rail
protector cover, Refit the heater plugs using the hose.
13C-8
PREHEATING
K9K, and 732
Connect the connector to the heater plugs.
Refit:
- the mounting bolts to the dipstick pipe,
- the dipstick,
- the injection rail protector mounting bolt and moun-
ting nut.
Clip on the injection rail protector cover.
Refit:
- the clip on the stainless steel pipe if necessary,
marking,
Clip the stainless steel pipes onto the turbocharger.
Refit:
- the air inlet duct on the damper valve.
Tighten the clip.
Connect:
Refitting ).
13C-9
PREHEATING
M9R, and 700
REFITTING
Equipment required
socket wrench for removing/refitting preheating CONCERNED
plugs
Refit the heater plugs.
Tightening torquesm
WARNING
heater plugs 16.5 Nm Ensure that no foreign bodies enter the cylinder
REMOVAL Bring the heater plugs just into contact.

Tighten to torque the heater plugs ( 16.5 Nm ) using
I - REMOVAL PREPARATION OPERATION a socket wrench for removing/refitting prehea-
ting plugs or a 1/4-inch square drive long socket 10
Remove the front engine cover. mm in diameter connected to a universal joint.
WARNING
Disconnect the heater plug connectors. The heater plugs are damaged by being tighte-
Clean and blast the outside of the plugs to prevent ned to any torque greater than 19 Nm .
any contamination of the cylinders.
Connect
CONCERNED
Unscrew then remove the plugs using a socket
Refitting ).
wrench for removing/refitting preheating plugs
or a 1/4-inch square drive long 10 mm socket with a Refit the engine cover.
universal joint.
If necessary, use a hose to unscrew the plugs com-
pletely.
13C-10
PREHEATING
Pre-postheating control 13C
F9Q, and 800 or 808
The pre/post heating function is controlled by the injec-
tion computer.
PRE/POST HEATING OPERATING PRINCIPLE
1 - Switching on the ignition preheating
a - Variable preheating
The duration the indicator light is lit and of the supply to
the heater plugs depends on the coolant temperature
and the battery voltage.
101188
X: Time in seconds
Y: Coolant temperature in C
101189
X: Time in seconds
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 sup-
plied 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 13C
K9K, and 722 or 728 or 729 or 732
The pre-postheating function is controlled by the injec- At idling speed with no depression of the accelerator
tion computer. pedal.
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 tem-
perature and the battery voltage.
103124
X: Time in seconds
103123
X: Time in seconds
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 conti-
nue 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 14A
I - OPERATING DIAGRAM OF THE CIRCUIT
F4R, and 776
2 6 1
8
3
4
106679
(1) Inlet manifold 106278
(2) Fuel vapour absorber bleed

solenoid valve (8) Fuel vapour absorber bleed
solenoid valve
(3) Fuel vapour absorber
(4) Tank
(5) Breather
(6) Anti-return valve (F4R 776 only)
10
11
12
102734
102724
(7) Fuel vapour absorber bleed (10) Fuel vapour recirculation coming
solenoid valve from the tank
14A-1
ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A
(11) Recirculation of fuel vapours

going to the engine
(12) Tank breather
WARNING
The breather should not be blocked during normal
engine operation.
II - OPERATING PRINCIPLE
The tank is vented by means of the fuel vapour absor-
ber.
Fuel vapour is trapped by the active charcoal contai-
ned in the absorber as it passes through.
Fuel vapour trapped in the absorber is eliminated and
burnt by the engine.
To do this, connect the fuel vapour absorber and the in-
let 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 cy-
clic 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 so-
lenoid valve.
14A-2
ANTIPOLLUTION
Fuel vapour recirculation circuit: check 14A
I - CHECKING THE OPERATION OF THE FUEL II - FUEL VAPOUR ABSORBER BLEEDING
VAPOUR ABSORBER BLEED CONDITIONS
The fuel vapour absorber bleed solenoid valve is
controlled by track C-E1 of the computer if:
Note:
- the coolant temperature is above 55C ,
A fault with this system may result in rough idling
or the engine stalling. - the air temperature is above 10C ,
- the engine is not at idle speed,
- a given load threshold is reached,
- the throttle potentiometer is not in the no load
6 1 position.
2
During on board diagnostic fault finding, fuel va-
pour absorber bleeding is not authorised.
6 The opening cyclic ratio of the fuel vapour absorber

bleed solenoid valve can be displayed using the dia-
gnostic tools by referring to parameter PR102: Fuel
5 vapour absorber bleed solenoid valve OCR .
The solenoid valve is closed for values below 1.2 % .
3
4
106679
(1) Inlet manifold

(2) Fuel vapour absorber bleed
solenoid valve
(4) Tank
(5) Breather
(6) Anti-return valve (F4R 776 only)
Check the conformity of the circuit (see 14A, Anti-

pollution, Fuel vapour rebreathing Operation ).
Check the condition of the pipes to the tank.
14A-3
ANTIPOLLUTION
Fuel vapour canister: Removal - Refitting 14A
The absorber is located on the fuel tank under the ve-
hicle.
REMOVAL
3 4
102734
Disconnect:
- pipe (2) bringing the fuel vapour from the tank,
102483
- pipe (3) taking the fuel vapours to the solenoid val-
ve,
Release absorber (1) from the fuel tank retaining
notch by pushing it in the direction of the arrow. - breather pipe (4) .
Remove the absorber.
REFITTING
14A-4
ANTIPOLLUTION
Fuel vapour canister:Checking 14A
Mot. 1311-01 Fuel pressure test kit
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 14A
B84 or C84 or S84, and K4J, and 730 or 732
I - LOCATION OF COMPONENTS
101495
(1) Oil vapour breather port (2) Oil vapour recovery plate loca-
ted on the cylinder head cover
(3) Sized port
3
101499
101869
14A-6
ANTIPOLLUTION
B84 or C84 or S84, and K4J, and 730 or 732
For information on removing oil vapour recovery plate (3) Air unit
(2) , (see 11A, Top and front of engine, Tightening
the cylinder head ). (4) Motorised throttle valve
(5) Inlet manifold
II - OPERATING DIAGRAM (6) Air inlet
(7) Sized port
A: At low loads, small quantities of oil vapour are
sucked back in via sized opening (7). III - CHECKING
To ensure the antipollution system works properly, the
oil vapour rebreathing circuit must be kept clean and in
7 4 3
good condition.
5
6
101956
B: At medium and high loads, large quantities of oil

vapour are sucked in by the gas throttle.
3
7 4
5 6
101957
(1) Engine
(2) Oil vapour recovery plate
14A-7
ANTIPOLLUTION
K4M, and 760 or 761
I - LOCATION OF COMPONENTS
102305
(1) Oil vapour breather pipe

(2) Sized opening
3
4
101820
(3) Oil vapour recovery plate on the 102073

cylinder head cover
(4) Oil vapour breather pipe For information on removing oil vapour recovery plate
(3) , (see 11A, Top and front of engine, Cylinder
head gasket ).
14A-8
ANTIPOLLUTION
K4M, and 760 or 761
II - OPERATING DIAGRAM (5) Air inlet
(6) Sized opening
A: At low loads, the oil vapours are rebreathed in
small quantities through the sized opening (6) III - CHECKING
4 6 3 To ensure the antipollution system works properly, the
good condition.
5
102308
B: Under average and heavy loads, the oil vapours

are rebreathed in large quantities through the gas
throttle valve.
4 6 3
102309
(1) Engine
(3) Motorised throttle
(4) Inlet manifold
14A-9
ANTIPOLLUTION
K9K, and 722 or 728 or 729 or 732
I - PRESENTATION OF THE CIRCUIT 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
II - CHECK
2
To ensure the correct operation of the anti-pollution
system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
3
4 6 5
20965
1
2
6
4 5
20965-1
(1) Cylinder head cover

(2) Oil vapour breather pipe
(3) Oil vapour rebreathing valve
(4) Air inlet duct
(5) Turbocharger
(6) Atmospheric pressure
A : Under low load, the vacuum in the air inlet duct is

below the spring calibration. The oil vapours are re-
breathed in large volumes by the vacuum in the air inlet
duct.
14A-10
ANTIPOLLUTION
F9Q, and 800 or 808
I - CIRCUIT PRESENTATION
1
3
2
4
5
2
6
3
100054
100053
(1) Oil vapour rebreathing pipe con-
(1) Engine nected to the intake pipes
(2) Oil separator (2) Cylinder block outlet oil vapour
(3) Air filter unit rebreathing pipe
(4) Air duct (3) Separator filter oil return pipe
(5) Turbocharger (4) Oil separator
(6) Inlet manifold
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.
14A-11
ANTIPOLLUTION
F4R, and 770 or 771 or 776
I - PRESENTATION OF COMPONENTS
102723
(1) Oil vapour breather pipe (3) Oil vapour recovery plate on the
(2) Oil vapour recirculation valve cylinder head cover
102729
14A-12
ANTIPOLLUTION
F4R, and 770 or 771 or 776
F4R, and 776
B A
106629
(A) Circuit upstream of turbochar-

ger, used for medium and high
loads. The vapour is sucked
back in by the prevailing vacuum
pressure in the inlet manifold
(B) 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
106588
Oil vapour recovery plate located on the rocker cover
14A-13
ANTIPOLLUTION
F4R, and 770 or 771 or 776
For removal, (see 11A, Top and front of engine, Cy-
linder head gasket ).
II - OIL VAPOUR RECIRCULATION CIRCUIT

3
102738
(4) Throttle upstream oil vapour

recirculation aperture
5
9
10
102745
14A-14
ANTIPOLLUTION
F4R, and 770 or 771 or 776
(5) Air duct

(6) Throttle valve
(7) Inlet manifold
(8) Throttle valve upstream oil
vapour rebreathing port
(10) Oil vapour rebreathing valve
III - CHECKING
good condition.
14A-15
ANTIPOLLUTION
F9Q, and 804
I - THE CIRCUIT
100054
100053
(1) Oil vapour rebreathing pipe con-
(1) Engine nected to the inlet pipes
(2) Oil separator (2) Cylinder block outlet oil vapour
(3) Air filter unit rebreathing pipe
(4) Air duct (3) Oil separator filter return pipe
(5) Turbocharger (4) Oil separator
(6) Inlet manifold
II - CHECK
good condition.
14A-16
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
K9K, and 722 or 728 or 729
I - THE CIRCUIT
Note:
5 3
A The position of the exhaust gas recirculation sole-
noid valve is a determining factor in the calculation
of the quantity of air admitted by the engine.
IV - OPERATING CONDITIONS
4
The following parameters determine actuation of the
1 exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
7 6 - atmospheric pressure,
- accelerator pedal position,
8 - diesel injected,
- engine speed.
102364
Operating point for checking the exhaust gas
(1) Engine recirculation solenoid valve
(2) Air filter unit The exhaust gas recirculation solenoid valve is actua-
ted if:
(3) Plenum chamber
(4) Exhaust manifold - the air temperature is between -30C and 67 C , in-
clusive,
with solenoid valve - or the coolant temperature is between 0C and 127C
inclusive,
(6) Turbocharger
(7) Injection computer - the engine speed is above 500 rpm ,
(8) Intercooler - the diesel fuel injection flow is between 10 and 31
(A) Air inlet mg/stroke inclusive,
(B) Exhaust gas outlet - the atmospheric pressure is above 421 mbar .
If so, the diagnostic tool indicates an exhaust gas recir-
II - PURPOSE OF THE EXHAUST GAS culation solenoid valve position opening cylinder ratio
RECIRCULATION SYSTEM value equal to 4 and 60% .
Exhaust gas recirculation is used to reduce the nitro- Exhaust gas recirculation is cut off if:
gen oxide (NOx) content of the exhaust gases. - the battery voltage is below 9 V ,
The computer regulates the passage of gases by ac- - the engine speed is below 500 rpm ,
tuating a solenoid valve.
- the mapping (engine speed - load) exceeds a thres-
hold,
- the air conditioning compressor is actuated.
The solenoid valve is controlled by an opening cyclic
ratio signal issued by the injection computer. The ope- The exhaust gas recirculation solenoid valve is not
ning cyclic ratio signal modulates the opening of the supplied after starting for 2 seconds .
solenoid valve, and consequently the quantity of ex- The exhaust gas recirculation solenoid valve is no lon-
haust gas directed back to the inlet manifold.
ger supplied if there is a fault on:
The computer runs a constant test to keep track of the
- the exhaust gas recirculation solenoid valve,
position of the exhaust gas recirculation solenoid val-
ve. - the turbocharging pressure sensor,
14A-17
ANTIPOLLUTION
K9K, and 722 or 728 or 729
15761
Track Description
1 Solenoid supply
2 Position potentiometer supply
3 Not used
4 Position potentiometer earth
5 Solenoid earth control
6 Position potentiometer signal
14A-18
ANTIPOLLUTION
F9Q, and 800 or 808
I - THE CIRCUIT
9 7
5
4 8
10
3
11
2
1
23244
(1) Engine The solenoid valve is controlled by an opening cyclic
(2) Injection computer ratio signal issued by the injection computer. The ope-
(3) Inlet manifold ning cyclic ratio signal modulates the opening of the
solenoid valve, and consequently the quantity of ex-
(4) Exhaust manifold haust gas directed back to the inlet manifold.
(5) Turbocharger
(6) Exhaust gas recirculation sole- position of the exhaust gas recirculation solenoid val-
noid valve ve.
(7) Air flowmeter
(8) Air inlet IV - OPERATING CONDITIONS
(9) Exhaust gas outlet The following parameters determine activation of the
(10) Intercooler inlet exhaust gas recirculation solenoid valve:
(11) Intercooler outlet - coolant temperature,
- the air temperature,
II - PURPOSE OF THE EXHAUST GAS - atmospheric pressure,
RECIRCULATION SYSTEM
- the injection flow,
Exhaust gas recirculation is used to reduce the nitro-
gen oxide (NOx) content of the exhaust gases. - the engine speed.
Exhaust gas recirculation is cut off if:
The injection computer allows gas to pass by actuating
a solenoid valve. - the battery voltage is below 9 V ,
14A-19
ANTIPOLLUTION
F9Q, and 800 or 808
- If the engine speed is above 2,950 rpm when the pe-
dal is released (low pedal value),
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 Description
1 Solenoid supply
2 Sensor feed
4 Sensor earth
5 Solenoid earth
6 Sensor output
103127
X Time in seconds
Y Coolant temperature in C
The exhaust gas recirculation solenoid valve is no lon-

ger supplied if there is a fault on:
- the coolant temperature sensor,
- the air temperature sensor,
- the turbocharging pressure sensor,
- the atmospheric pressure sensor.
14A-20
ANTIPOLLUTION
F9Q, and 804
I - DIAGRAM
114451
(1) Engine
(2) Exhaust gas cooler
(4) Inlet manifold
(5) Exhaust manifold
(6) Turbocharger
II - PURPOSE OF THE EXHAUST GAS

Exhaust gas recirculation is used to reduce the nitro-
gen oxide (NO X) content of the exhaust gases.
The injection computer authorises gas passage by run-
ning an electric motor which actuates a valve linking
the exhaust manifold and the inlet manifold.

The principle of the exhaust gas recirculation consists
of reintroducing some of the exhaust fumes into the en-
gine air breathing cycle.
The EGR valve is controlled by a direct current motor.
14A-21
ANTIPOLLUTION
K9K, and 732
I - THE CIRCUIT
Note:
The position of the exhaust gas recirculation sole-
noid 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) Engine
(2) Air filter unit
(3) Plenum chamber
(4) Exhaust manifold
with solenoid valve
(6) Turbocharger
(8) Intercooler
(A) Air inlet
(B) Exhaust gas outlet
II - PURPOSE OF THE EXHAUST GAS

Exhaust gas recirculation is used to reduce the con-
centration of nitrogen oxides (NOx) in exhaust fumes.
The computer regulates the passage of gases by ac-
tuating a solenoid valve.

The solenoid valve is controlled by an opening cyclic
ratio signal issued by the injection computer. The ope-
ning cyclic ratio signal modulates the opening of the
solenoid valve, and consequently the quantity of ex-
haust gas directed back to the inlet manifold.
position of the exhaust gas recirculation solenoid val-
ve.
14A-22
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
K9K, and 722

Tightening torquesm
exhaust gas recircula- 21 Nm 2

tion unit mounting bolt
metal air inlet tube 21 Nm

mounting bolt
lifting eye (timing end) 21 Nm

102126
mounting bolts for the 12 Nm Disconnect the wiring harness (2) .
heat shield on the
exhaust gas recircula- Move the wiring harness to one side.
tion solenoid valve

3
6 5
bolts
REMOVAL
terminal. 4
102119
1 Disconnect:
- turbocharging pressure regulation valve pipe (3)
from the air duct,
- air inlet pipe (4) on the exhaust gas recirculation
unit.
Remove:
- bracket (5) ,
102120
Remove: - engine lifting eye (6) ,
- the engine covers, - air intake metal pipe (7) .
- the air duct (1) .
14A-23
ANTIPOLLUTION
K9K, and 722
8
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:
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 ex-

haust gas recirculation solenoid valve ( 12 Nm )
.
nal.
WARNING
Tighten to torque the engine cover mounting bolts

( 4 Nm ) .
14A-24
ANTIPOLLUTION
K9K, and 728 or 729 or 732

2
Tightening torquesm
1
metal inlet air tube 21 Nm

mounting bolts
lifting eye (timing end) 21 Nm

tion solenoid valve heat
shield mounting bolts
front engine cover 4 Nm

mounting bolts 110323
Undo bolt (1) .
Note:
For vehicles fitted with the K9K 732 engine (see
Workshop Repair Manual 370 Mechanics, Sc-
nic II ).
REMOVAL
Disconnect the battery, starting with the negative 3
terminal.
102126
Disconnect the wiring harness (3) .
110325
Pull the clip.
14A-25
ANTIPOLLUTION
K9K, and 728 or 729 or 732
REFITTING
Replace the exhaust gas recirculation tube complete
6 4
with new clips.
7
Tighten the new clips using (Mot. 1567) .
Replace the O-rings on the metal air inlet tube.
Tighten to torque:
5
bolts ( 21 Nm ) ,
- the metal inlet air tube mounting bolts ( 21 Nm )
8 ,
- the lifting eye (timing end) ( 21 Nm ) ,
102119 - the exhaust gas recirculation solenoid valve
heat shield mounting bolts ( 12 Nm ) .
Disconnect:
- the turbocharging pressure regulation valve pipe
(4) from the air duct,
nal.
- the air inlet pipe (5) on the exhaust gas recircula-
tion unit.
WARNING
Remove: Carry out the necessary programming (see 80A,
- the bracket (6) ,
Tighten to torque the front engine cover mounting
- the engine lifting eye (7) , bolts ( 4 Nm ) .
- the air inlet metal tube (8) .
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
F9Q, and 804
Tightening torquesm


tion pipe mounting bolts

bolts
REMOVAL
terminal.
Remove the battery.
Remove the air duct (see 12A, Fuel mixture, Inlet
111964
111861
Remove the mounting bolts (1) from the exhaust gas
recirculation pipe.
113177

recirculation unit.
WARNING
Never remove the exhaust gas recirculation sole-
noid valve from the unit.
REFITTING
14A-27
ANTIPOLLUTION
F9Q, and 804
Tighten to torque:
bolts ( 25 Nm ) ,
- the exhaust gas recirculation pipe mounting
bolts ( 18 Nm ) .
nal.
WARNING
Reconnect the connectors.

( 4 Nm ) .
14A-28
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
K9K, and 722 or 728 or 729 or 732
Mot. 1729 Pin spanner for remo-

ving the EGR valve
Tightening torquesm

tion solenoid valve
mounting bolts
Note:
For vehicles fitted with the K9K 732 engine (see
Workshop Repair Manual 370 Mechanics, Sc-
nic 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 moun-
ting bolts,
- the exhaust gas rebreathing solenoid valve by uns-
crewing it gradually,
- the exhaust gas recirculation solenoid valve by gra-
dually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve seal with a new one

Tighten to torque the exhaust gas recirculation
solenoid valve mounting bolts ( 9 Nm ) .
14A-29
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
F9Q, and 800 or 808
Mot. 1729 Pin spanner for remo-

ving the EGR valve
Tightening torquesm
mounting bolts on the 9 Nm

exhaust gas recircula-
tion solenoid valve
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 so-
lenoid valve,
- the exhaust gas recirculation solenoid valve by gra-
dually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve gasket with a new one

Tighten to torque the mounting bolts on the ex-
haust gas recirculation solenoid valve ( 9 Nm ) .
14A-30
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
Ms. 583 Hose clamps

Equipment required
diagnostic tool
Tightening torquesm
bolts mounting the 12 Nm

exhaust gas cooler on 112816
its two supports Remove the oil vapour rebreather pipe (1) .
bolt mounting the 25 Nm Disconnect the connector (2) from the oil vapour re-
exhaust gas cooler sup- circulation solenoid valve.
ports on the cylinder
head
mounting bolts of the 35 Nm

rigid exhaust gas recir-
culation pipe
coolant circulation 10 Nm
cover mounting bolts
bolts mounting the lif- 10 Nm

ting bracket on the
timing end
REMOVAL

Remove: 112811
Pull out the clip.
- Refitting ).
14A-31
ANTIPOLLUTION
K9K, and 732
112991 113475
Remove the mounting bolt (3) from the stainless Remove the mounting bolts (7) from the injection rail
steel pipe. protector cover mounting bracket.
Move the air inlet duct (4) to one side.
112815
Disconnect the connector (5) from the air inlet pres-
sure sensor.
Loosen the clip (6) and move the air inlet duct aside.
Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting ).
14A-32
ANTIPOLLUTION
K9K, and 732
- the air inlet metal tube (11) ,
- the mounting bolts from the exhaust gas inlet pipe
(12) ,
- the mounting bolts from the exhaust gas recircula-
tion unit assembly (13) ,
- the exhaust gas recirculation unit assembly.

CONCERNED
114341
Position the (Ms. 583) on the exhaust gas cooler in-

let and outlet hoses.
coolant recirculation cover.
Move the exhaust gas coolant recirculation cover to

one side. 112326
At the workbench, remove:
Remove the seals from the cover.
- the bolt mounting the exhaust gas cooler on its two
supports,
Note:
- the exhaust gas cooler,
Make preparations for coolant outflow.
- the exhaust gas inlet pipe snap-fit clamp,
- the exhaust gas inlet pipe.
112329
Remove:
- the lifting bracket mounting bolts (9) from the timing

end,
- the lifting bracket on the timing end (10) ,
14A-33
ANTIPOLLUTION
K9K, and 732
REFITTING

All the bearing faces on each removed part must be
carefully cleaned.
WARNING
Take care not to damage the bearing faces to
prevent any risk of coolant leaks.
WARNING
Always replace: 112326
- the metal air inlet tube and its O-rings, Refit:

- the exhaust gas inlet pipe, its mounting bolts, its - the mounting bolts to the cooler, without making
seal and its snap-fit clamp, contact so that the cooler can move,
- the cooler seals and its supports, - the exhaust gas recirculation unit assembly, with its
- the seals of the coolant circulation cover within cooler, onto the cylinder head.
the exhaust gas cooler,
- the mounting bolts for the two exhaust gas cooler
- the seal between the downstream duct of the supports.
cut-off valve and the exhaust gas cooler sup-
port, Tighten the bolts mounting the two exhaust gas coo-
ler supports on the cylinder head until they make
- the seal between the catalytic converter and the contact.
turbocharger.
Adjust the exhaust gas cooler on its two supports so
that it is immobilised.
CONCERNED Tighten the mounting bolts of the exhaust gas cooler
on its two supports until they make contact, in order
Refit the exhaust gas cooler on its two supports fit-
to immobilise it.
ted with new seals.
Remove the exhaust gas recirculation unit assembly
with its cooler.
WARNING
Ensure that the seals between the cooler and its At the workbench, tighten to torque the bolts moun-
two supports are correctly positioned to avoid ting the exhaust gas cooler on its two supports (
any coolant leaks. 12 Nm ) .
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 sup-

ports on the cylinder head.
Tighten to torque the bolt mounting the exhaust

gas cooler supports on the cylinder head ( 25
Nm ) .
14A-34
ANTIPOLLUTION
K9K, and 732
Refit: Tighten:
- the new rigid exhaust gas recirculation pipe with a - the bolts mounting the rail protector mounting brac-
new seal, ket on the exhaust gas cooler assembly,
- the new exhaust gas recirculation pipe mounting - the nut mounting the rail protector on the mounting
bolts, bracket.
Refit the damper valve (see 12A, Fuel mixture,
Fit the new snap-fit clamp.
Damper valve: Removal - Refitting ).
Connect the air inlet pressure sensor connector.
WARNING
Refit the clip on the air inlet duct if necessary.
Ensure that you do not squeeze the exhaust gas
inlet pipe before fitting the snap-fit clamp. Position the air inlet duct.
Clip the air inlet duct onto the turbocharger.
Tighten the rigid exhaust gas recirculation pipe
mounting bolts until they make contact. Refit the air inlet duct mounting bolt.
Tighten the air inlet duct bolt.
Adjust the rigid exhaust gas recirculation pipe in re-
lation to the cooler support on the timing end. Connect the exhaust gas recirculation solenoid val-
ve connector.
Lock the snap-fit clamp of the rigid exhaust gas re-
circulation pipe using the (Mot. 1567) . Refit the oil vapour rebreathing pipe.
Tighten to torque the mounting bolts of the rigid Connect the battery (see 80A, Battery: Removal -
exhaust gas recirculation pipe ( 35 Nm ) ). Refitting).
Bleed the coolant (see 19A, Cooling, Cooling cir-
cuit: Bleeding ).
III - FINAL OPERATIONS
Refit:
Refit:
tic converter: Removal - Refitting ). - the engine covers.
Clear any faults stored by the computer using the
- the coolant circulation cover diagnostic tool .
- the coolant circulation cover mounting bolts
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

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 14A
K9K, and 732
For removing and refitting the supports for the exhaust
gas recirculation (see 14A, Emission control, Ex-
haust gas cooler: Removal - Refitting ).
14A-36
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting 14A
K9K, and 732
REFITTING
Mot. 1567 Remote operation I - REFITTING PREPARATION OPERATION

All the bearing faces must be carefully cleaned.
Tightening torquesm WARNING
mounting bolts of the 35 Nm

rigid exhaust gas recir- Always replace:
culation pipe on the
manifold - the exhaust gas inlet pipe, its seal on the cylin-
der head and its snap-fit clamp,
- the seals between the catalytic converter and
REMOVAL the turbocharger.
I - REMOVAL PREPARATION OPERATION II - REFITTING OPERATION FOR PART

Position the vehicle on a two-post lift (see 02A, Lif- CONCERNED
ting equipment, Underbody lift ). Refit:
Remove the engine covers. - the rigid exhaust gas recirculation pipe with a new
Disconnect the battery (see 80A, Battery: Removal - seal,
Refitting - the new exhaust gas recirculation pipe mounting
bolts,
Remove:
Fit a new snap-fit clamp.
tic converter: Removal - refitting ). WARNING
Ensure that you do not squeeze the exhaust gas
inlet pipe before fitting the snap-fit clamp.
CONCERNED 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 re-
circulation pipe using the (Mot. 1567) .
Tighten to torque the mounting bolts of the rigid
exhaust gas recirculation pipe on the manifold (
35 Nm ) .

Refit:
113842
Remove: tic converter ),
- the mounting bolts (1) from the exhaust gas recir- - the engine undertray.
culation pipe,
- the snap-fit clamp (2) using the (Mot. 1567) , Refitting ).
- the rigid exhaust gas recirculation pipe (3) . Refit the engine covers.
14A-37
STARTING - LOAD
Alternator: General information 16A
F4R or F9Q or K4J or K4M or K9K or M9R
I - OPERATION
Engine Alternator Current
These vehicles are fitted with an alternator with internal strength
ventilation and incorporated regulator, plus a warning
light on the instrument panel, which operates as fol- VALEO : TG11 C018
lows:
VALEO : TG11 C040 110 A
- when the ignition is switched on, the warning light co-
mes on, VALEO : TG11 C049
- when the engine starts, the warning light goes out,
VALEO : SG12 B078
- if the warning light comes on while the engine is run-
ning, this indicates a charge fault. VALEO : SG12 B081
125 A
F9Q
VALEO : SG15 B092
II - IDENTIFICATION
VALEO : SG15 B098
Engine Alternator Current BOSCH : LIE8 0 124 525

strength 101
150 A
VALEO : TG11 C011 BOSCH : 0 124 525 044
110 A
K4J and VALEO : TG11 C027 VALEO : SG15 L027 155A
K4M
BOSCH : LIE8 0 124 525 150 A BOSCH : LIE6 0 124 0AC 120A
028 473B
VALEO : TG11 C040 M9R VALEO : TG15 C059 150 A

110 A
VALEO : TG11 C049 MELCO : 8GM A004 TJ0 210 A
F4R 281
VALEO : SG12 B092
125 A
VALEO : SG12 B098
Note:
VALEO : TG11 C041
There is a configuration in the Protection and Swit-
110 A
VALEO : TG11 C034 ching Unit for the alternator fitted to the vehicle (see
87G, Engine compartment connection unit, Pro-
BOSCH : LIE8 0 124 525 tection and Switching Unit ).
082
150 A
K9K BOSCH : LIE8 0 124 525
081
MELCO : 8GM A004 TJ0

581
210 A
MELCO : 8GM A004 TJ0
481
16A-1
STARTING - LOAD
Alternator: Removal - Refitting 16A
K9K, and 722 or 724 or 728 or 729 or 732
Fit the cooling assembly to the upper cross member
using the safety belt .
Equipment required
safety belt
Tightening torquesm
bolts

free pulley support 21 Nm

mounting bolts

ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL
- the side stiffener mounting bolts,
REMOVAL PREPARATION OPERATION
- the side reinforcements (1) .
Remove the engine cover.

Disconnect:
Refitting ).
- the electrical connections.
Remove the alternator harness.
Remove:
- the front wheels,
Refitting ).
102008
Note:
Remove:
When fitting the safety strap, take care:
- not to crush the cooling hoses, - the half sub-frame mounting nuts and bolts (2) ,
- not to strap up the half sub-frame. - the half sub-frame.
16A-2
STARTING - LOAD
K9K, and 722 or 724 or 728 or 729 or 732
CA or CAREG
19703
109537
Note:
Disconnect:
Take care not to constrain the compressor air
- the pressostat connector (3) , conditioning pipes during this operation.
- the air conditioning compressor connector (4) ,
Remove the air conditioning compressor mounting
Move the electric wiring harness to one side. bolts (5) .
Remove the air conditioning compressor and attach
it using a safety belt .
16A-3
STARTING - LOAD
K9K, and 722 or 724 or 728 or 729 or 732
OPERATION FOR REMOVAL OF PART
CONCERNED
CHAUFO
19703
111079
Remove:
WARNING
- the free pulley support mounting bolts (6) ,
Do not damage the cooling unit vanes (radiator,
- the idler pulley support. 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
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
Refit:
- the free pulley support,
- the free pulley support mounting bolts.
Tighten to torque the free pulley support moun-
ting bolts ( 21 Nm ) .

of engine, Accessories belt ).
Apply a drop of LOCTITE - FRENEBLOC on the
sub-frame mounting bolts.
Refit:
- the side reinforcements.
Tighten to torque:
18987
Refit the rings (8) using pliers or a vice.
Refit:
CONCERNED Exterior protection, Front bumper: Removal -
Refitting ).
Refit:
- the alternator,
- the alternator mounting bolts. - the front wheels.
Torque tighten the alternator mounting bolts ( 21 Tighten to torque the wheel bolts ( 110 Nm ) .
Nm ) .
Connect:
III - FINAL OPERATION - the electrical connections,

Refitting ).
CA or CAREG
Refit the engine cover.
Refit:
- The air conditioning compressor,
- the air conditioning compressor mounting bolts.
Connect:
- the pressostat connector,
- the air conditioning compressor connector.
16A-5
STARTING - LOAD
F4R, and 770 or 771 or 776
Tightening torquesm
bolts

bolts
wheel bolts 110 Nm
REMOVAL
Position the vehicle on a two-post lift. 1
terminal.
101212
Remove:
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)
at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pi-
pes.
16A-6
STARTING - LOAD
F4R, and 770 or 771 or 776
F4R, and 776
3
2
5 7
4
102504
104342
Remove:
- intercooler air duct (7) ,
- the accessories belt tension wheel.
6
102365
Remove:
- the clip (4) ,
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the accessories belt (See 11A, Top and front of
Disconnect the alternator electrical connections.
16A-7
STARTING - LOAD
F4R, and 770 or 771 or 776
REFITTING
19703
Remove: 18987
- the alternator mounting bolts (8) , Refit the rings (9) using pliers or a vice to facilitate fit-
ting.
- the alternator using a screwdriver.
WARNING
WARNING
Do not force it against the air conditioning hose: tension wheels and idler pulleys.
there is a risk of refrigerant fluid escaping.
Torque tighten the alternator mounting bolts ( 25
Nm ) .
Note: Replace the accessories belt.
To facilitate removal of the alternator, shift the Tension the accessories belt (see 11A, Top and
cooling assembly gently forward (be careful not front of engine, Accessories belt ).
to deform the condenser pipes).
nal.
WARNING
Tighten to torque:
16A-8
STARTING - LOAD
F9Q, and 800 or 804 or 808
Tightening torquesm
bolts
wheel bolts 110 Nm 3

2
bolts
5
4
REMOVAL
terminal.
1
102365
Remove:
- the clip (4) ,
101212 - the mounting (5) ,
Remove: - the front end panel mounting bolts (6) ,
- the engine covers, - the front end panel,
- the front wheels, - the accessories belt (see 11A, Top and front of
- the half sub-frame side reinforcement (1) , Disconnect the alternator electrical connections.
- the bumper (see MR 365 Bodywork, 55A, Exte- Remove the accessories belt tensioning roller.
rior protection, Front bumper ).
16A-9
STARTING - LOAD
F9Q, and 800 or 804 or 808
REFITTING
19703
Remove: 18987
- the alternator mountings (7) , Refit the rings (8) using a vice to facilitate fitting.
- the alternator using a screwdriver. Refit the alternator.
To facilitate removal of the alternator, shift the coo- Torque tighten the alternator mounting bolts ( 25
ling assembly forward gently (be careful not to da- Nm ) .
mage the condenser pipes). Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt ).
nal.
WARNING

( 4 Nm ) .
16A-10
STARTING - LOAD
K4J, and 730 or 732 K4M, and 760 or 761
Tightening torquesm
bolts
alternator strut moun- 21 Nm

ting bolts
nut securing the strut to 21 Nm

the stud on the engine
side

bolts
wheel bolts 110 Nm
REMOVAL
101212
Disconnect the battery, starting with the negative Remove:
terminal.
- 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.
Disconnect the windscreen washer fluid reservoir pi-
pes.
16A-11
STARTING - LOAD
K4J, and 730 or 732 K4M, and 760 or 761
3 7
2
5
4
102504
19703
Remove:
- the alternator mounting bolts (7) ,
6
WARNING
Do not force it against the air conditioning hose:
there is a risk of refrigerant fluid escaping.
102365
Unclip the bonnet opening cable (3) . Note:
Remove: To facilitate removal of the alternator, shift the

cooling assembly gently forward (be careful not
- the clip (4) , to deform the condenser pipes).
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the accessories belt (See 11A, Top and front of
Remove the alternator retaining strut.
16A-12
STARTING - LOAD
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
18987
Refit the rings (9) using pliers or a vice to facilitate fit-

ting.
WARNING
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 en-

gine side ( 21 Nm ) ,
Replace the accessories belt.
Tension the accessories belt (see 11A, Top and

front of engine, Accessories belt ).

nal.
WARNING
Tighten to torque:
16A-13
STARTING - LOAD
Tightening torquesm Refitting ).
bolts

bolts
REMOVAL
Note:
The tensioning roller and the inertia reel must be
102504
replaced when the accessories belt is replaced.


102365
Remove:
- the clip (4) ,
- the mounting (5) ,
- the impact cross member mounting bolt (6) ,
106077 Disconnect the alternator electrical connections.
Remove: Remove the accessories belt tensioning roller.
- the right-hand wheel arch liner,
- the side stiffener (1) ,
- the fog lights connector,
16A-14
STARTING - LOAD
19703 18987
Remove: Refit the rings (8) using pliers or a vice to facilitate fit-
ting.
- the alternator mountings (7) ,
Refit:
- the alternator,
To ease alternator removal, slightly move the coo-
ling system toward the front (be careful not to bend - the alternator mounting bolts.
the condenser pipes).
Tighten to torque the alternator mounting bolts (
25 Nm ) .
REFITTING Refit the new accessories belt.
WARNING of engine, Accessories belt: Removal - Refitting
).
The belt must be replaced with a new one if it
has been removed. Tighten to torque the wheel mounting bolts ( 130
Nm ) .
moval - Refitting .
( 4 Nm ) .
16A-15
STARTING - LOAD
M9R, and 700
Tightening torquesm
bolts
positive terminal moun- 8 Nm

ting nut
air inlet hose clip on the 5.5 Nm

damper valve
air inlet hose clip on the 5.5 Nm

intercooler
turbocharger pressure 8 Nm
sensor mounting nut

mounting bolts
front end panel lower 44 Nm 101212

mounting bolts
Remove:
- the right-hand sub-frame side stiffener (1) ,
REMOVAL
I - REMOVAL PREPARATION STAGE
Remove:
114855
fitting ).
16A-16
STARTING - LOAD
M9R, and 700
102504
and Switching Unit.
Remove:
114933
Unclip the air inlet scoop (2) . - the clip (6) ,
- the front end panel upper mounting bolt (7) .
102365
Remove:
- the front end panel lower mounting bolts (8) ,
112658
Remove the Protection and Switching Unit cover - the front end panel.
mounting bolts (3) . Remove the cooling radiator - condenser -
intercooler assembly from its housing and push it
forwards.
16A-17
STARTING - LOAD
M9R, and 700
CONCERNED
114409
Disconnect the turbocharging pressure sensor con-

114860
nector (9) .
Disconnect the alternator's electrical connector (12)
Remove the turbocharger pressure sensor mounting .
nut on the air inlet valve stay.
Remove the positive terminal mounting nut (13) .
Undo the air inlet hose clip on the damper valve.
114859
114649 Remove the alternator mounting bolts (14) .
Remove: Remove the alternator.
- the air inlet duct clip (10) from the intercooler,
- the air inlet clip mounting bolt (11) from the conden-
ser,
16A-18
STARTING - LOAD
M9R, and 700
REFITTING II - FINAL OPERATION

Refit the Cooling radiator - condenser -
I - REFITTING OPERATION FOR PART intercooler group in its housing.
CONCERNED
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 con-
denser.
Refit the turbocharger pressure sensor on the dam-

per valve stay.
Tighten to torque the turbocharger pressure sen-
sor mounting nut ( 8 Nm ) .
Connect the turbocharging pressure sensor connec-
tor.
Connect the screen washer pipes.

Refit:
18987
Refit the rings (15) using pliers or a vice to facilitate
fitting. - front end panel mounting bolts,
Fit the alternator in place. Tighten to torque:
Tighten to torque - the front end panel upper mounting bolts ( 21
- the alternator mounting bolts ( 25 Nm ) , Nm ) ,
- the positive terminal mounting nut ( 8 Nm ) . - the front end panel lower mounting bolts ( 44
Nm ) .
Connect the alternator electrical connector.
Clip:
- the bonnet opening cable,
- the air inlet scoop.

Refit clips.
Refit:

engine, Accessories belt: Removal - Refitting )
- the half sub-frame side stiffener,

16A-19
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and CA
Mot. 1732 Tool for removing and

refitting the alternator
pulley
Tightening torquesm
alternator decoupling 80 Nm
pulley
- the tensioning roller,
- the tensioning roller mounting bolts.
essential equipment
110266
- tool box for removing and refitting the alternator pulley Hold the alternator in a vice.
(Mot. 1732)
CONCERNED
110276
It is essential to replace an alternator decoupling

110267
pulley with a decoupling pulley.
Fit the hexagon socket (1) from the tool box for re-
moving and refitting the alternator pulley (Mot. 1732)
REMOVAL into the alternator pulley.
Remove the alternator (see 16A, Starting - Char-

ging, Alternator: Removal - Refitting ).
16A-20
STARTING - LOAD
110268 110270
Fit the drive (2) from the tool box for removing and Hold the hexagon socket (6) using an open-jawed
refitting the alternator pulley (Mot. 1732) (correspon- spanner (7) .
ding to the alternator mark) into the hexagon socket
Loosen the decoupling pulley (8) using a ratchet (9)
(3) .
(turning the ratchet clockwise).
Remove the decoupling pulley.
110269
Position the drive adapter (4) in socket (5) .
16A-21
STARTING - LOAD
REFITTING

CONCERNED
110269
Fit:
110266
- the hexagon socket (10) in the alternator,
Screw the new decoupling pulley onto the alternator - the drive (11) (corresponding to the socket in the
rotor. alternator rotor),
- the drive adapter (12) onto the drive (11) .
Note:
Check that the torque wrench is capable of tigh-
tening in an anticlockwise direction.
16A-22
STARTING - LOAD
110266
Tighten to torque the alternator decoupling pulley
( 80 Nm ) using a torque wrench.
Refit the alternator to the vehicle (see 16A, Starting
- Charging, Alternator: Removal - Refitting ).
16A-23
STARTING - LOAD
Starter: Identification 16A
Engine Starter motor
K4J and K4M VALEO : D7E27
K9K MITSUBISHI
F9Q and F4R VALEO : D7R49
16A-24
STARTING - LOAD
Starter: Removal - Refitting 16A
F4R, and 770 or 771
REFITTING
Tightening torquesm
starter mounting bolts 38 Nm

bolts
REMOVAL
terminal.
101482
Check that the centring dowel (1) is in place.
nal.
WARNING
Tighten to torque:
14853 - the starter mounting bolts ( 38 Nm ) ,
Disconnect:
- the oil level sensor connector,
- the starter connections,
Remove:
- the starter motor mounting bolts,
- the starter motor.
16A-25
STARTING - LOAD
F9Q, and 800 or 808
Tightening torquesm
wheel bolts 110 Nm

bolts 4
REMOVAL
terminal.
Remove:
3
- the front right wheel, 5
- the battery,
- the battery tray, 101120
- the air hose between the air filter and turbocharger Remove:
duct, - the bracket (3) ,
- the catalytic converter (4) mounting plate on the
gearbox,
- the catalytic converter (5) (see 19B, Exhaust, Ca-
talytic converter ).
Disconnect the starter motor electrical connections.
1 2
102421
Remove:
- the air hose (1) and gently separate the hose (2) ,
- the engine tie-bar.
102427
Remove:
- the starter motor mounting bolts (6) ,
16A-26
STARTING - LOAD
F9Q, and 800 or 808
REFITTING
Check that the centring dowel is in place.
nal.
WARNING
Tighten to torque:
- the engine cover mounting bolts ( 4 Nm ) .
16A-27
STARTING - LOAD
K9K, and 722
Tightening torquesm
wheel bolts 110 Nm

bolts
REMOVAL 4
terminal. 5
Remove:
102268
Remove:
- the starter mountings (4) ,
- the starter (5) .
REFITTING
Tighten to torque the starter mounting bolts ( 44
Nm ) .
nal.
1
3
WARNING
104175
Remove: Battery: Removal - refitting ).
- the catalytic converter stay (1) ,
Tighten to torque:
- catalytic converter stay (2) on the gearbox,
- the catalytic converter (3) (see 19B, Exhaust, Ca-
talytic converter ). - the battery cover mounting bolts ( 4 Nm ) .
Disconnect the starter motor electrical connections.
16A-28
STARTING - LOAD
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
Tightening torquesm

bolts
REMOVAL
1
terminal.
101482
nal.
WARNING
Battery: Removing - refitting ).
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
14853 - the battery cover mounting bolts ( 4 Nm ) .
Remove:
- the air resonator mounting (K4J),
- the air filter outlet duct (K4M),
Disconnect:
- the starter connections,
Remove:
- the starter motor mounting bolts,
16A-29
STARTING - LOAD
F4R, and 776
Tightening torquesm
the catalytic converter 21 Nm

downstream strut nut
heat shield mounting 8.5 Nm

bolts

bolts
3
REMOVAL
The engine needs to be removed if the starter motor
is being replaced (see 10A, Engine and periphe-
rals, Engine - gearbox ).
Catalytic converter ). 21921
Remove:
2 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
F4R, and 776
REFITTING
21935
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 ) .
nal.
WARNING

( 4 Nm ) .
16A-31
STARTING - LOAD
K9K, and 728 or 729
Tightening torquesm

bolts
REMOVAL
terminal.
Disconnect the gearbox earth.
106201
Disconnect the oil level sensor.
106205
Disconnect:
- the starter electrical connections (1)
- the rail pressure sensor (2) .
16A-32
STARTING - LOAD
K9K, and 728 or 729
106191
Remove:
- the starter mountings,
REFITTING
Tighten to torque the starter mounting bolts ( 44
Nm ) .
nal.
WARNING

( 4 Nm ) .
16A-33
STARTING - LOAD
F9Q, and 804
Tightening torquesm
starter motor mounting 44 Nm

bolts

pipe mounting bolts

bolts
wheel bolts 110 Nm
REMOVAL
terminal.
Remove: 111865
- the engine covers, Remove the turbocharger oil return pipe (2) .
- the battery,
- the battery tray,
- the air hose between the air filter and turbocharger
duct,
Remove the catalytic pre-converter. (see 19B; Ex-
haust, Catalytic pre-converter: Removal - Refit-
ting ).
111868
Disconnect the wiring harness from the starter mo-

tor.
111860 Remove the starter motor mounting bolts (3) .

Remove the air duct (1) from the turbocharger. Remove the starter motor.
REFITTING
Tighten to torque the starter motor mounting bolts
( 44 Nm ) .
16A-34
STARTING - LOAD
F9Q, and 804
Replace the turbocharger oil return pipe seals.
Tighten to torque the turbocharger oil return pipe
nal.
WARNING
Tighten to torque:
16A-35
STARTING - LOAD
M9R, and 700
Equipment required
filling station
Tightening torquesm

bolts
starter base mounting 8 Nm

nut
solenoid excitation 5 Nm
mounting nut

intercooler
intercooler downs- 5.5 Nm 112658

damper valve Remove:
front end panel upper 21 Nm - the Protection and Switching Unit cover mounting
mounting bolts bolts (1) ,
front end panel lower 44 Nm - the Protection and Switching Unit cover.
mounting bolts

bolts

tray
REMOVAL

102504
Remove:
- the engine protectors, and Switching Unit.
- the battery (see 80A, Battery, Battery: Removal - Unfasten the bonnet opening cable (3) .
Refitting ).
Remove:
- the front bumper (see MR365, Bodywork, 55A, - the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Drain the coolant circuit using the filling station
(see 62A, Air conditioning, Maintenance ). Disconnect the screen washer tubes.
16A-36
STARTING - LOAD
M9R, and 700
102365
Remove:

112659
Disconnect the injection computer connector (6) .
Remove:
Unclip the wiring harness (9) from the battery - termi-

nal.
114649
Remove the intercooler downstream duct mounting

bolt (12) on the cooling radiator.
Loosen:
- the intercooler downstream duct clip (13) on the in-

tercooler,

valve.
Remove the intercooler downstream duct from the

intercooler.
114933
Remove the cooling assembly from its housing and
Unclip the air inlet scoop (10) . push the assembly forwards.
16A-37
STARTING - LOAD
M9R, and 700
CONCERNED
109537
Remove the air dehydration canister conditioning
pipe mounting bolt (14) from the air conditioning 114628
compressor. Remove:
- the mounting nut (15) from the starter base,
Note: - the mounting nut (16) from the solenoid excitation.
Plugs must be fitted to the pipe and the compres-
sor to prevent moisture from entering the system.
Remove the air dehydration canister conditioning

pipe from the air conditioning compressor.
114998
Remove the earth wire mounting bolt (17) on the
starter.
Move the starter motor wiring harness to one side.
16A-38
STARTING - LOAD
M9R, and 700
113312
Remove:
- the starter mounting bolts (18) .
REFITTING

CONCERNED
Fit the starter.

( 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
M9R, and 700
II - FINAL OPERATION - the injection computer connectors.
Refit: Refit:
- the air dehydration canister conditioning pipe onto - the clips,
the air conditioning compressor,
- the air dehydration canister conditioning pipe bolts,
mounting bolt onto the air conditioning compressor
(see 62A, Air conditioning, Compressor: Remo-
val - Refitting ).
Fit the cooling assembly.
Refit:
- the intercooler downstream duct onto the intercoo-
Refitting ).
ler and damper valve,
Fill the coolant circuit using the filling station (see
- the intercooler downstream duct mounting bolt
onto the cooling radiator.
Tighten to torque:
- the intercooler downstream duct clip on the in-
tercooler ( 5.5 Nm ) ,
- the intercooler downstream duct clip on the
damper valve ( 5.5 Nm ) .
Refit:
Tighten to torque:
Nm ) ,
Nm ) ,
Clip:
- the bonnet opening cable.
Refit:
- the battery tray,
- the wiring harness mounting nut onto the battery
tray.
Tighten to torque:
tray ( 8 Nm )
Clip the battery - terminal wiring harness.
Connect:
16A-40
STARTING - LOAD
K9K, and 732
Tightening torquesm

bolts
REMOVAL

ting equipment; underbody lift ).
Remove the engine cover.
- Refitting ).
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
K9K, and 732
REFITTING


CONCERNED
Refit:
- the starter motor,
- the starter mounting bolts.
( 44 Nm ) .

Refit the starter nuts.
Clip on the diesel fuel drain pipe.
106205
Connect:
Remove the starter electrical connections (3) .
- injection rail pressure sensor connector,
Disconnect the injector rail pressure sensor connec-
tor.
- the oil pressure sensor connector.
Move the wiring harness against the cylinder block.
II - OPERATION FOR REMOVAL OF PART Connect the battery (see 80A, Battery: Removal -
CONCERNED Refitting ).
Refit the engine cover.
106191
Remove:
- the starter mounting bolts (4) .

16A-42
STARTING - LOAD
Tightening torquesm
starter mountings 38 Nm
catalytic converter 44 Nm
downstream stay nut
heat shield mountings 8.5 Nm
REMOVAL
Removal of the starter requires the engine to be re-
moved (see 10A, Engine and peripherals, Gear-
box - motor assembly: Removal - Refitting ).
21921
Remove:
106249
Remove:
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
16A-43
STARTING - LOAD
REFITTING
21935
Tighten to torque:
- the starter mountings ( 38 Nm ) ,
- the catalytic converter downstream stay nut (
44 Nm ) ,
- the heat shield mountings ( 8.5 Nm ) .
16A-44
IGNITION
Coils Removal - Refitting 17A
F4R, and 770 or 771 K4J, and 730 or 732 K4M, and 760 or 761
REMOVAL
Tightening torquesm
ignition coil mounting 1.5 daNm

screws to torque
the battery cover moun- 0.4 daNm

ting bolts to
The power module is incorporated in the injection com-

puter. The ignition system uses the same sensors as
the injection system.
101490
Disconnect:
- the battery starting with the negative terminal.
14851
- the connectors (1) from the ignition coils.
There are four ignition coils secured directly onto the
spark plugs by bolts on the cylinder head cover.
WARNING
The coils are in series in pairs by the injection com-
puter: Damaged connectors must be replaced.
- track C M4 for cylinders 1 and 4, Remove the coil mounting screws (2) .
- track C M3 for cylinders 2 and 3.
REFITTING
To refit, proceed in the reverse order of removal.
If necessary, replace the coil O-rings.
Tighten the ignition coil mounting screws to tor-
que ( 1.5 daNm ) .
WARNING
Connect the battery; carry out the necessary pro-
gramming ( (see 80A, Battery) ).
Tighten the battery cover mounting bolts to ( 0.4

daNm ) .
17A-1
IGNITION
REMOVAL
Tightening torquesm
ignition coil mounting 15 Nm

bolts

bolts
The power module is built into the injection computer.

The ignition system uses the same sensors as the in-
jection system.
101490
Disconnect:
14851
- the ignition coil connectors (1) .
There are four ignition coils, and they are mounted
directly onto the spark plug by a bolt on the rocker Remove the coil mounting bolts (2) .
cover.
The coils are supplied in series two by two by the in-
jection computer:
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
17A-2
IGNITION
F4R, and 776
106589
Remove the coil mounting bolts (3) .
WARNING
Be sure to replace any damaged connectors.
REFITTING
17A-3
IGNITION
106443
Apply to the four ignition coils a bead (4) of FLUORI-
NE 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 ) ,
17A-4
IGNITION
Spark plugs 17A
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 Brand Type
EYQUEM RFN58LZ
K4J and K4M
CHAMPION RC87YCL
Flat skirt with seal

Gap: 0.95 ( 0.05 mm )
F4R 770 / 771 CHAMPION RC87YCL

Gap 0.90 ( 0.05 mm )
F4R 776 NGK PFR6G-9

Gap 0.85 ( 0.05 mm )
17A-5
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
K4J, and 730 or 732
1 2 3 4 5 6
10 9 8 7
101099
(1) Fuel vapour recirculation sole-

noid valve
(2) Manifold pressure sensor
(3) Motorised throttle valve
(4) Ignition coil
(8) Pinking sensor
(9) Air temperature sensor
(10) Injector rail and injectors
17B-1
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
K4M, and 760 or 761
11 12 13 14 15 17 18
16
22 21 20 19
101804

K4J, and 730 or 732
noid valve
(12) Camshaft dephaser solenoid
valve
(14) Ignition coil
(15) Camshaft position sensor 23
(20) Pinking sensor
(22) Injector rail and injectors 102107
17B-2
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
27
25
29
25
30
24
28
101493 101101
(24) Injector rail (27) Fuel vapour recirculation sole-

(25) Injectors noid valve
26
(30) Ignition coils
101800
31
(26) Motorised throttle valve 32
101498

(32) Pinking sensor
17B-3
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
K4M, and 760 or 761 40
41
34 42
34
33
39
101809
(39) Pinking sensor

101810
valve
(33) Injector rail
(41) Camshaft position sensor
(34) Injectors
35 36
43
38
38
37
101796

noid valve 101811

(38) Ignition coils
17B-4
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
K4M, and 760 or 761
44
46
102144

102735 sor
47
45
102204
101105
17B-5
PETROL INJECTION
K4J, and 730 or 732 K4M, and 760 or 761
48 51
101798 102483
(48) Upstream oxygen sensor (51) Fuel vapour recirculation absor-

ber
49
50
101501
(49) Downstream oxygen sensor

17B-6
PETROL INJECTION
F4R, and 770 or 771 or 776
F4R, and 770 or 771
1 2 3 4 5 6 7
11 10 9 8
102722

noid valve
valve
(4) Ignition coil
(9) Pinking sensor
17B-7
PETROL INJECTION
F4R, and 770 or 771 or 776
F4R, and 776
12 23 13 14 15
22 21 20 19 18 17 16
106078
(12) Ignition coil

noid valve
24
(21) Pinking sensor
(23) Electric water pump
106280
17B-8
PETROL INJECTION
F4R, and 770 or 771 or 776
F4R, and 770 or 771
32
26
27
28
25
31
102732
(31) Pinking sensor

101809
valve
(25) Pinking sensor
valve 33
(27) Camshaft position sensor
(28) Coolant temperature sensor 34
36
36
30
35
30
102724
29 (33) Fuel recirculation solenoid valve

102730 (36) Ignition coil
(29) Injector rail

(30) Injectors
17B-9
PETROL INJECTION
F4R, and 770 or 771 or 776
F4R, and 776
37
39
40
102735
(37) Throttle valve

101809
(39) Pinking sensor

42
38
41
106269
102144 (41) Injector rail

(42) Injectors
sor
17B-10
PETROL INJECTION
F4R, and 770 or 771 or 776
43 46
45
106787

(46) Ignition coils
106633
48
47
44
106279

106278

noid valve
17B-11
PETROL INJECTION
F4R, and 770 or 771 or 776
49 51
101105 102483
(49) Protection and Switching Unit (51) Fuel vapour recirculation absor-
ber
F4R, and 770 or 771
50
52
102204
101798
(52) Upstream oxygen sensor
17B-12
PETROL INJECTION
F4R, and 770 or 771 or 776
56
53
54
101501 106253
(53) Downstream oxygen sensor (56) Downstream oxygen sensor

F4R, and 776
55
106244
(55) Upstream oxygen sensor
17B-13
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
F4R, and 770 or 771 K4M, and 760 or 761 K4J, and 730 or 732
II - DOWNSTREAM OXYGEN SENSOR

gen sensors
2
Tightening torquesm
oxygen sensor 45 Nm
REMOVAL
I - UPSTREAM OXYGEN SENSORS
101501
Remove lambda sensor. (2)
REFITTING
1
Tighten to torque the oxygen sensor ( 45 Nm )
using a 24 mm fork socket for the downstream sen-
sor and tool (Mot. 1495-01) for the upstream oxygen
sensor.
101798
Remove lambda sensor (1) using the tool (Mot.
1495-01) .
17B-14
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
F4R, and 776
II - DOWNSTREAM OXYGEN SENSOR

gen sensors
Tightening torquesm
2
REMOVAL
I - UPSTREAM OXYGEN SENSORS
21926
Remove:
- the oxygen sensor (2) using (Mot. 1495-01) .
REFITTING
106244
Tighten to torque the oxygen sensors ( 34 Nm )
Remove the front engine cover. using tool (Mot. 1495-01) .
Disconnect the oxygen sensor.
Remove the oxygen sensor (1) using the tool (Mot.
1495-01) .
17B-15
PETROL INJECTION
Accelerator pedal potentiometer: Removal - Refitting 17B
F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732
- the pedal.
Tightening torquesm
REFITTING
battery cover mounting 4 Nm Proceed in the reverse order to removal.
bolts
The accelerator pedal potentiometer is incorporated in nal.
the accelerator pedal. If it is replaced, the accelerator
pedal must also be replaced.
WARNING
There are two types of pedal: with or without a resis-
tance point .
Vehicles equipped with cruise control/speed limiter
have an accelerator pedal with a point of resistance at
the end of their travel (kickdown) Note:
This kickdown point is used for exiting the speed limiter A fault on the accelerator pedal position potentio-
function if the driver has to increase his speed. meter results in changes in the idle speed or
engine operation (see 17B, Petrol injection, Idle
speed correction ).
WARNING
A pedal fitted with a kickdown point may be fitted in
4 Nm ) .
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 accelerator pedal connector.
Remove:
- pedal mounting bolts ,
17B-16
PETROL INJECTION
Position and speed sensor 17B
Equipment required F4R, and 776
diagnostic tool
F4R, and 770 K4M, and 760 K4J, and 730 or

732
102485
Program with the engine flywheel target after repla-
cing speed and position sensor (1) or the engine
flywheel
102144
Program the engine flywheel target, after replacing
In third gear, accelerate twice in succession to 4000
speed and position sensor (1) or the engine
rpm , then decelerate to power take-up speed.
flywheel.
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 17B
F4R, and 771 K4M, and 761
Equipment required
diagnostic tool
102144
Program the engine flywheel target, after replacing
speed and position sensor (1) or the engine
flywheel.
Note:
Do not shift the gear lever to D

Check that the vehicle is operating correctly.
17B-18
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
Equipment required F4R, and 770 or 771 or 776
diagnostic tool
Tightening torquesm

bolts

bolts
2 3
REMOVAL
terminal.
4
K4M, and 760 or 761 K4J, and 730 or 732
101822
Remove the battery.
Remove:
1 - the battery tray (3) mounting bolts,
- the electrical wiring harness (4) .
102107
Remove:
- the bolts securing the computer to the mounting,
- the computer.
17B-19
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
REFITTING
21 Nm ) .
nal.
WARNING
5
Note:
When the ignition is switched on, the motorised
throttle valve should go through a cycle of pro-
gramming for its minimum and maximum posi-
tions.
101811
Use the diagnostic tool to check that this program-
Remove the injection computer (5) and its mounting. ming has been completed correctly ET051: Throttle
stop programming .
Perform flywheel target programming during a road
test.
Check that the vehicle is functioning correctly.
( 4 Nm ) .
101890
Remove the four computer mounting bolts.
17B-20
PETROL INJECTION
Special notes 17B
SPECIAL NOTES FOR MULTIPOINT INJECTION 6 - Idle speed (warm engine)
SAGEM S3000
Nominal idle speed
1 - 128-track computer
Engine Engine speed (rpm)
It is marked SAGEM and is a type S3000 FLASH K4J 730 / 750 +/- 50
EEPROM controlling the injection and ignition. 732
K4M 760 700 +/- 30

2 - Multipoint injection functioning in sequential
K4M 761
mode.
F4R 770 750 +/- 50
F4R, and 770 or 771 or 776 K4J, and 730 or 732 F4R 771
F4R 776
Without cylinder n1 marking sensor on the camshaft
Therefore, engine phasing is carried out by software The idle speed is corrected depending on:
using the TDC sensor. Starting the engine in semi-se-
- the engine coolant temperature,
quential mode (for engine phasing) then entering
phased sequential mode. - the battery voltage,
- the air conditioning,
- the engine oil pressure (K4M engine).

- the position of the automatic gearbox selector lever
(F4R engine).
K4M, and 760 or 761
With cylinder n1 marking sensor on the camshaft The- 7 - Maximum speed

refore, engine phasing (cylinder n1 recognition) is car-
ried out using the cylinder marking sensor signal. a - Engine overspeed protection, cold engine
Starting the engine in semi-sequential mode (for engi-
ne phasing) then entering phased sequential mode.
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 .
3 - Injection warning light on the instrument panel
Installation of a special injection warning light (OBD in-

dicator light On Board Diagnostic ) warning light. It K4M, and 760 or 761
is part of the on board diagnostic OBD fault finding
When the coolant temperature is below 75C or for 10
system. 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, in-

volving 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
5 - Fuel circuit without return to the tank. is 5900 rpm .
The pressure regulator is located on the pump/sen-

der unit assembly.
17B-21
PETROL INJECTION
Special notes 17B
b - Engine overspeed protection, warm engine 11 - Operation of the fuel pump
Once the engine is warm, the cut-off returns to its nor- The request is made by the injection computer. It recei-
mal value: ves its power supply from the Protection and Switching
Unit.
K4J, and 730 or 732 K4M, and 760 or 761

12 - Cruise control / speed limiter
The cut-off speed is 6500 rpm whichever gear is enga-
ged (manual or automatic gearbox). The configuration of the cruise control / speed limiter
and the air conditioning is automatic.
13 - Oxygen sensor
Use of two oxygen sensors located upstream and
F4R, and 770 or 771 or 776 downstream of the catalytic converter.
The cut-off speed is 6000 rpm whichever gear is enga-
ged (manual gearbox), and 6300 rpm (automatic gear- 14 - Throttle valve
box).
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
It supplies:
K4M, and 760 or 761
- the fuel pump,
It is continuously varied from 0 to 43 of the crankshaft.
It is controlled by a solenoid valve supplied by an ope- - the air conditioning compressor,
ning cyclic ratio signal operated by the injection com- - the fan assembly,
puter.
- various injection actuators (injectors, fuel vapour ab-
sorber solenoid valve, etc.).
The protection and switching unit is located in the engi-
ne compartment near the battery. It contributes to the
F4R, and 770 or 771 or 776 protection of certain electrical components.
It is controlled by a solenoid valve which is supplied by In this capacity, it comprises:

an all or nothing system from the injection computer. - fuses,
- several internal relays including:
the + after ignition feed relay,
the fuel pump relay,
9 - Operation of the engine cooling fan and the
coolant temperature warning light the air conditioning compressor relay
The request is made from the injection computer throu- the engine cooling fan relays,
gh the multiplex network (coolant temperature centra-
the starter relay (starter motor solenoid operation)
lised control function). The engine cooling fan is
supplied by the Protection and Switching Unit. These relays cannot be removed.
10 - Air conditioning compressor operation 16 - Injection computer

The request is made by the injection computer through It constantly receives from the multiplex network, the
the multiplex network. The request depends on the air signal indicating the electrical power available from the
conditioning , but also the coolant temperature. The air alternator. This is to prevent the vehicle's electrical
conditioning compressor is supplied by the Protection consumption from exceeding the capacity of the alter-
and Switching Unit. nator. The aim is to give priority to charging the battery.
17B-22
PETROL INJECTION
Special notes 17B
17 - Accelerator pedal
Replacement of the accelerator pedal poses no parti-
cular problems.
The computer adopts the value read when the ignition
was switched on as the no load position reference va-
lue.
A twin-track potentiometer is used to inform the com-
puter of the accelerator pedal position. It has two 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 sup-
plied.
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-23
PETROL INJECTION
The S 3000 injection system manages the lighting of 5 - When a fault causing excessive exhaust gas
three warning lights and the display of warning messa- pollution levels is detected
ges according to the severity of the faults detected,
The on board diagnostic indicator light depicting an
with the aim of informing the customer and directing
engine lights up:
fault finding.
- flashing in the event of a fault which might cause
The injection computer controls the lighting of warning destruction of the catalytic converter (destructive mis-
lights and message displays on the instrument panel. fires). If this happens, the vehicle will stop immedia-
These warning lights are lit during the starting phase, in tely.
the event of an injection fault or engine overheating.
- continuously in the event that depollution stan-
The signals to light up the warning lights reach the ins- dards have not been adhered to (polluting engine
trument panel via the multiplex network. misfires, catalytic converter fault, oxygen sensor fault,
inconsistency between the oxygen sensors and fuel
vapour absorber fault).
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 le-
vel 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 ma-

trix 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 immedia-
tely.
17B-24
PETROL INJECTION
Immobiliser function 17B
This vehicle is equipped with an immobiliser which re-
quires a specific procedure for replacing the computer.
REPLACING AN INJECTION COMPUTER

To program the immobiliser code (see 82A, Engine
immobiliser, Injection computer: Programming:
).
WARNING
- The injection computer retains its immobiliser
code for life.
- 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-25
PETROL INJECTION
Injection - air conditioning programming 17B
F4R, and 770 or 771 or 776
I - INJECTION COMPUTER - AIR CONDITIONING II - COMPRESSOR FUNCTION PROGRAMMING
COMPUTER CONNECTION
In certain operating phases, the injection computer di-
Climate control is managed by several computers. sables the air conditioning compressor.
The injection computer is responsible for:
- managing the request for cold air in response to pas-
senger compartment controls and the circuit pressure To facilitate starting on a hill, operation of the air condi-
level. tioning compressor is prevented for 20 seconds .
- determining the power absorbed by the air conditio-
ning compressor based on the pressure of the circuit, 2 - Maximum engine speed protection
programming
- authorising the fan assembly control according to ve-
hicle speed and circuit pressure. Operation of the air conditioning compressor is preven-
ted if:
- authorising or disables the compressor clutch.
- the instantaneous engine speed is above 6300 rpm ,
When climate control is activated, the climate control
panel requests authorisation for air conditioning com- - the constant engine speed is above 5760 rpm for
pressor operation. more than 10 seconds .
The injection computer authorises or prevents:

- air conditioning compressor operation,
Operation of the air conditioning compressor is preven-
- fan assembly operation, ted if the coolant temperature is above 115C at high
speed and high load.
- an accelerated idle speed.
Entry conditions:
This speed depends on the power absorbed by the
compressor: - Engine speed greater than 4512 rpm ,
- 900 rpm . - and inlet manifold pressure below 700 mbar .
The request to run the fan assembly and compressor is Exit conditions:
made by the injection computer via the multiplex
- for a time of 10 seconds ,
network. This request depends on the air conditioning
but also on the coolant temperature and vehicle speed. - and certain conditions of the coolant temperature
centralised management function.
The engine cooling fan and the compressor are sup-
plied by the Protection and Switching Unit.
The data used for the function is exchanged via the
multiplex network:
- Track A A4 CAN HIGH multiplex connection,
- Track A A3 CAN LOW multiplex connection.
The injection computer also receives the refrigerant
pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
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
K4J, and 730 or 732
COMPUTER CONNECTION
senger compartment controls and the circuit pressure To facilitate starting on a hill, operation of the air condi-
level. tioning compressor is prevented for 10 seconds .
ning compressor based on the pressure value of the 2 - Maximum engine speed protection
circuit, programming
- authorising the fan assembly control according to ve- The compressor does not work if:
hicle speed and circuit pressure.
- the instantaneous engine speed is above 6688 rpm ,
- the constant engine speed is above 6112 rpm for
When climate control is activated, the climate control more than 10 seconds .
panel requests authorisation for air conditioning com-
pressor operation.
The injection computer authorises or prevents:
The compressor does not work if the coolant tempera-
- air conditioning compressor operation, ture is above 119C at high speed and high load.
- fan assembly operation, Entry conditions:
- an accelerated idle speed. - engine speed greater than 6496 rpm ,
This speed depends on the power absorbed by the - and inlet manifold pressure below 1046 mbar .
compressor:
Exit conditions:
- 850 rpm .
- engine speed below 6496 rpm ,
The request to run the fan assembly and compressor is
made by the injection computer via the multiplex - and coolant temperature below 119C ,
network. This request depends on the air conditioning - and inlet manifold pressure below 1046 mbar .
but also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup- 4 - Performance return programming
plied by the Protection and Switching Unit.
The compressor is prevented from operating for 5 se-
The data used for the function is exchanged via the conds .
multiplex network:
Entry conditions:
- throttle fully open,
- and engine speed below 2016 rpm ,
The injection computer also receives the refrigerant
pressure sensor signal on tracks: - and engine speed below 10 mph (16 km/h) .
- B J3 refrigerant pressure sensor signal, Exit conditions:
- B J2 refrigerant pressure sensor + 5 V supply, - throttle not fully open,
- B K2 refrigerant pressure sensor earth. - or for a time of 5 seconds ,
The compressor is of variable displacement type. - 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 5 - Performance return programming for hill starts
by the AC compressor is never 0 , irrespective To facilitate hill-starting, under certain load and engine
of the status of the compressor. The minimum value operating conditions, operation of the air conditioning
reading is approximately 250 to 300 W . compressor is prevented for 5 seconds .
17B-27
PETROL INJECTION
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 .

coolant temperature is above 119C at high speed and
high load.
17B-28
PETROL INJECTION
K4M, and 760 or 761
COMPUTER CONNECTION
senger compartment controls and the circuit pressure The compressor is prevented from operating for 10 se-
level. conds after engine start.
ning compressor based on the pressure value of the 2 - Performance return programming
circuit,
The compressor is prevented from operating for 5 se-
- authorising the fan assembly control according to ve- conds .
hicle speed and circuit pressure.
Entry conditions:
- throttle fully open,
When climate control is activated, the climate control
- and engine speed below 2016 rpm ,
panel requests authorisation for air conditioning com-
pressor operation. - and engine speed below 10 mph (16 km/h) .
The injection computer authorises or prevents: Exit conditions:
- air conditioning compressor operation, - throttle not fully open,
- fan assembly operation, - or for a time of 5 seconds ,
- an accelerated idle speed. - or engine speed at or above 2048 rpm ,
This speed depends on the power absorbed by the - or vehicle speed greater than 16 mph (26 km/h) .
compressor:
- 850 rpm . 3 - Performance return programming for hill starts
The request to run the fan assembly and compressor is To facilitate hill-starting, under certain load and engine
made by the injection computer via the multiplex operating conditions, operation of the air conditioning
network. This request depends on the air conditioning compressor is prevented for 5 seconds .
but also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup- 4 - Maximum engine speed protection
plied by the Protection and Switching Unit. programming
The data used for the function is exchanged via the The air conditioning compressor does not work if the
multiplex network: engine speed is above 6496 rpm .
The injection computer also receives the refrigerant coolant temperature is above 119C at high speed and
pressure sensor signal on tracks: high load.
- 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.
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 17B
I - THROTTLE BODY ding to the position of the accelerator. Therefore, the
maximum engine speed under full load or in neutral is
The throttle valve ensures that idle speed regulation 2500 rpm .
and engine air intake modulation are performed cor-
rectly. It is composed of an electric motor and two
throttle position potentiometers. 4 - Pedal information mode
If the signal from the inlet manifold vacuum is lost, ope-
When the engine is idling, the throttle position is regu-
lated according to the idle speed setpoint. This setpoint ning of the throttle is directly proportional to pressure
takes into account the major power consumers (air on the accelerator pedal.
conditioning) and operating conditions (air temperature
and coolant temperature).
Note:
When the driver depresses the accelerator pedal, his Each of these modes results in the injection fault
request is translated into an angle of throttle opening. warning light on the instrument panel lighting up.
However, to improve driving pleasure, the throttle ope-
ning is not directly proportional to the drivers request.
To eliminate misfires, facilitate gear changes and per-

form 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 val-
ve.
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 res-
tricts 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 si-
gnal 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 in-
jection computer imposes a set accelerator pedal posi-
tion 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 thrott-
le). In this case, the throttle is returned to its mechani-
cal 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-30
PETROL INJECTION
Idle speed correction 17B
F4R, and 770 or 771 or 776
COOLANT TEMPERATURE
Coolant temperature Engine speed

( C ) ( rpm )
- 20 1072
20 976 (1)
40 896
80 752
100 752
120 848
(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 swit-
ched on when the battery is not sufficiently charged. It
starts when the voltage falls below 12.7 V and may in-
crease the engine speed by a maximum of 160 rpm ,
i.e. 910 rpm .
III - IDLE SPEED ADJUSTMENT WHEN THERE IS A

MANIFOLD PRESSURE SENSOR FAULT
In the event of a manifold pressure sensor fault is set at
1024 rpm .
Note:
If the engine is started when the coolant tempera-
ture 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
K4J, and 730 or 732
COOLANT TEMPERATURE

( C ) ( rpm )
- 20 1152
20 1008 (1)
40 960
80 752
100 752
120 896

BALANCE
i.e. 910 rpm .

If the manifold pressure sensor is faulty, the idle speed
is set at 896 rpm .
Note:
17B-32
PETROL INJECTION
K4M, and 760 or 761
COOLANT TEMPERATURE

( C ) rpm )
- 20 1150
20 944 (1)
40 850
80 700
100 700
120 752

BALANCE
i.e. to 860 rpm .

If the manifold pressure sensor is faulty, the idle speed
is set at 896 rpm .
Note:
17B-33
PETROL INJECTION
Adaptive idle speed correction 17B
I - ADAPTIVE IDLE SPEED CORRECTION
WARNING
Principle After the computer memory has been cleared, it is
imperative to start the engine, stop it, then leave it
In normal warm-engine operating conditions, the idle
running at idle speed so that the adaptive correction
speed OCR PR091 varies between a high and low va-
can recalibrate itself correctly.
lue 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 tempe-

rature 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 ra-
tio 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-34
PETROL INJECTION
Richness regulation 17B
F4R, and 770 or 771 or 776 K4M, and 760 or 761
III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: downstream oxygen
diagnostic tool
sensor voltage on the diagnostic tool
An engine operating with the S 3000 computer is fitted The value read represents the voltage supplied to the
with two oxygen sensors called the upstream sensor computer by the oxygen sensor located upstream of
and the downstream sensor after their position on the the catalytic converter, expressed in millivolts.
catalytic converter.
The function of this sensor is to locate faults on the ca-
talytic converter and to perform a second, more preci-
I - SENSOR HEATING se, check on the richness. This second richness check
is called the slow regulation loop . This function is
Oxygen sensor heating is controlled by the computer if
activated only after the engine has been operating for a
all of the following conditions are met:
certain time.
- the inlet manifold pressure is below a threshold which
When the engine is looped (when the computer
depends on a function table of the engine speed,
corrects the richness according to the two sensors, the
- the road speed is below ( 84 mph (135 km/h) , engine is said to be looped ), the voltage should be
in the region of 600 mV (except at idle speed when it
- after a certain mapped engine operating time which may be difficult to stabilise). When the vehicle is dece-
depends on the engine's top dead centre (excluding lerating, the voltage should be approximately 100 mV .
no load operation) and the coolant temperature.
Oxygen sensor heating is stopped if the following con-

Note:
ditions are met:
Do not take into account the voltage on the dia-
- the vehicle speed is greater than 85 mph (140 km/h) gnostic tool at idle speed.
(value given for information only),
- when the engine is under heavy load.

IV - RICHNESS CORRECTION
II - UPSTREAM SENSOR VOLTAGE 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 rich-
Reading parameter PR098: upstream oxygen ness corrections applied by the computer depending
sensor voltage on the diagnostic tool on the richness of the fuel mixture as determined by
the oxygen sensor located upstream of the catalytic
The value read represents the voltage supplied to the converter (the oxygen sensor in fact analyses the oxy-
computer by the oxygen sensor located upstream of gen content of the exhaust gas).
the catalytic converter. It is expressed in millivolts. With
a looped engine (when the engine corrects the rich- The centre point of the correction value is 50% and the
ness according to the two sensors, the engine is said to end value 0 to 100% .
be looped ); the voltage should oscillate quickly
between two values: - value less than 50% : request for decrease in rich-
ness,
- 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 1 - Loop mode
and maximum values, the poorer the signal from
the sensor. Richness regulation starts after a maximum delay of 10
seconds and if the coolant temperature is above 10C
If the difference is small, check the sensor heater. (manual gearbox) and 2.5C (automatic gearbox).
17B-35
PETROL INJECTION
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 vol-
tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN

SENSOR FAULT
When the voltage from the oxygen sensor is incorrect
(varying only slightly or not at all) during mixture regu-
lation, the computer will only enter defect mode if 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 en-
ters the open loop mode directly.
17B-36
PETROL INJECTION
K4J, and 730 or 732
III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: downstream oxygen
diagnostic tool sensor voltage on the diagnostic tool
An engine operating with the S 3000 computer is fitted The value read represents the voltage supplied to the
with two oxygen sensors called the upstream sensor computer by the oxygen sensor located upstream of
and the downstream sensor after their position on the the catalytic converter, expressed in millivolts.
catalytic converter.
The function of this sensor is to locate faults on the ca-
talytic converter and to perform a second, more preci-
I - SENSOR HEATING se, check on the richness. This second richness check
is called the slow regulation loop . This function is
Oxygen sensor heating is controlled by the computer if activated only after the engine has been operating for a
all of the following conditions are met: certain time.
- the inlet manifold pressure is below a threshold which When the engine is looped (when the computer
depends on a function table of the engine speed, corrects the richness according to the two sensors, the
engine is said to be looped ), the voltage should be
- the speed is below ( 84 mph (135 km/h) , in the region of 600 mV (except at idle speed when it
may be difficult to stabilise). When the vehicle is dece-
- after a certain mapped engine operating time which lerating, the voltage should be approximately 100 mV .
depends on the engine's top dead centre (excluding
no load operation) and the coolant temperature.
Oxygen sensor heating is stopped if the following con- Note:

ditions are met: Do not take into account the voltage on the dia-
gnostic tool at idle speed.
- the vehicle speed is greater than 85 mph (140 km/h)
(value given for information only),
IV - RICHNESS CORRECTION
- when the engine is under heavy load.
The richness correction value read on the diagnostic
tool i n p a r a m e t e r PR 138: RICHNESS
II - UPSTREAM SENSOR VOLTAGE
CORRECTION represents the average of the rich-
ness corrections applied by the computer depending
Reading parameter PR098: upstream oxygen on the richness of the fuel mixture as determined by
sensor voltage on the diagnostic tool the oxygen sensor located upstream of the catalytic
converter (the oxygen sensor in fact analyses the oxy-
The value read represents the voltage supplied to the gen content of the exhaust gas).
computer by the oxygen sensor located upstream of
the catalytic converter. It is expressed in millivolts. With The centre point of the correction value is 50% and the
a looped engine (when the engine corrects the rich- end value 0 to 100% .
ness according to the two sensors, the engine is said to - value less than 50% : request for decrease in rich-
be looped ); the voltage should oscillate quickly ness,
between two values:
- value above 50% : request for increase in richness.
- 100 mV and 450 mV for a lean mixture,
- 450 mV and 900 mV for a rich mixture. V - ENTERING RICHNESS REGULATION MODE
1 - Loop mode
Note:
The smaller the difference between the minimum The start of richness regulation is effective following a
and maximum values, the poorer the signal from period which depends on the engine coolant tempera-
the sensor. ture when the engine is started. At 20C , the start of
the richness loop is effective after approximately 8 se-
If the difference is small, check the sensor heater. conds .
17B-37
PETROL INJECTION
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 vol-
tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN

SENSOR FAULT
When the voltage from the oxygen sensor is incorrect
(varying only slightly or not at all) during mixture regu-
lation, the computer will only enter defect mode if 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 en-
ters the open loop mode directly.
17B-38
PETROL INJECTION
Adaptive richness correction 17B
K4J, and 730 or 732 K4M, and 760 or 761
I - PRINCIPLE Pressure zones which must be passed through
during the test
In looping phase, the richness regulation corrects the
injection time to obtain fuel dosing as close as possible There are five pressure zones to scan during road tes-
to a richness of 1. Richness correction value PR138 is ting. These zones are defined by the following calibra-
tions:
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 re- Range mbar
gulation at 50 % .
N1 258 to 458 Average 358
Adaptive corrections take 50% as the average value
after reinitialising the computer (clearing the memory),
and have end values. n3 536 to 614 Average 575

Deactivation of the adaptive programs in the case
of prolonged idle speed regulation with a hot N5 692 to 813 Average 752
engine
If the coolant temperature is above 90C while idling for II - INTERPRETING VALUES OBTAINED FROM A
more than 10 minutes (K4M engine) and 1 minute ROAD TEST
(K4J engine), the adaptives are fixed until the end of
In the event of a lack of fuel (injectors clogged, pressu-
idling.
re and fuel flow too low, etc), the richness regulation in-
creases to obtain a richness as close as possible to 1
Programming conditions for adaptive richness and the richness adaptive corrections increase until the
correction richness correction is again fluctuating around 50% .
If there is an excess of fuel, the logic is inverted.
- 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 va-
ried driving over a distance of 3 to 6 miles (5 to 10 km)
. After the test, read the adaptive values. Initially 50% ,
they should have changed. If not, take the readings
again, taking care to observe the test conditions strict-
ly.
PR138 Richness correction 30%

< or = X < or =
98%
PR143 Richness adaptive 25%

gain
< or = X < or =
63%

offset
< or = X < or =
63%
17B-39
PETROL INJECTION
Adaptive richness correction 17B
F4R, and 770 or 771 or 776
I - PRINCIPLE Pressure zones which must be passed through
during the test
In looping phase, the richness regulation corrects the
There are five pressure zones to scan during road tes-
injection time to obtain fuel dosing as close as possible
ting. These zones are defined by the following calibra-
to a richness of 1. Richness correction value PR138 is
tions:
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 re- Range mbar
gulation at 50 % .
Adaptive corrections take 50% as the average value N2 398 to 516 Average 457
after reinitialising the computer (clearing the memory),
and have end values. n3 516 to 637 Average 576

Deactivation of the adaptive programs in the case
of prolonged idle speed regulation with a hot N5 753 to 872 Average 812
engine
If the coolant temperature is above 80C while idling for II - INTERPRETING VALUES OBTAINED FROM A
more than 1 minute , the adaptives are fixed until the ROAD TEST
end of idling. In the event of a lack of fuel (injectors clogged, pressu-
re and fuel flow too low, etc), the richness regulation in-
creases to obtain a richness as close as possible to 1
Programming conditions for adaptive richness and the richness adaptive corrections increase until the
correction richness correction is again fluctuating around 50% .
- Warm engine: coolant temperature above 80C , If there is an excess of fuel, the logic is inverted.
- 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 va-
ried 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 12.5%

gain
< or = X < or =
87.5%

offset
< or = X < or =
87.5%
17B-40
PETROL INJECTION
Central coolant temperature management 17B
The fan assembly is controlled by the injection compu-
ter.
I - ANTI-PERCOLATION FUNCTION
The anti-percolation function is controlled by the injec-

tion computer.
The coolant temperature signal used is that from the in-

jection system.
K4J, and 730 or 732 K4M, and 760 or 761
After switching the ignition off, the system enters moni-

toring 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 acti-
vated.
F4R, and 770 or 771 or 776
After switching the ignition off, the system enters moni-

toring 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 tem-

perature exceeds 98C and stops when the temperatu-
re falls below 96C .
The fan assembly is operated at high speed if the coo-

lant 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 17B
F4R, and 770 or 771 K4M, and 760 or 761
I - SPECIAL NOTES 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
F4R, and 770 or 771 K4M, and 760 or 761 to be adjusted.
Its role is to modify the valve timing.
To improve cylinder filling at all speeds, K4M and F4R 2

engines are fitted with an inlet camshaft dephaser (1) .
15200
The operation of the camshaft dephaser varies conti-

nuously.
The computer supplies the solenoid valve with a varia-
ble opening cyclic ratio proportional to the desired de-
phasing.
Dephasing is varied continuously from 0 to 43 of 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 101814
must be closed. The camshaft dephaser control solenoid valve is con-
trolled 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 - outside idling speed and no load,
The oil is supplied to the dephaser by a solenoid valve - threshold of mapping according to load and engine
(2) located on the cylinder head. speed reached,
17B-42
PETROL INJECTION
Camshaft dephaser: Description 17B
F4R, and 770 or 771 K4M, and 760 or 761
- coolant temperature between 10 and 120C ,
- engine oil temperature too high. Note:

Defect modes: Up to 1,500 rpm , the solenoid valve is no longer
supplied. The mechanism is locked by the piston.
- dephaser returns to initial position, As soon as the solenoid valve is supplied, at
speeds above 1,500 rpm , the oil pressure pushes
- zero dephasing. 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 significant 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) lo-
cated 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,
3
- 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
From 1,500 to 4,300 rpm , the computer supplies the A solenoid valve which is blocked open leads to an
solenoid valve. unstable idle speed and too high a pressure in the
manifold at idling speed.
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 me-
chanism.
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 The fault may not be re-detected:
Continuous illumination of the light after several conse- - if the fault is fleeting in nature,
cutive detections of a fault (depending on the compo- - due to the driving style of the customer, which may
nent). not always cover all of the fault detection condi-
tions.
2 - Combustion misfiring that could destroy the
catalytic converter
Immediate illumination and flashing of the warning li-
ght.
3 - Catalytic converter or oxygen sensor fault,

polluting misfires
Continuous illumination of the light after a fault is de-
tected three times consecutively.
WARNING
The diagnostics of the catalytic converter and ups-

tream oxygen sensor are sequential and are run:
- once when driving (they take several seconds per
test),
- only under certain specific driving conditions.
Under certain driving conditions, it may be the case
that fault finding for certain functions are not perfor-
med (e.g. when in a traffic jam).
II - MANAGEMENT OF THE ONBOARD

DIAGNOSTIC (OBD) WARNING LIGHT
1 - Warning light comes on

If the same OBD fault is detected during three conse-
cutive journeys or there is an electrical fault.
2 - Warning light flashes

If misfires that could destroy the catalytic converter 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 clea-
red from the computer without using the fault finding to-
ol.
17B-44
PETROL INJECTION
Conditions for carrying out fault finding (when driving) 17B
I - CONDITIONS FOR ENTERING FAULT FINDING Power take-up speed is the moment when, during de-
MODE celeration under no load and the injection cut out, the
computer authorises injection again.
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 tem- 2 - Programming of richness adaptive parameters
perature read by the sensor is not between -7.5C and To perform this programming, the vehicle must be dri-
119.39C , or if the difference between 1046 mbar and ven within the pressure ranges (see 17A, Petrol injec-
the manifold pressure is greater than 273 mbar (altitu- tion, Adaptive richness correction ).
de 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 injec-
tion 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 ab-
sorber bleed is closed and the richness adaptive para-
meters are frozen at their last value.
II - TEST PROCEDURE
Before performing the tests, carry out the following in
the sequence shown:
- repair all electrical faults,
- clear all faults,

- carry out injection system programming,
- check the OBD system.
III - COMPLETE INITIALISATION OF THE OBD
In order to reinitialise the OBD function, it is necessary

to carry out following operations:
- clear stored faults,
- clear OBD faults,

- clear all programming.
IV - PROGRAMMING NECESSARY FOR OBD

Programming must be reinitialised when replacing:
- an injection computer,
- an engine flywheel target,
- an engine speed sensor.
1 - Engine flywheel target programming

17B-45
PETROL INJECTION
Combustion misfire fault finding 17B
IV - CONDITIONS FOR DETECTION
Equipment required Check that programming has been correctly carried
out.
diagnostic tool
Check that the prerequisites for switching on the igni-
The purpose of detecting misfiring is to detect any mal- tion and for detecting misfiring correspond.
functions which could cause hydrocarbon pollutant Detection is carried out as soon as the coolant tempe-
emissions to exceed the OBD limit, or cause damage rature is above 7.5C , in three operating ranges
to the catalytic converter. between idle speed and 4,500 rpm .
The pollutant misfiring test can also be carried out by
Note: maintaining the engine at idle speed with all the power
consumers on for 10 minutes .
- In comparison to the Sagem 2000 injection,
Sagem 3000 has the following functions:
injection cut-off to cylinders causing misfiring, WARNING
At the end of this test, it is essential that the ignition
appearance of a fault indicating non-conformity
is not switched off before the result is read on the
of the flywheel target.
diagnostic tool. Switching the ignition off will lead to
- If distortion of the target is too marked, the compu- the results being misinterpreted.
ter cannot implement an adjustment that is suffi-
cient to detect misfiring correctly.
V - REPAIR CONFIRMATION
Using the tool diagnostic tool , check:
I - THE FAULT FINDING SYSTEM CAN DETECT:
- clogging or flooding of a spark plug,
ET 057 Misfiring on cylinder 1 No
- clogging of the injectors or an injector flow fault,
- incorrect operation of the supply system (pressure re-
gulator, fuel pump, etc.), ET 059 Misfiring on cylinder 3 No
- a faulty connection in the petrol or injection circuits
(coil secondary, etc.).
Following this test, if the diagnostic tool has indicated
II - MEASUREMENT OF ENGINE MISFIRINGS misfiring faults DF065 , DF059 , DF060 , DF061 , or
DF062 , refer to the appropriate fault finding procedure
Fault finding is performed by measuring the instanta- for the symptom concerned.
neous 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 de-
tected, 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 li-
ght 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.
17B-46
PETROL INJECTION
Catalytic converter fault finding 17B
The purpose of catalytic converter fault finding is to de- III - REPAIR CONFIRMATION
tect a fault which could cause hydrocarbon pollutant
If after the test, the diagnostic tool has detected a cata-
emissions to exceed the OBD limit.
lytic converter fault DF110: Catalytic converter
The catalytic converter's capacity to store oxygen is in- refer to the fault finding procedure for this fault.
dicative 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 car-
ried out after the engine has been running for about
16.5 minutes , and if all the necessary conditions for
switching on the ignition are still met:
- no electrical faults,
- no misfiring detected,
- no catalytic converter fault finding performed 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 stabi-

lised 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 oxy-

gen 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 sen-
sor fluctuates (the OBD warning light comes on after
three journeys).
WARNING
At the end of this test, it is essential that the ignition
diagnostic tool. Switching off the ignition will lead to
the results being misinterpreted.
17B-47
PETROL INJECTION
Oxygen sensor fault finding 17B
Equipment required
WARNING
diagnostic tool At the end of this test, it is essential that the ignition
The purpose of fault finding on the upstream oxygen diagnostic tool. Switching off the ignition will lead to
sensor is to detect faults that would cause emissions of the results being misinterpreted.
hydrocarbon, carbon monoxide or nitrogen oxide to ex-
ceed the OBD limit. It is carried out by measuring and
comparing periods of upstream oxygen sensor vibra- V - REPAIR CONFIRMATION
tion. If, after the test, the diagnostic tool has detected an
upstream oxygen sensor fault DF092: Upstream
I - POSSIBLE CAUSES OF FAULTS oxygen sensor circuit refer to the fault finding pro-
cedure for this fault.
There are possible types of fault in the upstream oxy-
gen sensor:
- mechanical damage to an electrical component

(breakage, cut in wire) which leads to an electrical
fault,
- chemical damage to the component, which causes
the response time of the sensor to slow down, thus in-
creasing its switching period.
II - CONDITIONS FOR STARTING FAULT FINDING
When test conditions are reached, the computer 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 mi-
nutes , and if all the necessary conditions for switching
on the ignition are still met:
- no electrical faults detected,

- programming has been carried out,
- no oxygen sensor fault finding performed since 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.
17B-48
PETROL INJECTION
Speed limiter: Operating principle 17B
Entry conditions:
- switch in speed limiter position,
- 19 mph (30 km/h) minimum, 125 mph (200 km/h)
maximum (guideline only),
- + , - or R buttons pressed.
Exit conditions:
- accelerator depressed firmly (beyond the safety resis-
tance point),
- switch in the off position,
- 0 button depressed,
- injection computer intervention (fault or overspeed),
Note:
If the warning light on the instrument panel flashes,
it informs to the driver that the cruising speed can-
not be maintained.
17B-49
COOLING SYSTEM
General information 19A
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drive
IMPORTANT
belt,
The circuits are designed to be pressurised; take
care at high temperatures (risk of serious scalding). - that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
Never remove the valve from the expansion bottle air.
while the engine is hot.
Vehicles in the current range have cooling circuits with
Similarly, take care when working under the bonnet, the following basic specifications:
as the radiator fan(s) may start up unexpectedly.
- Pressurised sealed circuit (expansion bottle valve),
Do not open the bleed valve(s) while the engine is
running.
Note:
Summary of expansion bottle valve ratings.
WARNING
Expansion bottle valve with:
The coolant helps to keep the engine running pro-
perly (heat exchange). a yellow hand: 1.4 bar
The system does not operate using pure water. a white hand: 1.6 bar
a grey hand: 1.8 bar
- circuit using type D coolant only.

WARNING
Drain with the engine warm.
Note:
Flushing and refilling should be carried out with a
warm or cold engine. Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guideli-
Never flush a hot engine (risk of serious thermal nes marked on the container.
shock).
WARNING
When carrying out a repair that requires a the cir-
cuit to be completely drained, it is essential to flush
the circuit with clean water, blow compressed air
through the circuit to eliminate water, fill and drain
the circuit and then measure the effective protec-
tion.
The criteria to be met are:
- Protection down to - 25C 2 for cold and tempe-
rate climates,
- Protection down to - 40 C 2 for very cold clima-
tes
Note:
Refer to the vehicle's maintenance service 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 19A
Grade and quantity of coolant
Engine Suffix Quantity Grade

(litres)
730
K4J 6
732
760 6
K4M
761 6.5
722 5.3
728 6.5 GLACEOL RX

K9K
(type D).
729 6.8
Only use
732 7.5
coolant
770 6
fluid
F4R 771
6.5
776
800 7.2
F9Q 804 7.6
808 7.2
M9R 700 7.5
Thermostat
Engine Start of ope- End of ope-

ning (C) ning (C)
K4J 89 99 2
K4M 89 99 2
K9K 89 99 2
F9Q 89 99 2
F4R 89 99 2
M9R 89 99 2
19A-2
COOLING SYSTEM
Checking 19A
I - RECOMMENDATIONS FOR REPAIR II - CHECKING THE CIRCUIT SEALING
IMPORTANT Note:
The circuits are designed to be pressurised; take The expansion bottle valve must be replaced if
care at high temperatures (risk of serious scal- coolant is leaking from the valve.
ding).
Never remove the valve from the expansion
Checking the cooling system and the expansion
bottle while the engine is hot.
bottle valve
Similarly, take care when working under the bon-
net, as the radiator fan(s) may start up unexpec-
tedly.
Do not open the bleed valve(s) while the engine
is running.
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 Works-
hop Repair Manual of the vehicle concerned.
19A-3
COOLING SYSTEM
Diagram 19A
K4J, and 730 or 732 K4M, and 760 or 761
9
3
5 9
1
4
6
7
10
2
8
105003
(1) Engine
(2) Cooling radiator
(3) Heating radiator
(4) Expansion tank
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Automatic gearbox coolant-oil
intercooler (if fitted to the vehi-
cle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-4
COOLING SYSTEM
Diagram 19A
K9K, and 722 or 728 or 729
9
7
1
5
4 8
10
11
110741
(1) Engine
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 11 mm choke (K9K 722)
(8) 9 mm by-pass choke (K9K 728 /
729)
(9) Bleed screws
(10) Coolant-engine oil intercooler
(11) Coolant-oil intercooler (K9K
729)
Note:
bar .
19A-5
COOLING SYSTEM
Diagram 19A
F9Q, and 800 or 808
9
3
9
7
5 1
4
10
8
2
102269
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 9 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
Note:
bar .
19A-6
COOLING SYSTEM
Diagram 19A
F4R, and 770 or 771
9
3
9
10 1
4 5
7
6
2
11
102740
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) 8.3 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
(11) Automatic gearbox coolant-oil
intercooler (if fitted to the vehi-
cle)
Note:
bar .
19A-7
COOLING SYSTEM
Diagram 19A
F4R, and 776
9
12 3
1 11
5
4
6 9 8
10
13
106628
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Water-oil intercooler
(11) Thermostat mounting
(12) Turbocharger
Note
The expansion bottle valve rating is 1.4 bar .
19A-8
COOLING SYSTEM
Diagram 19A
F9Q, and 804
12 9
11 7 3
1
5
4
6
9 13
10
14
112266
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 16 mm choke
(9) Bleed screws
(11) Cylinder head coolant outlet unit
(12) Turbocharger
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEM
Diagram 19A
K9K, and 732
7
7
3
9
5 1 7
112268
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Bleed screws
Note:
bar .
19A-10
COOLING SYSTEM
Diagram 19A
M9R, and 700
114452
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Choke
(8) Choke
(9) Bleed screws
(10) Water-oil heat exchanger
noid valve
Note:
bar .
19A-11
COOLING SYSTEM
Cooling circuit: Draining - Refilling 19A
Special tooling required WARNING
When carrying out a repair that requires a complete
Car. 1363 Trim removal lever change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
Mot. 1202-01 Clip pliers for hose clips (large
drive out the water, fill and bleed the circuit and
model)
then measure the effective protection.
Mot. 1202-02 Clip pliers for hose clips (small The parameters to be observed are:
model)
- Protection down to - 25C 2 for cold and tempe-
Mot. 1448 Remote operation pliers for coo- rate climates,
ling system hose clips - Protection down to - 40 C 2 for very cold clima-
tes.
Mot. 1700 Cooling system filling and dia-
gnostic tool
Note:
IMPORTANT Before carrying out any operation, protect electrical
The circuits are designed to be pressurised; take equipment using plastic bags.
care at high temperatures (risk of serious burns).
Never remove the cap from the expansion bottle
while the engine is hot. Note:
Similarly, take care when working under the bonnet, The engine must be switched off and the air condi-
as the radiator fan(s) may start up unexpectedly. tioning system deactivated to prevent the engine
Do not open the bleed valve(s) while the engine is cooling fans operating as soon as the engine is
running. started.
DRAINING
WARNING
Use the following tools:
The coolant helps to keep the engine running pro-
perly (heat exchange). - (Car. 1363) ,
The system does not operate using pure water. - (Mot. 1202-01) ,
- (Mot. 1202-02) ,
WARNING - (Mot. 1448) .

Drain the fluid with the engine warm. Remove the expansion bottle cap.
Flushing and refilling should be carried out with a Open the cooling system at the cooling radiator bot-
warm or cold engine. tom hose using the (Car. 1363) .
Never flush a hot engine (risk of serious thermal
Blast compressed air into the circuit through the ex-
shock). pansion 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 19A
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 over-
flows.
Refit the expansion bottle cap.
Bleed the circuit (see 19A, Cooling system, Coo-
ling circuit: Bleeding, page 19A-15) .
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
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 fluid with the engine warm.
Flushing and refilling should be carried out with a
warm or cold engine.
Never flush 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 flush the engine
cooling radiator.
Blast compressed air into the circuit through the ex-

pansion bottle cap orifice to remove as much water
as possible.
Connect the top and bottom hoses.
19A-14
COOLING SYSTEM
Cooling circuit: Bleeding 19A
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.
K9K, and 722 or 728 or 729 or 732

Run the engine at 1500 rpm , rapidly varying the en-
gine speed (until you reach maximum speed) 2 to 3
times approximately every 2 minutes until the engi-
ne 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 coo-
ling fan has run three times (time required for auto-
matic degassing).
19A-15
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
Car. 1363 Trim removal lever Remove:
Mot. 1202-01 Clip pliers for cooling - the engine covers,

system hose clips - the front wheels,
(large model)
Mot. 1202-02 Pliers for small hose - the wheel arch liners.
clips
Disconnect:
- the fog lights connector (if fitted to vehicle),
tem hose clips - the headlight washer pipes (if fitted).
Remove:
Tightening torquesm
- the bumper.
intercooler hose clip 5.5 Nm

bolts

2
REMOVAL
1
F4R, and 776 F9Q, and 800 or 804 or 808 K9K,

and 722 or 728 or 729 or 732 4
3
WARNING
102504
Procedure for removing the air inlet duct on the Disconnect the two connectors (1) .
intercooler: Unclip the bonnet opening cable (2) .
- risk of leaks and of coming loose if this proce- Remove:
dure is not adhered to.
- the clip (3) ,
- detach the hose using tool (Car. 1363) ,
- the mounting (4) .
- do not use degreaser, brake cleaner, or any
other product, Disconnect the windscreen washer pipes.
- clean the bearing face on the intercooler and

- 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,
19A-16
COOLING SYSTEM
and 722 or 728 or 729 or 732
102365
Remove the cross member (5) . 6
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
102474
Disconnect the intercooler inlet ducts (6) and outlet
ducts (7) .
Remove the intercooler.
19A-17
COOLING SYSTEM
Separate the condenser from the radiator. Tighten to torque:
WARNING - the wheel mounting bolts ( 110 Nm ) .
piping.
Note
Remove the radiator.
Be sure to initialise the xenon bulb system (if fit-
Separate the fan unit from the radiator. ted on vehicle; see 80C, Xenon bulbs, Xenon
headlight: Adjustment ).
REFITTING

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 fins of the cooling unit (radiator,
condenser) are not damaged when moved.

- fill the cooling circuit (see 19A, Cooling, Draining
- filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Blee-
nal.
WARNING
19A-18
COOLING SYSTEM
K9K, and 732

system hose clips
(large model)

clips

tem hose clips
front end panel upper 21 Nm Disconnect the connectors (1) from the relay board,
mounting bolts
Unclip the bonnet opening cable (2) ,
mounting bolts
- the clip (3) ,
wheel bolts 110 Nm - the mounting (4) .
- fitting ).
Remove:
- the front wheels,
Exterior protection, Front bumper ). 102365
Remove:
- the front end panel bolts (5) ,
Drain the cooling system via the radiator bottom ho-
se, using tool (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
19A-19
COOLING SYSTEM
K9K, and 732
102473 109537
102474 112661
Disconnect the ducts (6) and (7) from the intercoo- Disconnect:
ler.
- the cooling radiator top hose,
Remove the intercooler.
- the expansion bottle hoses (8) ,
- the fan unit resistor connector (9) .
- the fan unit connector
19A-20
COOLING SYSTEM
K9K, and 732
Connect:
CA or CAREG - the hoses onto the cooling radiator,
Separate the condenser from the cooling radiator. - the fan unit connectors;
- the fan unit resistor connector,
WARNING Refit the intercooler.
Be careful not to damage the air conditioning Connect the intercooler ducts.
piping.
Refit the front end panel.
Tighten to torque:
Nm )
CONCERNED - the front end panel lower mounting bolts ( 44
Nm )
Remove the radiator assembly from the fan unit.
Clip the bonnet opening cable
Separate the cooling radiator from the fan unit.
Reconnect:
REFITTING - the connectors to the relay board,

- the screen washer pipes.
I - REFITTING OPERATION FOR PART Fill with and bleed the coolant (see 37A, Cooling,
CONCERNED Bleeding the cooling circuit ).
Position the fan unit on the cooling radiator. Refit:
Refit the cooling radiator assembly and the fan unit. - the front bumper (see MR 371, Bodywork, 55A,
II - FINAL OPERATION - the right and left-hand wheel arch liners,
- the front wheels,
CA or CAREG
Reposition the condenser on the cooling radiator.
WARNING Refitting ).
piping.
19A-21
COOLING SYSTEM
Water pump: Removal - Refitting 19A
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
REFITTING
Tightening torquesm
water pump mounting 9 Nm IMPORTANT

bolts Do not scratch the aluminium sealing surfaces.
front right-hand wheel 110 Nm Wear goggles.

mounting bolts Wear gloves during the operation.
REMOVAL Clean the gasket faces using DECAPJOINT to dis-

Position the vehicle on a two-post lift (see 02A, Lif- solve any seal still adhering.
Disconnect the battery (see 80A, Battery, Battery: approximately ten minutes, then remove the residue
Removal - Refitting . using a wooden spatula.
Remove: Replace the water pump seal every time the water
pump is removed.
WARNING
Drain the cooling system (see 19A, Cooling, Coo- from grease (avoid finger marks).
ling system: Draining - Refilling ).
Remove:
Note:
engine, Accessories belt: Removal - Refitting ). Apply two drops of LOCTITE FRENETANCH to
the water pump mounting bolts.
Timing belt: Removal - Refitting ). Refit:
- the water pump,
- the water pump mounting bolts.
102422
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
19A-22
COOLING SYSTEM
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
102422
Tighten to torque and in order the water pump
Refit:
Fill the cooling system (see 19A, Cooling, Draining
- Filling the cooling system ).
Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-
ding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheel
19A-23
COOLING SYSTEM
K4J, and 730 or 732 K4M, and 760 or 761
Tightening torquesm
water pump M8 moun- 22 Nm

ting bolt
water pump M6 moun- 10 Nm

ting bolts
front right-hand wheel 110 Nm

mounting bolts
REMOVAL
Remove
- the engine covers, 14505
- the front right-hand wheel, Remove:
- the engine undertray - the timing tensioning roller,

Drain the engine cooling system (see 19A, Cooling, - the water pump.
Remove:
REFITTING
IMPORTANT
Wear goggles.
Wear gloves during the operation.


WARNING
WARNING
squeezed out when parts are tightened. The pro-
duct-fluid mix may cause damage to some com-
ponents (engine, radiator, etc.).
19A-24
COOLING SYSTEM
K4J, and 730 or 732 K4M, and 760 or 761
10063
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm
to 1 mm wide.
19A-25
COOLING SYSTEM
K4J, and 730 or 732 K4M, and 760 or 761
Refit:
1 6 7 - the engine undertray,
4
5 2 8
14505
Note:
Apply one to two drops of LOCTITE FRENE-
TANCH to the mounting bolts (1) and (4) of the
water pump.
Refit:
- the water pump,
Pretighten the water pump M6 mounting bolts to 8
Nm and the water pump M8 mounting bolts to 8
Nm .
- the water pump M8 mounting bolt ( 22 Nm ) ,
- the water pump M6 mounting bolts ( 10 Nm ) .
Refit:

Refit the front right-hand wheel
19A-26
COOLING SYSTEM
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
water pump mounting 11 Nm

bolts
front right-hand wheel 110 Nm

mounting bolts
1
REMOVAL
2
Remove:
102267
Cooling system: Draining-refilling ). Remove the alternator upper mounting (1) .
Remove: Undo the alternator lower mounting (2) .
- the accessories belt (see 11A, Top and front of Tilt the alternator forward.
102266
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
19A-27
COOLING SYSTEM
K9K, and 722 or 728 or 729 or 732
1 2
4 4
102262 102262
Remove:
- the water pump mounting bolts (4) , WARNING
- the water pump. The sealing surfaces must be clean, dry and free
REFITTING
Note:
IMPORTANT Apply two drops of LOCTITE FRENETANCH to

Wear goggles. Refit:
Wear gloves during the operation. - the water pump,

- the water pump mounting bolts (1) to (5) .
solve any sealant still adhering. Tighten to torque and in order the water pump
Replace the water pump seal every time the water
pump is removed.
19A-28
COOLING SYSTEM
K9K, and 722 or 728 or 729 or 732
102266
Refit:
- the inner timing cover (5) ,
Timing belt ),
Refitting ).
Refit:
Tighten to torque:
- the front right-hand wheel mounting bolts ( 110
Nm )
19A-29
COOLING SYSTEM
F4R, and 770 or 771 or 776
REFITTING
Tightening torquesm
water pump mounting 9 Nm IMPORTANT

bolts Do not scratch the aluminium sealing surfaces.
front right-hand wheel 110 Nm Wear goggles.

mounting bolts Wear gloves during the operation.
REMOVAL Clean the gasket faces using DECAPJOINT to dis-

Position the vehicle on a two-post lift (see 02A, Lif- solve any seal still adhering.
Disconnect the battery (see 80A, Battery, Battery: approximately ten minutes, then remove the residue
Removal - Refitting . using a wooden spatula.
Remove: Replace the water pump seal every time the water
pump is removed.
WARNING
Drain the cooling system (see 19A, Cooling, Coo- from grease (avoid finger marks).
Remove:
Note:
engine, Accessories belt: Removal - Refitting ). Apply two drops of LOCTITE FRENETANCH to
Timing belt: Removal - Refitting ). Refit:
- the water pump,
102422
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
19A-30
COOLING SYSTEM
F4R, and 770 or 771 or 776
4 1
3
2
102422
Refit:
Refitting ).
Refit:
- the engine undertrays,
19A-31
COOLING SYSTEM
K9K, and 732

system hose clips
(large model)

clips

tem hose clips
Tightening torquesm

bolts

bolts Loosen the alternator lower mounting bolt by three
turns.
REMOVAL Remove the alternator upper mounting bolt.

Tilt the alternator against the radiator assembly.
terminal.
Remove:
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 ).
Timing belt
102266
Remove:
- the inner timing cover mounting bolts,
- the timing cover.
19A-32
COOLING SYSTEM
K9K, and 732
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
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 FRENE-
TANCH 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 102262
dissolve the part of the gasket still present. Refit:
Apply the product to the part to be cleaned, wait - the water pump,
approximately 10 minutes, then remove residue
19A-33
COOLING SYSTEM
K9K, and 732
102266
Refit:
- the inner timing cover,
- the alternator,
- the timing belt (see 11A, Top and front of engine:

Timing belt ),

- fill the cooling circuit (see 19A, Cooling, Draining

- Filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Blee-

Connect the battery starting with the positive termi-

nal (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
M9R, and 700
REMOVAL
Mot. 1390 Support for removing I - REMOVAL PREPARATION OPERATION

and refitting the
engine and gearbox Position the vehicle on a two-post lift (see 02A, Lif-
assembly ting equipment, Underbody lift ).
Tightening torquesm
WARNING
bolts When carrying out a repair that requires a com-
plete change, it is essential to flush the circuit
water pump pulley 21 Nm with clean water, blast compressed air through
mounting bolts the circuit to drive out the water, fill and bleed the
circuit and then measure the effective protection.
mounting bolts The parameters to be observed are:
- protection down to - 25 C 2 for cold and tem-
front end panel lower 44 Nm perate countries,
mounting bolts
- 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).
When working under the bonnet, be aware that
the radiator cooling fan(s) may start without war-
ning.
Do not open the bleed screw(s) with the engine
running.
Remove:
19A-35
COOLING SYSTEM
M9R, and 700
101212 114933
Remove: Unclip the air inlet scoop (2) .
- 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
).
112658
Remove the Protection and Switching Unit cover
mounting bolts (3) .
114855
fitting ).
19A-36
COOLING SYSTEM
M9R, and 700
102504 102365
Disconnect the connectors (4) . Remove:
Unfasten the bonnet opening cable (5) . - the front end panel mounting bolts (8) ,
Remove: - the front end panel.
- the clip (6) , Remove the Cooling radiator - condenser -
intercooler assembly from its housing and move it
- the mounting (7) .
forwards.
Fit the (Mot. 1390) on two pads.
Drain the cooling system (see 19A, Cooling, Coo-
Undo
ling system: Draining - Filling ).
- the right-hand suspended mounting support moun-
ting bolts,
- the upper engine tie-bar mounting bolts.
Remove the upper engine tie-bar.
19A-37
COOLING SYSTEM
M9R, and 700
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, lif-
ting the right-hand suspended engine mounting (9)
and bring the compressor pulley (10) level.
19A-38
COOLING SYSTEM
M9R, and 700
Tighten to torque the water pump pulley mounting

bolts ( 21 Nm ) .
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 ).
Tighten to torque:

Nm ) ,

114863 Nm ) .
Remove: Clip:
- the water pump mounting bolts, - the bonnet opening cable,
- the water pump (13) . - the air inlet scoop.
Refit the clips.

REFITTING Connect the screen washer pipes.
Refit:
CONCERNED - the front bumper (see MR 365 Bodywork, 55A Ex-
The water pump seal must be replaced.
engine, Accessories belt: Removal - Refitting )
WARNING - the rear suspended engine mounting (see 19D,
Clean the pump shaft cooling hole on the cylin- Engine mounting, Rear suspended engine
der block. mounting: Removal - Refitting ).
- the half sub-frame cross member side stiffener,

Apply soapy water to the seal before refitting the wa-
ter pump. - the front right-hand wheel arch liner,
Refit the water pump. - the engine undertray.
Check that the water pump is supported by the cylin- Disconnect the battery (see 80A, Battery, Battery:
der block before tightening the bolts. Removal - Refitting ).
19A-39
COOLING SYSTEM
Plenum chamber: Removal - Refitting 19A
M9R, and 700
REMOVAL
Mot. 1202-01 Clip pliers for cooling I - REMOVAL PREPARATION OPERATION

system hose clips
(large model) Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1202-02 Pliers for small hose Remove the battery (see 80A, Battery, Battery: Re-
clips moval - Refitting ).
tem hose clips
Mot. 1700 Cooling circuit filling

and diagnostic tool
Tightening torquesm
coolant outlet unit 11 Nm

cylinder head

bolts

ting nut
112659
WARNING
When carrying out a repair that requires a complete
change, it is essential to flush the circuit with clean Remove:
water, blast compressed air through the circuit to - the battery tray mounting bolts (2) ,
drive out the water, fill and bleed the circuit and
then measure the effective protection. - the wiring harness mounting nut (3) .
The parameters to be observed are: Move the wiring harness to one side.
- protection down to -25C 2 for cold and tempe- Unpick the wiring harness (4) from the battery - ter-
rate countries, minal.
- protection up to -40C 2 for countries with extre- Remove the battery tray.
mely cold climates. 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).
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 run-
ning.
19A-40
COOLING SYSTEM
M9R, and 700
114934 113291
Disconnect the coolant temperature sensor connec- Remove:
tor (5) .
- the coolant outlet unit mounting bolts,
- the coolant outlet unit.
CONCERNED
REFITTING

replace the seal of the coolant outlet unit.
WARNING
The seal faces must be clean, dry and free from
grease (avoid finger marks).
II - REFITTING PART CONCERNED

Remove:
113293 - the coolant outlet unit.
Remove the cooling hose clips using the (Mot. - the coolant outlet unit mounting bolts,
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
M9R, and 700
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 out-
let unit.
Connect the coolant temperature sensor connector.
Refit the battery tray.
Remove:
- the wiring harness,
- the wiring harness mounting nut.
Tighten to torque:
- the wiring harness mounting nut ( 8 Nm ) .
Connect the injection computer connectors.
Clip on the battery - terminal wiring harness.
Refit the battery (see 80A, Battery, Battery: Remo-

val - Refitting ).
Fill the cooling system using the (Mot. 1700) (see

19A, Cooling, Cooling system: Draining - Refil-
ling ).
19A-42
EXHAUST
General information 19B
F4R, and 776
Mot. 1199-01 35/50 mm diameter
and 50/95 mm diame-
ter exhaust pipe cut-
ting tool. Complete
assembly in kit.
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. 109581
All seals removed must be replaced.
Take care not to damage the catalytic converter
during removal and refitting.
SPECIAL NOTES ON THE EXHAUST PIPE
1 - Exhaust pipe cutting line

The exhaust pipe is a single unit type.
When replacing one of the components, cut the ex-
haust pipe:
- correctly identify the area to be cut.
- use the cutting tool correctly (Mot. 1199-01) , 109580
- correctly position the After-Sales sleeve. Before cutting the pipe between the catalytic converter
and the expansion chamber, remove the protective
plate.
2 - Identifying the cut zone
Two punch marks on the exhaust pipe indicate the
area to be cut (see 19B, Exhaust, General informa-
tion on exhausts ).
19B-1
EXHAUST
Cut zone 1
D
P1
P2
80 mm
101504 100649
Before cutting the pipe, mark the halfway point (D)

Cut zone 2 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
4 - Special notes on the replacement part Cut zone 1
60 mm
101960
WARNING
When replacing the middle section of the exhaust
pipe (pipe on diesel version, expansion chamber on 101501
petrol versions), the replacement part needs to be
shortened by 60 mm . Cut zone 2
5 - Fitting the After-Sales sleeve

Apply exhaust pipe mastic inside the sleeve.
To prevent any exhaust leaks, position the sleeve cor-
rectly on both lugs.
Place the sleeve on the worn section of the pipe. 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
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.
Tighten to torque the nut (1) on the exhaust sleeve

(25 Nm) .
When tightening to torque, a click indicates that the tor-
que of (25 Nm) has been reached.
Check that:
- there is no contact with the underbody,
- the presence and correct positioning of all the ex-
haust pipe heat shields.
19B-4
EXHAUST
Pipe assembly 19B
(1) Cut zone 1

K4J, and 730 or 732 (2) Cut zone 2
K4M, and 760 or 761
112063
112062
19B-5
EXHAUST
Pipe assembly 19B
(1) Cut zone 1 (1) Cut zone 1

F4R, and 770 or 771 or 776
112061
19B-6
EXHAUST
Pipe assembly 19B
K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808
(1) Cut zone 1

K9K, and 722 (2) Cut zone 2
K9K, and 728 or 729 or 732
112060
112059
19B-7
EXHAUST
Pipe assembly 19B

F9Q, and 800 or 808 F9Q, and 804
2
2
112059 112058
19B-8
EXHAUST
Pipe assembly 19B
(1) Cut zone 1

(2) Cut zone 2
19B-9
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F4R, and 776
Tightening torquesm
upstream stay moun- 38 Nm

ting bolts (on the
engine) 2
catalytic converter 8.5 Nm

mounting bolt (on the
upstream stay) 6
upper bracket moun- 8.5 Nm

ting bolt (on the exhaust
manifold)
upper bracket moun- 8.5 Nm

ting bolt (on the catalytic
converter)
3
catalytic converter nuts 40 Nm
(on the turbocharger) 4
5
21926
Disconnect the oxygen sensor connectors (2) .
exhaust flange studs 8.5 Nm Remove:
Remove the engine in order to remove the catalytic - the upper bracket (3) and upstream stays (4) ,
pre-converter (see 10A, Engine and peripherals, En- - the catalytic converter/gearbox stay mounting (5) ,
gine - gearbox ).
- the catalytic converter mounting nuts, (6) on the
turbocharger,
REMOVAL
- the catalytic converter.
Remove the oxygen sensor on the workbench.
REFITTING
Refit the oxygen sensors.
WARNING
1 Be sure to replace all the exhaust flange and tur-
bocharger 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 tur-
bocharger,
- the upstream catalytic converter stay mounting
106246
bolt.
Remove:
- the catalytic converter mounting bolt (on the
- the heat shield. upstream stay) ( 8.5 Nm ) ,
19B-10
EXHAUST
F4R, and 776
- the upper bracket mounting bolt (on the ex-
haust manifold) ( 8.5 Nm ) ,
- the upper bracket mounting bolt (on the cataly-
tic converter) ( 8.5 Nm ) ,
- the catalytic converter nuts (on the turbochar-
ger) ( 40 Nm ) ,
- the exhaust flange studs ( 8.5 Nm ) .
19B-11
EXHAUST
F9Q, and 804
- the exhaust mounting bolts,
Tightening torquesm - the front right-hand driveshaft (see 29A, Drives-

hafts, Front right-hand driveshaft: Removal -
connector clip between 20 Nm Refitting ).
the turbocharger and - the lower engine tie-bar (see 19D, Engine moun-
the catalytic pre-conver- ting, Suspended engine mounting: Removal -
ter Refitting ).
catalytic pre-converter 30 Nm
upstream stay moun-
ting nuts on the engine
upstream stay moun-
ting nuts on the cataly-
tic pre-converter
gearbox-side downs-
tream stay mounting
bolts on the engine
gearbox-side downs-
tream stay mounting 1
bolts on the catalytic
pre-converter
timing-end downstream 111864
stay mounting bolts on
Remove:
the engine
- the catalytic pre-converter lower stay mounting
catalytic pre-converter 30 Nm bolts (1)
timing-end downstream
stay mounting nuts on - the catalytic pre-converter lower stay.
the catalytic pre-conver-
ter
outlet exhaust flange
studs
exhaust flange nuts 21 Nm

bolts
Remove:

ting, Suspended engine mounting: Removal -
Refitting ).
Remove:
19B-12
EXHAUST
F9Q, and 804
111862
Remove:
- the catalytic pre-converter upper stay mounting
bolts (2) ,
- the catalytic pre-converter upper stay,
- the turbocharger and catalytic pre-converter moun-
ting clip bolt (3) ,
- the catalytic pre-converter.
19B-13
EXHAUST
F9Q, and 804
REFITTING and the catalytic pre-converter ( 20 Nm ) ,
- the catalytic pre-converter upstream stay

mounting nuts on the engine ( 30 Nm ) ,
WARNING
- the catalytic pre-converter upstream stay
Always replace: mounting nuts on the catalytic pre-converter (
- the catalytic converter seal, 30 Nm ) ,
- the connector clip between the turbocharger - the catalytic pre-converter gearbox-side
and the catalytic pre-converter. downstream stay mounting bolts on the engine
( 50 Nm ) ,
On the workbench, refit the gearbox-side downs-
tream stay to the catalytic pre-converter. - the catalytic pre-converter gearbox-side
downstream stay mounting bolts on the cataly-
Tighten the gearbox-side downstream stay moun- tic pre-converter ( 50 Nm ) ,
ting bolts on the catalytic pre-converter so that they
make contact. - the catalytic pre-converter timing-end downs-
Fit the catalytic pre-converter to the engine. tream stay mounting bolts on the engine ( 50
Nm ) ,
Tighten the gearbox-side downstream stay moun-
ting bolts on the engine so that they make contact. - the catalytic pre-converter timing-end downs-
tream stay mounting nuts on the catalytic pre-
Refit: converter ( 30 Nm ) .
- the connector clip between the turbocharger and
the catalytic pre-converter,
Note:
- the catalytic pre-converter upstream stay.
Make sure there is no contact between the cata-
Pretighten in order: lytic pre-converter and the turbocharger oil return
- the catalytic pre-converter upstream stay mounting pipe.
nuts on the engine,
Tighten to torque:
- the catalytic pre-converter upstream stay mounting
nuts on the catalytic pre-converter, - the catalytic pre-converter outlet exhaust flan-
ge studs ( 7 Nm ) .
Loosen then tighten in order and until they make
contact: - the exhaust flange nuts ( 21 Nm ) ,
- the catalytic pre-converter gearbox-side downs-
tream stay mounting bolts on the engine, Proceed in the reverse order to removal.
- the catalytic pre-converter gearbox-side downs- Make sure that there is no contact with the underbo-
tream stay mounting bolts on the catalytic pre-con- dy.
verter.
Refit the catalytic pre-converter downstream stay on
WARNING
the timing end.
- the catalytic pre-converter timing-end downstream Connect the battery, starting with the positive termi-
stay mounting bolts on the engine, nal.
- the catalytic pre-converter timing-end downstream

stay mounting nuts on the catalytic pre-converter, WARNING
- the connector clip between the turbocharger and carry out the necessary programming (see 80A,
the catalytic pre-converter. Battery: Removal - Refitting ).
Tighten to torque:
tighten to torque the battery cover mounting bolts
- the connector clip between the turbocharger ( 4 Nm ) .
19B-14
EXHAUST
Catalytic converter: Removal - Refitting 19B

gen sensors
Tightening torquesm
oxygen sensor 45 Nm
exhaust bracket studs 7 Nm
exhaust bracket nuts) 21 Nm

1
bolts
REMOVAL
Put the vehicle on a two-post lift. 101793
Disconnect the battery, starting with the negative Remove:
terminal.
- the exhaust bracket mounting nuts (1) ,
F4R, and 770 or 771 K4J, and 730 or 732 K4M,

and 760 or 761
Remove the downstream oxygen sensor.
Cut the exhaust pipe (see 19B, Exhausts, General

information ).
19B-15
EXHAUST
REFITTING
WARNING
with the underbody.
Refit the downstream oxygen sensor.
Tighten to torque the oxygen sensor ( 45 Nm )

Refit and tighten to torque if necessary the exhaust
bracket studs ( 7 Nm ) .
Fit:
- the catalytic converter,
- the sleeve (see 19B, Exhausts, General informa-

tion ).
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 ensu-
re alignment.
Reconnect the oxygen sensor.


dy.

nal.
WARNING

( 4 Nm ) .
19B-16
EXHAUST
F9Q, and 800 or 808
Tightening torquesm
nuts mounting the cata- 30 Nm

lytic converter onto the
turbocharger
catalytic converter stay 30 Nm

nut (timing end)
catalytic converter stay 44 Nm 1

mounting bolt (timing
end)
catalytic converter stay 21 Nm

mounting nut (flywheel
end)
exhaust bracket studs 7 Nm

(at the catalytic conver-
ter outlet)
101118
exhaust bracket nuts (at 21 Nm
Remove the nuts (1) from the exhaust bracket (at
the catalytic converter
the catalytic converter outlet).
outlet)
exhaust pipe support 21 Nm Note:

mounting bolt (on the
body) Mark with a pen the position of the exhaust rub-
ber mounting bush supports on the vehicle body.
bolts
wheel bolts 110 Nm
REMOVAL 2
terminal.
Remove:
102116
Remove the mounting bolt (2) from the exhaust pipe
rubber mounting bush on the body.
19B-17
EXHAUST
F9Q, and 800 or 808
102117 101120
Remove the (3) silencer rubber mounting bush bolt. Remove:
Withdraw the exhaust pipe towards the rear of the - the catalytic converter stay mounting bolts (5) (timi-
vehicle. ng end),
- the catalytic converter stay (timing end).
102479
Remove the catalytic converter stay mounting bolts 102313
(4) (flywheel end).
Remove the engine tie-bar (6) .
19B-18
EXHAUST
F9Q, and 800 or 808
Refitting the stay at the timing end
8 9
101121 101120
Remove: Tighten to torque and in order:
- the engine lifting bracket, - the catalytic converter stay nut (timing end) ( 30
Nm ) (8) ,
- the nuts (7) securing the catalytic converter to the
turbocharger, - the catalytic converter stay mounting bolt (timi-
ng end) ( 44 Nm ) (9) .
- the catalytic converter from underneath the vehicle.
REFITTING
WARNING
with the underbody.
The order for fitting catalytic converter stays must be

respected.
WARNING
The gaskets must always be replaced.
- 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
F9Q, and 800 or 808
Refitting the stay at the timing end Tighten to torque:

10
102479
Tighten to torque and in order the catalytic conver-
ter stay mounting nut (flywheel end) ( 21 Nm )
(10) .
Note:
lytic conver ter and the turbocharger oil return
pipe.

Tighten to torque:
- the exhaust bracket studs (at the catalytic con-
verter outlet) ( 7 Nm ) .
- the exhaust bracket nuts (at the catalytic con-
verter outlet) ( 21 Nm ) ,
- the exhaust pipe support mounting bolt (on the
body) ( 21 Nm ) .
dy.
nal.
WARNING
19B-20
EXHAUST
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
turbocharger outlet 7 Nm
studs
mounting nuts on the 1
turbocharger

ting bolts on the engine
d ownstream stay 21 Nm
mounting bolts on the 2
gearbox 3
ting bolt on the catalytic
converter
d ownstream stay 21 Nm 102076

Remove:
catalytic converter
- the exhaust pipe bracket mounting bolts (1) ,
bolt securing the 21 Nm
exhaust pipe bracket - the catalytic converter stay mounting bolt (2) .
onto the body Loosen the other stay mountings on the gearbox.
catalytic converter out- 7 Nm Remove the stay (3) .

let exhaust bracket
studs
ball joint bracket bolts 21 Nm

with their springs

bolts
REMOVAL
terminal.
19B-21
EXHAUST
K9K, and 722 or 728 or 729 or 732
102116 102077
Remove the mounting bolt (4) from the exhaust pipe Remove:
rubber mounting bush on the body. - the catalytic converter upstream stay mounting
bolts,
Note: - the catalytic converter stay (6) ,
Mark with a pen the position of the exhaust rub- - the catalytic converter mounting nuts on the turbo-
ber mounting bush supports on the vehicle body. charger (7) ,
102117
Remove the mounting bolt (5) from the silencer rub-

ber mounting bush.

vehicle.
19B-22
EXHAUST
K9K, and 722 or 728 or 729 or 732
REFITTING - the exhaust bracket nuts ( 21 Nm ) .
WARNING
Always replace: K9K, and 732
- the catalytic converter seal, Tighten to torque the ball joint bracket bolts with
their springs ( 21 Nm ) .
- the turbocharger - catalytic converter bracket
studs. Proceed in the reverse order to removal.
Tighten to torque the turbocharger outlet studs ( 7

Nm ) .
Fit the catalytic converter.
Pretighten in order: dy.
- the upstream stay bolts on the engine,

WARNING
- the upstream stay bolts on the catalytic converter,
- the downstream stay bolts on the gearbox,
- the downstream stay bolts on the catalytic conver- nal.
ter,
- the catalytic converter/turbocharger mounting nuts. WARNING

Tighten to torque and in order Carry out the necessary programming (see 80A,
- the catalytic converter mounting nuts on the
turbocharger ( 26 Nm ) , Tighten to torque the battery cover mounting bolts
( 4 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 cataly-

tic converter ( 25 Nm ) ,
- the downstream stay mounting bolt on the cata-

lytic converter ( 21 Nm ) ,
- the bolt securing the exhaust pipe bracket onto

the body ( 21 Nm ) ,
Note:
lytic 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
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool
safety belt equipment, Underbody lift ).
Tightening torquesm
Remove:
studs on the turbochar- 14.5 Nm
ger
catalytic converter 21 Nm 55A, Exterior protection, Scuttle panel grille ),
mounting clamp moun-
ting bolts on the cylinder - the acoustic protection clips on the scuttle panel
block partition,
- the acoustic protection.
mounting nuts on the
turbocharger
catalytic converter half- 21 Nm

clamp mounting bolts
stay mounting bolt on 8 Nm

stay mounting nuts on 21 Nm

the cylinder block
stay mounting nuts on 21 Nm

bolts of the ball-jointed 21 Nm

bracket with springs
silencer rubber moun- 21 Nm

ting bush mounting bolt
exhaust pipe rubber 21 Nm

114986
mounting bush moun-
ting bolt Remove:
- the nuts (1) mounting the catalytic converter to the
turbocharger,
IMPORTANT
Wear protective gloves during all operations.
19B-24
EXHAUST
M9R, and 700
114771 114991
Remove: Remove the bolts from the ball-jointed bracket (5)
with springs.
ting, rear suspended engine mounting: Remo-
val - Refitting ).
- the catalytic converter stay mounting bolt (2) ,
- the catalytic converter stay mounting nuts (3) ,
- the nuts (4) mounting the stay on the cylinder
block,
- the catalytic converter stay,
- the catalytic converter studs using a roller-type
stud removal tool .
19B-25
EXHAUST
M9R, and 700
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 rub-
ber 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
M9R, and 700
REFITTING

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
Finger tighten the catalytic converter mounting
Remove: clamp mounting bolts on the cylinder block until con-
- the catalytic converter mounting clamp mounting tact is made.
bolts (10) , Tighten to torque the catalytic converter mounting
- the catalytic converter mounting clamps. clamp mounting bolts on the cylinder block ( 21
Nm ) .
Remove the safety belt .
Move the engine towards the front of the vehicle.
114843
Remove the catalytic converter.
19B-27
EXHAUST
M9R, and 700
II - REFITTING OPERATION FOR PART - the stay mounting bolt on the catalytic conver-
CONCERNED ter ( 8 Nm ) ,
- the stay mounting nuts on the cylinder block (

21 Nm ) ,
- the stay mounting nuts on the catalytic conver-

ter ( 21 Nm ) .

mounting, Rear suspended engine mounting:
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:
Move the engine towards the front of the vehicle. - the exhaust pipe rubber mounting bush mounting
Fit: bolt, aligning the marks,
- the new seal between the turbocharger and the ca- - the silencer rubber mounting bush mounting bolt,
talytic converter, aligning the marks,
- the catalytic converter. - the ball-jointed bracket bolts with springs.

Refit the catalytic converter onto the turbocharger. Tighten to torque:
Fit:
- the bolts of the ball-jointed bracket with springs
- the new catalytic converter nuts onto the turbochar- ( 21 Nm ) ,
ger,
- the silencer rubber mounting bush mounting
- the new catalytic converter half-clamps. bolt ( 21 Nm ) ,
Refit:
- the exhaust pipe rubber mounting bush moun-
- the catalytic converter studs using a roller-type ting bolt ( 21 Nm ) .
stud removal tool ,
Refit:
- the catalytic converter half-clamp mounting bolts,
- the catalytic converter stay,
- the catalytic converter stay mounting bolt, - the acoustic protection,
- the stay mounting nuts on the catalytic converter, - the acoustic protection clips on the scuttle panel
partition,
- the stay mounting nuts on the cylinder block.
Tighten to torque:
- the catalytic converter mounting nuts on the
turbocharger ( 21 Nm ) , - the engine protectors.
- the catalytic converter half-clamp mounting Connect the battery (see 80A, Battery, Battery: Re-
bolts ( 21 Nm ) , moval - Refitting ).
19B-28
EXHAUST
Expansion chamber: Removal - Refitting 19B
REFITTING
Tightening torquesm
bolts securing the rub- 8 Nm WARNING

ber mounting bush sup- Cut the new expansion chamber pipe (see 19B,
port on the expansion Exhaust, General Vehicle Information ).
chamber
Fit:
bolts securing the rub- 21 Nm
- the expansion chamber,
ber mounting bush sup-
port on the body - the sleeve (see 19B, Exhausts, General informa-
tion ).
Tighten to torque:
REMOVAL
- the bolts securing the rubber mounting bush
Position the vehicle on a lift.
support on the expansion chamber ( 8 Nm ) ,
Cut the exhaust pipe (see 19B, Exhausts, General support on the body ( 21 Nm ) .
Vehicle Information ).
Tighten the sleeves, while easing the exhaust pipe
to ensure the correct alignment of the pipe .
1 Make sure that all the exhaust pipe heat shields are
dy.
WARNING
The sleeve tightening nuts and bolts assem-
bly must be positioned so that it cannot come
into contact with the underbody.
101818
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 19B
REFITTING
Tightening torquesm Fit:
- the silencer,
bolts securing the rub- 8 Nm
ber mounting bush on - the sleeve (see 19B, Exhausts, General informa-
the silencer tion ).
bolts securing the rub- 21 Nm Tighten to torque:

ber mounting bush sup- - the bolts securing the rubber mounting bush on
port on the body the silencer ( 8 Nm ) ,
REMOVAL support on the body ( 21 Nm ) .
Position the vehicle on a two-post lift. Tighten the sleeve, while easing in the exhaust pipe
to ensure the correct alignment of the pipe.
Cut the exhaust pipe (see 19B, Exhausts, General
information ). Make sure that all the exhaust pipe heat shields are
dy.
WARNING
1 The sleeve tightening nut and bolts assembly

must be positioned so that it cannot come into
contact with the underbody.
101817
Remove:
- the silencer mounting bolts (1) on the rubber moun-
ting 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
fitting assembly .
19B-30
EXHAUST
Particle filter: Function 19B
F9Q, and 804
The extent to which the particle filter is clogged de-
pends on the user's driving style:
Equipment required
- during an average trip (combined cycle and motorway
diagnostic tool of more than 15 minutes ), the particle filter automa-
tically burns the particles without being noticed by the
customer (apart from some white smoke): this is
I - SAFETY ADVICE spontaneous regeneration ,
- if the operating temperature is not high enough to trig-
Due to the dangers of high temperatures, be sure to ger spontaneous regeneration, clogging increases
observe the following instructions: until it exceeds 35 g ; an acceleration request to trig-
ger spontaneous regeneration is then sent to the dri-
- never open or separate the pressure tapping circuit, ver via an instrument panel warning light; the same
except at the level of the unions on the exhaust pipe happens if several attempts to regenerate have failed.
(only the supplier can guarantee pressure tapping cir-
cuit sealing), - if these conditions are still not met and clogging rea-
ches 45 g (min) . Static regeneration , using dia-
gnostic tool must be performed in the workshop (
- Position the pressure pipes correctly. If the pipes are
SERVICE warning light comes on and the
not positioned correctly, their flexible sections may be
CHECK ANTIPOLLUTION message appears:
twisted which will create low points and this may re- (see 19B, Exhaust, Particle filter: Cleaning ).
sult in the pipes rupturing when fluid freezes and ex-
pands.
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 fu-
mes (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 fu-
mes upstream and downstream of the particle filter.
The injection computer continuously evaluates the le-

vel of clogging of the particle filter using the pressure
difference upstream and downstream of the particle fil-
ter. When it is clogged, the two temperature values in-
form the injection computer that the temperature
conditions are high enough (approximately 600C ) to
trigger regeneration.
This consists of burning the particles held in the parti-

cle filter: to do this, the injection switches to delayed
injection mode and the fuel not burned in the com-
bustion chambers burns the residues contained in the
particle filter cells.
19B-31
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm
rubber mounting bush 25 Nm

support mounting nut on
the particle filter

between the connection
hose and the catalytic
pre-converter

nuts on the sub-frame
exhaust sleeve nut 25 Nm
downstream pressure 21 Nm
measurement tapping
on its adapter
connection clip bolt 25 Nm 106673

between the silencer
Remove the downstream pressure pipe (1) from its
and the particle filter
adapter (2) bolted to the exhaust pipe.
between the connection WARNING
hose and the catalytic
pre-converter When the pressure measurement tapping is
removed, the adapter must be held (2) with a
nuts mounting the rub- 25 Nm lock wrench.
ber mounting bush sup-
port onto the sub-frame
WARNING
The pressure measurement circuit must never be
REMOVAL opened except at the adapters on the exhaust
Position the vehicle on a two-post lift. pipe.

terminal.
Cut the exhaust pipe after the particle filter (see 19B,
Exhaust : repair precautions ) and (see 19B, Ex-
haust: General information ).
19B-32
EXHAUST
F9Q, and 804
111881 111885
Remove the heat shield (3) mounting clip then move
Disconnect the upstream and downstream tempera-
it aside slightly
ture sensor offset connectors (6) .
Unpick the downstream pressure measurement tap-
ping and also the downstream temperature sensor Unpick the upstream and downstream temperature
cabling from the heat shield. sensor offset connectors (6) .
Pass the downstream pressure measurement tap-
ping into the engine compartment whilst leaving the
pressure sensor complete.
111885
Remove:
111882
- the bolt (7) securing the filter particle pressure sen-
Disconnect the particle filter pressure sensor con-
sor mounting located in the engine compartment.
nector (4) located in the engine compartment.
Remove the retaining clip (5) from the cabling on the - the particle filter pressure sensor assembly (8) and
particle filter pressure sensor mounting. its mounting.
19B-33
EXHAUST
F9Q, and 804
107038
Remove: REFITTING
- the nuts (9) on the exhaust flange between the con-
nection hose and the catalytic pre-converter,
WARNING
- the sub-frame rubber mounting bush bolts (10) ,
- the particle filter. Always replace:
Remove the particle filter assembly: - the seal between the hose and particle filter,
- the rubber mounting bush, - the seal between the hose and the catalytic pre-
converter,
- the upstream and downstream temperature sen-
sors from their adapters on the exhaust line (see - any adapter on the exhaust pipe that has been
19B, Exhaust, Particle filter temperature sen- loosened,
sor: Removal - Refitting ).
- the upstream pressure measurement tapping at its
WARNING
adapter on the exhaust pipe (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit- Always clean the bearing surfaces of the connec-
ting ). tion hose - par ticle filter flanges thoroughly.
- the connection hose (see 19B, Exhaust, Connec- With particle filter removed, refit:
tion hose: Removal - Refitting ).
- the connection hose and its new seals (see 19B,
Exhaust, Connection hose: Removal - Refitting
).
19B-34
EXHAUST
F9Q, and 804
- the upstream and downstream temperature sen-
sors on their adapters on the exhaust pipe (see
19B, Exhaust, Particle filter temperature sen-
sors: Removal - Refitting ).
adapter on the exhaust line (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit-
ting ).
- the rubber mounting bush on the particle filter.
Torque tighten the rubber mounting bush 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 connec-
tion hose and the catalytic pre-converter ( 21
Nm ) .
- the rubber mounting bush nuts on the sub-fra-
106673
me ( 25 Nm ) .
Fit the exhaust sleeve (see 19B, Exhaust : General
Vehicle Information ) by applying sealing mastic for WARNING
the exhaust. All the adapters on the exhaust pipe (12) must be
Tighten to torque the exhaust sleeve nut ( 25 Nm ) replaced.
at the same time as making sure that the exhaust
pipe is correctly aligned.
WARNING
When fitting the particle filter, be sure to pass the
downstream pressure measurement tapping
behind the heat shield.
Coat the downstream pressure measurement tap-

ping threads with ANTI-SEIZE high temperature
grease.
WARNING
Make sure that the grease does not flow beyond
the threading.
19B-35
EXHAUST
F9Q, and 804
106672
Fit the rigid part of the downstream pressure measu-
rement tapping then position it so that it is parallel (
3 ) to the exhaust pipe longitudinal axis. WARNING
Make sure, after tightening the pressure measu-
Tighten to torque the downstream pressure
rement tappings, that this pressure measurement
measurement tapping on its adapter ( 21 Nm )
tapping has no low points (siphon) susceptible to
bolted to the exhaust pipe.
water accumulation.
To do this:
Tighten to torque:
- check that the rigid sections of the pressure
- the connection clip bolt between the silencer pipes are correctly positioned in relation to the
and the particle filter ( 25 Nm ) , exhaust pipe longitudinal axis,
- the exhaust flange nuts between the connec- - at the retaining clips, manipulate the pressure
tion hose and the catalytic pre-converter ( 21 measurement tappings on the heat shield (turn
Nm ) , the tapping in the clip so as to avoid the low
points).
- the nuts mounting the rubber mounting bush
support onto the sub-frame ( 25 Nm ) .
WARNING

dy.
19B-36
EXHAUST
F9Q, and 804
WARNING
Connect the battery, starting with the positive ter-
minal. carry out the necessary programming (see
80A, Battery: Removal - Refitting ).
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 filter.
Command SC030 enables the parameters to be re-

set to 0 depending on the type of operation carried
out.
- PR391 : distance travelled since the particle filter
was last replaced,
- PR415 : distance travelled since the last regenera-
tion
- PR412 : time since the last regeneration,
- PR383 : mass of soot in the particle filter.
Once the command has finished, check that the pa-
rameters are at 0, so that the computer 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 19B
F9Q, and 804
Tightening torquesm
upstream pressure 21 Nm
measurement tapping
on its union bolted onto
the exhaust pipe
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, Parti-
cle filter: Removal and Refitting ).
19B-38
EXHAUST
F9Q, and 804
3
2 4
6
106670 111885
Remove the upstream pressure pipe (1) from its in- Remove:
termediary adapter (2) bolted to the exhaust pipe.
- the mounting nut (3) from the particle filter pressure
sensor mounting (4) ,
WARNING - the particle filter pressure sensor:
When removing the pressure measurement tap-
ping (1) from its adapter it is essential to open
the adapter (2) with a lock wrench. WARNING
Never separate the pressure measurement tap-
pings (5) from the particle filter pressure sensor
WARNING (6) ; replace the sensor - pipes - end pieces
The pressure measurement circuit must never be assembly if necessary, this is supplied assem-
opened except at the level of the adapters on the bled by the Parts Department (see Particle
exhaust pipe. filter : repair precautions, Safety instructions
).
19B-39
EXHAUST
F9Q, and 804
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
the threading.
19B-40
EXHAUST
F9Q, and 804
106672
Fit the rigid part of the upstream pressure measure- be stored by the injection computer before restarting
ment tapping then position it so that it is parallel ( the engine.
3 ) with the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measure-
ment tapping on its union bolted onto the ex-
haust pipe ( 21 Nm ) .
Refit the particle filter (see 19B, Exhaust, Particle
WARNING
Make sure, after tightening the pressure measu-
rement tappings, that this pressure measurement
line assembly has no low points (siphon) suscep-
tible 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).
Use the diagnostic tool to clear any faults which may
19B-41
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm
Equipment required
adapter, if it has been 44 Nm
diagnostic tool replaced
downstream particle fil- 30 Nm

Tightening torquesm ter temperature sensor
adapter, if it has been 44 Nm

replaced
upstream particle filter 30 Nm

temperature sensor.
107038
(A) Upstream particle filter temperature sensor I - (A) UPSTREAM PARTICLE FILTER
TEMPERATURE SENSOR
(B) Downstream particle filter temperature sensor
1 - Removal
Remove the particle filter (see 19B, Exhaust, Parti-
cle filter: Removal - Refitting ).
19B-42
EXHAUST
F9Q, and 804
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
Refit the particle filter (see 19B, Exhaust, Particle
II - (B) DOWNSTREAM PARTICLE FILTER

TEMPERATURE SENSOR
1 - Removal
terminal.
106671
Remove the upstream particle filter temperature

sensor (1) from its adapter (2) bolted onto the ex-
haust pipe.
WARNING
When the upstream particle filter temperature
sensor (1) is removed, the adapter must be held
(2) with a lock-wrench.
2 - Refitting
WARNING
111882
Always replace any adapter (2) that has been
removed from the exhaust pipe. Disconnect the downstream particle filter temperatu-
re sensor offset connector (3) .
Tighten to torque the adapter, if it has been repla-
ced ( 44 Nm ) .
Coat the threads on the upstream particle filter tem-
perature sensor with ANTI-SEIZE high temperature
grease.
WARNING
the threading.
Tighten to torque the upstream particle filter tem-

perature sensor. ( 30 Nm ) .
Check that:
- that there is no contact with the wiring harness,
19B-43
EXHAUST
F9Q, and 804
2 - Refitting
WARNING
Always replace any adapter (3) that has been
removed from the exhaust pipe.
Tighten to torque the adapter, if it has been repla-

ced ( 44 Nm ) .
Coat the threads on the downstream particle filter
temperature sensor with ANTI-SEIZE high tempera-
ture grease.
WARNING
the threading.
Tighten to torque the downstream particle filter

temperature sensor ( 30 Nm ) .
111885 Check that:
Unpick the downstream particle filter temperature - there is no contact with the wiring harness,
sensor offset connector (3) from its mounting. - the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
nal
WARNING
Carry out the necessary programming (see sec-
tion 80A, Battery: Removing - Refitting ).
Before restarting the engine, use the diagnostic

tool to clear any faults stored by the injection com-
puter.
106671
Remove the downstream particle filter temperature

sensor (4) from its adapter (5) bolted onto the ex-
haust pipe.
WARNING
When the downstream particle filter temperature
sensor (4) is removed, the adapter must be held
(5) with a lock wrench.
19B-44
EXHAUST
Connecting hose: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm Particle filter pressure sensor: Removal - Refit-
ting ).
Tighten to torque the exhaust flange nuts ( 21 Nm
) between the connection hose and the particle filter.
REMOVAL Refit the particle filter (see 19B, Exhaust, Particle
Remove:
- the particle filter (see 19B, Exhaust, Particle fil-

ter: Removal - Refitting ).
- the upstream temperature sensor and its adapter

on the exhaust pipe (see 19B, Exhaust, Particle
filter temperature sensor: Removal - Refitting ).

Particle filter pressure sensor: Removal - Refit-
ting ).
Remove:
- the nuts for the exhaust flange between the con-

nection hose and the particle filter,
- the connection hose.
REFITTING
WARNING
Always replace:
- the flange seal between the connection hose
and the catalytic pre-converter,
- the flange seal between the connection hose
and particle filter,
WARNING
Always clean the bearing surfaces thoroughly on:

- the hose connection flanges for the catalytic
pre-converter connection,
- the flange between the connection hose and
the particle filter,
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 19B
F9Q, and 804
PROCEDURE FOR FORCED REGENERATION OF Follow this procedure:
THE PARTICLE FILTER USING THE CLIP
- run command SC017 or VP040 ,
DIAGNOSTIC TOOL
- during regeneration, the engine speed will be held
at 1500 rpm , and the engine noise changes (de-
Command SC017: REGENERATION OF THE
layed injection),
PARTICLE FILTER
- the exhaust fumes rise in temperature and burn the
soot retained in the particle filter,
Note: - the command lasts for approximately 30 minutes ,
Only run this command under the following con- - when the engine speed returns to idle speed the
ditions: command has terminated,
- fault DF308 Particle filter clogged , or DF312 - check the quantity of soot contained in the particle
Number of regenerations exceeded , or filter PR383 < 10 .
DF383 Particle filter regeneration impossible
present,
Note:
- soot weight in the particle filter greater than
45 g . Be prepared for strong odours and thick smoke
during particle filter regeneration.
IMPORTANT Once forced regeneration of the particle filter is com-

plete:
During the forced regeneration of the particle fil-
ter, the temperature in the exhaust pipe rises - deal with the present faults,
significantly.
- clear the stored faults.
Try to carry out this procedure outside the works-
Allow the engine to cool down.
hop if possible or use an exhaust gas extractor
approved for high temperatures. Drain the engine oil.
Replace the oil filter.
WARNING Top up the oil.
Check the engine oil level before running the
command to avoid any engine racing.
Note:
The level should be between MIN and
The level should be between MIN and
MAX on the dipstick.
MAX on the dipstick.
To run this command, select the specific com-
mands 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 succes-
sion.
19B-46
EXHAUST
F9Q
For the particle filter forced regeneration procedure,
Special tooling required see MR 366 or MR 372 Fault finding, 13B, Diesel
injection, Fault finding, Interpretation of com-
mands, Particle filter regeneration .
ter removing tool
Mot. 1018 Sump plug tool.

Note:
Equipment required If required, the forced regeneration procedure

may be stopped by pressing the engine Start but-
diagnostic tool ton twice in succession.
kit for particle filter

Note:
Be prepared for strong odours and thick smoke
Tightening torquesm
during particle filter forced regeneration.
engine drain plug 20 Nm
When particle filter forced regeneration is complete,
rubber mounting 21 Nm using the diagnostic tool:
bushes on the body - deal with the present faults,
rubber mounting bush 8 Nm - clear the stored faults.

on the connector pipe Put the vehicle on a two-post lift.
on the rear silencer IMPORTANT
Allow the engine to cool before draining the oil.
PROCEDURE FOR PARTICLE FILTER FORCED
Remove the oil filter using the (Mot. 1329) .
REGENERATION USING THE CLIP DIAGNOSTIC
TOOL Coat the new oil filter sealing ring with engine oil.
Connect the diagnostic tool to the vehicle. Tighten the oil filter until the seal makes contact with
the engine.
IMPORTANT Tighten the new oil filter manually 3/4 of a turn.

During forced regeneration of the particle filter, Wipe away any excess oil.
the temperature in the exhaust pipe rises signifi-
Remove the engine oil filler cap.
cantly.
Be sure either to carry out the operation outside
the workshop, or to use the kit for particle filter Remove the sump drain plug using the (Mot. 1018)
, approved for high temperatures, on the exhaust or an 8 mm square male drain pipe union .
gas extractors in the workshop.
Allow all the engine oil to flow into a drain tray.
WARNING
To prevent engine racing, check the engine oil
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
F9Q
Rubber-lipped seal 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 direc-
tion).
Tighten to torque the engine drain plug ( 20 Nm ) .
Clean any traces of the drained oil from the sump.
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 opera-

tion, 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 bo-
dy.
19B-48
RESERVOIR
Draining the fuel tank 19C
DRAINING THE FUEL TANK
Mot. 1311-08 Union for measuring K4J, and 730 or 732 F4R, and 770 or 771 or 776
fuel pressure
WARNING
2
During this operation, it is essential to:
- refrain from smoking or bringing red hot objects 3
close to the work area,
- guard against petrol splashes caused by the resi-
dual pressure in the pipes,
WARNING
The ignition must be switched off during this opera-
tion. 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 con-
tainer to the T -union outlet.
19C-1
RESERVOIR
K4M, and 760 or 761 4
102502
Place the electrical connector (4) to one side without
101803
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 con-
tainer to the T -union outlet. 6
Remove the protection and switching unit cover.
102503
Disconnect the brown connector (6) from the Protec-
tion and Switching Unit.
19C-2
RESERVOIR
12 1
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 catalo-
gue entitled Equipment) , to be adapted on the
union at T (Mot. 1311-08) .
19C-3
RESERVOIR
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
Equipment required
petrol or diesel tank drain pneumatic siphoning

pump
IMPORTANT

close to the work area,
union,
DRAINING THE FUEL TANK

102460
Remove the carpet retaining clip.
Take out the carpet.
99641
terminal.
Note:
Since diesel vehicles are not fitted with an electri-
cal fuel pump, the petrol or diesel tank drain
pneumatic siphoning pump tool must be used
to drain the tank. 102461
Lift up the cushion from the rear bench seat (see Remove:
Workshop repair Manual 365 Bodywork, 76A,
- the closure panel mounting bolts (1) ,
Rear seat mountings and runners, Complete
seat base ). - the closure panel,
- the inspection flap blanking cover (2) .
19C-4
RESERVOIR
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
4 3
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 die-
sel tank drain pneumatic siphoning pump to the
diesel fuel supply quick-release union, and the si-
phoning pump's backflow pipe to the container (5) .
Run the petrol or diesel tank drain pneumatic si-
phoning pump .
Let the fuel flow out until it comes intermittently.
Drain the tank.
nal.
WARNING
19C-5
RESERVOIR
Fuel tank: Description 19C
F4R or K4J or K4M
2 11
2
8
9
10
2
12
13 7
5
5
2 6
102487
No. Description
1 Tank
2 Mounting holes
3 Filler neck
4 Neck mounting clips
5 Brake pipe retaining clips
6 Fuel supply pipe
7 Petrol vapour supply pipe
8 Petrol vapour absorber supply pipe (from the tank)
9 Fresh air vent
10 Petrol vapour absorber
11 Overfill prevention valve and leak prevention valve in case of vehicle roll-over
12 Anti-backflow pipe (degassing - filling)
13 Petrol suction assembly
19C-6
RESERVOIR
F4R or K4J or K4M
3
4
2 10
13036
No. Description
1 Connection to petrol vapour absorber
2 Overfill prevention ball
19C-7
RESERVOIR
F4R or K4J or K4M
No. Description
3 Filling anti-backflow pipe
4 Restriction valve
5 Excess pressure/underpressure safety valve
6 Air outlet hole during filling
7 Volume of air allowing fuel expansion
8 Fuel inlet for filling
9 Usable fuel volume
10 Overfill prevention valve and vehicle roll-over leak prevention valve
ROLE OF THE FILLER NECK AND VALVES - a valve blocking the filling opening (to prevent petrol
vapour release or backflow of petrol),
1 - Overpressure/underpressure safety valves - a leak-tight cap.
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,
19C-8
RESERVOIR
8 1
2
2
4
9 2
10
5
2 6
110881
No. Description
1 Tank
2 Mounting holes
3 Filler neck
4 Neck mounting clips
5 Brake pipe retaining clips
6 Fuel supply pipe
7 Fuel return pipe
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
9 Anti-backflow pipe (degassing - filling)
10 Diesel suction assembly
19C-9
RESERVOIR
2
8
13036-1
No. Description
1 Fresh air vent
2 Overfill prevention ball
19C-10
RESERVOIR
No. Description
3 Filling anti-backflow pipe
4 Air outlet hole during filling
5 Volume of air allowing fuel expansion
6 Fuel inlet for filling
7 Usable fuel volume
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
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 re-
main 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 F4R or K4J or K4M
component jack Remove the petrol vapour absorber (see 14A, Anti-
pollution, Petrol vapour absorber ).
Unclip the petrol vapour absorber pipes.
Tightening torquesm
Disconnect the connectors on the Pump-Sender-
wheel bolt 110 Nm Filter assembly (see 19C, Fuel tank, Pump-Sen-
der-Filter ).
fuel tank mounting 21 Nm

bolts
IMPORTANT
1
- refrain from smoking or bringing red-hot objects
near the working area,
- watch out for fuel splashes when disconnecting
the union,
2
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining 3
the fuel tank ).
Remove the pump-sender-filter assembly (see
19C, Fuel tank, Pump-sender-filter ) for petrol en-
102465
gines or the sender (see 19C, Fuel tank, Sender )
for diesel engines. Remove:
Put the vehicle on a two-post lift. - the mounting bolts (1) from the fuel tank and the
heat shield,
terminal. - the heat shield mounting clips (2) ,
Remove: - the heat shield (3) .

- the nuts mounting the exhaust clamp on the mani-
fold,
- 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 linka-
ge (depending on vehicle equipment level).
19C-12
RESERVOIR
102467 102466
Remove mounting clips (4) from the brake and fuel Position the component jack under the tank.
pipes. Remove the fuel tank mounting bolts (6) .
Unclip:
Lower the fuel tank.
- the fuel pipe unions at the catalytic converter,
- the clips from the fuel pipes.
102459
5
Remove the tank by turning it around the exhaust pi-
102468 pe.
Remove fuel tank filler neck hose connection clips Take care not to damage the brake pipes or the par-
(5) . king brake cable.
Move the hoses to one side.
19C-13
RESERVOIR
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 repla-
ced.
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 die-
sel engines.
nal.
WARNING

( 4 Nm ) .
19C-14
RESERVOIR
Filler neck: Removal - Refitting 19C
Tightening torquesm

bolts
3
IMPORTANT

near the working area,
- watch out for fuel splashes when disconnecting
the union,
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining 102469
the fuel tank ). Remove the filler neck mounting bolts (3) .
terminal.
4
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch liner.
104559
Remove:
- the filler neck mounting bolts (4) ,

2 - the filler neck.
1
102468
REFITTING
Disconnect the anti-backflow pipe (1) . Always replace the clips with new ones.
Remove filler pipe clips (2) . Proceed in the reverse order to removal.

nal.
WARNING
19C-15
RESERVOIR
Filler neck: Removal - Refitting 19C
( 4 Nm ) .
19C-16
RESERVOIR
Sender unit: Removal - Refitting 19C
F9Q or K9K or M9R
Mot. 1397 Universal spanner for

removing fuel sender
nut
Tightening torquesm

bolts
IMPORTANT

union, 102461
- protect sensitive areas from fuel outflow. Remove:

REMOVAL - the closure panel,
Disconnect the battery, starting with the negative - the blanking cover (2) on the inspection flap.
terminal.
Lift up the rear bench seat base (see MR 365 Bo-
dywork, 76A, Rear seat runners and frames,
Complete seat base ).
Move the carpet to one side.
19C-17
RESERVOIR
F9Q or K9K or M9R
104546 104547
Disconnect: Remove the nut from the sender using tool (Mot.
1397) (5) .
- electrical connectors (3) ,
Remove the sender unit, being careful with the float.
- quick-release union(s) (4) .
Prepare for fuel outflow.
WARNING
Fit the correct blanking plugs into the unions (see
Refit the sender nut as soon as the sender has
MR 364 Mgane, 13B, Injection: Cleanliness gui-
been removed to prevent any deformation of the
delines ).
fuel tank.
19C-18
RESERVOIR
F9Q or K9K or M9R
REFITTING
102470
Replace the O-ring seal.
Refit the sender unit by aligning mark (6) on the sen-
der with mark (7) on the tank.
Position nut (9) .
Tighten the nut (9) until mark (8) on the nut is aligned
with mark (7) on the tank and mark (6) on the sen-
der.
nal (see MR 364 Mgane, 80A, Battery: Removal -
Refitting ).
( 4 Nm ) .
19C-19
RESERVOIR
Pump-sender unit-filter: Removal - Refitting 19C
K4M F4R K4J
Mot. 1397 Universal spanner for

removing fuel sender
nut
1
Tightening torquesm

bolts
2
IMPORTANT

union, 102461
- protect sensitive areas from fuel outflow. Remove:

REMOVAL - the closure panel,
terminal. - the blanking cover (2) on the inspection flap.
Lift up the rear bench seat base (see MR 365 Bo-

dywork, 76A, Rear seat runners and frames,
Complete seat base ).
Move the carpet to one side.
104546
Disconnect:
- electrical connectors (3) ,
- quick-release union(s) (4) .
Prepare for fuel outflow.
19C-20
RESERVOIR
Pump-sender unit-filter: Removal - Refitting 19C
K4M F4R K4J
REFITTING
104547
Remove the nut from the pump/sender/filter assem- 102470
bly using tool (Mot. 1397) (5) . Replace the O-ring seal.
Remove the pump/sender/filter assembly, being ca- Refit the pump/sender/filter assembly, aligning mark
reful not to damage the float. (6) on the pump/sender/filter assembly with mark (7)
on the tank.
WARNING Position the nut (9) .
Refit the pump/sender/filter assembly nut as Tighten the nut (9) until the mark (8) on the nut is ali-
soon as the pump/sender/filter assembly has gned with mark (7) on the tank and mark (6) on the
been removed to prevent any deformation of the pump/sender/filter assembly.
fuel tank.
nal (see MR 364 Mechanical systems, 80A, Batte-
ry: Removal - Refitting ).
( 4 Nm ) .
19C-21
RESERVOIR
Petrol filter: General information 19C
102299
The fuel filter is located in the fuel tank; it is built into
the pump-sender-filter assembly and cannot be re-
moved.
WARNING
The pump-sender-filter assembly must be repla-
ced 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 deli-
very rate is the equivalent of running fault finding on the
pump-sender-filter assembly.
19C-22
RESERVOIR
Fuel level sensor: Checking 19C
Checking the sender unit
Capacity Resistance value Height H (mm) 6mm

between terminals A1
and B2 () 10
Tank full 20 upper stop
Tank 3/4 full 95 150
Tank 1/2 full 170 111
Tank 1/4 full 245 72
Spare 290 40
Tank empty 320 lower stop
MEASURING HEIGHT H
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 19D
K4J, and 730 or 732 K4M, and 760, and JR5
6
4 5
1 3
103235
Tightening torques (in Nm)
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
19D-1
ENGINE MOUNTING
K9K, and 722 or 728
10
9
4
8
7
6
1 3
7
2
103236
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 21
(8) 62
(9) 180
(10) 62
19D-2
ENGINE MOUNTING
F9Q, and 800 or 804 or 808
6 12
7
11
10
5
9
3 4
103237
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21 for M8 bolts

62 for M10
bolts
(10) 62
(11) 180
(12) 62
19D-3
ENGINE MOUNTING
K4M, and 761
4 6
9
8
3
1
8
5
2
103274
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
(8) 21 for M8 bolts

62 for M10
bolts
(9) 62
19D-4
ENGINE MOUNTING
F4R, and 770 or 771 or 776
12
7 6
11
9 10
3
9
4
8
2
1
103275
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-5
ENGINE MOUNTING
F4R, and 770 or 771 or 776
7 6 12
11
9
10
9
5
3
13 8
4
103244
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-6
ENGINE MOUNTING
7
9
8
4
5 6
7
3
1
110743
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 62
(8) 62
(9) 62
19D-7
ENGINE MOUNTING
K9K, and 732
113926
(1) 62
(2) 62
(3) 105
(4) 115
(5) 62
(6) 180
(7) 105
(8) 62
(9) 105
(10) 62
(11) 62
19D-8
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
K9K, and 732
113926
No. Description Tightening

torque
(Nm)
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 62
(9) Bolt mounting the left-hand suspended mounting support on the body 62
(10) Left-hand rubber pad mounting nut on the gearbox mounting 62
(11) Left-hand rubber pad mounting bolts on the body mounting 105
19D-9
ENGINE MOUNTING
M9R, and 700
114630
No. Description Tightening tor-

que (Nm)
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(3) Lower engine tie-bar support mounting bolt 62
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 105
(9) Bolt mounting the left-hand suspended mounting support on the body 62
(10) Left-hand rubber pad mounting nut on the gearbox mounting 62
(11) Left-hand rubber pad mounting bolts on the body mounting 62
19D-10
ENGINE MOUNTING
106075
No. Tightening torque (Nm)
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 62
(10) 21
(11) 105
(12) 180
(13) 62
19D-11
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732

port with retaining
straps
Tightening torquesm
left-hand suspended 62 Nm
gearbox
left-hand suspended 62 Nm
body
left-hand rubber pad 105 Nm

body mounting
101822
left-hand rubber pad 62 Nm
Disconnect the engine management computer con-
mounting nut on the
nectors (1) .
gearbox mounting
Unclip:
REMOVAL - the battery negative terminal wiring harness,
I - REMOVAL PREPARATION OPERATION - the wiring harness from the battery tray.
Remove:
Remove: - the battery tray mounting bolts (2) ,
- the battery tray with the computer and its support.
- the scuttle panel grille (see MR365 Bodywork,
- the battery (see 80A, Battery: Removal - Refit-
ting ).
102450
Mark the position of the suspended mounting on the

body.
19D-12
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
II - OPERATION FOR REMOVAL OF PART Tighten to torque the left-hand suspended moun-
CONCERNED ting 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 ) .
Refit:
- the battery tray with the engine management com-
puter and its support,
- the battery tray mounting bolts.
112655
Clip:
Remove:
- the battery negative terminal wiring harness,
- the left-hand rubber pad mounting nut (3) on the - the wiring harness onto the battery tray.
gearbox mounting,
Connect the engine management computer connec-
- the left-hand rubber pad mounting bolts (4) on the tors.
body mounting,
Refit:
- the rubber pad,
- the scuttle panel grille (see MR 365, 55A, Exterior
- the bolts (5) mounting the left-hand suspended protection, Scuttle panel grille ),
mounting on the body,
- the left-hand suspended mounting on the body,
- the bolts (6) mounting the left-hand suspended Refitting ).
mounting on the gearbox.
- the gearbox left-hand suspended mounting.
REFITTING

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 moun-
ting 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 19D
K9K, and 732

port with retaining
straps
Tightening torquesm
bolts mounting the 62 Nm

right-hand suspended
mounting on the body
bolts mounting the 62 Nm 102450

right-hand suspended
mounting support on the Position the (Mot. 1453) .
engine
Mark the position of the suspended mounting on the
upper engine tie-bar 115 Nm body.
engine
upper engine tie-bar 105 Nm CONCERNED
body
REMOVAL

- Refitting ).
Remove the scuttle panel grille (see MR 365, Bo-
dywork, 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 bolts (3) mounting the suspended mounting on

the body,
19D-14
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
- the bolts (4) mounting the suspended mounting on
the engine,
- the suspended mounting.
REFITTING

CONCERNED
Refit:
- the right-hand suspended mounting support,
- the bolts mounting the right-hand suspended
mounting support on the body,
mounting on the engine,
- the upper engine tie-bar mounting bolt onto the bo-
dy,
- the upper engine tie-bar mounting bolt onto the en-
gine,
Tighten to torque:
mounting on the body ( 62 Nm )
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 )
Remove the (Mot. 1453)
Refit the scuttle panel grille (see MR 365, Bo-
dywork, 55A, Exterior protection, Scuttle panel
grille ).
Refitting).
19D-15
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting 19D
K9K, and 732
REFITTING
Tightening torquesm
bolt mounting the 180 Nm Refit:
engine tie-bar on its
support - the bolt mounting the engine tie-bar on its support
bolt mounting the 105 Nm - the bolt mounting the engine tie-bar on the sub-fra-
engine tie-bar on the me
sub-frame Tighten to torque:
- the bolt mounting the engine tie-bar on its sup-
port ( 180 Nm ) ,
REMOVAL
- the bolt mounting the engine tie-bar on the sub-
frame ( 105 Nm ) .
equipment, Underbody lift ). Refit the engine undertray.
Disconnect the battery (see 80A, Battery: Removal Connect the battery (see 80A, Battery: Removal -
Refitting ).
- Refitting ).
Remove the engine undertray

CONCERNED
112653
Remove:
- the bolt mounting the engine tie-bar on the sub-fra-

me (1) ,
- the bolt mounting the engine tie-bar on its support

(2) .
19D-16
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting 19D
M9R, and 700
Tightening torquesm
bolt mounting the 180 Nm

engine tie-bar on its
support
bolt mounting the 105 Nm

engine tie-bar on the
sub-frame
REMOVAL

Disconnect the battery (see 80A, Battery: Removal 114632

- Refitting ). Remove the engine tie-bar.
Remove the engine undertray. - by pushing it back (1) to detach it from its support,
- by pivoting it (2) to the right.
CONCERNED REFITTING

Refit:
- the bolt mounting the engine tie-bar on its support
me
Tighten to torque:
- the bolt mounting the engine tie-bar on its sup-
port ( 180 Nm ) ,
- the bolt mounting the engine tie-bar on the sub-
frame ( 105 Nm ) .
Refitting ).
114650
Remove:

me,
- the bolt mounting the engine tie-bar on its support.
19D-17

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1 Engine and peripherals

10A ENGINE AND LOWER ENGINE ASSEMBLY

11A TOP AND FRONT OF ENGINE

12A FUEL MIXTURE

13A FUEL SUPPLY

13B DIESEL INJECTION

16A STARTING - LOAD

17B PETROL INJECTION

77 11 318 022 FEBRUARY 2003 Edition Anglaise

Renault s.a.s. 2005

19D ENGINE MOUNTING

X84, and B84 or C84 or G84 or S84

77 11 318 022 FEBRUARY 2003 Edition Anglaise

Renault s.a.s. 2005

Engine identification 10A-1 Timing chain: Removal -

Oil pressure 10A-16

Oil pressure sensor:

Oil level sensor: Removal - Specifications 12A-1

Inlet manifold: Removal -

Accessories belt: Removal - Injector holder shim:

12A FUEL MIXTURE 13B DIESEL INJECTION

Exhaust manifold: Removal - Diesel injection: Precautions

Throttle valve: Removal - Description 13B-31

Injection warning light 13B-62

Injection / air conditioning

High pressure pump:

Diesel fuel supply circuit 13A-2 Injectors: Configuration 13B-130

Petrol filter: General High-pressure pipe between

Electric fuel: Checking 13A-20 Rail pressure sensor:

Fuel flow actuator: Removal -

13B DIESEL INJECTION 14A ANTIPOLLUTION

Diesel temperature sensor: Exhaust gas recirculation

Diesel injection computer:

Fuel vapour recirculation Spark plugs 17A-5

Fuel vapour canister:

17B PETROL INJECTION 19A COOLING SYSTEM

Petrol injection computer: Cooling circuit: Draining -

Special notes 17B-21 Engine cooling circuit:

Richness regulation 17B-35

Adaptive richness correction 17B-39 19B EXHAUST

Central coolant temperature General information 19B-1

Conditions for carrying out Expansion chamber:

Combustion misfire fault Silencer: Removal - Refitting 19B-30

Connecting hose: Removal -

Particle filter: Cleaning 19B-46

Draining the fuel tank 19C-1

Fuel tank: Description 19C-6

Fuel tank: Removal -

Filler neck: Removal -

Sender unit: Removal -

Petrol filter: General

Fuel level sensor: Checking 19C-23

19D ENGINE MOUNTING

Suspended engine mounting 19D-1

Left-hand suspended engine

Rear suspended engine

XNOW 776 9.5/1

XM02 728 17.9/1

XM1E 732 15.3/1

XM0G 800 18.4/1

XM0L F9Q 804 1870 80 93 17/1

XM00 808 18.4/1

List of engine Workshop Repair Manuals to be consul-