Motor Si Accesorii 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 J84
JANUARY 2006 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. 2006

17C LPG INJECTION
19A COOLING SYSTEM
19B EXHAUST
19C RESERVOIR
19D ENGINE MOUNTING
X84, and J84
JANUARY 2006 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. 2006

Scénic II - Section 1 ContentsPage
Scénic II - Section 1
Contents
Page
10A ENGINE AND LOWER ENGINE ASSEMBLY 12A FUEL MIXTURE
Engine identification 10A-1 Specifications 12A-1
Oil consumption Check 10A-3 Air inlet 12A-12
Oil filter: Removal - Refitting 10A-4 Air resonator: Removal -

Refitting 12A-22
Oil pressure sensor:
Removal - Refitting 10A-10 Air filter: Replacement 12A-23
Oil level sensor: Removal - Air filter: Removal - Refitting 12A-24

Refitting 10A-14
Air filter unit: Removal -
General information 10A-15 Refitting 12A-26
Engine/gearbox assembly: Air inlet duct: Removal -

Removal - Refitting 10A-16 Refitting 12A-40
Sump: Removal - Refitting 10A-99 Inlet manifold: Removal -

Refitting 12A-43
Oil pump: Removal -
Refitting 10A-118 Injector holder shim:
Removal - Refitting 12A-55
Multifunction support:
Removal - Refitting 10A-121 Manifolds: Removal -
Refitting 12A-61
Exhaust manifold: Removal -

Refitting 12A-64
11A TOP AND FRONT OF ENGINE
Throttle valve: Removal -
Accessories belt: Removal - Refitting 12A-83
Refitting 11A-1
Air inlet flap: Removal -
Timing belt: Removal - Refitting 12A-88
Refitting 11A-11
Engine stop device 12A-89
Timing chain: Removal -
Throttle valve: Cleaning 12A-90
Refitting 11A-109
Tightening the cylinder head 11A-110
Cylinder head gasket :

12B TURBOCHARGING
Crankshaft seal at timing end Turbocharging pressure

Removal - Refitting 11A-199 regulation valve 12B-1
Cylinder head: Removal - Pressure regulator: Checking 12B-5

Refitting 11A-202
Contents
12B TURBOCHARGING 13B DIESEL INJECTION
Turbocharger: Removal - High pressure pipe:

Refitting 12B-10 Checking 13B-66
Intercooler: Removal - Diesel injector: check 13B-69

Refitting 12B-40
Leak flow from injectors:
Check 13B-70
High pressure pump:

13A FUEL SUPPLY Removal - Refitting 13B-74
Diesel injector: Removal -

Petrol supply circuit 13A-1
Refitting 13B-104
Diesel fuel supply circuit 13A-2
Diesel injector adjustment
Petrol filter: General value 13B-120
information 13A-5
High-pressure pipe between
Diesel filter: Removal - the pump and rail: Removal -
Refitting 13A-6 Refitting 13B-122
Injector rail - Injectors: High-pressure pipe between

Removal - Refitting 13A-14 the rail and injector: Removal
- Refitting 13B-130
Fuel pressure
regulator:Checking 13A-20 Injector rail: Removal -
Refitting 13B-141
Electric fuel: Checking 13A-22
Rail pressure sensor:
Removal - Refitting 13B-156
Fuel flow actuator: Removal -

13B DIESEL INJECTION Refitting 13B-163
Specifications 13B-1 Fuel pressure regulator:

Diesel injection: Precautions
for repair 13B-16 Diesel temperature sensor:
Location of components 13B-31
Leak flow from injectors:
Flow regulation solenoid Check 13B-178
valve: Removal - Refitting 13B-53
Accelerometer: Removal -
Pressure regulation solenoid Refitting 13B-182
valve: Removal - Refitting 13B-54
Venturi: Removal - Refitting 13B-183
Injection warning light 13B-55
Diesel injector fuel return rail:
Injection / air conditioning Removal - Refitting 13B-185
programming 13B-57
Injector rail protector:
Idling speed 13B-60 Removal - Refitting 13B-189
Centralised coolant Accelerator pedal sensor

temperature management 13B-62 general information 13B-190
Computer configuration 13B-64

Contents
13B DIESEL INJECTION 14A ANTIPOLLUTION
Accelerator pedal Exhaust gas recirculation

potentiometer: Removal - mounting: Removal -
Refitting 13B-191 Refitting 14A-53
Diesel injection computer: Exhaust gas recirculation

Removal - Refitting 13B-192 rigid pipe: Removal -
Refitting 14A-54
Engine speed and position
sensor: Removal - Refitting 13B-196
16A STARTING - LOAD
13C PREHEATING
General alternator
information 16A-1
Pre/postheating unit:
Removal - Refitting 13C-1 Alternator: Removal -
Refitting 16A-2
Heater plugs Removal -
Refitting 13C-2 Starter: Identification 16A-27
Pre-postheating control 13C-9 Starter: Removal - Refitting 16A-28
Alternator pulley: Removal -

Refitting 16A-46
14A ANTIPOLLUTION
Petrol vapour rebreathing:

17A IGNITION
Operation 14A-1
Fuel vapour recirculation Coils Removal - Refitting 17A-1

circuit: check 14A-3
Spark plugs 17A-4
Fuel vapour canister:
Fuel vapour
canister:Checking 14A-5 17B PETROL INJECTION
Oil vapour rebreathing 14A-6 Fuel injection parts

description 17B-1
Exhaust gas recirculation:
Description 14A-16 Oxygen sensors: Removal -
Refitting 17B-16
Exhaust gas recirculation:
List and location of Accelerator pedal
components 14A-24 potentiometer: Removal -
Refitting 17B-18
Exhaust gas recirculation
unit: Removal - Refitting 14A-25 Position and speed sensor 17B-19
Exhaust gas recirculation Petrol injection computer:
solenoid valve: Removal - Removal - Refitting 17B-21
Refitting 14A-37
Injection warning light 17B-23
Intercooler: Removal -
Refitting 14A-47 Immobiliser function 17B-24
Contents
17B PETROL INJECTION 17C LPG INJECTION
Throttle valve: Operating 17B-25 LPG injector: Check 17C-29
Special notes on the system LPG computer: Removal -

(when driving) 17B-26 Refitting 17C-30
Conditions for carrying out

fault finding (when driving) 17B-28
Combustion misfire fault 19A COOLING SYSTEM

finding 17B-29
Engine cooling: Parts and
Catalytic converter fault
consumables for the repair
finding 17B-30
work 19A-1
Oxygen sensor fault finding 17B-31
Engine cooling 19A-2
Specifications 19A-3
Checking 19A-4
17C LPG INJECTION
Diagram 19A-5
LPG injection: Precautions
for repair 17C-1 Cooling circuit: Draining -
Refilling 19A-13
LPG tank - pipe neck:
Removal - Refitting 17C-2 Engine cooling circuit:
Cleaning 19A-15
LPG tank: Removal -
Refitting 17C-4 Cooling circuit: Bleeding 19A-16
LPG tank: Draining 17C-8 Cooling radiator: Removal -

Refitting 19A-17
LPG level gauge: Removal -
Refitting 17C-14 Water pump: Removal -
Refitting 19A-20
LPG expansion valve:
Removal - Refitting 17C-15 Plenum chamber: Removal -
Refitting 19A-33
LPG pressure sensor:
Removal - Refitting 17C-18 Electric water pump:
LPG expansion valve
solenoid valve: Removal -
Refitting 17C-20
LPG expansion valve outlet 19B EXHAUST

union: Removal - Refitting 17C-22
General information 19B-1
Coolant circuit union:
Removal - Refitting 17C-23 Pipe assembly 19B-4
LPG injection rail: Removal - Catalytic pre-converter:

Refitting 17C-24 Removal - Refitting 19B-11
LPG injector: Removal - Catalytic converter: Removal

Refitting 17C-28 - Refitting 19B-16
Expansion chamber:
Contents
19B EXHAUST 19D ENGINE MOUNTING
Silencer: Removal - Refitting 19B-34 Left-hand suspended engine

mounting: Removal -
Particle filter: Function 19B-35 Refitting 19D-9
Particle filter: Parts Rear suspended engine
description 19B-36 mounting: Removal -
Particle filter: Removal - Refitting 19D-14
Refitting 19B-37
Particle filter pressure

sensor: Removal - Refitting 19B-44
Particle filter temperature

sensors: Removal - Refitting 19B-48
Connecting hose: Removal -

Refitting 19B-51
Particle filter: Cleaning 19B-52
19C RESERVOIR
Draining the fuel tank 19C-1
Fuel tank: Removal -

Refitting 19C-6
Fuel tank: Description 19C-9
Filler neck: Removal -

Refitting 19C-15
Sender unit: Removal -

Refitting 19C-17
Petrol filter: General

information 19C-21
Pump-sender unit-filter:
Removal - Refitting 19C-22
Fuel level sensor: Checking 19C-26
19D ENGINE MOUNTING
Suspended engine
mounting: Tightening torque 19D-1
Suspended engine mounting 19D-2

ENGINE AND LOWER ENGINE ASSEMBLY
Engine identification 10A
Vehicle type Engine type Engine suf- Cubic Bore (mm) Stroke Compression
fix capacity (mm) ratio
(cc) 3
JM0B K4J 730 1390 79.5 42 (70) 10:1

JM0H
JM1A
JM0C 761 9.8:1

JM0J
JM1B
JM0Y K4M 764 1598 79.5 80.5 10:1
JM0C 782 9.8:1

JM0J
JM1B
JM0B 770
JM0U
JM1N
JM0B 771
9.8:1
JM0U
F4R 1998 82.7 93
JM1M
JM1N
JM1U
JM0W 776 9.5:1

JM1T
18.25:1
JM0F
722 17.9:1
JM0T
17.6:1
JM1F K9K 724 1461 76 80.5 17.9:1
JM02 17.9:1
728
JM13 17.6:1
JM1E 732 15.3:1
10A-1
Engine identification 10A
Vehicle type Engine type Engine suf- Cubic Bore (mm) Stroke Compression
fix capacity (mm) ratio
(cc) 3
JM1D 804 17:1

JM14
JM15
JM17 F9Q 1870 80 93
JM0G 812 18.4:1

JM1G
JM12
JM1K M9R 700 1995 84 90 15.7:1
List of engine Workshop Repair Manuals to be consul-

ted depending on the engine type:
- K4J and K4M engines Technical Note 3784A,
- K9K engine, Technical note 6006A,
- F9Q engine, Technical Note 3652A,
- F4R engine, Technical Note 6027 A,
- M9R engine, Technical Note 6017 A.
10A-2
Oil consumption Check 10A
PROCEDURE FOR MEASURING OIL
CONSUMPTION
1 - Filling to the maximum level
Switch off the engine.
Note:
The operation should be carried out with the
engine warm after the fan unit has started opera-
ting.
Wait 2 minutes for all the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the « MAXIMUM » 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 1200 miles

(2000 km) , without letting the oil level reach the
« MINIMUM » mark.
3 - Topping up
Switch off the engine.
Note:
The operation should be carried out with the
engine warm after the fan unit has started opera-
ting.
Wait 2 minutes for all the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the « MAXIMUM » 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 li-

tres)/number of kilometres (in thousands).
10A-3
Oil filter: Removal - Refitting 10A
K4J, and 730 – K4M, and 761 or 782
Special tooling required
Mot. 1329 Oil filter removing tool

(76 mm diameter).
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Remove the engine undertray.
110385
Position the (Mot. 1329) (1) on the oil filter.
Remove the oil filter.
REFITTING
Lubricate the oil filter seal with new engine oil.
Tighten the oil filter until it comes into contact with
the oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
Top up the engine oil.
Wipe any oil run-off with a cloth.
Refit the engine undertray.
10A-4
K9K, and 722 or 728 or 732
III - FINAL OPERATION
(76 mm diameter).
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Lifting

equipment, Underbody lift ).
111850
II - OPERATION FOR REMOVAL OF PART

CONCERNED
REFITTING
I - REFITTING PREPARATION OPERATION
II - REFITTING OPERATION FOR PART

CONCERNED

Tighten the oil filter three-quarters of a turn by hand.
10A-5
F4R, and 770 or 771 or 776

(76 mm diameter).
Tightening torquesm
air conditioning com- 44 Nm 2

pressor strut mounting
bolts
REMOVAL
111852
REFITTING
1 Tighten the oil filter three-quarters of a turn by hand.

Refit the air conditioning compressor strut.
Tighten to torque the air conditioning compressor
strut mounting bolts (44 Nm) .
111851
Remove:
- the air conditioning compressor strut mounting
bolts (1) ,
- the air conditioning compressor strut.
10A-6
M9R, and 700
Tightening torquesm
cover 25 Nm
REMOVAL

114779
Remove the « cover - filter element » assembly.

CONCERNED
114653
Gently loosen the cover (1) .
Allow the engine oil to run down the thread before
removing the « cover - filter element » 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) to the cover (7) ,
Correctly position the new O-ring (5) in its housing - the « cover - filter element » assembly.
on the cover. Tighten to torque the cover (25 Nm) .
Lubricate the O-ring with new engine oil.
10A-8
F9Q
REFITTING
Mot. 1329 Oil filter removing tool I - REFITTING PREPARATION OPERATION

(76 mm diameter).
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 manage 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 - Refilling
REMOVAL ).
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 - Refilling ).
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
Oil pressure sensor: Removal - Refitting 10A
M9R, and 700
Mot. 1495-01 22 mm socket for

removing/refitting oxy-
gen sensors.
Tightening torquesm
oil pressure sensor 44 Nm
front end panel lower 44 Nm

mounting bolts
upper mounting bolts of 21 Nm

the front end panel
REMOVAL
I - REMOVAL PREPARATION OPERATION 112658
Position the vehicle on a two-post lift (see 02A, Lif- Remove:

Disconnect the battery (see 80A, Battery, Battery: - the engine component unit cover mounting bolts
Removal - Refitting ). (1) ,
Remove: - the engine component unit cover.

- the engine protectors,
- the engine undertray,
- the front bumper (see MR 371 Bodywork, 55A Ex-
terior protection, Front bumper ).
115585
Disconnect the engine component unit connectors

(2) .
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Disconnect the screen washer tubes.
10A-10
M9R, and 700
CONCERNED
114933
Unclip the air inlet scoop (6) .
114061
Disconnect the oil pressure sensor connector (8) .
102365
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
10A-11
M9R, and 700
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
Refit the oil pressure sensor.
Tighten to torque the oil pressure sensor (44 Nm)

using the (Mot. 1495-01).
Connect the oil pressure sensor connector.
II - FINAL OPERATION
Refit:
- the front end panel,
- the upper mounting bolts of the front end panel,

115022
- the lower mounting bolts of the front end panel.
Tighten to torque:
- the front end panel lower mounting bolts (44

Nm) ,
- the upper mounting bolts of the front end panel

(21 Nm) .
Clip on the air inlet scoop.
Connect the screen washer tubes.
Fit the bonnet opening cable.
Connect the engine component unit connectors.
Refit:
115021 - the clips,

Remove the oil pressure sensor using the (Mot.
1495-01) (1) . - the engine component unit cover,
- the engine component unit cover mounting bolts,

Note:
Be careful not to damage the air conditioning
compressor connector. terior protection, Front bumper ),
- the engine protectors.
Connect the battery (see 80A, Battery, Battery: Re-

moval - Refitting ).
10A-12
F9Q
Use the (Mot. 1495) and tighten to torque the oil
Special tooling required pressure sensor (32 Nm) .
Mot. 1495 22 mm oxygen sensor
removal/refitting soc- II - FINAL OPERATION
ket - 1/2" square drive
Connect the oil pressure sensor.
and a 24 mm Allen
key. Refit the engine undertray.
Tightening torquesm
oil pressure sensor 32 Nm
REMOVAL


CONCERNED
115619
Disconnect the oil pressure sensor connector (1) .
Remove the oil pressure sensor (2) using the (Mot.

1495).
REFITTING

CONCERNED
Refit the oil pressure sensor.
10A-13
Oil level sensor: Removal - Refitting 10A
M9R, and 700
Connect the connector to the oil level sensor.
Tightening torquesm
oil level sensor 25 Nm Refit:
front right-hand wheel 130 Nm - the heat insulating material around the oil level
sensor,
- the front right-hand wheel.
REMOVAL
Tighten to torque the front right-hand wheel (130
Nm) .
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
Remove the front right-hand wheel.
Move aside the heat insulating material around the
oil level sensor.

CONCERNED
114932
Disconnect the connector (1) from the oil level sen-

sor.
Remove the oil level sensor.
REFITTING

CONCERNED
Refit the oil level sensor.
Tighten to torque the oil level sensor (25 Nm) .
10A-14
General information 10A
Attach the (Mot. 836-05) fitted with suitable end pie-
Special tooling required ces.
Mot. 836-05 Oil pressure gauge kit. Connect the battery (see 80A, Battery, Battery: Re-
I - ENGINES AND THEIR MATCHING END PIECES Start the vehicle.

Carry out the check.
Check the values.
Engine End pieces
K4J E+C+F
Min pressure (bar)
K4M E+C+F Engine
Engine
suffix Idling 3000 rpm
F4R B+F speed
K9K E+C+F K4J 730 1 3
F9Q B+F 760

K4M 1 3
M9R C+F 782
770
II - PRECAUTION FOR CHECK 1 3
F4R 771
The oil pressure check must be carried out with the en-
gine warm (≈80˚C). 776 1.2 3.5
722
III - TEST PROCEDURE
K9K 728 1.2 3.5
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ). 732
Remove the oil pressure sensor (see 10A, Engine and 804
peripherals, Oil pressure sensor: Removal - Refit- F9Q 1.2 3.5
ting ). 812
M9R 700 0.9 4

Removal - Refitting ).
Remove the (Mot. 836-05) with these end pieces.
Refit the oil pressure sensor (see 10A, Engine and pe-
ripherals, Oil pressure sensor: Removal - Refitting
).
87363
10A-15
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 812
- Drain the coolant circuit using the filling station
Special tooling required (see 62A, Air conditioning, Maintenance ).
Mot. 1202-01 Pliers for large hose Remove the scuttle panel grille (see MR 371 Bo-
clips. dywork, 55A, Exterior Protection, Scuttle Panel
Grille ).
Mot. 1202-02 Pliers for small hose
clips.
Mot. 1448 Long nose pliers for

hose clips.
Mot. 1390 Support for removing/ 1

refitting the engine -
2
gearbox assembly.
Equipment required
filling station
Tightening torquesm
104343
front end panel upper 21 Nm Remove:

mounting bolt - the air filter access panel mounting bolts (1) ,
front end panel lower 44 Nm - the air filter access panel,
mounting bolt
- the scuttle panel partition mounting bolt (2) .
half sub-frame front 105 Nm
mounting bolt 3
half sub-frame rear 21 Nm
mounting bolt
wheel bolt 130 Nm
REMOVAL
Remove:
- the engine protectors, 104246

Remove:
- the battery (see 80A, Battery, Battery: Removal -
Refitting ). - the scuttle panel partition mounting bolts (3) ,
- the front wheels, - the scuttle panel partition.
- the right and left-hand wheel arch liners,
Drain:
- the gearbox (see 05A, Draining - Refilling, Gear-

box ),
- the engine (see 05A, Draining - Refilling, Engine
),
10A-16
F9Q, and 812
4
102504
Disconnect the connectors (6) .
Unclip the bonnet opening cable (7) .
Remove:
101212 - the clip (8) ,
Remove: - the mounting bolt (9) .
- the half sub-frame side reinforcements (4) , Disconnect the screen washer tubes.
- the front bumper (see MR 371, Bodywork, 55A,
Exterior protection, Front bumper ).
102365
Remove:
- the front end panel mounting bolts (10) ,
Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining - Refilling ).
112660
Remove the air sleeve (5) .
10A-17
F9Q, and 812
106275
109537
Disconnect:
- the hoses from the expansion bottle on the cooling
radiator side (13) ,
- the pressostat connector on the condenser lower
air conditioning pipe (14)
Remove:
- the air conditioning pipes from the condenser (15) .
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister (16)
.
112661 WARNING
Disconnect: Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
- the intercooler hose (11) , system.
- the fan unit resistor connector (12) ,
- the cooling radiator top hose using the (Mot. 1202-
01) or (Mot. 1202-02) or (Mot. 1448).
- the fan unit connector.
Unclip the wiring harness from the fan unit.
10A-18
F9Q, and 812
102473 102500
Disconnect the duct (17) . Remove the air filter outlet duct (21) .
Remove the cooling assembly. Disconnect the flowmeter connector (22) .
104338
Remove:
- the fuel supply pipe (18) ,

- the fuel return pipe (19) .
101822
Disconnect the computer connectors.
WARNING
Remove:
Follow the cleanliness guidelines closely (see
13B, Diesel injection, Diesel injection: Pre- - the battery tray mounting bolts (23) ,
cautions during repair ).
- the battery tray.
Watch out for diesel fuel splashes when discon-
necting the supply union.
Fit plugs on the openings.

Disconnect the water sensor connector (20) .
10A-19
F9Q, and 812
112657
106280
Remove the computer mounting (24) .
104553
Move the retaining tabs (25) slightly away from the
air filter unit upstream air duct.
Remove:
- the air filter unit upstream air duct,
- the air filter unit (26) .
10A-20
F9Q, and 812
104245 104322
Remove: Remove the brake servo pipe (31) from the vacuum
pump.
- the Protection and Switching Unit mounting bolt,
Disconnect the heating radiator hoses (32) from the
- the fuse box (27) , side of the scuttle panel using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
- the relay box (28) .
Disconnect the connectors from the Protection and

Switching Unit.
104085
Remove the gearbox controls, using a screwdriver.
104340
Remove:
- the pre-postheating unit connector (29) ,
- the earth strap (30) .
10A-21
F9Q, and 812
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (34) .
111879
101740
Pull out clip (33) .

Disconnect the hydraulic clutch supply pipes.
Note:
Plug the pipes to prevent fluid from escaping.
111880
Fit the (Mot. 1390).
102008
Remove:
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ),
10A-22
F9Q, and 812
REFITTING
If carrying out a standard engine replacement opera-
tion (see Technical Note 3652A, Diesel engine -
High pressure Common Rail - 4 cylinders cast-
iron, 10A, Engine and peripherals, Standard re-
placement ).
Position the « engine - gearbox » assembly in the
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ) in accordance
with the marks,
- the suspended gearbox mounting (see 19D, Engi-

ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting ),
- the upper engine tie-bar (see 19D, Engine moun-
102742
hafts, Front right-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt (21
Nm) ,
- the front end panel lower mounting bolt (44 Nm)
,
- the half sub-frame front mounting bolt (105 Nm)
,
- the half sub-frame rear mounting bolt (21 Nm) ,
- the wheel bolt (130 Nm) .

Add the brake fluid to the brake fluid reservoir.
102419
Mark the suspended engine mounting in relation to IMPORTANT

the body.
Correctly attach the brake hose and ABS sensor
wiring.
Remove:
Do not twist the brake hoses.
- the suspended engine mounting,
Perform the following operations:
- the suspended gearbox mounting, - bleed the clutch system (see 37A, Mechanical
component controls, Bleeding the clutch sys-
Rotate the « engine - gearbox » assembly in order to tem: ),
remove it.
- top up the gearbox oil (see 05A, Draining - Refil-
Remove the « engine - gearbox » assembly. ling, Gearbox ),
10A-23
F9Q, and 812
- top up the engine oil (see 05A, Draining - Refil-
ling, Engine ),
- top up the engine cooling system (see 19A, Coo-
ling, Cooling system: Draining - Refilling ),
- bleed the engine cooling system (see 19A, Coo-
ling, Bleeding the cooling system ).
Fill the coolant circuit using the filling station (see
62A, Air conditioning, Maintenance ).
Refit the battery (see 80A, Battery, Battery: Remo-
val - Refitting ).
Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the system; (see 80C,
Xenon bulbs, Xenon headlights: Adjustment
).
Adjust the headlights (see 80B, Headlights,

Halogen headlights: Adjustment ).
10A-24
K4M, and 761 or 782

AIR CONDITIONING or CLIMATE CONTROL
Mot. 1202-01 Pliers for large hose
clips. Drain the coolant circuit using the filling station
(see 62A, Air conditioning, Maintenance ).
clips.

hose clips. Remove the scuttle panel grille (see MR 371 Bo-
dywork, 55A, Exterior protection, Scuttle panel
Mot. 1390 Support for removing/
grille ).
gearbox assembly.
Equipment required
filling station
2
Tightening torquesm
1
front end panel upper 21 Nm
mounting bolt

mounting bolt
half sub-frame front 105 Nm 104343

mounting bolt
Remove:
wheel bolt 130 Nm - the air filter access panel,

REMOVAL
Remove:

Refitting ).
- the front wheels,
Drain: 104246
- the gearbox (see 05A, Draining - Refilling, Gear- Remove:

box ),
- the scuttle panel partition mounting bolts (3) ,
). - the scuttle panel partition.
10A-25
K4M, and 761 or 782
4
102504
Remove:
101212 - the clip (8) ,
Remove: - the mounting (9) .
- the half sub-frame side reinforcements (4) , Disconnect the screen washer tubes.
102365
Remove:
- front end panel mounting bolts (10) ,
112660
10A-26
K4M, and 761 or 782
101795 109537
Disconnect the hoses from the expansion bottle on
Disconnect the fuel inlet pipe (11) from the injector
the cooling radiator side (13) .
rail.

Disconnect the pressostat connector from the lower
air conditioning pipe on the condenser (14) .
Remove:
.
WARNING
Plugs must be fitted to the hoses and the expan-
system.
Remove the cooling assembly.

112661
Disconnect:

01) or (Mot. 1202-02) or (Mot. 1448).
10A-27
K4M, and 761 or 782
101807
Remove the air filter outlet duct (17) .
106280
Unclip the air resonators.
101822
Remove:
- the battery tray mounting bolts (18) ,
- the battery tray.
104553
Remove the air filter unit.
10A-28
K4M, and 761 or 782
104245 101812
Remove: Remove the brake servo hose (23) .
- the fuse box (20) ,
Switching Unit.
104240
Disconnect:
- hoses (24) and (25) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
- the downstream oxygen sensor connector.
111051
Disconnect the earth strap (22) .
10A-29
K4M, and 761 or 782
- the multifunction switch cable (27) by loosening the
sleeve stop.
K4M, and 782
101743
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A),
- pull the pin at (B),
- lift the gearbox control at (C). 101699

Remove the gearbox controls (28) .
K4M, and 761
103409
Remove:
- the multifunction switch cable ball joint (26) ,
10A-30
K4M, and 761 or 782
- the half sub-frame cross member (30) .
K4M, and 761
101740
111616
Note:
111619
Fit (Mot. 1390).
102008
Remove:
hafts, Front right-hand driveshaft ).
10A-31
K4M, and 761 or 782
K4M, and 782
111620
101866
Mark the suspended engine mounting in relation to

the body.
Remove the suspended engine mounting.
K4M, and 761
111615
Fit (Mot. 1390).
103273
Remove the suspended engine mounting from the

gearbox.
10A-32
K4M, and 761 or 782
hafts, Front left-hand driveshaft ).
K4M, and 782
Tighten to torque:

Nm) ,

,

,
- the half sub-frame rear mounting bolt (21 Nm) .
IMPORTANT
102112
wiring.
Remove the suspended engine mounting from the
gearbox.

Rotate the « engine - gearbox » assembly in order to ling, Gearbox ),
remove it.
Remove the « engine - gearbox » assembly. ling, Engine ),

REFITTING ling, Cooling system: Draining - Filling ),
If carrying out a standard engine replacement opera- - bleed the engine cooling system (see 19A, Coo-
tion (see Technical Note 3784A, Petrol engine - 4 ling, Bleeding the cooling system ).
cylinders - K4, 10A, Engine and peripherals,
Standard replacement ).
Position the « engine - gearbox » assembly in the AIR CONDITIONING or CLIMATE CONTROL
vehicle.
Fill the refrigerant circuit using the filling station
Refit: (see 62A, Air conditioning, Maintenance ).

with the marks,

K4M, and 782
- the lower engine tie-bar (see 19D, Engine moun- Bleed the clutch system (see 37A, Mechanical
ting, Suspended mounting ), component controls, Clutch system: Bleeding ).

10A-33
K4M, and 761 or 782
Note:
).

10A-34
K9K, and 722 or 728
REMOVAL
Car. 1363 Trim removal lever. ting equipment, Underbody lift ).
Mot. 1202-01 Pliers for large hose Remove:
clips.
clips. - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
hose clips. - the front wheels,
Mot. 1390 Support for removing/ - the right and left-hand wheel arch liners,
gearbox assembly.
Drain:
Equipment required
filling station box ),

Tightening torquesm ).

mounting bolt AIR CONDITIONING or CLIMATE CONTROL
front end panel lower 44 Nm Drain the coolant circuit using the filling station
mounting bolt (see 62A, Air conditioning, Maintenance ).

mounting bolt
half sub-frame rear 21 Nm Remove the scuttle panel grille (see MR 371 Bo-
mounting bolt dywork, 55A, Exterior protection, Scuttle panel
grille ).
wheel bolts 130 Nm
WARNING
Procedure for removing the air inlet duct on the

intercooler (there is a danger of leakage and dislo-
cation if this procedure is not complied with):
- separate the hose, using the (Car. 1363) tool,
- do not use a degreaser, brake cleaning product, or
any other product,
- clean the intercooler bearing face and the hose
using a dry, lint-free cloth,
104343
- refit the clip in the same recess if the hoses are
not replaced, Remove:
- it is essential to replace the hoses and/or the inter- - the air filter access panel mounting bolts (1) ,
cooler if they are damaged.
If this procedure is not followed the pipes may leak - the air filter access panel,
or come undone. - the scuttle panel partition mounting bolt (2) .
10A-35
K9K, and 722 or 728
104246
Remove:
- the scuttle panel partition.
112660
102504
101212 Unfasten the bonnet opening cable (7) .

Remove: Remove:
- the half sub-frame side reinforcements (4) , - the clip (8) ,
- the front bumper (see MR 371, Bodywork, 55A, - the mounting (9) .
10A-36
K9K, and 722 or 728
102365
Remove:
Drain the engine cooling circuit (see 19A, Cooling, 102514
Cooling circuit: Draining - Refilling ). Remove:
- fuel inlet pipe (11) ,
- fuel return pipe (12) .
WARNING
- Follow the cleanliness guidelines closely (see
13B, Diesel injection, Diesel injection, Pre-
- Watch out for diesel fuel splashes when discon-
10A-37
K9K, and 722 or 728
106275
109537

Remove:
.
112661
Note:
Disconnect:
- the intercooler hose (13) ,
- the fan unit resistor connector (14) , system.
01) or (Mot. 1202-02) or (Mot. 1448).
10A-38
K9K, and 722 or 728
K9K, and 728

Move the turbocharger pressure solenoid valve to
one side.
102473
Disconnect the duct (19) .
106280
Disconnect:
- the air duct between the air filter unit and the turbo-
charger.
- the flowmeter connector (if fitted to the vehicle).
101822
Remove:
- the battery tray.
10A-39
K9K, and 722 or 728
112657
104245
Remove:

Switching Unit.
104553
Move the retaining tabs (22) slightly away from the
air filter unit upstream air duct.
Remove:
104340
Disconnect:
- the earth strap on the body (27) .
10A-40
K9K, and 722 or 728
102263 104085
Remove the brake servo pipe (28) from the vacuum Remove the gearbox controls.
pump.
Disconnect the heating radiator hose from the scutt-
le panel (2 9) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448)
102264
Disconnect the heating radiator hose (30) using the 101740
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448). Pull out clip (31) .
Disconnect the clutch hydraulic control.
10A-41
K9K, and 722 or 728
110317
102008
Remove:
110318
- the half sub-frame (32) . Fit (Mot. 1390).
10A-42
K9K, and 722 or 728
REFITTING
iron, 10A, Engine and peripherals, Standradre-
placement ).
vehicle.
Refit:
- the suspended engine mounting following the
marks (see 19D, Engine mounting, Suspended
mounting ),
102114 hafts, Front right-hand driveshaft ),
Tighten to torque:
Nm) ,
,
,
- the wheel bolts (130 Nm) .
IMPORTANT
102112
wiring.
Mark the suspended engine mounting in relation to Do not twist the brake hoses.
the body.
Remove: - top up the gearbox oil (see 05A, Draining - Refil-
ling, Gearbox ),
- the suspended gearbox mounting, ling, Engine ),
Rotate the « engine - gearbox » assembly in order to
ling, Cooling system: Draining - Filling ),
remove it.
Remove the « engine - gearbox » assembly. ling, Bleeding the cooling system ),
10A-43
K9K, and 722 or 728
- bleed the clutch system (see 37A, Mechanical
component controls, Clutch system: Bleeding
).

Fill the refrigerant circuit using the filling station

Note:
).

10A-44
K4J, and 730

clips. Drain the coolant circuit using the filling station
clips.

hose clips. Remove the scuttle panel grille (see MR 371 Bo-
grille ).
gearbox assembly.
Equipment required
filling station
2
Tightening torquesm
1
mounting bolt

mounting bolt
half sub-frame front 105 Nm 104343

mounting bolt
Remove:
wheel bolt 130 Nm - the air filter access panel,

REMOVAL
Remove:

Refitting ).
- the front wheels,
Drain: 104246
- the gearbox (see 05A, Draining - Refilling, Gear- Remove:

box ),
). - the scuttle panel partition.
10A-45
K4J, and 730
4
102365
Remove:
- front end panel mounting bolts (9) ,
101212 Drain the engine cooling circuit (see 19A, Cooling,
Remove:
- the half sub-frame side reinforcements (4) ,
6 5 10
7 101802
Disconnect the fuel supply union (10) .
102504
Remove:
- the clip (7) ,
- the mounting (8) .
10A-46
K4J, and 730

Remove:
.
WARNING
system.
112661 Remove the cooling assembly.
Disconnect:

01) or (Mot. 1202-02) or (Mot. 1448).
101103
Remove:
- the air resonator mounting (16) ,
- the air resonator.
109537

10A-47
K4J, and 730
101822 104245
Disconnect the computer connectors. Remove:
Remove: - the Protection and Switching Unit mounting bolt,
- the battery tray mounting bolts (17) , - the fuse box (19) ,
- the battery tray. - the relay box (20) .
Switching Unit.
106280
Remove the computer mounting (18)
111051
10A-48
K4J, and 730
101812 101743
Remove the brake servo hose (22) . Unclip the lever cables on the gearbox:
- grip the gearbox control at (A),
- pull the pin at (B),
- lift the gearbox control at (C).
104240
Disconnect:
- hoses (23) and (24) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
101699
- the downstream oxygen sensor connector.
10A-49
K4J, and 730
101740 102008
Pull out clip (26) . Remove:
Disconnect the hydraulic clutch supply pipes. - the front right-hand driveshaft (see 29A, Drives-
Note: - the front left-hand driveshaft (see 29A, Drives-

Fit (Mot. 1390).
10A-50
K4J, and 730
REFITTING
tion (see Technical Note 3784A, Petrol engine - 4
vehicle.
Refit:
with the marks,
101866
Tighten to torque:
Nm) ,
,
,
- the wheel bolt (130 Nm) ,
IMPORTANT
102112 wiring.
Mark the suspended engine mounting in relation to Do not twist the brake hoses.
the body.
Remove: - top up the gearbox oil (see 05A, Draining - Refil-
ling, Gearbox ),
- the suspended gearbox engine mounting, ling, Engine ),
remove it.
Remove the « engine - gearbox » assembly. ling, Bleeding the cooling system ),
10A-51
K4J, and 730
component controls, Clutch system: Bleeding
).

Fill the coolant circuit using a filling station (see

Note:
).

10A-52
F4R, and 770 or 771 or 776
REMOVAL
Car. 1363 Trim removal lever. ting equipment, Underbody lift ).
Mot. 1202-01 Pliers for large hose Remove:
clips. - the engine protectors,
Mot. 1202-02 Pliers for small hose - the battery (see 80A, Battery, Battery: Removal -
clips. Refitting ).
Mot. 1448 Long nose pliers for - the front wheels,

hose clips. - the right and left-hand wheel arch liners,
Mot. 1390 Support for removing/ - the engine undertray.

refitting the engine - Drain:
gearbox assembly.
box ),
Equipment required
filling station ),
Tightening torquesm (see 62A, Air conditioning, Maintenance ).
Remove the scuttle panel grille (see MR 371 Bo-
front end panel upper 21 Nm dywork, 55A, Exterior protection, Scuttle panel
mounting bolt grille ).
mounting bolt

mounting bolt
half sub-frame rear 21 Nm 2

mounting bolt
wheel bolt 130 Nm 1
WARNING
Procedure for removing the air inlet duct on the F4R

104343
776 intercooler (there is a danger of leakage and
dislocation if this procedure is not complied with): Remove:
- detach the hose using the (Car. 1363) , - the air filter access panel mounting bolts (1) ,
- do not use a degreaser, brake cleaning product, or - the air filter access panel,
any other product, - the scuttle panel partition mounting bolt (2) .
using a dry, lint-free cloth,
- refit the clip in the same recess if the hoses are
not replaced,
- always replace the hose and/or the intercooler if
they have been damaged.
If this procedure is not followed the pipes may leak
or come undone.
10A-53
F4R, and 770 or 771 or 776
F4R, and 770 or 771
104246
Remove:
112660
Remove the sleeve (5) .
101212
Remove:
- the front bumper (see MR 371, Bodywork, 55A, 102504
Unpick the bonnet opening cable (7) .
Remove:
- the clip (8) ,
- the attachment (9) .
10A-54
F4R, and 770 or 771 or 776
F4R, and 776
102365
Remove:
- the front end panel mounting bolts (10) , 106271
- the front end panel. Disconnect the fuel supply pipe (12) from the injector
rail.
F4R, and 770 or 771 Disconnect:

01) or (Mot. 1202-02) or (Mot. 1448).
- the fan unit connectors.
F4R, and 776
101795
Disconnect the fuel supply pipe (11) from the injector
101807
rail.
Remove the intercooler air duct (13) .
10A-55
F4R, and 770 or 771 or 776
109536 109536
Disconnect: Disconnect:
- the cooling radiator expansion bottle hoses (19) ,
- the turbocharging pressure sensor connector (14) .
- the air temperature sensor connector (15) air conditioning pipe (20)
- the fan unit resistor connector (16) , Remove:

Remove the air duct (17) .
.
WARNING
F4R, and 770 or 771
system.
101807
Remove the air filter outlet duct (18) .
10A-56
F4R, and 770 or 771 or 776
101822
Remove:
- the battery tray.
10A-57
F4R, and 770 or 771 or 776
F4R, and 776
106280
106278
Remove the computer mounting (28)
Unclip the air resonators.
106632
Move the fuel vapour recirculation solenoid valve to

one side (24) . 104553
Remove the air filter unit.
Undo bolt (25) .
Pull the mounting bracket away from the electric

coolant pump.
Move aside the electric coolant pump (26)
Remove the electric pump mounting (27) .
10A-58
F4R, and 770 or 771 or 776
F4R, and 770 or 771
104245
Remove:
- the Protection and Switching Unit mounting bolt, 101812
- the fuse box (29) , Remove the brake servo hose (32) .

Disconnect the relay plate wiring harness connec-
tors.
F4R, and 776
106787
Remove the brake servo hose (33) .
111051
10A-59
F4R, and 770 or 771 or 776
F4R, and 770
104240
Disconnect hoses (34) and (35) using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448).
101699

F4R, and 770 or 771
Disconnect the downstream oxygen sensor connec-

tor.
F4R, and 771
101743
Unpick the lever cables on the gearbox:

- grip the gearbox control at (A), 103409
- pull the pin at (B), Remove:
- lift the gearbox control at (C). - the multifunction switch cable ball joint (37) ,
10A-60
F4R, and 770 or 771 or 776
- the multifunction switch cable (38) by unlocking the
sleeve stop.
F4R, and 770 or 776
F4R, and 776
101740
Note:
104085 Plug the pipes to prevent fluid from escaping.

Remove the gearbox controls.
10A-61
F4R, and 770 or 771 or 776
F4R, and 770 or 776
109534
102008
Remove:
- the front right-hand driveshaft (see 29A Drives-
hafts, Front right-hand driveshaft),
hafts, Front left-hand driveshaft),
109533
10A-62
F4R, and 770 or 771 or 776
F4R, and 771
111617
102742
the body.
F4R, and 770 or 776
111618
102112
Remove the suspended gearbox mounting.
10A-63
F4R, and 770 or 771 or 776
REFITTING
F4R, and 771 If carrying out a standard engine replacement opera-
tion (see Technical Note 6027A, Petrol engine - 4
vehicle.
Refit:
with the marks,
ting, Suspended mounting ).
- the front right-hand driveshaft (see 29A Drives-
hafts, Front right-hand driveshaft),
103273
Remove the suspended gearbox mounting. hafts, Front left-hand driveshaft),
Tighten to torque:
Nm) ,
,
,
- the wheel bolt (130 Nm) ,
IMPORTANT
wiring.
109535 Perform the following operations:

Rotate the « engine - gearbox » assembly in order to - top up the gearbox oil (see 05A, Draining - Refil-
remove it. ling, Gearbox ),
Remove the « engine - gearbox » assembly. - top up the engine oil (see 05A, Draining - Refil-
ling, Engine ),
10A-64
F4R, and 770 or 771 or 776
ling, Bleeding the cooling system ),
- fill the coolant circuit using a filling station (see
F4R, and 770 or 776

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

Note:
).

10A-65
F9Q, and 804
Special tooling required (see 62A, Air conditioning, Maintenance ).
Mot. 1202-01 Pliers for large hose Remove the scuttle panel grille (see MR 371 Bo-
clips. dywork, 55A, Exterior Protection, Scuttle Panel
Grille ).
clips.

hose clips.
Mot. 1390 Support for removing/ 1 2

gearbox assembly.
Equipment required
filling station
Tightening torquesm
104343

front end panel lower 44 Nm - the air filter access panel,
mounting bolt
mounting bolt
half sub-frame rear 21 Nm 3

mounting bolt
wheel bolt 130 Nm
REMOVAL
Remove:

Remove:
Refitting ). - the scuttle panel partition mounting bolts (3) ,
- the front wheels, - the scuttle panel partition.
Drain:

box ),
- the engine (see 05A, Draining - Refilling, Gear-
box ),
10A-66
F9Q, and 804
4 5
101212 112660
Disconnect the electric coolant pump.
Move the electric coolant pump to one side.
Remove:
6
112658
Remove:
- the air duct (5) ,
- the relay plate cover mounting bolts (6) .
10A-67
F9Q, and 804
10
9
12
102504 106275
Remove:
- the clip (9) ,
- the mounting (10) .
13
11
112661
Disconnect:
102365
Remove: - the fan unit resistor connector (13) ,
- the front end panel mounting bolts (11) , - the cooling radiator top hose using the (Mot. 1202-
01) or (Mot. 1202-02) or (Mot. 1448).
Cooling circuit: Draining - Refilling ). Unclip the wiring harness from the fan unit.
10A-68
F9Q, and 804
17
15
14
18
16
109537 102473
Disconnect: Disconnect the duct (18) .
- the hoses from the expansion bottle on the cooling Remove the cooling assembly.
radiator side (14) ,
air conditioning pipe (15)
Remove:
.
WARNING
21 19
20
system.
104338
Remove:

WARNING
Follow the cleanliness guidelines closely (see
13B, Diesel injection, Diesel injection: Pre-
Watch out for diesel fuel splashes when discon-
Disconnect the water sensor connector (21) .

Insert plugs into the openings.
10A-69
F9Q, and 804
23
26
22
24
112657
25
112659
Disconnect the computer connectors (22) .
Detach:
- the wiring harness from the battery negative termi-
nal connector,
- the wiring harness (23) .
Remove:
27
- the battery tray,
- the mounting bolt (25) from the wiring harness.
Move the turbocharging pressure regulator solenoid
valve wiring harness to one side.
104553
Disconnect the flowmeter connector. Move the retaining tabs (26) slightly away from the
Remove the air duct between the air filter unit and air filter unit upstream air duct.
the turbocharger. Remove:
10A-70
F9Q, and 804
112459
Remove the brake assistance pipe from the vacuum
pump.
Disconnect the heating radiator hoses (30) from the
side of the scuttle panel using the (Mot. 1202-01) or
104245 (Mot. 1202-02) or (Mot. 1448).
Remove:

Switching Unit.
104085
Remove the gearbox controls, using a screwdriver.
104340
Remove:
- the pre-postheating unit connector (30) .
- the earth strap (31) ,
10A-71
F9Q, and 804
111879
101740
Pull the clutch pipes clip (31) .

Note:
111880
102008
Remove:
10A-72
F9Q, and 804
REFITTING
iron, 10A, Engine and peripherals, Standard re-
placement ).
vehicle.
Refit:
with the marks,

102742
Tighten to torque:
Nm) ,
,
,

102419
Mark the suspended engine mounting in relation to IMPORTANT

the body.
wiring.
Remove:
- the suspended gearbox mounting, - bleed the clutch system (see 37A, Mechanical
component controls, Bleeding the clutch sys-
Rotate the « engine - gearbox » assembly in order to tem: ),
remove it.
Remove the « engine - gearbox » assembly. ling, Gearbox ),
10A-73
F9Q, and 804
ling, Engine ),
ling, Bleeding the cooling system ).
Note:
essential to initialise the system (see 80C,
Xenon bulbs, Xenon headlights: ). Adjust-
ment ).

10A-74
K9K, and 732

WARNING
Car. 1363 Trim removal lever.
Mot. 1202-01 Pliers for large hose Procedure for removing the air inlet duct on the
clips. intercooler (there is a danger of leakage and dislo-
cation if this procedure is not complied with):
Mot. 1202-02 Pliers for small hose - separate the hose, using the (Car. 1363) tool,
clips.
- do not use a degreaser, brake cleaning product, or
Mot. 1448 Long nose pliers for any other product,
hose clips.
Mot. 1390 Support for removing/ using a dry, lint-free cloth,
refitting the engine - - refit the clip in the same recess if the hoses are
gearbox assembly. not replaced,
- it is essential to replace the hoses and/or the inter-
Equipment required cooler if they are damaged.
filling station If this procedure is not followed the pipes may leak
or come undone.
Tightening torquesm
half sub-frame front 105 Nm REMOVAL

mounting bolts
half sub-frame rear 21 Nm I - REMOVAL PREPARATION OPERATION

mounting bolts
ball joint bracket bolts 21 Nm ting equipment, Underbody lift ).
with their springs
Remove:
battery tray mounting 21 Nm
bolts - the engine protectors,
front end panel lower 44 Nm - the battery (see 80A, Battery, Battery: Removal -
mounting bolt Refitting ).
front end panel upper 21 Nm - the front wheels,

mounting bolt
side reinforcement 21 Nm
mounting bolts
wheel bolts 130 Nm
Drain:

box ),

),


grille ).
10A-75
K9K, and 732
104343
Remove:
- the air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) . 101212
Remove:
- the side reinforcement mounting bolts,
104246
Remove:
10A-76
K9K, and 732
102504
Disconnect the connectors (7) from the Protection
and Switching Unit.
Unpick the bonnet opening cable (8) .
Remove:
112660
- the clips (9) ,
- the upper mounting bolts (10) .
102365
Remove:
112658
Remove: - front end panel mounting bolts (11) ,
- the air sleeve (5) , - the front end panel.
- the Protection and Switching Unit cover mounting Drain the engine cooling circuit (see 19A, Cooling,
bolts (6) . Cooling circuit: Draining - Refilling ).
10A-77
K9K, and 732
106275
109537
Remove:
.
Note:
112661 Plugs must be fitted to the hoses and the expan-

Disconnect: system.
01) or (Mot. 1202-02) or (Mot. 1448).
10A-78
K9K, and 732
102473 112656
Disconnect the air duct from the intercooler (18) . Remove:
Remove the cooling assembly. - the fuel supply pipe (19) ,
WARNING
13B, Diesel injection, Diesel injection: Pre-
- Watch out for diesel fuel splashes when discon-
10A-79
K9K, and 732
112657
112659
Unclip:
nal,
- the wiring harness (22) from the computer connec-
tor.
Remove:
- the battery tray.
Move the turbocharger pressure solenoid valve to
one side.
104553
Disconnect the air flowmeter connector.
Move the retaining tabs (24) slightly away from air fil-
Remove the air duct between the air filter unit and ter unit upstream air duct.
the turbocharger.
Remove:
10A-80
K9K, and 732
104245 112946
Remove: Remove the brake servo pipe (30) from the vacuum
pump.
Disconnect:
- the heating radiator hose from the scuttle panel
- the relay box (27) . (31) using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) ,
Switching Unit. - the heating radiator hose (32) using the (Mot.
1202-01) or (Mot. 1202-02) or (Mot. 1448).
104340
Disconnect:
- the earth strap on the body (29) .
10A-81
K9K, and 732
104085 101740
Disconnect the clutch hydraulic control.
112947
102008
Remove:
- the ball joint bracket bolts with their springs,
- the half sub-frame mounting bolts,
10A-82
K9K, and 732

CONCERNED
112814
112654
112813
Fit (Mot. 1390).
112655
the body.
Remove:
- the acoustic mass,
- the suspended gearbox mounting.
remove it.
Remove the « engine - gearbox » assembly.
10A-83
K9K, and 732
REFITTING Refit:
If carrying out a standard engine replacement opera- hafts, Front right-hand driveshaft ).
iron, 10A, Engine and peripherals, Standard re- IMPORTANT
placement ). Correctly attach the brake hose and ABS sensor
wiring.
II - REFITTING OPERATION FOR PART Connect the clutch hydraulic control.

CONCERNED
Push in the clip.
Position the « engine - gearbox » assembly in the Refit the gearbox controls.
vehicle.
Connect:
Refit: - the heater radiator hose using the (Mot. 1202-01)
or (Mot. 1202-02) or (Mot. 1448).
ne mounting, Suspended mounting ), - the heater radiator hose from the scuttle panel
using the (Mot. 1202-01) or (Mot. 1202-02) or
- the suspended engine mounting following the (Mot. 1448).
marks (see 19D, Engine mounting, Suspended
mounting ), Reconnect the brake assistance pipe to the vacuum
pump.
- the upper engine tie-bar (see 19D, Engine moun- Connect:
- the earth strap on the body shell,
- The acoustic mass (see 19D, Engine mounting, - the pre-postheating unit connector,
Suspended mounting ).
- the Protection and Switching Unit connectors.
Remove the (Mot. 1390).
Refit:
- the relay box,
- the fuse box,
Refit: - the Protection and Switching Unit mounting bolt,
- the half sub-frame, - the air filter unit,
- the air duct upstream of the air filter.
- the half sub-frame mounting bolts.
Refit the air duct between the air filter unit and the
Tighten to torque: turbocharger
- the half sub-frame front mounting bolts (105 Connect the air flowmeter connector.
Nm) , Refit:
- the half sub-frame rear mounting bolts (21 Nm) . - the turbocharging pressure adjustment solenoid
valve,
Refit:
- the battery tray,
- the lower engine tie-bar (see 19D, Engine moun- - the battery tray mounting bolts.
Tighten to torque the battery tray mounting bolts
- ball joint bracket bolts with their springs. (21 Nm) .
Fit:
Tighten to torque the ball joint bracket bolts with
their springs (21 Nm) . - the wiring harness for the computer connector,
10A-84
K9K, and 732
- the battery negative terminal connector wiring har- - the air filter hose,
ness.
Connect the computer connectors. Exterior protection, Front bumper ),
Remove the blanking plugs.
- the half sub-frame side reinforcements,
Refit:
- the side reinforcement mounting bolts.
- the fuel return pipe,
- the fuel supply pipe, Tighten to torque the side reinforcement moun-
ting bolts (21 Nm) .
- the cooling system.
Refit:
Connect the air duct to the intercooler.
Refit: - the scuttle panel partition,
- the air conditioning pipe between the air conditio- - the scuttle panel partition mounting bolts,
ning compressor and the dehydration canister.
- the air conditioning pipes to the condenser.
- the air filter access panel mounting bolts,
Connect:
- the pressostat connector on the condenser lower - the scuttle panel grille (see MR 371 Bodywork,
air conditioning pipe, 55A, Exterior protection, Scuttle panel grille ).
- the hoses from the expansion bottle on the cooling Perform the following operations:
radiator side,
Fit the fan unit wiring harness. component controls, Clutch system: Bleeding
Connect: ),
- the fan unit connector, - the gearbox (see 05A, Draining - Refilling, Gear-
box ),
01) or (Mot. 1202-02) or (Mot. 1448). - the engine (see 05A, Draining - Refilling, Engine
- the fan unit resistor connector, ),
- the intercooler hose, - top up the cooling circuit (see 19A, Cooling, Coo-
Refit: ling circuit: Draining - Filling ),
- the front end panel, - bleed the cooling circuit (see 19A, Cooling, Blee-
ding the cooling circuit ),
- the front end panel lower mounting bolts.
- the front end panel upper mounting bolts, - fill the coolant circuit using the filling station (see
Tighten to torque:
, Refit:
Nm) ,
Connect the screen washer tubes. - the right and left-hand wheel arch liners,
Refit clips. - the front wheels.

Fit the bonnet opening cable. Tighten to torque the wheel bolts (130 Nm) .
Connect the Protection and Switching Unit connec-
Refit:
tors.
Refit: - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
- the Protection and Switching Unit cover mounting
bolts, - the engine protectors.
10A-85
K9K, and 732
Note:
Xenon bulbs, Xenon headlight: Adjustment ).
10A-86
M9R, and 700
REMOVAL

Mot. 1202-01 Pliers for large hose Position the vehicle on a two-post lift (see 02A, Lif-
clips. ting equipment, Underbody lift ).
Mot. 1202-02 Pliers for small hose Remove:
clips.
hose clips. - the battery (see 80A, Battery, Battery: Removal -
Refitting ),
refitting the engine - - the front wheels (see 35A, Wheels and tyres,
gearbox assembly. Wheel: Removal - Refitting ),
- the right-hand and left-hand wheel arch liners,

Equipment required
filling station
Drain:
Tightening torquesm - the gearbox (see 05A, Draining - Refilling, Gear-

box ),
half sub-frame moun- 21 Nm
ting nuts - the engine (see 05A, Draining - Refilling, Engine
),
ting bolts
side stiffener mounting 21 Nm
Remove the scuttle panel grille (see Workshop Re-
bolts
pair Manual 371 Bodywork, 55A, Exterior protec-
ball joint bracket bolts 21 Nm tion, Scuttle panel grille ).
with their springs
engine accessories unit 10 Nm

mounting bolt
turbocharger outlet air 5.5 Nm

pipe on the intercooler
side
connecting hose moun- 8 Nm

ting bolts
intercooler outlet air 5.5 Nm

pipe clip

mounting bolts 104343

mounting bolts - the mounting bolts (1) from the air filter access pa-
nel,
- the mounting bolt (2) from the scuttle panel parti-

tion.
10A-87
M9R, and 700
104246
Remove:
- the radiator tank partition mounting bolts (3) ,
- the scuttle panel partition,
- the front bumper (see MR 371, Bodywork, 55A, 112658
Remove:
- the engine accessories unit cover mounting bolts

(5) ,
- the engine component unit cover.
114933
115585
Disconnect the connectors (6) from the engine ac-
cessories unit.
Remove:
- the clips (8) ,
- the front end panel upper mounting bolts (9) .
Disconnect the screen washer pipes.
10A-88
M9R, and 700
102365
Remove:
- the front end panel lower mounting bolts (10) ,
Drain the engine cooling system (see 19A, Cooling, 115023
Cooling system: Draining - Refilling ). Remove the mounting bolt (11) from the intercooler
Clean the engine cooling system (see 19A, Coo- outlet air pipe.
ling, Engine cooling system: Cleaning
Loosen the intercooler outlet air pipe clip (12) on the
Remove the air filter unit (see 12A, Fuel mixture, intercooler side.
Air filter unit: Removal - Refitting ).
Disconnect:
- the hoses between the expansion bottle and the
cooling radiator (13) on the cooling radiator side,
- the evaporator-condenser connecting hose pres-
sure sensor connector (14) .
Unclip the pressure sensor connector wiring har-
ness on the fan unit.
Remove:
- the evaporator-condenser connecting hose moun-
ting bolt (15) on the condensor side,
- the condensor-compressor connecting hose moun-
ting bolt (16) on the condensor side,
- the compressor-dehydration canister connecting
hose mounting bolt (17) on the dehydration canis-
ter side.
10A-89
M9R, and 700
Disconnect:
- the evaporator-condenser connecting hose on the
condensor side,
- the condensor-compressor connecting hose on the
condenser side,
hose on the dehydration canister side.
Note:
Plugs must be fitted on the pipes, the dehydra-
tion canister and the condenser to prevent mois-
ture from entering the circuit.
112661
Disconnect:
115702
Undo the intercooler outlet air pipe clip (18) on the
damper valve side.
Disconnect the intercooler outlet air pipe on the in-
tercooler side.
10A-90
M9R, and 700
115703 115209
Detach the hose using the (Car. 1363). Disconnect:
Undo the turbocharger outlet air pipe clip (20) on the - the fuel supply pipe (22) ,
intercooler side.
- the fuel return pipe (23) from the diesel filter,
Remove the clip (21) from the cooling radiator top
hose, using the (Mot. 1202-01) or the (Mot. 1202- - the fuel return pipe (24) on the fuel pipe,
02) or the (Mot. 1448).
Disconnect:
WARNING
- the cooling radiator top hose.
- the turbocharger outlet air pipe on the intercooler 13B, Diesel injection, Diesel injection: Pre-
side. cautions during repair ).
Remove the cooling assembly. - Watch out for diesel fuel splashing when dis-
connecting the supply union.
Fit blanking plugs in the fuel pipe openings.
115202
Remove the engine accessories unit mounting bolt

(25) .
10A-91
M9R, and 700
115203
Remove the engine accessories unit support (26) .
115205
cessories unit.
115204
Remove:
- the fuse holder (27) ,
104340
Disconnect the pre-postheating unit connector (30) .
Remove the earth strap mounting nut (31) on the bo-
dy.
Disconnect the earth strap from the body.
10A-92
M9R, and 700
115207 104085
Disconnect the brake servo pipe mounting connec-
tor (32) on the vacuum pump.
Remove the clip (33) from the plenum chamber hea-
ter radiator hose using the (Mot. 1202-01) or the
(Mot. 1202-02) or the (Mot. 1448).
Disconnect:
- the heater radiator hose from the plenum chamber,
- the plenum chamber heater radiator hose, by
squeezing the clip (34) .
Note:
Position the gear lever in fourth gear to remove
the gear levers.
115212
10A-93
M9R, and 700
115003 101212
Pull the clip (36) . Remove:
Disconnect the clutch hydraulic control. - the side stiffener mounting bolts,
- the side stiffeners (38) .
114992
Remove: 102008
- the ball joint bracket bolts (37) with their springs, Remove:
- the rear suspended engine mounting (see 19D, - the half sub-frame mounting nuts (39) ,
Engine mounting, Rear suspended engine
- the half sub-frame mounting bolts (40) ,
mounting: Removal - Refitting ),
- the half sub-frame.
10A-94
M9R, and 700
CONCERNED
115000
115208
Remove the left-hand suspended engine mounting
nut (41) .
114999
Position the (Mot. 1390).
116055
Remove:
- the sound insulation mounting bolt (42) ,
- the sound insulation.
Unclip the manual priming pump from its support.
Mark the right-hand suspended engine mounting in
relation to the bodywork.
Remove:
- the manual priming pump support,
10A-95
M9R, and 700
- the bolt (43) securing the right-hand suspended en- Clean the intercooler bearing face and the hoses
gine mounting on the engine stand, using a dry, lint-free cloth.
- the bolts (44) securing the right-hand suspended
engine mounting on the body, II - REFITTING OPERATION FOR PART
CONCERNED
- the upper engine tie-bar mounting bolts,
Position the « engine and gearbox » assembly in the
- the upper engine tie-bar (45) . vehicle.
Refit the gearbox suspended engine mounting.
Fit without tightening the gearbox suspended engine
mounting bolts.
Tighten to torque the gearbox suspended engine
mounting bolts (see 19D, Engine mounting, Sus-
pended engine mounting: Tightening torque ).
Fit without tightening the left-hand suspended engi-
ne mounting nut
Refit the upper engine tie-bar.
Screw without tightening:
- the right-hand suspended engine mounting bolts
on the body by aligning the marks,
- the bolts securing the right-hand suspended engi-
ne mounting on the engine stand.
Tighten to torque:
115321
- the left-hand suspended engine mounting nut (see
Remove: 19D, Engine mounting, Suspended engine
- the mounting bolts (46) from the gearbox suspen- mounting: Tightening torque ),
ded engine mounting, - the upper engine tie-bar mounting bolts (see 19D,
Engine mounting, Suspended engine moun-
- the gearbox suspended engine mounting.
ting: Tightening torque ),
Rotate the « engine and gearbox » assembly in or-
- the bolts mounting the right-hand suspended engi-
der to remove it.
ne mounting on the body (see 19D, Engine moun-
Remove the « engine and gearbox » assembly. ting, Suspended engine mounting: Tightening
torque ),
REFITTING
ne mounting on the engine stand (see 19D, Engine
mounting, Suspended engine mounting: Tigh-
I - REFITTING PREPARATION OPERATION tening torque ).
To carry out a normal engine replacement operation Refit the manual priming pump support.
(see Technical Note 6017A, Diesel engine - M9R, Clip the manual priming pump on its support.
10A, Engine and peripherals, Normal replace-
ment ). Refit:
- the sound insulation,
WARNING - the sound insulation mounting bolt,
Do not use degreaser, brake cleaner or any other Tighten to torque the sound insulation mounting bolt
product. (see 19D, Engine mounting, Suspended engine
It is essential to replace the hose and/or the mounting: Tightening torque ).
intercooler if they are damaged. Remove the (Mot. 1390).
10A-96
M9R, and 700
III - FINAL OPERATION Fit the clip to the plenum chamber heater radiator
hose using the (Mot. 1202-01) or the (Mot. 1202-02)
Apply HIGH RESISTANCE BOLT LOCKING
or the (Mot. 1448)
AGENT part no. 77 11 230 112 to the half sub-frame
mounting bolts. Connect:
Refit the half sub-frame. - the brake servo pipe mounting connector on the
vacuum pump,
- the earth strap on the body.
Refit the earth strap nut on the body.
- the half sub-frame mounting nuts.
Connect:
Tighten to torque:
- the pre-postheating unit connector,
- the half sub-frame mounting nuts (21 Nm) ,
- the engine accessories unit connectors.
- the half sub-frame mounting bolts (105 Nm) .
Refit:
Refit:
- the relay box,
- the side stiffeners,
- the fuse holder,
- the side stiffener mounting bolts.
- the engine accessories unit mounting,
Tighten to torque the side stiffener mounting bolts
(21 Nm) . - the engine accessories unit mounting bolt.
Refit: Tighten to torque the engine accessories unit
mounting bolt (10 Nm) .
hafts, Front left-hand driveshaft ), Remove the blanking plugs from the fuel pipes.
- the front right-hand driveshaft (see 29A, Drives- Connect:
- the fuel return pipe to the fuel pipe,
- the rear suspended engine mounting (see 19D,
- the fuel return pipe to the diesel filter,
mounting: Removal - Refitting ). - the fuel supply pipe.
Tighten to torque the rear suspension (see 19D, En- Refit the cooling assembly.
gine mounting, Suspended engine mounting: Ti-
ghtening torque ). Connect:
- the cooling radiator bottom hose,
Refit the ball joint bracket balls with their springs.
- the cooling radiator top hose.
their springs (21 Nm) . Fit:
Fill the gearbox with oil (see 05A, Draining-Filling, - the cooling radiator bottom hose clip, using the
Gearbox ). (Mot. 1202-01) or the (Mot. 1202-02) or the (Mot.
Connect the clutch hydraulic control. 1448) ,
Push in the clip. - the cooling radiator top hose clip, using the (Mot.
1202-01) or the (Mot. 1202-02) or the (Mot. 1448).
Bleed the clutch system (see 37A, Mechanical
Connect the turbocharger outlet air pipe on the inter-
component controls, Clutch circuit: Bleeding ).
cooler side.
Tighten to torque the turbocharger outlet air pipe
Note: on the intercooler side (5.5 Nm) .
Position the gear lever in fourth gear to refit the Connect the fan unit connector.
gear levers.
Clip the fan unit wiring harness into place.
Refit the gearbox controls.
Connect the fan unit resistor connector.
Clip on the plenum chamber heater radiator hose.
Remove the blanking plugs from the air conditioning
Connect the plenum chamber heater radiator hose. pipes, condenser and dehydration canister.
10A-97
M9R, and 700
Connect: - the front end panel upper mounting bolts (21
Nm) .
hose on the dehydration canister side, Clip on the air inlet scoop.
- the condensor-compressor connecting hose on the
condenser side,
- the evaporator-condenser connecting hose on the Refit the clips.
condensor side.
Refit:
hose mounting bolt on the dehydration canister si- Refit:
de,
- the engine component unit cover,
- the condensor-compressor connecting hose moun-
ting bolt on the condensor side, - the engine accessories unit mounting bolts,
- the evaporator-condenser connecting hose moun- - the front bumper (see MR 371, Bodywork, 55A,
ting bolt on the condensor side. Exterior protection, Front bumper: Removal -
Tighten to torque the connecting hose mounting Refitting ),
bolts (8 Nm) .
Connect the evaporator-condenser connecting hose
pressure sensor connector. - the right-hand and left-hand wheel arch liners,
Clip the pressure sensor connector wiring harness - the front wheels (see 35A, Wheels and tyres,
on the fan unit. Wheel: Removal - Refitting ),
Connect: - the scuttle panel partition,
- the hoses between the expansion bottle and the
- the scuttle panel partition mounting bolts,
cooling radiator on the cooling radiator side,
- the intercooler outlet air pipe on the intercooler si- - the air filter access panel,
de.
Tighten to torque the intercooler outlet air pipe
clip (5.5 Nm) . - the scuttle panel grille (see MR 371 Bodywork,
55A, Exterior protection, Scuttle panel grille:
Refit the intercooler outlet air pipe mounting bolt on Removal - Refitting ).
the intercooler side.
Fill up the engine oil (see 05A, Draining-Filling, En-
Refit the air filter unit (see 12A, Fuel mixture, Air fil-
gine ).
ter unit: Removal - Refitting ).
Perform the following operations: Refit:
- fill the coolant circuit using the filling station (see - the battery (see 80A, Battery, Battery: Removal -
62A, Air conditioning, Maintenance ), Refitting ),
- fill the cooling system (see 19A, Cooling, Cooling - the engine protectors.
system: Draining - Refilling ).
Refit the front end panel.
- bleed the cooling system (see 19A, Cooling, Coo-
ling system: Bleeding ),
- the front end panel upper mounting bolts,
- adjust the xenon headlights (if fitted to the vehicle),
- the front end panel lower mounting bolts. (see 80C, Xenon bulbs, Xenon headlight: Ad-
Tighten to torque: justment ),
- the front end panel lower mounting bolts (44 - adjust the headlights (see 80B, Headlights,
Nm) , Halogen headlights: Adjustment ).
10A-98
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 732
Equipment required
safety belt
Tightening torquesm
sump mounting bolts 14 Nm
sump - gearbox moun- 44 Nm

ting bolts
bolt mounting the sump 21 Nm

on the multifunction
support
catalytic converter ups- 21 Nm

tream strut mounting
bolts
half sub-frame moun- 105 Nm 101212

ting bolts
Remove:
half sub-frame moun- 21 Nm - the half sub-frame side reinforcement mounting
ting nuts bolts,
half sub-frame side 21 Nm - the half sub-frame side reinforcements (1) .
reinforcement mounting Fit the cooling assembly to the upper cross member
bolts using a safety belt.
wheel bolts 130 Nm
Note:
REMOVAL When fitting the safety belt , be careful:

- not to crush the cooling hoses,
I - REMOVAL PREPARATION OPERATION - not to strap up the half sub-frame.
K9K, and 732
Remove:
Move the diesel drain pipe away from the injector rail
- the engine protectors, protector.
- the dipstick.
Remove:
- the front wheels,
- the wheel arch liners,
Drain the engine oil (see 05A, Draining - Refilling,
Engine ).
10A-99
K9K, and 722 or 728 or 732

Remove the mounting bolt from the sump on the
multifunction support.
Disconnect the oil level sensor.

CONCERNED
Remove:
- the sump mounting bolts,
- the sump.
REFITTING
102008
Remove:
- the half sub-frame mounting nuts, K9K, and 732

Wipe the strainer with a cloth.
Clean the gasket faces using DECAPJOINT to dis-

K9K, and 732 solve any seal still adhering.
Apply the product to the section to be cleaned: wait
Remove: approximately ten minutes, then remove the residue
using a wooden spatula.
- the lower engine tie-bar mounting bolts,

WARNING
- the engine tie-bar mounting lower bolt. The gasket faces must be clean, dry and free
from grease (avoid finger marks).
Loosen the lower engine tie-bar upper mounting
bolt.
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
Remove: could cause damage to certain components
(engine, radiator, etc.).
- 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.
10A-100
K9K, and 722 or 728 or 732
CONCERNED
1 - FIRST FITTING
20167
20170
Refit the oil splash plate onto the cylinder block.
Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positio-
ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent damage to the clutch
housing.
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVE
SEAL with a diameter of 5 mm
- two points of SILICONE ADHESIVE SEAL at (5) ,
7 mm in diameter, at the connection between the
crankshaft closure panel and the cylinder block.
10A-101
K9K, and 722 or 728 or 732
2 - SECOND FITTING
20171
Refit the oil sump fitted with a new seal. 108881
Fit:
- the sump mounting bolts without blocking them,
- the sump - gearbox mounting bolts without bloc-
king them.
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 sump - gearbox mounting
bolts (44 Nm) .
20171
Refit the oil sump fitted with a new seal.
Fit:

king them.

bolts 14 Nm .

10A-102
K9K, and 722 or 728 or 732
Tighten to torque the sump - gearbox mounting - the half sub-frame mounting nuts (21 Nm) .
bolts 44 Nm .

Connect the oil level sensor. K9K, and 732
Fit the diesel drain pipe on the injector rail protector.
Refit the bolt mounting the sump on the multifunction
support.
Remove the safety belt.
Tighten to torque the bolt mounting the sump on
Refit:
the multifunction support (21 Nm) .
- the half sub-frame side reinforcements,
- the half sub-frame side reinforcement mounting
bolts.
Refit the catalytic converter upstream strut.
Tighten to torque and in order the half sub-frame
Tighten the catalytic converter upstream strut moun- side reinforcement mounting bolts (21 Nm) .
ting bolts until contact is made.
Refit:
Tighten to torque the catalytic converter upstream
strut mounting bolts (21 Nm) .
Exterior protection, Front bumper ),
Refit:
- the relay bearing,
- the bolts mounting the relay bearing on the sump, - the front wheels.
- the bolts mounting the right-hand driveshaft brac- Tighten to torque the wheel bolts (130 Nm) .
ket on the relay bearing,
K9K, and 732
Top up the engine oil (see 05A, Draining - Refilling,
Refit the lower bolt on the lower engine tie-bar Engine ).
mounting (see 19A, Engine mounting, Suspended
Refit:
mounting ).
- the dipstick,
Tighten the upper bolt on the lower engine tie-bar
mounting (see 19A, Engine mounting, Suspended - the engine protectors.
mounting ).
Refit the lower engine tie-bar (see 19A, Engine
mounting, Suspended mounting ).
Note:
Apply a drop of LOCTITE - FRENBLOC on the
half sub-frame mounting bolts.
Refit:
- the half sub-frame mounting nuts.
- the half sub-frame.
Tighten to torque:
- the half sub-frame mounting bolts (105 Nm) ,
10A-103
K4J, and 730 – K4M, and 761 or 782
Equipment required
safety belt
Tightening torquesm
sump - gearbox moun- 44 Nm

ting bolts
bolt mounting the sump 21 Nm

on the multifunction
support 1
ting bolts

ting nuts 101212
wheel bolts 130 Nm Remove:

- the half sub-frame side reinforcement mounting
bolts,
REMOVAL
- the half sub-frame side reinforcements (1) .
equipment, Underbody lift ). Fit the cooling assembly to the upper cross member
using a safety belt.
Remove:
Note:
- the dipstick.
When fitting the safety belt , be careful:
Removal - Refitting ). - not to crush the cooling hoses,
Drain the engine oil (see 05A, Draining - Refilling, - not to strap up the half sub-frame.
Engine ).
Remove:
- the front wheels,
10A-104
K4J, and 730 – K4M, and 761 or 782
approximately ten minutes, then remove the residue
WARNING
The gasket faces must be clean, dry and free
WARNING
could cause damage to certain components
102008
Remove:
- the half sub-frame mounting nuts,
Remove:
- the mounting bolts of the right-hand driveshaft

bracket on the relay bearing,
- the bolts mounting the relay bearing on the sump.
Remove the mounting bolt from the sump on the

multifunction support.
Remove:
- the sump.
REFITTING
solve any seal still adhering.
10A-105
K4J, and 730 – K4M, and 761 or 782
I - FIRST FITTING
3
20167
20170
Refit the oil splash plate onto the cylinder block.
Note:
When refitting the sump, check that:
5
- the tabs (6) on the oil splash plate are positio-
ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent damage to the clutch
housing.
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHERESI-
VE SEAL 5 mm in diameter.
- two points of SILICONE ADHESIVE SEAL at (5) ,
7 mm in diameter, at the connection between the
crankshaft closure panel and the cylinder block.
10A-106
K4J, and 730 – K4M, and 761 or 782
II - SECOND FITTING
20171
Refit the oil sump, fitted with a new seal. 108881
Fit:
king them.
bolts (14 Nm) .
bolts (44 Nm) .
20171
Refit the oil sump with a new seal.
Fit:

king them.

bolts 14 Nm .

10A-107
K4J, and 730 – K4M, and 761 or 782
bolts 44 Nm .
III - REFITTING (FOR FIRST AND SECOND

FITTINGS)

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:
Engine ).
10A-108
F9Q, and 804 or 812
Equipment required
safety belt
Tightening torquesm

ting bolts

ting nuts
wheel bolts 130 Nm
REMOVAL
Remove: 101212
- the engine protectors. Remove:
- the dipstick. - the half sub-frame side stiffeners mounting bolts,

Disconnect the battery (see 80A, Battery, Battery: - the half sub-frame side stiffeners (1) .
Removal - Refitting ). Fit the cooling assembly to the upper cross member
Drain the engine oil (see 05A, Draining - Refilling, using a safety belt.
Engine ).
Remove: Note:
- the front wheels, When fitting the safety belt , be careful:
- the wheel arch liners, - not to crush the cooling hoses,
- the engine undertray, - not to strap up the half sub-frame.
10A-109
F9Q, and 804 or 812
WARNING
WARNING
Note:
There are two fitting procedures for preparing the
cylinder block gasket face when refitting:
102008
- the first fitting procedure is used if the cranks-
Remove: haft closure panel has been sealed with SILI-
- the mounting nuts from the half sub-frame, CONE ADHESIVE SEAL ,
- the half sub-frame mounting bolts, - the second fitting procedure is used if the
crankshaft closure panel sealing is fitted with a
- the half sub-frame (2) . seal.
- the lower engine tie-bar mounting bolts,
- the lower engine tie-bar, I - FIRST FITTING
- the sump.
REFITTING
15159
Apply a bead of SILICONE ADHESIVE SEAL :
- at (A) , on each side of bearing No. 1
- at (B) , the joint between the cylinder block and the
crankshaft closure panel.
10A-110
F9Q, and 804 or 812
Refit the oil sump, fitted with a new seal. REFITTING (FOR FIRST AND SECOND FITTINGS)
II - SECOND FITTING
15195
Stage 1:
15159 • Tighten to torque and in order, bolts (8) , (15) , (4)
, (19) , (11) , (12) to (18 Nm).
Note: - Stage 2:
Do not cut the two crankshaft closure panel seal • Tighten to torque and in order, bolts (10) , (13) ,
tabs which sit higher than the cylinder block gas- (9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18)
ket face (B) . , (3) , (20) , (2) , (21) , (1) , (22) to (15 Nm).
Refit the lower engine tie-bar (see 19D, Engine
Apply a bead of SILICONE ADHESIVE SEAL silico- mounting, Suspended mounting ).
ne at (A) , on the connection between the crankshaft
closure panel and the cylinder block. Tighten to torque:
Refit the oil sump, fitted with a new seal. - the half sub-frame mounting bolts (105 Nm) ,
Engine ).
10A-111
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm

ting bolts

ting nuts
wheel mounting bolts 130 Nm 1
REMOVAL
Remove: 101212
- the engine protectors, Remove:
- the dipstick. - the half sub-frame side reinforcement mounting

bolts,
Removal - Refitting ). - the half sub-frame side reinforcements (1) .
Drain the engine oil (see 05A, Draining - Refilling, Fit the cooling assembly to the upper cross member
Engine ). using a safety belt.
Remove:
Note:
- the front wheels,
When fitting the safety belt , be careful:
- not to strap up the half sub-frame.
10A-112
F4R, and 770 or 771 or 776
102008 15159
Remove:
- the half sub-frame mounting nuts, Note:

Do not cut the two crankshaft closure panel seal
tabs which sit higher than the cylinder block gas-
- the half sub-frame (2) , ket face (B) .
- the lower engine tie-bar mounting bolts, Apply a bead of SILICONE ADHESIVE SEAL at (A)
, on the connection between the crankshaft closure
- the lower engine tie-bar, panel and the cylinder block.
- the sump mounting bolts, Refit the sump with a new gasket.
- the sump.
REFITTING

WARNING
WARNING
10A-113
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) to (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) , (22) to (15 Nm).
mounting, Suspended mounting ).
Tighten to torque:
- the wheel mounting bolts (130 Nm) .
Engine ).
10A-114
M9R, and 700
Mot. 1716 Removes housing with

silicone seals.
Equipment required
safety belt
Tightening torquesm

mounting bolts

ting nuts
side stiffener lower 21 Nm

Attach the cooling assembly to the upper cross
member using a safety belt.
REMOVAL
Note:
When fitting the safety belt , be careful not to:
Position the vehicle on a lift (see 02A, Lifting equi-
pment, Underbody lift ). - pinch the cooling hoses,
Disconnect the battery (see 80A, Battery, Battery: - deform the air conditioning pipes,
- strap the half sub-frame.
Remove:
Remove:
- the lower mounting bolts (1) from the side stiffe-
- the dipstick, ners,
- the front wheels, - the half sub-frame mounting nuts (2) ,
- the front wheel arch liners, - the half sub-frame mounting bolts (3) ,
- the engine undertray, - the half sub-frame.
Drain the engine oil (see 10A, Engine and periphe-
Exterior protection, Front bumper ). rals, Engine oil: Draining-refilling ).
10A-115
M9R, and 700
CONCERNED
114264
Gradually detach the sump.
114997
Remove the sump mounting bolts.
Note:
To prevent deformation, use a series of small
movements.
Remove the sump.
REFITTING

Check that the sump is not:
- scratched,
- deformed.
If this is the case, replace the sump.
114263
Cut the sump's silicone seal (except at the coupling
face side and the lower engine tie-bar support side)
using the (Mot. 1716).
10A-116
M9R, and 700
Check that the baseplate is not scratched. III - FINAL OPERATION
Apply HIGH RESISTANCE BOLT LOCKING
AGENT part no. 77 11 230 112 to the half sub-frame
IMPORTANT
mounting bolts.
- Do not scratch the aluminium sealing surfaces.
Refit:
- Wear goggles.
- the half sub-frame,
- Wear gloves during the operation.
- the half sub-frame mounting nuts,
WARNING - the side stiffener lower mounting bolts.
Applying excess sealant could cause it to be
Tighten to torque:
squeezed out when parts are tightened. The pro-
duct mix may damage some components - the half sub-frame front mounting bolts (105
(engine, radiator, etc). Nm) ,
WARNING - the side stiffener lower mounting bolts (21 Nm) .

The sealing surfaces must be clean, dry and free Remove the safety belt.
from grease (avoid finger marks). Refit:
II - REFITTING OPERATION FOR PART Exterior protection, Front bumper ),
CONCERNED - the engine undertray,
- 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-
rals, Engine oil: Draining-refilling ).
Refit:
- the dipstick,
114410
Apply a bead of SILICONE ADHESIVE SEAL (77

11 227 484) 5 mm ± 2 in diameter to the sump to
seal it.
Fit the sump.
Finger tighten the sump mounting bolts.

bolts (16 Nm) .
10A-117
Oil pump: Removal - Refitting 10A
F4R or F9Q or K4J or K4M or K9K
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 cover mounting 4 Nm
Battery: Removal / Refitting ).
bolts
Tighten to torque the battery cover mounting bolts
(4 Nm) .
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative

terminal.
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 (2) oil pump bolts,
- the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts (25

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

Sump ).
Refill the engine oil.
10A-118
M9R, and 700
CONCERNED
Tightening torquesm
bolts mounting the oil 25 Nm

pump on the cylinder
block

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

Remove the engine protectors.

113157
Removal - Refitting ). Remove the oil pump mounting bolt from the anti-
splash plate.
Remove:
- the front bumper (see MR 371, Bodywork, 55A, Note:

Be careful not to damage the oil level sensor.
Remove:
Drain the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ). - the oil pump mounting bolts (2) on the cylinder
block,
Remove the sump (see 10A, Engine and periphe-
- the oil pump.
rals, Sump: Removal - Refitting ).
REFITTING

If necessary, use a locally-produced hook to fit the
oil pump chain to the oil pump sprocket.
113156
Remove:
- the strainer mounting bolts (1) ,
- the strainer.
10A-119
M9R, and 700
CONCERNED
Refit the oil pump.
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 bolts mounting the oil pump
on the cylinder block (5 Nm) .
Tighten to torque:
- the bolts mounting the oil pump on the cylinder
block (25 Nm) ,
- the bolts mounting the oil pump on the anti-
splash plate (10 Nm) ,

Replace the oil strainer O-ring.
Refit the oil pump strainer.
Finger tighten the oil strainer mounting bolts.
Tighten the strainer mounting bolts (10 Nm) .
Refit:
- the sump (see 10A, Engine and peripherals,
Sump: Removal - Refitting .
Fill up the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ).
Start the engine and wait until the engine oil warning
light goes out.
Check the engine oil level.
Refit the engine protectors.
10A-120
Multifunction support: Removal - Refitting 10A
K4J, and 730 – K4M, and 761 or 782
Tightening torquesm AIR CONDITIONING or CLIMATE CONTROL
multifunction support 44 Nm
mounting bolts
mounting bolt on the
sump
REMOVAL
Remove:
- the front wheels,
- the engine undertray, 102265
Remove:
Exterior protection, Front bumper: Removal - - the multifunction support mounting bolts (1) ,
Refitting ),
- the bolts (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-121
K4J, and 730 – K4M, and 761 or 782
REFITTING
BASIC HEATING
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-122
K4J, and 730 – K4M, and 761 or 782
BASIC HEATING
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


Exterior protection, Front bumper: Removal -
Refitting ),
- the front wheels.

10A-123
K9K, and 722 or 724 or 728 or 732
CONCERNED
Tightening torquesm
multifunction support 44 Nm AIR CONDITIONING or CLIMATE CONTROL

mounting bolts
mounting bolt on the
sump
REMOVAL

Remove:
- the front wheels,
102265
Remove:
- the multifunction support mounting bolts (1) ,
Refitting ), - the bolts (2) mounting the multifunction support on
the sump,
engine, Accessories belt: Removal - Refitting ), - the multifunction support.
10A-124
K9K, and 722 or 724 or 728 or 732
REFITTING
BASIC HEATING
CONCERNED
111057
Remove:
- the multifunction support. 102265
Refit:
- the multifunction support mounting bolts (44
Nm) ,
- the multifunction support mounting bolt on the
sump (21 Nm) .
10A-125
K9K, and 722 or 724 or 728 or 732
BASIC HEATING
111057
Refit:
Tighten to torque and in order the multifunction

support mounting bolts (44 Nm) .
Refit:



Refitting ),
- the front wheels.

10A-126
F4R, and 770 or 771 or 776
REFITTING
Tightening torquesm Refit:
mounting bolts - the multifunction support mounting bolts.
Tighten to torque the multifunction support moun-
REMOVAL
Refit:
Position the vehicle on a two-post lift (see 02A, Lif- - the alternator (see 16A, Starting-charging, Alter-
ting equipment, Underbody lift ). nator ),
Remove the engine protectors. engine, Accessories belt: Removal - Refitting ).
Disconnect the battery (see 80A, Battery, Battery: - the front bumper (see MR 371, Bodywork, 55A,
Removal - Refitting ). Exterior protection, Front bumper: Removal -
Refitting ).
Remove: - the engine undertray,
- the front wheels, - the right and left-hand wheel arch liners,
- the front wheels.
- the engine undertray, moval - Refitting ).
Refitting ).

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

ternator ).
104337
Remove:
10A-127
F9Q, and 804 or 812
REFITTING
Tightening torquesm Refit:
mounting bolts - the multifunction support mounting bolts.
Tighten to torque the multifunction support moun-
REMOVAL
Refit:
Position the vehicle on a two-post lift (see 02A, Lif- - the alternator (see 16A, Starting-charging, Alter-
ting equipment, Underbody lift ). nator ),
Remove the engine protectors. engine, Accessories belt: Removal - Refitting ).
Disconnect the battery (see 80A, Battery, Battery: - the front bumper (see MR 371, Bodywork, 55A,
Removal - Refitting ). Exterior protection, Front bumper: Removal -
Refitting ).
Remove: - the engine undertray,
- the front wheels, - the right and left-hand wheel arch liners,
- the front wheels.
- the engine undertray, moval - Refitting ).
Refitting ).

- the alternator (see 16A, Starting - Charging, Al-

ternator ).
104337
Remove:
10A-128
M9R, and 700
Fit the air conditioning compressor on the half sub-
frame.
Tightening torquesm
Unclip the fuel pipes from the fuel circuit support.
the fuel circuit support 10 Nm
mounting bolts II - OPERATION FOR REMOVAL OF PART
CONCERNED
mounting bolts
air conditioning com- 25 Nm

pressor mounting bolts
REMOVAL


Remove:

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 aside.
10A-129
M9R, and 700

CONCERNED
If replacing the multifunction support
114862
Position the multifunction support.
Finger tighten in order the multifunction support
114862
mounting bolts.
Remove the mounting bolts (4) from the fuel circuit Tighten to torque and in order the multifunction
support. support mounting bolts (44 Nm) .
Refit:
- the fuel circuit support on the new multifunction
support,
- the fuel circuit support mounting bolts.
Tighten to torque the fuel circuit support moun-
10A-130
M9R, and 700
Clip the fuel pipes onto the fuel circuit support.
Fit the air conditioning compressor.
Refit the air conditioning compressor mounting
bolts.
mounting bolts (25 Nm)
Connect the connector to the air conditioning com-
pressor.
Refit:
10A-131
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K4J, and 730 – K4M, and 761 or 782 – K9K, and 722 or 728 or 732 – AIR CONDITIONING or CLIMATE
CONTROL
Tightening torquesm
tensioning roller moun- 40 Nm

ting bolt
wheel bolts 130 Nm

bolts
IMPORTANT 1
Wear protective gloves throughout the operation.
WARNING
Never turn the engine in the opposite direction to its
normal operation.
101212
Remove the right-hand side stiffener (1) .
WARNING
It is essential to replace the accessories belt and
the tensioning roller.
WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft and the accesso-
ries pulley.
REMOVAL
Remove:
- the engine covers, 101878
- the front right-hand wheel, Turn the accessories belt auto tensioner clockwise
using a 16 mm spanner.
- the front right-hand wheel arch liner.
Remove:
- the accessories belt,
- the tensioning roller.
11A-1
K4J, and 730 – K4M, and 761 or 782 – K9K, and 722 or 728 or 732 – AIR CONDITIONING or CLIMATE
CONTROL
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) .
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 tooth (2) remains free.
Refit the accessories belt.

Rotate the crankshaft twice to correctly position the
accessories belt.
Tighten to torque:
- the wheel bolts (130 Nm) ,
- the battery cover mounting bolts (4 Nm) .
11A-2
K4J, and 730 – K4M, and 761 or 782 – K9K, and 722 or 728 – BASIC HEATING
REMOVAL
Mot. 1638 Accessories belt ten- ting equipment, Underbody lift ).
sion tool. For engines
fitted with a mechani- Disconnect the battery (see 80A, Battery, Battery:
cal tensioning roller. Removal - Refitting ).
Remove:
Mot. 1505 Belt tension setting
tool (frequency meter) - the engine covers,
Mot. 1715 Belt tension checking - the front right-hand wheel,

tool (frequency indica- - the front right-hand wheel arch liner.
tor).
Tightening torquesm

ting bolts
wheel bolt 130 Nm

bolts
IMPORTANT 1
Wear protective gloves throughout the operation.
WARNING
101212
normal operation.
Remove the side stiffeners (1) .
Loosen the tensioning roller bracket mounting bolts.
WARNING Remove:
It is essential to replace the accessories belt and - the accessories belt,
WARNING REFITTING
Do not run the engine without the accessories belt Use a brush to remove any deposits from the
to avoid damaging the crankshaft and the accesso- crankshaft pulley V-grooves.
ries pulley.
WARNING
The two Torx mounting bolts of the tensioning rol-
ler must be replaced by M8 x 20 bolts (part num-
ber 77 03 002 059 ).
Refit:
- the tensioning roller with its new bolts,
- the accessories belt.
11A-3
K4J, and 730 – K4M, and 761 or 782 – K9K, and 722 or 728 – BASIC HEATING
2
20845
WARNING
The accessories belt has five teeth, while the
free pulley has six. When fitting the accessories
107503
belt, it is essential to check that the tooth (2)
remains free. Tension the accessories belt using the (Mot. 1638) ,
tightening the nut (3) (with the two tensioning roller
mounting bolts loosened).
Check at (4) 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) , otherwi-
se readjust the tension.
bolts (35 Nm) .
Tighten to torque:
- the battery cover mounting bolts (4 Nm)
11A-4
F4R, and 770 or 771 or 776 – F9Q, and 804 or 812 – AIR CONDITIONING or CLIMATE CONTROL
Tightening torquesm

ting bolt
wheel bolts 130 Nm

bolts
IMPORTANT
Wear protective gloves throughout the operation. 1
WARNING
normal operation.
101212
Remove the right-hand side stiffener (1) .
WARNING
It is essential to replace the accessories belt and
WARNING
to avoid damaging the crankshaft and the accesso-
ries pulley.
REMOVAL
Remove:
- the front right-hand wheel, Turn the accessories belt auto tensioner anti-cloc-
kwise using a 16 mm spanner.
Remove:
11A-5
F4R, and 770 or 771 or 776 – F9Q, and 804 or 812 – AIR CONDITIONING or CLIMATE CONTROL
REFITTING
Use a brush to remove any deposits from the
Refit:
- the tensioning roller,
- the accessories belt.
bolt (50 Nm) .
Rotate the crankshaft twice to position the accesso-
ries belt correctly.
Tighten to torque:
11A-6
M9R, and 700
Mot. 1770 Crankshaft pulley loc-

king tool.
Tightening torquesm
fixed roller mounting 44 Nm

bolt

ting bolt
crankshaft accessories 50 Nm + 85˚ ±

pulley mounting bolt 6˚
IMPORTANT
Wear protective gloves during all operations.
101212
Remove:
- the front right-hand wheel (see 35A, Wheels and
REMOVAL tyres, Wheel: Removal - Refitting ),
- the front right-hand wheel arch liner,
- the bolts mounting the right-hand side stiffener on
Position the vehicle on a two-post lift (see 02A, Lif- the half sub-frame cross member,
- the right-hand side stiffener from the half sub-frame
Disconnect the battery (see 80A, Battery, Battery: cross member (1) .
11A-7
M9R, and 700
CONCERNED
114854
114854 Slightly pivot the accessories belt tensioning roller

clockwise.
Fit the (2) 3 mm Allen key into the tensioning roller
hole.
Remove the (3) 3 mm Allen key.
Turn the accessories belt tensioning roller clockwise
until the Allen key is fully inserted. Pivot the accessories belt tensioning roller anti-cloc-
kwise as much as possible.
Remove the accessories belt.
116142
Remove:
- the tensioning roller mounting bolts (4) ,
11A-8
M9R, and 700
114857 114849
Remove: Remove:
- the protector (5) from the fixed roller,
- the crankshaft accessories pulley mounting bolt
- the fixed roller mounting bolts (6) , using the (Mot. 1770) (1) ,
- the fixed roller (7) .
- the washer,
WARNING - the crankshaft accessories pulley.
When replacing the accessories belt recommen-

ded by the manufacturer, always replace: REFITTING
- the tensioning roller and fixed roller, I - REFITTING PREPARATION OPERATION
- the crankshaft accessories pulley bolt, Use a brush to remove any deposits from the
- the crankshaft accessories pulley.
WARNING
Only use brushes with plastic or non-corrosive
metal (brass) bristles.
WARNING
Do not run the engine without the accessories
belt so as not to damage the crankshaft accesso-
ries pulley.
Fit the new fixed roller.
Fit the fixed roller mounting bolt without tightening it.
Tighten to torque the fixed roller mounting bolt (44

Nm) .
11A-9
M9R, and 700
Refit the fixed roller protector. III - FINAL OPERATION
Refit:
Note: - the right-hand side stiffener from the half sub-frame
cross member,
The Parts Department supplies the tensioning
roller pin. - the right-hand side stiffener mounting bolts on the
half sub-frame cross member,
Fit the new tensioning roller. - the front right-hand wheel arch liner,
Fit the tensioning roller mounting bolts without tigh- - the front right-hand wheel (see 35A, Wheels and
tening them. tyres, Wheel: Removal - Refitting ),
WARNING Connect the battery (see 80A, Battery, Battery: Re-

When replacing the accessories belt recommen-
ded by the manufacturer, always replace:
- the tensioning roller and fixed roller,
- the crankshaft accessories pulley bolt,
- the crankshaft accessories pulley.

bolt (25 Nm) .
Refit the new crankshaft accessories pulley by inser-

ting it onto the two crankshaft flat surfaces.
Refit the washer inside the crankshaft accessories

pulley by inserting it onto the two crankshaft flat sur-
faces.
WARNING
Check that the washer fits properly on the
crankshaft flat surfaces.
Fit the new crankshaft accessories pulley mounting

bolt without tightening it.
Tighten to torque and angle the crankshaft acces-

sories pulley mounting bolt (50 Nm + 85˚ ± 6˚)

CONCERNED
Refit the new 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-10
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728
- the front right-hand wheel,
- the right-hand wheel arch liner,
Mot. 1453 Multiple-adjusting
engine mounting sup-
port with retaining
straps.
Mot. 1453-01 Additional winder nut

on engine lift support
Mot. 1453. 1
Mot. 1489 TDC locating pin. 2

Mot. 1430 Set of 5 crankshaft
and camshaft pulley
timing pins.
Tightening torquesm
104343
tensioning roller bolt 25 Nm Remove:
accessories pulley 60 Nm + 100 ˚ - the scuttle panel grille (see MR 371 Bodywork,
mounting bolt (M12 ± 10˚ 55A, Exterior protection, Scuttle panel grille ),
bolt): - the air filter access panel mounting bolts (1) ,
accessories pulley 120 Nm + 95 ˚ - the air filter access panel,
mounting bolt (M14 ± 15˚
- the scuttle panel mounting bolt (2) .
bolt):
tensioning roller moun- 25 Nm 3

ting bolts
TDC pin plug 20 Nm
cylinder head suspen- 21 Nm

ded mounting bolts
wheel bolts 130 Nm

bolts
WARNING 104246
Never turn the engine in the opposite direction to its Remove:

normal operation.
REMOVAL - the accessories belt (see 11A, Top and front of
Position the vehicle on a two-post lift (see 02A, Lif- engine, Accessories belt: Removal - Refitting ).
Remove:
11A-11
K9K, and 722 or 728
102450
102115
Remove the lower engine tie-bar bolts (4) .
Remove the lower engine tie-bar.
102451
Install the (Mot. 1453) and the (Mot. 1453-01) with
the retaining straps.
102114
Mark the position of the suspended mounting in rela-

tion to the body.
Loosen the bolt (5)
WARNING
Do not damage the air conditioning pipe.
11A-12
K9K, and 722 or 728
19654
Remove the upper timing cover by unclipping tabs
(6) .
11A-13
K9K, and 722 or 728
19654-1
Remove:
- the high pressure pump camshaft sensor (7) ,
- the plastic bolt (8) .
Unclip the tabs (9) .
Remove the lower timing cover.
11A-14
K9K, and 722 or 728
19654-2
Remove the cylinder head suspended mounting. Positioning the timing at the setting point
12
11
10
19702
19650
Rotate the crankshaft in a clockwise direction (timing
Remove the TDC setting pin plug (10) . end) to position the hole (11) in the camshaft pulley
almost in line with the hole (12) in the cylinder head.
11A-15
K9K, and 722 or 728
1
19650-1 19655
Screw in the TDC setting pin (1) (Mot. 1489). Insert the pin (2) (Mot. 1430) in the camshaft pulley
and cylinder head holes.
Remove:
- the pin (Mot. 1430) ,
- the TDC setting pin (Mot. 1489).
14489-1
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft comes in contact with the TDC
setting pin (Mot. 1489).
11A-16
K9K, and 722 or 728
19656
Remove the crankshaft accessories pulley, locking
the flywheel with a screwdriver.
11A-17
K9K, and 722 or 728
13
19656-1
Undo the tensioning roller bolt (13) to slacken the ti- REFITTING
ming belt.
Remove:
WARNING
- the timing belt,
Replace the timing belt, the tensioning roller, the
- be careful not to drop the crankshaft sprocket, crankshaft accessories pulley and bolt.
- the timing sprocket,
- the tensioning roller. WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft accesso-
ries pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
11A-18
K9K, and 722 or 728
19710
Refit the timing sprocket.
11A-19
K9K, and 722 or 728
I - ADJUSTING THE TIMING
17
16
15
14
18
19656-2
Note:
Check that the tensioning roller lug (14) is cor-
rectly positioned in the groove (15) .
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 high pressure pump pulley mark (16)
is in line with the bolt head (17) .
14489
Check that the crankshaft is in contact with the TDC

setting pin (Mot. 1489) (crankshaft groove (18)
upwards).
11A-20
K9K, and 722 or 728
19
19657 19658
Fit the new timing belt, aligning the marks on the belt Position the tensioning roller adjustable index mar-
with those on the camshaft sprockets and the high ker (19) opposite the lug using a 6 mm Allen key,
pressure pump. turning it anti-clockwise.
Tighten to torque the tensioning roller bolt (25
Note: Nm) .
19 belt tooth spaces between the camshaft Refit the crankshaft accessories pulley.
sprocket and pump marks. Torque and angle-tighten (crankshaft in contact with
the TDC setting pin):
- the accessories pulley mounting bolt (M12
bolt): (60 Nm + 100 ˚ ± 10˚) ,
- the accessories pulley mounting bolt (M14
bolt): (120 Nm + 95 ˚ ± 15˚) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430).
11A-21
K9K, and 722 or 728
22
21
23
20
19702 19655
Rotate the crankshaft clockwise through two revolu- Check:
tions (timing end).
- the timing pin (Mot. 1430) is correctly inserted in
Before the camshaft pulley hole (20) comes in line the camshaft and cylinder head holes,
with the cylinder head hole (21) , screw the TDC set-
- that there are 19 belt tooth spaces between the
ting pin (Mot. 1489) into the cylinder block.
camshaft sprocket mark (22) and the high pressure
Bring the crankshaft slowly and smoothly into con- pump sprocket mark (23) .
tact with the pin.
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430).
Note:
After two turns, the tensioning roller index mar-
kers may be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-22
K9K, and 722 or 728
First position Second position
24 26
111083 111082
24 26
25 27
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 marker (24) in Gradually align the adjustable index marker (26) in
the middle of the timing window (25) , by turning the the middle of the timing window (27) , by turning the
key anti-clockwise. key clockwise.
II - REFITTING

bolts (25 Nm) .
Refit the TDC pin plug, applying a drop of SILICONE
ADHESIVE SEAL to the thread hole.
11A-23
K9K, and 722 or 728
Torque tighten the TDC pin plug (20 Nm) . Torque tighten the cylinder head suspended
mounting bolts (21 Nm) .
19654-2
Refit the cylinder head suspended mounting.
11A-24
K9K, and 722 or 728
19654-1
28
29
19659
Refit the lower timing cover, positioning the tab (28)
in the lower timing cover hole (29) .
11A-25
K9K, and 722 or 728
19654
Refit:
- the upper timing cover,
mounting, Suspended engine mounting ) in ac-
cordance with the marks,
Tighten to torque:
11A-26
K4M, and 761 or 782
Special tooling required Tightening torquesm
Mot. 1453 Multiple-adjusting upper timing cover bolts 41 Nm

engine mounting sup- and nuts
port with retaining
straps. wheel bolts 130 Nm
Mot. 1453-01 Additional winder nut battery cover mounting 4 Nm

on engine lift support bolts
Mot. 1453.
Mot. 1489 TDC locating pin. WARNING

Mot. 1368 Tool for tightening ten-
normal operation.
sioner bolt. 8 mm Torx
wrench, 12.7 mm
square
REMOVAL
Mot. 799-01 Timing gear wheel Position the vehicle on a two-post lift (see 02A, Lif-
immobiliser. ting equipment, Underbody lift ).
Mot. 1496 Tool for setting cams- Disconnect the battery (see 80A, Battery, Battery:
haft. Removal - Refitting ).
Mot. 1490-01 Locking and adjusting
camshaft pulleys.
grille ).
Mot. 1487 Tool for removing the
camshaft covers (57
mm diameter).

camshaft covers (43
mm diameter). 2
1
Tightening torquesm

bolt

pulley bolt 15˚ 104343
Remove:
ting nut - the air filter access panel mounting bolts (1) ,
inlet camshaft pulley 75 Nm
dephaser bolt - the scuttle panel partition mounting bolt (2) .
inlet camshaft depha- 15 Nm

ser blanking cover
exhaust camshaft pul- 30 Nm + 84˚ ±

ley nut 4
TDC pin plug 20 Nm
11A-27
K4M, and 761 or 782
104246 102450
Remove:
Remove:
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) with re-
taining straps.
11A-28
K4M, and 761 or 782
101866 14491
Mark the suspended engine mounting in relation to Pierce the middle of the plugs on the end of the
the body. camshaft using a screwdriver.
Remove: Remove:
- the « engine - suspended engine mounting » as- - the sealing plugs at the camshaft end with a
sembly, screwdriver,
- the lower engine tie-bar. - the TDC setting pin plug (6) .
WARNING
101807
Remove:
- the air filter outlet duct (4) ,
- the throttle valve (5) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
11A-29
K4M, and 761 or 782
ADJUSTING THE TIMING
14490
14491-1 Check that the camshaft grooves are horizontal and
Position the camshaft grooves (7) almost horizontal- offset downwards.
ly and offset towards the bottom turning the cranks-
haft in the direction of operation (clockwise timing
end).
Screw in the TDC setting pin (8) (Mot. 1489).
10
11
14487
Remove:
- the crankshaft accessories pulley (9) , locking the
flywheel with a screwdriver,
14489
- the upper timing cover (10) ,
Turn the crankshaft in its operating direction (timing
end clockwise), until the crankshaft comes into con- - the lower timing cover (11) .
tact with TDC setting pin.
11A-30
K4M, and 761 or 782
REFITTING - PROCEDURE 1

The first procedure is used when replacing any timi-
ng component that does not require one or more
camshaft pulleys to be loosened.
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the fixed
13 roller.
12
WARNING
Always degrease:
• the end of the crankshaft (timing end),
• the timing sprocket bore and contact surfaces,
101872
• the accessories pulley contact surfaces,
Undo the tensioning roller bolt (12) to slacken the ti-
ming belt. • the camshaft ends (timing end),
Remove: • the camshaft sprocket bores and contact surfa-

ces.
- the fixed roller (13) using the (Mot. 1368) ,
- This is to avoid slippage between:
- the timing belt, taking care not to drop the cranks-
haft sprocket. • the timing,
- the timing sprocket, • the crankshaft,
- the tensioning roller. • the camshaft sprockets.

- This slippage causes engine damage.
11A-31
K4M, and 761 or 782
14490 103260
Position the camshaft grooves horizontally and off- Mount the (Mot. 1496) on the ends of the camshafts.
set towards the bottom by turning the camshafts with
the (Mot. 799-01) if necessary.
27 75
36 31
17
16
19
10
13
d9
10
21
103308
Use a locally-produced mounting bracket to hold the
(Mot. 1496) in place.
11A-32
K4M, and 761 or 782
15
14
17
103269
Check that mark (14) on the dephaser is vertical and

pointing upwards.
Make a mark (15) with a pencil between the depha-
16
ser belt and the rocker cover.
14489
Check that:
- the crankshaft is correctly in contact with the TDC
setting pin (Mot. 1489) (16) with the crankshaft
groove (17) upwards,
11A-33
K4M, and 761 or 782
- the inlet camshaft dephaser wheel is correctly loc-
ked (wheel does not rotate right or left).
II - REFITTING
21
18 19
20
14487-3
Refit:
- the tensioning roller (19) ,
14505 - the timing sprocket (20) ,

- the timing belt,
Note: - the fixed roller (21) .
When refitting the tensioning roller, make sure

that the lug of the tensioning roller is correctly
positioned in the groove (18) .
14487-2
Nm) using the (Mot. 1368).
11A-34
K4M, and 761 or 782
III - BELT TENSION
26
23
25
22
27
24
103263
103263 Check that the adjustable index marker (25) coinci-
Using a 6 mm Allen key, bring the adjustable index des with slot (26) , or:
marker (22) opposite the notch (23) , by turning the
- loosen the tensioning roller nut by up to one turn,
eccentric (24) clockwise.
holding the adjustable index marker with a 6 mm
Torque tighten the tensioning roller mounting nut Allen key,
(7 Nm) .
- gradually move the adjustable index marker (25)
Refit the crankshaft accessories pulley. opposite the notch (26) turning the eccentric (27) in
a clockwise direction.
Tighten to torque and angle the crankshaft acces-
sories pulley bolt (40 Nm + 115˚ ± 15˚) (crankshaft
in contact with the TDC setting pin).
Remove:
- the camshaft setting tool (Mot. 1496) ,
Rotate the crankshaft through two clockwise revolu-
tions (timing end) before aligning the marks (on
camshaft dephaser):
- screw the TDC pin (Mot. 1489) into the cylinder
block.
- move the crankshaft slowly and smoothly to rest on
the TDC setting pin.
Remove the TDC setting pin (Mot. 1489).
11A-35
K4M, and 761 or 782
30
29
28
103267
Tighten to torque the tensioning roller mounting 2 - Checking the timing

nut (27 Nm) (28) .
Check that the tensioning roller indexes are correctly
Check that the dephaser mark (29) is aligned with positioned before checking the timing setting.
mark (30) . Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
IV - CHECKING THE TIMING AND TENSION Move the crankshaft slowly and smoothly until it is
resting against the pin.
1 - Checking the tension
Rotate the crankshaft through two clockwise revolu-

tions (timing end) before aligning the marks (on
camshaft dephaser):
- screw in the TDC setting pin (Mot. 1489) ,

the TDC setting pin (Mot. 1489).
Remove the TDC setting pin.
WARNING
Check that the tensioning roller index markers
are aligned. If not, repeat the tensioning proce-
dure.
11A-36
K4M, and 761 or 782
REFITTING -PROCEDURE 2

The second procedure is used for replacing all com-
ponents requiring one or more of the camshaft pul-
leys to be slackened.
WARNING
If the stud is loosened with the nut (see Techni-
cal Note 3887A, Replacing K9 - K4 camshaft
pulley studs, 11A, Top and front of engine,
Camshaft ).
WARNING
roller.
14490
Fit the camshaft setting tool (Mot. 1496) without for- WARNING
cing (the camshaft grooves must be horizontal and
offset downwards). Always degrease:
WARNING • the timing sprocket bore and contact surfaces,
If the tool cannot be engaged, readjust the timing
and the tension.
• the camshaft ends (timing end),
• the camshaft sprocket bores and contact surfa-
ces.
• the timing,
• the crankshaft,
• the camshaft sprockets.
Refit the camshaft pulleys and the old nuts, tighte-

ning them to a torque of 15 Nm .
11A-37
K4M, and 761 or 782
27 75
36 31
17
16
19
10
13
d9
10
21
14490 103308
Use a locally produced mounting bracket to hold the
103261
Position the camshaft grooves horizontally and off-
set towards the bottom by turning the camshafts with 103260
(Mot. 1496) if necessary.
Mount the (Mot. 1496) on the ends of the camshafts.
11A-38
K4M, and 761 or 782
31
14489
35
33
34
32
103269
Check that the crankshaft is in contact with the TDC - the exhaust camshaft pulley with a new nut,
setting pin (Mot. 1489) (31) (crankshaft groove (32)
should be at the top). - the inlet camshaft dephaser with a new bolt, chec-
king that the inlet camshaft dephaser wheel is cor-
Refit: rectly locked (wheel does not rotate right or left).
11A-39
K4M, and 761 or 782
Position:
- the RENAULT logo (33) etched on the camshaft
pulley spokes vertically and towards the top,
- the dephaser marking (34) vertically and pointing
upwards.
Make a mark (35) with a pencil between the depha-
ser belt and the rocker cover.
II - REFITTING
37
38
36
14487-3
Refit:
- the timing sprocket (38) ,
- the timing belt on the camshaft pulleys (without mo-
ving the camshaft pulleys).
14505
39
Note:
103265
Fit the camshaft pulley locking tool (Mot. 1490-01)
(39) (use the timing cover mountings to fix the tool).
11A-40
K4M, and 761 or 782
Torque tighten the tensioning roller mounting nut
(7 Nm) .
Remove camshaft pulley immobilising tool (Mot.
1490-01).
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pul-
40 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).
45
44
14487-3
Refit the fixed roller (40) .

46
Refit the crankshaft accessories pulley (without tigh-
tening the bolt, with 2 to 3 mm play between bolt
and pulley).
III - BELT TENSION
42
41
103263
Check that the adjustable index marker (44) coinci-
des with slot (45) , or:
- Loosen the tensioning roller nut by up to one turn,
43 Allen key,
opposite the notch (45) turning the eccentric (46) in
a clockwise direction.
103263
Using a 6 mm Allen key, bring the adjustable index

11A-41
K4M, and 761 or 782
49
47
48
103268
(27 Nm) .
Check that:
- the RENAULT badge (47) etched on the exhaust
camshaft pulley stem vertically and pointing
upwards,
- the dephaser marking (48) is aligned with the mar-
king (49) already made by the operator.
103265
Fit the camshaft pulley immobilising tool (Mot. 1490-
01).
11A-42
K4M, and 761 or 782
50
51
14489 103265
Tighten to torque the inlet camshaft pulley depha-
ser bolt (75 Nm) .
WARNING
Refit the new inlet camshaft dephaser blanking co-
Check that the crankshaft is pressing against the
ver (51) .
TDC setting pin (Mot. 1489) (50) .
Tighten to torque the inlet camshaft dephaser
Tighten to torque and angle the crankshaft acces- blanking cover (15 Nm) .
in contact with the TDC setting pin), Tighten to torque and angle the exhaust camshaft
pulley nut (30 Nm + 84˚ ± 4) .
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool,
IV - CHECKING THE TIMING AND TENSION

Rotate the crankshaft clockwise (timing end) throu-
gh two revolutions and before completing the se-
cond revolution:
- screw the TDC setting pin (Mot. 1489) into the cy-
linder block,
- Slowly and smoothly position the crankshaft in con-
tact with the TDC setting pin (Mot. 1489).
WARNING
Check that the fixed roller indexes are aligned. If
not, repeat the tensioning process.
11A-43
K4M, and 761 or 782
2 - Checking the timing

positioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
Move the crankshaft slowly and smoothly into posi-

tion against the pin.
15103-1
Refit:
mounting, Suspended engine mounting ),
ting, Suspended engine mounting ),
- new inlet camshaft sealing plugs (Mot. 1487) ,
14490
- new exhaust camshaft sealing plugs (Mot. 1488).
Fit the camshaft setting tool (Mot. 1496) without for-
cing (the camshaft grooves must be horizontal and Proceed in the reverse order to removal.
offset downwards). Connect the battery (see 80A, Battery, Battery: Re-
Tighten to torque:
WARNING
and the tension. - the battery cover mounting bolts (4 Nm) .
REFITTING
Refit the TDC setting pin cap, applying a drop of

RHODORSEAL 5661 onto the thread.
Torque tighten the TDC pin plug (20 Nm) .
Refit the lower cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover bolts and

nuts (41 Nm) .
11A-44
F4R, and 770 or 771 or 776
Mot. 1672 Lower engine support. upper timing cover M10 38 Nm

bolts
Mot. 1054 TDC setting pin.
wheel bolts 130 Nm
Mot. 1509 Camshaft sprocket
locking tool. battery cover mounting 4 Nm
bolts
Mot. 1509-01 Adapter kit for tool
Mot.1509.
Note:
Mot. 799-01 Timing gear wheel
immobiliser. The timing belt procedure is the same for engines
with or without camshaft dephasers.
Mot. 1496 Tool for setting cams-
haft.
Mot. 1487 Tool for removing the WARNING

camshaft covers (57
mm diameter). normal operation.
camshaft covers (43
mm diameter).
WARNING
so as not to damage the crankshaft accessories
Tightening torquesm pulley.

bolt
WARNING
tensioning roller nut 28 Nm
On the F4R engine, it is essential to fit the cranks-
inlet camshaft pulley 100 Nm haft sprocket with the integrated cotter.
dephaser bolt
exhaust camshaft pul- 30 Nm + 86˚ ±

ley nut 6˚ WARNING
inlet camshaft depha- 25 Nm Replace the following parts when they are removed:
ser blanking cover
- the camshaft pulley nuts,
inlet and exhaust cams- 30 Nm + 86˚ ± - the crankshaft accessories pulley,
haft pulley nut 6˚
- the crankshaft accessories pulley bolt.
crankshaft accessories 40 Nm + 110˚
pulley mounting bolt +/- 10˚
lower timing cover M6 80 Nm WARNING

bolts When replacing the belt, always replace the tensio-
ning rollers and fixed rollers.
lower timing cover M8 20 Nm
bolts
upper timing cover M8 18 Nm

bolts
11A-45
F4R, and 770 or 771 or 776
REMOVAL - the front right-hand wheel arch,
Position the vehicle on a two-post lift (see 02A, Lif- - the engine covers,
ting equipment, Underbody lift ). - the front bumper (see MR 371, Bodywork, 55A,
Disconnect the battery (see 80A, Battery, Battery: Exterior protection, Front bumper ).
Remove the battery (see 80A, Battery, Battery: Re- F4R, and 776
grille ).
5
2
7
6
1
102504

104343 Remove:
Remove: - the clip (6) ,
- the air filter access panel mounting bolts (1) , - the mounting (7) .
- the air filter access panel, Disconnect the screen washer tubes.
3
8
102365
104246 Remove:
Remove: - the front end panel mountings (8) ,
- the scuttle panel partition mounting bolts (3) , - the front end panel.
11A-46
F4R, and 770 or 771 or 776
105432
9
Position the (Mot. 1672) with their retaining straps.
101212
Remove:
- the radiator cross member right-hand side stiffener
(9) ,
- the lower engine tie-bar.
Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting ).
F4R, and 770 or 771
11
102742
the body.
Remove the suspended engine mounting assembly.
10
Note:
Be careful not to bend the air conditioning pipe.
101807
Remove:
- the throttle valve (11) ,
- the connector on the lifting bracket.
11A-47
F4R, and 770 or 771 or 776
F4R, and 776
13
14
106632
12
Loosen nut (13) .
106278
Remove fuel vapour recirculation solenoid valve Pull the mounting bracket away from the electric
(12) . coolant pump.
Move aside the electric water pump (14) .
Remove the wiring harness mounting bracket.
15
15102
Remove the TDC setting pin cap (15) .
11A-48
F4R, and 770 or 771 or 776
15105 15163-2
Remove the camshaft sealing plugs. Gently turn the engine in the same direction, inser-
ting the TDC setting pin (Mot. 1054) as far as the
setting point.
15106-1
15106
At the setting point, the camshaft grooves must be
Rotate the engine clockwise (timing end) so that the
horizontal and offset below the centre line, as shown
camshaft grooves are offset below the centre line
in the drawing.
and almost horizontal, as shown in the drawing.
Insert TDC setting pin (Mot. 1054) so that it is
between the balancing hole and the crankshaft set-
ting groove.
11A-49
F4R, and 770 or 771 or 776
Correct position
15163-1 106519
Incorrect position
15303
Remove:
15163
Remove the TDC setting pin (Mot. 1054). - the flywheel guard,
- the crankshaft pulley, locking the flywheel with a
screwdriver.
Reposition the TDC setting pin (Mot. 1054).
11A-50
F4R, and 770 or 771 or 776
F4R, and 770 or 771
16
17
18433
Remove:
- the lower timing cover (17) .
11A-51
F4R, and 770 or 771 or 776
F4R, and 776
18
106338
19
20
104719
Remove: - the upper timing cover (19) ,

- the heat shield (18) ,
11A-52
F4R, and 770 or 771 or 776
- the lower timing cover (20) .
21
22
18433-2
Relax the timing belt by loosening the tensioning rol-
ler nut (21) .
WARNING
Remove:
Never turn the engine in the opposite direction to
- the fixed roller (22) , its normal operation.
- the timing belt,
- the crankshaft timing sprocket.
WARNING
When replacing the timing belt, always replace
the tensioning roller and fixed roller.
WARNING
The belt must be replaced with a new one if it
has been removed.
11A-53
F4R, and 770 or 771 or 776
II - ADJUSTING THE TIMING
104703
WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and bearing faces (23)
,
- the crankshaft accessories pulley bearing
faces,
to prevent slippage between the timing gear and
the crankshaft.
This slippage causes engine damage.
WARNING
Never turn the engine in the opposite direction to
its normal operation.
WARNING
In this case, the old camshaft pulley nuts must be
removed in order to correctly set the belt tension.
11A-54
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-55
F4R, and 770 or 771 or 776
16019 16019-3
Fit the (Mot. 1509) with the sprocket (Mot. 1509-01). Tighten the bolt and collar nut (28) .
Fit the spacer (24) from the (Mot. 1509-01) on stud Bring the toothed sprocket of the (Mot. 1509) into
(25) . contact with the camshaft pulleys.
Tighten the toothed sprocket nuts (80 Nm) (29) .
Remove:
- the inlet camshaft dephaser blanking cover (30) ,
- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
- the camshaft pulleys.
WARNING
cal Note 3884A, Replacing F4 camshaft pulley
studs, Top and front of engine, Camshaft ).
16019-1
Fit the upper bolt (26) while positioning the spacer
(27) (Mot. 1509-01) between the tool and the cylin-
der head cover (do not tighten the bolt).
11A-56
F4R, and 770 or 771 or 776
Torque tighten the old mountings (15 Nm max.)
using the (Mot. 799-01).
F4R, and 776
WARNING
When replacing the timing belt, it is essential to

replace:
- the crankshaft accessories pulley,
- the tensioner pulley and fixed roller,
- the accessories and timing belts.
104711
Install the (Mot. 1509) with its toothed sprocket
(Mot. 1509-01).
Tighten the bolt and collar nut (31) .
Bring the toothed sprockets into contact with the
camshaft pulleys.
Tighten the toothed sprocket nuts (80 Nm) (32)
Remove:
15106-1
- the camshaft pulley nuts, Position the grooves offset horizontally below the
- the (Mot. 1509) , centre-line as shown above by turning the cams-
hafts using the (Mot. 799-01).
WARNING
cal Note 3884A, Replacing F4 camshaft pulley
studs, Top and front of engine, Camshaft ).
Refit the degreased camshaft pulleys with the old

mountings.
11A-57
F4R, and 770 or 771 or 776
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 centred.
The crankshaft groove (33) must be between the
two ribs (34) .
11A-58
F4R, and 770 or 771 or 776
15201
Refit the tensioning roller, correctly positioning (35)
the tensioning roller in the groove (36) .
15815-1
Refit:
- the timing sprocket,
- the timing belt,
- the fixed roller (37) .
Nm) .
11A-59
F4R, and 770 or 771 or 776
III - BELT TENSION
F4R, and 770 or 771
15256
104728
Note: Fit the (Mot. 1509) with the toothed sprockets (Mot.
1509-01) for locking the camshaft pulleys.
Do not rotate the tensioning roller anti-clockwise.
Tighten the bolt and collar nut (39) .
Align the tensioning roller marks (38) and (39) using
Offer up the toothed sprocket nuts against the cams-
a 6 mm Allen key at (40) .
haft pulleys.
Torque tighten the tensioning roller nut to 7 Nm .
Tighten:
- the toothed sprocket nuts (80 Nm) (40) ,
- 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-60
F4R, and 770 or 771 or 776
F4R, and 776
21877
Make a pencil mark (43) between the camshaft pul-
104711
leys and the camshaft bearing cap.
Fit camshaft pulley locking tool (Mot. 1509). Remove the following tools:
Tighten the bolt and collar nut (41) . - TDC setting pin (Mot. 1054) ,
Offer up the toothed sprocket nuts against the cams- - Camshaft setting tool (Mot. 1496).
haft pulleys. Rotate the crankshaft clockwise through two revolu-
Tighten to torque: tions (timing end).
- the toothed sprocket nuts (80 Nm) (41) ,

- the old inlet and exhaust camshaft pulley nuts
(30 Nm) (42) .
01).
11A-61
F4R, and 770 or 771 or 776
15104
Fit the camshaft setting tool (Mot. 1496).
15163-2
Before completing two turns (i.e. half a tooth before
alignment of the marks made previously by the ope-
rator), 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 setting point.
11A-62
F4R, and 770 or 771 or 776
F4R, and 770 or 771 F4R, and 776
15104 104711
Position the (Mot. 1509) with the toothed sprockets Fit the (Mot. 1509) for locking the camshaft pulleys.
(Mot. 1509-01) for locking the camshaft pulleys.
Tighten the bolt and the collar nut (46) .
Offer up the toothed sprocket nuts against the cams-
Offer up the toothed sprocket nuts against the camshaft pulleys.
haft pulleys.
Loosen:
Loosen:
- the old inlet camshaft pulley nut,
- the old inlet camshaft dephaser pulley mounting
- the old exhaust camshaft pulley nut.
bolt,
- the old exhaust camshaft pulley nut.
Remove the camshaft pulley locking tool (Mot.
1509).
Remove the (Mot. 1509) with the toothed sprockets
(Mot. 1509-01) for locking the camshaft pulleys.
11A-63
F4R, and 770 or 771 or 776
15256
Align marks (48) with mark (49) by loosening the
tensioning roller nut a maximum of one turn, holding
it with a 6 mm Allen key (50) .
Tighten fully the tensioning roller nut (28 Nm) .
11A-64
F4R, and 770 or 771 or 776
Rotate the crankshaft clockwise through two revolu-
tions (timing end).
F4R, and 770 or 771
F4R, and 776
104728
Position the (Mot. 1509) with the toothed sprocket
for locking the camshaft pulleys.
104711
Bring the toothed sprocket nuts into contact with the
camshaft pulleys. Fit the camshaft pulley locking tool (Mot. 1509).
Tighten the toothed sprocket nuts (80 Nm) (51) . Tighten the bolt and the collar nut (53) .
Remove: Bring the toothed sprocket nuts into contact with the
camshaft pulleys.
- the old inlet camshaft dephaser pulley mounting
bolt, Tighten the toothed sprocket nuts (80 Nm) (54) .
- the old exhaust camshaft pulley nut. Remove:
Refit: - the old inlet camshaft pulley nut,
- a new bolt on the inlet camshaft dephaser pulley, - the old exhaust camshaft pulley nut.
- a new nut on the exhaust camshaft pulley. Refit a new nut onto the inlet and exhaust camshaft
pulley.
Tighten to torque the inlet camshaft pulley depha-
ser bolt (100 Nm) . Tighten to torque and angle the inlet and exhaust
camshaft pulley nut (30 Nm + 86˚ ± 6˚) .
Tighten to torque and angle the exhaust camshaft
pulley nut (30 Nm + 86˚ ± 6˚) Remove the camshaft setting tool (Mot. 1496).
Remove the camshaft setting tool (Mot. 1496). Remove the following tools:
Tighten to torque the inlet camshaft dephaser - TDC setting pin (Mot. 1054) ,
blanking cover (25 Nm) - Tool for locking camshaft pulleys (Mot. 1509).
Remove the following tools: Rotate the crankshaft clockwise through two revolu-
- TDC setting pin (Mot. 1054) , tions (timing end).
- Camshaft pulley locking tool (Mot. 1509) with too-

thed sprocket (Mot. 1509-01).
11A-65
F4R, and 770 or 771 or 776
15104
15649 Fit the camshaft setting tool (Mot. 1496) without for-
cing it.
Before completing two turns (i.e. half a tooth before
alignment of the marks made previously by the ope- If the tool does not engage, repeat the timing and
rator), insert the crankshaft TDC setting pin ( (Mot. tensioning procedure.
1054) (so that it is between the balancing hole and
the timing hole). REFITTING
Check that mark (55) is aligned with mark (56) on Refit:
the tensioning roller before checking the timing ad-
- the lower timing cover,
justment.
- the upper timing cover.
WARNING
The crankshaft accessories pulley and bolt must
be replaced.
15106-1
The offset grooves (57) should be facing horizontally

downwards.
11A-66
F4R, and 770 or 771 or 776
15303 15103-1
Block the flywheel using a large screwdriver. Refit:
Tighten to torque and angle the crankshaft acces- - the new sealing plugs:
sories pulley mounting bolt (40 Nm + 110˚ +/- 10˚)
• on the inlet camshaft (Mot. 1487) ,
.
• to the exhaust camshaft (Mot. 1488) ,
WARNING - the right-hand suspended engine mounting (see

19D, Engine mounting, Suspended engine
To avoid damaging the crankshaft accessories
mounting ) in accordance with the marks.
pulley, do not start the engine without the acces-
sories belt. Proceed in the reverse order to removal.
Refit: Tighten to torque:
- the crankshaft accessories belt (see 11A, Top and - the lower timing cover M6 bolts (80 Nm) ,
front of engine, Accessories belt: Removal - - the lower timing cover M8 bolts (20 Nm) ,
Refitting ).
- the upper timing cover M8 bolts (18 Nm) ,
- the TDC pin plug, applying a drop of SILICONE
ADHESIVE SEAL to the thread hole. - the upper timing cover M10 bolts (38 Nm) ,
11A-67
F9Q, and 804 or 812

port with retaining
straps.
1
on engine lift support 2
Mot. 1453.
Mot. 1054 TDC setting pin.
Mot. 1543 Tool for pretensioning

timing belt.
104343
Mot. 1705 Adapter for the timing
belt pretensioning tool. Remove:
To be used with - the air filter access panel mounting bolts (1) ,
Mot.1543.
Mot. 1505 Belt tension setting - the scuttle panel partition mounting bolt (2) .
tool (frequency meter)
Mot. 1715 Belt tension checking

tool (frequency indica-
3
tor).
Tightening torquesm

ting nut
new crankshaft acces- 4 Nm + 110˚ +/

sories pulley mounting - 10˚
bolt
104246
wheel bolts 130 Nm
Remove:
bolts
WARNING
Never turn the engine in the opposite direction to its engine, Accessories belt ).
normal operation.
REMOVAL

terminal.
grille ).
11A-68
F9Q, and 804 or 812
102450
102420
Remove:
Mark the position of the suspended engine mounting
in relation to the body.
Slacken the bolt (4)
WARNING
Do not damage the air conditioning pipes (if fitted
to the vehicle).
102451
taining straps.
11A-69
F9Q, and 804 or 812
15102
104329
Remove:
Rotate the crankshaft clockwise (timing end); bring
- the TDC setting pin cap. the camshaft pulley mark to half a tooth before the
mark on the guard.
- the engine flywheel guard flap,
104330
104739 When the mark on the camshaft pulley is half a tooth

before the mark on the guard, press in the TDC set-
Remove: ting pin (Mot. 1054) until the crankshaft is timed.
- the crankshaft accessories pulley, locking the

- the timing cover mounting bolts (5) ,
- the timing cover.
11A-70
F9Q, and 804 or 812
104326 104336
Loosen the tensioning roller mounting nut (6) to re- Refit the tensioning roller, taking care to position it
lax the tensioning roller. correctly on the pin (7) .
Remove the timing belt.
REFITTING 9
9
WARNING
ries pulley bolt, the tensioning roller and the
crankshaft accessories pulley.
8
10
16187
Check that the TDC setting pin (Mot. 1054) is in pla-

ce.
Note:
The crankshaft groove (8) should be in the mid-
dle of the two crankshaft closure cover ribs (9) .
The crankshaft timing sprocket mark (10) should
be offset one tooth to the left of the vertical axis
of the engine.
11A-71
F9Q, and 804 or 812
11
104327 16563
Fit the new timing belt, aligning the marks on the belt
with those on the crankshaft, camshaft and high
pressure pump sprockets (there should be 28 belt
tooth gaps between the mark on the camshaft sproc-
ket and the mark on the high pressure pump sproc-
ket).
Press the tensioning roller against the belt by tighte-
ning the bolt (11) on the tensioning roller support.
Note:
The bolt (11) is manufactured locally.

Fit the old crankshaft accessories pulley bolt.
12
104331
Mount the timing belt pretensioning tool (Mot. 1543)
fitted with the cover (Mot. 1705) (12) on the cranks-
haft accessories pulley bolt.
11A-72
F9Q, and 804 or 812
(10 Nm) .
Turn the crankshaft through four revolutions.
Reposition the TDC setting pin (Mot. 1054).
Position the timing at its setting point (start pressing
on the rod half a tooth before the camshaft pulley
mark and the protection plate mark are aligned, to
prevent it falling into a crankshaft balancing hole).
Apply a pretensioning torque between the cranks-
haft timing sprocket and the tensioning roller using
the (Mot. 1543) and a torque wrench set to a torque
of (11 Nm) .
Place the sensor of the (Mot. 1505) between the
crankshaft sprocket and the tensioning roller.
Check that the tension value is 80 ± 5 Hz ; if not, rea-
djust.
104332 Tighten to torque the tensioning roller mounting
Pretension the timing belt between the crankshaft ti- nut (45 Nm) .
ming sprocket and the tensioning roller using the Remove the (Mot. 1543).
(Mot. 1543) and a torque wrench set to a torque of
(11 Nm) .
13
104333
Position the sensor of the (Mot. 1505) or the (Mot.
1715) between the crankshaft sprocket and the ten-
sioning roller.
Tension the belt to obtain the recommended value
90 ± 3 Hz by turning the bolt (13) .
11A-73
F9Q, and 804 or 812
105435
Remove the old crankshaft accessories pulley bolt.
Refit the crankshaft accessories pulley, without se-
parating its two component parts.
Tighten to torque and angle the new crankshaft ac-
cessories pulley mounting bolt (4 Nm + 110˚ +/-
10˚) .
Refit:
engine, Accessories belt ).
nal.
WARNING
Battery: Removal - Refitting ).
Tighten to torque:
- the battery cover mounting bolts (4 Nm) ,
11A-74
K4J, and 730

WARNING
engine mounting sup- Never turn the engine in the opposite direction to its
port with retaining normal operation.
straps.

on engine lift support Note:
Mot. 1453. The timing belt procedures the same for engines
with and without camshaft dephaser.
Mot. 1489 TDC locating pin.
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 Tool for setting cams-
haft.
grille ).
camshaft pulleys.

camshaft covers (57
mm diameter).
2
camshaft covers (43
mm diameter). 1
Tightening torquesm

bolt 104343
Remove:
pulley bolt 15˚ - the air filter access panel mounting bolts (1) ,
ting nut - the scuttle panel partition mounting bolt (2) .
new camshaft pulley 30 Nm + 84˚ ±

nuts 4˚
TDC setting pin cap 20 Nm
upper timing cover bolts 41 Nm

and nuts
wheel bolts 130 Nm

bolts
11A-75
K4J, and 730
104246 102450
Remove:
Remove:
102451
taining straps.
11A-76
K4J, and 730
101866 101103
Mark the suspended engine mounting in relation to Remove:
the body.
- the air cleaner mounting,
Remove:
- the « engine - suspended engine mounting » as- - the air resonator.
sembly,
WARNING
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 (4) ,
- the TDC setting pin plug.
11A-77
K4J, and 730
14490
14491-1 Check that the camshaft grooves are horizontal and
Position the camshaft grooves (5) almost horizontal- offset downwards.
ly and offset towards the bottom turning the cranks-
haft in the direction of operation (clockwise timing
end).
Screw in the TDC setting pin (6) (Mot. 1489).
14487
Remove:
- the crankshaft accessories pulley (7) , locking the
14489
Turn the crankshaft in its operating direction (timing
end clockwise), until the crankshaft comes into con- - the lower timing cover (9) .
tact with TDC setting pin.
11A-78
K4J, and 730
REFITTING - PROCEDURE 1

The first procedure is used when replacing any timi-
ng component that does not require one or more
camshaft pulleys to be loosened.
WARNING
11 roller.
10
WARNING
Always degrease:
101872
Undo the tensioning roller bolt (10) to slacken the ti-
ming belt. • the camshaft ends (timing end),
Remove: • the camshaft sprocket bores and contact surfa-

ces.
- the fixed roller (11) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the timing
sprocket. • the timing,
- the timing sprocket, • the crankshaft,
- the tensioning roller. • the camshaft sprockets.

11A-79
K4J, and 730
14490 103261
Set the camshaft grooves horizontally and offset
downwards, by turning the camshafts with the (Mot.
799-01) if necessary.
27 75
36 31
17
16
19
10
13
d9
10
21
103308
Use a locally produced mounting bracket to hold
11A-80
K4J, and 730
12
103260 14489
13
14487-1
setting pin (Mot. 1489) (12) (crankshaft groove (13)
should be at the top).
11A-81
K4J, and 730
II - REFITTING - the fixed roller (17) .
14
14505 14487-2
Note:
When refitting the tensioning roller, make sure III - BELT TENSION
positioned in the groove (14) . There are two tensioning roller versions.
17
15
16
14487-3
Refit:
- the timing sprocket (16) ,
- the timing belt,
11A-82
K4J, and 730
1 - Type one 2 - Second type
18 23
19
22
21
24
20
14505-1 103263
Move the adjustable index marker (18) on the ten- Using a 6 mm Allen key, bring the adjustable index
sioning roller 7 to 8 mm past the fixed index (19) , marker (22) opposite the notch (23) , by turning the
using a 6 mm Allen key i at (20) . eccentric (24) clockwise.
Note: (7 Nm) .
Position (21) is the rest position of the adjustable Refit the crankshaft accessories pulley.
indexing mark. Tighten to torque and angle the crankshaft acces-
in contact with the TDC setting pin).
Remove:
- the camshaft setting tool (Mot. 1496) ,
cond revolution:
- screw the Top Dead Centre pin (Mot. 1489) into
the cylinder block.
the TDC setting pin.
For the first tensioning roller version, check that the
adjustable index marker (18) is aligned with the fixed
index (19) , otherwise:
Allen key.
- align the adjustable index marker (18) with the
fixed index marker (19) .
11A-83
K4J, and 730
26 Check that the tensioning roller indexes are correctly

positioned before checking the timing setting.
25 der block.
Move the crankshaft slowly and smoothly until it is
resting against the pin.
27
103263
For the second tensioning roller version, check that

the adjustable index marker (25) is opposite notch
(26) , otherwise:

Allen key,
14490
opposite the notch (26) turning the eccentric (27) in Fit the camshaft setting tool (Mot. 1496) without for-
a clockwise direction. cing (the camshaft grooves must be horizontal and
offset downwards).
nut (27 Nm) .
WARNING
IV - CHECKING THE TIMING AND TENSION and the tension.


cond revolution:
- screw in the TDC setting pin (Mot. 1489) ,

the TDC setting pin (Mot. 1489).
WARNING
Check that the tensioning roller index markers
are aligned. If not, repeat the tensioning proce-
dure.
11A-84
K4J, and 730
REFITTING -PROCEDURE 2

The second procedure is used for replacing all com-
ponents requiring one or more of the camshaft pul-
leys to be slackened.
WARNING
Camshaft ).
WARNING
roller.
14490
WARNING
Always degrease:
• the camshaft ends (timing end),
• the camshaft sprocket bores and contact surfa-
ces.
• the timing,
• the crankshaft,
• the camshaft sprockets.
Refit the camshaft pulleys and the old nuts, tighte-

103261
ning to a torque of (15 Nm) .
Position the camshaft grooves horizontally and off-
set towards the bottom by turning the camshafts with
the (Mot. 1496) if necessary.
11A-85
K4J, and 730
28
27 75
36 31
17
16
19
10
13
d9
10
21
103308 14489
Use a locally produced mounting bracket to hold the
30
29
14487-1
103260 setting pin (Mot. 1489) (28) (crankshaft groove (29)
should be at the top).
Position the RENAULT badge (30) etched on the
Remove the old nuts from the camshaft pulleys and
camshaft pulley stems vertically and pointing
replace them with new nuts (without locking the
upwards.
nuts, clearance of 0.5 to 1 mm between the nuts
and the pulleys).
11A-86
K4J, and 730
II - REFITTING - the timing belt on the camshaft pulleys (without mo-
ving the camshaft pulleys).
31
34
14505
101876
Fit the camshaft pulley locking tool (Mot. 1490-01)

Note:
(34) (use the timing cover mountings to fix the tool).
35
32
33 14487-3
Refit the fixed roller (35) .

14487-3 Tighten to torque the fixed roller mounting bolt (45
Refit: Nm) using the (Mot. 1368).
- the tensioning roller (32) , Refit the crankshaft accessories pulley (without tigh-
tening the bolt, with 2 to 3 mm play between bolt
- the timing sprocket (33) , and pulley).
11A-87
K4J, and 730
III - BELT TENSION 2 - Second type
There are two tensioning roller versions.
41
1 - Type one
40
37 36
42
39
38
103263
Using a 6 mm Allen key, bring the adjustable index

14505-1
Move the adjustable index marker (36) on the ten-
sioning roller 7 to 8 mm past the fixed index (37) , Tighten to torque the tensioning roller mounting
using a 6 mm Allen key at (38) . nut (7 Nm) .
Note: Remove camshaft pulley immobilising tool (Mot.

1490-01).
Position (39) is the rest position of the adjustable
indexing mark.
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).
For the first tensioning roller version, check that the

adjustable index marker (36) is aligned with the fixed
index (37) otherwise:

Allen key.
- align the adjustable index marker (36) with the

fixed index marker (37) .
11A-88
K4J, and 730
44
43
45
103263 14839
For the second tensioning roller version, check that Fit the camshaft pulley immobilising tool (Mot. 1490-
the adjustable index marker (43) is opposite notch 01).
(44) otherwise:
Allen key.
opposite notch (44) turning the eccentric (45) in a
clockwise direction.
nut (27 Nm) .
14489
WARNING
Check that the crankshaft is in contact with the
TDC setting pin (Mot. 1489).
Tighten to torque and angle:
- the crankshaft accessories pulley bolt (40 Nm +

115˚ ± 15˚) (crankshaft in contact with the TDC set-
ting pin),
11A-89
K4J, and 730
- the new camshaft pulley nuts (30 Nm + 84˚ ± 4˚)
starting with the exhaust pulley.
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool,

tions (timing end); before two complete revolutions:
- screw the TDC setting pin (Mot. 1489) into the cy-
linder block,
- slowly and smoothly position the crankshaft in con-
tact with the TDC setting pin (Mot. 1489).
Remove the TDC setting pin. 14490
Fit the camshaft setting tool (Mot. 1496) without for-
cing (the camshaft grooves must be horizontal and
WARNING
offset downwards).
Check that the fixed roller indexes are aligned. If
not, repeat the tensioning process.
WARNING
and the tension.
positioned before checking the timing setting. Remove the TDC setting pin.
der block. REFITTING
Bring the crankshaft slowly and smoothly into con- Refit the TDC setting pin cap, applying a drop of
tact with the pin. RHODORSEAL 5661 onto the thread.
Tighten to torque the TDC setting pin cap (20 Nm) .
Refit the lower timing cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover bolts and
nuts (41 Nm) .
11A-90
K4J, and 730
15103-1
Refit:
ting, suspended engine mounting ),
- new inlet camshaft sealing plugs (Mot. 1487) ,
- new exhaust camshaft sealing plugs (Mot. 1488).
Tighten to torque:
11A-91
K9K, and 732
I - PRECAUTIONS DURING REPAIR

engine mounting sup- IMPORTANT
port with retaining Wear protective gloves when handling.
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 damage the crankshaft accesso-
ries pulley.
When replacing the belt, always replace the ten-
Tightening torquesm sioning rollers and fixed rollers.
the camshaft pulley 14 Nm

wheel 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 bolt.
the crankshaft accesso- 120 Nm + 95˚ ±
ries pulley M14 bolt 15˚ Consumables:
- Silicone adhesive seal part no. 77 11 227 484
TDC pin plug 20 Nm
cylinder head suspen- 21 Nm III - EQUIPMENT REQUIRED

ded mounting bolts
Equipment:
ball joint bracket moun- 21 Nm - Protective gloves,
ting bolts with their
springs - Large screwdriver,
- Female torx socket (14),
- Allen key (6 mm),
- Offset spanner (18 mm),
- Bolt tightening gauge,
- Torque wrench.
11A-92
K9K, and 732
IV - REMOVAL
1 - REMOVAL PREPARATION OPERATION

Remove:
- the engine undertray. 104246
Remove:
engine, Accessories belt ).
104343
Remove:
- the scuttle panel grille (see MR 371 Bodywork,
55A, Exterior protection, Scuttle panel grille ).
11A-93
K9K, and 732
102450
112654
Remove the acoustic mass (4) .
Detach the manual priming pump.
Remove:
- the engine suspended mounting.
WARNING
piping.
102451
Position the (Mot. 1453) fitted with the (Mot. 1453-
01) with the retaining strap.
Remove:
- the exhaust ball joint bracket mounting bolts,
- the lower engine tie-bar mounting bolts.
11A-94
K9K, and 732
112998
112990
Remove:
- the upper timing cover,
112989
Turn the timing belt gently.
Remove the cylinder head suspended mounting (8) .
11A-95
K9K, and 732
19650 19650-1
Remove the TDC setting pin cap (9) . Screw in the TDC setting pin (12) (Mot. 1489).
2 - OPERATION FOR REMOVAL OF PART

CONCERNED
14489
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft comes in contact with the TDC
107270 setting pin.
Turn the crankshaft to position the hole (10) of the
camshaft pulley almost opposite the hole (11) in the
cylinder head.
11A-96
K9K, and 732
109049 109046
Insert the pin (13) (Mot. 1430) in the camshaft pul- Undo the tensioning roller bolt (14) to slacken the ti-
ley and cylinder head holes. ming belt.
Remove: Remove:
- the camshaft pulley timing pin (Mot. 1430) , - the timing belt,
- the TDC setting pin (Mot. 1489). - the timing tensioning roller.
107260
Remove the crankshaft accessories pulley, locking
the flywheel with a screwdriver.
11A-97
K9K, and 732
V - REFITTING - the mark on the high pressure pump (18) is offset
by one tooth to the right of the vertical axis (19) ,
1 - REFITTING OPERATION FOR PART - the crankshaft is in contact with the TDC setting pin
CONCERNED (Mot. 1489) (crankshaft timing sprocket cotter (20)
at the top).
109042
14489
109043
109042
Refit the timing tensioning roller. Remove one bolt from the camshaft pulley wheel.
Place the tensioning roller lug (15) in the cylinder Loosen the two other camshaft pulley wheel bolts
head groove (16) . (22) by one turn.
Engage the pin (17) (Mot. 1430) in the camshaft
pulley and cylinder head holes using an 18 mm off-
set spanner if necessary.
Check that:
11A-98
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 camshaft sprocket marks and the high
pressure pump, and 51 tooth spaces between the
crankshaft sprockets and the high pressure pump.
11A-99
K9K, and 732
19658
Position the tensioning roller adjustable index mar-
ker (23) opposite the lug (24) 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-100
K9K, and 732
109045
Refit the bolt to the camshaft pulley wheel.
Tighten to torque the camshaft pulley wheel bolts
(14 Nm) .
Remove:
- the TDC setting pin,
- the camshaft pulley timing pin.
107272
Tighten the old crankshaft accessories pulley bolt fit-
ted with a spacer (which does not cover the timing
sprocket mark) (25) onto the crankshaft.
11A-101
K9K, and 732
107270 109048
Rotate the crankshaft clockwise through two revolu- If the pin (Mot. 1430) does not engage:
tions (timing end). Before the camshaft pulley hole
- loosen the camshaft pulley wheel bolts by one turn
(26) is opposite the cylinder head hole (27) .
only,
- turn the camshaft pulley hub using an offset span-
der block.
ner to facilitate the setting of the camshaft pulley
Bring the crankshaft slowly and smoothly against the hub,
TDC setting pin.
- do not retighten the camshaft pulley wheel bolts.
109049
Set the camshaft pulley using (Mot. 1430).
11A-102
K9K, and 732
109045
Check that the crankshaft timing sprocket cotter (28)
is positioned vertically at the top.
After two turns, the tensioning roller index mar-

kers may be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-103
K9K, and 732
111083
111081
Loosen the tensioning roller bolt by no more than
one turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index marker (29) in
the middle of the timing window (30) , by turning the
key anti-clockwise.
11A-104
K9K, and 732
- camshaft pulley timing pin (Mot. 1430).
tions (timing end). Before the camshaft pulley hole is
opposite the cylinder head hole.
der block.
Bring the crankshaft slowly and smoothly into con-
tact with the TDC setting pin.
111082
109049
Set the camshaft pulley using the (Mot. 1430).
If this is not possible, repeat the timing belt refitting
operation.
111081
Loosen the tensioning roller bolt by no more than

one turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index marker (31) in

the middle of the timing window (32) , by turning the
key clockwise.
Tighten to torque:
- the tensioning roller bolt (27 Nm) ,

- the camshaft pulley wheel bolts (14 Nm) .
Remove the tools:

- TDC setting pin (Mot. 1489) ,
11A-105
K9K, and 732
107260 112989
Refit the accessories crankshaft pulley with a new Refit the cylinder head suspended mounting (33) .
bolt.
Tighten to torque the cylinder head suspended
Tighten to torque and angle (crankshaft in contact mounting bolts (21 Nm) .
with the TDC setting pin) the crankshaft accesso-
ries pulley M14 bolt (120 Nm + 95˚ ± 15˚)
Remove the tools:
- TDC setting pin (Mot. 1489) ,
- camshaft pulley timing pin (Mot. 1430).
2 - FINAL OPERATION
Refit the TDC setting pin cap, coating the thread with
SILICONE ADHESIVE SEAL .
Torque tighten the TDC pin plug (20 Nm) .
11A-106
K9K, and 732
112990 112990
Refit the upper timing cover (38)
19659
Refit: 112654
- the lower timing cover (34) , positioning the tab (35) Refit:
in the hole (36) in the inner timing cover,
- the timing cover plastic bolt (37) . mounting, Suspended engine mounting ),
ting, Suspended engine mounting ).
Replace the manual priming pump.
Refit the acoustic mass (39) (see 19D, Engine
mounting, Suspended engine mounting ).
Remove the retaining strap of the (Mot. 1453) fitted
with the (Mot. 1453-01).
11A-107
K9K, and 732
Refit:
ting, Suspended engine mounting ),
- the exhaust ball joint bracket mounting bolts
Tighten to torque the ball joint bracket mounting
bolts with their springs (21 Nm) .
Refit:
engine, Accessories belt ),
- the scuttle panel mounting bolt,
- the engine covers.
11A-108
Timing chain: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removal of the timing chain requires removal of the
engine - gearbox assembly (see 10A, Engine and
peripherals, Engine - gearbox assembly: Remo-
val - Refitting ).
For removal of the timing chain (see Technical Note
6017A, M9R engine ).
REFITTING
For refitting the timing chain (see Technical Note
Refit the engine - gearbox assembly (see 10A, En-
gine and peripherals, Engine - gearbox assem-
bly: Removal - Refitting ).
11A-109
Tightening the cylinder head 11A
K4J, and 730 – K4M, and 761 or 782
CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
cylinder head moun- 20 Nm

ting bolts
cylinder head moun- 240˚ +/- 6˚

ting bolts
14500
Tighten to torque and in order the cylinder head

WARNING
Check that all of the cylinder head mounting bolts
Reuse the bolts if the length under the head
are tightened to the correct torque (20 Nm).
does not exceed 117.7 mm (otherwise replace
all the bolts). Angle-tighten in order the cylinder head mounting
bolts (240˚ +/- 6˚) .
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. WARNING
Do not oil the new bolts. The bolts must be oiled Do not re-tighten the cylinder head bolts after
if reused. applying this procedure.
Note:
11A-110
K9K, and 722 or 728 or 732
Tightening torquesm

ting bolts
cylinder head moun- 255˚ ± 10˚

ting bolts
8 4 1 5 9
7 3 2 6 10
19712
WARNING
Always replace all of the cylinder head bolts with
new ones after removal.
To ensure that the bolts are correctly tightened,
use a syringe to draw off any oil that may be in
the cylinder head mounting holes.
Do not oil the new bolts.
Note:


Angle-tighten in order the cylinder head mounting

bolts (255˚ ± 10˚) .
WARNING
Do not re-tighten the cylinder head bolts after
applying this procedure.
11A-111
F9Q, and 804 or 812
Tightening torquesm
cylinder head moun- 30 Nm are tightened to the correct torque (30 Nm).
ting bolts Angle-tighten in order the cylinder head mounting
bolts (230˚ +/- 6˚) .
ting bolts
WARNING
CYLINDER HEAD TIGHTENING PROCEDURE Do not re-tighten the cylinder head bolts after
10 6 2 3 7
9 5 1 4 8
16189
WARNING
Systematically replace all cylinder head bolts
after removal.
To ensure correct tightening, use a syringe to
remove any oil that may be in the cylinder head
mounting holes.
Do not oil the new bolts.
Note:
the gasket faces must be clean, dry and free
11A-112
F4R, and 770 or 771 or 776
Tightening torquesm

ting bolts

ting bolts

ting bolts
1 10
4 6
8 2
3
7
15153
WARNING Note:
Systematically replace all cylinder head bolts The gasket faces must be clean, dry and free
after removal. from grease (avoid finger marks).
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which Tighten to torque and in order the cylinder head
may be in the cylinder head mounting holes. mounting bolts (20 Nm) .
Do not oil the new bolts. Check that all of the cylinder head mounting bolts
Step 1
- angle-tighten in order the cylinder head mounting
bolts (100˚ +/- 6˚) .
11A-113
F4R, and 770 or 771 or 776
Step 2
- Angle-tighten in order the cylinder head moun-
ting bolts (100˚ +/- 6˚) .
WARNING
Do not re-tighten the cylinder head bolts after
11A-114
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728

WARNING
Mot. 1672 Lower engine support. Procedure for removing the air inlet duct (K9K 728):
- draw a marking on the inlet duct between the
Mot. 1453 Multiple-adjusting stainless steel pipe and the hose,
port with retaining - separate the hose, using the (Car. 1363) tool,
straps. - do not use degreasing agent, brake cleaning pro-
duct or any other product,
on engine lift support - clean the stainless steel pipe and the hose with a
Mot. 1453. dry, lint-free cloth,
Mot. 1202-01 Pliers for large hose - if the hose is not being replaced, replace the clip
clips. on the same marking,
- turn on clip on its pivot to facilitate its torque tigh-
Mot. 1202-02 Pliers for small hose tening,
clips.
- the hose and/or stainless steel pipe must be repla-
Mot. 1448 Long nose pliers for ced if they are damaged.
hose clips.
- It is essential to replace the clip.
Equipment required There is a risk of leaks and unseating if this proce-

dure is not followed.
diagnostic tool
cylinder head testing tool REMOVAL

angular tightening wrench Position the vehicle on a two-post lift (see 02A, Lif-
Remove:
Tightening torquesm
- the front engine covers,
rocker cover mounting 10 Nm - the engine undertray.
bolts
turbocharger oil return 9 Nm Removal - Refitting ).
pipe
Remove:
intercooler hose clip 5.5 Nm - the battery (see 80A, Battery, Battery: Removal -
Refitting ),
bolts - the scuttle panel grille (see MR 371 Bodywork,
IMPORTANT
Before any operation:

- connect the diagnostic tool ,
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
- be aware of the fuel temperature,
- order the special high pressure injection circuit
plug kit.
11A-115
K9K, and 722 or 728
104343 19626
Fit the engine stand (Mot. 1672).
Remove:
Remove the (Mot. 1453) and the (Mot. 1453-01).
- the scuttle panel partition mounting bolts (2) .
104246
Remove:

- the timing belt (see 11A, Top and front of engine,

Timing belt: Removal - Refitting ).


Cooling circuit: Oil change ).
11A-116
K9K, and 722 or 728
K9K, and 722 K9K, and 728
7 4 6
9
12
5
11
10
102081 110326
Disconnect: Disconnect:
- the air temperature and pressure sensor connector - the air temperature and pressure sensor connector
(4) , (9) ,
- the exhaust gas recirculation valve control connec- - the exhaust gas recirculation valve control connec-
tor (5) , tor (10) ,
- the air hoses (6) , - the engine speed and position sensor connector
(11) ,
- the air hose (7) ,
- the air hose (12) ,
- the turbocharging pressure regulation valve rubber
pipe, - the rubber hose from the turbocharging pressure
regulator valve.
- the air sleeve from the air filter unit,
- the oil vapour rebreathing pipe from the rocker co-
ver.
Remove the resonator unit mounting strut (8) .
11A-117
K9K, and 722 or 728
16
17
18
110325 102086
Pull the clip. Disconnect:
- the injector connectors,
- the heater plug connectors,
- the rail pressure sensor connector,
15 - the diesel fuel supply pipe from the pump,
- the diesel return pipe from the pump,
13 14
- the diesel temperature sensor (16) ,
- the fuel flow actuator connector (17) .
Remove the wiring and diesel return pipe support
(18) .
110322
Make a mark on the intake pipe between the stain-
less steel pipe and the hose (13) .
Undo bolt (14) .
Remove air duct (15) .
11A-118
K9K, and 722 or 728
21 20
19
22
102263 104175
Disconnect: Disconnect the turbocharger oil return pipe (22) .
- the scuttle panel hoses (19) using tool (Mot. 1202-
01) or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (20) on the vacuum
pump side,
- the coolant temperature sensor connector from the
scuttle panel.
- the radiator top hose from the cylinder head water
outlet using the (Mot. 1202-01) or (Mot. 1202-02)
or (Mot. 1448).
Unclip the heater radiator hose (21) . 23
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
19710
Remove the inner timing cover (23) .
11A-119
K9K, and 722 or 728
I - CLEANING
Clean the cylinder head.
IMPORTANT
Do not scratch the aluminium sealing surfaces.
During the operation, wear:
- goggles,
24 - gloves.
Clean the gasket faces with the product DÉ-

CAPJOINT to dissolve the section of the gasket
which is still attached.
Apply the product to the section to be cleaned; wait
WARNING
19711
To prevent any foreign bodies from entering the
Remove: oil galleries (pipes in both the cylinder block and
- the rocker cover mounting bolts (24) , cylinder head).
- the rocker cover.

WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oilways.
25
Failure to follow this advice could block the pipe,
causing rapid camshaft damage.
II - CHECKING THE GASKET FACE

Check for gasket face deformation using a ruler and
a set of shims.
The maximum deformation is 0.05 mm .
25
WARNING
No regrinding of the cylinder head is permitted.
19712
Remove: Test the cylinder head to detect any possible cracks
using cylinder head testing tool.
- the cylinder head mounting bolts (25) ,
For the cylinder head stripping procedure (See
- the cylinder head. Technical Note 6006A, 4-cylinder Cast Iron 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-120
K9K, and 722 or 728
Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head. 5
6 1
3
WARNING
The gasket faces must be clean, dry and free 2
from grease (avoid finger marks). 7
Refit the cylinder head.

4
Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head ) using
the angular tightening wrench.
8
WARNING
The seal faces must be clean, dry and free from
grease (avoid finger marks).
WARNING
19711
squeezed out when parts are tightened. The mix- Refit the rocker cover.
ture of the product and coolant can cause some Tighten to torque and in order the rocker cover
components (engine, radiator) to deteriorate. mounting bolts (10 Nm) .
Reconnect the turbocharger oil return pipe, fitted
with new seals.
26
Tighten to torque the turbocharger oil return pipe
(9 Nm) .
26
26
19712-1
Fit the new rocker cover gasket.
Apply beads (26) of SILICONE ADHESIVE SEAL 2
mm in diameter.
19709
Reconnect:
- the oil vapour rebreathing pipe,
- the new turbocharger air sleeves.
K9K, and 728

Reconnect the air pipe by aligning the marks.
11A-121
K9K, and 722 or 728
Tighten to torque the intercooler hose clip (5.5
Nm) .
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ),
Timing belt: Removal - Refitting ),
Fill the cooling system (see 19A, Cooling, Cooling
system: Oil change ).
Reprime the diesel circuit (see 13B, Fuel supply,
Diesel fuel supply circuit ).
Bleed the cooling system (see 19A, Cooling, Coo-
ling system: Bleeding ).
(4 Nm) .
11A-122
K4M, and 761 or 782
Mot. 1672 Lower engine support. camshaft dephaser 10 Nm

solenoid valve bolt
engine mounting sup- spark plugs 25 to 30 Nm
port with retaining
straps. coil mounting bolts (if 12 Nm
the holes are already
Mot. 1669 Fitting cam follower threaded)
tappet.
coil mounting bolts (if 15 Nm
Mot. 1453-01 Additional winder nut holes not threaded)
Mot. 1453. camshaft position sen- 10 Nm
sor mounting bolt
camshaft pulleys. inlet manifold mounting 9 Nm
bolts
Mot. 1573 Cylinder head support
Mot. 104 Cylinder head ali- bolts
gning tool
Mot. 1513 Tool for refitting cams- REMOVAL

haft dephaser solenoid
valve lip seal.
Ele. 1382 Spark plug spanner Remove:
toolkit 16 & 21 mm tor-
que 1.75 & 28 Nm + - the front engine covers,
square adapter 9-9.52 - the engine undertray.
for spanner Ele. 1086
Mot. 1632 Tool for fitting PTFE Removal - Refitting ).
camshaft seal Remove:
Mot. 1487 Tool for removing the - the battery (see 80A, Battery, Battery: Removal -
camshaft covers (57 Refitting ),
mm diameter).
Mot. 1488 Tool for removing the 55A, Exterior protection, Scuttle panel grille ).
camshaft covers (43
mm diameter).
Equipment required
cylinder head testing tool
Tightening torquesm
mounting bolts no. 22, 12 Nm

23, 20 and 13 of the
cylinder head cover
oil decanter mounting 15 Nm

bolts
11A-123
K4M, and 761 or 782
1 1
104343 19626
Remove: Set up the engine stand (1) (Mot. 1672).
- the air filter access panel mounting bolts (1) , Remove the (Mot. 1453) and (Mot. 1669).
- the scuttle panel partition mounting bolt (2) . 2
104246
103265
Remove:
Remove the camshaft pulleys using the (2) Mot.
- the scuttle panel partition mounting bolts (3) , 1669 (Mot. 1669) camshaft pulley locking tool.

IMPORTANT
Be careful of petrol splashing out when discon-
necting the fuel supply union.
WARNING
Drain the engine cooling circuit (see 19A, Cooling, pulley studs, 11A, Top and front of engine,
Cooling circuit: Oil change ). Camshaft ).
11A-124
K4M, and 761 or 782
Remove:
- the injector rail protector,
- the fuel supply pipe from the injection rail.
Move the fuel supply pipe aside.
5
4
14889
18699 7
Remove the bracket mounting bolt (4) .
Move the bracket to one side.
102735
Remove the wiring harness bracket mounting bolts

(5) .
Disconnect:
- connector (6) from the coolant temperature sensor,
- the water unit hoses using the (Mot. 1453) or (Mot.

1453-01) or (Mot. 1490-01) ,
- the brake servo vacuum pipe (7) on the inlet mani-

fold side.
Move the bracket/wiring harness assembly aside.
11A-125
K4M, and 761 or 782
- the catalytic converter upstream oxygen sensor
connector.
9
14
8
15
11 10
12
18666
Disconnect:
104240
- the ignition coil connectors (8) , Disconnect the injector connector (14) .
- the air temperature sensor connector (9) , Unfasten clip (15) .
- the camshaft dephaser solenoid valve connector Move the wiring harness to one side.
(10) ,
Remove:
- the inlet manifold pressure sensor connector (11) ,
- the ignition coils,
- the fuel vapour recirculation solenoid valve pipe
(12) , - the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
13
101809
Disconnect:
- the camshaft position sensor connector (13) ,
11A-126
K4M, and 761 or 782
Remove the camshaft pulleys using the (Mot. 1490-
01).
16 20
17
21
103272
Remove:
103255
- the lifting bracket (16) ,
- the inlet manifold mounting bolts (17) ,
WARNING
- the inlet manifold.
Do not remove the bolt (20) as it acts as a stop
for the squared cam tappet.
Remove:
18 - the oil decanter mounting bolts (21) ,

- the oil decanter.
19
101793
Remove:
- the catalytic converter-gearbox stay mounting bolts
(18) ,
- the catalytic converter/gearbox stay,
- the exhaust pipe mounting nuts (19) .
Move the exhaust pipe to one side.
11A-127
K4M, and 761 or 782
23
24
22
22
103256 14499
Remove: Remove:
- the rocker cover mounting bolts,
- the valve rockers (23) ,
- detach the rocker cover vertically, tapping the lugs
- the hydraulic tappets (24) .
(22) with a copper hammer.
WARNING Note:
Do not damage the aluminium surfaces. To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
Remove:
- the cylinder head mounting bolts,
- the cylinder head.
Mount the cylinder head on the cylinder head moun-

ting (Mot. 1573).
Remove the cylinder head gasket from the cylinder

block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
103258 - goggles,
Remove the inlet and exhaust camshafts. - gloves.
Clean the gasket faces with DÉCAPJOINT to dissol-

ve off the parts of the seal still attached.
11A-128
K4M, and 761 or 782
WARNING 26 25
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 galleries.
Failure to follow this guideline could lead to the
blocking of the oilways, resulting in rapid and
serious damage to the engine.

Use a ruler and set of shims to check that there is no
gasket face bow.
Maximum distortion: 0.05 mm 14689
Check that the centring dowel is present (25) on the
WARNING cylinder block.
No regrinding of the cylinder head is permitted. Set up tool (Mot. 104) (26) on the cylinder block.
Test the cylinder head to detect any possible cracks

using the cylinder head testing tool. REFITTING
For the cylinder head stripping procedure (see NT Fit the new cylinder head gasket.
3784A, 4 cylinder - K4 petrol engine, 10A, Engine Refit the cylinder head.
and peripherals, Rebuilding the cylinder head ).
Check the cylinder head tightening bolts (see 11A,
Position the pistons at mid-stroke to prevent any Top and front of engine, Tightening the cylinder
contact with the valves when refitting the camshafts. head ).
Always degrease: Tighten the cylinder head (see 11A, Top and front
- the combustion face of the cylinder head, of engine, Tightening the cylinder head ).
- the combustion face of the cylinder block.
11A-129
K4M, and 761 or 782
I - CAMSHAFT MARKINGS
Inlet camshaft
27
28
14499
Reprime the hydraulic tappets (hydraulic tappets
may be empty after a long down time). 102507
To check if repriming is necessary, press the top of
the tappet (27) with your thumb. (28) The inlet camshaft is fitted with
the camshaft sensor target.
If the tappet piston depresses:
- immerse the tappets in a container full of diesel
Exhaust camshaft
fuel,
- refit the hydraulic tappets.
Refit:
- the valve rockers,
- the camshafts, oiling the bearings. 29
102506
(29) The exhaust camshaft is fitted

with the square cam.
11A-130
K4M, and 761 or 782
30 31
36
32
35
33
103685 103687
Position the pin (30) of tool (Mot. 1669) against the Tighten the bolt (35) until the pin (36) is hard up
bottom of the groove by turning the bolt (31) . against the bottom of the groove.
Mount the tool (Mot. 1669) on the rocker cover, cor-
rectly positioning the pin (32) in the rocker cover
hole (33) .
34
37
103688
Position the bolt of tool (Mot. 1669) in place of the
original bolt at (37) to hold the tappet in the com-
103684 pressed position.
Fit rocker cover tool (Mot. 1669) using the bolts (34)
.
11A-131
K4M, and 761 or 782
39
38
103686 15106-1
Turn the bolt (38) until the pin (39) is hard up against Position the camshaft grooves horizontally and off-
the bottom of the groove. set downwards.
Remove the (Mot. 1669) from the rocker cover.
Note:
The gasket faces on the cylinder head cover
must be clean, dry and free from grease (remove
any finger marks).
Note:
could damage certain components (engine,
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-132
K4M, and 761 or 782
40
14517
Using a stipple roller, apply LOCTITE 518 to the
camshaft rocker cover gasket face until it turns red-
dish.
Using a cloth, remove the LOCTITE 518 from (40)
on the six camshaft rocker cover bearings.
Refit the rocker cover.
11A-133
K4M, and 761 or 782
II - TIGHTENING PROCEDURE
14497
- cylinder head cover mounting bolts 22, 23, 20
and 13 (8 Nm) ,
- cylinder head cover mounting bolts 1 to 12, 14
to 19 and 21 to 24 (12 Nm) .
Loosen in order mounting bolts 22, 23, 20 and 13.
Tighten to torque and in order mounting bolts no.
22, 23, 20 and 13 of the cylinder head cover (12
Nm) .
11A-134
K4M, and 761 or 782
10 1
9
4 5
8
3
6 2
101820
Refit the oil decanter.
Tighten to torque and in order the oil decanter

102073
Remove bolt (10) of tool (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 .
of grease.
41
WARNING
radiator).
Using a stipple roller, apply LOCTITE 518 on the

gasket face until it is reddish.
16016
Refit:
- the camshaft dephaser solenoid valve seal using

(Mot. 1513) (41) ,
- the camshaft dephaser solenoid valve.
Tighten to torque the camshaft dephaser solenoid

valve bolt (10 Nm) .
11A-135
K4M, and 761 or 782
42
106443
On the ignition coils, apply a bead (42) of FLUORI-

NATED GREASE 82 00 168 855 2 mm in diameter
to the inner circumference of the high tension cap.
11A-136
K4M, and 761 or 782
4
3
8
1
43 7
6
103257 103272
Refit the plugs. Tighten to torque and in order the inlet manifold
Torque tighten the spark plugs (25 to 30 Nm) using
the spark plug spanner set (Ele. 1382).
III - REPLACING THE CAMSHAFT SEALS
Refit the coils.
Tighten to torque:
- the coil mounting bolts (if the holes are already
threaded) (12 Nm) ,
- the coil mounting bolts (if holes not threaded)
(15 Nm) .
Refit the camshaft position sensor (43) with a new
seal.
Torque tighten the camshaft position sensor
mounting bolt (10 Nm)
Always replace all the inlet manifold seals.
44
45
20257
The elastomer seal is for this engines fitted with a
flat lip (44) and a protector (45) (which also assists in
fitting the seal to the engine).
11A-137
K4M, and 761 or 782
1 - Fitting the exhaust camshaft seal
48
46 47
105531
18687
WARNING
It is very important to hold the protector (4 6)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (47) in order to prevent any oil
leaks once the seal is fitted to the engine.
48
21687
Screw the stud of (48) tool (Mot. 1632) onto the
camshaft.
11A-138
K4M, and 761 or 782
21687-1 21687-3
Fit the protector, with a seal, to the camshaft. Screw on the collar nut until the cover touches the
cylinder head.
Remove the nut, cover, protector and threaded rod.
2 - Fitting the inlet camshaft seal
49
50 WARNING
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 housing (49) and the collar nut ring bolt (50)
of tool (Mot. 1632).
11A-139
K4M, and 761 or 782
51
52
105531
105532
Fit the protector (51) , with a seal, to the camshaft.
Push the middle of the protector so that the seal
squeezes into the housing.
52
105534
camshaft.
105533
Remove the seal protector, taking care not to drop
the seal.
11A-140
K4M, and 761 or 782
53
54
105535 15103-1
Fit the housing (53) and the collar nut ring bolt (54) Refit:
of (Mot. 1632).
- new inlet camshaft sealing plugs using the (Mot.
Screw on the collar nut until the cover touches the 1487) ,
cylinder head.
- new exhaust camshaft sealing plugs using tool
Remove the nut, cover, protector and threaded rod. (Mot. 1488) ,
IV - REFITTING
Refit the timing belt (see 11A, Top and front of en- system: Oil change ).
gine, Timing belt ).
WARNING Bleed the cooling system (see 19A, Cooling, Coo-
Follow the second timing belt refitting procedure. ling system: Bleeding ).
Refit the accessories belt (see 11A, Top and front Tighten to torque the battery cover mounting bolts
of engine, Accessories belt: Removal - Refitting (4 Nm) .
).
11A-141
F4R, and 770 or 771
Mot. 1672 Lower engine support. spark plugs 25 to 30 Nm
Mot. 1509 Camshaft sprocket coil mounting bolts (if 12 Nm

locking tool. holes threaded)
Mot. 1509-01 Adapter kit for tool coil mounting bolts (if 15 Nm
Mot.1509. non-threaded holes)
Mot. 1202-01 Pliers for large hose inlet manifold mounting 11 Nm

clips. bolts
Mot. 1202-02 Pliers for small hose battery cover mounting 4 Nm

clips. bolts

hose clips. REMOVAL
Mot. 1573 Cylinder head support Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1517 Camshaft seal fitting
tool. Remove:
Mot. 1512 Camshaft oil seal fit- - the engine covers,

ting tool (28 x 47). - the engine undertray.
Mot. 1487 Tool for removing the Disconnect the battery (see 80A, Battery, Battery:
camshaft covers (57 Removal - Refitting ).
mm diameter).
Remove:
camshaft covers (43 - the battery (see 80A, Battery, Battery: Removal -
mm diameter). Refitting ),

Equipment required 55A, Exterior protection, Scuttle panel grille ).
angular tightening wrench
Tightening torquesm
2
mounting bolts 22, 23, 8 Nm
20 and 13 on the rocker
cover
1
rocker cover mounting 12 Nm

bolts 1 to 12, 14 to 19
and 21 to 24
new or original oil 10 Nm 104343

decanter mounting bolts
(in tapped holes) Remove:

new oil decanter moun- 15 Nm
ting bolts (in non-tap- - the air filter access panel,
ped holes)
11A-142
F4R, and 770 or 771
5
6
104246
Remove: 4
- the accessories belt (see 11A, Top and front of 16019-4
engine, Accessories belt: Removal - Refitting ), Fit the (Mot. 1509) with the sprocket (Mot. 1509-01).
Tighten the collar nut (4) and the bolt (5) , then bring
the sprockets of the (Mot. 1509) into contact with the
Drain the engine cooling circuit (see 19A, Cooling, camshaft pulleys while torque tightening the nuts
Cooling circuit: Draining - Refilling ). (80 Nm) (6) .
Remove the inlet camshaft dephaser blanking cover
using a 14 mm Allen key.
19626
Leave the engine mountings (Mot. 1672) in place.
11A-143
F4R, and 770 or 771
16019-4 18699
Remove: Remove the bracket mounting bolt (7) .
- the exhaust camshaft pulley nut, Move the bracket to one side.
- inlet camshaft dephaser bolt,
WARNING
Camshaft ).
11A-144
F4R, and 770 or 771
11
12
9
11
15 14 13
8
14889 18666
Disconnect:
- the ignition coil connectors (11) ,
- the air temperature sensor connector (12) ,
10
- the camshaft dephaser connector (13) ,
(15) ,
- the injector connectors,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Move the wiring harness to one side.
Remove:
- the plugs,
102735 - the dephaser solenoid valve.

(8) .
Disconnect:
- the connector (9) from the coolant temperature

sensor,
- the scuttle panel hoses using (Mot. 1202-01) or

(Mot. 1202-02) or (Mot. 1448).
- the brake servo vacuum pipe (10) on the inlet ma-

nifold side.
11A-145
F4R, and 770 or 771
20
16
21
17
102939 102940
Remove: Remove:
- the engine lifting bracket (16) on the timing end, - the oil decanter mounting bolts.
- the oil decanter (20) ,
- the lifting bracket on the flywheel end (21) .
18
19
101793
Remove:
- the catalytic converter-gearbox stay mounting bolts

(18) ,
11A-146
F4R, and 770 or 771
22
22
102941
Remove the rocker cover bolts.
Remove the rocker cover vertically, tapping the lugs
(22) with a copper hammer.
WARNING
Do not damage the aluminium surfaces.
Remove the camshaft seals.
11A-147
F4R, and 770 or 771
15151
Remove the inlet and exhaust camshafts.
11A-148
F4R, and 770 or 771
14499
Remove:
- the hydraulic tappets (24) .
Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
11A-149
F4R, and 770 or 771
15153
Remove: Apply the product to the section to be cleaned; wait

- the cylinder head bolts, using a wooden spatula.

WARNING
Mount the cylinder head on the cylinder head moun- - Do not allow this product to drip on to the pain-
ting (Mot. 1573). twork.
Remove the cylinder head gasket from the cylinder - Clean the cylinder head carefully to prevent
block. foreign matter entering the oilways.
- Failure to follow this advice could lead to bloc-
king of the various oil channels, resulting in rapid
I - CLEANING destruction of the engine.
IMPORTANT II - CHECKING THE GASKET FACE

Do not scratch the aluminium sealing surfaces. Use a cylinder head adjuster and set of shims to
During the operation, wear: check the gasket face bow.
- goggles, Maximum distortion: 0.05 mm

- gloves.
WARNING
ve off the parts of the seal still attached. No regrinding of the cylinder head is permitted.
11A-150
F4R, and 770 or 771
using the cylinder head testing tool.
For the cylinder head stripping procedure (see NT
6027A, 4 cylinder - F4 petrol engine, 10A, Engine
and peripherals, Rebuilding the cylinder head ). 25
Position the pistons at mid-stroke to prevent any
contact with the valves when the camshafts are
being refitted.
Always degrease:
- 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 ). 14499
Tighten the cylinder head (see 11A, Top and front Re-prime the hydraulic tappets (hydraulic tappets
of engine, Tightening the cylinder head ) using a may empty if they have been removed for some ti-
angular tightening wrench. me).
To check if re-priming is necessary, press the top of
the tappet at (25) with your thumb.
If the tappet piston depresses:
- immerse the thrust bearings in a container full of
diesel fuel,
Refit:
- the valve rockers,
- the camshafts, oiling the bearings.
11A-151
F4R, and 770 or 771
26 27
15152 15106-1
The camshafts are identified by the pulley moun- Position the camshaft grooves as shown in the dia-
tings. gram.
Detailed view of the pulley mountings:
- (26) : exhaust camshaft, WARNING
- (27) : inlet camshaft.
Refit the camshafts, positioning them correctly (see
10A, Engine and peripherals, Engine periphe-
rals: Specifications for camshaft identification ). WARNING
squeezed out when parts are tightened. The sea-
ling compound/fluid mixture can cause damage
to certain components (engine, radiator, etc.).
WARNING
Do not apply oil on the sealing surface of the
camshaft bearing cap cover.
11A-152
F4R, and 770 or 771
28
14517
crankshaft cylinder head joint face until the joint face
is reddish in colour.
Note:
Using a cloth, remove the LOCTITE 518 from
(28) on the camshaft rocker cover bearings.
Refit the rocker cover.
11A-153
F4R, and 770 or 771
14497
- mounting bolts 22, 23, 20 and 13 on the rocker
cover (8 Nm) .
- the rocker cover mounting bolts 1 to 12, 14 to 19
and 21 to 24 (12 Nm) .
Slacken bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order mounting bolts 22,
23, 20, 13 (12 Nm) .
11A-154
F4R, and 770 or 771
3
2
5 9
6
4
1
8
7
102738 102729
WARNING Tighten to torque and in order:

The gasket faces must be clean, dry and free - the new or original oil decanter mounting bolts
from grease (avoid finger marks). (in tapped holes) (10 Nm) ,
- the new oil decanter mounting bolts (in non-
tapped holes) (15 Nm) .
WARNING
squeezed out when parts are tightened. The sea-
ling compound/fluid mixture can cause damage
to certain components (engine, radiator, etc.).

gasket face until it turns reddish.
11A-155
F4R, and 770 or 771
29
106443
Apply to the four ignition coils a bead (29) of FLUO-
RINE GREASE 82 00 169 855 , 2 mm in diameter
around the inner edge of the high voltage cap to im-
prove sealing.
11A-156
F4R, and 770 or 771
1 3
6 7
5 4
102939 15103-1
Refit:
Refit the plugs.
- the new sealing plugs:
Tighten to torque the spark plugs (25 to 30 Nm) .
• on the inlet camshaft (Mot. 1487) ,
Refit the coils. • to the exhaust camshaft (Mot. 1488) ,
Tighten to torque: - the right-hand suspended engine mounting (see

- the coil mounting bolts (if holes threaded) (12 mounting ).
Nm) , Proceed in the reverse order to removal.
- the coil mounting bolts (if non-threaded holes) Fill the cooling system (see 19A, Cooling, Cooling
(15 Nm) . system: Draining - Refilling ).
Refit the inlet manifold with its new seal. moval - Refitting ).
Tighten to torque and in order the inlet manifold Bleed the cooling system (see 19A, Cooling, Coo-
mounting bolts (11 Nm) . ling system: Bleeding ).
Refit the camshaft dephaser solenoid valve, with a
(4 Nm) .
new seal.
Replacing the camshaft seals:
- use the (Mot. 1517) for the inlet camshaft seal.
- use the (Mot. 1512) for the exhaust camshaft seal.
Refit:
- the timing belt (it is essential to follow the procedu-

re (see 11A, Top and front of engine, Timing
belt: Removal - Refitting ),

11A-157
F9Q, and 812

WARNING
Mot. 1672 Lower engine support.
Fit plugs into the openings.
Mot. 1453 Multiple-adjusting Be sure to follow the safety instructions.
port with retaining Refer to (see 13B, Diesel injection, Cleanliness
straps. guidelines ).

Mot. 1453. REMOVAL
Mot. 1202-01 Pliers for large hose Position the vehicle on a two-post lift (see 02A, Lif-
clips. ting equipment, Underbody lift ).
Mot. 1202-02 Pliers for small hose Remove:

clips.
hose clips. - the engine undertray.
Equipment required Disconnect the battery (see 80A, Battery, Battery:

diagnostic tool
Remove:
angular tightening wrench Refitting ),
- the battery tray,

Tightening torquesm
oil supply pipe bolt on 22.5 Nm
the turbocharger
oil supply pipe bolt on 22.5 Nm

the cylinder block
oil return pipe bolts 12 Nm
battery cover mounting 4 Nm 1

bolts
2
IMPORTANT

- connect the diagnostic tool ,
- establish dialogue with the injection computer, 104343
Remove:
- the air filter access panel (1) mounting bolts,
plug kit.
- the scuttle panel partition mounting bolts (2) .
11A-158
F9Q, and 812
3
8 4
6
7
104246
Remove:
9
- the accessories belt (see 11A, Top and front of 105511
engine, Accessories belt: Removal - Refitting ), Disconnect:
- the timing belt (see 11A, Top and front of engine, - the air filter outlet duct (4) ,
- the air duct (5) to the turbocharger,
Exterior protection, Front bumper ). - the oil vapour rebreathing pipe (6) ,
Drain the engine cooling circuit (see 19A, Cooling, - the engine - damping device valve pipe (7) .
Cooling circuit: Oil change ). Remove:
- the air duct (8) from the inlet manifold,
- the oil decanter (9) .
105432
Remove the (Mot. 1453) and the (Mot. 1453-01).
11A-159
F9Q, and 812
10 12 13
14
15 14
11
19 16 15
17
18983
Remove the vacuum tank mounting bolts (10) . 20
18
Disconnect:
- the turbocharger pressure regulation solenoid val-
ve pipes,
105512
- the engine damping device solenoid valve connec-
Disconnect:
tor (11) ,
- the exhaust gas recirculation solenoid valve con-
- the camshaft sensor connector (12) .
nector (13) ,
Remove the vacuum tank.
- the injector connectors (14) ,
- the heater plug connectors (15) ,
- the rail pressure sensor connector (16) ,
- the high-pressure pump pressure regulator con-
nector (17) ,
- the diesel return temperature sensor connector
(18) ,
- the diesel filter connector,
- the diesel supply pipe (19) ,
- the diesel return pipe (20) .
Fit the blanking plugs.
11A-160
F9Q, and 812
21
23
24
104323 18997
Disconnect: Remove:
- the cylinder head outlet water unit hoses using the - the catalytic converter (see 19B, Exhaust, Cataly-
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , tic converter: Removal - Refitting ),
- the connector (21) from the coolant temperature - the oil supply pipe (23) ,
sensor.
- the oil return pipe mountings (24) from the turbo-
charger.
22
102348
Remove bolts (22) securing the high pressure pump.
11A-161
F9Q, and 812
WARNING
oil pipes (pipes in both the cylinder block and
cylinder head).
25 WARNING
from entering the cylinder head oil supply galle-
ries.
Failure to follow this advice could block the oil
supply pipes, causing rapid camshaft damage.

16189 Check for gasket face bow using a ruler and a set of
Remove the cylinder head mounting bolts (25) . shims.
WARNING
When removing the cylinder head, take care not WARNING
to cause any damage to its gasket face as it pas-
ses the turbocharger above it.
Remove the cylinder head. This operation requires
two people.
For the cylinder head stripping procedure (see
Technical Note 3652A, 4-cylinder Cast Iron High
I - CLEANING
Pressure Common Rail Diesel Engine, 10A, En-
Clean the cylinder head. gine and peripherals, Rebuilding the cylinder
head ).
IMPORTANT
Do not scratch the aluminium joint surfaces. REFITTING
During the operation, wear: Bring the pistons to mid-stroke position to prevent
- goggles, the cylinder head.
- gloves. Fit the new cylinder head gasket.
Clean the gasket faces with DÉCAPJOINT to dissol- Refit the cylinder head.
ve off the parts of the seal still attached to the sump
and the cylinder block.
of engine, Tightening the cylinder head ) using a
angular tightening wrench.
Tighten to torque:
- the oil supply pipe bolt on the turbocharger
(22.5 Nm) ,
- the oil supply pipe bolt on the cylinder block
(22.5 Nm) ,
11A-162
F9Q, and 812
- the oil return pipe bolts (12 Nm) .
Refit:
(4 Nm) .
11A-163
F4R, and 776
WARNING
When removing and refitting the turbocharger the
repair procedures must be carefully applied to
ensure the system is sealed: FAILURE TO FOL-
LOW THESE INSTRUCTIONS COULD HAVE
SERIOUS SAFETY 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 ).
For the cylinder head gasket stripping procedure
(see Technical Note 6027A, F4 4-cylinder petrol
engine, 10A, Engine and peripherals, Rebuilding
the cylinder head ).
11A-164
K4J, and 730
Mot. 1448 Long nose pliers for (new or original) oil 10 Nm .

hose clips. decanter mounting bolts
in the pre-threaded hou-
Mot. 1453 Multiple-adjusting sings
port with retaining spark plugs 25 to 30 Nm
straps.
Mot. 1453-01 Additional winder nut the holes are already
on engine lift support threaded)
Mot. 1453.
Mot. 1672 Lower engine support. holes not threaded)
Mot. 1490-01 Locking and adjusting inlet manifold mounting 9 Nm

camshaft pulleys. bolts
Mot. 1202-01 Pliers for large hose battery cover mounting 4 Nm

clips. bolts

clips. REMOVAL
Mot. 1573 Cylinder head support Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 104 Cylinder head ali- Remove:
gning tool
Ele. 1382 Spark plug spanner
que 1.75 & 28 Nm + Disconnect the battery (see 80A, Battery, Battery:
square adapter 9-9.52 Removal - Refitting ).
Remove:
Mot. 1491 Camshaft oil seal fit- - the battery (see 80A, Battery, Battery: Removal -
ting tool. Refitting ),
Mot. 1632 Tool for fitting PTFE - the scuttle panel grille (see MR 371 Bodywork,
camshaft seal 55A, Exterior protection, Scuttle panel grille ).
Mot. 1669 Fitting cam follower

tappet.
Equipment required
Tightening torquesm
mounting bolts nos. 22, 12 Nm

23, 20 and 13 of the
cylinder head cover
oil decanter mounting 15 Nm

bolts (new) in the non-
threaded housings
11A-165
K4J, and 730
1 1
104343 19626
Remove: Set up the engine stand (1) Mot. 1448 .

Remove (Mot. 1453) ; and (Mot. 1453-01).

2
101876
104246
Remove the camshaft pulleys using the camshaft
Remove: pulley locking tool (2) Mot. 1672 (Mot. 1490-01).

IMPORTANT
Be careful of petrol splashing out when discon-
- the accessories belt (see 11A, Top and front of necting the fuel supply union.
If the stud is loosened with the nut (see Technical
Note 3887A, Replacing K9 - K4 camshaft pulley
studs, 11A, Top and front of engine, Camshaft ).
Remove:
Exterior protection, Front bumper ). - the injector rail protector,
- the fuel supply pipe from the injection rail.
Cooling circuit: Draining - Refilling ). Move the fuel supply pipe aside.
11A-166
K4J, and 730
8
6
10
11
18699
18666
Disconnect:
- the ignition coil connectors (8) ,
- the air temperature sensor connector (9) ,
7 (11) ,
- the catalytic converter upstream oxygen sensor
connector.
5
14889
Remove the bracket mounting bolt (4) .
Move the bracket to one side.

(5) .
Disconnect:
- the brake servo vacuum pipe (6) on the inlet mani-
fold side.
- connector (7) from the coolant temperature sensor,

- the water unit hoses using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
11A-167
K4J, and 730
12
15
13
14
104240 18706
Disconnect the injector connector (12) . Remove:
Unfasten clip (13) . - the lifting bracket (14) ,
Move the wiring harness to one side. - the inlet manifold mounting bolts (15) ,
Remove: - the inlet manifold.
- the plugs,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting ), 16
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting ).
17
101793
Remove:
- the catalytic converter/gearbox strut mounting bolts
(16) ,
Move the exhaust pipe to one side.
11A-168
K4J, and 730
18
18431
Remove:
- the oil decanter mounting bolts (18) ,
- the oil decanter.
19
19
103256
Remove:
- the rocker cover mounting bolts,
- detach the cylinder head cover vertically, tapping
the lugs (19) with a copper hammer.
WARNING
Do not damage the aluminium surfaces.
11A-169
K4J, and 730
14498
Remove the inlet and exhaust camshafts.
11A-170
K4J, and 730
20 using a wooden spatula.
WARNING
21 Do not allow this product to drip onto the pain-
twork.
Clean the cylinder head carefully to prevent
foreign bodies from entering the oilways.
Failure to follow this guideline could lead to the
blocking of the oilways, resulting in rapid and
serious damage to the engine.

Use a ruler and set of shims to check that there is no
gasket face bow.
Maximum distortion: 0.05 mm
14499
Remove: WARNING
- the hydraulic tappets (21) . Test the cylinder head to detect any possible cracks
For the cylinder head stripping procedure (see NT
Note: 3784A, 4 cylinder - K4 petrol engine, 10A, Engine
To prevent any risk of unpriming the hydraulic and peripherals, Rebuilding the cylinder head ).
tappets make sure that they are vertical. Position the pistons at mid-stroke to prevent any
contact with the valves when refitting the camshafts.
Remove:
Always degrease:
- the cylinder head mounting bolts,
- the combustion face of the cylinder head,
- the cylinder head. - the combustion face of the cylinder block.
Mount the cylinder head on the cylinder head moun-
ting (Mot. 1573).
Remove the cylinder head gasket from the cylinder

block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
- goggles,
- gloves.

ve off the parts of the seal still attached.
11A-171
K4J, and 730
23 24
22
14689 14499
Check that the centring dowel is present (22) on the Reprime the hydraulic tappets (hydraulic tappets
cylinder block. may be empty after a long down time).
Set up tool (Mot. 104) (23) on the cylinder block. To check if repriming is necessary, press the top of
the tappet (24) with your thumb.
REFITTING If the tappet piston depresses:
Fit the new cylinder head gasket. - immerse the thrust bearings in a container full of
diesel fuel,
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Tightening the cylinder Refit:
head ). - the valve rockers,
Tighten the cylinder head (see 11A, Top and front - the camshafts, lubricating the bearings.
of engine, Tightening the cylinder head ).
11A-172
K4J, and 730
I - CAMSHAFT MARKINGS
Inlet camshaft
101880
Position the groove (25) horizontally on the end of
the camshaft (groove below the centre line of the
camshaft).
The cams (26) for cylinder 1 must be located to the
right of the vertical axis (27) , flywheel end view.
11A-173
K4J, and 730
Exhaust camshaft
101881
Position the groove (28) horizontally on the end of
the camshaft (groove below the centre line of the
camshaft).
The cams (29) for cylinder 1 must be located to the
left of the vertical axis (30) , flywheel end view.
11A-174
K4J, and 730
31
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 at (31) from

the six cylinder head cover bearings.
The gasket faces on the cylinder head cover
must be clean, dry and free from grease (remove Refit the rocker cover.
any finger marks).
WARNING
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-175
K4J, and 730
II - TIGHTENING PROCEDURE
14497
- cylinder head cover mounting bolts 22, 23, 20
and 13 (8 Nm) ,
- cylinder head cover mounting bolts 1 to 12, 14
to 19 and 21 to 24 (12 Nm) .
Loosen in order mounting bolts 22, 23, 20 and 13.
Tighten to torque and in order mounting bolts nos.
22, 23, 20 and 13 of the cylinder head cover (12
Nm) .
11A-176
K4J, and 730
3
2
6 8
4
5 1
7
101869 18431
WARNING Tighten to torque and in order:

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

gasket face until it is reddish.
11A-177
K4J, and 730
32
106443
On the ignition coils, apply a bead (32) of FLUORI-
NATED GREASE 82 00 168 855 , 2 mm in diameter
to the inner edge of the high-tension cap.
Refit the plugs.
Torque tighten the spark plugs (25 to 30 Nm) using
the spark 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 holes not threaded)
(15 Nm) .
Always replace all the inlet manifold seals.
11A-178
K4J, and 730
1
6 3
14497-1
Tighten to torque and in order the inlet manifold
Refit:
- the throttle valve (see 12A, Fuel mixture, Throttle 33
valve: Removal - Refitting ),
unit: Removal - Refitting ).
III - REPLACING THE CAMSHAFT SEALS

There are two types of elastomer camshaft seal
which are easy to identify.
34
20256
The first type of elastomer seal is fitted with a spring
(33) and a lip seal (34) in a « V » shape.
11A-179
K4J, and 730
1 - Fitting first version camshaft seals
37
35
36
38
20257
The second type of elastomer seal is fitted with a flat 14892
lip seal (35) and a protector (36) (which also assists Fit the seals using tool (Mot. 1491) (37) and the old
in fitting the seal to the engine). nuts (38) .
Note:
Both 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-180
K4J, and 730
2 - Fitting the second type of seal to the camshaft
41
39 40
105531
18687
WARNING
It is very important to hold the protector (3 9)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (40) in order to prevent any oil
leaks once the seal is fitted to the engine.
41
21687
camshaft.
11A-181
K4J, and 730
21687-1 21687-3
Fit the protector, with a seal, to the camshaft. Screw on the collar nut until the cover touches the
cylinder head.
Remove the nut, cover, protector and threaded rod.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of en-
42
43 gine, Timing belt ).
WARNING
Follow the second timing belt refitting procedure.
Refit the accessories belt (see 11A, Top and front

of engine, Accessories belt: Removal - Refitting
).
21687-2
Fit the housing (42) and the collar nut (43) of tool
(Mot. 1632).
11A-182
K4J, and 730
15103-1
Refit:
- the new inlet camshaft sealing plugs using tool
(Mot. 1669) ,
- the new exhaust camshaft sealing plugs using tool
(Mot. 1669).
(4 Nm) .
11A-183
F9Q, and 804
Always respect the repair precautions (see 13B,
Special tooling required Diesel injection, Diesel injection: Repair precau-
tions ).
Remove:
engine mounting sup- - the battery (see 80A, Battery, Battery: Removal -
port with retaining Refitting ),
straps. - the engine covers,
Mot. 1453-01 Additional winder nut - the battery tray,

on engine lift support - the lower engine tie-bar (see 19D, Engine moun-
Mot. 1453. ting, Suspended engine mounting: Removal -
Refitting ).
Equipment required
Remove the catalytic pre-converter (see 19B, Ex-
cylinder head testing equipment haust, Catalytic Pre-converter: Removal - Refit-
ting ).
angular tightening wrench Remove:
Tightening torquesm engine, Accessories belt: Removal - Refitting) ,
Timing belt: Removal - Refitting).
bolts
IMPORTANT

- connect the diagnostic tool (After-Sales),
- establish dialogue with the injection computer,
plug kit.
105432
REMOVING - REFITTING Fit the engine stand using the (Mot. 1672).
Position the vehicle on a two-post lift (see 02A, Lif- Remove the (Mot. 1453) and the (Mot. 1453-01).
Remove:

Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling ).
WARNING
11A-184
F9Q, and 804
7
13
6
11
1 4
2 15
12
3
14
5
111887 111886
Disconnect:
- the vacuum pipe from the vacuum pump (11) ,

8
- the EGR connector (13) ,
10
- the coolant temperature sensor (14) ,
- the turbocharger vacuum pipes (15) .

9
111888
16
Disconnect:
17
- the oil vapour rebreathing pipe (1) , 17
- the air inlet duct (see 12A, Fuel mixture, Air inlet:
Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the throttle valve connector (5) ,
- the turbocharging pressure solenoid valve connec-
tor (6) , 111965
- the air flow sensor connector (7) , Disconnect:

- the rail pressure sensor connector (8) , - the camshaft sensor connector (16) ,
- the diesel pressure regulator connector (9) .
Remove:
Fit the blanking plugs.
- the injection rail protector (10) (see 13B, Diesel in-
jection, Injection rail protector ). Move the wiring harness to one side.
11A-185
F9Q, and 804
18
18
19
20
111889
Disconnect:
- the diesel return temperature sensor connector,
- the high pressure pump pressure regulator con-
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
to cause any damage to its gasket face as it pas-
Disconnect the cylinder head outlet water unit ho-
ses the turbocharger above it.
ses.
11A-186
F9Q, and 804
I - CLEANING
Clean the cylinder head.
IMPORTANT
21 During the operation, wear:
- goggles,
- gloves.
Clean the gasket faces with DECAPJOINT to dissol-

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

approximately 10 minutes, then remove residue
WARNING
21 oil galleries (galleries in both the cylinder block
and cylinder head).
WARNING
Protect the oil outlet duct to prevent any foreign
bodies from entering the cylinder head oilways.
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 II - CHECKING THE GASKET FACE
gas recirculation pipe.
Remove the mounting clip from the exhaust gas re- Check for gasket face deformation using a ruler and
circulation pipe. a set of shims.
Remove the cylinder head mounting bolts. The maximum deformation is 0.05 mm .
Remove the cylinder head.
WARNING
Regrinding is not permitted.

using a cylinder head testing equipment.
(see Technical Note 3652A, 4-cylinder Cast Iron

High Pressure Common Rail Diesel Engine, 10A,
Engine and peripherals, Rebuilding the cylinder
head) for the procedure for stripping down the cylin-
der head.
11A-187
F9Q, and 804
REFITTING
Bring the pistons to mid-stroke position to prevent
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
angular tightening wrench.
Refit the catalytic pre-converter (see 19B, Exhaust,
Catalytic Pre-converter: Removal - Refitting ).
Refit the timing belt (see 11A, Top and front of en-
gine, Timing belt: Removal - Refitting ).
of engine, Accessories belt: Removal - Refitting
).
(4 Nm) .
11A-188
K9K, and 732

IMPORTANT
Before carrying out any work on the injection sys-
Mot. 1202-01 Pliers for large hose tem, check using the diagnostic tool :
clips.
- that the injector rail is not under pressure,
Mot. 1202-02 Pliers for small hose - that the fuel temperature is not too high.
clips.
It is essential to follow the safety and cleanliness
Mot. 1448 Long nose pliers for advice specified in this document whenever work is
hose clips. carried out on this system (see 13B, Diesel injec-
tion, cleanliness guidelines ).

engine mounting sup- WARNING
port with retaining
straps. Procedure for removing the air inlet duct (risk of
leaking and slipping if this procedure is not obser-
Mot. 1453-01 Additional winder nut ved):
Mot. 1453. - detach the hose using the (Car. 1363) ,
- do not use degreaser, brake cleaning agents, or
Equipment required any other products,
- clean the bearing face on the intercooler and on
diagnostic tool
the hose with a dry, lint-free cloth,
hydraulic crane - Always replace the clip with a new one,
load positioner - place the clip in the same position if the hose is
not replaced,
- it is essential to replace the hose and/or the inter-
angular tightening wrench cooler if they are damaged,
Tightening torquesm REMOVAL
rocker cover mounting 10 Nm I - REMOVAL PREPARATION OPERATION

bolts
alternator mounting 21 Nm ting equipment, Underbody lift ).
bolts
Remove
air inlet duct clip 5.5 Nm - the front engine covers,
- the bonnet (see MR 371, Bodywork, 48A, Non-
side opening element, Bonnet ).
WARNING
Before starting work on the vehicle, obtain: Removal - Refitting ).
- a new plug kit (part no. 77 01 476 857) , Remove the engine undertray.
- some cleaning cloths (part no. 77 11 211 707) ,

- cleaning product (part no. 77 11 224 188) .
11A-189
K9K, and 732
104343
Remove:

55A, Exterior protection, Scuttle panel grille ),
- the air filter access panel mounting bolts (1) , 104175

Disconnect the turbocharger oil return pipe (4) .
Drain the cooling system via the radiator bottom ho-
- the scuttle panel mounting bolt (2) . se, using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
104246
Remove:
- the accessories belt (see 11A, Top and front of 19710

engine, Accessories belt ), Remove:
- the timing belt (see 11A, Top and front of engine, - the inner timing cover (5) mounting bolts,
Timing belt ).
- the inner timing cover.

tic converter ).
11A-190
K9K, and 732
19626 112815
01).
102473
Disconnect the air inlet pressure sensor connector
(6) .
Loosen clip (7) and (8) .
Remove the air inlet duct (9) .
11A-191
K9K, and 732
112811 112992
Pull the clip. Unclip injector rail protector cover (13) .
Remove:
- the mounting nut and bolt (14) from the injector rail
protector cover,
- the injection rail protector cover,
- the dipstick,
- the dipstick tube mounting bolts (15) .
Move the dipstick tube to one side.
112991
Make a mark (10) 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 (11) from the stainless steel pipe,
- the stainless steel pipe (12) .
112993
Disconnect:
- the injector connector (16) ,
11A-192
K9K, and 732
- the heater plugs connector (17) .
102267
112994 Remove the upper mounting bolt (25) from the alter-
Disconnect: nator.
- the connector (18) from the damper valve, Loosen lower alternator mounting bolt (26) .
- the cylinder marking sensor connector (19) , Tilt the alternator forward.
- the pressure regulation solenoid valve connector
(20) ,
- the flow regulation solenoid valve connector (21) ,
- the diesel temperature sensor connector (22) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (23) .
Remove the wiring harness clip mounting nut (24) .
11A-193
K9K, and 732
112656 113475
Pour cleaning product into a container. Remove:

- the mounting bolts (29) from the injector rail protec-
tor cover mounting bracket,
IMPORTANT
- the injector rail protector cover retaining bracket.
Wear protective gloves when using cleaning pro-
duct.
Soak the brush with cleaning product and clean the

fuel supply and return pipe unions.
Blast the cleaned areas with compressed air then

dry using new cloths.
IMPORTANT
Wear protective glasses.
WARNING
Do not blow compressed air once the fuel circuit 111748
is open, otherwise impurities may enter the sys-
Unclip the diesel evacuation pipe.
tem. Use wipes if necessary.
Remove:
Disconnect: - the injector rail protector support bolt and mounting
- the fuel supply pipe (27) , nuts (30) ,
- the injector rail protector support,
- the damper valve (see 12A, Fuel mixture, Dam-
per valve: Removal - Refitting ).
Note:
Make preparations for fuel outflow. Clean with
new cloths.
Fit the correct blanking plugs.
11A-194
K9K, and 732
112996
Disconnect the oil vapour rebreathing pipe (31) on

the rocker cover side.
Remove the air inlet duct (32) .
113476
Remove:
- the rocker cover mounting bolts (36) ,
- the rocker cover.

CONCERNED
112997
Disconnect:

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

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

19712
pump side,
Remove:
scuttle panel. - the cylinder head mounting bolts (37) ,
- the cylinder head using a hydraulic crane fitted
- the radiator top hose from cylinder head coolant with a load positioner.
outlet housing (35) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the turbocharging pressure adjustment solenoid

valve hose on the vacuum pump side,

valve hose on the pressure regulation valve side.
11A-195
K9K, and 732
REFITTING II - OPERATION FOR REFITTING PART

CONCERNED
I - REFITTING PREPARATION OPERATION Fit the new cylinder head gasket, centred by two
dowels.
1 - CLEANING Bring the pistons to mid-stroke position to prevent

Clean the cylinder head. the cylinder head.
IMPORTANT Note:
Wear goggles. from grease (avoid finger marks).
Wear gloves during the operation.
Refit the cylinder head using a hydraulic crane fit-
Clean the gasket faces with the product ted with a load positioner.
DÉCAPJOINT to dissolve the section of the gas-
ket which is still attached. Tighten the cylinder head (see 11A, Top and front
Apply the product to the section to be cleaned; of engine, Tightening the cylinder head ) using
wait approximately ten minutes, then remove the the angular tightening wrench.
residue using a wooden spatula.
Note:
WARNING The seal faces must be clean, dry and free from
oil pipes (pipes in both the cylinder block and
cylinder head).
Fit the new rocker cover gasket.

WARNING
from entering the cylinder head oil supply galle-
ries.
Failure to follow this advice could block the pipe,
causing rapid camshaft damage.
2 - CHECKING THE GASKET FACE
Check for gasket face deformation using a ruler and

a set of shims.
19712-1
WARNING
No regrinding of the cylinder head is permitted. Apply beads of (38) de RHODORSEAL 5661 2 mm
in diameter.
using cylinder head testing tool.
Note:
For the cylinder head stripping procedure (See
Technical Note 6006A, 4-cylinder Cast Iron High- Applying excess sealant could cause it to be
Pressure Common Rail Diesel Engine, 10A, En- squeezed out when parts are tightened. The mix-
gine and peripherals, Rebuilding the cylinder ture of the product and coolant can cause some
head ). components (engine, radiator) to deteriorate.
11A-196
K9K, and 732
Refit:
- the injector rail protector cover retaining bracket,
- the injector rail protector cover retaining bracket
mounting bolts.
Connect:
- the fuel supply pipe,
- the fuel return pipe.
Refit the upper alternator mounting bolt.
Torque tighten the alternator mounting bolts (21
Nm) .
Fit the wiring harness.
Refit the wiring harness clip mounting nut.
Clip on the wiring harness retaining clip.
Connect:
113476
Refit the rocker cover. - the rail pressure sensor connector,
Tighten to torque and in order the rocker cover - the diesel temperature sensor connector,
mounting bolts (10 Nm) . - the connector of the flow regulation solenoid valve,
Connect: - the connector of the pressure regulation solenoid
- the turbocharging pressure adjustment solenoid valve,
valve hose on the pressure regulation valve side. - the cylinder marking sensor connector,
- the connector on the damper valve,
valve hose on the vacuum pump side,
- the heater plug connector.
- the radiator top hose from the cylinder head coo-
lant outlet housing using (Mot. 1202-01) or (Mot. - the injectors' connector.
1202-02) or (Mot. 1448) ,
Refit:
scuttle panel. - the dipstick tube,
- the brake servo vacuum pipe on the vacuum pump - the dipstick tube mounting bolts.
side, - the dipstick,
- the scuttle panel hoses using (Mot. 1202-01) or - the injection rail protector cover,
(Mot. 1202-02) or (Mot. 1448) ,
- the injector rail protector cover mounting nut and
Refit the air inlet duct between the air filter unit outlet bolt,
and the turbocharger inlet.
Clip the injector rail protector cover.
Connect the oil vapour rebreathing pipe on the roc-
ker cover side. Refit:
Refit: - the clip on the stainless steel pipe if necessary,
- the damper valve (see 12A, Fuel mixture, Dam- - the stainless steel pipe on the hose, aligning the
per valve: Removal - Refitting ), marking,
- the injector rail protector support, - the air inlet duct clip between the turbocharger and
the intercooler.
- the mounting nuts and bolt of the injector rail pro-
tector support. Tighten to torque the air inlet duct clip (5.5 Nm) .
Clip the diesel evacuation pipe. Clip the stainless steel pipe to the turbocharger.
11A-197
K9K, and 732
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct between the air inlet flap and the
intercooler.
Tighten the clips.
Connect the air inlet pressure sensor connector.
Fit the (Mot. 1453) fitted with the (Mot. 1453-01).
Remove the engine stand (Mot. 1672).
Refit:
- the inner timing cover,
- the inner timing cover mounting bolts.
Connect the turbocharger oil return pipe.
Refit:

tic converter ),


Timing belt ).

- the scuttle panel mounting bolts.




Refit:
- the bonnet (see MR 371, Bodywork, 48A, Non-

side opening element, Bonnet ),
- the engine covers.
11A-198
Crankshaft seal at timing end Removal - Refitting 11A
M9R, and 700
CONCERNED
Tightening torquesm
crankshaft sealing ring 47 Nm

timing end
right-hand side stiffe- 21 Nm

ner mounting bolts
REMOVAL


Remove:
114853
tyres, Wheel: Removal - Refitting . Remove the crankshaft sealing ring using tool (2)
supplied in the spare parts kit for the new gasket.
101212
Remove:
- the right-hand side stiffener mounting bolts,
- the right-hand side stiffener (1) ,

11A-199
M9R, and 700

CONCERNED
114850
113656
Position the notches on the new sealing (3) opposite
the notches on the timing cover (4) .
Note:
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.
11A-200
M9R, and 700
114852
Using the tool supplied in the new gasket spare
parts kit tighten to torque the crankshaft sealing
ring timing end (47 Nm) .

Refit:
- the right-hand side stiffener,
- the right-hand side stiffener mounting bolts.
Tighten to torque the right-hand side stiffener
Refit:
tyres, Wheel: Removal - Refitting ).
11A-201
Cylinder head: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removal of the cylinder head requires removal of
the engine - gearbox assembly (see 10A, Engine
and peripherals, Engine - gearbox assembly: Re-
For removal of the cylinder head (see Technical
Note 6017A, M9R engine ).
REFITTING
For refitting the cylinder head (see Technical Note
Refit the engine - gearbox assembly (see 10A, En-
gine and peripherals, Engine - gearbox assem-
bly: Removal - Refitting ).
11A-202
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Engine
Gear- Type Suffix Bore Stroke Cubic Compression
Vehicle
box capacity
(mm) (mm) ratio
(cm 3)
JM0U
JM1N ND0 770
JM05
JM0U 9.8/1
F4R 82.7 93 1998
JM1M
DD0 771
JM1N
JM05
JM0W 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 (λ) octane
speed
rating)
(rpm)
F4R 770 / 750 ± 50 0.5 14.5 100 0.97<λ<1.03 Super

771 / unleaded
maximum maximum maximum
776 (octane
rating 95)
(1)for
a coolant temperature above 80˚C and after the (3)for the legal values, see specifications by country
engine speed has stabilised at 2500 rpm for approxi-
mately 30 seconds . (4)at 2000 rpm CO should be 0.3 % (maximum)
(2)octane rating 91 unleaded compatible
Temperature in ˚C ± 1 -10 25 50 80 110 120
Negative temperature coefficient air tem- 10454 2174 to 857 to 326 to 143 to 112 to
perature sensor (resistance in Ω) to 8623 1928 763 292 127 98
Negative temperature coefficient coolant 13588 2364 to 850 to 290 to 117 to 90 to 86

temperature sensor (resistance in Ω) to 11332 2140 772 275 111
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 bar ± 0.06
Minimum flow: 80 to 120 l/h
SAGEM Four coils

Primary resistance: tracks 1 and 2 approximately 0.5
Ω
Secondary resistance: track 1 and high voltage out-
put: 10.5 kΩ ± 1.5
2-track connector:
- 1: + 12 V supply
- 2: earth control
Ignition coils
BERU (F4R776 only) Four coils
Primary resistance: track 1 and 2 approximately 0.5
Ω
put: 6.70 kΩ ± 0.7
2-track connector:
- 1: + 12 V supply
- 2: earth control
SIEMENS - DEKA 4 Bi-jet solenoid injector

Resistance: 14.5 Ω ± 0.7 at 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors
SIEMENS - DEKA 7 Bi-jet solenoid injector
(F4R776 only) Resistance: 12 Ω ± 0.5 at 20˚C
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 with a new one whenever it is remo-
ved.
3-track connector:
- A: earth
- B: signal
Manifold pressure sensor - C: + 5 V supply
BOSCH Piezoelectric type sensor

(F4R776 only) Replace the seal with a new one whenever it is remo-
ved.
3-track connector:
- 1: + 5 V supply
- 2: earth
- 3: signal
Firing order - 1-3-4-2

no. 1 at flywheel end
Accelerator pedal potentio- CTS Dual gang potentiometer

meter
Resistance values:
- gang 1: tracks 3 and 5: 1700 Ω ± 900
- gang 2: tracks 2 and 6: 2850 Ω ± 2050
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 Ω at 23˚C
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 850 ˚C .
Heating resistor: 9 Ω at 20˚C
4-track connector:
- A: + heating resistor
- B: - heating resistor
- C: + signal
- D: - signal
Warm engine:
- Rich mixture > 800 mV
- Lean mixture < 50 mV
Fuel vapour absorber sole- SAGEM Resistance: 26 Ω ± 4 at 23˚C

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 INSTRUMENTS 3-track connector:

- A: earth
- B: + 5 V supply
- C: signal
Fault finding diagnostic tool CLIP only
12A-4
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
VDO Egas 5 Direct current geared electronic motor

60 mm diameter 6-track connector:
(F4R, and 770 or 771) - 1: potentiometer gang no. 1 signal
- 2: 5 V potentiometer supply
- 3: + motor
- 4: potentiometer gang no. 2 signal
- 5: - motor
- 6: common earth
Motor resistance: approximately 2.3 Ω at 23˚C
Potentiometer resistance:
tracks 2 and 6: 1000 Ω ± 250
Throttle valve
VDO EgasT Direct current geared electronic motor
Diameter 40 mm 6-track connector:
(F4R776 only) - 1: earth
- 2: Potentiometer signal 1
- 3: - motor
- 4: + motor
- 5: + 5 V potentiometer supply
- 6: Potentiometer signal 2
tracks 1 and 5: 1000 Ω ± 250
Camshaft dephaser solenoid AISIN It is controlled as all or nothing.

valve
(F4R, and 770 or 771) Resistance: 7.2 Ω ± 0.5 at 20˚C
2-track connector:
- 1: +12 V supply
- 2: earth
CHAMPION RC 87 Single electrode spark plugs

YCL
Gap: 0.90 mm ± 0.05
(F4R, and 770 or 771)
Torque: 25 to 30 Nm
Ignition spark plug
NGK PFR6G-9 Single electrode spark plugs
(F4R776 only) Gap: 0.90 mm ± 0.01
Torque: 25 to 30 Nm
Catalytic converter EBERSPÄCHER C175

(F4R, and 770 or 771 or 776)
12A-5
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
Equipment required
diagnostic tool
Engine
Gear- Type Suffix Bore Stroke Cubic Compression
Vehicle
box capacity
(mm) (mm) ratio
(cm 3)
JM0B
JM0H JH3 K4J 730 42 (70) 1390 10 : 1
JM1A
JM0C
JM0J DP0 761 79.5
JM1B
K4M 80.5 1598 9.8 : 1
JM0C
JM0J JR5 782
JM1B
Test carried out at idle speed(1)

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

0.5 14.5 100 unleaded
K4M 761 / 700 ± 40 0.97<λ<1.03
maximum maximum maximum (octane
782 rating 95)
(1)for
a coolant temperature above 80˚C and after the (3)for the legal values, see specifications by country
engine speed has stabilised at 2500 rpm for approxi-
mately 30 seconds . (4)at 2000 rpm CO should be 0.3 % (maximum)
(2)octane rating 91 unleaded compatible
Temperature in ˚C ± 1 -10 25 50 80 110 120
Negative temperature coefficient air tem- 10454 2174 to 857 to 326 to 143 to 112 to
perature sensor (resistance in Ω) to 8623 1928 763 292 127 98
Negative temperature coefficient coolant 13588 2364 to 850 to 290 to 117 to 90 to 86

temperature sensor (resistance in Ω) to 11332 2140 772 275 111
12A-6
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
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 bar ± 0.06
Minimum flow: 80 to 120 l/h
Ignition coils SAGEM Four coils

Primary resistance: tracks 1 and 2 approximately 0.5
Ω
put: 10.5 kΩ ± 1.5
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors SIEMENS - DEKA 4 Bi-jet solenoid injector

2-track connector:
- 1: + 12 V supply
- 2: earth control
Manifold pressure sensor SIEMENS - MAP03 Piezoelectric type sensor

Replace the seal with a new one whenever it is remo-
ved.
3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Firing order - 1-3-4-2

no. 1 at flywheel end
12A-7
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
Accelerator pedal potentio- CTS Dual gang potentiometer

meter
Resistance values:
- gang 1: tracks 3 and 5: 1700 Ω ± 900
- gang 2: tracks 2 and 6: 2850 Ω ± 2050
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 Ω at 23˚C
K4J
Upstream and DELPHIOSP+ Heating resistor: 10 Ω at 20˚C

downstream oxy-
4-track connector:
gen sensors
- C: + signal
- D: - signal
Warm engine:
12A-8
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
K4M
Upstream and BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaust gas temperature
downstream oxy- rises above 850 ˚C .
gen sensors
Heating resistor: 9 Ω at 20˚C
4-track connector:
- C: + signal
- D: - signal
Warm engine:
Fuel vapour absor- SAGEM Resistance: 26 Ω ± 4 at 23˚C

ber solenoid valve
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature JAEGER Negative temperature coefficient thermistor (see previous table)
sensor
Coolant tempera- JAEGER ELTH Negative temperature coefficient thermistor (see previous table)
ture sensor
or SILEA
Refrigerant sensor TEXAS INSTRU- 3-track connector:

MENTS
- A: earth
- B: + 5 V supply
- C: signal
Fault finding diagnostic tool CLIP only
12A-9
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
K4J
Throttle valve VDO EI Direct current geared electronic motor

- 1: common earth
- 3: - motor
- 4: + motor
tracks 1 and 5: 1000 Ω ± 250
K4M
Throttle valve VDO Egas 5 Direct current geared electronic motor

- 3: + motor
- 5: - motor
- 6: common earth
tracks 2 and 6: 1000 Ω ± 250
Camshaft depha- DELPHI It is actuated by an opening cyclic ratio.

ser solenoid valve
2-track connector:
- 1: +12 V supply
- 2: earth
12A-10
FUEL MIXTURE
Specifications 12A
K4M, and 761 or 782 – K4J, and 730
Ignition spark plug EYQUEMR FN 58 Single electrode spark plugs

LZ o r CHAMPION
Gap: 0.95 mm ± 0.05
RC 87 YCL
Torque: 25 to 30 Nm
Catalytic converter EBERSPÄCHER C150
12A-11
FUEL MIXTURE
Air inlet 12A
F4R, and 770 or 771
DIAGRAM OF THE AIR INTAKE CIRCUIT
4
5
6
2 3
102744
(1) Air intake sleeve

(2) Air resonator
(3) Air filter unit
(4) Throttle valve
(5) Intake manifold
(6) Injector holder shim
(7) Air intake
12A-12
FUEL MIXTURE
Air inlet 12A
K4J, and 730
Diagram of the air inlet circuit
1
7 8
102071
(1) Air intake trunking

(2) Air resonator
(3) Air filter box
(4) Air unit
(5) Throttle valve
(6) Intake manifold
(8) Air intake
12A-13
FUEL MIXTURE
Air inlet 12A
K4M, and 761 or 782
4
5
6 3
7
1
2
101190
(1) Air intake sleeve

(2) Air resonator
(3) Air filter box
(4) Throttle valve
(5) Intake manifold
(7) Air intake
12A-14
FUEL MIXTURE
Air inlet 12A
F9Q, and 812
114617
(1) Air inlet

(2) Air filter
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Engine stop flap
(7) Intercooler
12A-15
FUEL MIXTURE
Air inlet 12A
K9K, and 722
Air intake circuit diagram
5 4
3
7
2
8
102070
(1) Air intake trunking

(2) Air filter unit
(3) Exhaust gas recirculation unit
(4) Air resonator
(5) Metal air intake tube
(6) Air-to-air intercooler
(7) Turbocharger
(8) Air intake
12A-16
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) Intake distributor input
12A-17
FUEL MIXTURE
Air inlet 12A
K9K, and 728
4
3
5 7
8
1 2
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-18
FUEL MIXTURE
Air inlet 12A
F9Q, and 804
5 9 4 3 8
6
2
112269
(1) Air inlet

(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Damper flap
(7) Intercooler
(8) Air filter
(9) EGR solenoid valve
12A-19
FUEL MIXTURE
Air inlet 12A
K9K, and 732
8 5 3
112302
(1) Air inlet

(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Damper flap
(6) Air filter
(7) Intercooler
(8) Air resonator
12A-20
FUEL 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 REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING OPERATION FOR PART

CONCERNED
Remove the front bumper (see MR 371, Bodywork,
55A, Exterior protection, Front bumper ).

CONCERNED
115171
Position the air resonator.
Clip on the air resonator (4) then at (5) .
115171 II - FINAL OPERATION

Unclip:
Refit the front bumper (see MR 371, Bodywork,
- the air resonator (1) , 55A, Exterior protection, Front bumper ).
- the retaining tab from the air resonator, then the air
resonator (2) .
Remove the air resonator (3) .
12A-22
FUEL MIXTURE
Air filter: Replacement 12A
K4J, and 730
I - REPLACING THE FILTER ELEMENT
Remove the engine covers.
1
2
104548
Disconnect brake servo vacuum pipe (2) from the in-
101103 let manifold.
Remove:
- the air resonator mounting bolt (1) , WARNING
Do not damage the vacuum outlet on the inlet
- the air resonator housing.
manifold. If it is damaged, the inlet manifold will
need to be replaced.
Remove:
- air filter cover mounting bolts (3) ,
- the filter element.
II - REFITTING
12A-23
FUEL MIXTURE
Air filter: Removal - Refitting 12A
K4M – F4R – K9K – F9Q – M9R
Mot. 1608 Torque screwdriver.
Tightening torquesm

bolts
I - REMOVAL PRE PARATION OPERATION
104551
Cut out air filter access (3) .
Remove:
- the air filter access panel.
K4M, and 761 or 782 – F4R, and 770 or 771 or 776

– K9K, and 722 or 728 – F9Q, and 812
103629
Remove the lip seal (1) .
103630
Remove: 104549
- the mounting nuts (2) from the scuttle panel grille, Remove:
- the scuttle panel grille. - the mounting bolts (5) from the battery cover,
12A-24
FUEL MIXTURE
Air filter: Removal - Refitting 12A
K4M – F4R – K9K – F9Q – M9R
- the battery cover. III - REFITTING PREPARATION OPERATION
Note:
II - OPERATION FOR REMOVAL OF PART Clean the inside of the air filter unit.
CONCERNED
IV - REFITTING OPERATION FOR PART

CONCERNED
Refit the filter element into its cover.
WARNING
Correctly replace:
- the filter element in its cover,
- the « cover - filter element » assembly in the air
filter unit.
Non-filtered air may be directed to the engine if
101806 this is incorrectly positioned.
Remove the mounting bolts (6) from the cover.
Refit:
- the « cover - filter element » assembly,
- the cover mounting bolts.
V - FINAL OPERATION
K4M, and 761 or 782 – F4R, and 770 or 771 or 776

– K9K, and 722 or 728 – F9Q, and 812
Refit:
- the battery cover,
- the mounting bolts to the battery cover.

(4 Nm) using the (Mot. 1608).
104550
Remove:
- the « cover - filter element » assembly, Refit:
- the filter element from its cover. - the air filter access panel,
- the scuttle panel grille,
- the scuttle panel grille mounting nuts,
- the lip seal.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4J, and 730
Tightening torquesm 3
air filter unit mounting 9 Nm
bolt

bolts
REMOVAL
terminal.
104246
Remove:
1
2
104343
Removal
- the scuttle panel grilles (see Workshop Repair
Manual 371 Bodywork, 55A, Exterior protec-
tion, Scuttle panel grille ), 4
- the air filter access flap mounting bolts (1) ,
101103
Remove:
- the air resonator mounting bolt (4) ,
- the air resonator.
12A-26
FUEL MIXTURE
K4J, and 730
5
8
104548 101494
Disconnect brake servo vacuum pipe (5) from the in- Remove:
let manifold.
- the oxygen sensor connector (7) ,
- the retaining bracket (8) .
WARNING
manifold. If it is damaged, the inlet manifold will
need to be replaced.
Remove:
- air filter cover mounting bolts (6) ,
- the filter element.
101488
Remove air unit mounting bolts (9) .
Withdraw the air filter unit.
12A-27
FUEL MIXTURE
K4J, and 730
REFITTING
Replace:
- the throttle body seal each time it is removed using
grease to make fitting easier,
- the plastic rivets and clips every time they are re-
moved.
Tighten to torque the air filter unit mounting bolt (9
Nm) .
nal.
WARNING
Battery: Removal - refitting ).

(4 Nm)
12A-28
FUEL MIXTURE
F9Q, and 812 – K9K, and 722 or 728
Tightening torquesm - the engine covers,

- the battery.
bolts

bolts
REMOVAL
terminal.
1
2
104556
Disconnect the injection computer connectors (4) .
104343
F9Q, and 812 – K9K, and 728
Remove: Disconnect the air flowmeter connector.
- the scuttle panel grilles (see MR 371 Bodywork,

- the air filter access flap mounting bolts (1) , Remove:
- the air filter access panel, - the battery tray mounting bolts (5) ,
- the scuttle panel partition mounting bolt (2) . - the wiring harness strap (6) .
Unclip the wiring harnesses from the battery tray.
3 Remove the battery tray.
104246
Remove:
12A-29
FUEL MIXTURE
F9Q, and 812 – K9K, and 722 or 728
101811 104554
Remove the injection computer and its support (7) . Remove:
- the air inlet sleeve (9) ,
F9Q, and 812 – K9K, and 728 - the air ducts (10) .
104555
104553
Remove the pipes (8) from the turbocharger regula- Remove the air filter unit.
tion solenoid valve.
Move the solenoid valve to one side.
12A-30
FUEL MIXTURE
F9Q, and 812 – K9K, and 722 or 728
REFITTING
(21 Nm) .
nal.
WARNING

(4 Nm) .
12A-31
FUEL MIXTURE
F4R, and 770 or 771 or 776 – K4M, and 761 or 782
bolts

bolts
REMOVAL
terminal.
104246
Remove the battery.
Remove:
1
2
5
104343
Remove:
- The scuttle panel grilles (see MR 371 Bodywork,
6
101822
Remove:
- the wiring harness strap (6) .
Remove the battery tray.
12A-32
FUEL MIXTURE
F4R, and 770 or 771 or 776 – K4M, and 761 or 782
101811 101808
Remove the injection computer and its support (7) . Remove:
8 - the air ducts (10) ,
REFITTING
(21 Nm) .
nal.
WARNING

(4 Nm) .
104241
Unfasten clips (8) .
Remove the air duct.
12A-33
FUEL MIXTURE
K9K, and 732 – F9Q, and 804
Tightening torquesm - the engine covers,

- the battery.
bolts

bolts
5
REMOVAL
terminal.
6
7
4
1
2
112659
Unclip:
104343 - the wiring harness for the computer connector,
Remove: - the wiring harness from the turbocharger regulation
solenoid valve,
55A, Exterior protection, Scuttle panel grille ), - the wiring harness (5) .
- the air filter access panel mounting bolts (1) , Remove:
- the air filter access panel, - the computer support upper mounting bolt,
- the scuttle panel partition mounting bolt (2) . - the mounting bolts (6) from the computer support,
- the injection computer with its support,
- the mounting bolts (7) from the battery tray,
- the wiring harness mounting bolt (8) .
3 Remove the battery tray.
Disconnect the air flowmeter connector.
104246
Remove:
12A-34
FUEL MIXTURE
K9K, and 732 – F9Q, and 804
104555 104553
Move the turbocharger regulation solenoid valve (9) Remove the air filter unit.
to one side.
REFITTING
11 Proceed in the reverse order to removal.
(21 Nm) .
nal.
10
WARNING
11 Tighten to torque the battery cover mounting bolts
(4 Nm) .
104554
Remove:
- the air ducts (11) .
12A-35
FUEL MIXTURE
M9R, and 700
Tightening torquesm
air filter unit air outlet 5.5 Nm

pipe clip on the air flow-
meter side

mounting bolts

mounting bolts

bolts
REMOVAL

Position the vehicle on a two-post lift (see 02A, Lif- 112659
Disconnect:
Remove
- the injection computer connectors (1) ,
- the battery (see 80A, Battery, Battery: Removal - - the air flowmeter connector,
Refitting ).
- the turbocharger regulation solenoid valve connec-
tor.
Unclip:
- the wiring harness (2) from the injection computer

connector,

nal,
- the wiring harness from the turbocharger regulation

solenoid valve and air flowmeter,
- the turbocharger regulation solenoid valve on the

air filter unit,
- the wiring harness from the injection computer con-

nectors, turbocharger regulation solenoid valve
and air flowmeter.
Remove:
- the mounting nut (4) from the wiring harness.
Remove the battery tray with the injection computer

support.
12A-36
FUEL MIXTURE
M9R, and 700
112658
114933
Remove:
(5) ,
- the engine accessories unit cover,


Refitting ).
102365
Remove:
115585

cessories unit.

Remove:
- the clips (8) ,

12A-37
FUEL MIXTURE
M9R, and 700
114847 115019
Undo the air filter unit air outlet pipe clip (12) on the Remove the « air inlet scoop - anti-noise air pipe - air
air flowmeter side. filter unit inlet air pipe » assembly (14) .
Disconnect the air filter unit air outlet pipe on the air
flowmeter side. II - OPERATION FOR REMOVAL OF PART
CONCERNED
115171
Remove the air resonator (13) . 115020
Remove air filter unit (15) .
12A-38
FUEL MIXTURE
M9R, and 700
REFITTING Fit the wiring harness.

Refit:
I - REFITTING PREPARATION OPERATION - the wiring harness mounting nut,
- the battery tray mounting bolts.
Note: Tighten to torque the battery tray mounting bolts
(21 Nm) .
Check that the air filter unit rubber contact studs
are all in position. Clip:
- the wiring harness for the injection computer con-
nectors, turbocharger regulation solenoid valve
and air flowmeter,
CONCERNED
- the turbocharger regulation solenoid valve on the
Refit the air filter unit.
air filter unit,
solenoid valve and air flowmeter,
Connect the air filter unit air outlet pipe on the air
flowmeter side.
nal,
Tighten to torque the air filter unit air outlet pipe
- the wiring harness to the injection computer con-
clip on the air flowmeter side (5.5 Nm) .
nector.
Refit: Connect:
- the « air inlet scoop - anti-noise air pipe - air filter
unit inlet air pipe » assembly, tor,
- the air resonator, - the air flowmeter connector,
- the front end panel, - the injection computer connectors.
- the front end panel upper mounting bolts, Refit:
- the front end panel lower mounting bolts. - the battery (see 80A, Battery, Battery: Removal -
Tighten to torque: Refitting ),
- the front end panel lower mounting bolts (44 - the engine protectors.
Nm) , Perform the following operations:
- the front end panel upper mounting bolts (21 - Adjust the xenon headlights (if fitted to the vehicle),
Nm) . (see 80C, Xenon bulbs, Xenon headlight: Ad-
Clip on the air inlet scoop. justment ),
Connect the screen washer pipes. - Adjust the headlights (see 80B, Headlights,
Refit the clips.
Connect the engine accessories unit connectors.
Refit:
Refitting ),
- the engine accessories unit mounting bolts,
- the battery tray with the injection computer support.
12A-39
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
F9Q, and 812
inlet duct mounting 8 Nm
bolts
inlet duct nut 21 Nm

bolts
REMOVAL
Disconnect the battery, starting with the negative 104246
terminal. Remove:
1
104343
Remove:
- the scuttle panel grilles (see Workshop Repair
Manual 371 Bodywork, 55A, Exterior protec-
tion, Scuttle panel grille ),
4
- the air filter access panel securing bolts (1) ,
101893
Disconnect the turbocharging pressure sensor (4) .
12A-40
FUEL MIXTURE
F9Q, and 812
REFITTING
6
5
101892
Loosen the clip (5) . 101884

Replace the seal.
Disconnect the air inlet hose.
Replace the inlet duct.
Move aside the air inlet hose.
Tighten to torque in order:
Disconnect the vacuum hose from the (6 )
- the inlet duct mounting bolts (8 Nm) ,
diaphragm.
- the inlet duct nut (21 Nm) .
nal.
7
WARNING

(4 Nm) .
101884
Remove:
- inlet duct mounting bolts (7) ,
- the air inlet duct (8) mounting nut,
- the air inlet duct.
12A-41
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 nut 21 Nm - the inlet duct mounting bolts (25 Nm) ,
- the inlet duct nut (21 Nm) .
bolts To refit, proceed in the reverse order to removal.
nal.
REMOVAL
Remove the engine covers. WARNING
Disconnect the battery, starting with the negative Carry out the necessary programming (see 80A,
terminal. Battery: Removal - Refitting ).

(4 Nm) .
111887
Disconnect:
- the oil vapour rebreather pipe,
- 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-42
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
K4J, and 730
Tightening torquesm
inlet manifold bolts 9 Nm
throttle valve bolts 13 Nm
air unit bolts 9 Nm

bolts
REMOVAL

terminal.
Remove:
- the air filter unit (see 12A, Fuel mixture, Air filter 101794
unit ),
Remove:
- the throttle valve (see 12A, Fuel mixture, Throttle - the inlet manifold bolts,
valve ).
- the manifold.
REFITTING
2 Always replace all of the seals with new ones.
101100
Disconnect:
- the manifold pressure sensor (1) ,
- the ignition coils (2) ,
- the air temperature sensor (3) .
12A-43
FUEL MIXTURE
K4J, and 730
7
5
3
4
101794
bolts (9 Nm) .
Torque tighten:
- the throttle valve bolts (13 Nm) ,
- the air unit bolts (9 Nm) .
nal.
WARNING
Torque tighten the battery cover mounting bolts

(4 Nm) .
12A-44
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782
Tightening torquesm
3
inlet manifold bolts 9 Nm
motorised throttle valve 13 Nm

bolts

bolts
REMOVAL
terminal. 104246
Remove:
1 - the scuttle panel partition.

2
104343
Remove:
Exterior protection, Scuttle panel grille ),
101807
Remove:
- the air duct (4) .
12A-45
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782
10
7
9
5 8 8
102735 101795
Disconnect: Disconnect the wiring harness (8) .
- the throttle valve connector (5) , Move the wiring harness to one side.
- the brake servo vacuum pipe (6) on the inlet mani- Disconnect the fuel inlet pipe (9) from the injector
fold. rail.
WARNING IMPORTANT
manifold. If it is damaged, the inlet manifold will During this operation, it is essential to:
need to be replaced. - refrain from smoking or bringing red hot objects
close to the working area,
Disconnect the fuel vapour recirculation pipe (7) on
the throttle valve. - beware of fuel splashes when disconnecting the
supply union,
- protect sensitive areas from fuel outflow.
IMPORTANT
Unclip fuel vapour recirculation pipe (10) from the in-

let manifold.
12A-46
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782
7
6
8 5
1 2
102726 102726
Remove the inlet manifold bolts. Tighten to torque and in order the inlet manifold
bolts (9 Nm) .
ON THE WORKBENCH Torque tighten the motorised throttle valve bolts
(13 Nm) tightening the bolts evenly.
Remove the throttle valve.
nal.
REFITTING
Always replace all of the seals with new ones.
WARNING
Proceed in the reverse order to removal. Carry out the necessary programming (see 80A,

(4 Nm) .
12A-47
FUEL MIXTURE
F4R, and 776
Tightening torquesm
inlet manifold mounting 21 Nm

bolts
4
motorised throttle valve 21 Nm
mounting bolts

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

Remove the petrol vapour rebreather pipe (2) .
Disconnect the motorised throttle valve connector.
6
106787
Disconnect:
- the turbocharging pressure sensor connector (5) ,
- the vacuum pipe (6) from the brake servo,
- (7) the oil vapour recirculation pipe.
106272
Remove the air pipe (3) between the turbocharger

and the intercooler.
12A-48
FUEL MIXTURE
F4R, and 776
REFITTING
Be sure to replace all the seals with new ones when
they are removed.
Proceed in the reverse order to removal
9 13 10
8
106271
Disconnect:
11 14 12
- the injector rail petrol supply pipe (8) ,
- the injector connectors. 106337

IMPORTANT
Torque tighten the motorised throttle valve moun-
During this operation, it is essential to:
- refrain from smoking or bringing red hot objects nal.
- beware of fuel splashes when disconnecting the
supply union, WARNING

IMPORTANT (4 Nm) .
Pull the electric wiring harness to one side.
106337
Remove the inlet manifold bolts.
12A-49
FUEL MIXTURE
M9R, and 700

clips.

clips.

hose clips.
Tightening torquesm
inlet manifold studs 9 Nm

104343
inlet manifold mounting 25 Nm Remove:
bolts and nuts
- the mounting bolts (1) from the air filter access pa-
bolt mounting the dips- 10 Nm nel,
tick guide on the inlet - the air filter access panel,
manifold
front end panel lower 44 Nm tion.
mounting bolts

mounting bolts
REFITTING

Removal - Refitting ). 104246
Remove the scuttle panel grille (see MR 371 Bo- Remove:
grille ).
Refitting ).
12A-50
FUEL MIXTURE
M9R, and 700
115585
cessories unit.
Remove:
114933
Unclip the air inlet scoop (4) . - the clips (8) ,
102365
Remove:
112658
Remove: - the front end panel.

(5) ,
12A-51
FUEL MIXTURE
M9R, and 700
115723 115716
Remove: Fit a hose clamp on the coolant outlet hose (13) from
the EGR cooler.
per valve: Removal - Refitting ), Remove the clip (14) from the EGR cooler coolant
- the rigid EGR pipe between the EGR solenoid val- outlet hose using the (Mot. 1202-01) , (Mot. 1202-
ve and EGR cooler (see 14A, Emission control, 02) or (Mot. 1448).
Rigid EGR pipe: Removal - Refitting ), Disconnect the coolant outlet hose from the EGR
- the EGR solenoid valve (see 14A, Emission con- cooler.
trol, Exhaust gas recirculation solenoid valve:
Removal - Refitting ), II - OPERATION FOR REMOVAL OF PART
- the « oil filler cap - dipstick » assembly (11) , CONCERNED
- the dipstick guide tube mounting bolt (12) ,

- the dipstick guide tube.
Plug the opening of the dipstick guide tube on the
cylinder block.
115724
Unpick the wiring harness on the inlet manifold.

Remove:
- the inlet manifold mounting nuts (15) ,
- the inlet manifold mounting studs,
12A-52
FUEL MIXTURE
M9R, and 700
- the inlet manifold, II - REFITTING OPERATION FOR PART
CONCERNED
- the inlet manifold seal.
REFITTING

Clean the mating faces of:
- the inlet manifold in case of reuse,
WARNING
115724
Refit:
- the new inlet manifold seal,
Finger tighten the new studs until they make contact
with the inlet manifold.
Tighten to torque the inlet manifold studs (9 Nm) .
Tighten by hand until secure:
- the inlet manifold mounting nuts,
- the inlet manifold mounting bolts.
- the inlet manifold mounting nuts and bolts (15
Nm) ,
- the inlet manifold mounting bolts and nuts (25
Nm) .
Note:
the torque for mounting bolt 7 is given as an
example.
12A-53
FUEL MIXTURE
M9R, and 700
III - FINAL OPERATION - the scuttle panel partition,
Clip the wiring harness onto the inlet manifold. - the scuttle panel partition mounting bolts,
Connect the coolant outlet hose to the EGR cooler. - the air filter access panel,
Fit the clip to the EGR cooler coolant outlet hose - the air filter access panel mounting bolts,
using the (Mot. 1202-01) , (Mot. 1202-02) or (Mot.
1448).
Remove the hose clamp on the EGR cooler coolant - the front bumper (see MR 371, Bodywork, 55A,
outlet hose.
Remove the plug from the dipstick guide tube ope- Refitting ),
ning on the cylinder block. - the engine undertray.
Lubricate the new dipstick guide tube seal with engi- Connect the battery (see 80A, Battery, Battery: Re-
ne oil. moval - Refitting ).
Refit the dipstick guide tube into the cylinder block. Refit the engine protectors.
Finger tighten the mounting bolts until they are in Perform the following operations:
contact with the dipstick guide.
- Fill the cooling system (see 19A, Cooling, Cooling
Tighten to torque the bolt mounting the dipstick system: Draining - Refilling ),
guide on the inlet manifold (10 Nm) .
- Bleed the cooling system (see 19A, Cooling, Coo-
Refit: ling system: Bleeding ),
- the « oil filler cap - dipstick » assembly, - Adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon headlights, Xenon headlight:
- the EGR solenoid valve (see 14A, Emission con-
Adjustment ),
trol, Exhaust gas recirculation solenoid valve:
Removal - Refitting ), - Adjust the headlights (see 80B, Headlights,
- the rigid EGR pipe between the EGR solenoid val-
ve and EGR cooler (see 14A, Emission control,
Rigid EGR pipe: Removal - Refitting ),
per valve: Removal - Refitting ),
Tighten to torque:
Nm) ,
- the front end panel upper mounting bolts (21
Nm) .
Connect the screen washer pipes.
Refit the clips.
Refit:
12A-54
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4J, and 730
Tightening torquesm
injector holder shim 25 Nm

mounting bolts 11 and
12
injector holder shim 21 Nm

mounting bolts 13 and
20
timing upper cover bolt 44 Nm

1
suspended mounting 44 Nm
bolt
101801
battery cover mounting 4 Nm Remove nuts (1) securing the injector rail guard.
bolts
REMOVAL
terminal.
Remove the inlet manifold (see 12A, Fuel mixture,
Inlet manifold ).
3
IMPORTANT
2
During this operation, it is essential to: 4
3
- refrain from smoking or bringing red hot objects
- expect fuel splashes when disconnecting the 101802
supply union,
Disconnect:
- the fuel supply union (2) ,
- the injectors (3) ,
IMPORTANT - the pinking sensor (4) .
12A-55
FUEL MIXTURE
K4J, and 730
REFITTING
9 10
12 16
7 11
19 15
8
17
13
5
20 18 14
101792
The injector holder shim seal must always be repla-

6 ced.
101493 Insert all the mounting bolts.
Remove bolts (5) securing the injector rail.
Lie the injector holder shim flat against the upper ti-
ming cover and tighten bolt (8) finger-tight.
Pull the injection rail gently towards yourself to re-
move it. Lie the injector holder shim flat against the suspen-
ded engine mounting and tighten bolt (9) finger-tight.
Remove:
Position the injector holder shim against the (10)
- the nut (6) securing the wiring harness, shims on the rocker cover.
- the dipstick guide tube mounting (7) . Tighten to torque and in order:
- injector holder shim mounting bolts 11 and 12

(25 Nm) ,
- injector holder shim mounting bolts 13 and 20

(21 Nm) .
Tighten to torque:
- the timing upper cover bolt (44 Nm) .
- the suspended mounting bolt (44 Nm) .

101792 nal.
Remove:
WARNING
- the mounting bolt (9) from the suspended engine
mounting cover, Carry out the necessary programming (see 80A,
- the mounting bolt (8) ,
- the injector holder shim mounting bolts. (4 Nm) .
12A-56
FUEL MIXTURE
K4M, and 761 or 782
Tightening torquesm
bolts 5 and 6 of the 25 Nm

injector holder shim
bolts 7 to 14 of the injec- 21 Nm

1
tor holder shim
suspended mounting 44 Nm
bolt
upper timing cover bolt 44 Nm

bolts 2
REMOVAL
terminal.
101810
Remove the inlet manifold (see 12A, Fuel mixture, Disconnect the injectors (1) .
Inlet manifold ).
Remove:
IMPORTANT
- the bolts (2) securing the injector rail,
- the injector rail, pulling it carefully towards you.
- expect fuel splashes when disconnecting the
supply union,
IMPORTANT
102303
Remove:
- the mounting bolt (3) from the suspended engine
mounting cover,
- the mounting bolt (4) ,
- the injector holder shim mounting bolts.
12A-57
FUEL MIXTURE
K4M, and 761 or 782
REFITTING
6
9 5
13
14 10
7 11
12 8
3
102303

ced.
Fit all the mounting bolts.
ming cover and tighten the bolt (3) finger-tight.
Lie the injector holder shim flat against the suspen-

ded engine mounting and tighten the bolt (4) finger-
tight.
- bolts 5 and 6 of the injector holder shim (25 Nm)

,
- bolts 7 to 14 of the injector holder shim (21 Nm)

.
Tighten to torque:
- the suspended mounting bolt (44 Nm) ,
- the upper timing cover bolt (44 Nm) .

nal.
WARNING

(4 Nm) .
12A-58
FUEL MIXTURE
F4R, and 770 or 771
Tightening torquesm
bolts 7 and 8 of the 25 Nm

injector holder shim
bolts 9 to 16 of the injec- 21 Nm

tor holder shim
bolt 6 from the suspen- 44 Nm

ded mounting
1
upper timing cover bolt 44 Nm
5

bolts
Remove nuts (1) securing the injector rail guard.
REMOVAL
terminal.
3
Inlet manifold ).
IMPORTANT
2
supply union, 102728
- protect sensitive areas from fuel outflow. Disconnect:
- the fuel supply union (2) ,
IMPORTANT - the injection (3) wiring harness.
12A-59
FUEL MIXTURE
F4R, and 770 or 771
REFITTING
4
12
8
7
11
15
16
13
9
5 10
14
101792
ced.
Fit all the mounting bolts.
102730
Remove: ming cover and tighten the bolt (5) finger-tight.
- the bolts (4) securing the injector rail, Lie the injector holder shim flat against the suspen-
- the injector rail, pulling it carefully towards you. ded mounting and tighten the bolt (6) finger-tight.
- bolts 7 and 8 of the injector holder shim (25 Nm)
,
- bolts 9 to 16 of the injector holder shim (21 Nm)
.
Tighten to torque:
- bolt 6 from the suspended mounting (44 Nm) ,
- upper timing cover bolt 5 (44 Nm) .
nal.
101792
Remove: WARNING
- the mounting bolt (6) from the suspended engine Carry out the necessary programming (see 80A,
mounting cover, Battery: Removal - Refitting ).
- the mounting bolt (5) , Tighten to torque the battery cover mounting bolts
- the injector holder shim mounting bolts. (4 Nm) .
12A-60
FUEL MIXTURE
Manifolds: Removal - Refitting 12A
F9Q, and 812
REFITTING
Tightening torquesm Be sure to replace the manifold gaskets.
For studs removed when removing the manifolds:
manifold mounting 8 Nm
studs - apply LOCTITE FRENBLOC to the cylinder head
thread holes inlet,
manifold mounting nuts 28 Nm
- wipe any run-off after refitting the studs,
battery cover mounting 4 Nm - Tighten to torque the manifold mounting studs (8
bolts Nm) .
Refit the manifolds.
REMOVAL Tighten to torque the manifold mounting nuts (28
Disconnect the battery, starting with the negative Nm) .
terminal. Proceed in the reverse order to removal.
Remove: Connect the battery, starting with the positive termi-
- the inlet duct (see 12A, Fuel mixture, Inlet duct ), nal.
- the exhaust gas recirculation unit (see 14A, Emis-

sion control, Exhaust gas recirculation unit ), WARNING
- the turbocharger (see 12B, Turbocharging, Tur- Carry out the necessary programming (see 80A,
bocharger ). Battery: Removal - Refitting ).

1 (4 Nm) .
104423
Remove:
- the engine lifting bracket (1) ,
- the manifold mounting nuts,
- the manifolds.
12A-61
FUEL MIXTURE
F9Q, and 804
Tightening torquesm
manifold mounting 8 Nm
studs
manifold mounting nuts 28 Nm

bolts
REMOVAL
terminal.
Put the vehicle on a lift.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
- the injector rail protector (see 13B, Diesel injec- 111872
tion, Injector rail protector: Removal - Refitting
),
- the exhaust gas recirculation unit (see 14A, Emis-
sion control, Exhaust gas recirculation unit ),
- the exhaust gas recirculation pipe,
- the catalytic pre-converter (see 19B, Exhaust, Ca-
talytic pre-converter: Removal - Refitting ),
- the starter motor (see 16A, Starting-charging,
Starter motor: Removal - Refitting ),
bocharger: Removal - Refitting ).
111873
Remove:
- the Front Turbocharger Exhaust gas temperature
sensor,
- the manifold mounting nuts,
- the exhaust manifold (1) ,
- the inlet manifold (2) .
12A-62
FUEL MIXTURE
F9Q, and 804
REFITTING
Be sure to replace the manifold gaskets.
For studs removed when removing the manifolds:
- apply LOCTITE FRENBLOC to the cylinder head
thread holes inlet,
- wipe any run-off after refitting the studs,
- Tighten to torque the manifold mounting studs (8
Nm) .
Refit the manifolds.
Tighten to torque the manifold mounting nuts (28
Nm) .
nal.
WARNING
Refit the engine lifting bracket.

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 ).
(4 Nm) .
12A-63
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 722 or 728

3
EGR duct clips.
Tightening torquesm
exhaust manifold studs 9 Nm
exhaust manifold 26 Nm
mounting nuts
exhaust gas recircula- 21 Nm

tion unit mounting bolts
104246
metal air inlet tube 21 Nm
Remove:
mounting bolts
- the mounting bolts (3) from the scuttle panel parti-
lifting eye 21 Nm
tion,
bolts - the scuttle panel partition.
REMOVAL 7 5
8
Place the vehicle on a two-post lift.

terminal.
4
6
8
2 102074
1
Remove:
- the lifting eye (5) ,
- the metal air inlet tube (6) ,

104343 bocharger ),
Remove:
- the metal exhaust gas recirculation tube (4) ,
55A, Exterior protection, Scuttle panel grille ), - the exhaust gas recirculation unit mounting bolts
(7) ,
- the exhaust gas recirculation unit,
- the air filter access panel
- the manifold mounting nuts (8) ,
- the mounting bolt (2) from the scuttle panel moun-
ting. - the manifold.
12A-64
FUEL MIXTURE
K9K, and 722 or 728
REFITTING
8
4
2 7
6 3
1
5
20848-1
Tighten to torque the exhaust manifold studs (9 Connect the battery, starting with the positive termi-
Nm) . nal.
Replace the manifold gasket.
Refit the manifold. WARNING
Tighten to torque and in order the exhaust manifold
mounting nuts (26 Nm) .
Fit: Tighten to torque the battery cover mounting bolts
(4 Nm) .
- the exhaust gas recirculation unit,
- the new exhaust gas recirculation unit tube,
- the new clips on the new tube of the unit.
Tighten the new clips using the (Mot. 1567).
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolts (21 Nm) ,
- the metal air inlet tube mounting bolts (21 Nm) ,
- the lifting eye (21 Nm) .
Refit the turbocharger (see 12B, Turbocharging,
Turbocharger ).
12A-65
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782 – K4J, and 730

gen sensors.
1
2
Tightening torquesm
manifold nuts (K4J and 23 ± 3 Nm

K4M engines)
manifold nuts (F4R 18 Nm

engine)
104343
heat shield bolt 10 Nm
Remove:
oxygen sensors 45 Nm
bolts mounting the 21 Nm 55A, Exterior protection, Scuttle panel grille ),
exhaust pipe supports
onto the body - the air filter access panel mounting bolts (1) ,
stay bolt on the exhaust 8 Nm - the air filter access panel,

manifold
nut for the exhaust 21 Nm
manifold stay on the
gearbox
exhaust bracket nuts 20 Nm

bolts
REMOVAL
Position the vehicle on a two-post lift.
terminal.
104246
Remove:
- the mounting bolts (3) from the scuttle panel parti-

tion,
K4J
Remove the air filter unit (see 12A, Fuel mixture,

Air filter unit ).
12A-66
FUEL MIXTURE
F4R or K4M
Inlet manifold ).
6
5
4
101793
Remove exhaust bracket mountings (6) .
Remove the exhaust manifold stay (5) .
Note:
Mark with a pen the position of the exhaust rub-
101501 ber mounting bush supports on the body.
Disconnect the downstream oxygen sensor (4) .
102116
Remove mounting bolt (7) from the exhaust pipe ru-
bber mounting supports on the body.
12A-67
FUEL MIXTURE
102117 101797
Remove mounting bolt (8) from the silencer rubber Remove:
mounting bush on the body.
- the exhaust manifold mounting nuts,
Withdraw the exhaust pipe towards the rear of the
- the exhaust manifold.
vehicle.
ON THE WORKBENCH
10
101798
Remove oxygen sensor (9) using the (Mot. 1495-
01). 101502
Remove the upper heat shield (10) from the exhaust Remove the lower heat shield.
manifold.
REFITTING
Always replace:
- the manifold gaskets,
12A-68
FUEL MIXTURE
- the exhaust bracket gaskets,
- the manifold nuts.
101797
- the manifold nuts (K4J and K4M engines) (23 ±

3 Nm) ,
- the manifold nuts (F4R engine) (18 Nm) ,
- the heat shield bolt (10 Nm) ,
- the oxygen sensors (45 Nm) ,
- the bolts mounting the exhaust pipe supports

onto the body (21 Nm) ,
- the stay bolt on the exhaust manifold (8 Nm) ,
- the nut for the exhaust manifold stay on the

gearbox (21 Nm) (for F4R engines only),
- the exhaust bracket nuts (20 Nm) .

nal.
WARNING

(4 Nm) .
12A-69
FUEL MIXTURE
F4R, and 776
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
mounting nuts WARNING
the battery cover moun- 4 Nm Always replace:

ting bolts
- the exhaust manifold seal,
- the exhaust manifold mounting nuts.
REMOVAL
terminal.
Remove:
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
bocharger ).
21936
Remove:
12A-70
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
Removal and refitting of the turbocharger requi-
res careful application of the repair procedures to
ensure that the system is sealed correctly.
FAILURE TO COMPLY WITH THESE INSTRUC-
TIONS MAY HAVE SERIOUS SAFETY-RELA-
TED CONSEQUENCES FOR THE DRIVER.
12A-71
FUEL MIXTURE
K9K, and 732

EGR duct clips.
Tightening torquesm
mounting studs
mounting bolts

104246
Remove:
mounting bolts of the 35 Nm
rigid exhaust gas recir- - the scuttle panel partition mounting bolts (3) ,
culation pipe - the scuttle panel partition.
REMOVAL


112815
Disconnect the (4) connector from the air inlet pres-
sure sensor.
Loosen the clip (5) and move the air inlet duct (6) to
one side.
104343
Remove:
- the scuttle panel grille (see 371 Bodywork, 55A,
Exterior protection, Scuttle panel grille ).

12A-72
FUEL MIXTURE
K9K, and 732
112810 113842
Remove:
Disconnect the damper flap connector (7) .
- the clip (10) from the rigid exhaust gas recirculation
Remove: pipe using the (Mot. 1567) ,
- the mounting bolts (11) from the rigid exhaust gas
- the mounting bolt (8) from the damper flap moun-
recirculation pipe,
ting bracket,
- the rigid exhaust gas recirculation pipe (12) .

tic converter: Removal - Refitting ).

- the bolts securing the timing end lifting eye.
113558
Loosen the mounting bolts (13) on the exhaust gas
recirculation unit.
Move the exhaust gas recirculation unit to one side.
113475
Remove the mounting bolts (9) from the injection rail

protector cover mounting bracket.
12A-73
FUEL MIXTURE
K9K, and 732
CONCERNED
113561
Remove:
REFITTING

It is essential to clean the joint faces carefully.
12A-74
FUEL MIXTURE
K9K, and 732
CONCERNED
20848-1
Tighten to torque the exhaust manifold mounting Fit the new snap-fit clamp.
studs (9 Nm) .
Fit the new exhaust manifold gasket. WARNING
Refit: Ensure that you do not constrain the rigid
exhaust gas recirculation pipe before fitting the
- the exhaust manifold, snap-fit clamp.
- the exhaust manifold mounting nuts.
Tighten the mounting bolts of the rigid exhaust gas
Tighten to torque the exhaust manifold mounting recirculation pipe on the manifold until they make
bolts (26 Nm) . contact.
Adjust the rigid exhaust gas recirculation pipe in re-
III - FINAL OPERATION lation to the cooler support.
Fit the exhaust gas recirculation unit. Lock the snap-fit clamp of the rigid exhaust gas re-
circulation pipe using the (Mot. 1567).
Torque tighten the exhaust gas recirculation unit
mounting bolts (25 Nm) . Tighten to torque the mounting bolts of the rigid
exhaust gas recirculation pipe (35 Nm) .
Refit:
Refit:
- the new rigid exhaust gas recirculation pipe with a
new seal, - the injector rail protector cover retaining bracket
mounting bolts,
- the new exhaust gas recirculation pipe mounting
bolts, - the bolts securing the timing end lifting eye,
12A-75
FUEL MIXTURE
K9K, and 732
- the damper flap mounting bracket mounting bolt.
Connect the damper flap connector.
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Remove:
Refit the engine covers.
12A-76
FUEL MIXTURE
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool
Tightening torquesm Remove:
exhaust manifold studs 9 Nm - the battery (see 80A, Battery, Battery: Removal -
Refitting ),
exhaust manifold initial torque:
mounting nuts 18 Nm
exhaust manifold 30 Nm Removal - Refitting ).
mounting nuts
bolts mounting the rigid 35 Nm

EGR pipe on the EGR
cooler
bolts mounting the rigid 35 Nm

EGR pipe on the
exhaust manifold
bolt mounting the rigid 10 Nm

EGR pipe on the cylin-
der head

EGR pipe heat shield on
104343
the cylinder head
Remove:
EGR pipe heat shield on
nel,
the exhaust manifold
mounting bolts - the mounting bolt (2) from the scuttle panel parti-
tion.
mounting bolts
air filter unit air outlet 5.5 Nm

pipe clip on the air flow-
meter side

bolts
IMPORTANT
104246
Remove:
12A-77
FUEL MIXTURE
M9R, and 700

114847
Undo the air filter unit air outlet pipe clip (8) on the air
flowmeter side.
Disconnect the air filter unit air outlet pipe on the air
flowmeter side.
112659
Remove the front bumper (see MR 371 Bodywork,
Disconnect: 55A, Exterior protection, Front bumper: Removal
- Refitting ).
- the air flowmeter connector,

tor.
Unclip:
- the wiring harness (5) from the negative battery ter-

minal,
- the wiring harness from the injection computer con-

nector,

solenoid valve.
Remove:
- the mounting nut (7) from the wiring harness. 114933

Unpick the wiring harness from the injection compu-
ter connectors.

support.
12A-78
FUEL MIXTURE
M9R, and 700
102365
Remove:

112658
Remove:

(10) ,
- the engine accessories unit cover.
113280
115585

cessories unit.
Remove:
113295
- the clips (13) ,
Remove:
- the mounting bolt (16) from the rigid EGR pipe heat
Disconnect the screen washer pipes. shield on the exhaust manifold,
12A-79
FUEL MIXTURE
M9R, and 700
- the bolt (17) mounting the rigid EGR pipe heat II - OPERATION FOR REMOVAL OF PART
shield on the cylinder head, CONCERNED
- the bolt (18) mounting the rigid EGR pipe on the cy-
linder head.
Remove the heat shield from the rigid EGR pipe.
113279
Remove:
- the exhaust manifold spacers,
- the exhaust manifold,
- the exhaust manifold gasket.
113311
REFITTING
Remove the bolts (19) mounting the rigid EGR pipe
on the EGR cooler side. I - REFITTING PREPARATION OPERATION
Clean and degrease the mating faces of:
- the exhaust manifold if it is to be reused,
- the cylinder head face,
- of the rigid EGR pipe.
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) using a roller-type stud removal tool.
113281
Remove the bolts (20) mounting the rigid EGR pipe

on the exhaust manifold.
Remove the rigid EGR pipe.
Remove:
- the seal between the EGR cooler and the rigid

EGR pipe,
- the seal between the rigid EGR pipe and the ex-
haust manifold.
12A-80
FUEL MIXTURE
M9R, and 700
Refit:
- the new seal on the rigid EGR pipe, on the exhaust
manifold side,
- the new seal on the rigid EGR pipe, on the EGR
cooler side.
Fit the rigid EGR pipe.
- the bolts mounting the rigid EGR pipe on the ex-
haust manifold,
- the bolts mounting the rigid EGR pipe on the EGR
113279 cooler,
- the bolt mounting the rigid EGR pipe on the cylin-
der head.
Note:
Tighten to torque:
Check that the manifold gasket is positioned cor-
rectly. - the bolts mounting the rigid EGR pipe on the
EGR cooler (35 Nm) ,
Position the tab at (21) .
- the bolts mounting the rigid EGR pipe on the
Refit the new gasket on the exhaust manifold, as in- exhaust manifold (35 Nm) ,
dicated above. - the bolt mounting the rigid EGR pipe on the cy-
linder head (10 Nm) .
II - REFITTING OPERATION FOR PART Fit the heat shield.
CONCERNED
Refit:
Refit:
- the bolt mounting the rigid EGR pipe heat shield on
- the exhaust manifold, the cylinder head,
- the spacers. - the bolt mounting the rigid EGR pipe heat shield on
Fit the new exhaust manifold mounting nuts without the exhaust manifold.
tightening them. Tighten to torque:
- the bolt mounting the rigid EGR pipe heat
shield on the cylinder head (10 Nm) ,
- the bolt mounting the rigid EGR pipe heat
shield on the exhaust manifold (10 Nm) .
Refit:
Tighten to torque:
Nm) ,
113279
Pretighten in order and to torque the exhaust mani-
Nm) .
fold mounting nuts (initial torque: 18 Nm) .
mounting nuts (30 Nm) . Connect the screen washer pipes.
12A-81
FUEL MIXTURE
M9R, and 700
Refit the clips. - the scuttle panel grille (see MR 371 Bodywork,
Removal - Refitting ),
Refit: Refitting ).
- the engine accessories unit cover, Perform the following operations:

- the engine accessories unit mounting bolts, - Adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon bulbs, Xenon headlights: Ad-
- the front bumper (see MR 371 Bodywork, 55A, justment ),
Refitting ). - Adjust the headlights (see 80B, Headlights,
Connect the air filter unit air outlet pipe on the air
flowmeter side.
Tighten to torque the air filter unit air outlet pipe
clip on the air flowmeter side (5.5 Nm) .
Refit the battery tray with the injection computer sup-
port.
Position the injection computer connectors wiring
harness.
Refit:
- the wiring harness mounting nut,
(21 Nm) .
Fit:
- the turbocharger regulation solenoid valve wiring
harness,
nal,
nector.
Connect:
tor,
- the injection computer connectors.
Refit:
bocharger: Removal - Refitting ),
12A-82
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4J, and 730
throttle valve bolt 13 Nm
air filter unit bolts 9 Nm

bolts
REMOVAL
terminal. 104246
Remove:
1 - the scuttle panel partition mounting bolts (3) ,

2
4
104343
Remove:
- the air filter access flap,
6
101489
Remove the air filter unit (4) (see 12A, Fuel mixtu-
re, Air filter unit ).
Disconnect:
- the fuel vapour recirculation pipe (6) on the control
solenoid valve.
12A-83
FUEL MIXTURE
K4J, and 730
101800
Remove:
- the mounting bolts (7) ,
- the throttle valve.
REFITTING
Replace the throttle valve seal each time it is remo-

ved (use lubricant to make it easier to fit).
Tighten to torque:
- the throttle valve bolt (13 Nm) ,
- the air filter unit bolts (9 Nm) .

nal.
WARNING

(4 Nm) .
Reinitialise the programming of the stops (see MR

Fault finding, 17B, Petrol injection, Fault finding
-configurations and programming ).
12A-84
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782
throttle valve mounting 13 Nm

bolts

bolts
REMOVAL
terminal.
104246
Remove:
1
2
104343
Remove:
104241
12A-85
FUEL MIXTURE
F4R, and 770 or 771 – K4M, and 761 or 782
5 7
102735
Disconnect:
- the fuel vapour recirculation pipe (6) on the control

solenoid valve.
Remove:
- bolts (7) securing the throttle valve,
- the throttle valve.
REFITTING
Replace the throttle valve seal with a new one each
time it is removed.
Torque tighten the throttle valve mounting bolts

(13 Nm) distributing the tightening evenly.

nal.
WARNING

(4 Nm) .

12A-86
FUEL MIXTURE
F4R, and 776
- the motorised throttle valve.
Tightening torquesm
REFITTING
motorised throttle valve 10 Nm Be sure to replace all the sealing joints with new
mounting bolts
ones when they are removed.
REMOVAL
Tighten to torque the motorised throttle valve
Disconnect the battery, starting with the negative mounting bolts (10 Nm) .
terminal.
Remove the engine covers. nal.
WARNING
2 Battery: Removal - Refitting ).

106270
Disconnect:
- the air duct (1) and remove it,
- the fuel vapour rebreathing pipe (2) .
106633
Remove:
- motorised throttle valve mounting bolts (3) ,
12A-87
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
K9K, and 732
Tighten to the inlet flap bolts by hand until contact is
made.
Tightening torquesm
Tighten to torque the inlet flap mounting bolts (12
inlet flap mounting bolts 12 Nm Nm) .
Reconnect:
REMOVAL - the vacuum pipe to the brake servo,
Disconnect the battery, starting with the negative - the connector to the inlet flap
terminal. Refit the inlet duct.
1 nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal-Refitting ).
112815
Loosen the air duct clip (1) .
112810
Disconnect:
- the connector (2) from the air inlet flap,
- the vacuum pipe from the brake servo.
Move the inlet duct to one side.
Remove:
- the inlet flap mounting bolts (3) ,
- the inlet flap.
REFITTING
Refit the inlet flap.
12A-88
FUEL MIXTURE
Engine stop device 12A
F9Q, and 812
I - OBJECTIVE
The system is intended to stop the engine quickly after
the ignition is switched off.
3
II - DESCRIPTION
104953
- a solenoid valve (3) ,
1
101892
104421
1
- a vacuum (4) .
101894 III - OPERATING PRINCIPLE

The system consists of:
When the ignition is switched off, the solenoid valve
- a diaphragm (1) acting on the throttle, connects the vacuum and the diaphragm.
- a throttle (2) , The diaphragm is submitted to the vacuum; this closes
the air inlet flap.
The engine can no longer take in air and stops running

immediately.
12A-89
FUEL MIXTURE
Throttle valve: Cleaning 12A
F4R, and 770 or 771 or 776 – K4J, and 730 – K4M, and 761 or 782
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Note:
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, Part No. 77 11 171 437

on the inside of the cylinder until the dirt has been
cleared.
WARNING
Do not spray any cleaning product onto the out-
side of the cylinder, inside the spring housing or
onto the connector.
106899
Remove the external O-ring seals from the throttle
valve.
Note:
The Renault carburettor cleaning product, Part
No. 77 11 171 437 damages seals.
106900
Remove the cleaning product residue and the resi-

due of the dirt using a cloth, Part No. 77 11 211 707 .
12A-90
FUEL MIXTURE
Throttle valve: Cleaning 12A
106902
Use a hot air gun along the edge of the throttle valve
and then on the outside of the cylinder.
Note:
If the throttle valve is dropped or receives any
other impact, it will need to be replaced.
It is essential to replace the throttle valve O-rings.

Refit the throttle valve (see 12A, Fuel mixture,
Throttle valve ).
nal.
WARNING

Fault finding, 17B, Petrol injection, Replacement
of components ).
12A-91
TURBOCHARGING
Turbocharging pressure regulation valve 12B
F9Q, and 812
WARNING
It is essential to mark the supply and return pipes
1 on the turbocharging solenoid valve if the turbo-
charging solenoid valve is to be removed.
102480
103128
Axis Description
X Time in seconds
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.
The turbocharging pressure regulation valve is normal-

ly open. The engine operates as naturally aspirated.
The solenoid valve, normally closed, is supplied after

the engine is started following a delay which varies ac-
cording to the coolant temperature.
12B-1
TURBOCHARGING
F4R, and 776
21927
Pressure regulation valve diaphragm (1) is controlled
by solenoid valve (2) , which is in turn controlled by the
injection computer.
The pressure adjustment valve is closed in the rest po-
sition. 107010
The solenoid valve (2) is open in the rest position.

In the open position, the solenoid valve (2) compares Axis Description
the 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 the solenoid valve (2) is controlled, the turbo-
charging pressure signal (taken at the turbocharger
outlet) is diverted to the turbocharger inlet. Conse-
quently, the diaphragm is not submitted to turbochar-
ging pressure, the pressure adjustment valve closes.
The solenoid valve is open in the rest position and is
supplied when the engine is started. However, during a
timed delay which depends on coolant temperature,
the turbocharging pressure is limited and the engine
speed cannot exceed 2500 rpm.
This ensures that the oil has sufficient time to reach the
turbocharger bearings.
12B-2
TURBOCHARGING
K9K, and 728
The turbocharging pressure regulator solenoid valve is
closed in the rest position; it is powered once the engi-
ne is started and after a delay which is dependent on
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.
106553
101889
Turbocharging pressure regulation valve diaphragm

(1) is controlled by a turbocharging pressure regulator
solenoid valve (2) located on the computer mounting.
This solenoid valve is controlled by the injection com-
puter.
This solenoid valve may, according to engine operating

ranges, vary the underpressure 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-3
TURBOCHARGING
K9K, and 732
The turbocharging pressure regulation solenoid valve
is closed in the rest position; it is powered once the en-
gine is started and after a delay which is dependent on
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 underpressure 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-4
TURBOCHARGING
Pressure regulator: Checking 12B
F9Q, and 812
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.
TURBOCHARGING PRESSURE REGULATION

VALVE
1 - Check
21869
Remove the turbocharger (see 12B, Turbochar-

ging, Turbocharger ).
Note:
The check cannot be carried out with the turbo-
charger in place.
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).
Gradually apply an underpressure to the control val-

ve using the pressure and vacuum pump.
2 - Value
- For an underpressure value of 265 mbar , the rod

movement must be between 0.5 and 3.5 mm .
- For a pressure value greater than 600 mbar , the
rod is at the stop.
12B-5
TURBOCHARGING
K9K, and 722 or 724 or 728 or 732
WARNING K9K, and 724

pressure regulation valve rod in the turbocharger. 3 - Check

VALVE
K9K, and 722
1 - Check
21869
Note:
charger in place.
21869 Use a magnetic holder fitted with a dial gauge pla-
Remove the turbocharger (see 12B, Turbochar- ced on the end of the control valve stem (as far as
ging, Turbocharger ). possible in the axis of the stem).
Gradually apply pressure to the regulation valve
using a vacuum/pressure pump.
Note:
4 - Value
charger in place.
For an underpressure value of 0.6 bar , the rod mo-
Use a magnetic holder fitted with a dial gauge pla- vement must be 7 mm ± 0.5
Gradually apply pressure to the regulation valve
using a vacuum/pressure pump.
2 - Value
For a pressure value of 1.4 bar , the rod movement
must be 4.3 mm
12B-6
TURBOCHARGING
K9K, and 722 or 724 or 728 or 732
K9K, and 728 or 732
5 - Check
110748
Note:
charger in place.
Use a set of shims between the regulation valve rod

and the tappet (as far as possible into the rod shaft).
6 - Value
For an underpressure value of 0.5 bar , the rod gap
must be 1.7 mm
12B-7
TURBOCHARGING
F4R, and 776
WARNING
TURBOCHARGING PRESSURE CONTROL VALVE
1 - Check
22807

Note:
charger in place.

Gradually apply increasing pressure to the control

valve using the pressure and vacuum pump.
2 - Value
- For a pressure value of 331 mbar , the rod move-

ment must be 1 mm.
- For a pressure value of 544 mbar , the rod move-

ment must be 5 mm.
12B-8
TURBOCHARGING
F9Q, and 804
WARNING

VALVE
1 - Check
21869

Note:
charger in place.

2 - Value
- For an underpressure value of 200 mbar , the rod

movement must be between 2 and 4 mm .
- For an underpressure value of above 550 mbar ,
the rod movement must be between 8.6 and 11
mm .
12B-9
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728
Equipment required
diagnostic tool
2
turbocharger mounting 7 Nm
studs on the turbochar-
ger
studs on the exhaust
manifold
104343
Remove:
nuts on the exhaust
manifold - the scuttle panel grilles (see MR 371 Bodywork,
turbocharger oil inlet 22.5 Nm
pipe union on the cylin- - the air filter access panel mounting bolts (1) ,
der head - the air filter access panel,
hollow bolt securing the 22.5 Nm - the scuttle panel mounting bolt (2) .
turbocharger oil inlet
duct on the turbochar-
ger 3
bolts mounting the tur- 12 Nm
bocharger oil return pipe
on the turbocharger

tion solenoid valve heat
shield mounting bolts

bolts
104246
REMOVAL
Remove:
terminal.
12B-10
TURBOCHARGING
K9K, and 722 or 728
K9K, and 722 K9K, and 728
9 6 4
102081 110325
Disconnect air duct (4) . Pull out the clip.
Remove the air duct (5) from the turbocharger.
Disconnect:
- the turbocharging pressure sensor (6) ,
- the exhaust gas recirculation solenoid valve (7) , 11
1
- the turbocharging pipe (8) on the turbocharger,
10
- the pipe (9) between the turbocharging pressure
regulation valve and the air duct.
110323
Undo bolt (10) .
12B-11
TURBOCHARGING
K9K, and 722 or 728
12
13
15
16
14
110326 102076
Disconnect: Remove:
- the turbocharging pressure sensor connector (12) , - the exhaust bracket mountings (15) ,
- the exhaust gas recirculation solenoid valve con- - the strut mounting on the catalytic converter,
nector (13) ,
- the strut mountings on the gearbox,
- the turbocharging pipe (14) on the turbocharger,
- the strut (16) .
- the pipe between the turbocharging pressure regu-
lation valve and the turbocharging pressure regula-
tion solenoid valve. Note:
Mark with a pen the position of the exhaust rub-
ber mounting bush supports on the vehicle body.
12B-12
TURBOCHARGING
K9K, and 722 or 728
17
20
19
102116 102077
Remove mounting bolt (17) from the exhaust pipe si- Remove:
lentbloc supports on the body.
- the catalytic converter strut (19) ,
- the nuts (20) securing the catalytic converter to the
turbocharger,
- the catalytic converter.
18
21
22
102119
102117 Remove:
Remove mounting bolt (18) from the silencer silent- - the bracket (21) ,
bloc bracket on the body.
- the exhaust gas recirculation solenoid valve heat
Withdraw the exhaust pipe towards the rear of the shield (22) .
vehicle.
12B-13
TURBOCHARGING
K9K, and 722 or 728
23
25
24
102079
Remove:
- the oil inlet pipe (23) ,
- the oil return pipe (24) ,
- the turbocharger upper mounting nuts (25) ,
- the turbocharger lower mounting nut from under-
neath,
- the turbocharger.
12B-14
TURBOCHARGING
K9K, and 722 or 728
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 (see 80A, Battery, Battery: Re-
completely or partially blocked by scale. Also moval - Refitting ).
check that the sealing is perfect; if not, replace it.
Before starting, disconnect the 4 injectors (starting
the engine is prohibited).
WARNING Run the starter motor until the oil pressure warning
Check that the intercooler is not full of oil. If this light goes out (wait for a few seconds).
is the case, remove it, rinse with a cleaning agent
Switch off the ignition.
and then let it dry.
Reconnect the 4 injector connectors.
Start the engine.
WARNING
Let the engine idle then depress the accelerator se-
Always replace: veral times under no load.
- all the O-rings and both copper seals on the tur- Switch off the ignition.
bocharger oil inlet duct, Make sure that there are no oil leaks.
- the exhaust bracket seal. Connect the diagnostic tool and clear the stored
- any damaged heat shield. faults.
Make sure that all the exhaust pipe heat shields are
Tighten to torque: in place and properly secured.
- the turbocharger mounting studs on the turbo- Make sure that there is no contact with the underbo-
charger (7 Nm) , dy.
- the turbocharger mounting studs on the ex- Tighten to torque the battery cover mounting bolts
haust manifold (7 Nm) . (4 Nm) .
Position the turbocharger on the exhaust manifold.
Tighten to torque the turbocharger mounting nuts
on the exhaust manifold (26 Nm) .
Apply LOCTITE FRENTANCH to the threads of the
turbocharger oil inlet pipe union on the cylinder
head.
Position the oil supply pipe on the turbocharger and
on the cylinder head, fitted with new seals.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cy-
linder head (22.5 Nm) ,
- the hollow bolt securing the turbocharger oil in-
let duct 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.
Tighten to torque the bolts mounting the turbo-
charger oil return pipe on the turbocharger (12
Nm) .
12B-15
TURBOCHARGING
F9Q, and 812
Special tooling required terminal.
Mot. 1566 Spanner for removing
high pressure pipes.
Tightening torquesm
studs
nuts
hollow bolt mounting 22.5 Nm

the turbocharger supply
pipe
104343
nut mounting the oil 22.5 Nm Remove:
supply pipe on the cylin-
der block
bolt mounting the oil 25 Nm - the air filter access panel mounting bolts (1) ,
supply pipe on the cylin-
der block - the air filter access panel,
turbocharger oil return 12 Nm
pipe mounting bolt
studs
turbocharger union end 26 Nm

piece
nuts
oil supply pipe moun- 22.5 Nm

ting nut, turbocharger
side
oil supply pipe moun- 22.5 Nm 104246

ting nut, cylinder block
Remove:
side
turbocharger oil return 12 Nm
pipe mounting bolts - the scuttle panel partition.

bolts
REMOVAL
12B-16
TURBOCHARGING
F9Q, and 812
104424 104421
Disconnect: Disconnect the turbocharger air inlet and outlet pi-
pes (6) .
- the oil vapour rebreathing pipe (4) ,
- the turbocharger pressure regulation valve pipe (5)
.
Note:
During factory fitting, 2 types of oil supply pipe
may be fitted to this turbocharger.
The removal procedure for the turbocharger
depends on the type of pipe fitted.
12B-17
TURBOCHARGING
F9Q, and 812
I - OIL SUPPLY PIPE WITH A HOLLOW BOLT II - THE OIL SUPPLY PIPE WITH NUT UNION
UNION (TURBOCHARGER SIDE) (TURBOCHARGER SIDE)
114207 104417
Remove: Remove the bolt (10) mounting the oil supply pipe on
the cylinder block.
- the mounting bolt (7) from the oil supply pipe,
Unscrew the oil supply pipe unions on:
- the hollowo bolt (8) mounting the oil supply pipe
union on the turbocharger. - the cylinder block,
Unscrew the union (9) from the cylinder block. - the turbocharger (11) using the (Mot. 1566).
Remove the oil supply pipe, passing it between the Remove the turbocharger oil supply pipe.
wheels of the turbocharger.
Remove:
Remove:
- the oil return pipe mounting bolts,
- the oil return pipe ,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger bracket mounting nuts,
- the turbocharger.
- the turbocharger.
Note:
In the Parts Department, there is only one part
number for the supply pipe. Only the oil supply
pipe with the hollow bolt union is available.
12B-18
TURBOCHARGING
F9Q, and 812
I - OIL SUPPLY PIPE WITH A HOLLOW BOLT
UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mounting
studs (8 Nm) .
Refit the turbocharger.
(26 Nm) .
Position the oil supply pipe:
- screw (without tightening) the nut mounting the oil
supply pipe union on the cylinder block,
- screw (without tightening) the hollow bolt mounting
the supply pipe,
- screw (without tightening) the bolt mounting the oil
supply pipe on the cylinder block,
Refit the oil return pipe.
Tighten to torque:
114467 - the hollow bolt mounting the turbocharger sup-
When replacing the oil supply pipe: ply pipe (22.5 Nm) ,
- the nut mounting the oil supply pipe on the cy-
- remove the end piece from the oil supply union (12)
. This stage prepares the turbocharger for the sup- linder block (22.5 Nm) ,
ply pipe to be refitted with a hollow bolt union. - the bolt mounting the oil supply pipe on the cy-
linder block (25 Nm)
REFITTING - the turbocharger oil return pipe mounting bolt
(12 Nm) .
Note:
During factory fitting, 2 types of oil supply pipe
may be fitted to this turbocharger.
The refitting procedure for the turbocharger
depends on the type of pipe fitted.
WARNING
Ensure that no impurities enter the turbine or
compressor during the refitting operation.
Check that the turbocharger oil return pipe is not
completely or partially blocked by scale.
Also check that it is perfectly sealed. If not,
replace it.

Always replace:
- the oil supply pipe with a hollow bolt union, turbo-
charger side (depending on version),
- the seals for the oil supply pipe with a nut union,
turbocharger side (depending on version),
- the seals on the turbocharger oil return pipe.
12B-19
TURBOCHARGING
F9Q, and 812
II - OIL SUPPLY PIPE WITH NUT UNION To refit, proceed in the reverse order to removal.
(TURBOCHARGER SIDE)
in place and properly secured.
Refit the exhaust pipe, aligning the marks made be-
fore.
Make sure that there is no contact with the underbo-
dy.
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- leave the engine to idle,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Always replace the seal on the end piece of the (4 Nm) .
union (13) , if the end piece is removed.
Tighten to torque:
- the turbocharger mounting studs (8 Nm) ,
- the turbocharger union end piece (26 Nm) , if re-
moved.
(26 Nm) .
Position the oil supply pipe:
- screw (without tightening) the oil supply pipe moun-
ting nuts,
- screw (without tightening) the bolt mounting the oil
supply pipe on the cylinder block,
Refit the oil return pipe.
Tighten to torque:
- using the tool, the oil supply pipe mounting nut,
turbocharger side (22.5 Nm) ,
- the oil supply pipe mounting nut, cylinder block
side (22.5 Nm) ,
- the turbocharger oil return pipe mounting bolts
(12 Nm)
III - AFTER REFITTING

Refit the catalytic converter (see 19B, Exhaust, Ca-
12B-20
TURBOCHARGING
F4R, and 776
Equipment required
diagnostic tool 1
Tightening torquesm
bolts for the oil return 12 Nm

pipe (to the cylinder
block)
3
turbocharger cooling 12 Nm 2
duct bolts 4
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
oil return and oil supply 21 Nm 5

pipes mounting bolt
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.
Place the hose clamp and remove the turbocharger
Disconnect the battery, starting with the negative cooling hoses (5) .
terminal.
Removal of the turbocharger requires the engine to
be removed (see 10A, Engine and peripherals,
Engine - gearboxes ).
Catalytic converter ).
12B-21
TURBOCHARGING
F4R, and 776
21929 21931
Remove: Remove:
- the heat shield bolt (6) ,
- the mounting bolts (8) from the turbocharger oil re-
- the engine cover mounting and the turbocharger turn pipe,
strut (7) ,
- the turbocharger oil return pipe (10)
- the turbocharger - intercooler air duct.
- the turbocharger oil supply pipe (9) .
21930
Remove the starter heat shield. 21933
Remove:
- the nuts (11) securing the turbocharger to the inlet

manifold,
- the turbocharger.
12B-22
TURBOCHARGING
F4R, and 776
REFITTING
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.
21931
Fit and finger tighten:
- the turbocharger mountings on the exhaust mani-

fold,
- the oil supply pipe mountings on the turbocharger,
- the fuel return pipe to the cylinder block,
- the turbocharger-intercooler air pipe,
- the turbocharger strut mounting.
22809
On the workbench, refit and tighten to torque:
- the bolts for the oil return pipe (to the cylinder
block) (12 Nm) (12) ,
- the oil return pipe bolt (13) .
Pretighten the turbocharger cooling duct bolts
(12 Nm) (14) ,
Tighten to torque the turbocharger cooling duct
bolts (27 Nm) .
106273
Tighten:
- the clip (15) on the intercooler-turbocharger pipe to

position the turbocharger,
- the turbocharger strut (16) .
12B-23
TURBOCHARGING
F4R, and 776
WARNING
All removed seals must be replaced including
those on the cooling pipe as well as the intercoo-
ler-turbocharger air pipe.
Fill and bleed the cooling system (see 19A, Coo-

ling, Filling - Bleeding ).
nal.
WARNING
WARNING
- Before starting the engine, connect the dia-
21933 gnostic tool (CLIP) and lock the injection sys-
tem.
- Activate the starter motor until the oil pressure
warning light goes out (wait a few seconds)
then unlock the injection system.
- Start the engine then accelerate with no load
several times.
- Switch off the ignition and check 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 carry
out a road test.
- Clear the faults using the diagnostic tool
(CLIP).
- Switch off the ignition and check 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 oil return and oil supply pipes mounting

bolt (21 Nm) (22) .
12B-24
TURBOCHARGING
F9Q, and 804
Equipment required
diagnostic tool
Tightening torquesm
nuts
turbocharger oil supply 22.5 Nm

pipe hollow mounting
bolts
hollow bolts mounting 44 Nm

the oil supply pipe on
the housing
bolt mounting the oil 25 Nm

supply pipe on the hou-
sing 111866
turbocharger oil return 12 Nm Remove the turbocharger cooling hoses.

pipe

bolts
REMOVAL
terminal.
Drain the cooling system (see 19A, Cooling, Coo-
ling system: Draining - filling ).
111860
Remove the catalytic pre-converter (see 19B, Ex-
haust, Catalytic Pre-converter: Removal - Refit- Remove the air duct from the turbocharger.
ting ).
12B-25
TURBOCHARGING
F9Q, and 804
111869 111868
Remove the duct between the turbocharger and the Remove the starter motor (see 16A, Starting-Char-
air filter. ging, Starter motor: Removal - Refitting ).
Disconnect the turbocharger underpressure hoses.
111867
111865 Remove the turbocharger heat shield.

Remove the turbocharger oil return pipes.
12B-26
TURBOCHARGING
F9Q, and 804
111870 112457
Remove the turbocharger oil supply pipes.
112458
111871 Remove the turbocharger.
Remove the turbocharger mounting nuts.
Remove the oil return pipe union if the turbocharger
REFITTING
is replaced.
WARNING
completely or partially blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
12B-27
TURBOCHARGING
F9Q, and 804
Proceed in the reverse order to removal. Tighten to torque the battery cover mounting bolts
(4 Nm) .
Always replace:
- the turbocharger oil supply pipe,
system: Draining - filling ).
- the oil supply pipe hollow mounting bolts,
- the seals on the turbocharger oil return pipe, ling system: Bleeding ).
- the sealant between the turbocharger and the ex-
haust manifold,
Note:
The turbocharger - manifold gasket has a direc-
tion of fitting.
The tab of the gasket should be on the turbo-
charger side.
Tighten to torque:
- the turbocharger mounting nuts (37 Nm) ,
- the turbocharger oil supply pipe hollow moun-
ting bolts (22.5 Nm) ,
- the hollow bolts mounting the oil supply pipe
on the housing (44 Nm) ,
- the bolt mounting the oil supply pipe on the
housing (25 Nm) ,
- the turbocharger oil return pipe (12 Nm) .
Refit:
- the starter motor (see 16A, Starting-charging,
Starter motor: Removal - Refitting ).
- the catalytic pre-converter (see 19B, Catalytic
pre-converter: Removal - Refitting ).
dy.
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- leave the engine to idle,
- check that there are no oil leaks.
Connect the diagnostic tool and clear the stored
faults.
12B-28
TURBOCHARGING
K9K, and 732
Tightening torquesm
studs
bolts
bolts securing the oil 22.5 Nm

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

inlet pipe on the cylinder
head 104246
Remove:
oil return pipe mounting 12 Nm
bolts - the scuttle panel partition mounting bolts (3) ,
REMOVAL

112811
Pull out the clip.
104343
Remove:
12B-29
TURBOCHARGING
K9K, and 732
CONCERNED
112991
Remove the mounting bolt (4) from the stainless
steel pipe. 102079
Disconnect the hose from the turbocharging pressu-
Move the air inlet duct (5) to one side.
re regulation valve, pressure regulation valve side.
Remove:
- the bolt (8) securing the oil inlet pipe on the turbo-
charger,
- the bolt the securing the oil inlet pipe on the cylin-
der head,
- the oil inlet pipe,
- the oil return pipe (9) ,
- the turbocharger upper mounting nuts (10) ,
- the turbocharger lower upper mounting nuts,
- the turbocharger.
112816
Disconnect:
- the oil vapour rebreathing pipe (6) , rocker cover si-
de,
- the air inlet duct (7) , turbocharger side.
12B-30
TURBOCHARGING
K9K, and 732
REFITTING Refit:
- the oil return pipe,

- the oil return pipe mounting bolts.
It is essential to clean the joint faces carefully.
Tighten to torque the oil return pipe mounting
WARNING bolts (12 Nm) .
Ensure that no foreign bodies enter the turbine or
Connect the hose to the turbocharging pressure re-
gulation valve.
partially or completely blocked by the scale.
Check that there are no leaks. If there are, III - FINAL OPERATION
replace the part.
Connect:
- the air inlet duct, turbocharger side.

WARNING
Check that the intercooler is not full of oil. If it is, - the oil vapour rebreathing pipe, rocker cover side.
remove and rinse it with the cleaning agent, then
let it drip dry. Refit the catalytic converter (see 19B, Exhaust, Ca-
WARNING
All damaged heat shields must be replaced. Note:
Make sure that there is no contact between the
catalytic converter and the turbocharger oil return
pipe.
CONCERNED
Tighten to torque the turbocharger mounting Refit the clip on the stainless steel pipe, if necessa-
studs (9 Nm) . ry.
Fit the new turbocharger seal.
Clip the stainless steel pipe to the turbocharger.
Refit:
Refit:
- the turbocharger.
- the turbocharger mounting nuts. - the stainless steel pipe mounting bolt,
Tighten to torque the turbocharger mounting bolts - the scuttle panel partition,
(26 Nm) .
Refit:
- the new oil inlet pipe, - the scuttle panel mounting bolt,
- the bolt securing the oil inlet pipe on the turbochar- - the air filter access panel,
ger,
- the bolt securing the oil inlet pipe on the cylinder
head.
Tighten to torque: 55A, Exterior protection, Scuttle panel grille ),
- the bolts securing the oil inlet pipe on the turbo- - the engine undertray.
charger (22.5 Nm) ,
- the bolts securing the oil inlet pipe on the cylin- Connect the battery (see 80A, Battery, Battery: Re-
der head (22.5 Nm) . moval - Refitting ).
Position the new oil return pipe seals. Refit the engine covers.
12B-31
TURBOCHARGING
M9R, and 700
Equipment required
IMPORTANT
roller-type stud removal tool Wear protective gloves during all operations.
tweezers
REMOVAL
diagnostic tool

Tightening torquesm Place the vehicle on a two-post lift (see 02A, Lifting
stud on the exhaust 9 Nm
manifold Disconnect the battery (see 80A, Battery, Battery:
studs on the turbochar- 14.5 Nm
ger dywork, 55A, Exterior protection, Scuttle panel
grille ).
turbocharger strut 25 Nm
mounting bolts, flywheel
end
turbocharger lower 28 Nm
mounting nuts
turbocharger upper 28 Nm
mounting nut
turbocharger side 25 Nm
mounting bolt
turbocharger strut 25 Nm
mounting bolt, timing
end
104343
heat shield mounting 7.4 Nm
bolts Remove:
lifting eye mounting 25 Nm
bolts, timing end - the air filter access panel,
air inlet duct mounting 8 Nm - the scuttle panel partition mounting bolt (2) .
bolts
air inlet duct clip, turbo- 5.5 Nm

charger side

pipe on the turbochar-
ger
hollow bolt securing the 16 Nm

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

pipe on the cylinder
block
12B-32
TURBOCHARGING
M9R, and 700
104246
Remove:
114982
Remove:
- the bolts (6) mounting the oil pipe on the turbochar-

ger,
- the oil pipe mounting bolt (7) on the cylinder block,
- the hollow bolt (8) mounting the turbocharger oil

pipe on the cylinder block,
- the turbocharger oil pipe.
114845
Remove:
tion,
- the mounting nut (5) from the scuttle panel parti-
tion,
113277
Remove the lower mounting nuts (9) from the turbo-

charger.
12B-33
TURBOCHARGING
M9R, and 700
114846
Disconnect:
- the turbocharging pressure regulator hose (10)
from the control diaphragm,
- the oil vapour rebreathing hose (11) from the oil se-
113155
parator.
Remove the bolts (13) mounting the air inlet duct on
Loosen the clip on the air duct, turbocharger side.
the inlet manifold.
Disconnect the air inlet duct, turbocharger side.
Move the air duct to one side, towards the intercoo-
ler.
113282
Rotate the clip (12) securing the air duct on the tur-
bocharger.
114984
Remove:
- the mounting bolts (14) from the lifting eye, timing
end,
- the timing end lifting eye,
12B-34
TURBOCHARGING
M9R, and 700
114983 114848
Remove: Remove:
- the heat shield mounting bolts (15) , - the turbocharger.

- the gasket between the turbocharger and the ex-
- the heat shield.
haust manifold.

CONCERNED
114471
Remove:
113277
- the mounting bolts (18) from the turbocharger strut,
Remove: - the turbocharger strut.
- the turbocharger upper mounting nut (16) on the

exhaust manifold,
- the side mounting bolt (17) from the turbocharger,
12B-35
TURBOCHARGING
M9R, and 700
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 the new stud on the exhaust manifold using a
Tighten to torque the stud on the exhaust mani-
fold (9 Nm) .
Remove the turbocharger studs if the turbocharger
is being reused.
Refit the new studs onto the turbocharger if the tur-
bocharger is being reused.
Tighten to torque the studs on the turbocharger 115069
(14.5 Nm) . Refit the new turbocharger air inlet duct seal.
Note:
Check that the seal (19) on the turbocharger air
inlet duct is fitted the correct way round.
115068
Remove the turbocharger air inlet duct seal using a
tweezers.
12B-36
TURBOCHARGING
M9R, and 700
II - REFITTING OPERATION FOR PART - the new turbocharger upper mounting nut,
CONCERNED
- the new turbocharger lower mounting nuts.
Tighten to torque:
- the s turbocharger lower mounting nuts (28 Nm)

,
- the turbocharger upper mounting nut (28 Nm) .
Undo the turbocharger strut mounting bolt on the ti-

ming end (20) .
Tighten to torque:
- the turbocharger side mounting bolt (25 Nm) ,
- the turbocharger strut mounting bolt, timing

end (25 Nm) (20) .
Refit:
114471 - the heat shield,

Fit the new turbocharger strut. - the heat shield mounting bolts.
Finger tighten the mounting bolts (20) and (21) on
Tighten to torque the heat shield mounting bolts
the turbocharger strut.
(7.4 Nm) .
Refit:
WARNING
The turbocharger strut must move freely. - the timing end lifting eye,
Fit the turbocharger without its seal and hold the tur- - the bolts securing the timing end lifting eye.
bocharger flat against the exhaust manifold.
Tighten to torque the lifting eye mounting bolts, ti-
Push the turbocharger strut until it is pressing ming end (25 Nm) .
against the turbocharger at the flywheel end.
Rotate the air inlet duct retaining clip to return the re-
Slowly tighten the turbocharger strut mounting bolt taining clip to its housing.
on the timing end (20) .
Clip the air inlet duct onto the turbocharger.
WARNING Refit the bolts mounting the air inlet duct on the inlet
manifold.
Do not tighten the bolt too quickly to prevent the
turbocharger strut from rotating. Tighten to torque the air inlet duct mounting bolts
(8 Nm) .
Move the turbocharger to one side.
Connect:
Tighten to torque the turbocharger strut mounting
bolts, flywheel end (25 Nm) (21) . - the air inlet duct onto the turbocharger.
Position a new seal between the turbocharger and - the oil vapour rebreathing hose onto the oil separa-
the exhaust manifold. tor.
Tighten to torque the air inlet duct clip, turbochar-
Finger tighten the new turbocharger side mounting ger side (5.5 Nm) .
bolt by several turns.
Connect the turbocharging pressure regulator hose
Tighten until contact: onto the control diaphragm.
12B-37
TURBOCHARGING
M9R, and 700
Position the turbocharger oil pipe, first fitting it inside
the cylinder block (21) .
WARNING
Do not rotate the turbocharger oil pipe O-ring at
the cylinder block end when inserting.
After fitting, check that the turbocharger oil pipe
O-ring has not come out of its housing.
Check for the two copper seals on the oil supply
union, cylinder block end.
Finger tighten:
- the mounting bolts (22) on the turbocharger oil pi-
114845 pe,
Refit: - the hollow bolt (23) securing the oil pipe on the cy-
linder block,
- the scuttle panel partition, - the bolt (24) securing the oil pipe on the cylinder
block.
- the scuttle panel partition mounting nut,
Tighten to torque:
- the scuttle panel partition mounting bolt. - the bolts mounting the oil pipe on the turbo-
charger (10 Nm) (22) ,
- the hollow bolt securing the oil pipe on the cy-
linder block (16 Nm) (23) ,
- the bolt securing the oil pipe on the cylinder
block (25 Nm) (24) .
Refit:
114982
Lubricate the new turbocharger oil pipe O-ring, cylin-

der block end.
WARNING
Check for the gasket between the turbocharger
and the turbocharger oil pipe.
Remove the protective plug on the oil supply union,

cylinder block end.
12B-38
TURBOCHARGING
M9R, and 700
WARNING
Disconnect the injector 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 pressure regulator connector to the
injection rail.
Start the engine.
Let the engine idle then depress the accelerator
several times under no load.
Make sure that there are no oil leaks.
Connect the diagnostic tool and clear the sto-
red faults.
12B-39
TURBOCHARGING
Intercooler: Removal - Refitting 12B
F4R, and 776 – K9K, and 722 or 728 or 732 – F9Q, and 804 or 812
Car. 1363 Trim removal lever. 1
clips 5.5 Nm

mounting bolts 3 4
mounting bolts

bolts Disconnect the two connectors (1) .
WARNING Remove:
- the clip (3) ,
intercooler: - the mounting (4) .
- detach the hose, using the (Car. 1363) , Disconnect the screen washer pipes.
- do not use degreasing agent, brake cleaning pro-

duct or any other product,
- clean the intercooler bearing face and the hoses
using a dry lint-free cloth,
- if the hoses are not being replaced, replace the
clip on the same marking,
- it is essential to replace the hoses and/or the inter-
cooler in the event of damage,
- it is essential to replace the clip.
There is a risk of leaks and unseating if this proce-
dure is not followed.
REMOVAL
terminal.
Remove:
- the bumper mountings,
- the fog lights connector (if fitted to the vehicle),
- the headlight washer pipes (if fitted to the vehicle),
- the bumper.
12B-40
TURBOCHARGING
F4R, and 776 – K9K, and 722 or 728 or 732 – F9Q, and 804 or 812
REFITTING
WARNING
Check that the intercooler is not full of oil. If this
is the case, clean it with a cleaning agent and
then let it dry.
Torque tighten the clips (5.5 Nm) .
Torque tighten:
Nm) ,
6 - the front end panel lower mounting bolts (44
Nm) ,
- the battery cover mounting bolts (4 Nm)
nal.
102473
WARNING
Note:
essential to initialise the system; see 80C,

102474
Remove:
Disconnect the inlet (6) and outlet (7) ducts from the
intercooler.
Remove the intercooler.
12B-41
TURBOCHARGING
M9R, and 700
Tightening torquesm

pipe clips

pipe clip on the inter-
cooler side

mounting bolts

mounting bolts
114933
REMOVAL
Remove:
Refitting ).
112658
Remove:
(2) ,
12B-42
TURBOCHARGING
M9R, and 700
CONCERNED
115585
cessories unit.
Remove:
- the clips (5) ,
115703
Undo the turbocharger outlet air pipe clip (8) on the
intercooler side.
Detach the turbocharger outlet air pipe using the
(Car. 1363).
Disconnect the turbocharger outlet air pipe on the in-
tercooler side.
102365
Remove:
12B-43
TURBOCHARGING
M9R, and 700
REFITTING

Use a dry, lint-free cloth to clean the mating faces of:
- the intercooler, if it is to be reused,
- the intercooler outlet air pipe,
- the turbocharger outlet air pipe.
WARNING
Check that the intercooler is not full of oil. If it is,
clean it using a cleaning tray or water jet then dry
it using a compressed air gun and let it drip dry.

CONCERNED
Clip on the intercooler, positioning it correctly in the
115023 cooling radiator tabs.
Connect the intercooler outlet air pipe on the inter-
cooler side.
Tighten to torque the intercooler outlet air pipe
clips (5.5 Nm) .
Refit the bolt mounting the intercooler outlet air pipe
on the cooling radiator.
Connect the turbocharger outlet air pipe on the inter-
cooler side.
Tighten the intercooler outlet air pipe clip on the
intercooler side (5.5 Nm) .

Refit:
115702 - the front end panel lower mounting bolts.
Remove the mounting bolt (9) from the cooling ra- Tighten to torque:
diator intercooler outlet air pipe. - the front end panel lower mounting bolts (44
Nm) ,
Loosen:
- the intercooler outlet air pipe clip (10) on the inter- Nm) .
cooler side,
- the intercooler outlet air pipe clip (11) on the dam-
per valve side. Refit the clips.
Disconnect the intercooler outlet air pipe on the in-
tercooler side. Connect the engine accessories unit connectors.
Unclip the intercooler. Clip on the air inlet scoop.
12B-44
TURBOCHARGING
M9R, and 700
Refit:
- the engine component unit cover mounting bolts.
Refit:
Refitting ),
Adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon bulbs, Xenon headlight: Adjust-
ment ).
12B-45
FUEL SUPPLY
Petrol supply circuit 13A
Operating diagram of the petrol 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 absorber (6) .
13A-1
FUEL SUPPLY
Diesel fuel supply circuit 13A
K9K, and 722 or 724 or 728
Operating diagram of the diesel fuel supply circuit
102847
The circuit comprises: It is forbidden:
- a gauge (1) , - to dismantle the interior of the pump or injectors. Only

the fuel flow actuator, the diesel fuel temperature sen-
- a priming pump (2) , sor and the Venturi tube can be replaced,
- a fuel filter (3) that may be fitted with a water detection - to remove the pressure sensor from the fuel rail (for
sensor, circuit contamination faults). If the pressure sensor
fails, the pressure sensor, the rail and the five high
- a high pressure pump (4) with a built-in mechanical pressure pipes must be replaced.
low pressure pump (transfer pump),
- a fuel flow actuator (5) ,
- an injector rail (6) fitted with a diesel fuel pressure

sensor (7) ,
- four solenoid injectors (8) fitted with discharge valves,
- a Venturi tube (9) ,
- various sensors,
- an injection computer.
IMPORTANT
Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
13A-2
FUEL SUPPLY
F9Q, and 804 or 812
100821
The circuit comprises:
- a priming pump (1) (located in the engine compart-
ment),
- a fuel filter (2) that may be fitted with a water detection
sensor,
- a high pressure regulator (3) mounted on the pump,
- a high pressure pump (4) ,
sensor and a pressure limiter (6) ,
- four solenoid injectors (7) ,
- a fuel temperature sensor (8) (only for F9Q 812),
IMPORTANT
13A-3
FUEL SUPPLY
K9K, and 732
114450
The circuit comprises: It is forbidden:
- a gauge (1) , - to dismantle the interior of the pump or injectors. Only

the fuel flow actuator, the diesel fuel temperature sen-
- a priming pump (2) , sor and the Venturi tube can be replaced,
- to remove the pressure sensor from the fuel rail (for
- a fuel filter (3) that may be fitted with a water detection circuit contamination faults). 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) ,

sensor (7) ,
- four solenoid injectors (8) fitted with discharge valves,
- various sensors,
IMPORTANT
13A-4
FUEL SUPPLY
Petrol filter: General information 13A
102299
The fuel filter is located in the fuel tank; it is integrated
into the « pump-sender-filter » assembly and cannot
be removed.
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-5
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 722 or 728
Tightening torquesm

bolts
wheel bolts 130 Nm
IMPORTANT

- watch out for diesel fuel splashing when discon-
necting the supply union,
cap kit.
WARNING 104544
- 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 clips,
ght. It is contained in a removable cartridge. This car-
tridge has a built-in diesel fuel heater, comprising a - the wheel arch liner.
resistor and temperature switch.
Note:
Remove the diesel filter assembly to remove the
cartridge.
REMOVAL
Then disconnect the battery, starting with the nega-
tive terminal.
13A-6
FUEL SUPPLY
K9K, and 722 or 728
102124
Prime the fuel system with the priming pump (1)
(automatic degassing).
104560
nal.
Remove the diesel filter from its holder, pushing it
upwards.
WARNING
Disconnect all the filter pipe unions.
Cap the openings. Battery: Removal - refitting ).

WARNING (4 Nm) .
Keep the pipe unions away from contaminated
areas.
REFITTING
Fit the new diesel filter (do not remove the caps until
the last moment).
Reconnect the pipe unions.
13A-7
FUEL SUPPLY
K9K, and 722 or 728
3
2
21749
Note:
- Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug (2) .
- Some vehicles have a sensor for detecting
water in the diesel fuel (3) , located on the filter.
If water is detected, the injection fault warning
light comes on.
Tighten to torque the wheel bolts (130 Nm) .
13A-8
FUEL SUPPLY
F9Q, and 804 or 812
Tightening torquesm

bolts
wheel bolts 130 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:
- Follow the cleanliness guidelines closely.
The diesel filter is located behind the right-hand headli- - the mounting bolts (1) from the wheel arch liner,
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. - 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 804 or 812
102477 19317
Disconnect the diesel heater connector (3) from the
Mark the position of the diesel filter cover in relation
diesel filter.
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 the 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 804 or 812
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.
Tighten to torque the wheel bolts (130 Nm)
19317
102124
Reprime the supply circuit:
- Turn the air bleed screw (8) 360 degrees,
- operate the manual priming pump (9) until the fuel
runs without air bubbles,
- retighten the bleed screw (8) ,
- activate the manual priming pump (9) once more.
nal.
WARNING

(4 Nm) .
13A-11
FUEL SUPPLY
K9K, and 724 or 732 – M9R, and 700
CONCERNED
Tightening torquesm
wheel mounting bolts 130 Nm
WARNING
During this operation:

union,
Note:
Make sure you have a new diesel filter before ope-
ning the fuel circuit.
114559
Remove the diesel filter from its mounting on the

REMOVAL body by pushing the « filter - metal strap » assembly
upwards.
Disconnect all the unions from the fuel supply pipes
Place the vehicle on a two-post lift (see 02A, Lifting on the diesel filter.
Note:
Make preparations for fuel outflow.
WARNING
Prevent the hose unions from coming into con-
tact with a polluted environment.
Take the diesel filter out of the vehicle.
Note:
Only use cloths with the part number 77 11 211
707 to clean the filter and the pipes once the fuel
circuit is opened.
REFITTING
104544
Remove:
CONCERNED
Connect the fuel supply pipes onto the new diesel fil-
- the front right-hand wheel arch liner (1) . ter.
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 fixed and positio-
ned on its mounting by shaking it: the filter must
not move.
If necessary, remove the filter and gently manipu-
late the retaining brackets of the metal straps on
its mounting.
114731
Check there are no leaks at the unions on the filter.
Note:
- Regularly drain the water from the diesel filter
via bleed plug (3) .
- Some vehicles have a sensor for detecting
102124
water in the diesel fuel, located in the base of
Prime the fuel circuit using the manual priming pump the filter. If water is detected in the circuit, a
(2) (automatic degassing). fault warning light on the instrument panel
comes on.
Refit:
Tighten to torque the wheel mounting bolts (130
Nm) .
13A-13
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
K4J, and 730
Tightening torquesm
injector rail mounting 9 Nm

bolts

bolts
REMOVAL 3
Disconnect the battery, starting with the negative 2 3
terminal.
101802
Disconnect:
- the injector and pinking sensor wiring harness (3) .
IMPORTANT

1 close to the working area,
supply union,
101801 - protect sensitive areas from fuel outflow.
Remove the nuts (1) securing the injector rail guard.
Move the wiring harness to one side. IMPORTANT
13A-14
FUEL SUPPLY
K4J, and 730
REFITTING
The O-rings and the injector mounting clips must
always be replaced with new ones.
Fit the injector rail.
Tighten to torque the injector rail mounting bolts
(9 Nm) .
nal.
WARNING

(4 Nm) .
101493
Remove:
- the bolts (4) securing the injector rail,
ON THE WORKBENCH
5
6
101492
Remove:
- the injector clips (5) ,
- the injectors (6) .
13A-15
FUEL SUPPLY
F4R, and 770 or 771 or 776
- the injector and pinking sensor wiring harness (3) .
Tightening torquesm

bolts
F4R, and 776
bolts
REMOVAL
Disconnect the battery, starting with the negative 4 6
terminal.
F4R, and 770 or 771 5
106787
Disconnect:
- the turbocharging pressure sensor connector (4) ,
- the vacuum pipe from brake servo (5) ,
- the oil vapour recirculation pipe (6) .
7
101801
Remove the nuts (1) securing the injector rail guard.
3
106271
Disconnect the fuel supply pipe (7) from the injector
rail.
2
102728
Disconnect:
13A-16
FUEL SUPPLY
F4R, and 770 or 771 or 776
ON THE WORKBENCH
IMPORTANT
During this operation:

supply union,
IMPORTANT
10
102737
8 Remove:
REFITTING
(9 Nm) .
Remove: Connect the battery, starting with the positive termi-
- the bolts (8) securing the injector rail, nal.

WARNING

(4 Nm)
13A-17
FUEL SUPPLY
K4M, and 761 or 782
Tightening torquesm

bolts

bolts
REMOVAL 1
terminal.
Remove:
- the inlet manifold (see 12A, Fuel mixture, Inlet
manifold ).
IMPORTANT 101810
Disconnect the injector wiring harness (1) .
Remove:
close to the working area, - the bolts (2) securing the injector rail,
- expect fuel splashes when disconnecting the - the injector rail, pulling it carefully towards you.
supply union,
- protect sensitive areas from fuel outflow. ON THE WORKBENCH
IMPORTANT
4
3
101816
Remove:
REFITTING
13A-18
FUEL SUPPLY
K4M, and 761 or 782
(9 Nm) .
nal.
WARNING

(4 Nm) .
13A-19
FUEL SUPPLY
Fuel pressure regulator:Checking 13A

F4R, and 770 or 771 or 776 – K4J, and 730
Mot. 1311-01 Fuel pressure test kit.
Mot. 1311-08 Union for measuring

fuel pressure.
IMPORTANT 2

near the working area,
union,
- protect sensitive areas from fuel outflow. 1
3
IMPORTANT
Wear goggles with side protectors for this opera-
tion. 101496
Disconnect the petrol inlet duct from the injector rail.
Connect:
IMPORTANT
- the pipe (1) fitted with the pressure gauge contai-
Wear gloves during the operation. ned in the inspection kit (Mot. 1311-01) , with the
« T » union of the (Mot. 1311-08) (2) ,
- the « T » union to the rail,
- the fuel supply duct (3) to the « T » union.
13A-20
FUEL SUPPLY
Fuel pressure regulator:Checking 13A
K4M, and 761 or 782
3
1
101803
Disconnect the petrol inlet pipe from the injector rail.
Connect:
- the pipe (1) fitted with the pressure gauge contai-
ned in the inspection kit (Mot. 1311-01) , with the
« T » union of the (Mot. 1311-08) (2) ,
- the fuel supply pipe (3) to the « T » union.
Start the vehicle to activate the fuel pump.

Determine the pressure.
- The pressure must be constant (3.5 bar ± 0.06).
- It may take a few seconds to obtain a correct injec-
tor rail pressure reading.
13A-21
FUEL SUPPLY
Electric fuel: Checking 13A

F4R, and 770 or 771 or 776 – K4J, and 730

fuel pressure.
IMPORTANT
During this operation, be sure to: 2

union,
101496
Disconnect the fuel inlet pipe on the injection rail.
Connect:
- pipe (1) fitted with a pressure gauge and located in
test kit (Mot. 1311-01) , to the « T » union of tool
(Mot. 1311-08) (2) ,
- the fuel inlet pipe to the « T » union.
Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the igni-
tion off.
13A-22
FUEL SUPPLY
K4M, and 761 or 782
102502
Move the electrical connector (4) to one side without
101803
disconnecting it.
Disconnect the fuel inlet pipe on the injection rail.

Connect:
- pipe (1) fitted with a pressure gauge and located in 5
test kit (Mot. 1311-01) , to the « T » union of tool
(Mot. 1311-08) (2) ,
- the fuel inlet pipe to the « T » union.
Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the igni-
tion off.
Remove the Protection and Switching Unit cover.

102503
Disconnect the brown connector (5) from the Protec-
tion and Switching Unit.
13A-23
FUEL SUPPLY
12 5 1
102501
Connect terminal (5) of the brown connector to the
battery positive feed
Note:
The flow reading should be 80 to 120 l/hr .
13A-24
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Equipment required
diagnostic tool
Engine Engine speed (rpm) Smoke opacity
Vehicle Type Suffix Idling Maximum Maximum Homolo- Legal maxi-

type speed unladen laden gation mum (m -1)
value (m-
1)
JM0F 722 5000 ±

150
JM0T
4800 ±
K9K 805 ± 50 1.5 3
100
JM02 728 4950 ±
150
JM13
Description Make - type Special notes
High pressure pump DELPHI Pressure from 0 to 1400 bar
Low pressure pump DELPHI Built into the high pressure pump
Injection computer DELPHI 112-track computer (A 32, B 48, C

32)
Diesel fuel rail pressure sensor DELPHI Built into the rail
Resistance not measurable
Feed voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel fuel rail pressure sensor
earth
- 3: + 5 V feed
Injectors DELPHI / MNS HP Solenoid injector

Maximum pressure 1600 bar
Feed voltage: + 14 V
2-track connector:
- 1: control + injector
- 2: control - injector
13B-1
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Diesel fuel flow actuator DELPHI Located on the high pressure pump
Feed voltage: + 5 V
2-track connector:
- 1: + battery feed via protection
and switching unit
- 2: actuator control
Engine speed and position sensor MGI Variable reluctance sensor

Resistance: 760 Ω at 20˚C (K9K
722)
Resistance: 680 Ω at 20˚C (K9K
728)
2-track connector
- A: + signal
- B: - signal
Pre-postheating unit NAGARES BED 7-12 Pre-postheating function managed

by the computer
9-track connector
- 1: heater plug no. 3 feed
- 3: + batter y feed
- 6: spark plug no. 1 feed
- 7: plug no. 2 feed
- 8: injection computer control
- 9: fault finding
Heater plugs CHAMPION ou BERU Resistance: 0.6 Ω
13B-2
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance
- gang 1: tracks 3 and 5: 1700 Ω ±
900
1025
6-track connector:
- 1: gang 2 signal
- 2: + 5 V feed, gang 2
- 3: + 5 V feed, gang 1
- 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 kΩ at 25˚C
2-track connector:
- 1: signal
- 2: diesel fuel temperature sensor
earth
Atmospheric pressure sensor DELPHI Built into the computer
Accelerometer SAGEM Resistance not measurable

2-track connector:
- 1: signal
- 2: accelerometer earth
13B-3
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Engine coolant temperature sensor ELTH Negative temperature coefficient

thermistor
Resistance:
- 75780 Ω ± 7000 at - 40˚C
- 12460 Ω ± 1128 at - 10˚C
- 2252 Ω ± 112 at 25˚C
- 810 Ω ± 38 at 50˚C
- 282 Ω ± 8 at 80˚C
- 115 Ω ± 3 at 110˚C
- 88 Ω ± 2 at 120˚C
4-track connector:
- 3: engine coolant temperature
sensor signal
- 4: engine coolant temperature
sensor earth
Turbocharging air temperature and BOSCH / LDF6T 20-250 Pressure sensor with a negative
pressure sensor temperature coefficient thermistor
Feed voltage: + 5 V
Resistance:
- 20376 Ω ± 1110.5 at - 25˚C
- 15614 Ω ± 829 at - 20˚C
- 9426 Ω ± 475 at - 10˚C
- 5887 Ω ± 281.5 at 0˚C
- 3791 Ω ± 172.5 at 10˚C
- 2511 Ω ± 109 at 20˚C
- 1715.5 Ω ± 71 at 30˚C
- 1200 Ω ± 47 at 40˚C
- 851 Ω ± 32 at 50˚C
- 612 Ω ± 22 at 60˚C
- 446 Ω ± 15 at 70˚C
- 330 Ω ± 11 at 80˚C
4-track connector:
- 1: earth
- 2: air temperature sensor signal
- 3: + 5 V feed
- 4: pressure sensor signal
13B-4
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Exhaust gas recirculation solenoid PIERBURG Feed voltage: + 13.5 V

valve
Resistance: tracks 1 and 5: 8 Ω ±
0.5 at 20˚C
Exhaust gas recirculation solenoid PIERBURG Built into the exhaust gas recircula-
valve position potentiometer tion solenoid valve
Feed voltage: + 5 V
Resistance:
- tracks 2 and 4: 4 kΩ ± 1.6 at 20˚C
6-track connector:
- 1: solenoid valve + battery feed
via protection and switching unit
- 2: + 5 V potentiometer supply
- 3: Not used
- 4: potentiometer earth
- 5: solenoid valve earth
- 6: potentiometer signal
Refrigerant pressure sensor TEXAS INSTRUMENTS Feed voltage: + 5 V

3-track connector:
- A: earth
- B: + 5 V feed
- C: signal
Water in diesel fuel sensor PRESSAC 3-track connector:

- 1: feed
- 2: signal
- 3: earth
Inlet air flowmeter (K9K 728) SIEMENS / AG Air flowmeter with built in air tempe-
rature sensor
6-track connector:
- 1: air temperature signal
- 2: flow and air temperature earth
- 3: + 5 V reference feed
- 4: + 12 V
- 5: air flow signal
- 6: battery earth
13B-5
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728
Turbocharging pressure regulation BITRON Proportional solenoid valve

solenoid valve (K9K 728)
Feed voltage: 13.5 V
2-track connector:
- 1: feed
- 2: signal
Fault finding - diagnostic tool : CLIP only
13B-6
DIESEL INJECTION
Specifications 13B
F9Q, and 812
Equipment required
diagnostic tool
Engine
Vehicles Gearbox
Type Suffix Bore Stroke Cubic capa- Compres-
(mm) (mm) city (cc) sion ratio
JM0G ND0 F9Q 812 80 93 1870 19:1

JM1G
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%)
High pressure pump BOSCH CP3 Pressure from 250 to 1350 bar
Diesel fuel pressure sensor BOSCH Screwed onto the rail
Injectors BOSCH Solenoid injector

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

pump
Resistance: 3 ± 0.1 Ω at 20˚C
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 Ω connector dis-

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

Resistance:
- gang 1: 1700 ± 900 Ω
- gang 2: 3875 ± 1025 Ω
Inlet air temperature sensor SIEMENS Built into the air flowmeter
13B-7
DIESEL INJECTION
Specifications 13B
F9Q, and 812
Diesel fuel temperature sensor ELTH Resistance: 2050 Ω at 25˚C
Engine coolant temperature sensor ELTH Resistance: 2252 Ω ± 112 at 25˚C
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
Turbocharging pressure sensor BOSCH Output voltage, with ignition on and

engine switched off (between tracks
2 and 3):
- = 1.6 V for an atmospheric pres-
sure of 1013 mbar
- > 1.6V for an atmospheric pres-
sure > 1013 mbar
- < 1.6 V for an atmospheric pres-
sure < 1013 mbar
Always replace the seal each time it
is removed
Atmospheric pressure sensor - Built into the computer
Exhaust gas recirculation solenoid PIERBURG Gang resistance: 8 ± 0.5 Ω at 20˚C

valve (tracks 1 and 5)
Sensor resistance: 4 kΩ at 20˚C
(tracks 2 and 4)
Damper flap solenoid valve (engine BITRON ou EATON Resistance: 46 ± 3 Ω at 25˚C

stop solenoid valve)
Turbocharging pressure regulation PIERBURG Resistance: 15.4 ± 0.7 Ω at 20˚C

solenoid valve
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)
JM0L F9Q 804 800 ± 50 4850 ± 4500 ± 1.9 (54%) 3 (70%)

150 100
JM1D
JM14
High pressure pump BOSCH CP3.2 Pressure 1600 bar Max
Diesel fuel pressure sensor BOSCH Screwed onto the rail

Tightening torque: 3.5 ± 5 Nm
Injectors BOSCH Solenoid injector

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

pump
Resistance: 3 ± 0.1 Ω at 20˚C
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 Ω connector dis-

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

Resistance:
- track 1: 1700 ± 900 Ω
- gang 2: 2850 ± 2050 Ω
Inlet air temperature sensor SIEMENS Built into the air flowmeter
Engine coolant temperature sensor ELTH Resistance: 2252 Ω ± 112 at 25˚C
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
Turbocharging pressure sensor BOSCH Output voltage, with ignition on and

engine switched off (between tracks
2 and 3):
- = 1.6 V for an atmospheric pres-
sure of 1013 mbar
- > 1.6V for an atmospheric pres-
sure > 1013 mbar
- < 1.6 V for an atmospheric pres-
sure < 1013 mbar
Always replace the seal each time it
is removed
Atmospheric pressure sensor - Built into the computer
Exhaust gas recirculation solenoid SIEMENS Gang resistance: 2.96 ± 10 % at

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

solenoid valve
Turbocharger GARRET Calibration

- For an underpressure of 265
mbar , the rod should have a
stroke of between 0.5 and 3.5 mm
- for an underpressure greater than
600 mbar the rod should be at the
stop
Fault finding diagnostic tool : CLIP only
13B-10
DIESEL INJECTION
Specifications 13B
K9K, and 732
Equipment required
diagnostic tool

Emis-
Vehicle
Type Suffix Idling Maximum Maximum Homolo- Legal sions
type
speed unladen laden gation maximum standard
value
JM1E K9K 732 800 ± 50 5000 ± 150 5000 ± 150 1.5 m -1 2m -1 Euro IV
High pressure pump SIEMENS VDO Pressure from 0 to 1600 bar
Low pressure pump SIEMENS VDO Built into the high pressure pump
Injection computer SIEMENS VDO 128-track computer (A 32, B 48, C

48)
Diesel fuel rail pressure sensor SIEMENS VDO Built into the rail
Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: 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 Built into the high-pressure pump
Cannot be removed
Supply voltage: + 12 V
Pressure regulation solenoid valve SIEMENS VDO Built into the high-pressure pump
Cannot be removed
Supply voltage + 12 V
13B-11
DIESEL INJECTION
Specifications 13B
K9K, and 732
Engine speed and position sensor SIEMENS VDO Variable reluctance sensor
Resistance: 680 Ω ± 6.8 at 20˚C
2-track connector:
- 1: + signal
- 2: - signal
Pre-postheating unit NAGARES With pre-postheating function con-

trolled by the injection computer
8-track connector:
- 3: fault finding
- 4: + batter y feed
- 8: injection computer control
Heater plugs CHAMPION ou BERU Resistance: 0.6 Ω
Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance:
900
1025
6-track connector:
- 1: gang 2 signal
- 2: + 5 V feed, gang 2
- 3: + 5 V feed, gang 1
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Cylinder reference sensor JCAE Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: feed
13B-12
DIESEL INJECTION
Specifications 13B
K9K, and 732
Diesel temperature sensor ELTH Situated on the diesel return pipe at

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

Negative temperature coefficient
thermistor
Resistance:
- 44373 Ω ± 3118 at - 40˚C
- 15141Ω ± 871 at - 20˚C
- 9202 Ω ± 486 at - 10˚C
- 5774 Ω ± 276 at 0˚C
- 3714 Ω ± 161 at 10˚C
- 1671 Ω ± 58 at 30˚C
- 1150 Ω ± 36 at 40˚C
- 817 Ω ± 22 at 50˚C
- 583 Ω ± 14 at 60˚C
- 316 Ω ± 6 at 80˚C
- 183 Ω ± 2 at 100˚C
Turbocharging pressure sensor BOSCH / LDF6 20-300 Feed voltage: + 5 V

3-track connector:
- 1: feed
- 2: earth
- 3: signal
Damper valve JCAE Solenoid valve position potentiome-

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

thermistor
Resistance:
- 75780 Ω ± 7000 at - 40˚C
- 12460 Ω ± 1128 at - 10˚C
- 2252 Ω ± 112 at 25˚C
- 811 Ω ± 38 at 50˚C
- 282 Ω ± 8 at 80˚C
- 115 Ω ± 3 at 110˚C
- 88 Ω ± 2 at 120˚C
4-track connector:
- 1: not used
- 2: earth
- 3: signal
- 4: not used
Exhaust gas recirculation solenoid PIERBURG Feed voltage: + 13.5 V

valve
Resistance: tracks 2 and 6: 2.3 Ω
Exhaust gas recirculation solenoid PIERBURG Built into the exhaust gas recircula-
valve position potentiometer tion solenoid valve
Feed voltage: + 5 V
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: Not used
- 5: potentiometer signal
- 6: solenoid valve earth
Refrigerant pressure sensor TEXAS INSTRUMENTS Feed voltage: + 5 V

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

3-track connector:
- 1: feed
- 2: signal
- 3: earth
Inlet air flowmeter SIEMENS VDO Air flowmeter with built in air tempe-
rature sensor
6-track connector:
- 1: air temperature signal
- 2: earth
- 3: Not used
- 4: + 12 V feed
- 5: + 5 V feed
- 6: air flow signal
Turbocharging pressure regulation BIRTON Proportional solenoid valve

solenoid valve
Feed voltage: + 12 V
2-track connector:
- 1: computer output
- 2: feed
13B-15
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 732 – F9Q, and 804 or 812 – 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: be refitted and reused. Stored parts will therefore be
less subject to the risk of impurities.
• 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 propreté 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 pièces à remplacer systématiquement after to prevent contamination from entering: they both have
each removal and which are mentioned in the work the same end result and neither is preferred over the
procedures specific to each vehicle (see the relevant other.
Workshop Repair Manual).
3) Wear safety goggles fitted with side shields to pre- 1 - Using the injector cleaning agent
vent the cleaning product from splashing the eyes.
Clear the access to the unions that need opening, fol-
4) Wear latex safety gloves to avoid prolonged contact lowing the work procedures specific to the vehicle (see
with the skin. the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Note: Pour the injector cleaning agent into a container which

is free from impurities.
If wearing leather protective gloves, cover these
with latex 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, alternator, power- the container of injector cleaning agent.
assisted steering pump, sensors and electrical con-
nectors),
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: the ambient atmosphere can be a source of
pollution.
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 or 812
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
Location of components 13B
K9K, and 722 or 728
1 2 3 4 5 6 7 8 9
20 19 17 18 16 15 14 13 12 11 10
104543
(17) Diesel fuel temperature sensor
(1) Pr iming pump
(18) Diesel flow actuator
(2) Cylinder reference sensor
(19) High pressure pump
(3) Turbocharger
(20) Diesel filter
(4) Exhaust gas recirculation sole-
noid valve
(5) Injector
(6) Turbocharging air temperature
and pressure sensor
(7) Injection computer
(8) Air filter unit 21
(9) Protection and switching unit
(10) Air flow sensor with integrated
temperature sensor (K9K 728)
(11) Turbocharging pressure regula-
tion solenoid valve (K9K 728)
(12) Coolant temperature sensor
(13) Engine speed and position sen-
sor
(14) Rail pressure sensor
(15) Spherical injector rail
(16) Accelerometer 101811
13B-31
DIESEL INJECTION
K9K, and 722 or 728

24 26 30
22
25
27
29 28
102084
101105
(24) Venturi
(25) Fuel flow actuator
(22) Protection and switching unit (26) Diesel fuel temperature sensor
(28) Spherical injector rail
(29) Accelerometer
(30) Injector
23
K9K, and 722
31 32
102085
33
102082
13B-32
DIESEL INJECTION
K9K, and 722 or 728
(31) Turbocharging air temperature (34) Turbocharging air temperature

and pressure sensor and pressure sensor
(32) Exhaust gas recirculation sole- (35) Exhaust gas recirculation sole-
noid valve noid valve
(33) Turbocharging pressure regula- (36) Speed and position sensor
tion valve (37) Turbocharging pressure regula-
tion valve
K9K, and 728
35
34
36
110327
37
110319
13B-33
DIESEL INJECTION
K9K, and 722 or 728
38
19654-1
(38) Cylinder marking sensor
39
41
40
20796

(40) Speed and position sensor (K9K 102204
722)
(41) Accelerator pedal potentiometer
13B-34
DIESEL INJECTION
K9K, and 722 or 728
44
102124
(44) Priming pump

42
102125
(42) Pre-postheating unit
43
45
102128
(45) Refrigerant pressure sensor
104954
(43) Diesel filter
13B-35
DIESEL INJECTION
K9K, and 722 or 728
47
46
102077
(46) Catalytic converter

(47) Turbocharger
K9K, and 728
48
101889

tion solenoid valve
13B-36
DIESEL INJECTION
F9Q, and 812
104542
(16) Turbocharging pressure sensor
(1) Diesel filter
(17) Diesel temperature sensor (fuel
(2) Pr iming pump return)
(3) Cylinder position sensor (18) Diesel pressure regulator
(4) Rail pressure sensor (19) High-pressure pump
noid valve
(7) Engine stop system solenoid
valve
(6) Solenoid injectors
(8) Engine stop system vacuum
reserve
(9) Turbocharger regulation sole-
noid valve
(10) Flowmeter with air temperature
sensor
(12) Protection and Switching Unit
(13) Engine damper flap control
diaphragm
(14) Engine damper flap
(15) Pressure limiter (on injector rail)
13B-37
DIESEL INJECTION
F9Q, and 812
18297-1
(20) Diesel temperature sensor

(21) High-pressure pump
(22) Injection common rail
(23) Injector
(24) Pressure regulator
(25) Pressure sensor
(27) Pressure limiter
102485
(28) Engine speed and TDC sensor
13B-38
DIESEL INJECTION
F9Q, and 812
16181 101891
(29) Cylinder marking sensor (32) Pre-postheating unit
102479 101889
(30) Turbocharger (33) Turbocharging pressure regula-

(31) Catalytic converter tion solenoid valve
13B-39
DIESEL INJECTION
F9Q, and 812
101892 104953
(34) Damper unit (engine damper (37) Engine damper flap solenoid
flap) valve
(35) Engine damper flap control
diaphragm
104557
104421
(38) Priming pump
(36) Engine stop system vacuum

reserve
13B-40
DIESEL INJECTION
F9Q, and 812
104954 104413
(39) Diesel filter (42) Engine coolant temperature

sensor
104420
102352
noid valve (43) Turbocharging pressure sensor
(41) Exhaust gas recirculation inter-
cooler
13B-41
DIESEL INJECTION
F9Q, and 812
102204
13B-42
DIESEL INJECTION
F9Q, and 804
104542
(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
(12) Turbocharger pressure sensor
(15) Diesel pressure regulator
13B-43
DIESEL INJECTION
F9Q, and 804
18297-1

(17) Injection common rail
(18) Injectors
(19) Pressure regulator
(20) Pressure sensor
102485
(23) Engine speed and TDC sensor
13B-44
DIESEL INJECTION
F9Q, and 804
16181 101891
(24) Cylinder marking sensor (27) Pre-postheating unit
111864 101889
(25) Turbocharger (28) Turbocharging pressure regula-

(26) Catalytic pre-converter tor solenoid valve
13B-45
DIESEL INJECTION
F9Q, and 804
111887 104954
(29) Throttle valve unit. (32) Diesel filter

(30) Injector rail protector.
111964
104557
(31) Pr iming pump noid valve unit
(34) Exhaust gas recirculation inter-
cooler
13B-46
DIESEL INJECTION
F9Q, and 804
111886 102204
(35) Coolant temperature sensor (37) Accelerator pedal potentiometer
111856
13B-47
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
tor solenoid valve
101811
(14) Injector rail
(15) Injector rail pressure sensor (18) Injection computer
(17) Diesel filter
13B-48
DIESEL INJECTION
K9K, and 732
101105 112994
(19) Protection and Switching Unit (21) Cylinder marking sensor

(22) Damper valve
(23) Pressure regulation solenoid
valve
(24) Flow regulation solenoid valve
111748
13B-49
DIESEL INJECTION
K9K, and 732
114348
(25) Diesel injector fuel return rail

(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 clamp
(33) Spacer between the cylinder
head and injector clamp
102204
13B-50
DIESEL INJECTION
K9K, and 732
102124
(37) Priming pump
102125
(35) Pre-postheating unit
113840

(39) Turbocharger
104954
(36) Diesel filter
13B-51
DIESEL INJECTION
K9K, and 732
114185

tor solenoid valve
13B-52
DIESEL INJECTION
Flow regulation solenoid valve: Removal - Refitting 13B
K9K, and 732
114078
The flow regulation solenoid valve (1) is joined to the
high pressure pump.
Replace the high pressure pump - flow regulation sole-
noid valve assembly if there is a fault with the flow re-
gulation solenoid valve (see 13B, Diesel injection,
High pressure pump: Removal - Refitting ).
13B-53
DIESEL INJECTION
Pressure regulation solenoid valve: Removal - Refitting 13B
K9K, and 732
114077
The pressure regulation solenoid valve (1) is joined to
the high pressure pump.
Replace the high pressure pump - pressure regulation
solenoid valve assembly if there is a fault with the pres-
sure regulation solenoid valve (see 13B, Diesel injec-
tion, High pressure pump: Removal - Refitting ).
13B-54
DIESEL INJECTION
Injection warning light 13B
K9K, and 722 or 728
Vehicles using the DELPHI high pressure diesel fuel The faults are associated with:
system are equipped with fault warning symbols and
- delayed stop: the fuel flow actuator (loop discrepancy
written warning messages, depending on the level of
and overpressure),
severity of the faults detected, to inform the customer
and guide the fault finding procedure. - immediate stop:
The injection computer controls the illumination of war- • of the engine speed sensor,
ning lights and display of messages on the instrument
• the diesel fuel flow actuator,
panel. 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 feed voltage,
- if the engine is overheating.
• an internal computer fault.
The warning signals are sent to the instrument panel
via the multiplex network. If the engine overheats, the engine coolant temperatu-
re fault symbol appears with the message « Engine
overheating » (only on information display) followed by
WARNING LIGHT ACTIVATION PRINCIPLE. the « Stop » warning light and buzzer. If this happens,
the vehicle will stop immediately.
During the starting phase (Start button pressed, the
orange preheating symbol is lit during the preheating
phase, then goes out (see 13C, Preheating, Pre-pos- « On board diagnostics » excess pollution orange
theating control ). warning light
In the event of an injection fault (level 1), the message The orange warning light, represented by an engine,
« Check injection» is displayed and then the comes on when the ignition is switched on for approxi-
« Service » warning light comes on. This means a re- mately 5 seconds then goes out. It is never displayed
duced level of operation and a limited safety level. when the engine is running (not operational).
Repairs should be carried out as soon as possible.

These faults are associated with:
- the engine immobiliser,
- a C2I (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 to the vehicle).
If there is a serious injection fault (level 2), the red en-
gine symbol and the word « Stop » appears (only on in-
formation display), with the message « Injection
faulty » , followed by the « Stop » warning light and
buzzer.
13B-55
DIESEL INJECTION
F9Q, and 804 or 812
(see MR 372 Fault finding, 13B, Diesel injection,
System operation ).
(see MR 372 Fault finding, 13B, Diesel injection,
Fault summary table ).
13B-56
DIESEL INJECTION
Injection / air conditioning programming 13B
K9K, and 722 or 728
The air conditioning management is shared between I - AIR CONDITIONING COMPRESSOR OPERATION
several computers that communicate via the multiplex PROGRAMMING
network.
During certain phases of operation, the injection com-
The injection computer is responsible for: puter disables the compressor.
- managing the request for cold air in response to pas-

senger compartment controls and the circuit pressure 1 - Engine start programming
value.
Air conditioning compressor operation is inhibited for 1
- determining the power absorbed by the compressor second after the engine has started.
using the circuit pressure value,
- authorising the fan unit control according to vehicle 2 - Thermal protection programming
speed and circuit pressure.
The air conditioning compressor is not engaged if the
- authorising or disabling the compressor clutch. engine temperature is above 115˚C or above 110˚C at
high engine speeds, 4500 rpm for more than 10 se-
When the air conditioning is switched on, the air condi- conds .
tioning control panel requests authorisation to engage
the compressor clutch.
3 - Fan unit control programming
The injection computer either authorises or disables
the compressor clutch, actuates the fan unit via the With the engine idling or when driving, with the air con-
UPC and adopts a fast idle speed of 900 rpm . ditioning on, the fan unit is activated at high or low
speed, according to the refrigerant pressure and the
The injection computer authorises operation of the air vehicle speed.
conditioning compressor and the fan unit (both powe-
red by the Protection and Switching Unit), according to
the following conditions: 4 - Recovery of performance
- engine coolant temperature, If the accelerator pedal is depressed firmly (greater

than 75 % of its travel), the compressor is disengaged
- vehicle speed, for 5 seconds .
- air conditioning.
5 - Recovery of output when the vehicle is moving
The signals used for the air conditioning function are off
transmitted via:
To help the vehicle move off smoothly, the air conditio-
- track A A4 « multiplex line HIGH » multiplex connec- ning compressor is disengaged if the accelerator pedal
tion, position is above 30 % and the engine speed is less
- track A A3 « multiplex line LOW » multiplex connec- than 1250 rpm .
tion.
The connections between the injection computer and 6 - Anti-stalling function

the refrigerant pressure sensor are: The air conditioning compressor is disengaged if the
- C C3 refrigerant pressure sensor signal, engine speed is less than 740 rpm .
- C C4 refrigerant pressure sensor supply,

7 - Engine overspeed timed protection
- C G3 refrigerant pressure sensor earth. programming
The air conditioning compressor is disengaged if the
engine speed is above 4500 rpm for more than 3 se-
Note: conds .
The value of parameter ( PR044 ) « power absor-
bed by the air conditioning compressor » is never 0,
whatever the status of the air conditioning compres- Note:
sor. The minimum reading is approximately 250 W .
There is always a delay of more than 10 seconds
The air conditioning compressor is of the « variable after the air conditioning compressor is disengaged
displacement » type. before it can be disengaged again.
13B-57
DIESEL INJECTION
K9K, and 722 or 728
II - PASSENGER COMPARTMENT HEATING - and vehicle speed less than 2.4 mph (4 km/h) ,
RESISTORS OPERATION PROGRAMMING
- and gearbox in neutral.
To reduce the heating time, fit air heating resistors
Exit conditions:
known as « passenger compartment heating
resistors » in the passenger compartment heating cir- - engine speed above 2600 rpm ,
cuit.
- or vehicle speed greater than 3.6 mph (6 km/h) ,
The UCH determines the need to actuate the heating
- or a gear is engaged.
resistors, in accordance with the user's request.
The injection computer determines: 4 - Stalling prevention programming
- the number of heating resistors supplied (power con- When the engine speed falls below 760 rpm , the pas-
trol limitation) depending on the alternator charge, senger compartment heating resistors are temporarily
- whether resistor operation should be disabled, accor- disabled. When engine speed rises above 750 rpm ,
ding to engine speed, load and vehicle speed. the passenger compartment heating resistors are
reauthorised.
The heating resistors are supplied by the Protection
and Switching Unit.
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

The operation of passenger compartment heating re-
sistors is prohibited for 20 seconds after the engine is
started.
2 - Performance return programming under heavy

load
Under heavy load at low idle, the heating resistors are
temporarily disabled.
Entry conditions:
- engine speed less than 3000 rpm ,
- and vehicle speed less than 78 mph (130 km/h) .
Exit conditions:
- engine speed above 3500 rpm ,
- and vehicle speed greater than 90 mph (150 km/h)
(for your information).
3 - Performance return programming for hill starts

To assist hill starts, the heating resistors are tempora-
rily disabled.
Entry conditions:
- engine speed less than 900 rpm ,
13B-58
DIESEL INJECTION
F9Q, and 812
The air conditioning management is shared between II - PASSENGER COMPARTMENT HEATING
several computers that communicate via the multiplex RESISTOR OPERATION PROGRAMMING
network.
When the air conditioning is switched on, the air condi- ter disables the heating resistors.
tioning control panel requests authorisation to engage
the compressor clutch.
The injection computer authorises or inhibits the com- The heating resistors are disabled while the heater
pressor clutch, and controls the fan assembly via the plugs are in operation.
UPC.
When the engine starts, the heating resistor supply is
When the air conditioning function is selected, the authorised after a delay that depends on the engine
idling speed is not altered. coolant temperature.
This compressor is the variable output type.
Engine coolant tempe- Delay

I - AIR CONDITIONING COMPRESSOR OPERATION rature
PROGRAMMING (seconds)
(˚C ± 1)
ter disables the compressor. -30 30
-20 25
-10 15
Air conditioning compressor operation is inhibited for 2
seconds after the engine has started. 0 15
10 15
2 - Thermal protection programming
The air conditioning compressor is not engaged if the 20 15
engine coolant temperature is above 115˚C , it is reen-
gaged if the engine coolant temperature falls below 30 10
110˚C .
This vehicle is equipped with heating resistors located 2 - Stalling prevention programming
in the air conditioning unit. When the engine speed falls below 780 rpm , the hea-
These heating resistors are designed to heat up the air ting resistors are temporarily disabled. When the engi-
which is then directed to the passenger compartment. ne speed rises above 855 rpm , the heating resistors
are authorised.
When the heating resistors are activated, the injection
computer adopts a fast idle speed. This engine speed
is 900 rpm .
3 - Recovery of output when the vehicle is moving

off
To help the vehicle move off smoothly, the air conditio-
ning compressor clutch is disengaged if the accelerator
pedal position is above 25 % , if the engine speed is
below 1350 rpm and if the vehicle speed is below 3
mph (5 km/h) .
4 - Anti-stalling function
The air conditioning compressor is disengaged if the
engine speed is below 750 rpm .
It is reengaged if the engine speed is greater than 780
rpm .
13B-59
DIESEL INJECTION
Idling speed 13B
K9K, and 722 or 728
The computer calculates the idling speed to maintain II - IDLE SPEED CORRECTION IN THE EVENT OF
the idling speed at the recommended level and to com- AN ACCELERATOR PEDAL POTENTIOMETER
pensate for any variation in the mechanical or electrical FAULT
torque as a function of:
- If one of the two accelerator pedal potentiometer
- the coolant temperature, gangs is faulty, the injection computer defaults to an
idle speed of 1300 rpm . This defect mode limits per-
- the battery voltage,
formance. The « Check injection » message lights up,
- the gear selected, followed by the « Service » warning light.
- the electrical consumers (air conditioning, fan unit, - If the accelerator pedal potentiometer is jammed, no
passenger compartment heating electrical resistors, longer supplied, or is no longer sending an output si-
etc.), gnal, the injection computer imposes an idle speed of
1300 rpm . This defect mode limits performance. The
- any faults found.
« Check injection » message lights up, followed by
the « Service » warning light.
Note: - If there is inconsistency between the accelerator pe-
dal potentiometer signal and the brake switch signal,
At normal engine operating temperature, without
the injection computer imposes an idling speed of
major electrical consumers, the engine idling speed
1300 rpm .
is 805 ± 50 rpm .
III - IDLE SPEED CORRECTION IN THE EVENT OF

I - IDLE SPEED CORRECTION ACCORDING TO AN INJECTOR C2I CODING ERROR
ENGINE COOLANT TEMPERATURE
In the event of an injector C2I coding error (individual
adjustment of the injector flow), the injection computer
forces an idling speed of 1300 rpm . This defect mode
limits performance. The « Check injection » message
lights up, followed by the « Service » warning light.
IV - IDLE SPEED CORRECTION WHEN THE

VEHICLE IS BEING DRIVEN
At normal engine operating temperature, the idling
speed is modified according to the gear engaged:
- in neutral, the speed is 805 rpm ,
- in 1stand 2ndgear, the engine speed is 875 rpm ,
- in 3rdand 4thgear, the engine speed is 900 rpm ,
- in 5thgear, the engine speed is 950 rpm .
103122
X: Engine idling speed (rpm)
Y: Engine coolant temperature (˚C)
13B-60
DIESEL INJECTION
Idling speed 13B
F9Q, and 812
I - IDLE SPEED CORRECTION ACCORDING TO
ENGINE COOLANT TEMPERATURE
In all cases, this engine idling speed correction is deac-

tivated 10 minutes after the engine is started and
adopts a value 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 one of the two accelerator pedal potentiometer gangs

are faulty, the injection computer forces an idle speed
of 1400 rpm . When the brake pedal is depressed, the
idling speed returns 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 if 1stor 2ndgear is engaged,
- 900 rpm when a gear above 2ndgear is engaged.
13B-61
DIESEL INJECTION
Centralised coolant temperature management 13B
F9Q, and 812
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 120˚C . It goes out when the coolant
temperature drops below 115˚C .
13B-62
DIESEL INJECTION
Centralised coolant temperature management 13B
K9K, and 722 or 728
The coolant temperature sensor is a 2-track sensor:
- 1 track for the coolant temperature signal to the com-
puter (track B H3 ),
- 1 track for the coolant temperature sensor earth (track
B H2 ).
The instrument panel warning light is switched on and
off via the multiplex network.
This system allows the engine cooling fan to be con-
trolled by the injection computer. It consists of a single
temperature sensor used in the injection system, engi-
ne cooling fan, temperature indicator and engine coo-
lant temperature warning light functions in the
instrument panel.
The request to operate the engine cooling fan is made
by the injection computer via the multiplex network.
I - FAN UNIT OPERATION WITH THE ENGINE

RUNNING
The fan unit 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 is stopped when the temperature
falls below 96 ˚C ,
- at high speed if the engine coolant temperature ex-
ceeds 102 ˚C or if the low speed is defective, and is
stopped when the temperature falls below 99 ˚C .
The fan unit low and high speeds are controlled when
the air conditioning function is selected on the instru-
ment panel.
The fan will operate at high speed if low speed is faulty,
and under the low speed operating conditions.
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 118 ˚C . It goes out when the tempe-
rature drops below 115 ˚C .
13B-63
DIESEL INJECTION
Computer configuration 13B
K9K, and 722 or 728
After programming, reprogramming or replacing the
computer:
Equipment required
diagnostic tool
- start and then stop the engine (to initialise the com-
puter) and wait for 30 seconds ,
WARNING - switch on the ignition again.

- Switch on the diagnostic tool (connect to the - Use the diagnostic tool :
mains or the cigarette lighter).
• carry out the SC001 « Write saved data » com-
- Check the condition of the battery. mand to restore the C2I and engine parameters,
- Connect a battery charger (throughout the dura- • Enter the VIN using the VP010 « Write VIN »
tion of computer (re)programming, the engine coo- command,
ling fan is automatically engaged).
• correct all computers of any faults indicated by the
- Keep to the engine coolant temperature guidelines diagnostic tool ,
supplied in the diagnostic tool before carrying
• clear the computer memory,
out any (re)programming.
• carry out a road test,
PROGRAMMING, REPROGRAMMING OR • carry out a new check with the diagnostic tool.
REPLACING THE COMPUTER
The system can also be programmed and repro- WARNING
grammed through the diagnostic socket using the - The injection computer retains the immobiliser
diagnostic tool (see Technical Note 3585A, New code for life.
procedure for programming and reprogramming
computers, 01B, General vehicle information, - The system has no security code.
Programming - Reprogramming ) or follow the ins- - It is prohibited to run tests with computers bor-
tructions supplied by the diagnostic tool. rowed from the Parts Department or from ano-
Before programming, reprogramming or replacing ther vehicle which must then be returned.
the computer, save the following data in the dia- - These computers are permanently coded.
gnostic tool :
- the C2I parameters (individual injector correction),
Note:
- the engine adaptives using command SC003
« Save computer data » . If commands SC001 and SC003 are forgotten or
do not work, the C2I codes for each injector must
be entered manually after the computer has
been replaced or reprogrammed by reading the
C2I code on each injector (see 13B, Diesel
injection, Injectors: Configuration and pro-
gramming .
13B-64
DIESEL INJECTION
Computer configuration 13B
F9Q, and 812
After programming, reprogramming or replacing the
computer:
Equipment required
diagnostic tool
- start and then stop the engine (to initialise the com-
puter) and wait for 30 s ,
WARNING - switch on the ignition again.

- Connect the diagnostic tool to the mains or the - Use the diagnostic tool :
cigarette lighter.
• run the SC001 « Write saved data » command
- Check the condition of the battery. to restore the IMA (injector flow correction) codes
and engine parameters,
- Connect a battery charger (throughout the dura-
tion of computer (re)programming, the engine coo- • enter the VIN using the VP010 « Write VIN »
ling fan is automatically engaged). command,
- Comply with the engine coolant temperature • rectify any faults in computers indicated by the
values given in the diagnostic tool before diagnostic tool ,
carrying out any (re)programming.
• clear the computer memory,
• carry out a road test,
COMPUTER PROGRAMMING, REPROGAMMING
OR REPLACEMENT OPERATIONS • carry out a new check using the diagnostic tool.
The system can be programmed and reprogrammed

via the diagnostic socket using the diagnostic tool WARNING
(see Technical Note 3585A, New computer pro- - The injection computer retains the immobiliser
gramming and reprogramming procedure, 01B, code for life.
General vehicle information, Programming - Re-
programming ) or follow the instructions given by - The system has no security code.
the diagnostic tool. - Running tests with computers borrowed from
Before programming, reprogramming or replacing the Parts Department or from another vehicle
the computer, save the following data in the dia- which must then be returned is prohibited.
gnostic tool : - These computers are permanently coded.
- the IMA codes (injector flow correction),
- the engine parameters using the SC003 « Save Note:
computer data » is not present.
If commands SC001 and SC003 are not run or
cannot be run following programming, repro-
gramming or replacement of the computer, write
the IMA (injector flow correction) code of each
injector manually, reading the codes on the injec-
tors (see 13B, Diesel Injection, Injectors: Con-
figuration and programming ).
13B-65
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K, and 722 or 728
Equipment required
diagnostic tool
WARNING
After any operation, check that there are no diesel
fuel leaks.
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 to run fault finding
on a leak due to an incorrectly fitted or tightened
union. This command only works if the engine
coolant temperature is above 60˚C . The fault fin-
ding procedure 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 on the side of the engine
housing during the test phase (significant vibra-
tion).
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-66
DIESEL INJECTION
K9K, and 732
Equipment required
diagnostic tool
WARNING
After any operation, check that there are no diesel
fuel leaks.
Reprime the diesel circuit using the manual priming

pump.
112811
Pull the clip.
112815
(1) .
one side.
112991
Remove the stainless steel pipe mounting bolt (4) .
13B-67
DIESEL INJECTION
K9K, and 732
ling test » , in the « LPG/fuel circuit » tab.
WARNING
Do not leave anything on the side of the engine
housing during the test phase (significant vibra-
tion).
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 injector rail protector cover (6) . Refitting ),
Remove: - the air inlet pressure sensor connector.
- the mounting nut and bolt (7) from the injector rail Loosen the clip and move the air inlet duct to one si-
protector cover, de.
- the injector rail protector cover, Pull out the clip from the stainless steel pipe.
Remove the air inlet duct.

Refit the clip on the stainless steel pipe, if necessa-
ry. Refit:
Clip the stainless steel pipe to the turbocharger. - the injector rail protector cover,
Refit the air inlet duct onto the damper flap. - the injector rail protector cover mounting nut and
bolt,
Tighten the clip.
Connect: Refit the clip on the stainless steel pipe, if necessa-
ry.
- the connector of the air inlet pressure sensor,
Refitting ). Refit:
Note: - the air inlet duct on the damper valve.

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 to run fault finding
on a leak due to an incorrectly fitted or tightened - the air inlet pressure sensor connector,
union. This command only works if the engine
coolant temperature is above 60˚C . The fault fin- - the battery (see 80A, Battery, Battery: Removal -
ding procedure will not reveal small leaks due to Refitting ),
incorrect tightening. - the engine covers.
13B-68
DIESEL INJECTION
Diesel injector: check 13B
K9K, and 722 or 728
The command AC029 « high pressure circuit sea-
ling test » on the « fuel/LPG » tab also enables
the leakage rate of each injector to be checked in or-
der to determine an internal leak in one or several in-
jectors. This test only works when the engine
temperature is above 60˚C .
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.
ling test » on the « fuel/LPG » tab. The engine will
automatically carry out a cycle of four accelerations
and decelerations to increase the pressure in the rail
and check whether there are internal leaks on the in-
jectors' return circuit.
When the cycle is complete, the test must be run
again, to obtain a correct reading of the flow of each
injector.
At the end of the 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-69
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 722 or 728
Mot. 1711 Kit for measuring

injector leak rate.
Remove the front engine covers.

Connect the four transparent hoses of the (Mot.
1711) to the injectors instead of the injector fuel re-
turn pipes.
Fit the correct blanking plugs, in particular onto the
venturi pipe to prevent depriming the circuit.
Insert these hoses in the four graduated measuring
cylinders of the (Mot. 1711).
IMPORTANT
Do not leave any object (tools etc.) on the side of
the engine housing during the entire operation.
Position the tools so that they do not fall during
the « engine running » phase of the test.
Follow the procedures described in the Fault finding

MR (see MR 372 Fault finding, 13B, Diesel injec-
tion, Fault finding - Tests ).
Disconnect:
Refitting ),
- the four transparent hoses of the (Mot. 1711).
Refit the injector fuel return pipes.
Refit the front engine covers.
13B-70
DIESEL INJECTION
K9K, and 732
Mot. 1771 Kit for measuring SIE-

MENS injector leak
rate.

injector leak rate.
Switch off the ignition and wait 30 seconds before

working on the injection system.
112811
Pull the clip.
112815
(1) .
Loosen the clip (2) and move the air inlet duct (3)
aside .
112991
steel pipe.
Move the air inlet duct (5) to one side .
13B-71
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
IMPORTANT

Disconnect:
Refitting ),
112992 - the air inlet pressure sensor connector.
Unclip the injector rail protector cover (6) . Loosen the clip and move the air inlet duct aside.
Remove: Pull out the clip from the stainless steel pipe.
- the mounting nut and bolt (7) from the injector rail Remove the air inlet duct.
protector cover,
Remove:
- the injector rail protector cover, - the dipstick,
- the dipstick, - the dipstick tube mounting bolts.
- the dipstick tube mounting bolts (8) . Move the dipstick tube to one side.
Move the dipstick tube to one side. Disconnect the four transparent pipes from the (Mot.
1771).
Disconnect the four fuel return pipes of the four in-
jectors (see 13B, Diesel injector fuel return rail: Remove the blanking plugs.
Connect the four injector fuel return pipes.
Refit:
turn pipes. - the dipstick tube mounting bolts.
Place the correct blanking plug on the injector fuel - the dipstick,
return connectors.
- the injector rail protector cover,
bolt,
Refit: Clip on the injector rail protector cover.
- the dipstick tube mounting bolts, Refit the clip on the stainless steel pipe, if necessa-
- the dipstick. ry.
Refit the clip on the stainless steel pipe, if necessa- Clip the stainless steel pipe to the turbocharger.
ry. Refit:
Clip the stainless steel pipe to the turbocharger. - the stainless steel pipe mounting bolt,
Refit the air inlet duct onto the damper flap. - the air inlet duct on the damper valve.
Tighten the clip. Tighten the clip.
13B-72
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
Reprime the fuel circuit with the manual priming
pump.
13B-73
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728

WARNING
Mot. 1606 High pressure pump- Tighten to a torque of 38 Nm the « pump-rail » and
pulley retaining tool. « rail-injectors » high pressure pipes with the fol-
lowing part numbers:
Mot. 1525 Extractor for timing - 77 01 207 025 ,
gear with tapered hub.
- 77 01 207 026 ,
Mot. 1525-02 Adapter sockets for
- 77 01 207 027 ,
Mot.1525.
- 77 01 207 028 ,
Equipment required - 77 01 207 029 .
diagnostic tool For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
Tightening torquesm
high pressure injection 55 Nm IMPORTANT

pump pulley mounting
nut Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
rail mounting nuts 28 Nm • that the injector rail is not under pressure,
union at the rail end 24 Nm • that the fuel temperature is not too high.
union at the pump end 24 Nm - It is essential to respect the safety and cleanliness
advice given in this document whenever work is
battery cover mounting 4 Nm carried out on this system.
bolts - Loosening a high pressure pipe union when the
WARNING
Before starting work on the vehicle, obtain: WARNING

- Obtain a set of special high pressure injection cir-
- a new set of blanking plugs (part no.: 77 01 206
cuit plugs.
804 ),
- Always replace any high pressure pipe or high
- cleaning cloths (part no.: 77 11 211 707 ),
pressure pipe clip removed with a new one.
- cleaning product (part no.: 77 11 224 188 .
WARNING
normal operating direction.
13B-74
DIESEL INJECTION
K9K, and 722 or 728
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
Remove the engine covers
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 ), 104343
- the « pump-pulley » assembly. Remove:

- the scuttle panel support mounting bolt (2) .
13B-75
DIESEL INJECTION
K9K, and 722 or 728
K9K, and 728
104246
Remove:
K9K, and 722

110325
Pull the clip.
102120
Disconnect the air inlet duct (4) .
110323
Undo the bolt (5) .
13B-76
DIESEL INJECTION
K9K, and 722 or 728
102361 102360
Remove the dipstick guide tube (7) . Disconnect:
Plug the opening on the engine block. - the fuel return pipe connecting the injectors to the
pump (13) ,
Disconnect:
- the rail pressure sensor (14) ,
- the heater plug connectors (8) ,
- the accelerometer (15) ,
- the injectors,
- the oil level sensor (16) ,
- the fuel flow actuator electrical connector (9) , - the cylinder marking sensor (17) on the timing co-
- the diesel temperature sensor connector (10) , ver.
- the fuel supply and return pipes (11) . Unclamp the electrical harness and move it to one
side.
Remove the channel located on the injector rail.
102362
Remove the diesel fuel splash plate (12) .
13B-77
DIESEL INJECTION
K9K, and 722 or 728
102083 102114
Remove the (19) « pump-rail » high pressure pipe Mark the location of the cover mounting bolts on the
(see 13B, Diesel injection, High pressure pipe: suspended mounting.
Replacing ).
Remove the right-hand suspended mounting sup-
Slacken the rail mounting nuts (18) by a few turns. port along with its cover.
Loosen the nut at the pump end, then the nut at the
rail end.
Slide the nut down the tube keeping the olive in con-
tact with the taper.
Plug the openings on the injection circuit.
19626
Position the (Mot. 1672) (1) .
13B-78
DIESEL INJECTION
K9K, and 722 or 728
19654
Remove the upper timing cover by unclipping the
tabs (20) .
13B-79
DIESEL INJECTION
K9K, and 722 or 728
102115
Remove the engine tie-bar mounting bolts (21) on
the gearbox and on the engine sub-frame.
Raise the engine a few centimetres to access the
suspended mounting attachments on the cylinder
head and the high pressure pump pulley.
WARNING
Do not disconnect the right-hand driveshaft when
raising the engine.
13B-80
DIESEL INJECTION
K9K, and 722 or 728
19654-1
Remove:
- the camshaft marking sensor (22) ,
13B-81
DIESEL INJECTION
K9K, and 722 or 728
19654-2
Remove the suspended mounting (25) on the cylin-

der head.
23167
Position the engine at top dead centre. The cams-
haft pulley hole (26) should be opposite the cylinder
head hole (27) .
13B-82
DIESEL INJECTION
K9K, and 722 or 728
23168 23169
Position the (Mot. 1606) (2) . Fit the (Mot. 1525) (3) 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 (28) hol- WARNING
ding the pulley with an open-jawed spanner. Check that the tool pushrod is correctly oriented
and is pressing against the high pressure pump
shaft.
13B-83
DIESEL INJECTION
K9K, and 722 or 728
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

(29) .
Screw down the pushrod of the (Mot. 1525).
Separate 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.
Check that the pulley clamping pin is still in place.
Fit the high pressure injection pump.
Tighten to torque the high pressure injection

pump pulley mounting nut (55 Nm) .
WARNING
Always replace all the high pressure pipes remo-
ved.
13B-84
DIESEL INJECTION
K9K, and 722 or 728
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 to reprogram the injection computer.
If 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 provi-
ded to prevent the high pressure pump from
being damaged internally, due to running with no
load and no diesel lubrication.
110404
Connect the diagnostic tool to the vehicle.
Refit the high pressure pipe; to do this:
Establish dialogue with the diesel injection compu-
- remove the protective plugs, ter.
- insert the high pressure pipe olive in the pump out- Activate the command AC212 « FILL UP NEW
let taper, PUMP HOUSING » .
- insert the high pressure pipe olive in the rail inlet ta- Follow the instructions on the diagnostic tool until
per. the command is completed.
Finger tighten the high pressure pipe unions, star- Start the engine.
ting with the one located at the rail end.
Tighten to torque the rail mounting nuts (28 Nm) . Note:
Tighten to torque and in order: The starting phase can last up to 20 seconds .
- the union at the rail end (24 Nm) ,
If the engine does not start or if the start-up sequen-
- the union at the pump end (24 Nm) . ce is interrupted:
Proceed in the reverse order to removal. - switch off the ignition,
Refit the engine cover on the suspended mounting - wait for 30 seconds ,
in accordance with the markings.
- restart the engine.
Prime the diesel fuel supply circuit with the priming
pump (automatic degassing). Using the diagnostic tool , clear any faults stored
by the injection computer.
(4 Nm) .
13B-85
DIESEL INJECTION
K9K, and 722 or 728
Check the high pressure circuit sealing after the re-
pair operation (see 13B, Diesel injection, High
pressure pipe: Test ).
WARNING
Check that there are no diesel fuel leaks:

- let the engine run at idle speed until the engine
cooling fan starts to operate,
- check that there is no diesel fuel escaping.
13B-86
DIESEL INJECTION
F9Q, and 812

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 sockets for - that the fuel temperature is not too high.
Mot.1525. (for 33-tooth Loosening a high pressure pipe union when the
pulley). engine is running is strictly prohibited.
Mot. 1746 Offset spanner for
tightening high pres-
sure pump pipes. WARNING
Mot. 1566 Spanner 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
Always read the repair precautions (see 13B, Diesel
high pressure pump 30 Nm injection, Diesel injection: Repair precautions ).
mounting bolts on the
pump supports REMOVAL
high pressure pump 50 Nm Position 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
- the injector rail protector (see 13B, Diesel injec-
injector rail mounting 22 Nm tion, Injector rail protector: Removal - Refitting
nuts ), 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-86
DIESEL INJECTION
F9Q, and 812
102352 102353
Disconnect: Remove the pump-rail high pressure pipe.
- the diesel 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 high pressure pump mounting bolts (3)
on the high pressure pump rear support.
102351
Disconnect the diesel supply and return pipes.
Plug the openings.
Remove the retaining clip from the diesel pipes.
13B-87
DIESEL INJECTION
F9Q, and 812
102350 102894
Remove: Fit the pulley extractor (Mot. 1525) in place; fitted
with claws (Mot. 1525-03) (2) for pulleys with thirty-
- the high pressure pump mounting bolts (4) on the
three teeth.
high pressure pump front support,
- the high pressure pump with the high pressure Extract the pulley by tightening the pulley extractor
pump support. thrust bolt (6) .
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.
1668).
102893
Position the (Mot. 1668) (1) .
102345
Remove the high pressure pump pulley nut (5) .
Remove:
- the mounting bolts (7) from the high pressure
pump,
- the high pressure pump.
13B-88
DIESEL INJECTION
F9Q, and 812
REFITTING II - REFITTING THE PUMP-RAIL HIGH PRESSURE

PUMP
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
pipes.
Tighten to torque:
- Do not lubricate pipes supplied without an appli-
- the high pressure pump mounting bolts on the cator, these high pressure pipes are self-lubri-
pump supports (30 Nm) , cating.
- the high pressure pump pulley nut (50 Nm) by
immobilising the pulley with the (Mot. 1668).
WARNING
Do not remove the plugs from each component
until the last moment.
Insert the high pressure pipe olive in the pump outlet

taper.
Insert the high pressure pipe olive in the pump inlet
taper.
Finger tighten the high pressure pipe nuts, starting
with the one at the rail end.
Slightly pretighten the high pressure pipe nuts.
Tighten to torque the injector rail mounting nuts
(22 Nm) .
Tighten to torque using the (Mot. 1746) or (Mot.
1566) :
- the pump-rail high pressure pipe nut on the
pump side (29 Nm) ,
102349
- the pump-rail high pressure pipe nut on the rail
Push the ring (8) back as shown in the diagram. side (25 Nm) .
Loosen the two high pressure pump rear support Proceed in the reverse order to removal.
mounting bolts (9) 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 PUMP REAR

SUPPORT
Tighten the mounting bolts by hand to press the sup-
port against the high pressure pump and the cylinder
block.
Tighten to torque the high pressure pump rear
support mounting bolts on the cylinder block (44
Nm) .
13B-89
DIESEL INJECTION
F9Q, and 812
Refit:
Timing belt ),
engine, Accessories belts ).
For versions with injector rail protectors:
- Refit the air 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
inlet duct: Removal - Refitting ).
13B-90
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 sockets for - that the fuel temperature is not too high.
Mot.1525. (for 33-tooth Loosening a high pressure pipe union when the
pulley). engine is running is strictly prohibited.
sure pump pipes. WARNING
Mot. 1566 Spanner 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
high pressure pump 30 Nm injection, Diesel injection: Repair precautions ).
pump supports REMOVAL
high pressure pump 50 Nm Position 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-91
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 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 mounting bolts (4) securing the high
Disconnect the diesel supply and return pipes (2) .
pressure pump to the high pressure pump rear sup-
Plug the openings. port.
Remove the retaining clip from the diesel pipes.
13B-92
DIESEL INJECTION
F9Q, and 804
102350 102894
Remove: Fit the pulley extractor (Mot. 1525) in place; fitted
- the mounting bolts (5) securing the high pressure with claws (Mot. 1525-03) (8) for pulleys with thirty-
pump 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
Set up (Mot. 1668) (6) .
Remove the nut (7) from the high pressure pump 102345
pulley.
Remove:
- the high pressure pump mounting bolts (10) ,
- the high pressure pump.
13B-93
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 injection rail mounting bolts (the injection
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 the (Mot. 1668).
WARNING
Do not remove the caps from each component
until the last moment.
Refit a new pump/rail high pressure pipe.

with the one at the rail end.
(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
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
Tighten the mounting bolts by hand to press the sup-
port against the high pressure pump and the cylinder
block.
Tighten to torque:
- the high pressure pump rear support mounting
bolts on the cylinder block (44 Nm) ,
13B-94
DIESEL INJECTION
F9Q, and 804
Refit:
Timing belt ),
engine, Accessories belts ),
- the air inlet duct (see 12A, Fuel mixture, Air inlet
Note:
Prime the diesel circuit using the manual priming

pump.
nal.
WARNING
WARNING

- Run the engine at idle speed,
- Accelerate several times under no load,
- Switch off the ignition,

Refit the injector rail protector (see 13B, Diesel in-
ting ).
Refit the air inlet duct (see 12A, Fuel mixture, Air
(4 Nm) .
13B-95
DIESEL INJECTION
K9K, and 732

IMPORTANT
Mot. 855 Timing gear locking
strap. Before carrying out any work on the injection sys-
Mot. 1525 Extractor for timing
gear with tapered hub.
- that the fuel temperature is not too high.
Mot. 1768 Injection pump-pulley
It is essential to respect the safety and cleanliness
extractor claws.
advice specified in this document whenever work is
Mot. 1566 Spanner for removing carried out on this system (see 13B, Diesel injec-
high pressure pipes. tion, cleanliness guidelines ).

tightening high pres- REMOVAL
sure pump pipes.
Equipment required
diagnostic tool ting equipment, Underbody lift ).
32 mm offset wrench
Tightening torquesm Removal - Refitting ).
high pressure pump 55 Nm Remove:

pulley - the engine covers,
high pressure pump 21 Nm - the front right-hand wheel,
mounting bolts
high pressure pipe nuts 24 Nm - the engine undertray.
WARNING
Before starting work on the vehicle, obtain:

- a new plug kit (part no. 77 01 476 857) ,
WARNING

104343
- the high pressure pipe between the high pressure
Remove:
pump and the injector rail.
- the scuttle panel grille (see 371 Bodywork, 55A,
Exterior protection, Scuttle panel grille ).
13B-96
DIESEL INJECTION
K9K, and 732
104246
Remove:
- the mounting bolts (3) from the plenum chamber
partition,
112811
Pull the clip.
Timing belt ).
112815
(4) .
112991
Loosen the clip (5) and move the air inlet duct (6) to Remove the mounting bolt (7) from the stainless
one side. steel pipe.
Move the air inlet duct to one side (8) .
13B-97
DIESEL INJECTION
K9K, and 732
112992
Unclip injector rail protector cover (9) . 112994
Disconnect:
Remove:
- the connector (14) from the damper valve,
protector cover, - the cylinder marking sensor connector (15) ,
- the injection rail protector cover, - the pressure regulation solenoid valve connector
(16) ,
- the dipstick,
112993
Disconnect:
13B-98
DIESEL INJECTION
K9K, and 732
112656
Protect the alternator from fuel outflow.
Pour cleaning product into a container.
IMPORTANT
duct.


IMPORTANT
WARNING
Do not blow compressed air once the fuel circuit
Disconnect:

new cloths.
13B-99
DIESEL INJECTION
K9K, and 732

new cloths.

CONCERNED
111748
Remove:
- the injector rail protector support bolt and mounting

nuts (23) ,
- the injector rail protector support.
Pour cleaning product into a container. 112789

Remove:
IMPORTANT - the high pressure pump mounting bolts (24) ,
Wear protective gloves when using cleaning pro- - the high pressure pump.
duct.
soak the brush with cleaning product and clean the REFITTING
high pressure pipe unions between the high pressu-
re pump and the injector rail I - REFITTING PREPARATION OPERATION
dry using new cloths. 1 - Remove the high pressure pump pulley
IMPORTANT
WARNING
If the high pressure pump is being replaced,
recover the high pressure pump pulley and refit it
to the new high pressure pump.
WARNING
Remove the high pressure pipe between the high

pressure pump and the injector rail and dispose of it
in a bin.
WARNING
When loosening the connector of the high pres-
sure pipe, the intermediate nut must be secured
on the pump using a lock wrench.
13B-100
DIESEL INJECTION
K9K, and 732
Fit the (Mot. 1525) equipped with (Mot. 1768) on the
high pressure pump pulley.
Protect the points of contact between the (Mot.
1768) and the high pressure pump pulley.
Extract the high pressure pump pulley.
WARNING
Take care not to mark the high pressure pump
pulley when removing it with the (Mot. 1525) fit-
ted with (Mot. 1768).
A damaged high pressure pump pulley must
always be replaced.
WARNING
Only remove the blanking plugs immediately
before connecting the fuel circuit pipes.
111743
The plugs are single-use. Do not reuse them;
dispose of the whole set after use.
Hold the high pressure pump in a vice, using the
lower securing point on the pulley side.
2 - Refitting the high pressure pump pulley
Immobilise the high pressure pump pulley using a 32 Take the high pressure pump out of its plastic bag.
mm offset wrench and remove the pulley mounting
nut (25) .
WARNING
If replacing a high pressure pump, only remove
the new high pressure pump from its original
packaging when it is about to be fitted.
Refit the high pressure pump pulley mounting nut.

Immobilise the high pressure pulley using a 32 mm
offset wrench or using the (Mot. 855).
Tighten to torque the high pressure pump pulley
(55 Nm) .
II - REFITTING PART CONCERNED

Take the high pressure pump out of its plastic bag.
WARNING
If replacing a high pressure pump, only remove
the new high pressure pump from its original
packaging when it is about to be fitted.
111744
Refit:
- the high pressure pump,
Note: - the high pressure pump mounting bolts.
The high pressure pump pulley can also be Tighten to torque the high pressure pump moun-
immobilised with the (Mot. 855). ting bolts (21 Nm) .
13B-101
DIESEL INJECTION
K9K, and 732
III - FINAL OPERATION Clip the injector rail protector cover.
Remove the blanking plugs. Refit the clip on the stainless steel pipe, if necessa-
ry.
Fit the new high pressure pipe between the injector
rail and the high pressure pump. Clip the stainless steel pipe to the turbocharger.
Refit:
Note: - the stainless steel pipe mounting bolt,
If the new pipes kit does not contain an applica- - the air inlet duct on the damper valve.
tor, it is not necessary to lubricate the pipe
threads (as they are self-lubricating pipes). Tighten the clip.
with the one at the injector rail side. Refit:
Tighten to torque the high pressure pipe nuts (24 - the timing belt (see 11A, Top and front of engine,
Nm) using the (Mot. 1566) or (Mot. 1746) and star- Timing belt ),
ting with the injector rail side. - the accessories belt (see 11A, Top and front of
Refit: engine, Accessories belt ),
- the injector rail protector support, - the scuttle panel partition,
- the mounting nuts and bolt of the injector rail pro- - the scuttle panel partition mounting bolts,
tector support. - the scuttle panel mounting bolt,
Clip the diesel evacuation pipe. - the air filter access panel,
Remove the blanking plugs. - the air filter access panel mounting bolts,
Connect: - the scuttle panel grille (see MR 371 Bodywork,
- the fuel supply pipe, 55A, Exterior protection, Scuttle panel grille ).
- the fuel return pipe. - the engine undertray,
Fit the wiring harness. - the right-hand wheel arch liner,
Refit the wiring harness clip mounting nut. - the front right-hand wheel,
Clip on the wiring harness retaining clip. - the engine covers.
Connect: Connect the battery (see 80A, Battery, Battery: Re-

- the diesel temperature sensor connector, pump.
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoid
valve,
- the cylinder marking sensor connector,
- the injectors' connector.
Refit:
- the dipstick tube mounting bolts.
- the dipstick,
bolt,
13B-102
DIESEL INJECTION
K9K, and 732
Using the diagnostic tool , clear any faults stored
by the injection computer, before restarting the engi-
ne.
WARNING
- check the sealing after repair (see 13B, Diesel
injection, High pressure pipe: Test),
- accelerate several times under no load,
- carry out a road test,
- check that there are no diesel fuel leaks.
Using the diagnostic tool , check that there are no

stored faults; clear them if necessary.
13B-103
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728

WARNING
high pressure pipes. Always replace any high pressure pipe or high pres-
sure pipe clip removed with a new one.
Equipment required It is forbidden:

- to remove the injector filter rods,
diagnostic tool
- to open the injectors.
low torque wrench
Injectors may be replaced individually. Only remove
high-pressure pipe wrench (DM19) the high pressure pipe concerned.
pipe socket for tightening injector-rail high pressure
pipes ("Crowfoot 18-17" wrench) REMOVAL
pipe socket for tightening the pump-rail high-pres- Remove the engine covers.
sure pipe (19-17 mm Crowfoot spanner)
terminal.
Tightening torquesm Remove the rail-injector high pressure pipes (see
13B, Diesel injection, High pressure pipe: Repla-
injector mounting clamp 28 Nm cing ).
rail nuts 28 ± 3 Nm
nut on the injector side 38 Nm
nut on the rail side 38 Nm

bolts
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
advice whenever work is carried out on this sys-
tem (see 13B, Diesel injection, Cleanliness gui-
delines ). 20803
- Loosening a high pressure pipe union when the Disconnect the diesel return pipe from the injector.
Plug the openings.
If reusing an injector, always mark a removed injec-
tor in relation to its cylinder.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector clamp mounting bolt (1) ,
13B-104
DIESEL INJECTION
K9K, and 722 or 728
- the injector and its clamp, Tighten to torque the injector mounting clamp (28
Nm) .
- the heat protection washer.
Before fitting the new high pressure pipe, lightly lu-
bricate the nut threads with the oil from the applica-
REFITTING tor provided in the new parts kit.
I - CLEANING THE INJECTORS

WARNING
- Some pipes are supplied with applicator and
some without.
WARNING
- The pipes supplied without applicator are self-
It is strictly forbidden to clean the injectors with: lubricating pipes. The torque is still the same
(38 Nm) .
- a wire brush,
- an emery cloth, Fit the high pressure pipe:
- an ultrasonic cleaner. - remove the protective plugs,
Soak the injectors in degreaser. - insert the high pressure pipe olive in the injector in-
let taper,
Wipe with new cloths, part number 77 11 211 707 .
- insert the high pressure pipe olive in the rail outlet
taper.
II - REFITTING THE INJECTORS
Finger tighten the nut, first at the injector end then
the rail end.
WARNING Pretighten slightly.

Do not remove the plugs from each component Fit a new clip supplied with the new pipe onto the
until the last moment. high pressure pipes:
Using cloths part number 77 11 211 707 soaked in - insert the first half-shell using adjustable pliers,
fresh solvent, clean: - insert the second half-shell using adjustable pliers.
- the injector wells,
- the injector bodies, WARNING
- the injector clamps. Observe the direction of fitting of the second
shell. The lugs located in the centre of the clip
Use a new cloth to dry components that have been will only engage in one position.
cleaned.
Replace the heat protection washer with a new one.
Note:
If one or more injectors are replaced, note the
alphanumeric code (C2I) and the cylinder on
which it is fitted.
Refit the injector with its clamp.
13B-105
DIESEL INJECTION
K9K, and 722 or 728
19723 19724
Tighten to torque the rail nuts (28 ± 3 Nm) . Program the alphanumeric code (C2I) (2) for the re-
placed injector(s) using the diagnostic tool (see
13B, Diesel injection, Injectors: Configuration ).
WARNING
- Do not touch the pipes with the spanner when
tightening. WARNING
- When tightening the high pressure pipes, make Check that there are no diesel fuel leaks:
sure the central union of the injector is held
secure. - Let the engine run at idle speed until the engine
cooling fan starts up.
Tighten to torque and in order: - Accelerate several times at no load.
- the nut on the injector side (38 Nm) , - Carry out a road test.
- the nut on the rail side (38 Nm) , - Switch off the ignition.
using the (Mot. 1566) , possibly equipped with one - Check that there is no diesel fuel escaping.
of the following:
- low torque wrench ,
(4 Nm)
- high-pressure pipe wrench (DM19) ,
- pipe socket for tightening injector-rail high
pressure pipes ("Crowfoot 18-17" wrench) ,
- pipe socket for tightening the pump-rail high-
pressure pipe (19-17 mm Crowfoot spanner).
Prime the diesel circuit using the priming pump.
nal.
WARNING
13B-106
DIESEL INJECTION
F9Q, and 804 or 812
For versions without injector rail protectors:
- remove the inlet duct (see 12A, Fuel mixture, Air
Mot. 1566 Spanner for removing inlet duct: Removal - Refitting ), if necessary.

sure pump pipes.
Equipment required
diagnostic tool
Tightening torquesm
injector clamp bolt 25 Nm
nut on the injector side 25 Nm
nut on the rail side 29 Nm

bolts
IMPORTANT

- Loosening a high pressure pipe union when the
During each operation, always read the precautions for

repair (see 13B, Diesel injection, Diesel injection:
Repair precautions ).
WARNING
Opening the injectors is prohibited.
Injectors may be replaced individually. Only remove

the high pressure pipe concerned.
REMOVAL

terminal.

injection, Injector rail protection: Removal - Re-
fitting ), if fitted to the vehicle.
13B-107
DIESEL INJECTION
F9Q, and 804 or 812
18297-1
Disconnect the injector connector.
Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the return rail.
Fit blanking plugs into the openings.
13B-108
DIESEL INJECTION
F9Q, and 804 or 812
REFITTING
I - CLEANING INJECTORS (IF THEY ARE REUSED)
WARNING
It is strictly forbidden to clean the injectors with:

- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
Clean, using new cloths soaked in cleaning product

(see 13B, Diesel injection, Diesel injection: Re-
pair precautions ):
- the injector wells,
- the injector bodies,
1327 - the injector clamps.

Remove the « injector-rail » high pressure pipe Use a new cloth to dry components that have been
using the (Mot. 1566) or (Mot. 1746). cleaned.
WARNING II - REFITTING THE INJECTOR

The injector filter rod must not be removed.
WARNING
WARNING Do not remove the blanking plugs from each
When loosening the injector pipe unions (1) on
the injectors, be sure to hold the filter rod retai-
ning nuts (2) with a lock wrench.

If reusing an injector, always mark a removed injec-
tor in relation to its cylinder.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector clamp mounting bolt,
- the injector and its clamp,
13B-109
DIESEL INJECTION
F9Q, and 804 or 812
1326
Replace the heat protection washer (3) 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 clamp.

Tighten to torque the injector clamp bolt (25 Nm) .
WARNING
Do not put high pressure pipes under stress.
WARNING
Be sure to replace all high pressure pipes remo-
ved.
Tighten by hand the high pressure pipe nuts until

contact is made with the rail and injector.
WARNING
Always hold the filter rod mounting nuts on the
injector holder with a lock wrench when tighte-
ning.
Tighten to torque using the (Mot. 1566) or (Mot.

1746) :
- the nut on the injector side (25 Nm) ,
- the nut on the rail side (29 Nm) ,
13B-110
DIESEL INJECTION
F9Q, and 804 or 812
18297-1
Refit the return rail (4) . Program the alphanumeric code (IMA) for the injec-
tor(s) replaced using the diagnostic tool (see MR
372 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.
To refit, proceed in the reverse order to removal.
- Run the engine at idle speed.
inlet duct: Removal - Refitting ), if removed. - Accelerate several times under no load.
- Switch off the ignition.
Note: - Check that there is no diesel fuel escaping.
For versions with injector rail protectors: 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 13A, Diesel in-
WARNING ting ),
Carry out the necessary programming (see 80A, - Refit the inlet duct (see 12A, Fuel mixture, Air in-
Battery, Battery: Removal - Refitting ). let duct: Removal - Refitting ).
13B-111
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 pipes. - that the fuel temperature is not too high.
Equipment required advice specified in this document whenever work is
carried out on this system (see 13B, Diesel injec-
diagnostic tool tion, cleanliness guidelines ).

injector clamp mounting 30 Nm
bolt I - REMOVAL PREPARATION OPERATION
nuts
high-pressure pipe nuts 24 Nm
WARNING

WARNING

- all the high-pressure pipes which have been remo-
ved. 112815
- any injector that has been opened, contrary to ins-
(1) .
tructions,
Loosen the clip and (2) move the air inlet duct aside
- any damaged mounting clips for the fuel return
(3) .
pipe on the injector.
13B-112
DIESEL INJECTION
K9K, and 732
112811 112992
Pull the clip. Unclip the injector rail protector cover (6) .
Remove:
protector cover,
- the dipstick,
- the mounting bolts (8) from the dipstick duct.
Move the dipstick duct to one side.
IMPORTANT
duct.
Soak the brush with cleaning product, then clean the

unions:
112991
- of the high-pressure pipes between the injector rail
Remove the mounting bolt (4) from the stainless and the injectors
steel pipe.
- the fuel return connectors of the injectors.
13B-113
DIESEL INJECTION
K9K, and 732
IMPORTANT
WARNING
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.
Remove:
- the nut of the high-pressure pipe between the injec-
tor rail and the injector on the rail end,
114075
- the nut of the high-pressure pipe between the injec-
Disconnect the injector connector (9) . tor rail and the injector on the injector end,
Remove the high-pressure pipe in question and dis-
card it.
Note:
new cloths.
13B-114
DIESEL INJECTION
K9K, and 732
CONCERNED
111749
Using a thin, flat-blade screwdriver, push the lower
bracket of the retaining clip (12) of the fuel return
connector on the injector towards the rocker cover.
WARNING
Ensure that you do not remove the clip comple-
111746
tely from its housing in order to prevent piercing it
during contact with the rocker cover. Remove:
- the injector clamp mounting bolt (13) ,
- the injector clamp,
- the spacer between the cylinder head and the in-
jector clamp,
- the injector,
- the heat protection washer situated at the bottom of
the injector well in the cylinder head.
111751
Extract the fuel return connector from the injector
while pushing the lower bracket of the retaining clip
downwards.
Fit the correct blanking plug.
Remove the fuel return pipe from the injector.
13B-115
DIESEL INJECTION
K9K, and 732
114010 112993
Disconnect:
Note: - the injector connector (14) ,
If the injector is jammed in its well and does not - the heater plugs connector (15) .
come out, turn the injector at the flat support sur-
faces of the injector clamp using a 13 mm open
end wrench.
Fit the appropriate blanking plug on the injector's no-

se.
WARNING
If it is to be reused, keep the injector(s) in a sea-
led plastic bag until required.
WARNING
Ensure that no impurities enter into the cylinder
via the injector well in the cylinder head: plug the
orifice using a clean cloth.
Removal of four injectors
Note:
This procedure only applies if removing all the
injectors and, after having removed them all, in
preparation for refitting them.
13B-116
DIESEL INJECTION
K9K, and 732
112994 112656
Disconnect: Pour cleaning product into a container.
- the cylinder marking sensor connector (17) , IMPORTANT
- the pressure regulation solenoid valve connector Wear protective gloves when using cleaning pro-
(18) , duct.
- the flow regulation solenoid valve connector (19) , Soak the brush with cleaning product and clean the
- the diesel fuel temperature sensor connector (20) , fuel supply and return pipe unions.
- the rail pressure sensor connector. Blast the cleaned areas with compressed air then
Detach the retaining clip (21) from the electrical har- dry using new cloths.
ness.
Remove the mounting nut (22) from the electrical IMPORTANT
harness clip. Wear protective glasses.
WARNING
Disconnect:
Note:
new cloths.
13B-117
DIESEL INJECTION
K9K, and 732
Remove the injector from its plastic bag.
WARNING
If replacing the injector, do not remove it (them)
from its (their) packaging until just before you refit
it (them).
Remove the blanking plugs on the nose of the injec-

tor.

CONCERNED
Refit:
111748 - a new heat protection washer at the bottom of the
Unclip the diesel evacuation pipe. injector well in the cylinder head.
- the injector,
Remove:
- the spacer between the cylinder head and the in-
- the mounting nuts and bolt (25) from the injector jector clamp,
rail protector support,
- the injector clamp,
- the injector rail protector support. - the injector clamp mounting bolt.
Loosen the injector rail mounting nuts by a few turns Tighten to torque the injector clamp mounting bolt
(the injector rail should be loose). (30 Nm) .
REFITTING Fit the new high-pressure pipe(s) between the injec-

tor rail and the injector.

Note:
If the new pipes kit does not contain an applica-
Cleaning the injectors
threads (as they are self-lubricating pipes).
WARNING Finger tighten the high pressure pipe nuts, starting

with the one at the injector rail end.
It is strictly forbidden to clean the injectors with:
- a wire brush, 1 - Refitting the four high-pressure pipes
- an emery cloth, Tighten to torque the injector rail mounting nuts

(28 Nm) .
- an ultrasonic cleaner.
Refit:
Leave the injectors to soak in degreaser. - the injector rail protector support,
Clean using new wipes.
tector support.
Clip the diesel evacuation pipe into place.
WARNING
before connecting the fuel circuit pipes. Connect:
The plugs are single-use. Do not reuse them; - the fuel supply pipe,
dispose of the whole set after use. - the fuel return pipe.
13B-118
DIESEL INJECTION
K9K, and 732
Fit the wiring harness. Refit:
Refit the wiring harness clip mounting nut. - the stainless steel pipe mounting bolt,
Clip on the wiring harness retaining clip. - the air inlet duct on the damper valve.
Connect: Tighten the clip.
- the rail pressure sensor connector, Connect:

- the diesel temperature sensor connector,
- the connector of the flow regulation solenoid valve, Refitting ).
- the connector of the pressure regulation solenoid Reprime the fuel circuit with the manual priming
valve, pump.
- the cylinder marking sensor connector, Refit the engine covers.
- the connector on the damper valve, Using the diagnostic tool , clear any faults stored
- the heater plugs connector,
ne.
WARNING
2 - All types Check that there are no diesel fuel leaks:
Tighten to torque the high-pressure pipe nuts (24 - check the sealing after repair (see 13B, Diesel
Nm) using the (Mot. 1566) or (Mot. 1746) and star- injection, High pressure pipe: Test ),
ting at the injector rail end.
Remove the blanking plugs. cooling fan starts to operate,
Push the retaining clip of the fuel return connector - accelerate several times at no load,
on the injector to the front of the vehicle in order to - carry out a road test,
place it in its initial position.
Clip on the fuel return connector of the injector.
WARNING Using the diagnostic tool , check that there are no

Check the condition of the seal on the fuel return
connector of the injector.
Change the diesel return rail if one of its compo-
nents is damaged.
Refit:
- the dipstick duct mounting bolts.
- the dipstick,

bolt,
Clip the injector rail protector cover into place.
ry.
13B-119
DIESEL INJECTION
Diesel injector adjustment value 13B
F9Q, and 812
Equipment required
note:
diagnostic tool This command is valid for both one-off entry and
batch entry.
REPLACING THE INJECTORS
note:
A 6-character « alphanumeric » code known as the
IMA (Injector Flow Correction) is marked on the
injectors. This code is specific to each injector, and
takes into account manufacturing dispersion and
specifies the flow of the injector.
When replacing one or more injectors, program the

code of the new injector or injectors into the computer.
If this operation is not carried out then the engine
speed will be limited to 1800 rpm .
These correction values are etched onto the bakelite
body of each « alphanumeric » injector and then ente-
red into the computer, which can then control each in-
jector in view of their variations in manufacture.
The system can be coded via the diagnostic socket
using the diagnostic tool.
When replacing one or more injectors, replace the IMA

codes. To do this, re-enter the IMA codes into the com-
puter using the following command:
- SC002 « Enter injector codes »
107035
Note down the IMA codes etched on the bakelite body

of each injector, and follow the on-screen instructions.
13B-120
DIESEL INJECTION
Diesel injector adjustment value 13B
K9K, and 722 or 728
REPLACING THE INJECTORS
Note:
The C2I (individual injector correction) parameters
are set in production for each injector to adjust the
flow of each injector precisely, taking into account
variations 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 using the diagnostic
socket with the RENAULT CLIP diagnostic tool.
When replacing one or more injectors, replace the C2I
parameters. To do this, re-enter the C2I parameters
into the computer using the following commands:
- To enter the four C2Is when replacing the computer,
run the SC002 « Enter injector codes » command.
- 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 » com-
mand.
13B-121
DIESEL INJECTION
High-pressure pipe between the pump and rail: Removal - Refitting 13B
K9K, and 732
Mot. 1566 Spanner for removing Removal - Refitting ).

sure pump pipes.
Equipment required
diagnostic tool
Tightening torquesm
112815
WARNING Disconnect the air inlet pressure sensor connector
(1) .
Loosen the clip and (2) move the air inlet duct (3)
- a new plug kit (part no. 77 01 476 857) , aside .
WARNING

ved.
IMPORTANT
It is essential to respect the safety advice and 112811
cleanliness guidelines specified in this document Pull the clip.
whenever work is carried out on this system (see
13B, Diesel injection, Cleanliness guidelines ).
REMOVAL

13B-122
DIESEL INJECTION
K9K, and 732
112991
Remove the mounting bolt (4) from the stainless 112993
steel pipe. Disconnect:

Move the air inlet duct (5) to one side. - the injector connector (9) ,
112992
Unclip the injector rail protector cover (6) .

Remove:
protector cover,
- the dipstick,
- the mounting bolts (8) of the dipstick tube.
13B-123
DIESEL INJECTION
K9K, and 732
112994 112656
Disconnect: Protect the alternator from fuel outflow.
- the connector (11) from the damper valve, Pour the cleaning product into a container.
- the cylinder marking sensor connector (12) ,
- the pressure regulation solenoid valve connector IMPORTANT
(13) ,
Wear protective gloves when using the cleaning
- the flow regulation solenoid valve connector (14) , product.
- the diesel fuel temperature sensor connector (15) ,
- the rail pressure sensor connector. fuel supply and return pipe unions.
Unclip the retaining clip (16) from the wiring harness. Blast the cleaned areas with compressed air then
Remove the mounting nut (17) from the wiring har- dry using fresh wipes.
ness clip.
Move the wiring harness to one side. IMPORTANT
WARNING
Disconnect:

fresh wipes.
13B-124
DIESEL INJECTION
K9K, and 732
CONCERNED
Remove the high-pressure pipe between the high-

in a bin.
WARNING
When loosening the connector of the high-pres-

111748
fresh wipes.
Remove: Fit the correct blanking plugs.
- the mounting nuts and bolt (20) from the injector

rail protector support, REFITTING
Pour the cleaning product into a container. I - REFITTING PREPARATION OPERATION
IMPORTANT
Wear protective gloves when using the cleaning WARNING
product. Only remove the blanking plugs immediately
unions: The plugs are single-use. Do not reuse them;
dispose of the whole set after use.
- on the high-pressure pump fuel return pipe, taking
care not to soak the diesel fuel temperature sensor, Take the new high-pressure pipe out of its plastic
- on the high-pressure pipe between the high-pres- bag.
sure pump and the injector rail.
dry using fresh wipes.
CONCERNED
IMPORTANT
Wear protective goggles. Fit the new high-pressure pipe between the injector
rail and the high-pressure pump.
WARNING
Note:
is open, otherwise impurities may enter the sys- If the new pipe kit does not contain an applicator,
tem. Use wipes if necessary. lubrication of the pipe threads will be unneces-
sar y (as they are self-lubricating pipes).
Finger tighten the high-pressure pipe nuts, starting

with the one at the injector rail side.
Tighten to torque the high-pressure pipe nuts (24

Nm) using the (Mot. 1566) or (Mot. 1746) and star-
ting with the injector rail side.
13B-125
DIESEL INJECTION
K9K, and 732
III - FINAL OPERATION - the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Refit:
pump.
- the mounting nuts and bolt of the injector rail pro- Refit the front engine covers.
tector support.
Clip the diesel evacuation pipe. by the injection computer, before restarting the engi-
Remove the blanking plugs. ne.
Connect:
WARNING
- the fuel return pipe.
- Check the sealing after repair (see 13B, Diesel
Fit the wiring harness. injection, High-pressure pipe: Check ),
Refit the mounting nut of the wiring harness clip. - let the engine run at idle speed until the engine
Clip on the retaining clip of the wiring harness.
Connect:
- the diesel fuel temperature sensor connector,
Using the diagnostic tool , check that there are no
- the connector of the pressure regulation solenoid stored faults; and clear them if necessary.
valve,
- the connector on the injectors.
Refit:
- the dipstick tube mounting bolts,
- the dipstick,
bolt,
ry.
Refit:
- the inlet manifold on the damper valve.
Tighten the clip.
Connect:
13B-126
DIESEL INJECTION
K9K, and 722 or 728
REMOVAL

sure pump pipes.
Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
Equipment required
diagnostic tool K9K, and 722
Tightening torquesm
high pressure pipe 24 Nm
IMPORTANT
before carrying out any work on the injection circuit,

check using the diagnostic tool :
102120
During each operation, always respect the repair
precautions relating to diesel injection. Disconnect the air inlet duct (1) .

engine is running is prohibited.
K9K, and 728

WARNING

- a new plug kit (part no.: 77 01 206 804 ),
- cleaning cloths (part no.: 77 11 211 707 ).
WARNING
Torque tighten to (38 Nm) the « pump-rail » and

« injector rail » high pressure pipes with one of the
following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 028 .
for high pressure pipes with different part numbers, 110325
tighten to a torque of (24 Nm) . Pull the clip.
13B-127
DIESEL INJECTION
K9K, and 722 or 728
REFITTING
110323
Undo the bolt (2) .
20960
Unclip the dipstick. WARNING

Before fitting a new high pressure pipe, lightly
Remove the dipstick.
lubricate the nut threads with oil from the applica-
tor provided in the new part.
Be careful not to allow oil into the high pressure
CONCERNED
pipe.
Clean the « pump-rail » pipe (see 13B, Diesel injec-
Do not lubricate high pressure pipes supplied
tion, Diesel injection: Repair precautions ).
without an applicator, as these high pressure
Loosen: pipes are self-lubricating.
- the high pressure pipe nut at the pump end,
- the high pressure pipe nut at the injector rail end. WARNING
Fit blanking plugs into the openings. Do not remove the blanking plugs from each
Throw away the pipe.
13B-128
DIESEL INJECTION
K9K, and 722 or 728
CONCERNED
Insert the high pressure pipe olive in the high pres-
sure pump high pressure outlet taper.
Insert the high pressure pipe olive into the injector

rail inlet taper.
with nut at the rail end.
Tighten to torque the high pressure pipe (24 Nm)


Insert the dipstick.
K9K, and 722

Connect the air inlet duct.
Tighten the clip.
K9K, and 728

Position the air inlet duct on to the turbocharger.
Fit the clip.

Tighten the air inlet duct bolt on the rocker cover.
Connect the battery (see 80A, Battery: Removal -

Refitting ).
Check that there are no diesel leaks by checking the
seal after repair (see 13B, Diesel injection, High
pressure pipe: Check ).
WARNING
Check that there are no diesel leaks:

- run the engine at idle speed,
- confirm that there is no diesel leak.
13B-129
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
REMOVAL

Mot. 1746 Offset spanner for Switch off the ignition and wait 30 seconds before
tightening high pres- working on the injection system.
sure pump pipes.
Equipment required Disconnect the battery (see 80A, Battery, Battery:

diagnostic tool
Tightening torquesm

nuts
high pressure pipe nuts 24 Nm
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 and (2) move the air inlet duct (3) to
WARNING one side.

- all the high pressure pipes which have been remo-
ved.
IMPORTANT
tion, Cleanliness guidelines ).
112811
Pull the clip.
13B-130
DIESEL INJECTION
K9K, and 732
IMPORTANT
duct.
Soak the brush with cleaning product then clean the

high pressure pipe unions between the injector rail
and the injectors.
IMPORTANT
112991
WARNING
steel pipe. is open, otherwise impurities may enter the sys-
Move the air inlet duct (5) to one side. tem. Use cloths if necessary.

CONCERNED
112992

Remove:
1327
protector cover,
WARNING
When loosening the high pressure pipe unions
- the dipstick, (9) on the injector holder, it is essential to hold
- the dipstick tube mounting bolts (8) . the filter rod retaining nut (10) with a lock wrench.
13B-131
DIESEL INJECTION
K9K, and 732
Remove:
- the nut of the high pressure pipe between the injec-
tor rail and the injector on the rail end,
- the nut of the high pressure pipe between the injec-
tor rail and the injector on the injector end,
Remove the high pressure pipe in question and dis-
card it.
Note:
new cloths.
Removing the four high pressure pipes
Note:
112994
This procedure only applies if removing all the
Disconnect:
high pressure pipes and, after having removed
them all, in preparation for refitting them. - the connector (13) from the damper valve,
- the pressure regulation solenoid valve connector
(15) ,
112993
Disconnect:
- the heater plug connector (12) .
13B-132
DIESEL INJECTION
K9K, and 732
111748
Remove:
- the injector rail protector support bolt and mounting
nuts (22) ,
112656
Loosen the injector rail mounting nuts by a few turns
(the injector rail should be loose).
IMPORTANT
Wear protective gloves when using cleaning pro- REFITTING
duct.
Soak the brush with cleaning product and clean the I - REFITTING PREPARATION OPERATION

WARNING
IMPORTANT The plugs are single-use. Do not reuse them;
Wear protective glasses. dispose of the whole set after use.
Take the new high pressure pipe out of its plastic

bag.
WARNING
Do not blow compressed air once the fuel circuit Remove the blanking plugs.
tem. Use cloths if necessary. II - REFITTING OPERATION FOR PART
CONCERNED
Disconnect:
- the fuel supply pipe (20) , rail and the injector.
Note:
Note: If the new pipes kit does not contain an applica-

tor, do not lubricate the pipe threads (as they are
Make preparations for fuel outflow. Clean with self-lubricating pipes).
new cloths.
Fit the correct blanking plugs. with the one at the injector rail side.
13B-133
DIESEL INJECTION
K9K, and 732
1 - Refitting the four high pressure pipes Refit:
Tighten to torque the injector rail mounting nuts - the stainless steel pipe mounting bolt,
(28 Nm) .
- the air inlet duct on the damper valve.
Refit: Tighten the clip.
Connect:
tector support.
Clip the diesel evacuation pipe.
Refitting ).
Connect: pump.
- the fuel supply pipe, Refit the front engine covers.
- the fuel return pipe. Using the diagnostic tool , clear any faults stored
ne.
Refit the mounting nut of the wiring harness clip.
Clip on the wiring harness retaining clip. WARNING
Connect: Check that there are no diesel leaks:
- the rail pressure sensor connector, - Check the seal after repair (see 13B, Diesel
injection, High pressure pipe: Check ),
- the diesel temperature sensor connector,
- the connector of the pressure regulation solenoid
valve,
- the damper valve connector,
- check that there are no diesel leaks.
- the injectors' connector. Using diagnostic tool , check that there are no sto-
red faults; clear them if necessary.
2 - All types
Tighten to torque the high pressure pipe nuts (24
Nm) using (Mot. 1566) or (Mot. 1746) and starting
with the injector rail side.

Refit:
- the dipstick tube mounting bolts,
- the dipstick,
- the mounting nut and bolt of the injector rail protec-
tor cover,
ry.
13B-134
DIESEL INJECTION
K9K, and 732
13B-135
DIESEL INJECTION
K9K, and 722 or 728
Equipment required
WARNING
diagnostic tool
Torque tighten to 38 Nm the « pump-rail » and
« injector rail » high pressure pipes with one of the
following part numbers:
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 .
high pressure pipe nuts 24 Nm
of the « injector rail » For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
nut of the neck on the 21 Nm
rail
REMOVAL
bolts
IMPORTANT Removal - Refitting ).
- that the injector rail is not under pressure, K9K, and 722

During each operation, always respect the repair
precautions relating to diesel injection.
engine is running is prohibited.
WARNING

- a new plug kit (part no.: 77 01 208 804 ),
- cleaning cloths (part no.: 77 11 211 707 ).
102120
Disconnect air inlet duct (1) .
13B-136
DIESEL INJECTION
K9K, and 722 or 728
K9K, and 728
102362
Remove the diesel splash plate (4) .

110325
Pull the clip.
102361
Remove the dipstick guide (5) .

110323
Undo the bolt (2) . Plug the openings.
Remove the air duct (3) . Disconnect:
- the heater plugs (6) ,
- the injectors,
- the high pressure pump electrical connectors (7) ,
- the diesel supply and return pipes (8) .
13B-137
DIESEL INJECTION
K9K, and 722 or 728
102360 19724
Disconnect:
- the diesel return pipe (9) connecting the injectors to
the high pressure injection pump,
- the rail pressure sensor (10) ,
- the accelerometer (11) ,
- the oil level sensor (12) ,
- the cylinder marking sensor (13) from the timing
cover.
Release the wiring harness on the side.
Remove the neck located on the injector rail.
WARNING
Be sure to hold the intermediate injector union
(14) in place with a spanner when loosening the
Do not damage the injector leak return nozzle
20803
(15) .
Loosen the injector rail mounting nuts by several
turns (16) .
Remove the clips (17) connecting the high pressure
pipes to one another.

CONCERNED
Clean the pipe(s) to be removed (see 13B, Diesel
injection, Diesel injection: Repair precautions ).
13B-138
DIESEL INJECTION
K9K, and 722 or 728
Loosen: REFITTING
- the high pressure pipe nut at the injector end,
- the high pressure pipe nut at the injector rail end. I - REFITTING PREPARATION OPERATION
Note:
Loosen the nuts pipe by pipe.
Move the nuts along the tube, keeping the olive in

contact with the taper.
20960
WARNING
Before fitting a new high pressure pipe, lightly
lubricate the nut threads with oil from the applica-
tor provided in the new part.
20803
Be careful not to allow oil into the high pressure
Remove the high pressure pipes (18) one by one.
pipe.
Plug the openings.
Do not lubricate high pressure pipes supplied
Throw away the pipe(s). without an applicator, as these high pressure
pipes are self-lubricating.
WARNING
Do not remove the blanking plug from each com-
ponent until the last moment.
If replacing the four high pressure pipes:

- remove the anti-splash cover mounting,
- Undo the injector rail mounting nuts by a few turns

(the injector rail should be loose).

CONCERNED

Insert the high pressure pipe olive in the injector high
pressure inlet taper.
13B-139
DIESEL INJECTION
K9K, and 722 or 728
Insert the high pressure pipe olive into the rail high Check the sealing after repair (see 13B, Diesel in-
pressure outlet taper. jection, High pressure pipe: check ).
with the nut at the injector end. WARNING
Note:
The order of fitting the « injector-rail » high pres-
sure pipes is not important. - accelerate several times at no load,
Fit the new clip provided with the new high pressure
pipe. - confirm that there is no diesel leak.
If replacing the four high pressure pipes, torque tigh-

ten the injector rail mounting nuts (28 Nm) .
Tighten to torque and in order the « pump-rail »
high pressure pipe nuts (24 Nm) :
- pump end,
- rail end.
Tighten to torque and in order the high pressure
pipe nuts of the « injector rail » (24 Nm) .
- injectors end,
- rail end.
Note:
Tighten a pipe fully before moving on to the next
pipe.

Refit the neck to the injector rail and torque tighten
the nut of the neck on the rail (21 Nm) .
(4 Nm) .
13B-140
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728
REMOVAL
Equipment required Remove the engine covers.
diagnostic tool Disconnect the battery, starting with the negative

terminal.
low torque wrench
Remove:
- the rail-injector high-pressure pipes (see 13B, Die-
Tightening torquesm sel injection, High-pressure pipe: Replacement
).
neck nut on the rail 21 Nm
- the mounting bolts for the spherical injector rail,
battery cover mounting 4 Nm - the spherical injector rail.
bolts
REFITTING
IMPORTANT
Before carrying out any work on the injection sys- WARNING

tem, check using the diagnostic tool : Only remove the blanking plugs at the last
• that the fuel temperature is not too high. moment.

- It is essential to respect the safety and cleanliness WARNING
advice given in this document whenever work is Always replace all the high-pressure pipes remo-
carried out on this system. ved.
Fit a new high-pressure rail on the studs.
Finger tighten the nuts.
WARNING Note:
- Ensure that you have a special high pressure - Fit the pump-rail pipe before the injector-rail
injection circuit blanking plugs kit. pipes.
- Always replace any high pressure pipe or high - To remove the high-pressure pipes (see 13B,
pressure pipe clip removed with a new one. Diesel injection, High-pressure pipe: Repla-
cement ).
WARNING
- Working on the injectors is not permitted.
- The injector filter rod must not be removed.
- Be sure to replace any injector that has been ope-
ned.
- Separating the pressure sensor from the rail is
prohibited.
13B-141
DIESEL INJECTION
K9K, and 722 or 728
Tighten to torque the neck nut on the rail (21 Nm)
using the low torque wrench.
nal.
WARNING

(4 Nm)
WARNING

injection, High-pressure pipe: Test ),
13B-142
DIESEL INJECTION
F9Q, and 812


sure pump pipes.
Equipment required
diagnostic tool
Tightening torquesm

bolts
nuts on the injector side 25 Nm

and the nut on the injec-
tor pump side
nuts on the rail side 29 Nm

bolts
IMPORTANT

- Loosening a high-pressure pipe union when the

REMOVAL
terminal.
Remove:
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ),

), if fitted to the vehicle.
13B-143
DIESEL INJECTION
F9Q, and 812
18297-1
Disconnect: Plug the openings.

- the pressure sensor connector (1) ,
- the fuel temperature 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-144
DIESEL INJECTION
F9Q, and 812
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
6 the pump and injector side,
7 - screw, by hand, the high-pressure pipe nuts onto
the rail side.
Tighten to torque using the (Mot. 1566) or the (Mot.
1746) :
- the injector rail mounting bolts (25 Nm)
- the nuts on the injector side and the nut on the
injector pump side (25 Nm)
- the nuts on the rail side (29 Nm) .
WARNING
1327 Do not put high-pressure pipes under stress.
Remove the high-pressure diesel pipes using the Always hold the filter rod retaining nuts on the
(Mot. 1566) or the (Mot. 1746). injector holder when tightening.
WARNING
the injectors, be sure to hold the filter rod retai-
Plug the openings.

Remove:
- the injector rail bolts,
- the injector rail (5) .
REFITTING
WARNING
Do not remove the protective plugs from each
Always replace any high-pressure pipe removed
with a new one.
13B-145
DIESEL INJECTION
F9Q, and 812
18297-1
Refit the return rail (8) :

- 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 protectors: - 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 replacing 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-146
DIESEL INJECTION
F9Q, and 804


sure pump pipes.
Equipment required
diagnostic tool
Tightening torquesm
111965
injector rail mounting 25 Nm Disconnect:
bolts
nuts on the injector end 25 Nm - the cylinder marking sensor connector (2) ,
and the nut on the injec-
tion pump end - the fuel return pipe.
Plug the openings.
nuts on the rail end 29 Nm
bolts
Remove the diesel return pipe (3) .
IMPORTANT
Plug the openings.

REMOVAL
terminal.
Remove:
).
13B-147
DIESEL INJECTION
F9Q, and 804
REFITTING
WARNING
Do not remove the protective plugs from each
Always replace any high pressure pipe removed
with a new one.
Tighten the injector rail bolts, leaving clearance

between the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
the pump and injector side,
the rail side.
1327
Remove the high-pressure diesel pipes using the Tighten to torque using the (Mot. 1566) or the (Mot.
(Mot. 1566) or the (Mot. 1746). 1746) :
- the injector rail mounting bolts (25 Nm) ,
WARNING - the nuts on the injector end and the nut on the
injection pump end (25 Nm) ,
the injectors, be sure to hold the filter rod retai- - the nuts on the rail end (29 Nm) .
WARNING
Plug the openings.
Do not put high pressure pipes under stress.
Remove the oil separator. Do not touch the high pressure pipes with the
spanner when tightening them to torque.
Always hold the filter rod retaining nuts on the
injector holder when tightening.
111859
Remove:
- the injector rail bolts (6) ,
- the injector rail (7) .
13B-148
DIESEL INJECTION
F9Q, and 804
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

- confirm that there is no diesel fuel leak.

(4 Nm) .
13B-149
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 pipes. - that the fuel temperature is not too high.
Equipment required advice specified in this document whenever work is
diagnostic tool tion, cleanliness guidelines ).

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
WARNING

WARNING 112815
(1) .
Loosen the clip (2) and move aside the air inlet duct
ved.
(3) .
13B-150
DIESEL INJECTION
K9K, and 732
112811 112992
Pull the clip. Unclip the injector rail protector cover (6) .
Remove:
bolt (7) ,
- the dipstick,
- the dipstick duct mounting bolts (8) .
Move the dipstick duct to one side.
112991
steel pipe.
112993
Disconnect:
13B-151
DIESEL INJECTION
K9K, and 732
- the heater plug connector (10) .
112656
112994
Disconnect:
IMPORTANT
- the pressure regulating solenoid valve connector
(13) ,
duct.
- the flow regulating solenoid valve connector (14) ,
Detach the wiring harness retaining clip (16) . dry using new cloths.
Remove the wiring harness clamp mounting nut (17)
.
IMPORTANT
WARNING
Disconnect:

new cloths.
13B-152
DIESEL INJECTION
K9K, and 732
111748
Remove:
- the injector rail protector support mounting nuts
and bolt (20) ,
1327
WARNING
When loosening the high-pressure pipe unions
IMPORTANT (21) on the injector holders, it is essential to hold
Wear protective gloves when using cleaning pro- the filter rod mounting nut (22) with a lock
duct. wrench.
Soak the brush with cleaning product, then clean the Remove:
unions:
- the nuts from the four high-pressure pipes between
- of the high-pressure pipes between the injection the injector rail and the injector on the rail end,
rail and the diesel injectors
- the nuts from the four high-pressure pipes between
- the high-pressure pipe between the injector rail and the injector rail and the injector on the injector end,
the high-pressure pump.
Remove the four high-pressure pipes and dispose of
Blast the cleaned areas with compressed air then them in a bin.
Note:
IMPORTANT
Wear protective glasses. new cloths.

WARNING
13B-153
DIESEL INJECTION
K9K, and 732
Remove the high pressure pipe between the high REFITTING
in a bin.
WARNING
When loosening the connector of the high pres- WARNING
The plugs are single-use. Do not reuse them;
Note: dispose of the whole set after use.
Take the injector rail out of its plastic bag.
new cloths.
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.

rail and the high pressure pump.
Note:
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.

with the one at the injector rail side.
Tighten to torque the injector rail mounting nuts

(28 Nm) .
13B-154
DIESEL INJECTION
K9K, and 732
Tighten to torque: Refit:
- the high-pressure pipe nuts between the injec- - the stainless steel pipe mounting bolt,
tor rail and the injectors (24 Nm) using the (Mot.
1566) or the (Mot. 1746) starting with the rail end.
Tighten the clip.
- the high-pressure pipe nuts between the injec-
tor rail and the high-pressure pump (24 Nm) Connect:
using (Mot. 1566) or (Mot. 1746) starting with the
- the connector to the air inlet pressure sensor,
high-pressure pump end.
Refitting ).
Refit:
pump.
tector support. by the injection computer, before restarting the engi-
Clip the diesel evacuation pipe. ne.
WARNING
Connect:
- the fuel return pipe. injection, High pressure pipe: Test ),
Fit the wiring harness. - let the engine run at idle speed until the engine
Refit the wiring harness clip mounting nut. cooling fan starts to operate,
Clip on the wiring harness retaining clip. - accelerate several times at no load,
Connect: - carry out a road test,
- the rail pressure sensor connector, - switch off the ignition,
- the diesel temperature sensor connector, - check that there are no diesel fuel leaks.
- the connector to the flow regulation solenoid valve, Using the diagnostic tool , check that there are no
- the connector to the pressure regulation solenoid
valve,
Refit:
- the dipstick duct mounting bolts.
- the dipstick,
bolt,
ry.
13B-155
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
F9Q, and 812
For versions with injector rail protector covers:
Mot. 997-01 Tool for removing/refit-
- Remove the air inlet duct (see 12A, Fuel mixture,
ting injector holder fit-
Air inlet duct: Removal - Refitting ),
ted with cable.
- Remove the injector rail protector (see 13B, Diesel
Equipment required injection, Injector rail protector: Removal - Re-
fitting ).
diagnostic tool Before the operation, clean (see 13B, Diesel injec-
tion, Diesel injection: Repair precautions ):
Tightening torquesm - around the pressure sensor, using a brush and

some cleaning product,
pressure sensor (M12) 35 Nm
- wipe the area cleaned with new cloths,
pressure sensor (M18) 80 Nm - blow the area cleaned dry using a compressed air
gun.
bolts
WARNING
Once the warranty period for the injector rail has
expired, only the pressure sensor can be replaced.
During the injector rail warranty period, the injector
rail should be completely replaced if the pressure
sensor fails.
The injector rail may be fitted with 2 types of sensor:

- a sensor with an M12 diameter thread, fitted with a
seal,
- a sensor with an M18 diameter thread, fitted without a
seal.
The 2 types of sensor have different tightening torques.
IMPORTANT

During each operation, always read the repair precau-

tions (see 13B, Diesel injection, Diesel injection:
REMOVAL
Disconnect the battery starting with the negative ter-
minal.
13B-156
DIESEL INJECTION
F9Q, and 812
18297-1
Disconnect the pressure sensor connector (1) . II - PRESSURE SENSOR WITH AN M18 DIAMETER
THREAD (WITHOUT SEAL)
Remove the pressure sensor using the (Mot. 997-
01).
REFITTING
I - PRESSURE SENSOR WITH M12 DIAMETER

THREAD AND SEAL
Be sure to replace the seal.
Tighten the pressure sensor by hand.
using the (Mot. 997-01) , torque tighten the pressu-
re sensor (M12) (35 Nm) .
112662
Check the condition of the lip seal (2) :
- if the lip seal is marked, the pressure sensor must

be replaced.
using the (Mot. 997-01) , torque tighten the pressu-

re sensor (M18) (80 Nm) .
13B-157
DIESEL INJECTION
F9Q, and 812
III - CONTINUATION OF REFITTING PROCEDURE
Note:

nal.
WARNING

(4 Nm) .
WARNING

- check that there is no diesel escaping.

- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel in-
ting ),
13B-158
DIESEL INJECTION
F9Q, and 804
Mot. 997-01 Tool for removing/refit-

ting injector holder fit-
ted with cable.
Equipment required
diagnostic tool
Tightening torquesm
pressure sensor 80 Nm

bolts
injection, Injector rail protector: Removal - Refit-
ting ).
WARNING
Before the operation, clean (see 13B, Diesel injec-
Once the warranty period for the injector rail has
tion, Diesel injection: Repair precautions ):
expired, only the pressure sensor can be replaced.
During the injector rail warranty period, the injector - around the pressure sensor, using a brush and
rail should be completely replaced if the pressure some cleaning product,
sensor fails.
- wipe the area cleaned with new cloths,
- blow the area cleaned dry using a compressed air

IMPORTANT gun.
Remove the pressure sensor using the (Mot. 997-

01).
- that the injector rail is not under pressure, Fit blanking plugs into the openings.

Loosening a high pressure pipe union when the REFITTING
During each operation, always read the repair precau-

tions (see 13B, Diesel injection, Diesel injection:
REMOVAL
Disconnect the battery starting with the negative ter-
minal.
Remove the front engine cover.
112662
Check the condition of the lip seal (1) :
- if the lip seal is marked, the pressure sensor must

be replaced.
13B-159
DIESEL INJECTION
F9Q, and 804
Using the (Mot. 997-01) , tighten to torque the pres-
sure sensor (80 Nm) .
Note:
Refit the air inlet duct without refitting the injector
rail protector or replacing the duct seal.

nal.
WARNING

(4 Nm) .
WARNING

- check that there is no fuel escaping.

ting ).
13B-160
DIESEL INJECTION
K9K, and 732
114076
The injector rail pressure sensor (1) cannot be separa-
ted from the injector rail.
In the event of an injector rail pressure sensor fault, re-
place the injector rail pressure sensor - injector rail as-
sembly (see 13B, Diesel injection, Injector rail:
13B-161
DIESEL INJECTION
K9K, and 722 or 728
102086
The pressure sensor (1) cannot be removed from
the spherical injector rail.
In the event of a pressure sensor fault, replace the
« rail pressure sensor and high pressure pipe » as-
sembly (see 13B, Diesel injection, Injector rail ).
13B-162
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench

1
Tightening torquesm
flow actuator mounting 5.5 ± 0.6 Nm

bolts

bolts
102120
Disconnect:
IMPORTANT
- the battery, starting with the negative terminal,
Before carrying out any work on the injection sys- - the air inlet duct (1) .
carried out on this system.
2
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Always replace any high-pressure pipe or high-
REMOVAL
102362
Remove the diesel anti-splash plate (2) .
13B-163
DIESEL INJECTION
K9K, and 722
6
3
5
4
7
102514 102315
Disconnect: Remove the high-pressure pipe (6) from injector no.
4 (see 13B, Diesel injection, High-pressure pipe:
- the heater plugs,
Replacement ).
- the injector connectors (3) from cylinders 3 and 4,
- the pump electrical connectors (4) ,
Loosen the two bracket bolts (7) .
- the supply and return pipes (5) .
Remove the fuel flow actuator (by hand with small
successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
13B-164
DIESEL INJECTION
K9K, and 722
REFITTING
WARNING
WARNING Check that there are no diesel fuel leaks:
component until the last moment. - Check the sealing after repair (see 13B, Diesel
injection, High-pressure pipe: Test ).
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 old die-
sel 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 the low torque wrench.
Refit a new high-pressure pipe to injector no. 4 (see
13B, Diesel injection, High-pressure pipe: Repla-
cement ) and a new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
nal.
WARNING

(4 Nm) .
13B-165
DIESEL INJECTION
K9K, and 728
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
flow actuator mounting 5.5 ± 0.6 Nm

bolts

bolts
IMPORTANT

110325
Pull the clip.
- Loosening a high-pressure pipe union when the 2
WARNING
cuit plugs.
- Always replace any high-pressure pipe or high-
REMOVAL
110323
terminal.
Loosen bolt (1) .
13B-166
DIESEL INJECTION
K9K, and 728
102362 102315
Remove the diesel anti-splash plate (3) . Remove the high pressure pipe (7) from injector no.
4 (see 13B, Diesel injection, High-pressure pipe:
Replacement) .
Loosen the bracket bolts (8) .
4
Remove the fuel flow actuator (by hand with small
successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
6
5
102514
Disconnect:
- the heater plug connectors (4) for cylinders n˚3 and
n˚4,
- the injector connectors from cylinders nos. 3 and 4,
- the fuel flow actuator connector (5) ,
- the supply and return pipes (6) .
13B-167
DIESEL INJECTION
K9K, and 728
REFITTING
WARNING
WARNING Check that there are no diesel fuel leaks:
component until the last moment. - Check the sealing after repair (see 13B, Diesel
injection, High-pressure pipe: Test ).
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 old die-
sel 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 the low torque wrench.
Refit a new high-pressure pipe to injector no. 4 (see
13B, Diesel injection, High-pressure pipe: Repla-
cement ) and a new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
nal.
WARNING

(4 Nm) .
13B-168
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 812
Equipment required
low torque wrench
diagnostic tool WARNING

Once the warranty period for the high-pressure
pump has expired, only the pressure regulator can
Tightening torquesm be replaced separately.
regulator bolts 6 Nm Whilst the warranty period for the high-pressure

pump is still valid, the high-pressure pump should
battery cover mounting 4 Nm be replaced as a whole if the pressure regulator
bolts displays a fault.
REMOVAL
18297-1
Disconnect the battery, starting with the negative Remove:

terminal.
- the fuel pressure regulator bolts (1) ,
Blast the area with compressed air to clean impuri- - the fuel pressure regulator (remove manually: do
ties from around the fuel pressure regulator. not use a tool to lever it out).
Disconnect the fuel pressure regulator connector.
Clean the area with cleaning product (see 13B, Die-
sel injection, Diesel injection: Repair precau-
tions ).
13B-169
DIESEL INJECTION
F9Q, and 812
REFITTING
Clean the fuel pressure regulator pressure face on
the high-pressure pump, taking care not to introduce
any impurities.
Wipe the pressure face of the fuel pressure regulator
on the high-pressure pump using fresh wipes (see
13B, Diesel Injection, Diesel injection: Repair
precautions ).
Prepare the new regulator:
- remove the protective cap,
- check the position of the seals,

- 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
a low torque wrench.
Clean the area with fresh wipes.
Fit the fuel pressure regulator connector.

nal.
WARNING

(4 Nm) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool if
necessary.
WARNING

13B-170
DIESEL INJECTION
F9Q, and 804
REMOVAL
Equipment required
low torque wrench
diagnostic tool
Tightening torquesm
regulator bolts 6 Nm

bolts

Repair precautions ). 1
WARNING
Once the warranty period for the high-pressure
pump has expired, only the pressure regulator can 111887
be replaced separately. Disconnect the battery, starting with the negative
Whilst the warranty period for the high-pressure terminal.
pump is still valid, the high-pressure pump should Blast the area with compressed air to clean impuri-
be replaced if the pressure regulator displays a ties from around the fuel pressure regulator.
fault.
Disconnect the fuel pressure regulator connector.
Clean the area with cleaning product (see 13B, Die-
sel injection, Diesel injection: Repair precau-
tions ).
Remove:
- the fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not use
any tool for leverage).
13B-171
DIESEL INJECTION
F9Q, and 804
REFITTING
Clean the fuel pressure regulator pressure face on
the high-pressure pump, taking care not to introduce
any impurities.
Wipe the pressure face of the fuel pressure regulator
on the high-pressure pump using fresh wipes (see
13B, Diesel Injection, Diesel injection: Repair
precautions ).
Prepare the new regulator:
- remove the protective cap,
- check the position of the seals,

- 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
a low torque wrench.
Clean the area with fresh wipes.
Fit the fuel pressure regulator connector.

nal.
WARNING

(4 Nm) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool if
necessary.
WARNING

13B-172
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
1
Tightening torquesm
diesel temperature sen- 15 Nm

sor

bolts
102120
IMPORTANT
Disconnect the air inlet duct (1) .
• that the fuel temperature is not too high. 2
advice given in this document whenever work is 3
WARNING
cuit plugs.
- Always replace any high-pressure pipe and high-
pressure pipe clips that have been removed.
102514
REMOVAL
Disconnect:
terminal. - the heater plugs from cylinders no. 3 and 4,
Remove the engine covers. - the injectors (2) from cylinders no. 3 and 4,
- the diesel fuel temperature sensor connector (3) .
13B-173
DIESEL INJECTION
K9K, and 722
(4 Nm) .
4
WARNING

102317
Remove the diesel fuel temperature sensor (4) .
REFITTING
WARNING
Lubricate the O-ring with lubricant from the applica-

tor 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.

nal.
WARNING
13B-174
DIESEL INJECTION
K9K, and 728
Equipment required
1
diagnostic tool
low torque wrench
forked endpiece
Tightening torquesm
diesel temperature sen- 15 Nm

sor

bolts
IMPORTANT
Before carrying out any work on the injection sys- 102317

tem, check using the diagnostic tool : Remove the diesel fuel temperature sensor (1) .
advice given in this document whenever work is REFITTING
WARNING
WARNING
- Obtain a set of special high-pressure injection cir- Lubricate the O-ring with lubricant from the applica-
cuit plugs. tor supplied with the new part.
WARNING
Do not damage the O-ring when refitting.
REMOVAL
Fit the diesel fuel temperature sensor.
terminal. Torque tighten the diesel temperature sensor (15
Remove the engine covers. Nm) using the low torque wrench and the forked
endpiece.
Disconnect the diesel temperature sensor connec-
tor. Reconnect the electrical connector.

nal.
WARNING
13B-175
DIESEL INJECTION
K9K, and 728
(4 Nm) .
WARNING

13B-176
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-177
DIESEL INJECTION
K9K, and 722 or 728

injector leak rate.

turn pipes.
Fit the correct blanking plugs, in particular onto the
venturi pipe to prevent depriming the circuit.
IMPORTANT

Disconnect:
Refitting ),
- the four transparent hoses of the (Mot. 1711).
Refit the injector fuel return pipes.
13B-178
DIESEL INJECTION
K9K, and 732
Mot. 1771 Kit for measuring SIE-

MENS injector leak
rate.

injector leak rate.

112811
Pull the clip.
112815
(1) .
Loosen the clip (2) and move the air inlet duct (3)
aside .
112991
steel pipe.
Move the air inlet duct (5) to one side .
13B-179
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
IMPORTANT

Disconnect:
Refitting ),
112992 - the air inlet pressure sensor connector.
Unclip the injector rail protector cover (6) . Loosen the clip and move the air inlet duct aside.
Remove: Pull out the clip from the stainless steel pipe.
- the mounting nut and bolt (7) from the injector rail Remove the air inlet duct.
protector cover,
Remove:
- the injector rail protector cover, - the dipstick,
- the dipstick, - the dipstick tube mounting bolts.
- the dipstick tube mounting bolts (8) . Move the dipstick tube to one side.
Move the dipstick tube to one side. Disconnect the four transparent pipes from the (Mot.
1771).
Disconnect the four fuel return pipes of the four in-
jectors (see 13B, Diesel injector fuel return rail: Remove the blanking plugs.
Connect the four injector fuel return pipes.
Refit:
turn pipes. - the dipstick tube mounting bolts.
Place the correct blanking plug on the injector fuel - the dipstick,
return connectors.
bolt,
Refit: Clip on the injector rail protector cover.
- the dipstick tube mounting bolts, Refit the clip on the stainless steel pipe, if necessa-
- the dipstick. ry.
Refit the clip on the stainless steel pipe, if necessa- Clip the stainless steel pipe to the turbocharger.
ry. Refit:
Clip the stainless steel pipe to the turbocharger. - the stainless steel pipe mounting bolt,
Refit the air inlet duct onto the damper flap. - the air inlet duct on the damper valve.
Tighten the clip. Tighten the clip.
13B-180
DIESEL INJECTION
K9K, and 732
Connect:
Refitting ).
pump.
13B-181
DIESEL INJECTION
Accelerometer: Removal - Refitting 13B
K9K, and 722 or 728
REFITTING
Emb. 1596 2 4 mm socket for
removing/refitting Tighten to torque the accelerometer (20 Nm) using
clutch master cylinder. the low torque wrench.
Equipment required nal.
low torque wrench

WARNING
Tightening torquesm Battery: Removal - Refitting ).
accelerometer 20 Nm Tighten to torque the battery cover mounting bolts

(4 Nm) .
bolts
REMOVAL
2
1
102086
terminal.
Disconnect the accelerometer connector (1) .
Remove the accelerometer (2) using the (Emb.
1596).
13B-182
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 722 or 728
Equipment required K9K, and 722
diagnostic tool
low torque wrench

1
Tightening torquesm
Venturi mounting bolt 5.5 Nm

bolts
IMPORTANT
102120
tem, check using the diagnostic tool : Disconnect the air inlet duct (1) .
advice whenever work is carried out on this sys-
tem.
- Loosening a high-pressure pipe union when the 2
WARNING
- Obtain a set of special high pressure injection cir-
cuit plugs.
REMOVAL
terminal. 102514
Disconnect the supply and return pipes (2) .
13B-183
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 722 or 728
(4 Nm) .
3
WARNING

4 - check that there is no diesel fuel escaping.
102316
Disconnect the return pipe (3) connecting the injec-

tor to the pump.
Remove:
- the venturi mounting bolt (4) ,
- the venturi.
Fit a plug over the opening.
REFITTING
WARNING
Lubricate the O-ring with lubricant from the applica-

tor supplied 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) using the low torque wrench.
Connect the various pipes.

nal.
WARNING
13B-184
DIESEL INJECTION
Diesel injector fuel return rail: Removal - Refitting 13B
K9K, and 732
Equipment required
diagnostic tool
WARNING

112815
WARNING (1) .
Parts always to be replaced: Loosen the clip (2) and move the air inlet duct (3) to
one side.
- all the high pressure pipes which have been remo-
ved.
IMPORTANT
tion, Cleanliness guidelines ).
REMOVAL

Switch off the ignition and wait 30 seconds before 112811
working on the injection system. Pull the clip.
13B-185
DIESEL INJECTION
K9K, and 732
IMPORTANT
duct.

unions:
- of the injector fuel return connectors,
- of the fuel pipe on the high pressure pump, taking
care not to soak the diesel temperature sensor.
IMPORTANT
112991 Wear protective glasses.
steel pipe.
WARNING
112992

Remove:
- the injector rail protector cover mounting bolt and
mounting nut (7) ,
- the dipstick,
13B-186
DIESEL INJECTION
K9K, and 732
II - OPERATION FOR REMOVAL OF PART Fit the correct blanking plugs.
CONCERNED
Unclip the return rail assembly from the rocker co-
ver.
Remove the fuel return rail.
WARNING
If it needs to be reused, keep the fuel return rail
in a sealed plastic bag.
REFITTING
111749 I - REFITTING PREPARATION OPERATION

Using a fine, flat-blade screwdriver, push the lower
section of the clip (9) holding the fuel return connec-
tor on the injector towards the rocker cover. WARNING
WARNING before connecting the fuel circuit pipes.
Ensure that the clip is not fully removed from its The plugs are single-use. Do not reuse them;
housing to prevent it from being twisted when dispose of the whole set after use.
touching the rocker cover.
Remove the fuel return rail from its plastic bag.
WARNING
When replacing a fuel return rail, only remove it
from its packaging just before it is to be refitted.

CONCERNED
Refit the fuel return rail.
Clip the return rail assembly onto the rocker cover.

111751
Extract the fuel return connector from the injector
while pushing the lower section of the retaining clip Connect:
downwards.
Remove the fuel return pipe from the injector. - the return pipe on the high pressure pump,
Repeat the operation on the other fuel return con- - the return pipe to the diesel temperature sensor.
nectors.
Disconnect: Push the clip holding the fuel return connector on the
- the diesel return pipe from the diesel temperature injector towards the front of the vehicle to restore it
sensor, to its original position.
- the fuel return pipe from the high pressure pump. Repeat the operation on the other injectors.
13B-187
DIESEL INJECTION
K9K, and 732
Clip on the fuel return connector of the injector. Using the diagnostic tool , clear any faults stored
ne.
WARNING
Check the condition of the seal on the fuel return
connector of the injector. Replace the fuel return WARNING
pipe assembly if any of its components are Check that there are no diesel leaks:
damaged.
- Check the seals after repair (see 13B, Diesel
Repeat the operation on the other injectors. injection, High pressure pipe: Check ),
III - FINAL OPERATION cooling fan starts to operate,
Refit: - accelerate several times at no load,
- the dipstick tube mounting bolts, - carry out a road test,
- the dipstick, - switch off the ignition,
- the injector rail protector cover, - Check that there are no diesel leaks.
- the injector rail protector cover mounting nut and Using diagnostic tool , check that there are no sto-
bolt, red faults; clear them if necessary.
ry.
Refit:
Tighten the clip.
Connect:
- the air inlet pressure sensor connector,
Refitting ).
pump.
13B-188
DIESEL INJECTION
Injector rail protector: Removal - Refitting 13B
F9Q, and 804 or 812
Tightening torquesm
injector rail protector 8 Nm

mounting bolts

terminal.
Remove the air inlet duct (see 12A, Fuel mixture,
Air inlet duct: Removal - Refitting ).
111888
Disconnect the rail pressure connector (1) .
Remove:
- the injector rail protector mounting bolts (2) ,
- the injector rail protector.
REFITTING
Refit the injector rail protector.
Tighten to torque the injector rail protector moun-
ting bolts (8 Nm) .
Connect the rail pressure sensor connector.
Reconnect the battery, starting with the positive ter-
minal.
13B-189
DIESEL INJECTION
Accelerator pedal sensor general information 13B
K9K, and 722 or 728 or 732 – F9Q, and 804 or 812
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 the cruise control/speed limiter
have an accelerator pedal with a kickdown point at the
end of travel.
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-190
DIESEL INJECTION
Accelerator pedal potentiometer: Removal - Refitting 13B
K9K, and 722 or 728 or 732 – F9Q, and 804 or 812
REFITTING
Tightening torquesm Refit the accelerator pedal mounting bolts (1) .
Refit the accelerator pedal.
bolts Connect the battery, starting with the positive termi-
nal.
REMOVAL
WARNING
Disconnect:
- the battery, starting with the negative terminal, Battery, Battery: Removal - Refitting ).
- the accelerator pedal connector. Tighten to torque the battery cover mounting bolts
(4 Nm) .
Note:
A fault on the accelerator pedal position potentio-
meter results in changes in the idling speed or
engine operation.
102204
Remove:
- the pedal mounting bolts (1) ,
- the pedal.
13B-191
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 724 or 732 – F9Q, and 804 – M9R, and 700
Tightening torquesm
bolt securing the com- 21 Nm

puter mounting
WARNING
- The injection computer retains the immobiliser
code for life.
- The system has no security code.
- 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 ).
112659
Disconnect the connectors (1) from the computer.
REMOVAL
Unclip:
I - REMOVAL PREPARATION OPERATION - the battery negative terminal wiring harness,
Remove the engine covers. - the wiring harness (2) .
Remove the battery (see 80A, Battery, Battery: Re- Remove:
- the upper mounting bolt (3) from the computer
mounting,
- the mounting bolts (4) from the computer mounting,
- the computer and its mounting.
13B-192
DIESEL INJECTION
K9K, and 724 or 732 – F9Q, and 804 – M9R, and 700
II - OPERATION FOR REMOVAL OF PART - the engine covers.
CONCERNED
101890
Remove:
- the mounting nuts (5) from the computer,
- the computer from its mounting.
REFITTING

CONCERNED
Refit:
- the computer onto its mounting,
- the mounting nuts to the computer.
Refit the mounting bolt to the computer mounting.
Tighten to torque the bolt securing the computer
mounting (21 Nm) .
Refit the upper mounting bolt on the computer
mounting.
Clip on:
- the battery negative terminal wiring harness,
- the wiring harness.
Connect the computer connectors.
Refit:
Refitting ).
13B-193
DIESEL INJECTION
K9K, and 722 or 728 – F9Q, and 812
Tightening torquesm

bolts
2
bolts
WARNING
- The injection computer retains the immobiliser 1
code for life.
- It is forbidden to perform tests with computers bor-
rowed from the Parts Department or from another 3
vehicle, that must then be returned. These compu-
ters are permanently coded.
When replacing the computer (see MR 372 Fault fin- 101822

ding, 13B, Diesel injection, Fault finding - Replace-
Disconnect the connectors (1) from the computer.
ment of components ).
Move the turbocharger pressure regulation solenoid
valve to one side.
REMOVAL
Remove:
- the nut (3) from the wiring harness.
101888
terminal.
Remove the battery.
101811
Remove the computer and its mounting (4) .
13B-194
DIESEL INJECTION
K9K, and 722 or 728 – F9Q, and 812
REFITTING
101890
Remove: 101887
- the mounting nuts (5) from the computer, Proceed in the reverse order to removal.
- the computer from its mounting. Make sure you refit the battery tray properly on the
computer mounting
(21 Nm) .
nal
WARNING

(4 Nm) .
13B-195
DIESEL INJECTION
Engine speed and position sensor: Removal - Refitting 13B
M9R, and 700
Lubricate the engine speed and position sensor
seal.
Tightening torquesm
engine speed and posi- 10 Nm II - REFITTING OPERATION FOR PART

tion sensor mounting CONCERNED
bolt Refit the engine speed and position sensor.
Position the engine speed and position sensor so it
REMOVAL is pressing against the cylinder block.
Tighten the engine speed and position sensor
I - REMOVAL PREPARATION OPERATION mounting bolt until contact is made.
Remove the engine undertray. Tighten to torque the engine speed and position
sensor mounting bolt (10 Nm) .
Move the engine speed and position sensor heat in-
sulation to one side, Connect the engine speed and position sensor con-
nector.

CONCERNED III - FINAL OPERATION
Refit:
- the heat insulation around the engine speed and
position sensor,
114979
Disconnect the engine speed and position sensor
connector.
Remove:
- the mounting bolt (1) from the engine speed and
position sensor,
- the engine speed and position sensor (2) .
REFITTING

Replace the engine and position speed sensor O-
ring, if the engine speed and position sensor is being
reused.
13B-196
PREHEATING
Pre/postheating unit: Removal - Refitting 13C
F9Q, and 804 or 812 – K9K, and 722 or 728 or 732 – M9R, and 700
CONCERNED
Tightening torquesm
wheel bolts 130 Nm
Note:
It is located behind the front left-hand wheel arch
liner.
REMOVAL

102125
Disconnect the pre-postheating unit connector.
Remove:
- the pre-postheating unit mounting bolt ,
- the pre-postheating unit (1) .
REFITTING

CONCERNED
Connect the pre-postheating unit connector.
Refit:
101823
- the pre-postheating unit,
Remove:
- the pre-postheating unit mounting bolt.
- the front left-hand wheel,
- the front left-hand wheel arch liner.
Refit:
- the front left-hand wheel arch liner,
- the front left-hand wheel,

13C-1
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 722
Use a hose to untighten the plugs completely.
Tightening torquesm
WARNING
heater plugs 15 Nm Ensure that no foreign bodies enter the cylinder
during this operation.
bolts
REFITTING
REMOVAL Proceed in the reverse order to removal.
Tighten to torque the heater plugs (15 Nm) .
Disconnect the battery, starting with the negative nal.
terminal.
WARNING

(4 Nm) .
102120
Disconnect the air duct.
15762
Disconnect the electrical connector from the heater

plugs.
Clean around the outside of the heater plugs with a

compressed air gun to prevent contamination of the
cylinders.
Undo then remove the plugs using a 10 mm diame-

ter long socket connected to a universal joint.
13C-2
PREHEATING
F9Q, and 804 or 812
Tightening torquesm
WARNING
heater plugs 15 Nm Ensure that no foreign bodies enter the cylinder
bolts
REFITTING
REMOVAL
nal.
terminal.
WARNING
F9Q, and 804 Battery: Removal - Refitting ).
Remove: Tighten to torque the battery cover mounting bolts

(4 Nm) .
- the inlet duct (see 12A, Fuel mixture, Inlet duct:
- the injection rail protector (see 13B, Diesel injec-

tion, Injection rail protector: Removal - Refitting
).
15762

plugs.

cylinders.

13C-3
PREHEATING
K9K, and 728
Tightening torquesm
heater plugs 15 Nm

2
bolts
1
REMOVAL
terminal.
110323
Loosen the bolt (1) .
110325
Pull the clip.
15762

plugs.

cylinders.

WARNING
Ensure that no foreign bodies enter the cylinder
13C-4
PREHEATING
K9K, and 728
REFITTING
nal.
WARNING

(4 Nm) .
13C-5
PREHEATING
K9K, and 732
Tightening torquesm
heater plugs 15 Nm
REMOVAL

112811
Pull the clip.
112815
(1) .
one side.
112991
steel pipe.
13C-6
PREHEATING
K9K, and 732
CONCERNED
112992
112993
Remove:
- the mounting nut and bolt (7) from the injector rail Disconnect the connector from the heater plug.
protector cover,
Note:
- the dipstick,
Do not pull on the plug cable.
Move the dipstick tube to one side. Clean around the outside of the heater plugs with a
cylinders.

WARNING
Ensure that no foreign bodies enter the cylinder
REFITTING

CONCERNED
Refit the heater plugs using the hose.
Connect the connector to the heater plugs.
13C-7
PREHEATING
K9K, and 732
Refit:
- the mounting bolts to the dipstick tube,
- the dipstick,
- the injection rail protector mounting bolt and moun-
ting nut.
Clip on the injection rail protector cover.
ry.
Clip the stainless steel pipes onto the turbocharger.
Refit:
Tighten the clip.
Connect:
Refitting ).
13C-8
PREHEATING
Pre-postheating control 13C
K9K, and 722 or 728
The pre/post heating function is controlled by the injec- b - Fixed preheating
tion computer.
After the warning light goes out, the heater plugs conti-
nue to be supplied for a fixed period of 5 seconds .
PRE/POST HEATING OPERATING PRINCIPLE
2 - Starting
1 - Switching on the ignition « preheating » The plugs remain supplied while the starter is being ac-
tivated.
a - Variable preheating
3 - Engine running « postheating »
The time for which the warning light is lit and of the sup-
ply to the heater plugs depends on the coolant tempe- During this phase the plugs are supplied continuously
rature and the battery voltage. according to coolant temperature.
At idling speed with no depression of the accelerator
pedal.
103123
X: Time in seconds
103124
Y: Coolant temperature in ˚C X: Time in seconds
Y: Coolant temperature in ˚C
K9K, and 722
Whatever the situation, the heater plug warning light

cannot remain lit for more than 10 seconds (except in
the event of a coolant temperature sensor fault).
K9K, and 728
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).
13C-9
PREHEATING
Pre-postheating control 13C
F9Q, and 812
The pre/post heating function is controlled by the injec- At altitude, the postheating time may reach 45 se-
tion computer. conds .
PRE/POST HEATING OPERATING PRINCIPLE
1 - Switching on the ignition « preheating »
a - Variable preheating
The time for which the warning light is lit and of the sup-
ply to the heater plugs depends on the coolant tempe-
rature and the battery voltage.
101188
X: Time in seconds
101189
X: Time in seconds
In all cases, the period that the preheating warning light
is lit cannot exceed 12 seconds .
b - Fixed preheating
After the warning light goes out, the spark plugs conti-
nue to be supplied for a set period of 10 s .
2 - Starting
The plugs remain supplied while the starter is being ac-
tivated.
3 - Engine running « postheating »

During this phase the plugs are supplied continuously
according to coolant temperature.
At idling speed with the accelerator pedal not being de-
pressed.
13C-10
ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A
I - OPERATING DIAGRAM OF THE CIRCUIT
F4R, and 770 or 771 – K4J, and 730 – K4M, and

761 or 782
2 1
6
5
3
4
106679
(1) Inlet manifold

102724
(2) Fuel vapour absorber bleed
solenoid valve
(3) Fuel vapour absorber
(4) Tank
F4R, and 776
(5) Breather
(6) Non-return valve (only 776)
106278
14A-1
ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A
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.
7 8
102734

(6) Recirculation of fuel vapour from
the tank
(7) Recirculation of fuel vapours
going to the engine
(8) 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, the fuel vapour absorber and inlet manifold
are connected 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).
14A-2
ANTIPOLLUTION
Fuel vapour recirculation circuit: check 14A
II - FUEL VAPOUR ABSORBER BLEEDING
CONDITIONS
Equipment required
The petrol vapour absorber bleed solenoid valve is
diagnostic tool controlled by track C-E1 of the computer if:
- the coolant temperature is above 55˚C ,
I - CHECKING THE OPERATION OF THE FUEL - the air temperature is above 10˚C ,
VAPOUR ABSORBER BLEED
- the engine is not at idle speed,
- a given load threshold is reached,
Note:
- the throttle potentiometer is not in the « no load »
A fault with this system may result in rough idling position.
or the engine stalling.
During « on board diagnostic » fault finding, fuel va-
pour absorber bleeding is not authorised.
The opening cyclic ratio of the fuel vapour absorber
bleed solenoid valve can be displayed using the dia-
gnostic tool (CLIP) by referring to parameter
1
2 PR102: « Fuel vapour absorber bleed solenoid val-
ve OCR » .
The solenoid valve is closed at values below 1.2 % .
6
5
3
4
106679
(1) Inlet manifold

(2) Fuel vapour absorber bleed
solenoid valve
(4) Tank
(5) Breather
(6) Anti-return valve (only 776)
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
4
3
102734
Disconnect:
- the pipe (2) bringing the fuel vapour from the tank,
102483
- the pipe (3) taking the fuel vapours towards the so-
lenoid valve,
Remove the absorber (1) from the fuel tank retaining
notch by pushing in the direction of the arrow. - the breather pipe (4) .
Remove the absorber.
REFITTING
14A-4
ANTIPOLLUTION
Fuel vapour canister:Checking 14A
CHECKING THE FUEL VAPOUR

ABSORBER
On the fuel vapour absorber, plug the circuit coming
from the fuel tank.
Connect the pressure gauge of tool (Mot. 1311-01)
to the absorber breather outlet.
With the engine idling check that there is no vacuum
at the absorber breather outlet (in the same way, the
command value displayed by the diagnostic tool in
parameter: « Fuel vapour absorber bleed solenoid
valve OCR » remains minimal X no more than 1.5
% ).
Is there a vacuum?
- Yes: with the ignition off, use a vacuum pump to
apply a vacuum of 500 mbar to the outlet solenoid
valve. The vacuum should not vary by more than
10 mbar over 30 seconds .
Does the pressure change?
• Yes: replace the solenoid valve as it is faulty.
• No: there is an electrical fault, check the circuit.
- No: in bleeding conditions (see « Bleeding
conditions » ), the vacuum should increase (at the
same time the parameter value on the diagnostic
tool should 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
K4J, and 730
I - PRESENTATION OF COMPONENTS
101495
(1) Oil vapour rebreathing aperture (2) Oil vapour recovery plate loca-
ted on the rocker cover
(3) Calibrated jet
3
2
101499
101869
14A-6
ANTIPOLLUTION
K4J, and 730
To dismantle the oil vapour recovery plate (2) , see (3) Air unit
(11A, Top and front of engine).
(4) Motorised throttle
(5) Air distributor
II - PRESENTATION OF THE CIRCUIT
(6) Inlet air intake
(7) Calibrated jet
A: Under low loads, the oil vapours are rebreathed
in small quantities through the calibrated jet (7).
III - CHECK
7 4 3 To ensure the emission control system works properly,
the oil vapour rebreathing circuit must be kept clean
and in good condition.
5
6
101956
B: At medium and heavy loads, the oil vapours are

rebreathed in large quantities by the gas valve.
4
7 3
5
6
101957
(1) Engine
(2) Oil vapour recovery plate
14A-7
ANTIPOLLUTION
K4M, and 761 or 782
102305
(1) Oil vapour rebreathing pipe

(2) Calibrated jet
3
4
3
101820
(3) Oil vapour recovery plate loca- 102073

ted on the rocker cover
To dismantle the oil vapour recovery plate (3) , (see
(4) Oil vapour rebreathing aperture 11A, Top and front of engine ).
14A-8
ANTIPOLLUTION
K4M, and 761 or 782
II - PRESENTATION OF THE CIRCUIT (5) Air intake
(6) Calibrated jet
A: At low loads, the oil vapours are rebreathed in
small quantities through the calibrated jet (6) III - CHECK
4 6 To ensure the emission control system works properly,
5
102308
B: At medium and heavy loads, the oil vapours are

rebreathed in large quantities through the gas
throttle valve.
4 6 3
2
1
102309
(1) Engine
(3) Motorised throttle valve
(4) Inlet manifold
14A-9
ANTIPOLLUTION
K9K, and 722 or 724 or 728 or 732
I - PRESENTATION OF THE CIRCUIT B: At medium or high load, the vacuum pressure pre-
vailing in the air inlet duct pulls the valve diaphragm,
small quantities of oil vapour are rebreathed in via a ca-
librated jet.
1
2 II - CHECK
To ensure the emission control system works properly,
3 and in good condition.
5
4 6
20965
1
2
6 5
4
20965-1
(1) Rocker cover

(2) Oil vapour rebreathing duct
(3) Oil vapour rebreathing valve
(4) Air inlet duct
(5) Turbocharger
(6) Atmospheric pressure
A: At low load, the vacuum pressure prevailing in the

air inlet duct is below the spring calibration. Large
quantities of oil vapour are sucked back in by the va-
cuum prevailing in the air inlet duct.
14A-10
ANTIPOLLUTION
F9Q, and 804 or 812
I - PRESENTATION OF THE CIRCUIT
F9Q, and 812
4
2
100053
(1) Engine 100054
(2) Oil separator (7) Oil vapour rebreathing pipe con-

(3) Air filter unit nected to the intake pipes
(4) Air duct (8) Cylinder block outlet oil vapour
(5) Turbocharger rebreathing pipe
(6) Inlet manifold (9) Oil separator return pipe
II - CHECK
14A-11
ANTIPOLLUTION
F4R, and 770 or 771
102723
(1) Oil vapour rebreathing duct (3) Oil vapour recovery plate loca-
(2) Oil vapour recirculation valve ted on the rocker cover
3
4
102738
102729
14A-12
ANTIPOLLUTION
F4R, and 770 or 771
For dismantling, (see 11A, Top and front of engine ).
(4) Throttle upstream oil vapour
recirculation aperture II - OIL VAPOUR RECIRCULATION CIRCUIT
9
8
10
102745
(5) Air duct

(6) Throttle valve
(7) Inlet manifold
(8) Throttle upstream oil vapour
recirculation aperture
(10) Oil vapour recirculation valve
III - CHECK
14A-13
ANTIPOLLUTION
F4R, and 776
COMPONENTS
106629
(1) 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
(2) 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-14
ANTIPOLLUTION
F4R, and 776
102738
To dismantle the oil vapour recovery plate (see 11A,
Top and front of engine ).
II - CHECK
14A-15
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
K9K, and 722 or 728
I - PRESENTAION OF THE CIRCUIT
Note:
3
A The position of the exhaust gas recirculation sole-
5 noid valve is a determining factor in the calculation
of the quantity of engine inlet air.
2 IV - OPERATING CONDITIONS
4
The following parameters determine activation of the
1 exhaust gas recirculation solenoid valve:
B - coolant temperature,
- air temperature,
7 - atmospheric pressure,
6
- accelerator pedal position,
8 - diesel injection flow,
- engine speed.
102364
(1) Engine Operating point for checking the exhaust gas

recirculation solenoid valve
(2) Air filter unit
(3) Air distributor The exhaust gas recirculation solenoid valve is activa-
ted if:
(4) Exhaust manifold
(5) Exhaust gas recirculation unit - the air temperature is between - 30˚C and 67˚C inclu-
with solenoid valve sive,
(6) Turbocharger - or the coolant temperature is between 0˚C and 127˚C
(7) Injection computer inclusive,
(8) Heat exchanger - the engine speed is above 500 rpm ,
(A) Air inlet
- the diesel fuel injection flow is between 10 and 31
(B) Exhaust gas outlet mg/stroke inclusive,
- atmospheric pressure is greater than 421 mbar .

II - PURPOSE OF THE EXHAUST GAS
RECIRCULATION SYSTEM If so, the diagnostic tool indicates an exhaust gas recir-
culation solenoid valve position opening cyclic ratio va-
Exhaust gas recirculation is used to reduce the con- lue equal to 4 and 60 % .
centration of nitrogen oxides (NOx) in exhaust fumes.
Exhaust gas recirculation is cut off if:
The computer regulates the passage of gases by ac-
tuating a solenoid valve. - the mapping (engine speed - load) exceeds a thres-
hold,
III - OPERATING PRINCIPLE - the air conditioning compressor is activated.
The solenoid valve is controlled by an opening cyclic
The exhaust gas recirculation solenoid valve is not
ratio signal issued by the injection computer. The ope-
supplied after starting for 2 seconds .
ning cyclic ratio signal modulates the opening of the
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-16
ANTIPOLLUTION
K9K, and 722 or 728
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-17
ANTIPOLLUTION
F9Q, and 812
9 7
5
8
4
6
10
3
11
2
23244
III - OPERATING PRINCIPLE
(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
The computer runs a constant test to keep track of the
(6) Exhaust gas recirculation sole- position of the exhaust gas recirculation solenoid val-
noid valve ve.
(7) Air flowmeter
(8) Air intake IV - OPERATING CONDITIONS
(9) Exhaust pipe The following parameters determine activation of the
(10) Intercooler inlet exhaust gas recirculation solenoid valve:
(11) Intercooler outlet - battery voltage,
- the engine speed,
II - PURPOSE OF THE EXHAUST GAS - coolant temperature,

RECIRCULATION SYSTEM - air temperature,
Exhaust gas recirculation is used to reduce the nitro- - accelerator pedal position,
gen oxide (NOx) content of the exhaust gases. - vehicle 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-18
ANTIPOLLUTION
F9Q, and 812
- the engine speed is above 3650 rpm ,
Note:
There is no exhaust gas recirculation at altitude (>
1,200m).
- mapping (engine speed-load) exceeds a given thres-

hold,
- after 40 seconds , if:
• the vehicle speed is below 7 mph (12 km/h) ,
• the engine speed is below 1000 rpm .
• the coolant temperature is above 60˚C ,
• the air temperature is above 15˚C for 60 seconds .
The exhaust gas recirculation solenoid valve is not
controlled after engine start-up depending on coolant
temperature mapping.
15761
Track Description
1 Solenoid supply + 12 v
2 Sensor supply + 5 V
4 Sensor earth
5 Solenoid earth
6 Sensor output
The exhaust gas recirculation solenoid valve is sup-

103127
plied for 40 seconds each time the engine returns to
idling speed if the air temperature is above 15˚C. .
X Time in seconds The exhaust gas recirculation solenoid valve is no lon-
ger supplied if there is a fault on:
Y Coolant temperature in ˚C
- the air flowmeter,
The exhaust gas recirculation solenoid valve is no lon- - the exhaust gas recirculation solenoid valve.
ger supplied if there is a fault on:
- the coolant temperature sensor,
- the air temperature sensor,
- the turbocharger pressure sensor,
- the atmospheric pressure sensor.
14A-19
ANTIPOLLUTION
F9Q, and 804
I - DIAGRAM
114451
(1) Engine
(2) Exhaust gas cooler
(4) Inlet manifold
(6) Turbocharger

RECIRCULATION SYSTEM
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 activates a valve by linking
the exhaust manifold and the inlet manifold.

The principle of the exhaust gas recirculation consists
of reinserting part of the exhaust fumes in the engine
air breathing cycle.
The EGR valve is controlled by a direct current motor.
14A-20
ANTIPOLLUTION
K9K, and 732
I - PRESENTATION OF THE CIRCUIT The computer runs a constant test to keep track of the
position of the exhaust gas recirculation solenoid val-
ve.
Note:
The position of the exhaust gas recirculation sole-
noid valve is a determining factor in the calculation
of the quantity of engine inlet air.
IV - OPERATING CONDITIONS
The following parameters determine activation of the
exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- diesel injection flow,
102364
- engine speed.
(1) Engine
(2) Air filter unit
(3) Inlet manifold
with solenoid valve
(6) Turbocharger
(8) Intercooler
(A) Air inlet
(B) Exhaust gas outlet

RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the con-

centration of nitrogen oxides (NOx) in exhaust fumes.

tuating a solenoid valve.

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.
14A-21
ANTIPOLLUTION
M9R, and 700
113323
(1) Engine
(2) Air filter unit
(3) Turbocharger ning cyclic ratio signal modulates the opening of the
(4) Intercooler solenoid valve, and consequently the quantity of ex-
haust gas directed back to the inlet manifold.
(5) Damper valve
(6) EGR solenoid valve The computer continuously carries out a test to detect
(7) Inlet manifold the position of the EGR valve.

(9) EGR cooler IV - OPERATING CONDITIONS
(10) Computer
The parameters which determine the activation of the
EGR solenoid valve are as follows:
II - ROLE OF THE EGR SYSTEM
- coolant temperature,
Exhaust gas recirculation is used to reduce the nitro-
gen oxide (NOx) content of the exhaust gases. - air temperature,
- atmospheric pressure,
tuating a solenoid valve.
- diesel injection flow,
- engine speed.
14A-22
ANTIPOLLUTION
M9R, and 700
Operating points for testing the EGR valve:
The operating points for the EGR valve test are shown
in the Fault Finding Manual (see MR 372 Fault fin-
ding, 13B, Diesel injection, Fault finding - System
operation ).
14A-23
ANTIPOLLUTION
Exhaust gas recirculation: List and location of components 14A
K9K, and 732
112326
114189
(1) Exhaust gas recirculation solenoid valve
(2) Intercooler cooler
(3) Rigid exhaust gas recirculation pipe
(4) Cooler support, flywheel end
(5) Cooler support, timing end
14A-24
ANTIPOLLUTION
Exhaust gas recirculation unit: Removal - Refitting 14A
K9K, and 722
Mot. 1567 Long nose pliers for 3

EGR duct clips.
Tightening torquesm

tion unit mounting bolt

mounting bolt
lifting eye (timing end) 21 Nm

104246
mounting bolts for the 12 Nm Remove:
heat shield on the
exhaust gas recircula- - the mounting bolts (3) from the plenum chamber
tion solenoid valve partition,
- the plenum chamber partition.
bolts
REMOVAL
terminal.
Remove the engine covers. 4
2
102120
1 Remove the air duct (4) .
104343
Remove:

55A, Exterior protection, Scuttle panel grille ,
nel,
- the plenum chamber mounting bolt (2) .
14A-25
ANTIPOLLUTION
K9K, and 722
13 11
12
102126 102074
Disconnect the wiring harness (5) . Remove:
- the heat shield (11) on the exhaust gas recircula-
tion solenoid valve,
6 - the exhaust gas recirculation tube (12) ,
9 8
- exhaust gas recirculation unit mounting bolts (13) ,
- the exhaust gas recirculation unit.
7 REFITTING
Replace the exhaust gas recirculation tube complete
10 with new clips.
Tighten the new clips using tool (Mot. 1567).
102119
Replace the O-rings on the air inlet metal tube.
Disconnect: Tighten to torque:
- the valve pipe (6) on the turbocharging pressure re-
gulation from the air duct,
bolt (21 Nm) ,
- the air inlet pipe (7) from the exhaust gas recircula-
tion unit. - the metal air inlet tube mounting bolt (21 Nm) ,
Remove: - the lifting eye (timing end) (21 Nm) ,

- the bracket (8) , - the mounting bolts for the heat shield on the ex-
- the engine lifting eye (9) , haust gas recirculation solenoid valve (12 Nm) .
- the air inlet metal tube (10) . Proceed in the reverse order to removal.

nal.
WARNING
Battery: Removal: refitting ).

(4 Nm) .
14A-26
ANTIPOLLUTION
K9K, and 728
Mot. 1567 Long nose pliers for 3

EGR duct clips.
Tightening torquesm

tion unit mounting bolt

mounting bolt
lifting eye (timing end) 21 Nm

104246
mounting bolts for the 12 Nm Remove:
heat shield on the
exhaust gas recircula- - the mounting bolts (3) from the plenum chamber
tion solenoid valve partition,
- the plenum chamber partition.
bolts
REMOVAL
terminal.
2
1
110325
Pull the clip.
104343
Remove:

nel,
- the mounting bolt (2) from the plenum chamber.
14A-27
ANTIPOLLUTION
K9K, and 728
9 7
10
8
5
11
102119
Disconnect:
- the turbocharging pressure regulation valve pipe

(7) from the air duct,
110323
- the air inlet pipe (8) from the exhaust gas recircula-
Unscrew the bolt (4) . tion unit.
Remove:
- the bracket (9) ,
- the engine lifting eye (10) ,
- the air inlet metal tube (11) .
6 14 12
102126
Disconnect the wiring harness (6) .
13
102074
Remove:
- the exhaust gas recirculation solenoid valve (12)

heat shield,
- the exhaust gas recirculation tube (13) ,
- exhaust gas recirculation unit mounting bolts (14) ,
- the exhaust gas recirculation unit.
14A-28
ANTIPOLLUTION
K9K, and 728
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
Battery: removal: refitting ).

(4 Nm) .
14A-29
ANTIPOLLUTION
F9Q, and 812

clips. 1
Mot. 1202-02 Pliers for small hose 2
clips.
Tightening torquesm

tion intercooler moun-
ting bolts
104343
bleed valve mounting 9 Nm
bolt
exhaust gas recircula- 20 Nm 2

tion pipe mounting bolts

bolts
REMOVAL
terminal.
Remove the battery. 104246
Drain the cooling system via the cooling radiator Remove:
lower hose using tool (Mot. 1202-01) or tool (Mot.
1202-02). - the engine covers,
Remove the scuttle panel grille (see Workshop Re- - the air filter access panel mounting bolts (1) ,
pair Manual 371 Bodywork, 55A, Exterior protec- - the scuttle panel partition mounting bolts (2) ,
tion, Scuttle panel grille ).
14A-30
ANTIPOLLUTION
F9Q, and 812
102500 101811
Remove the air filter outlet duct (3) . Remove the injection computer (6) and its mounting.
8
5
4
101822 101808
Disconnect injection computer connectors (4) . Remove:
Remove: - air inlet sleeve (7) ,
- the battery tray mounting bolts (5) , - air duct (8) ,
- the wiring harness strap. - air filter unit (9) .
14A-31
ANTIPOLLUTION
F9Q, and 812
12 16
10
18
17
17
11
13
19
104424 104420
Disconnect the exhaust gas recirculation exchanger
Disconnect:
(16) .
- the exhaust gas recirculation connector (10) , Remove:
- the oil vapour rebreathing pipe (11) , - clips (17) ,

- the mounting bolts (1 8) from the pipe fitted
- the vacuum (12) inlet and outlet pipes,
between the exhaust manifold and the unit,
- the turbocharger pressure regulation valve (13) pi- - the mounting bolts (19) from the « exhaust gas re-
pe. circulation solenoid valve / gas recirculation ex-
changer assembly » ,
- the « exhaust gas recirculation solenoid valve / gas
recirculation exchanger » assembly.
14
15
104421
Remove the vacuum tank (14) .
Disconnect the scuttle panel (15) hose.
14A-32
ANTIPOLLUTION
F9Q, and 812
23
22
20
21
106211
II - ON THE WORKBENCH: REPLACE THE

EXHAUST GAS RECIRCULATION EXCHANGER.
WARNING
Never remove the exhaust gas recirculation sole- Remove:
noid valve (20) from the unit (21) .
- the hose (23) , mark its position for refitting,
I - ON THE WORKBENCH: REPLACE THE - the bleed valve mounting bolt (22) ,
EXHAUST GAS RECIRCULATION SOLENOID
VALVE. - the exchanger mounting bolts (21) on the exhaust
gas recirculation unit,
Remove:
- the exhaust gas recirculation exchanger mounting
- the bleed valve mounting bolt (22) ,
bolts from the unit (21) .
- the exhaust gas recirculation exchanger mounting
bolts from the unit (21) .
WARNING
make sure that no foreign bodies enter the mani-
folds.
Replace:
- the pipe seals fitted between the exhaust mani-
fold and the unit,
- clips (17) ,
- the seal between the exhaust gas recirculation
intercooler and the unit (21) .
14A-33
ANTIPOLLUTION
F9Q, and 812
REFITTING
Tighten to torque:
- the exhaust gas recirculation intercooler moun-
ting bolts (10 Nm) ,
- the bleed valve mounting bolt (9 Nm) ,
- the exhaust gas recirculation pipe mounting
bolts (20 Nm) .
nal.
WARNING

(4 Nm) .
14A-34
ANTIPOLLUTION
F9Q, and 804


tion pipe mounting bolts

bolts
REMOVAL
Disconnect the battery, starting with the negative 104246
terminal.
Remove:
Remove the scuttle panel grille (see Workshop Re-
pair Manual 371 Bodywork, 55A, Exterior protec-
tion, Scuttle panel grille ). - the scuttle panel partition.
Remove the air duct (see 12A, Fuel mixture, Inlet
4
1
2
104343
Remove:
- the air filter access panel mounting bolts (1) , 111861
Remove the mounting bolts (4) from the exhaust gas
recirculation pipe.
14A-35
ANTIPOLLUTION
F9Q, and 804
Tighten to torque:
bolts (25 Nm) ,
- the exhaust gas recirculation pipe mounting
5 bolts (18 Nm) .
nal.
WARNING

(4 Nm) .
111964
113177
Remove the mounting bolts (5) from the exhaust gas

recirculation unit.
WARNING
Never remove the exhaust gas recirculation sole-
noid valve from the unit.
REFITTING
14A-36
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
K9K, and 722 or 728
Mot. 1729 Pin wrench for remo-

ving the EGR valve.
Tightening torquesm

tion solenoid valve
mounting bolts
EGR solenoid valve 4 Nm

mounting stud
The exhaust gas recirculation solenoid valve is fitted

into the exhaust gas recirculation unit.
REMOVAL

Disconnect the EGR solenoid valve.
Remove the turbocharger outlet pipe and move it to

one side.
Remove:
- the heat shield,
- the bolts securing the exhaust gas recirculation so-

lenoid valve,
- the exhaust gas recirculation solenoid valve by gra-

dually turning it using the (Mot. 1729).
REFITTING
WARNING
Always replace the seal of the exhaust gas recir-
culation solenoid valve with a new one.

solenoid valve mounting bolts (12 Nm) .
If the EGR solenoid valve mounting stud is replaced,

tighten to torque the EGR solenoid valve moun-
ting stud (4 Nm) .
14A-37
ANTIPOLLUTION
K9K, and 732
Mot. 1729 Pin wrench for remo-

ving the EGR valve.
Equipment required 3
diagnostic tool
Tightening torquesm

tion solenoid valve
mounting bolts
104246
Remove:
REMOVAL - the scuttle panel partition mounting bolts (3) ,
Disconnect the battery, starting with the negative - the scuttle panel partition.
terminal.
dywork, 55A, Exterior protection, Scuttle panel 4
grille ).
112816
Remove the oil vapour rebreathing pipe (4) .
104343
Remove:
14A-38
ANTIPOLLUTION
K9K, and 732
5
6
112811 112812
Pull the clip Disconnect the exhaust gas recirculation solenoid
valve connector (5) .
Remove the inlet duct mounting bolt.
Remove:
Move the inlet duct to one side.
- the exhaust gas recirculation solenoid valve moun-
ting bolts (6) ,
- the exhaust gas recirculation solenoid valve using
the (Mot. 1729) ,
- the seal between the exhaust gas recirculation so-
lenoid valve and the cooler mounting on the
flywheel side.
Note:
When removing the exhaust gas recirculation
solenoid valve with the (Mot. 1729) , gently move
the solenoid valve until it comes away from its
mounting.
REFITTING
Refit the exhaust gas recirculation solenoid valve
with its new seal.
solenoid valve mounting bolts (10 Nm) .
14A-39
ANTIPOLLUTION
K9K, and 732
nal.
WARNING
Before restarting the engine, use the diagnostic

tool to clear any faults stored by the injection com-
puter.
14A-40
ANTIPOLLUTION
F9Q, and 804
112665
The exhaust gas recirculation solenoid valve is joi-
ned to the exhaust gas recirculation unit.
Replace the « EGR unit - EGR solenoid valve
assembly » if the EGR solenoid valve is faulty (see
14A, Emission control, EGR unit ).
14A-41
ANTIPOLLUTION
M9R, and 700
Equipment required
tweezers
Tightening torquesm
bolts mounting the 21 Nm

EGR solenoid valve on
the inlet manifold
bolts mounting the air 8 Nm

inlet duct between the
turbocharger and the
intercooler on the inlet 104343
manifold Remove:
front end panel lower 44 Nm - the mounting bolts (1) from the air filter access pa-
mounting bolts nel,
front end panel upper 21 Nm - the air filter access panel,

mounting bolts - the mounting bolt (2) from the scuttle panel parti-
tion.
REMOVAL

grille ).
104246
Remove:
Refitting ).
14A-42
ANTIPOLLUTION
M9R, and 700
115585
cessories unit.
Remove:
114933
- the upper front end panel mounting bolts (9) ,
102365
Remove:
- the lower mounting bolts (10) from the front end pa-
112658
nel,
Remove:
- the mounting bolts (5) from the engine accessories
unit, - the damper valve (see 12A, Fuel mixture, Dam-
per valve: Removal - Refitting ).
14A-43
ANTIPOLLUTION
M9R, and 700
CONCERNED
113282
Pivot the air duct retaining clip (11) between the tur-
bocharger and the intercooler on the turbocharger
side.
115721
Disconnect the EGR solenoid valve connector (13) .
Remove:
- the bolts (14) mounting the EGR solenoid valve on
the inlet manifold,
- the EGR solenoid valve,
- the EGR solenoid valve seal.
113155
Remove the mounting bolts (12) from the air inlet
duct between the turbocharger and the intercooler
on the inlet manifold.
Move aside the air inlet duct between the turbochar-
ger and the intercooler.
Remove the EGR rigid pipe between the EGR sole-
noid valve and the EGR cooler (see 14A, Emission
control, Exhaust gas recirculation rigid pipe: Re-
14A-44
ANTIPOLLUTION
M9R, and 700
REFITTING
115069
Fit the new seal to the air inlet duct between the tur-
bocharger and the intercooler on the turbocharger
115068 side.
Remove the air inlet duct seal between the turbo-
charger and the intercooler on the turbocharger side Note:
using a tweezers.
Check that the seal (15) on the air inlet duct
between the turbocharger and the intercooler on
the turbocharger side is fitted in the correct direc-
tion.
Clean the pressure faces:

- of the plenum chamber,
- of the EGR solenoid valve if it is to be re-used.
WARNING

CONCERNED
Fit:
- the new seal to the EGR solenoid valve,
- the EGR solenoid valve.
Finger tighten the mounting bolts until they make
contact with the EGR solenoid valve.
Tighten to torque the bolts mounting the EGR so-
lenoid valve on the inlet manifold (21 Nm) .
Connect the EGR solenoid valve connector.
14A-45
ANTIPOLLUTION
M9R, and 700
III - FINAL OPERATION - the engine undertray.
Refit the EGR rigid pipe between the EGR solenoid Connect the battery (see 80A, Battery, Battery: Re-
valve and the EGR cooler (see 14A, Emission con- moval - Refitting ).
trol, Exhaust gas recirculation rigid pipe: Remo-
val - Refitting ).
Pivot the air inlet duct retaining clip between the tur-
bocharger and the intercooler on the turbocharger - if replacing or removing - refitting the EGR solenoid
side. valve, reprogram by following command scenario
SC036 (see MR 372 Fault finding, 13B, Diesel in-
Clip on the air inlet duct between the turbocharger
jection, Fault finding - Interpretation of com-
and the intercooler on the turbocharger side
mands ) and (see MR 372 Fault finding, 13B,
Refit the bolts mounting the air inlet duct between Diesel injection, Fault finding - Replacement of
the turbocharger and the intercooler on the inlet ma- components ),
nifold.
Tighten to torque the bolts mounting the air inlet (see 80C, Xenon headlights, Xenon headlight:
duct between the turbocharger and the intercoo- Adjustment ),
ler on the inlet manifold (8 Nm) . - adjust the headlights (see 80B, Headlights,
Refit: Halogen headlights: Adjustment ).

Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Refit:
Refitting ),
14A-46
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
Ms. 583 Hose clamp pliers.

EGR duct clips.
Equipment required
diagnostic tool
Tightening torquesm
bolts mounting the 12 Nm

intercooler on its two 104343
supports Remove:
bolts mounting the two 25 Nm - the scuttle panel grille (see MR 371 Bodywork,
intercooler supports on 55A, Exterior protection, Scuttle panel grille ).
the cylinder head - the air filter access panel mounting bolts (1) ,
rigid exhaust gas recir- 35 Nm - the air filter access panel,
culation pipe mounting
bolts
lifting bracket mounting 10 Nm

bolts
bolts mounting the two 12 Nm

intercooler supports on
the cylinder head
REMOVAL

104246
Remove:
14A-47
ANTIPOLLUTION
K9K, and 732
112816
Disconnect:
- the connector (6) from the exhaust gas recircula-
tion solenoid valve,
- the oil vapour rebreathing pipe (7) on the rocker co-
112991
ver side.
steel pipe.
112815
112811 (8) .
Pull the clip. Loosen the clip and (9) move the air inlet duct (10) to
one side.
Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting ).
14A-48
ANTIPOLLUTION
K9K, and 732
113475 114341
Remove the mounting bolts (11) from the injector rail Position the (Ms. 583) on the exhaust gas cooler in-
protector cover mounting bracket. let and outlet hoses.
Remove the mounting bolts (12) from the exhaust
gas coolant circulation cover.
Move the exhaust gas coolant circulation cover to
one side.
Remove the seals on the exhaust gas coolant circu-
lation cover.
Note:
Make preparations for coolant outflow.
112329
Remove:
- the lifting bracket mounting bolts (13) from the timi-
ng end,
- the lifting bracket on the timing end (14) ,
14A-49
ANTIPOLLUTION
K9K, and 732
- the metal air inlet tube (15) , REFITTING
tic converter: Removal - Refitting ), I - REFITTING PREPARATION OPERATION
- the mounting bolts (16) from the rigid exhaust gas All the bearing faces on each removed part must be
recirculation pipe, carefully cleaned.
- the mounting bolts (17) from the exhaust gas recir-
culation unit assembly,
WARNING
- the exhaust gas recirculation unit assembly. Take care not to damage the bearing faces to
prevent any risk of coolant leaks.
CONCERNED
WARNING
Always replace:
- the metal air inlet tube and its O-rings,
- the exhaust gas inlet pipe, its mounting bolts, its
seal and its snap-fit clamp,
- the seals of the cooler on its supports,
- the seals of the coolant circulation cover within
the intercooler,
- the seal between the downstream duct of the
cut-off valve and the intercooler support,
- the seal between the catalytic converter and the
112326
turbocharger.
At the workbench, remove:

- the bolt (18) mounting the intercooler on its two II - REFITTING OPERATION FOR PART
supports, CONCERNED
- the intercooler, Refit the intercooler on its two supports fitted with
new seals.
- the snap-fit clamp (19) from the rigid exhaust gas
recirculation pipe,
WARNING
Ensure that the seals between the cooler and its
two supports are correctly positioned to avoid
any coolant leaks.
14A-50
ANTIPOLLUTION
K9K, and 732
112326
Refit: 112329
- the mounting bolts to the cooler, without making
Refit:
contact so that the cooler can move,
- the exhaust gas recirculation unit assembly with its - the new rigid exhaust gas recirculation pipe (21)
cooler, onto the cylinder head. with a new seal,
- the bolts mounting the two intercooler supports on
the cylinder head. - the new exhaust gas recirculation pipe mounting
bolts,
Finger tighten the mounting bolts of the two intercoo-
ler supports.
Adjust the intercooler in relation to its two supports. WARNING
Tighten the mounting bolts of the intercooler on its Ensure that you do not constrain the rigid
two supports until they make contact, in order to im- exhaust gas recirculation pipe before fitting the
mobilise it. snap-fit clamp.
Remove the exhaust gas recirculation unit assembly

Fit the new snap-fit clamp.
with its cooler.
At the workbench, tighten to torque the bolts moun- Tighten the rigid exhaust gas recirculation pipe
ting the intercooler on its two supports (12 Nm) . mounting bolts until they make contact.
Refit:
Adjust the rigid exhaust gas recirculation pipe in re-
- the exhaust gas recirculation unit assembly with its lation to the cooler support on the timing end.
cooler, onto the cylinder head.
- the mounting bolts for the intercooler supports. Lock the snap-fit clamp of the rigid exhaust gas re-
circulation pipe using the (Mot. 1567).
Tighten to torque the bolts mounting the two inter-
cooler supports on the cylinder head (25 Nm) .
Torque tighten the rigid exhaust gas recirculation
pipe mounting bolts (35 Nm) .
Refit:

- the metal air inlet tube,
- the lifting bracket on the timing end,
- the mounting bolts to the lifting bracket.
14A-51
ANTIPOLLUTION
K9K, and 732
Tighten to torque the lifting bracket mounting Refit:
bolts (10 Nm) .
WARNING
Clear any faults stored by the computer using the
Ensure that the water inlet and outlet hoses of
diagnostic tool.
the intercooler are correctly aligned so that they
are not kinked.
Fit the new seal to the exhaust gas coolant circula-

tion cover.
Refit the mounting bolts on the exhaust gas coolant
circulation cover.
Tighten to torque the bolts mounting the two inter-
cooler supports on the cylinder head (12 Nm) .
Remove the (Ms. 583) on the intercooler inlet and
outlet hoses.
Refit:
- the injector rail protector cover retaining bracket
mounting bolts,
Tighten the clip.
ry.
Refit the mounting bolt to the stainless steel pipe.
Connect:
- the oil vapour rebreathing pipe on the rocker cover
side,
nector.
Refit:
Bleed the cooling circuit (see 19A, Cooling, Coo-
ling circuit: Bleeding ).
14A-52
ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting 14A
K9K, and 732
For removing and refitting the supports for the intercoo-
ler (see 14A, Emission control, Intercooler: Remo-
val - Refitting ).
14A-53
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting 14A
K9K, and 732
REFITTING
Mot. 1567 Long nose pliers for I - REFITTING PREPARATION OPERATION

EGR duct clips.
All the bearing faces must be carefully cleaned.
Tightening torquesm II - REFITTING OPERATION FOR PART

CONCERNED
mounting bolts of the 35 Nm Refit:
rigid exhaust gas recir-
culation pipe on the - the new rigid exhaust gas recirculation pipe with a
manifold new seal,
- the new exhaust gas recirculation pipe mounting
bolts,
REMOVAL
Fit a new snap-fit clamp.

WARNING
Ensure that you do not squeeze the exhaust gas
pipe before fitting the snap-fit clamp.
Tighten the mounting bolts of the rigid exhaust gas
Disconnect the battery (see 80A, Battery, Battery: recirculation pipe on the manifold until they make
Removal - Refitting ). contact.
Remove: Adjust the rigid exhaust gas recirculation pipe in re-
lation to the cooler support on the timing end.
- the engine undertrays,
Lock the snap-fit clamp of the rigid exhaust gas re-
- the catalytic converter (see 19B, Exhaust, Cataly- circulation pipe using the (Mot. 1567).
tic converter: Removal - refitting ).
Tighten to torque the mounting bolts of the rigid
exhaust gas recirculation pipe on the manifold
II - OPERATION FOR REMOVAL OF PART (35 Nm) .
CONCERNED

Refit:
tic converter ),
Refitting ).
113842
Remove:
- the mounting bolts (1) from the exhaust gas recir-
culation pipe,
- the snap-fit clamp (2) using the (Mot. 1567) ,
14A-54
ANTIPOLLUTION
M9R, and 700
REMOVING THE EGR RIGID PIPE

BETWEEN THE EXHAUST MANIFOLD
Tightening torquesm
AND THE EGR COOLER
bolts securing the EGR 35 Nm
rigid pipe on the EGR I - REMOVAL PREPARATION OPERATION
cooler
bolts securing the EGR 35 Nm ting equipment, Underbody lift ).
rigid pipe on the exhaust
Remove:
manifold
bolt securing the EGR 10 Nm
rigid pipe on the cylinder - the battery (see 80A, Battery, Battery: Removal -
head Refitting ),
bolt securing the EGR 10 Nm 55A, Exterior protection, Scuttle panel grille:
rigid pipe heat shield on Removal - Refitting ).
the cylinder head
bolt securing the EGR 10 Nm

rigid pipe heat shield on
the exhaust manifold
air filter unit outlet air 5.5 Nm

pipe clips

rigid pipe on the EGR
solenoid valve

rigid pipe on the EGR
cooler
104343
positive terminal moun- 8 Nm
Remove:
ting nut
pipe clips - the air filter access panel,
turbocharger pressure 8 Nm
sensor mounting nut

mounting bolts

mounting bolts
IMPORTANT
14A-55
ANTIPOLLUTION
M9R, and 700
104246 113294
Remove: Disconnect the diesel temperature sensor connector
(7) .
- the plenum chamber (see 19A, Cooling, Plenum
chamber: Removal - Refitting ).
114846
Disconnect: 115714
- the turbocharger pressure regulating hose (4) on Disconnect the high pressure pump pressure regu-
the air filter unit outlet pipe, lator connector (8) .
- the oil vapour rebreathing hose (5) from the oil se- Detach the wiring harness from the high pressure
parator. pump pressure regulator and the diesel temperature
sensor.
Move aside the turbocharger pressure regulating so-
lenoid valve (6) .
Undo the clips on the air filter unit outlet air pipe.
Disconnect the air filter unit outlet air pipe.
14A-56
ANTIPOLLUTION
M9R, and 700
113280
114478
Remove the EGR rigid pipe heat shield (11) .

CONCERNED
113295
Remove:
- the bolt (9) securing the EGR rigid pipe heat shield
on the exhaust manifold,
- the bolt (10) securing the EGR rigid pipe heat
shield on the cylinder head.
113295
Remove the bolt (12) securing the EGR rigid pipe on
the cylinder head.
14A-57
ANTIPOLLUTION
M9R, and 700
113311 114477
Remove the bolts (13) securing the EGR rigid pipe Remove the EGR rigid pipe (15) between the ex-
on the EGR cooler. haust manifold and the EGR cooler.
REMOVING THE EGR RIGID PIPE

BETWEEN THE EGR SOLENOID VALVE
AND THE EGR COOLER

Remove:
113281
Remove the bolts (14) securing the EGR rigid pipe - the engine undertray,
on the exhaust manifold. - the front bumper (see MR 371, Bodywork, 55A,
Refitting ).
14A-58
ANTIPOLLUTION
M9R, and 700
115585
cessories unit.
Remove:
114933
102365
Remove:
112658
Remove: - the front end panel.

(2) ,
14A-59
ANTIPOLLUTION
M9R, and 700
115701 115702
Disconnect the turbocharger pressure sensor con- Undo the intercooler outlet air pipe clip (12) on the
nector (8) . damper valve end.
Remove the nut (9) securing the turbocharger pres- Disconnect the intercooler outlet air pipe.
sure sensor.
114860
115023 Disconnect the alternator connector (13) .
Remove the bolt (10) securing the intercooler outlet
Remove the positive terminal mounting nut (14) .
air pipe on the cooling radiator.
Undo the intercooler outlet air pipe clip (11) on the
intercooler end.
14A-60
ANTIPOLLUTION
M9R, and 700
II - OPERATION FOR REMOVAL OF PART Screw without tightening:
CONCERNED
- the bolts securing the EGR rigid pipe on the ex-
haust manifold,
- the bolts securing the EGR rigid pipe on the EGR
cooler,
- the bolt securing the EGR rigid pipe on the cylinder
head.
Tighten to torque:
- the bolts securing the EGR rigid pipe on the
EGR cooler (35 Nm) ,
- the bolts securing the EGR rigid pipe on the ex-
haust manifold (35 Nm) ,
- the bolt securing the EGR rigid pipe on the cy-
linder head (10 Nm) .

Refit the EGR rigid pipe heat shield.
114037
- the bolt securing the EGR rigid pipe heat shield on
Remove: the cylinder head,
- the EGR rigid pipe mounting bolts (15) between the - the bolt securing the EGR rigid pipe heat shield on
EGR solenoid valve and the EGR cooler, the exhaust manifold.
Tighten to torque:
- the EGR rigid pipe.
- the bolt securing the EGR rigid pipe heat shield
on the cylinder head (10 Nm) ,
REFITTING THE EGR RIGID PIPE
- the bolt securing the EGR rigid pipe heat shield
BETWEEN THE EXHAUST MANIFOLD
on the exhaust manifold (10 Nm) .
AND THE EGR COOLER
Connect:
I - REFITTING PREPARATION OPERATION - the high pressure pump pressure regulator con-
nector,
Remove the EGR rigid pipe seals. - the diesel fuel temperature sensor connector.
Clean: Clip the wiring harness on the high pressure pump
pressure regulator and the diesel temperature sen-
- the EGR rigid pipe seal faces if reusing,
sor.
- the EGR cooler seal face, Connect the air filter unit outlet air pipe.
- the exhaust manifold seal face. Torque tighten the air filter unit outlet air pipe
clips (5.5 Nm) .
Connect:
WARNING
The seal faces must be clean, dry and free from - the oil vapour rebreathing hose onto the oil separa-
grease (avoid finger marks). tor.
- the turbocharger pressure regulator hose on the air
inlet duct between the turbocharger and the air fil-
II - REFITTING OPERATION FOR PART ter unit.
CONCERNED
Position the turbocharger pressure regulating sole-
Refit the EGR rigid pipe with new seals. noid valve.
14A-61
ANTIPOLLUTION
M9R, and 700
Refit: III - FINAL OPERATION
- the plenum chamber (see 19A, Cooling, Plenum Refit the positive terminal mounting nut.
chamber: Removal - Refitting ),
Tighten to torque the positive terminal mounting
- the scuttle panel partition, nut (8 Nm) .
- the scuttle panel partition mounting bolts, Connect:
- the air filter access panel, - the alternator connector,
- the air filter access panel mounting bolts, - the intercooler outlet air pipe.
- the scuttle panel grille (see MR 371 Bodywork, Torque tighten the intercooler outlet air pipe clips
55A, Exterior protection, Scuttle panel grille: (5.5 Nm) .
Refit the bolt securing the intercooler outlet air pipe
- the battery (see 80A, Battery, Battery: Removal - on the cooling radiator.
Refitting ),
Refit the turbocharger pressure sensor mounting
- the engine protectors. nut.
Tighten to torque the turbocharger pressure sen-
REFITTING THE EGR RIGID PIPE sor mounting nut (8 Nm) .
BETWEEN THE EGR SOLENOID VALVE Connect the turbocharger pressure sensor connec-
AND THE EGR COOLER tor.
Refit:
Remove the EGR rigid pipe seals. - the front end panel upper mounting bolts,
Clean: - the front end panel lower mounting bolts.
- the EGR rigid pipe seal faces if reusing,
Tighten to torque:
- the EGR cooler seal face, - the front end panel lower mounting bolts (44
- the EGR solenoid valve seal face. Nm) ,
Nm) .
WARNING
The seal faces must be clean, dry and free from Clip on the air inlet scoop.
grease (avoid finger marks). Connect the screen washer tubes.
Refit the clips.
CONCERNED Fit the bonnet opening cable.
Refit the EGR rigid pipe with new seals. Connect the engine accessories unit connectors.
Refit:
- the bolts securing the EGR rigid pipe on the EGR
solenoid valve, - the engine accessories unit mounting bolts,
- the bolts securing the EGR rigid pipe on the EGR - the front bumper (see MR 371, Bodywork, 55A,
cooler. Exterior protection, Front bumper: Removal -
Refitting ),
Tighten to torque:
EGR solenoid valve (25 Nm) , Connect the battery (see 80A, Battery, Battery: Re-
EGR cooler (25 Nm) . Refit the engine protectors.
14A-62
ANTIPOLLUTION
M9R, and 700
(see 80C, Xenon bulbs, Xenon headlight: Ad-
justment ),
- adjust the headlights (see 80B, Headlights,
Halogen headlight: Adjustment ).
14A-63
STARTING - LOAD
General alternator information 16A
K4J – K4M – F4R – K9K – F9Q – M9R
I - OPERATION
Engine Alternator Current
These vehicles are fitted with an alternator with internal strength
ventilation and a built-in regulator, plus a warning light
on the instrument panel, which operates as follows: VALEO : TG11 C018
- when the ignition is switched on, the warning light co- VALEO : TG11 C040 110 A
mes on,
- when the engine starts, the warning light goes out, VALEO : TG11 C049
- if the warning light comes on while the engine is run- VALEO : SG12 B078
ning, this indicates a « battery charge » fault.
VALEO : SG12 B081
125 A
II - IDENTIFICATION F9Q
VALEO : SG15 B092
VALEO : SG15 B098

Engine Alternator Current
strength BOSCH : LIE8 0 124 525
101
150 A
VALEO : TG11 C011
110 A BOSCH : 0 124 525 044
K4J and VALEO : TG11 C027
VALEO : SG15 L027 155A
K4M
BOSCH : LIE8 0 124 525 150 A
028 BOSCH : LIE6 0 124 0AC 120 A
473B
VALEO : TG11 C040
110 A M9R VALEO : TG15 C059 150 A
VALEO : TG11 C049
F4R MELCO : 8GM A004 TJ0 210 A
VALEO : SG12 B092 281
125 A
VALEO : SG12 B098
VALEO : TG11 C041 Note:

110 A
VALEO : TG11 C034 There is a configuration in the Protection and Swit-
ching Unit for the alternator fitted onto the vehicle
BOSCH : LIE8 0 124 525 (see 87G, Engine compartment connection unit,
082 Protection and Switching Unit ).
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
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm
alternator mounting 21 Nm
bolts


ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL
I - REMOVAL PREPARATION OPERATION - the side reinforcements (1) .

Disconnect:
Refitting ).
- the electrical connections.
Remove the alternator harness.
Remove:
- the front wheels,

- the front bumper (see MR 365 Bodywork, 55A,
Refitting ).
102008
Remove:
Note: - the mounting nut and bolts (2) from the half sub-fra-
When fitting the safety strap, take care: me,
- not to crush the cooling hoses, - the half sub-frame.

Fit the cooling assembly to the upper cross member

using the safety belt.
16A-2
STARTING - LOAD
F4R, and 770 or 771 or 776
109537 19703
Disconnect:
Note:
- the pressostat connector (3) ,
Take care not to constrain the compressor air
- the air conditioning compressor connector (4) , conditioning pipes during this operation.
Move the electric wiring harness to one side. Remove the air conditioning compressor mounting
bolts (6) .
Remove the air conditioning compressor and attach
it using a safety belt.
111851
Remove:
- the air conditioning compressor bracket mounting

bolts (5) ,
- the air conditioning compressor bracket.
16A-3
STARTING - LOAD
F4R, and 770 or 771 or 776
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
19703
18987
WARNING Refit the rings (8) using pliers or a vice.
Do not damage the cooling unit vanes (radiator,
condenser, etc.) during handling.
CONCERNED
Note: Refit:
To ease alternator removal, move the cooling - the alternator,
system towards the front slightly.
- the alternator mounting bolts.
Remove: Torque tighten the alternator mounting bolts (21
- the mounting bolts (7) from the alternator, Nm) .
- the alternator.
Refit:
- The air conditioning compressor,
- the air conditioning compressor mounting bolts.
Refit:
- the air conditioning compressor bracket,
- the air conditioning compressor bracket mounting
bolts.
Connect:
- the pressostat connector,
- the air conditioning compressor connector.
16A-4
STARTING - LOAD
F4R, and 770 or 771 or 776
of engine, Accessories belt ).
Apply a drop of LOCTITE - FRENEBLOC on the
sub-frame mounting bolts.
Refit:
- the side reinforcements.
Tighten to torque:
- the half sub-frame mounting nuts (21 Nm) .
Refit:
Refitting ).
- the front wheels.
Connect:
- the electrical connections,
Refitting ).
16A-5
STARTING - LOAD
K9K, and 722 or 724 or 728 or 732
Equipment required
safety belt
Tightening torquesm
bolts


ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL
REMOVAL PREPARATION OPERATION - the side reinforcements (1) .

Disconnect:
Refitting ).
Remove:
- the front wheels,

Refitting ).
102008
Remove:
Note: - the mounting nuts and bolts (2) from the half sub-
When fitting the safety strap, take care: frame,


16A-6
STARTING - LOAD
K9K, and 722 or 724 or 728 or 732
19703
109537
Note:
Disconnect:
- the pressostat connector (3) , conditioning pipes during this operation.
- the air conditioning compressor connector (4) ,
Move the electric wiring harness to one side. bolts (5) .
16A-7
STARTING - LOAD
K9K, and 722 or 724 or 728 or 732
OPERATION FOR REMOVAL OF PART
CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING
- the free pulley support mounting bolts (6) ,
- the free pulley support. condenser, etc.) during handling.
Note:
To ease alternator removal, move the cooling
Remove:
- the mounting bolts (7) from the alternator,
- the alternator.
16A-8
STARTING - LOAD
K9K, and 722 or 724 or 728 or 732
REFITTING
BASIC HEATING
Refit:
- the free pulley support,
- the free pulley support mounting bolts.

Refit:
Tighten to torque:
Refit:
18987
Refit the rings (8) using pliers or a vice. - the front bumper (see MR 365 Bodywork, 55A,
Refitting ).
Refit:
- the front wheels.
- the alternator,
Connect:
Nm) . - the electrical connections,
III - FINAL OPERATION Refitting ).
Refit:
Connect:
16A-9
STARTING - LOAD
F9Q, and 804 or 812
Equipment required
safety belt
Tightening torquesm
bolts


ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL

Disconnect:
Refitting ).
Remove:
- the front wheels,

Refitting ).
102008
Remove:
Note: - the mounting nut and bolts (2) from the half sub-fra-
When fitting the safety strap, take care: me,


16A-10
STARTING - LOAD
F9Q, and 804 or 812
109537 19703
Disconnect:
- the pressostat connector (3) , Note:
- the air conditioning compressor connector (4) , Take care not to constrain the compressor air
Move the electric wiring harness to one side. conditioning pipes during this operation.

bolts (5) .
16A-11
STARTING - LOAD
F9Q, and 804 or 812
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
19703
18987
WARNING Refit the rings (7) using pliers or a vice.
condenser, etc.) during handling.
CONCERNED
Note: Refit:
To ease alternator removal, move the cooling - the alternator,
Remove:
- the mounting bolts (6) from the alternator, Nm) .
- the alternator.
Refit:
Connect:
16A-12
STARTING - LOAD
F9Q, and 804 or 812
Refit:
Tighten to torque:
Refit:
Refitting ).
- the front wheels.
Connect:
- the electrical connections,
Refitting ).
16A-13
STARTING - LOAD
K4J, and 730
Equipment required
safety belt
Tightening torquesm
bolts


ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL

Disconnect:
Refitting ),
Remove:
- the front wheels,

Refitting ).
102008
Remove:
Note: - the half sub-frame mounting nuts and bolts (2) ,
When fitting the safety strap, take care: - the half sub-frame.

16A-14
STARTING - LOAD
K4J, and 730
19703
109537
Note:
Disconnect:
Move the wiring harness to one side. bolts (5) .
16A-15
STARTING - LOAD
K4J, and 730
CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING
Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator mounting bolts (7) ,
- the alternator.
16A-16
STARTING - LOAD
K4J, and 730
REFITTING
BASIC HEATING
Refit:

Apply a drop of LOCTITE - FRENEBLOC on the half
Refit:
Tighten to torque:
Refit:
18987
Refitting ),
Refit:
- the front wheels.
- the alternator,
Connect:
Refit:
Connect:
16A-17
STARTING - LOAD
K4M, and 761 or 782
Equipment required
safety belt
Tightening torquesm
bolts


ting bolts

ting nuts
wheel bolts 110 Nm

101212
Remove:
REMOVAL

Disconnect:
Refitting ),
Move the alternator harness to one side.
Remove:
- the front wheels,

Refitting ).
102008
Remove:
Note: - the half sub-frame mounting nuts and bolts (2) ,
When fitting the safety strap, take care: - the half sub-frame.

16A-18
STARTING - LOAD
K4M, and 761 or 782
19703
109537
Note:
Disconnect:
Move the wiring harness to one side. bolts (5) .
16A-19
STARTING - LOAD
K4M, and 761 or 782
CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING
Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator.
16A-20
STARTING - LOAD
K4M, and 761 or 782
REFITTING
BASIC HEATING
Refit:

Apply a drop of LOCTITE - FRENEBLOC on the half
Refit:
Tighten to torque:
Refit:
18987
Refitting ),
Refit:
- the front wheels.
- the alternator,
Connect:
Refit:
Connect:
16A-21
STARTING - LOAD
M9R, and 700
Tightening torquesm
bolts
positive terminal moun- 8 Nm

ting nut
air inlet pipe clip on the 5.5 Nm

damper valve
air inlet pipe clip on the 5.5 Nm

intercooler
turbocharger pressure 8 Nm
sensor mounting nut

mounting bolts
front end panel upper 21 Nm 101212

mounting bolts
Remove:
right-hand side reinfor- 21 Nm
cement mounting bolts - the right-hand side reinforcement mounting bolts,
- the right-hand side reinforcement (1) ,

REMOVAL - the engine undertray,

I - REMOVAL PREPARATION STAGE
terior protection, Front bumper ),
ting equipment, Underbody lift ). - the accessories belt (see 11A, Top and front of
Remove:
tyres, Wheel: Removal - Refitting ),
114933
16A-22
STARTING - LOAD
M9R, and 700
102365
Remove:
112658
Remove:
- the engine component unit cover mounting bolts

(3) ,
114409
Disconnect the turbocharging pressure sensor con-
nector (9) .
115585
Remove:
Disconnect the engine component unit connectors
- the turbocharging pressure sensor mounting nut,
(4) .
- the damper valve stay turbocharger pressure sen-
Unfasten the bonnet opening cable (5) . sor.
Undo the air inlet pipe clip on the damper valve.
Remove:
- the clips (6) ,
16A-23
STARTING - LOAD
M9R, and 700
CONCERNED
114649
Undo the air inlet pipe clip (10) on the intercooler.
114860
Remove:
Disconnect the alternator connector (12) .
- the air inlet clip mounting bolt (11) on the cooling
Remove the positive terminal mounting nut (13) .
radiator,
Remove the cooling assembly from its housing and
move the assembly forwards.
114859
Remove:
- the alternator.
16A-24
STARTING - LOAD
M9R, and 700
REFITTING
18987
Refit the rings (15) using pliers or a vice to facilitate
fitting.

CONCERNED
Refit:
- the alternator,
Tighten to torque the alternator mounting bolts
(25 Nm) .
Refit the positive terminal mounting nut.
Tighten to torque the positive terminal mounting
nut (8 Nm) .
Connect the alternator connector.
16A-25
STARTING - LOAD
M9R, and 700
III - FINAL OPERATION - the right-hand side reinforcement mounting bolts.
Refit the cooling assembly into its housing. Tighten to torque the right-hand side reinforce-
ment mounting bolts (21 Nm) .
Refit the air inlet duct.
Refit:
Tighten to torque:
- the air inlet pipe clip on the damper valve (5.5
Nm) , - the front right-hand wheel (see 35A, Wheels and
- the air inlet pipe clip on the intercooler (5.5 Nm)
. - the engine protectors.
Tighten the air inlet duct mounting bolt on the coo- Connect the battery (see 80A, Battery, Battery: Re-
ling radiator. moval - Refitting ).
Refit:
- the turbocharger pressure sensor on the damper
valve stay,
- the turbocharger pressure sensor mounting nut.
Tighten to torque the turbocharger pressure sen-
sor mounting nut (8 Nm) .
Connect the turbocharging pressure sensor connec-
tor.
Refit:
Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Refit:
Refit:
terior protection, Front bumper ),
- the right-hand side reinforcement,
16A-26
STARTING - LOAD
Starter: Identification 16A
F4R, and 770 or 771 or 776 – F9Q, and 804 or 812 – K4J, and 730 – K4M, and 761 or 782 – K9K, and 722 or 728
Engine Starter motor
K4J and K4M VALEO D7E27
K9K MITSUBISHI
F9Q and F4R VALEO D7R49
16A-27
STARTING - LOAD
Starter: Removal - Refitting 16A
F4R, and 770 or 771 – K4J, and 730 – K4M, and 761 or 782
Disconnect:
Tightening torquesm - the oil level sensor connector,

- the starter electrical connections.
starter mounting bolts 44 Nm
battery cover mounting 4 Nm II - OPERATION FOR REMOVAL OF PART

bolts CONCERNED
REMOVAL

Remove:
- the scuttle panel grilles.
14853
Remove:
- the starter mounting bolts (2) ,
- the starter.
REFITTING
104343 I - REFITTING PREPARATION OPERATION

Remove:
Check that the centring dowel is in place.
- the two air filter access panel mounting bolts (1) ,
- the air filter access panel. II - REFITTING OPERATION FOR PART
CONCERNED
Refit the starter.
K4J
Remove the air resonator. Tighten to torque the starter mounting bolts (44
Nm) .

F4R – K4M
Remove the air filter outlet duct. moval - Refitting ).
(4 Nm) .
16A-28
STARTING - LOAD
K9K, and 722
Tightening torquesm
3
wheel bolts 130 Nm

bolts
REMOVAL
I - REMOVAL PREPARATION OPERATION 104246

Remove:
ting equipment, Underbody lift ). - the scuttle panel partition mounting bolts (3) ,
Remove:

tyres, Wheel: Removal - Refitting ). 5
1
2 4
6
104175
Remove:
- catalytic converter stay (4) ,
- catalytic converter stay (5) on the gearbox,
104343
- the catalytic converter (6) (see 19B, Exhaust, Ca-
Remove: talytic converter ).

- the scuttle panel mounting bolts (2) .
16A-29
STARTING - LOAD
K9K, and 722
CONCERNED
102268
Disconnect the starter electrical connections.
Remove:
- the starter mountings (7) ,
- the starter (8) .
REFITTING


CONCERNED
Refit the starter.
Tighten to torque the starter mounting bolts (44
Nm) .

talytic converter ).
Tighten to torque:
16A-30
STARTING - LOAD
F9Q, and 812
Tightening torquesm - the scuttle panel mounting bolts (2) ,

bolts
wheel bolts 130 Nm - the battery (see 80A, Battery, Battery: Removal -
Refitting ),
REMOVAL - the battery tray,

- the air hose between the air filter and turbocharger
duct.
dywork, Exterior protection, Scuttle panel grille
).
1
2
102421
Remove:
104343 - the air hose (3) and gently separate the hose (4) ,
104246
Remove:
16A-31
STARTING - LOAD
F9Q, and 812
101120 102427
Remove: Remove:
- the stay (5) , - the starter mountings (8) ,
- the catalytic converter (6) mounting plate on the - the starter.
gearbox,
- the catalytic converter (7) (see 19B, Exhaust, Ca- REFITTING
II - OPERATION FOR REMOVAL OF PART Tighten to torque the starter mounting bolts (44
CONCERNED Nm) .
Disconnect the starter electrical connections. Proceed in the reverse order to removal.
nal.
WARNING
Carry out the necessary programming (80A, Bat-
tery: Removal - Refitting).
Tighten to torque:
16A-32
STARTING - LOAD
F4R, and 776
CONCERNED
Tightening torquesm
catalytic converter 21 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, Engine/ 3
Gearbox ).
Catalytic converter ).
21921
Remove:
- the starter mountings (3) ,
- the starter.
REFITTING

2
4
106249
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream stay (2) .
21935
Check that the centring dowel (4) is in place.
16A-33
STARTING - LOAD
F4R, and 776
CONCERNED
Refit the starter.
Nm) .

Connect the starter electrical connections.
Tighten to torque:
- the catalytic converter downstream stay nut (21
Nm) ,
- the heat shield mountings (8.5 Nm) .
Refit the battery (see 80A, Battery, Battery: Remo-
val - Refitting ).
16A-34
STARTING - LOAD
K9K, and 728
Tightening torquesm

bolts
REMOVAL

106203
Disconnect the battery (see 80A, Battery, Battery: Disconnect the gearbox earth.
1 106201
Disconnect the oil level sensor.
106205
Disconnect:
- the starter electrical connections (1) ,
- the rail pressure sensor (2) .
16A-35
STARTING - LOAD
K9K, and 728
CONCERNED
106191
Remove:
- the starter mountings,
- the starter.
REFITTING

CONCERNED
Refit the starter.

Nm) .


(4 Nm) .
16A-36
STARTING - LOAD
F9Q, and 804
Tightening torquesm

bolts
wheel bolts 130 Nm
REMOVAL

6

Remove the scuttle panel grille (see MR 371 Bo- 111865

dywork, Exterior protection, Scuttle panel grille Remove the turbocharger oil return pipe (6) .
).
Remove: II - OPERATION FOR REMOVAL OF PART
CONCERNED

Refitting ),
- 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 ).
7
5
111868
Remove the starter mounting bolts (7) .
Remove the starter.
111860
Remove the turbocharger air duct.
16A-37
STARTING - LOAD
F9Q, and 804
REFITTING


CONCERNED
Refit the starter.
Nm) .

Tighten to torque:
16A-38
STARTING - LOAD
K9K, and 732
Tightening torquesm
REMOVAL

ting equipment; underbody lift ).
Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
113863
106201
Disconnect:
- the oil pressure sensor connector (1) ,
- the oil level sensor connector (2) ,
16A-39
STARTING - LOAD
K9K, and 732
REFITTING

Check that the centring dowel is in place and ensure
it is positioned correctly.

CONCERNED
Refit:
- the starter,
- the starter mounting bolts.
Nm) .

Refit the starter nuts.
106205 Clip the diesel evacuation pipe.
Remove the starter nuts (3) . Connect:
Disconnect the injector rail pressure sensor connec- - injector rail pressure sensor connector,
tor.
- the oil level sensor connector,
Move the wiring harness against the cylinder block.
- the oil pressure sensor connector.
CONCERNED Connect the battery (see 80A, Battery: Removal -
Refitting ).
106191
Remove:
- the starter mounting bolts (4) .

- the starter.
16A-40
STARTING - LOAD
M9R, and 700
Equipment required
filling station
Tightening torquesm
starter base mounting 8 Nm

nut
solenoid excitation 5 Nm
mounting nut
mounting bolt of the air 8 Nm

conditioning pipe
between the air dehy-
dration canister and air
conditioning compressor
112658
bolts Remove:
front end panel lower 44 Nm - the engine component unit cover mounting bolts
mounting bolts (1) ,
mounting bolts
REMOVAL

Remove:
Refitting ),
115585
terior protection, Front bumper ). Disconnect the engine component unit connectors
Drain the coolant circuit using the filling station (2) .
Remove:
- the clips (4) ,
16A-41
STARTING - LOAD
M9R, and 700
114933 112659
Unclip the air inlet scoop (6) . Disconnect:
tor.
Unclip:
- the injection computer connector wiring harness (9)
,
harness,
- the air filter unit turbocharger regulation solenoid
102365 valve,
Remove: - the wiring harness.
- the front end panel lower mounting bolts (7) , Remove:
- the front end panel. - the battery tray mounting bolts (10) ,
- the wiring harness mounting nut (11) .
mounting.
16A-42
STARTING - LOAD
M9R, and 700
CONCERNED
109537
Remove the mounting bolt from the air conditioning
pipe (12) between the air dehydration canister and 114628
air conditioning compressor, on the air conditioning Remove:
compressor side.
- the mounting nut (13) from the starter base,
- the mounting nut (14) from the solenoid excitation.
Note:
Plugs must be fitted to the pipe and the compres-
sor to prevent moisture from entering the system.
Remove the air conditioning pipe between the air

dehydration canister and air conditioning compres-
sor, on the air conditioning compressor side.
114998
Remove the earth wire mounting bolt (15) on the
starter.
Move the starter wiring harness to one side.
16A-43
STARTING - LOAD
M9R, and 700
113312
Remove:
- the starter mounting bolts (16) .
- the starter.
REFITTING

CONCERNED
Refit:
- the starter,
- the starter mounting bolts

Nm) .
Fit the starter wiring harness.
Refit:
- the starter base mounting nut,
- the solenoid excitation mounting nut,
- the earth wire mounting bolt.
Tighten to torque:
- the starter base mounting nut (8 Nm) ,
- the solenoid excitation mounting nut (5 Nm) .
16A-44
STARTING - LOAD
M9R, and 700
II - FINAL OPERATION Connect the screen washer pipes.
Refit: Refit the clips.
- the air conditioning pipe between the air dehydra- Fit the bonnet opening cable.
tion canister and air conditioning compressor, on
the air conditioning compressor side.
Refit:
- the mounting bolt to the air conditioning pipe
between the air dehydration canister and air condi- - the engine component unit cover,
tioning compressor, on the air conditioning com-
pressor side.
Tighten to torque the mounting bolt of the air con- 62A, Air conditioning, Maintenance ).
ditioning pipe between the air dehydration ca-
nister and air conditioning compressor (8 Nm) . Refit:
Refit the battery tray with the injection computer - the front bumper (see MR 371 Bodywork, 55A Ex-
mounting. terior protection, Front bumper ),
Fit the wiring harness. - the engine undertray,
Refit: - the battery (see 80A, Battery, Battery: Removal -

Refitting ).
- the wiring harness mounting nut,
(21 Nm) .
Fit:
- the wiring harness,
- the air filter unit turbocharger regulation solenoid
valve,
harness,
- the injection computer connector wiring harness.
Connect:
tor,
Refit:
Tighten to torque:
Nm) ,
Nm) .
16A-45
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and AIR CONDITIONING
Mot. 1732 Kit for replacing alter-

nator freewheels.
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

pulley with a decoupling pulley. 110267
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-46
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-47
STARTING - LOAD
REFITTING

CONCERNED
110269
Position:
110267
- 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) on the adapter (11) .
Note:
Check that the torque wrench is capable of tigh-
tening in a leftwards direction.
16A-48
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-49
IGNITION
Coils Removal - Refitting 17A
K4J, and 730 – K4M, and 761 or 782 – F4R, and 770 or 771 or 776
REMOVAL
Tightening torquesm
K4J, and 730 – K4M, and 761 or 782 – F4R, and
ignition coil mounting 15 Nm 770 or 771
bolts

bolts
The power module is integrated into the injection com-

puter. The ignition system uses the same sensors as
the injection system.
2
101490
14851 Remove the engine covers.

There are four ignition coils, and they are mounted Disconnect:
directly onto the spark plug by a bolt on the rocker - the battery, starting with the negative terminal,
cover.
- the ignition coil connectors (1) .
The coils are in supplied in series two by two by the
injection computer: Remove the coil mounting bolts (2) .
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
17A-1
IGNITION
F4R, and 776
106589
Remove the coil mounting bolts (3) .
Note:
Be sure to replace any damaged connectors.
REFITTING
17A-2
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-3
IGNITION
Spark plugs 17A
K4J – K4M – F4R
Ele. 1382 Spark plug spanner

que 1.75 & 28 Nm +
square adapter 9-9.52
Tightening torques
Spark plugs 25 to 30 Nm
Remove:
- the ignition coils (see 17A, Ignition, Coils ),
- the spark plugs using the (Ele. 1382).
Engines Brand Type
EYQUEM RFN58LZ
K4J and K4M
CHAMPION RC87YCL
Flat seat with seal

Gap: 0.95 (± 0.05 mm)
F4R 770/771 CHAMPION RC87YCL
Flat seat with seal

Gap: 0.90 (± 0.05 mm)
F4R 776 NGK PFR6G-9
Flat seat with seal

Gap: 0.90 (+0 / -0.1 mm)
17A-4
PETROL INJECTION
Fuel injection parts description 17B
J84, and F4R, and 770 or 771 or 776 – J84, and K4M, and 761 or 782 – J84, and K4J, and 730
K4J, and 730
104539
(1) Fuel vapour recirculation sole-

noid valve
(2) Manifold pressure sensor
(3) Ignition coil
(4) Air temperature sensor
(9) Pinking sensor
(10) Injector rail and injectors
17B-1
PETROL INJECTION
K4M, and 761 or 782
104540

noid valve
(5) Camshaft dephaser solenoid
valve
(3) Ignition coil
(6) Camshaft position sensor
(8) Pinking sensor
17B-2
PETROL INJECTION
F4R, and 770 or 771
104541

noid valve
(3) Ignition coil
valve
(6) Pinking sensor
17B-3
PETROL INJECTION
F4R, and 776
106078
(1) Ignition coil

K4J, and 730
noid valve
(8) Pinking sensor
(12) Electric coolant pump
101101
17B-4
PETROL INJECTION

noid valve
(3) Ignition coils
101105
101800
101498

(9) Pinking sensor
101811
17B-5
PETROL INJECTION
101493 102144
(10) Injector rail (12) Engine speed and position sen-

(10) Injectors sor
101798
102204
(11) Accelerator pedal potentiometer (13) Upstream oxygen sensor
17B-6
PETROL INJECTION
J84, and K4M, and 761 or 782
101501
(14) Downstream oxygen sensor

101796
noid valve
(4) Ignition coils
102483
(16) Fuel vapour recirculation absor-

ber
101809
17B-7
PETROL INJECTION
(10) Pinking sensor

valve
(5) Camshaft position sensor
101105
102735
101810
(12) Injector rail

(12) Injectors
101811
17B-8
PETROL INJECTION
102144 101798
(13) Engine speed and position sen- (15) Upstream oxygen sensor
sor
101501
102204
(14) Accelerator pedal potentiometer (17) Catalytic converter
17B-9
PETROL INJECTION
(3) Ignition coils

102483
(18) Fuel vapour recirculation absor-

102732
ber
valve
(6) Pinking sensor
F4R, and 770 or 771
102735
102724

noid valve
17B-10
PETROL INJECTION
101105 102730
(8) Protection and Switching Unit (10) Injector rail

(10) Injectors
102733
102204
17B-11
PETROL INJECTION
102485 106278
(13) Engine speed and position sen- (3) Fuel vapour recirculation sole-
sor noid valve
F4R, and 776
106787
101811
(1) Ignition coils

17B-12
PETROL INJECTION
106269
(7) Injector rail

(7) Injectors
101105
101809
(8) Pinking sensor
106633
17B-13
PETROL INJECTION
102483 102204
(13) Fuel vapour recirculation absor- (15) Accelerator pedal potentiometer

ber
106244
(16) Upstream oxygen sensor
102485
(14) Engine speed and position sen-

sor
17B-14
PETROL INJECTION
21926
17B-15
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
J84, and F4R, and 770 or 771 – J84, and K4M, and 761 or 782 – J84, and K4J, and 730
II - DOWNSTREAM OXYGEN SENSOR

gen sensors.
Tightening torquesm
REMOVAL
I - UPSTREAM OXYGEN SENSORS
101501
Remove the sensor.
REFITTING
Tighten to torque the oxygen sensors (45 Nm)
using a 24 mm fork socket for the downstream oxy-
gen sensor and using tool (Mot. 1495-01) for the
upstream oxygen sensor.
101798
Remove the sensor using tool (Mot. 1495-01).
17B-16
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
J84, and F4R, and 776
II - DOWNSTREAM OXYGEN SENSOR

gen sensors.
Tightening torquesm
2
REMOVAL
I - UPSTREAM OXYGEN SENSORS
21926
Disconnect the oxygen sensor connector.
Remove oxygen sensor (2) using tool (Mot. 1495-
01).
REFITTING
Remove the engine cover. Tighten to torque the oxygen sensors (34 Nm)
Disconnect the oxygen sensor connector. using a 24 mm fork socket for the downstream oxy-
gen sensor and using tool (Mot. 1495-01) for the
Remove oxygen sensor (1) using tool (Mot. 1495- upstream oxygen sensor.
01).
17B-17
PETROL INJECTION
Accelerator pedal potentiometer: Removal - Refitting 17B
REMOVAL
Tightening torquesm

bolts
The accelerator pedal potentiometer is incorporated in

the accelerator pedal. Its replacement therefore requi-
res replacement of the pedal.
There are two types of pedal: with or without kic-
kdown point .
Vehicles equipped with cruise control/speed limiter
have an accelerator pedal with a kickdown point at the
end of their travel.
This kickdown point is used for exiting the speed limiter
function if the driver has to increase his speed.
Note:
A pedal fitted with a kickdown point may be fitted in
place of a pedal without a kickdown point. Fitting a 102204
pedal without a kickdown point in place of a pedal Disconnect:
with a kickdown point is not permitted.
Refitting ),
- the accelerator pedal connector.
Remove:
- the pedal mounting bolts,
- the pedal.
REFITTING
(4 Nm) .
17B-18
PETROL INJECTION
Position and speed sensor 17B
J84, and F4R, and 770 or 776 – J84, and K4M, and 782 – J84, and K4J, and 730
Equipment required F4R, and 770 – F4R, and 776
diagnostic tool
K4J, and 730 – K4M, and 782
102485
Program the flywheel target after replacing the
speed and position sensor (1) or the flywheel.
102144
In third gear, accelerate twice in succession to 4000
rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, during
deceleration under no load and the injection cut out,
the computer authorises injection again.
Use the diagnostic tool (CLIP) to check that this
programming has been correctly completed ET089:
« Flywheel target programming » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is working correctly.
17B-19
PETROL INJECTION
Position and speed sensor 17B
J84, and F4R, and 771 – J84, and K4M, and 761
Equipment required
diagnostic tool
102144
In third gear, decelerate twice in succession from
4000 rpm to the power take-up speed.
Note:
Do not shift the gear lever to « D » (Automatic
transmission versions).
Power take-up speed is the moment when, during

deceleration under no load and the injection cut out,
Use the diagnostic tool (CLIP) to check that this
programming has been correctly completed ET089:
« Flywheel target programming » .
Check that the vehicle is working correctly.
17B-20
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
Equipment required F4R, and 770 or 771 or 776 – K4M, and 761 or 782
diagnostic tool
bolts
3
bolts
REMOVAL
terminal.
4
K4J, and 730
101822
Remove the battery.
Remove:
1
- the wiring harness strap (4) .
Disconnect the electric wiring harnesses from the
battery tray.
102107
Remove:
- the bolts securing the computer to the mounting,
- the computer.
17B-21
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
REFITTING
5 Tighten to torque:
- the battery tray mounting bolts (21 Nm) ,
- the battery tray mounting bolts (4 Nm) .
nal.
WARNING
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-
101811 tions.
Remove the injection computer and its mounting (5)
Using the diagnostic tool (CLIP), check that pro-
gramming has been carried out correctly ET051:
« Throttle valve programming » .
Perform flywheel target programming during a road
test.
The power take-up point is the moment when under
deceleration with no load and the injection cut off,
Using the diagnostic tool (CLIP), check that pro-
gramming has been carried out correctly ET089:
« Engine flywheel target programming » .
Check that the vehicle is functioning correctly.
101890
Remove the computer mounting bolts.
17B-22
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 the war- destruction of the catalytic converter (destructive mis-
ning lights and message displays on the instrument pa- fires). In this case the vehicle must be stopped imme-
nel. These warning lights are lit during the starting diately.
phase, in the event of an injection fault or engine ove-
rheating. - « continuously » in the event that depollution stan-
dards have not been adhered to (polluting engine
The signals to light up the warning lights reach the ins- misfires, catalytic converter fault, oxygen sensor fault,
trument panel via the multiplex network. 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. In this case the vehicle must be stopped imme-
diately.
17B-23
PETROL INJECTION
Immobiliser function 17B
This vehicle is equipped with an immobiliser which in-
volves a specific method for replacing the computer.
REPLACING AN INJECTION COMPUTER

To programme the immobiliser code (see 82A, En-
gine immobiliser, 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 car which must then be returned.
- These computers cannot be recoded.
17B-24
PETROL INJECTION
Throttle valve: Operating 17B
I - THROTTLE VALVE according to the position of the accelerator. Therefore,
the maximum engine speed under full load or in neutral
The throttle valve ensures that idle speed regulation is 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 valve is directly proportional to pres-
takes into account the major power consumers (air sure on the accelerator pedal.
conditioning) and operating conditions (air temperature
and coolant temperature).
Note:
When the driver depresses the accelerator pedal, their Each of these modes results in the injection fault
request is translated into an angle of throttle opening. warning light on the instrument panel coming on.
However, to improve driving pleasure, the throttle ope-
ning is not directly proportional to the driver’s request.
To eliminate bucking, 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 gearbox 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 (i.e. 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 out the injection and limits tor-
que by cutting out the cylinders (ignition and injection)
17B-25
PETROL INJECTION
Special notes on the system (when driving) 17B
Equipment required
Note:
diagnostic tool All electrical faults which result in exceeding the
pollution limit cause the OBD warning light to come
on.
I - INTRODUCTION
This vehicle is equipped with an « On Board III - OBD SYSTEM OPERATIONAL FAULT FINDING
Diagnostic » system (OBD). PROCEDURES
When a fault causing excessive exhaust gas pollution The operational fault finding procedures used for OBD
is detected, a warning light on the instrument panel li- are:
ghts up (OBD warning light). - misfiring which damages the catalytic converter fault
finding,
This computer fault finding program operates as fol-
lows: - pollutant misfiring fault finding,
Only engine misfiring is the subject of continuous fault - upstream oxygen sensor fault finding,
finding. The other emission control components are
- catalytic converter fault finding.
tested once while driving (i.e. fault finding is not conti-
nuous). However, these test sequences are not always
performed. The vehicle must be driven under certain
Note:
conditions for the test sequences to be carried out:
Fault finding of misfiring takes precedence over all
- temperature conditions, other fault finding. It is performed practically conti-
nuously as soon as the necessary driving condi-
- speed conditions (threshold, stability, etc.), tions are reached.
- timed starting period,
- engine conditions (inlet manifold vacuum, engine WARNING

speed, throttle angle, etc.).
At the end of each test, read the result on the dia-
The OBD management program supplements the ma- gnostic tool (CLIP) before switching off the igni-
nagement of conventional electrical faults. To meet this tion. Switching off the ignition will lead to the results
standard the requirements are: being misinterpreted.
- making the OBD warning light come on or flash,

IV - FAULTS CAUSING ON BOARD FAULT FINDING
- storing OBD faults. WARNING LIGHT TO LIGHT UP
II - IMPLICATIONS FOR FAULT FINDING AND 1 - Electrical fault

REPAIR Warning light is constantly lit after fault has been detec-
ted several times (depending on the component).
Due to the complexity of the system, it is essential to
question the customer about the conditions which led
to the warning light coming on. This information will 2 - Rate of combustion misfiring which can destroy
enable faults to be found more quickly. the catalytic converter
To prevent the OBD warning light from coming on once Immediate illumination and flashing of the warning li-
the vehicle has been returned to the customer, after ght.
any repairs (replacing the catalytic converter, oxygen
sensor, etc.), it is essential to confirm the repair by 3 - Catalytic converter or oxygen sensor fault,
carrying out a road test, observing the driving condi-
polluting combustion misfiring
tions specific to each component. This is because cer-
tain faults only appear while driving, when the Light comes on continuously after a fault is detected
adaptives have been programmed. three times consecutively.
17B-26
PETROL INJECTION
Special notes on the system (when driving) 17B
WARNING
Fault finding on the catalytic converter and the ups-

tream oxygen sensor is sequential and takes place:
- once when driving (they last several seconds per
test),
- only under certain specific driving conditions.
Under certain driving conditions (for example, traffic
jams), certain functions may not be diagnosed.
V - MANAGEMENT OF THE ONBOARD

DIAGNOSTIC WARNING LIGHT (OBD)
1 - Warning light on
If the same OBD fault is detected during three conse-
cutive journeys or there is an electrical fault.
2 - Warning light flashes

If misfiring leading to catalytic converter damage is de-
tected.
3 - Warning light goes out

If the OBD fault does not reappear during three conse-
cutive journeys, the warning light goes out and the fault
is stored in the injection computer.
The fault must not be detected for 40
consecutive journeys before its is cleared from the
computer memory without the use of the diagnostic to-
ol.
Note:
The fault may not be re-detected:
- if the fault is temporary,
- due to the driving style of the customer, which may
not always incorporate all the fault detection con-
ditions.
17B-27
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 -7.5˚C and 119.39˚C , if the coolant tem- 2 - Programming of richness adaptive parameters
perature read by the sensor is not between -7.5˚C and
To perform this programming, the vehicle must be dri-
119.39˚C , or if the difference between 1046 mbar and
ven within the pressure ranges.
the manifold pressure is greater than 273 mbar (altitu-
de of about 2500 metres), OBD is not authorised until
the ignition is switched on again.
In order for the OBD system to function correctly, there

must be no electrical faults in the injection system,
even if the OBD warning light is not lit.
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
- resolve 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 re-performed when replacing:
- an injection computer,
- an engine flywheel target,

- an engine speed sensor.
1 - Engine flywheel target programming

17B-28
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 deteriora- rature is above - 7.5˚C , in three operating ranges
tion of the catalytic converter. between idle speed and 4500 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-confor- is not switched off before the result is read on the
mance 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 diagnostic tool (CLIP):
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- ET 058 Misfiring on cylinder 2 No
gulator, fuel pump, etc.),
ET 059 Misfiring on cylinder 3 No
- a faulty connection in the petrol or injection circuits
(coil secondary, etc.). ET 060 Misfiring on cylinder 4 No
If after the test, the tool has detected combustion misfi-

II - MEASUREMENT OF ENGINE MISFIRINGS ring DF065 , DF059 , DF060 , DF061 , DF062 , refer to
the fault finding procedure for this fault.
Fault finding is performed by measuring the instanta-
neous variations in engine rotation speed.
If a drop in torque is detected, this is an indication 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% - results in catalytic
converter damage. Such misfiring causes the injec-
tion warning light to switch on immediately and flash.
- Pollutant misfiring - below 15% - causes the OBD pol-
lution limit to be exceeded. These cause the injection
warning light to come on if they are detected during
three consecutive journeys.
17B-29
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 tool has detected a catalytic conver-
emissions to exceed the OBD limit.
ter fault DF110: « Catalytic converter » refer to the
The catalytic converter's capacity to store oxygen is in- 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 75˚C ,

- 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 will remain at an average value.
2 - If it needs replacing
It rejects the oxygen and downstream oxygen sensor
PR099 starts to pulse. The oxygen sensor voltage fluc-
tuates (the OBD warning light comes on after three
journeys).
WARNING
At the end of this test, it is essential that the ignition
is not switched off before the result is read on the
diagnostic tool. Switching off the ignition will lead to
the results being misinterpreted.
17B-30
PETROL INJECTION
Oxygen sensor fault finding 17B
The purpose of fault finding on the upstream oxygen
sensor is to detect faults that would cause emissions of
hydrocarbon, carbon monoxide or nitrogen oxide to ex- WARNING
ceed the OBD limit. It is carried out by measuring and At the end of this test, it is essential that the ignition
comparing periods of upstream oxygen sensor vibra- is not switched off before the result is read on the
tion. diagnostic tool. Switching off the ignition will lead to
the results being misinterpreted.
I - POSSIBLE CAUSES OF FAULTS
V - REPAIR CONFIRMATION
There are two types of possible fault in the upstream
oxygen sensor: If, after the test, the diagnostic tool has detected a fault
in the upstream oxygen sensor DF092: « Upstream
- mechanical damage to an electrical component oxygen sensor circuit » refer to the fault finding pro-
(breakage, cut in wire) which leads to an electrical cedure for this fault.
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 75˚C ,
- 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-31
LPG INJECTION
LPG injection: Precautions for repair 17C
K4M, and 764
Apply leak detecting product (part number 77 11 143
071 ) to the open union(s).
Note:
Fill the fuel tank with a few litres of LPG , if it has been
It is essential that you follow the following safety bled (with the ignition switched off).
advice before carrying out any operation on a vehi-
Check that the gas unions are not leaking.
cle equipped with the LPG system.
Start the engine, switch to gas mode and check again
that there is no leak.
I - SPECIALLY EQUIPPED WORKSHOP
Fill the fuel tank (80% of total volume). Start the engi-
Repairs to the LPG system must only be carried out in ne, run it in gas mode and check that there are no
workshops that meet the requirements for this type of leaks.
operation.
After refitting, check that none of the rubber and shea-
Only workshops equipped with an LPG igniter for drai- thed steel hoses is touching a component likely to cau-
ning the system may carry out work on the LPG tanks. se wear, and consequently create a gas leak (use pins
to keep the hoses separate).
II - AUTHORISED STAFF
V - OPERATION ON THE TANK
Staff authorised to carry out work on a vehicle's LPG
system must have completed a special training pro- Before carrying out any work on the LPG system, drain
gram enabling them to do so. the pipes.
Drain the tank (see 17C, LPG injection, LPG tank:
III - GENERAL SAFETY ADVICE Draining ).
Any work on the LPG system must be carried out in a Other types of operation associated with a source of
ventilated area of a specially equipped workshop, by heat:
personnel who have undergone special training.
- in the event of an operation requiring the use of a
Only workshops equipped with an LPG igniter may blowpipe, drain the pipes and the LPG tank.
drain the system.
- if the vehicle must be subjected to high temperatures
When carrying out any type of work on the LPG sys- (above 80˚C), drain the pipes and the LPG tank and
tem, do not wear clothes containing acrylic or any other remove the LPG tank (see 17C, LPG injection, LPG
material which could generate static electricity. injection: LPG tank: Removal - Refitting ).
Keep naked flames and all ignition sources (sparks, ci- After any work is carried out on the LPG system, test
garettes, mobile phones, etc.) away from the work the sealing on the entire gas supply circuit using the
area. leak detector product (part number 77 11 143 071 ).
Carry out all work with the battery disconnected.
Never attempt to remove the fuel tank or any of its fixed
components, without first having bled it (risk of explo-
sion).
If a major gas leak occurs, the vehicle must be isolated
in the open air, away from buildings.
The emergency services may be required to intervene
if the situation cannot be controlled.
Do not attempt to open the expansion valve in order to
repair it. It is not adjustable.
Do not wash the engine compartment with a pressu-
rised system using detergent. These can cause the ex-
pansion valve membranes to deteriorate.
IV - OPERATION ON THE PIPES

After working on a gas union, check that it is not lea-
king after refitting.
17C-1
LPG INJECTION
LPG tank - pipe neck: Removal - Refitting 17C
K4M, and 764
Tightening torquesm
filler neck-tank pipe 21 Nm

mounting bolt
nut securing the filler 25 Nm

neck-tank pipe on the
LPG filler neck
nut securing the filler 8 Nm

neck-tank pipe on the
safety solenoid valve
safety solenoid valve 2 Nm

protector mounting bolts
REMOVAL
114227
WARNING
Disconnect the safety solenoid valve connector (3) .
It is essential to read the repair precautions
before carrying out any work on the LPG circuit.
Read the repair precautions (see 17C, LPG injec-

tion, LPG injection: Precautions during repair ).
Disconnect the battery (see MR 370 Mechanical,

80A, Battery, Battery: Removal - Refitting ).
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch trim.
114225
Remove:
- the mounting bolts (1) from the safety solenoid val-

ve protector,
- the safety solenoid valve protector (2) .
17C-2
LPG INJECTION
LPG tank - pipe neck: Removal - Refitting 17C
K4M, and 764
Manually tighten:
- the mounting bolt (7) on the filler neck-tank pipe,
- the nut (6) securing the filler neck-tank pipe on the

LPG filler neck,
- the nut (5) securing the filler neck-tank pipe on the

safety solenoid valve.
Clip on the filler neck-tank pipe at (4) .
Tighten to torque:
- the filler neck-tank pipe mounting bolt (21 Nm)

114228
at (7) ,
- the nut securing the filler neck-tank pipe on the

LPG filler neck (25 Nm) ,
- the nut securing the filler neck-tank pipe on the

safety solenoid valve (8 Nm) .
Connect the safety solenoid valve connector (3) .
Refit:
- the safety solenoid valve protector (2) ,
- the safety solenoid valve protector mounting bolts

(1) .
Tighten to torque the safety solenoid valve protec-

tor mounting bolts (2 Nm) .
Refit:
114223
Disconnect the filler neck-tank pipe at (5) . - the rear right-hand wheel arch trim.
- the rear right-hand wheel.

WARNING
When disconnecting the filler neck-tank pipe, Connect the battery (see MR 370 Mechanical, 80A,
take care not to damage the sealing ring. Battery, Battery: Removal - Refitting ).
Unclip the filler neck-tank pipe at (4) . Carry out a sealing check on all unions which have
been loosened (see 17C, LPG injection, LPG in-
Disconnect the filler neck-tank pipe from the LPG
filler neck at (6) . jection: Precautions during repair ).
Remove: Start the engine running and spray the leak detec-
- the mounting bolt (7) from the filler neck-tank pipe, tion product ( part number 77 11 143 071 ) onto the
loosened unions.
- the filler neck-tank pipe (8) .
Let the engine run for 5 minutes .
REFITTING If no air bubbles form around the unions which were
Position the filler neck-tank pipe (8) . loosened, they can be considered leak-tight.
17C-3
LPG INJECTION
LPG tank: Removal - Refitting 17C
K4M, and 764
Equipment required
component jack
Tightening torquesm
LPG tank mounting 21 Nm

bolts
exhaust pipe central 8 Nm

support mounting bolt
silencer rear support 8 Nm

tank-filler neck pipe 25 Nm Remove:

mounting nut
gas supply pipe moun- 25 Nm ve protector (2) ,
ting nut - the safety solenoid valve protector (2) .
REMOVAL
WARNING

114227
Disconnect:
- the safety solenoid valve connector (3) ,
- the gas filling pipe (4) ,
- the gas supply pipe (5) .
WARNING
When disconnecting the gas filling pipe, take
care not to damage the sealing ring.
Allow any gas inside the pipes to escape.
17C-4
LPG INJECTION
K4M, and 764
114368 114366
Remove:
- the mounting bolts (8) from the silencer heat shield

(9) ,
- the silencer heat shield (9) .
114367
Remove:
- the mounting bolts (6) from the exhaust pipe cen-
tral support,
- the mounting bolts (7) from the silencer rear sup-
port. 114229
Remove:
- the bolts (10) mounting the heat shield (11) on the

LPG tank,
- the heat shield (11) from the LPG tank.
Fit the component jack.
17C-5
LPG INJECTION
K4M, and 764
Tighten to torque the LPG tank mounting bolts (21
Nm) .
Refit:
- the heat shield (11) to the LPG tank,
- the bolts (10) mounting the heat shield (11) on the
LPG tank.
Refit:
- the silencer heat shield (9) ,
- the mounting bolts (8) on the silencer heat shield
(9) ,
- the mounting bolts (7) to the silencer rear support,
- the mounting bolts (6) to the exhaust pipe central
support.
Tighten to torque:
- the exhaust pipe central support mounting bolt
(8 Nm) ,
114242
- the silencer rear support mounting bolts (8 Nm)
.
Connect:
- the gas filling pipe (4) ,
- the gas supply pipe (5) .
WARNING
When connecting the gas filling pipe, take care
not to damage the sealing ring.
Tighten to torque:
- the tank-filler neck pipe mounting nut (25 Nm)
(4) ,
- the gas supply pipe mounting nut (25 Nm) (5) .
Refit:
114243
Remove: - the mounting bolts (1) to the safety solenoid valve

protector.
- the mounting bolts (12) from the LPG tank,
- the LPG tank. tor mounting bolts (2 Nm) .
Connect the battery (see MR 370 Mechanical, 80A,
REFITTING
Carry out a sealing check on all unions which have
Fit the component jack. been loosened (see 17C, LPG injection, LPG in-
Refit: jection: Precautions during repair ).
Start the engine running and spray the leak detec-
- the LPG tank,
tion product ( part number 77 11 143 071 ) onto the
- the mounting bolts (12) on the LPG tank. loosened unions.
17C-6
LPG INJECTION
K4M, and 764
If no air bubbles form around the unions which were
loosened, they can be considered leak-tight.
17C-7
LPG INJECTION
LPG tank: Draining 17C
K4M, and 764
DRAINING 1 - Connections
To connect the pilot flame hose:
WARNING - Clip the expansion valve onto the bottle. The valve
It is essential to read the repair precautions must be closed.
- Connect the quick-release union onto the end pie-
ce of the pilot flame.
tion, LPG injection: Precautions during repair ). - Position the tank to be emptied more than 10 m
Park the vehicle outside. away from the flare.
Disconnect the battery. To connect the LPG circuit:
- Connect the self-sealing union on the end of the

hose to the flare connection end piece, with the val-
ve closed.
- Fitting the special pipes onto the LPG tank output.

The connection to the tank must be made in accor-
dance with the recommendations of the vehicle
manufacturer's After-Sales procedures.
- Connect the self-sealing union on the end of the

hose to the special pipes connection end piece.
To connect the nitrogen circuit:
- Position the nitrogen bottle near the LPG tank.
114225 - Attach the expansion valve onto the nitrogen bottle

Remove: and tighten the expansion valve union.
- the mounting bolts (1) from the safety solenoid val- - Connect the special nitrogen pad to the LPG filling
ve protector (2) , opening and tighten it manually. (make sure there
is a seal).
- After checking that everything is tightened and cor-
There are two types of igniter approved by Renault rectly sealed, the installation is ready for start-up.
available:
- AEM flare,
2 - Starting the installation
- ALSIA flare.
Check that all the valves and all the circuits are
closed.
I - AEM IGNITER
Lighting the pilot flame (operator correctly attired):
- Open the « TWINY » bottle expansion valve

Note: switch.
Refer to the Owner's Manual for the AEM LPG
- Place a flame for lighting the pilot flame in the ope-
igniter, along with the fitting procedure described
ning provided on the flare cylinder.
below.
- Check that the pilot flame is correctly lit.
Position the flare securely on the flare area.
If it has not lit:
Position the « TWINY » bottle more than 5 m away
from the flare. - Air present in the hose: Continue trying to light the
pilot flame.
Note: - Empty gas bottle: replace it.
The propane bottle is not supplied. - Blocked injector: Remove and clean it.
17C-8
LPG INJECTION
K4M, and 764
- Try to open the progressive flow control valve
slowly so as to not trigger the tank safety valve. If
the valve triggers, start the operation again, closing
the progressive flow control valve.
- After the flow has equalised, open the nitrogen
bottle and adjust the expansion valve to a pressure
1 bar greater than the tank pressure (but not grea-
ter than 7 bar ).
Note:
Carry out this operation when the tank pressure
gauge shows approximately 2 bar . At this point,
add the nitrogen to a pressure of 3 bar until the
end of the flare procedure.
After the main flame has been extinguished, allow

the nitrogen flare to sweep at the rate of 1 min per
10 litres capacity (e.g.: for a 60 litre tank: sweeping
time = 6 min ).
114227
WARNING
The tank has not been degassed, the liquid
phase has been evacuated, the gaseous zone
contains mainly nitrogen, which is a neutral gas.
3 - Switching off the installation

Close the tank solenoid valve and remove the ma-
gnet.
Close the nitrogen circuit by resetting the expansion

valve and closing the tap on the on the N2 bottle.
Shut off the pilot flame by closing the expansion val-
106518 ve switch on the « TWINY » gas bottle.
To light the igniter: Close the progressive flow control valve.
- The operator must be at least 10 m away from the
flare and must ensure that this precaution is res- WARNING
pected by everyone.
The flare must remain where it is until it has coo-
- Remove the safety solenoid valve (1) . led down completely. Move the flare using the
two side handles.
- Control the tank solenoid valve using a magnet (2) .
- Open the progressive flow control valve to position

4 - Removal
1 (the highest position is 5).
Disconnect the special nitrogen pad from the LPG
- The igniter starts.
filling opening.
- Check the passage of liquid gas through the circu-
Remove the nitrogen expansion valve union.
lation indicator.
Loosen the special union from the tank and discon-
- Adjust the opening of the progressive flow control
nect on the self-sealing union side.
valve, increasing its opening to position 2 or 3 until
the flow lines equalise through the circulation indi- Disconnect the quick-release union from the end
cator. piece of the igniter.
17C-9
LPG INJECTION
K4M, and 764
Disconnect the quick-release union from the end
piece of the pilot flame.
Unclip the expansion valve from the « TWINY » bott-
le.
Wind up the hoses.
Put away the equipment.
II - ALSIA IGNITER
Note:
Refer to the Owner's Manual for the ALSIA LPG
igniter, along with the fitting procedure described
below.
17C-10
LPG INJECTION
K4M, and 764
114227
100014
17C-11
LPG INJECTION
K4M, and 764
106518
Control the safety solenoid valve using a magnet (9)
.
Check that the gas unions between the fuel tank and
the igniter are not leaking.
100015
Open the pilot flame valve on igniter (6) and ignite it
Connect the tank to earth. by putting a flame to light (7) .
Disconnect the gas supply pipe (1) . Check that the igniter is sufficiently far away from the
vehicle and any flammable material.
Place the igniter 20 m away from any flammable ob-
ject (buildings, fuel and combustible matter etc.). Open the main igniter valve (5) gradually.
Connect the igniter to earth. The flame can reach 3 to 4 m during 30 minutes .
Connect the safety solenoid valve output (2) onto As the igniter sucks the gas from the fuel tank, the
the igniter (8) (supplied with 10 m of pipe ), after ha- flame gradually changes colour.
ving first checked the compatibility of the sealing
Once the main flame has gone out, let the pilot flame
unions.
burn until it, too, goes out so there is no more pres-
Check that gas taps (5) and (6) are closed. sure in the fuel tank.
Connect the safety solenoid valve connector (3) . Close the main tap (5) to end the bleed with the pilot
flame.
Remove the safety solenoid valve (4) .
Try to reignite the pilot flame to check that the fuel
tank has been bled.
Finally, close the tap (6) and the pilot flame.
17C-12
LPG INJECTION
K4M, and 764
100009
If necessary, sweep the tank using the nozzle (10)
and a nitrogen canister (11) .
Connect the nozzle to the filler neck and adjust the
flow to a pressure of between 5 and 8 bar .
Open the main valve (5) .
Allow the bottle to discharge for 5 minutes .
Close the nitrogen bottle and disconnect the sole-
noid valve from the fuel tank.
17C-13
LPG INJECTION
LPG level gauge: Removal - Refitting 17C
K4M, and 764
114226
(1) LPG level gauge.
(2) Safety solenoid valve.
WARNING
The LPG level gauge is not removable.
Only the safety solenoid valve (2) is removable.
17C-14
LPG INJECTION
LPG expansion valve: Removal - Refitting 17C
K4M, and 764

clips.

clips.

hose clips.
Tightening torquesm
expansion valve unit 8 Nm

mounting bolt

114227
Disconnect the safety solenoid valve connector (3) .
REMOVAL Remove the LPG computer (see 17C, LPG injec-
tion, LPG computer: Removal - Refitting ).
WARNING

Remove the battery (refer to MR 370 Mechanical,

114356
Disconnect the connectors (4) from the pressure
sensor and the expansion valve solenoid valve.
114225
Remove:

ve protector,
17C-15
LPG INJECTION
K4M, and 764
114357 114358
Disconnect the gas supply pipe (5) . Position the (Ms. 583) on the coolant inlet and outlet
pipes (9) .
Remove the clip (6) .
Remove:
Disconnect:
- the clips (10) from the coolant inlet and outlet pipes
- the expansion valve-LPG injection rail pipe (7) ,
- the reference pressure pipe (8) . (Mot. 1448) ,
- the coolant inlet and outlet pipes (9) ,
- the mounting bolt (11) from the expansion valve
unit,
- the expansion valve unit.
REFITTING
Refit the expansion valve unit.
Tighten to torque the expansion valve unit moun-
ting bolt (8 Nm) .
Refit:
- the coolant inlet and outlet pipes (9) ,
- the clips (10) to the coolant inlet and outlet pipes
(Mot. 1448).
Remove the (Ms. 583) from the coolant inlet and
outlet pipes.
Connect the reference pressure pipe (8) .
Replace the clip (6) .
Connect:
- the expansion valve-LPG injection rail pipe (7) ,
- the gas supply pipe (5) ,
17C-16
LPG INJECTION
K4M, and 764
- the connector (4) to the pressure sensor and the
expansion valve solenoid valve.
Refit the LPG computer (see 17C, LPG injection,
LPG computer: Removal - Refitting ).
Refit:
- the mounting bolts (1) to the safety solenoid valve
protector.
tor mounting bolts (2 Nm) .
Refit the battery (refer to MR 370 Mechanical, 80A,
Fill the cooling circuit (see MR 370 Mechanics, 19A,
Cooling, Cooling circuit: Draining-refilling ).
Bleed the cooling circuit (see MR 370 Mechanics,
19A, Cooling, Cooling circuit: Bleeding ).
Carry out a sealing check on all unions which have
been loosened (see 17C, LPG injection, LPG in-
jection: Precautions during repair ).
17C-17
LPG INJECTION
LPG pressure sensor: Removal - Refitting 17C
K4M, and 764
Mot. 1608 Torque screwdriver.
Tightening torquesm
pressure sensor moun- 1.6 Nm

ting bolts
battery tray mountings 21 Nm
petrol injection compu- 21 Nm

ter support mountings
REMOVAL
WARNING
It is essential to read the repair precautions 114364
before carrying out any work on the LPG circuit. Disconnect the connectors (1) from the petrol injec-
tion computer.
tion, LPG injection: Precautions during repair ). Remove:
Remove the battery (refer to MR 370 Mechanical, - the support mountings (2) from the petrol injection
80A, Battery, Battery: Removal - Refitting ). computer,
- the petrol injection computer along with its support,
- the battery tray mountings (3) .
Unclip the wiring harness from the battery tray.
17C-18
LPG INJECTION
LPG pressure sensor: Removal - Refitting 17C
K4M, and 764
Start the engine and spray the leak detection pro-
duct ( part number 77 11 143 071 ) onto the pres-
sure sensor.
If no air bubbles form around the pressure sensor, it
can be considered leak-tight.
114353
Disconnect the connector (4) from the pressure sen-
sor (6) .
Remove:
- the pressure sensor mounting bolts (5) ,
- the pressure sensor (6) .
REFITTING
Refit:
- the pressure sensor (6) ,
- the pressure sensor mounting bolts (5) .
Using the (Mot. 1608) tighten to torque the pressu-
re sensor mounting bolts (1.6 Nm) .
Connect the pressure sensor connector (4) .
Refit the battery tray.
Tighten to torque the battery tray mountings (21
Nm) .
Clip the wiring harness onto the battery tray.
Refit the petrol injection computer along with its sup-
port.
Tighten to torque the petrol injection computer
support mountings (21 Nm) .
Connect the petrol injection computer connectors (1)
.
Refit the battery (see MR 370 Mechanical, 80A,
Carry out a sealing check on the LPG pressure sen-
sor.
17C-19
LPG INJECTION
LPG expansion valve solenoid valve: Removal - Refitting 17C
K4M, and 764
Tightening torquesm
expansion valve sole- 2 Nm

noid valve mounting bolt

REMOVAL
WARNING

tion: Precautions during repair ). 114364
Remove the battery (refer to MR 370 Mechanical, Disconnect the connectors (1) from the petrol injec-
80A, Battery, Battery: Removal - Refitting ). tion computer.
Remove:
- the support mountings (2) from the petrol injection
computer,
- the battery tray mountings (3) .
17C-20
LPG INJECTION
LPG expansion valve solenoid valve: Removal - Refitting 17C
K4M, and 764
114355
Disconnect the connector (4) from the expansion

valve solenoid valve (6) .
Remove the expansion valve solenoid valve moun-

ting bolt (5) .
Remove the expansion valve solenoid valve (6) .
REFITTING
Refit the expansion valve solenoid valve (6) .
Tighten to torque the expansion valve solenoid

valve mounting bolt (2 Nm) .
Connect the expansion valve solenoid valve con-

nector (4) .
Refit the battery tray.
Tighten to torque the battery tray mountings (21

Nm) .
Clip the wiring harness onto the battery tray.

port.

Connect the petrol injection computer connectors (1)

.

17C-21
LPG INJECTION
LPG expansion valve outlet union: Removal - Refitting 17C
K4M, and 764
Refit the expansion valve unit (see 17C, LPG injec-
tion, Expansion valve unit: Removal - Refitting ).
Tightening torquesm
LPG expansion valve 2.5 Nm Battery, Battery: Removal - Refitting ).
outlet union mounting Carry out a sealing check on all unions which have
bolts been loosened (see 17C, LPG injection, LPG in-
REMOVAL Start the engine and spray the leak detection pro-
duct ( part number 77 11 143 071 ) onto the loose-
ned unions.
WARNING Let the engine run for 5 minutes .
It is essential to read the repair precautions If no air bubbles form around the unions which were
before carrying out any work on the LPG circuit. loosened, they can be considered leak-tight.
Remove the expansion valve unit (see 17C, LPG in-
jection, Expansion valve unit: Removal - Refit-
ting ).
114239
Remove:
- the mounting bolts (1) from the LPG expansion val-
ve outlet union,
- the LPG expansion valve outlet union (2) .
REFITTING
Refit the LPG expansion valve outlet union
Tighten to torque the LPG expansion valve outlet
union mounting bolts (2.5 Nm) .
17C-22
LPG INJECTION
Coolant circuit union: Removal - Refitting 17C
K4M, and 764
REFITTING
Tightening torquesm Refit the cooling circuit unions.
cooling circuit union 2.5 Nm

mounting bolts WARNING
Replace the cooling circuit union sealing rings.
REMOVAL Tighten to torque the cooling circuit union moun-

ting bolts (2.5 Nm) .
Refit the expansion valve unit (see 17C, LPG injec-
WARNING tion, Expansion valve unit: Removal - Refitting ).
It is essential to read the repair precautions Connect the battery (see MR 370 Mechanical, 80A,
before carrying out any work on the LPG circuit. Battery, Battery: Removal - Refitting ).
Read the repair precautions (see 17C, LPG injec- Carry out a sealing check on all unions which have
tion, LPG injection: Precautions during repair ). been loosened (see 17C, LPG injection, LPG in-
80A, Battery, Battery: Removal - Refitting ). Start the engine and spray the leak detection pro-
duct ( part number 77 11 173 071 ) onto the loose-
Remove the expansion valve unit (see 17C, LPG in-
ned unions.
jection, Expansion valve unit: Removal - Refit-
ting ). Let the engine run for 5 minutes .
If no air bubbles form around the unions which were
loosened, they can be considered leak-tight.
114239
Remove:
- the mounting bolts (1) from the cooling circuit
unions,
- the cooling circuit unions (2) .
17C-23
LPG INJECTION
LPG injection rail: Removal - Refitting 17C
K4M, and 764
Tightening torquesm
LPG and petrol injec- 10 Nm

tion rail mounting nuts
injection rail protector 21 Nm

mounting nuts
injection rail wiring har- 10 Nm

ness mounting bolt
REMOVAL
WARNING
Read the repair precautions (see 17C, LPG injec- 114361

Remove:
80A, Battery, Battery: Removal - Refitting ). - the mounting bolt (2) from the injection rail wiring
harness,
- the mounting nuts (3) from the injection rail protec-
tor,
- the injection rail protector (4) .
Note:
Take care not to damage the cooling radiator
when removing the protector (4) .
114363
Remove the cooling radiator mountings (1) .
17C-24
LPG INJECTION
K4M, and 764
114362 114360
Remove the mounting nuts (5) from the LPG injec- Disconnect the petrol supply union (6) from the pe-
tion rail. trol injection rail.
Shift the LPG injection rail forwards.
WARNING
Beware of splashes of petrol when disconnecting
the petrol supply union: protect the alternator.
Disconnect the petrol injector connectors (7) .

Remove the petrol injection rail (8) .
WARNING
When removing the injectors and the petrol injec-
tion rail, be aware that there will be some fuel in
the rail and the unions.
17C-25
LPG INJECTION
K4M, and 764
REFITTING
Note:
When refitting, lightly lubricate the LPG injector
O-ring and seals. Use the engine oil to lubricate
as it prevents sticking.
Connect the gas pipe between the expansion valve

unit and the LPG injection rail.
Refit the clip to the gas pipe between the expansion
valve unit and the LPG injection rail.
WARNING
Always replace the snap-on clip (9) on the gas
pipe between the expansion valve unit and the
LPG injection rail.
Refit:
114359
- the LPG injectors,
Disconnect the LPG injector connectors (11) .
- the LPG injection rail.
Remove the LPG injector (12) .
Connect the LPG injector connectors.
Refit the petrol injection rail.
Note:
Tighten to torque the LPG and petrol injection rail
Remove the LPG injector using a flat-blade
screwdriver, inserted between the LPG injector
and the cylinder head. The LPG injectors can Connect:
then be removed from their housing by rotating
- the petrol injector connectors.
the handle.
- the petrol supply union to the petrol injection rail.
Remove the clip (9) from the gas pipe between the
expansion valve unit and the LPG injection rail. Refit the injection rail protector.
Disconnect the gas pipe (10) between the expansion Tighten to torque:
valve unit and the LPG injection rail. - the injection rail protector mounting nuts (21
Nm) .
IMPORTANT - the injection rail wiring harness mounting bolt
Beware of escaping gas when disconnecting the (10 Nm)
gas pipe between the expansion valve unit and
the LPG injection rail.
Angle the gas pipe between the expansion valve
unit and the LPG injection rail upwards to allow
the gas from the engine compartment to escape
without coming into contact with any hot compo-
nents or persons nearby.
Remove the LPG rail along with the injectors.
17C-26
LPG INJECTION
K4M, and 764
114363
Refit the cooling radiator mountings (12) .
Carry out a sealing check on the injectors (see 17C,
LPG injection, LPG injection: Check ).
17C-27
LPG INJECTION
LPG injector: Removal - Refitting 17C
K4M, and 764
REMOVAL Refit the LPG injection rail (see 17C, LPG Injection,
Injection rail: Removal - Refitting ).
WARNING Battery, Battery: Removal - Refitting ).
It is essential to read the repair precautions Carry out a sealing check on the injectors (see 17C,
before carrying out any work on the LPG circuit. LPG injection, LPG injection: Test ).
Remove the LPG injection rail (see 17C, LPG Injec-
tion, Injection rail). Removal - Refitting ).
114352
Remove:
- the clips (1) from the LPG injector hoses,
- the LPG injectors.
WARNING
The hoses connected to the LPG injection rail
and the LPG injectors are marked with a line at
each end. These marks help you to correctly
position the different components during refitting.
Before removing a component, note its position
in relation to the mark on the hose.
REFITTING
WARNING
It is essential to replace the LPG injector clips
and hoses.
Refit:
- the LPG injectors,
- the LPG injector hose clips.
17C-28
LPG INJECTION
LPG injector: Check 17C
K4M, and 764
Note:
After any work is carried out on the LPG injectors, a
sealing check must be carried out.
Two types of leak can be detected:

Scenario no. 1 : test for sealing between the injectors
and the flexible pipes:
- start the engine,
- press the « gas » button on the instrument panel to
enter « gas » mode,
- allow the engine to run in « gas » mode for 5 minutes
,
- wait approximately 5 minutes ,
- start the engine,
- allow the engine to run in « gas » mode.
If none of the indicator lights on the instrument panel
are lit, the sealing between the injectors and the flexi-
ble pipes is considered correct.
If an indicator light on the instrument panel is lit, repla-
ce the faulty parts.
Scenario no. 2 : test for sealing between the injectors
and the cylinder head:
- start the engine,
- allow the engine to run in « gas » mode for 5 minutes
,
- check that the idling speed is correct.
If the idling speed is correct, the sealing between the
injectors and the cylinder head is considered good.
If the idling speed is abnormally high, replace the faulty
injector.
17C-29
LPG INJECTION
LPG computer: Removal - Refitting 17C
K4M, and 764
Tightening torquesm
LPG computer moun- 8 Nm

ting nut

REMOVAL
Remove the battery (refer to MR 370 Mechanical,
114354
Disconnect the connector (4) from the LPG compu-

ter.
Remove the mounting nut (5) from the LPG compu-

ter.
Remove the LPG computer.
REFITTING
Refit the LPG computer.
Tighten to torque the LPG computer mounting nut

114364 (8 Nm) .
Disconnect the connectors (1) from the petrol injec-
tion computer. Connect the LPG computer connector.
Remove: Refit the battery tray.

- the support mountings (2) from the petrol injection
computer, Tighten to torque the battery tray mountings (21
Nm) .
- the battery tray mountings (3) . Clip the wiring harness onto the battery tray.
Remove the battery tray. port.

Connect the petrol injection computer connectors.

17C-30
COOLING SYSTEM
Engine cooling: Parts and consumables for the repair work 19A
CONSUMABLES
Use GLACEOL RX (TYPE D) coolant.
Note:
Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guideli-
nes marked on the container.
19A-1
COOLING SYSTEM
Engine cooling 19A
- that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
IMPORTANT air.
The circuits are designed to be pressurised; take Vehicles in the current range have cooling circuits with
care at high temperatures (risk of serious scalding). the following basic specifications:
Never remove the valve from the expansion bottle - Pressurised sealed circuit (expansion bottle valve),
while the engine is hot.
Take care when carrying out a repair under the bon-
net, as the radiator fan(s) may start to operate Note:
without warning. Summary of expansion bottle valve ratings.
Do not open the bleed screw(s) with the engine run- Expansion bottle valve with:
ning.
• a yellow hand: 1.4 bar
• a white hand: 1.6 bar
• a grey hand: 1.8 bar
WARNING
The coolant helps to keep the engine running pro- - circuit using type « D » coolant only.
perly (heat exchange).
The system does not operate using pure water.
Note:
Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guideli-
WARNING nes marked on the container.
Drain with the engine warm.
Flush and refill with the engine cold or warm.
Never flush a hot engine (risk of major thermal
shock).
WARNING
When carrying out a repair that requires a complete
circuit drain, it is essential to flush the circuit with
clean water, blow compressed air through the cir-
cuit to eliminate water, fill and drain the circuit and
then measure the effective protection.
The criteria to be met are:
- Protection down to - 25˚C ± 2 for cold and tempe-
rate climates,
- Protection down to - 40˚C ± 2 for very cold clima-
tes.
Note:
Refer to the vehicle's maintenance service booklet
for information on cooling circuit service intervals.
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drive

belt,
19A-2
COOLING SYSTEM
Specifications 19A
Grade and quantity of coolant
Engine Suffix Quantity Grade

(litres)
K4J 730 6
761 6.5
K4M
782 6
770 6
GLACEOL RX
F4R 771 (TYPE D)
6.5
776 Only use
coolant
722 5.3
fluid
K9K 728 6.5
732 7.5
804 7.6
F9Q
812 6.5
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-3
COOLING SYSTEM
Checking 19A
II - CHECKING THE CIRCUIT SEALING
Mot. 1700 Fault finding and fil-

ling-bleeding cooling Note:
system. The expansion bottle valve must be replaced if
coolant is leaking from the valve.
I - RECOMMENDATIONS FOR REPAIR
Checking the cooling system and the expansion
bottle valve
IMPORTANT
The circuits are designed to be pressurised; take
care at high temperatures (risk of serious scal-
ding).
Never remove the valve from the expansion
bottle while the engine is hot.
Take care when carrying out a repair under the
bonnet, as the radiator fan(s) may start to ope-
rate without warning.
Do not open the bleed screw(s) with the engine
running.
107138
Check the cooling system and the expansion bottle diagnostic and filling tool ).
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
19A-4
COOLING SYSTEM
Diagram 19A
K4J, and 730 – K4M, and 761 or 782
7
3
1
5
4
6 8
9
10
2
105003
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) Bleed screw
(8) 9 mm choke
(9) 6 mm choke for automatic trans-
mission (if fitted to the vehicle)
(10) Water-oil heat exchanger for the
automatic transmission (if fitted
to the vehicle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-5
COOLING SYSTEM
Diagram 19A
K9K, and 722 or 728
7
3
7
8
5 1
4
9
6
10
105004
(1) Engine
(3) Heater radiator
(5) Coolant pump
(6) Thermostat
(7) Bleed screw
(8) 11 mm choke (K9K 722)
(9) 9 mm by-pass choke (K9K 728)
(10) Water-oil heat exchanger
Note:
bar .
19A-6
COOLING SYSTEM
Diagram 19A
F9Q, and 812
3
11
5 1
8
4
7
6
10
9
2
105002
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Bleed screw
(8) 8 mm choke
(9) 9 mm choke
Note:
bar .
19A-7
COOLING SYSTEM
Diagram 19A
F4R, and 770 or 771
7
3
7
5
1
4
8
9
2
10
105005
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Bleed screw
(8) 8.3 mm choke
(9) 6 mm choke
(10) Water-oil heat exchanger for
automatic transmission (if fitted
to the vehicle)
Note:
bar .
19A-8
COOLING SYSTEM
Diagram 19A
F4R, and 776
7
12 3
1
5 13
8
4 7
6
10
11
106628
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Bleed screw
(8) 9 mm choke
(9) 16 mm choke
(12) Turbocharger
(13) Thermostat mounting
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEM
Diagram 19A
F9Q, and 804
13 8 12
3
1 7
5
4
6 7 14
10
11
112266
(1) Engine
(3) Heater radiator
(5) Coolant pump
(6) Thermostat
(7) Bleed screw
(8) 8 mm choke
(9) 16 mm choke
(10) Coolant-oil heat exchanger
(12) Turbocharger
(13) Thermostat mounting
Note
The expansion bottle valve rating is 1.4 bar .
19A-10
COOLING SYSTEM
Diagram 19A
K9K, and 732
7
7
3
9
5
1
4
112268
(1) Engine
(3) Heater radiator
(5) Water pump
(6) Thermostat
(7) Bleed screw
(8) Water-oil intercooler
Note:
bar .
19A-11
COOLING SYSTEM
Diagram 19A
M9R, and 700
114452
(1) Engine
(3) Heater radiator
(5) Coolant pump
(6) Thermostat
(7) Choke
(8) Choke
(9) Bleed screws
(10) Coolant-oil heat exchanger
noid valve
Note:
bar .
19A-12
COOLING SYSTEM
Cooling circuit: Draining - Refilling 19A
Special tooling required WARNING
Car. 1363 Trim removal lever circuit drain, it is essential to flush the circuit with
clean water, blow compressed air through the cir-
Mot. 1202-01 Clip pliers for hose clips (large
cuit to eliminate water, fill and drain the circuit and
model)
Mot. 1202-02 Clip pliers for hose clips (small The criteria to be met are:
model)
- Protection down to - 25˚C ± 2 for cold and tempe-
Mot. 1448 Remote operation clip pliers for rate climates,
cooling 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 scalding).
Never remove the valve from the expansion bottle
while the engine is hot. Note:
Take care when carrying out a repair under the bon- The engine must be switched off and the air condi-
net, as the radiator fan(s) may start to operate tioning system deactivated to prevent the engine
without warning. cooling fans operating as soon as the engine is
Do not open the bleed screw(s) with the engine run- started.
ning.
DRAINING
WARNING Use the following tools:
The coolant helps to keep the engine running pro- - (Car. 1363) ,
perly (heat exchange).
- (Mot. 1202-01) ,
The system does not operate using pure water.
- (Mot. 1202-02) ,
- (Mot. 1448) .
WARNING Remove the expansion bottle valve.
Open the cooling system at the cooling radiator bot-
Flush and refill with the engine cold or warm. tom hose using the (Car. 1363) .
Never flush a hot engine (risk of major thermal Blast compressed air into the circuit through the ex-
shock). pansion bottle valve orifice to remove as much coo-
lant as possible.
CLEANING
For cleaning (see 19A, Cooling, Cooling system:
Cleaning ).
FILLING
Use GLACEOL RX (TYPE D) coolant.
19A-13
COOLING SYSTEM
Cooling circuit: Draining - Refilling 19A
Refill the cooling system using the cooling system fil-
ling and diagnostic 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 valve.
Bleed the circuit (see 19A, Cooling system, Coo-
ling circuit: Bleeding, page 19A-16) .
19A-14
COOLING SYSTEM
Engine cooling circuit: Cleaning 19A
IMPORTANT
care at high temperatures (risk of serious scalding).
Never remove the valve from the expansion bottle
Take care when carrying out a repair under the bon-
net, as the radiator fan(s) may start to operate
without warning.
Do not open the bleed screw(s) with the engine run-
ning.
WARNING
Flush and refill with the engine cold or warm.
Never flush a hot engine (risk of major thermal
shock).
CLEANING THE COOLING SYSTEM

To clean the cooling system, fill with coolant 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.
Blow compressed air into the circuit through the ex-

pansion bottle valve orifice to remove as much coo-
lant as possible.
Connect the top and bottom hoses.
19A-15
COOLING SYSTEM
Cooling circuit: Bleeding 19A
Equipment required
pedal press
IMPORTANT
The circuits are designed to be pressurised, take
care at high temperatures (risk of serious scal-
ding).
Never remove the valve from the expansion
bottle while the engine is hot.
Take care when carrying out a repair under the
bonnet, as the radiator fan(s) may start to ope-
rate without warning.
Do not open the bleed screw(s) with the engine
running.
BLEEDING
Use the pedal press.
Start the engine.
Check that the air conditioning system is not activa-

ted.
K9K, and 722 or 728 or 732
Run the engine at 1500 rpm , rapidly varying the en-

gine speed (until maximum speed is reached) 2 to 3
times approximately every 2 minutes until the engi-
ne cooling fan starts up for a second time.

770 or 771 or 776 – F9Q, and 804 or 812 – M9R,
and 700
Run the engine at 2500 rpm , until the engine coo-

ling fan has run three times (time required for auto-
matic degassing).
Check that the heating is operating correctly.
Allow the engine to cool until the coolant temperatu-

re is less than 50˚C .
Top up the coolant level in the expansion bottle if ne-

cessary.
19A-16
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
or 732
Remove:
Car. 1363 Trim removal lever. - the front wheels,
Mot. 1202-01 Pliers for large hose - the engine undertray,
clips.
- the wheel arch liners.
Mot. 1202-02 Pliers for small hose Disconnect:
clips.
- the fog lights connector (if fitted to the vehicle),
- the headlight washer pipes (if fitted to the vehicle).
hose clips.
Remove the bumper (see MR 371, Bodywork, 55A,
Refitting ).
Tightening torquesm
intercooler hose clip 5.5 Nm
wheel bolts 130 Nm
2
REMOVAL
1
F4R, and 776 – F9Q, and 804 or 812 – K9K, and

722 or 728 or 732 4
3
WARNING
102504
Disconnect the two connectors (1) .
intercooler:
- detach the hose using the (Car. 1363) ,
Remove:
- do not use degreasing agent, brake cleaner or
any other product, - the clip (3) ,
- clean the mating faces on the intercooler and - the fastener (4) .
on the hose with a dry, lint-free cloth,
- replace the clip in the same position if the hose
is not replaced,
- it is essential to replace the hose and/or the
intercooler in the event of damage,
- it is essential to replace the clip.
There is a risk of leaks and unseating if this pro-
cedure is not followed.


19A-17
COOLING SYSTEM
or 732

722 or 728 or 732
102365
Remove the front cross member (5) . 6
ling system: Draining - Filling ).
Disconnect:
- the cooling radiator top hose,
- the cooling radiator expansion bottle hoses,
- the engine cooling fan connector. 102473
102474
Disconnect the inlet ducts (6) and the outlet ducts (7)
from the intercooler.
Remove the intercooler.
19A-18
COOLING SYSTEM
or 732
Separate the condenser from the cooling radiator (if
fitted to the vehicle).
WARNING
pipes.
Remove the cooling radiator.

Separate the engine cooling fan from the cooling ra-
diator.
REFITTING

722 or 728 or 732
Tighten to torque the intercooler hose clip (5.5
Nm) .
Refit the hose clips, using:

- 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 radiator, the
condenser or the cooler are not damaged during
refitting; protect them if necessary.

system: Draining - Filling ).
Refit:
- the front wheels,
- the front wheel bolts
Note:
essential to initialise the system; see 80C,
19A-19
COOLING SYSTEM
Water pump: Removal - Refitting 19A
F4R, and 770 or 771 or 776 – F9Q, and 804 or 812
REFITTING
Tightening torquesm
coolant pump moun- 9 Nm IMPORTANT

ting bolts Do not scratch the aluminium sealing surfaces.
front right-hand wheel 130 Nm Wear goggles.

bolts Wear gloves during the operation.
REMOVAL Clean the sealing 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 coolant pump seal every time the coo-
lant pump is removed.
WARNING
The seal faces must be clean, dry and free from
Drain the cooling system (see 19A, Cooling, Coo- grease (avoid finger marks).
ling system: Draining - Filling ).
Remove:
Note:
engine, Accessories belt: Removal - Refitting ), Apply two drops of LOCTITE FRENETANCH to
the coolant pump mounting bolts.
Timing belt: Removal - Refitting ). Refit:
- the coolant pump,
- the coolant pump mounting bolts.
102422
Remove:
- the coolant pump mounting bolts (6) ,
- the coolant pump.
19A-20
COOLING SYSTEM
F4R, and 770 or 771 or 776 – F9Q, and 804 or 812
102422
Tighten to torque and in order the coolant 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 bolts.
Tighten to torque the front right-hand wheel bolts
(130 Nm) .
19A-21
COOLING SYSTEM
K9K, and 722 or 728 or 732
Tightening torquesm
coolant pump moun- 11 Nm

ting bolts
front right-hand wheel 130 Nm

bolts
REMOVAL

Remove:
- the engine undertray, Disconnect the alternator electrical connections.
- the front right-hand wheel. Remove the alternator upper mounting (1) .
Drain the engine cooling system (see 19A, Cooling, Undo the alternator lower mounting (2) .
Cooling system: Draining- Filling ). Tilt the alternator forward.
Remove:
102266
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
19A-22
COOLING SYSTEM
K9K, and 722 or 728 or 732
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
102262 102262
Remove:
- the coolant pump mounting bolts (4) , WARNING
- the coolant pump. The seal faces must be clean, dry and free from
REFITTING
Note:
I - REFITTING PREPARATION OPERATION Apply two drops of LOCTITE FRENETANCH to
the coolant pump mounting bolts.
IMPORTANT Refit:
Do not scratch the aluminium sealing surfaces. - the coolant pump,
Wear goggles. - the coolant pump mounting bolts (1) to (5) .
Wear gloves during the operation. Tighten to torque and in order the coolant pump
Clean the sealing faces using DECAPJOINT to dis-
Replace the coolant pump seal every time the coo-
lant pump is removed.
19A-23
COOLING SYSTEM
K9K, and 722 or 728 or 732
102266
Refit:
- the inner timing cover (5) ,
- the inner timing cover mounting bolts.
Put the alternator in position.
Refit:
- the alternator mounting bolts,




Refitting ).

ding the cooling system ).
Refit:
- the engine cover,

(130 Nm)
19A-24
COOLING SYSTEM
K4J, and 730 – K4M, and 761 or 782

hose clips.
Tightening torquesm
M8 coolant pump 22 Nm
mounting bolts
M6 coolant pump 10 Nm
mounting bolts
front right-hand wheel 130 Nm

bolts
REMOVAL
14505
terminal. Remove:
Remove the engine covers. - the timing tension wheel,
Drain the engine cooling system via the engine coo- - the coolant pump.
ling radiator bottom hose using the (Mot. 1448).
Remove: REFITTING
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
Timing belt ).
- Wear goggles.
- Wear gloves during the operation.
- Clean the sealing faces using DECAPJOINT to
dissolve any seal still adhering.
- Apply the product to the section to be cleaned;
wait approximately ten minutes, then remove
the residue using a wooden spatula.
19A-25
COOLING SYSTEM
K4J, and 730 – K4M, and 761 or 782
Pretighten the M6 coolant pump mounting bolts to 8
Nm and the M8 coolant pump mounting bolts to 8
Nm .
- the M8 coolant pump mounting bolts (22 Nm) ,
- the M6 coolant pump mounting bolts (10 Nm) ,
Refit:
ding the cooling system: ).
10063
Refit the front right-hand wheel
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm
to 1 mm wide. Refit:
(130 Nm) .
14505
Note:
Apply one to two drops of LOCTITE FRENE-
TANCH to the coolant pump mounting bolts (1)
and (4) .
Refit:
- the coolant pump,
- the coolant pump mounting bolts.
19A-26
COOLING SYSTEM
M9R, and 700
REMOVAL

gearbox assembly.
Tightening torquesm Disconnect the battery (see 80A, Battery, Battery:

coolant pump moun- 25 Nm
ting bolts Remove:
coolant pump pulley 21 Nm - the engine protectors,

mounting bolts
front end panel lower 44 Nm tyres, Wheel: Removal - Refitting ),
mounting bolts
mounting bolts - the engine undertray.
right-hand side reinfor- 21 Nm

cement mounting bolts
WARNING
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
- protection down to - 25 ˚C ± 2 for cold and tempe-
rate countries,
- protection down to - 40 ˚C ± 2 for "extreme cold"
countries.
IMPORTANT
101212
care at high temperatures (risk of serious scalding). Remove:
Do not remove the cap from the expansion bottle
while the engine is hot. - the right-hand side reinforcement mounting bolts,
When working under the bonnet, be aware that the - the right-hand side reinforcement (1) ,
radiator cooling fan(s) may start without warning.
- the rear suspended engine mounting (see 19D,
Suspended engine mounting, Rear suspended
engine mounting: Removal - Refitting ),


19A-27
COOLING SYSTEM
M9R, and 700
115585

cessories unit.
114933 Remove:
102365
Remove:
112658
Remove:
(3) , Drain the cooling system (see 19A, Cooling, Coo-
- the engine accessories unit cover. ling system: Draining - Filling ).
Clean the engine cooling system (see 19A, Coo-
ling, Engine cooling system: Cleaning ).
Remove the « cooling radiator - condenser -

intercooler » assembly from its housing and move it
towards the front of the vehicle.
Rest the engine on the two pads of the (Mot. 1390).
19A-28
COOLING SYSTEM
M9R, and 700
116055
Remove:
- the sound insulation mounting bolt (9) ,
- the sound insulation.
Unclip the manual priming pump from its support.
Mark the right-hand suspended engine mounting in
relation to the bodywork. 114863
Remove: Move the (Mot. 1390) towards the front of the vehi-
cle while lifting the right-hand suspended engine
- the manual priming pump support, mounting (13) , until the air conditioning compressor
- the bolt (10) securing the right-hand suspended en- pulley (14) is flush with the end of the RH side mem-
gine mounting on the engine stand, ber.
- the bolts (11) securing the right-hand suspended

engine mounting on the body,
- the upper engine tie-bar (12) .
19A-29
COOLING SYSTEM
M9R, and 700
CONCERNED
114858
Remove:
- the coolant pump pulley mounting bolts (15) ,
- the coolant pump pulley (16) .
114863
Remove:
- the coolant pump mounting bolts (17) ,
- the coolant pump.
REFITTING

Clean:
- the cylinder block gasket face,
- the coolant pump sealing face if it is to be reused,
- the coolant pump housing if it is to be reused,
WARNING
The sealing faces and housing must be clean,
dr y and free from grease (avoid finger marks).
19A-30
COOLING SYSTEM
M9R, and 700
CONCERNED
Fit a new seal into the coolant pump housing.
Apply soapy water to the seal before refitting the

coolant pump.
Refit the coolant pump.
Note:
Check that the coolant pump is in contact with
the cylinder block before tightening the mounting
bolts.
114863
Fit the coolant pump mounting bolts without tighte-

ning them.
Tighten to torque and in order the coolant pump

Refit the coolant pump pulley.
Fit the coolant pump pulley mounting bolts without ti-

ghtening them.
Tighten to torque the coolant pump pulley moun-

19A-31
COOLING SYSTEM
M9R, and 700
III - FINAL OPERATION Clip on the air inlet scoop.
Position:
- the « engine - gearbox » assembly on the vehicle,
Refit the clips.
- the « cooling radiator - condenser - intercooler »
assembly on the half sub-frame. Position the bonnet opening cable
Refit:
- the upper engine tie-bar mounting bolts, Refit:
- the right-hand suspended engine mounting bolts - the front bumper (see MR 371, Bodywork, 55A,
on the body, Exterior protection, Front bumper ),
ne mounting on the engine stand. - the engine accessories unit cover,
Tighten to torque: - the engine accessories unit cover mounting bolts,

- the upper engine tie-bar mounting bolts (see 19D,
Engine mounting, Suspended engine moun- - the accessories belt (see 11A, Top and front of
ting: Tightening torque ), engine, Accessories belt: Removal - Refitting ),
- the bolts securing the right-hand suspended engi- - the rear suspended engine mounting (see 19D,
ne mounting on the body (see 19D, Engine moun- Engine mounting, Rear suspended engine
ting, Suspended engine mounting: Tightening mounting: Removal - Refitting ),
torque ),
- the bolts securing the right-hand suspended engi- - the engine undertray,
ne mounting on the engine stand (see 19D, Engine
mounting, Suspended engine mounting: Tigh- - the right-hand side reinforcement,
tening torque ),
- the right-hand side reinforcement mounting bolts.
Refit the manual priming pump support. Tighten to torque the right-hand side reinforce-
ment mounting bolts (21 Nm) .
Clip on the manual priming pump.
Refit: Refit:
- the sound insulation, - the front right-hand wheel arch liner,

- the sound insulation mounting bolt.
Tighten to torque the sound insulation mounting bolt tyres, Wheel: Removal - Refitting ).
(see 19D, Engine mounting, Suspended engine
mounting: Tightening torque ), Connect the battery (see 80A, Battery, Battery: Re-
Fill the cooling system (see 19A, Cooling, cooling moval - Refitting ).
system: Draining - Filling ).
Refit the front end panel.
Fit without tightening: Perform the following operations:
- the front end panel upper mounting bolts, - bleed the cooling system (see 19A, Cooling, Coo-
ling system: Bleeding ),
Tighten to torque: - adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon headlights, Xenon headlight:
Adjustment ),
Nm) ,
- the front end panel upper mounting bolts (21 - adjust the headlights (see 80B, Headlights,
Nm) . Halogen headlights: Adjustment ).
19A-32
COOLING SYSTEM
Plenum chamber: Removal - Refitting 19A
M9R, and 700
Special tooling required Refitting ),
Mot. 1202-01 Pliers for large hose - the engine undertray,
clips.
Mot. 1202-02 Pliers for small hose Exterior protection, Front bumper removal - re-
clips. fitting ).
Drain the engine cooling system (see 19A, Cooling,
Mot. 1448 Long nose pliers for Engine cooling system: Draining - Refilling ).
hose clips.
Clean the engine cooling system (see 19A, Coo-
ling, Engine cooling system: Cleaning ).
Tightening torquesm
coolant outlet unit 11 Nm

mounting bolts

bolts
WARNING
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
- protection down to - 25 ˚C ± 2 for cold and tempe-
rate countries,
- protection down to - 40 ˚C ± 2 for "extreme cold"
112659
countries.
Disconnect:
IMPORTANT - the air flowmeter connector,

The circuits are designed to be pressurised; take - the turbocharger regulation solenoid valve connec-
care at high temperatures (risk of serious scalding). tor.
Do not remove the cap from the expansion bottle Unclip:
- the wiring harness (2) from the injection computer
When working under the bonnet, be aware that the connector,
radiator cooling fan(s) may start without warning.
nal,
REMOVAL - the regulation solenoid valve wiring harness from

the turbocharger and the air flowmeter,
I - REMOVAL PREPARATION OPERATION - the wiring harness from the injection computer con-
nectors and the air flowmeter and turbocharger re-
Position the vehicle on a two-post lift (see 02A, Lif- gulation solenoid valve.
ting equipment, Underbody lift ). Remove:
Remove: - the battery tray mounting bolts (3) ,
- the engine protectors, - the mounting nut (4) from the wiring harness.
19A-33
COOLING SYSTEM
M9R, and 700
support.
Unclip the breather pipe from the gearbox.
113291
Remove:
- the mounting bolts (8) from the coolant outlet unit,
- the coolant outlet unit.
114934
Disconnect the coolant temperature sensor connec-
tor (5) . REFITTING
II - OPERATION FOR REMOVAL OF PART I - REFITTING PREPARATION OPERATION

CONCERNED Clean:
- the cylinder head gasket face,
- the coolant outlet unit gasket face if needed to be
reused,
- the coolant outlet unit gasket housing if needed to
be reused.
WARNING
The gasket faces and housing must be clean, dry
and free from grease (in particular, avoid finger
marks).
II - REFITTING PART CONCERNED

113293
Unpick the wiring harness (6) from the coolant outlet Position a new seal in the coolant outlet unit hou-
unit. sing.
Move the cooling hose clips away from the coolant Refit the coolant outlet unit.
outlet unit (7) using the (Mot. 1202-01) or (Mot. Screw on the coolant outlet unit mounting bolts wi-
1202-02) or (Mot. 1448). thout tightening them.
Disconnect the cooling hoses from the coolant outlet
unit.
19A-34
COOLING SYSTEM
M9R, and 700
Attach the wiring harness to the coolant outlet unit.
Connect the coolant temperature sensor connector.
Clip the breather pipe onto the gearbox.
Fill the cooling circuit (see 19A, Cooling, Cooling

circuit: Draining - Refilling ).
Refit the battery tray with the injection computer sup-

port.
Refit:
113291
Tighten to torque and in order the coolant outlet - the wiring harness mounting nut,
unit mounting bolts (11 Nm) .
Connect the coolant outlet unit cooling hoses.
Position the coolant outlet unit cooling hose clips Tighten to torque the battery tray mounting bolts
using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. (21 Nm) .
1448).
Clip:

nectors and the air flowmeter and turbocharger re-
gulation solenoid valve,
- the regulation solenoid valve wiring harness to the

turbocharger and the air flowmeter,
- the wiring harness to the battery negative terminal,

nector.
Connect:

tor,
Refit:

Refitting ),

Refitting ).

19A-35
COOLING SYSTEM
Electric water pump: Removal - Refitting 19A
F9Q, and 804
Remove the hose clamps (Ms. 583).
Reconnect the electric water pump connector.
Bleed the cooling circuit (see 19A, Cooling, Blee-
Mot. 1202-01 Pliers for large hose ding the cooling circuit ).
clips. Refit the engine undertray.
Mot. 1202-02 Pliers for small hose Connect the battery, starting with the positive termi-
clips. nal.

hose clips. WARNING
REMOVAL
terminal.
1
2
111919
Disconnect the electric water pump connector (1) .
Fit the hose clamps (Ms. 583) in accordance with
the marks (2) .
Disconnect the cooling hoses using tool (Mot. 1202-
01) or (Mot. 1202-02) or (Mot. 1448).
Remove the electric water pump.
REFITTING
Refit the electric water pump.
Reconnect the electric water pump cooling hoses
using tool (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
19A-36
EXHAUST
General information 19B
Cut zone 1
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 gasket
face and the catalytic converter must be perfect.
All seals that have been removed must be replaced.
Take care not to damage the catalytic converter
during removal and refitting. 101504
Cut zone 2
SPECIAL NOTES ON THE EXHAUST PIPE
1 - Cutting the exhaust pipe

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 (Mot. 1199-01) correctly.
Position the after sales sleeve correctly.
2 - Identifying the cut zone

Two punch marks on the exhaust pipe indicate the cut
zone (see 19B, Exhaust, Exhaust pipe assembly ).
101503
19B-1
EXHAUST
STANDARD CHASSIS
D
Special notes on the replacement part
P1 P2
X1
101960
100649
WARNING
Before cutting the pipe, mark the midpoint (D) between
When replacing the middle section of the exhaust
the two marks (P1) and (P2) .
pipe (pipe on diesel version, expansion chamber on
petrol versions), the replacement part needs to be
The distance between the two marks is (X1) = 90 mm .
shortened by 60 mm .
3 - Using tool Mot. 1199-01
4 - 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.
Position the sleeve on the worn section of the pipe.
Adjust the clip diameter by tightening slightly.
102118
Position the tool on the pipe.
Tighten the two bolts on the cutting tool so that the cu-
tting tool 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
Cut zone 2
95478 101500
Place the sleeve end on the worn section of the pipe.
Adjust the sleeve diameter by tightening gently. 5 - Special notes about cut zone 2
Remove the bolt securing the rubber mounting bush

Cut zone 1 (2) onto the body.
Lower the exhaust pipe.
Position the (Mot. 1199-01) on the pipe.
Cut the exhaust pipe .
WARNING
Do not reuse a used clip.
WARNING
Do not reuse a used sleeve.
The sleeve bolt and tightening nut must be positio-
ned so that they cannot come into contact with the
underbody.
101501
Tighten to torque the exhaust sleeve nut (25 Nm) .
When tightening to torque, a click indicates that the tor-

que of (25 Nm) has been reached.
Check:
- there is no contact with the underbody,
- the presence and correct positioning of all the ex-

haust pipe heat shields.
19B-3
EXHAUST
Pipe assembly 19B
K4J, and 730 – K4M, and 761 or 782 – F4R, and 770 or 771 or 776 – K9K, and 722 or 728 or 732 – F9Q, and 804
or 812 – M9R, and 700
(1) Cut zone 1

K4J, and 730 (2) Cut zone 2
112063
19B-4
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

K4M, and 761 or 782
(2) Cut zone 2
112062
19B-5
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

F4R, and 770 or 771 or 776
(2) Cut zone 2
112061
19B-6
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

K9K, and 722
(2) Cut zone 2
112060
19B-7
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

K9K, and 728 or 732 – M9R, and 700
(2) Cut zone 2
112059
19B-8
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

F9Q, and 804
(2) Cut zone 2
112058
19B-9
EXHAUST
Pipe assembly 19B
or 812 – M9R, and 700
(1) Cut zone 1

F9Q, and 812
(2) Cut zone 2
112059
19B-10
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F4R, and 776
REMOVAL
Tightening torquesm
downstream oxygen 34 Nm
sensor
catalytic converter nuts 40 Nm

(on the turbocharger)
upstream stay moun- 38 Nm

ting bolts (on the
engine) 1
upper bracket moun- 8 Nm

ting bolt (on the exhaust
manifold)
d ownstream stay 44 Nm
mounting nut on the
gearbox
mounting bolt (on the
106246
upstream stay)
Remove:
upper bracket moun- 8 Nm
ting bolt (on the catalytic - the heat shield mounting bolts (1) ,
converter) - the heat shield.
mounting bolt on the 2
downstream stay
exhaust bracket studs 8 Nm
upstream oxygen sen- 34 Nm

sor
Remove the engine in order to remove the catalytic

6
pre-converter (see 10A, Engine and peripherals, En-
gine - gearbox ).
3 4
21926
Disconnect the oxygen sensor connector (2) .
Remove:
- the upper bracket mounting bolts,
- the upper bracket (3) ,

- the upstream stay mounting bolts,
19B-11
EXHAUST
F4R, and 776
- the upstream stay (4) , Refit the upstream oxygen sensor connector on the
catalytic converter.
- the downstream stay mounting nut and bolt,
Tighten to torque the upstream oxygen sensor (34
- the downstream stay (5) ,
Nm) .
turbocharger,
Note:
Make sure there is no contact between the cata-
On the workbench, remove the oxygen sensors. lytic converter and the turbocharger oil return
pipe.
REFITTING Proceed in the reverse order to removal.

On the workbench, refit the downstream oxygen
sensor on the catalytic converter.
Tighten to torque the downstream oxygen sensor
(34 Nm) .
WARNING
Be sure to replace all the exhaust bracket and
turbocharger seals.
Tighten in order and until contact:

- the upstream stay mounting bolt (on the engine),
- the upper bracket mounting bolts,
- the nuts securing the catalytic converter to the tur-
bocharger,
- the catalytic converter mounting bolt on the ups-
tream stay,
- the downstream stay mounting nut on the gearbox,
- the catalytic converter mounting bolt on the downs-
tream stay,
- the catalytic converter nuts (on the turbochar-
ger) (40 Nm) ,
- the upstream stay mounting bolts (on the engi-
ne) (38 Nm) ,
- the upper bracket mounting bolt (on the ex-
haust manifold) (8 Nm) ,
- the downstream stay mounting nut on the gear-
box (44 Nm) ,
- the catalytic converter mounting bolt (on the
upstream stay) (8 Nm) ,
- the upper bracket mounting bolt (on the cataly-
tic converter) (8 Nm) ,
- the catalytic converter mounting bolt on the
downstream stay (8 Nm) ,
- the exhaust bracket studs (8 Nm) .
19B-12
EXHAUST
F9Q, and 804
Equipment required
IMPORTANT
safety belt
During this operation, secure the vehicle to the
lift with a safety belt , to prevent it from beco-
ming unbalanced.
Tightening torquesm
For the strap fitting procedure, (see 02A, Lifting
connector clip between 20 Nm equipment, Underbody lift ).
the turbocharger and
the catalytic pre-conver- Remove:
ter
catalytic pre-converter 30 Nm - the engine undertray.
upstream stay moun-
ting nuts on the engine Disconnect the battery, starting with the negative
terminal.
catalytic pre-converter 30 Nm Remove the scuttle panel grille (see MR 371 Bo-
upstream stay moun- dywork, 55A, Exterior Protection, Scuttle panel
ting nuts on the cataly- grille).
tic pre-converter
catalytic pre-converter 50 Nm
gearbox side downs-
tream stay mounting
bolts on the engine
1
catalytic pre-converter 50 Nm 2
gearbox side downs-
tream stay mounting
bolts on the catalytic
pre-converter
timing end downstream
stay mounting bolt on
the engine 104343
Remove:
timing end downstream - the air filter access panel mounting bolts (1) ,
stay mounting nuts on - the air filter access panel,
the catalytic pre-conver-
ter - the scuttle panel partition mounting bolt (2) .
output exhaust bracket
studs

bolts
19B-13
EXHAUST
F9Q, and 804
- the turbocharger - catalytic pre-converter connec-
tor clip mounting bolts (5) .
3
104246
Remove:
- the scuttle panel partition, 6

- the upper engine tie-bar. 7
111864
hafts, Front right-hand driveshaft: Removal - Remove:
Refitting ),
- the catalytic pre-converter downstream stay moun-
- the exhaust bracket nuts, ting nuts (6) on the timing end,
ting bolts (7) on the timing end,
- the catalytic pre-converter downstream stay on the
4 timing end,
ting bolts on the gearbox side,
- the catalytic pre-converter downstream stay on the
5 gearbox side,
- the catalytic pre-converter.
REFITTING
WARNING
Always replace:
- the catalytic converter seal,
- the connector clip between the turbocharger
and the catalytic pre-converter.
111862
Remove: On the workbench, refit the gearbox-side downs-

tream stay to the catalytic pre-converter.
- the catalytic pre-converter upstream stay mounting
bolts (4) , Tighten the gearbox-side downstream stay moun-
ting bolts on the catalytic pre-converter so that they
- the catalytic pre-converter upstream stay, make contact.
19B-14
EXHAUST
F9Q, and 804
Fit the catalytic pre-converter to the engine. Tighten to torque and in order:
Tighten the gearbox-side downstream stay moun- - the connector clip between the turbocharger
ting bolts on the engine so that they make contact. and the catalytic pre-converter (20 Nm) .
Refit:
- the catalytic pre-converter upstream stay
- the connector clip between the turbocharger and mounting nuts on the engine (30 Nm) ,
the catalytic pre-converter,
- the catalytic pre-converter upstream stay
- the catalytic pre-converter upstream stay. mounting nuts on the catalytic pre-converter
Tighten in order and until contact: (30 Nm) ,
- the catalytic pre-converter upstream stay mounting - the catalytic pre-converter gearbox side downs-
nuts on the engine, tream stay mounting bolts on the engine (50
- the catalytic pre-converter upstream stay mounting Nm) ,
nuts on the catalytic pre-converter, - the catalytic pre-converter gearbox side downs-
Loosen then tighten in order and until they make tream stay mounting bolts on the catalytic pre-
contact: converter (50 Nm) ,
- the catalytic pre-converter gearbox-side downs- - the catalytic pre-converter timing end downs-
tream stay mounting bolts on the engine, tream stay mounting bolt on the engine (50 Nm)
- the catalytic pre-converter gearbox-side downs- ,
tream stay mounting bolts on the catalytic pre-con-
- the catalytic pre-converter timing end downs-
verter.
tream stay mounting nuts on the catalytic pre-
Refit the catalytic pre-converter downstream stay on converter (30 Nm) .
the timing end.
Note:
- the catalytic pre-converter timing-end downstream
Make sure there is no contact between the cata-
stay mounting bolt on the engine,
lytic pre-converter and the turbocharger oil return
- the catalytic pre-converter timing-end downstream pipe.
stay mounting nuts on the catalytic pre-converter,
- the connector clip between the turbocharger and Tighten to torque:
the catalytic pre-converter.
- the catalytic pre-converter output exhaust brac-
ket studs (7 Nm) .
Make sure there is no contact with the underbody.
WARNING

nal.
WARNING

(4 Nm) .
19B-15
EXHAUST
Catalytic converter: Removal - Refitting 19B
F9Q, and 812
nuts securing the cata- 30 Nm
lytic converter to the tur- 2
bocharger
stay nut 30 Nm
stay mounting bolt 44 Nm
stay mounting nuts and 21 Nm

bolts

104343
Remove:
bolt securing the 180 Nm - the scuttle panel grilles (see MR 371 Bodywork,
engine tie-bar to the 55A, Exterior protection, Scuttle panel grille ),
engine
bolt securing the 105 Nm - the air filter access panel,
engine tie-bar to the
sub-frame - the scuttle panel mounting bolt (2) .
bolt securing the 21 Nm

exhaust pipe bracket to 3
the body

bolts
REMOVAL
terminal.
104246
Remove:
19B-16
EXHAUST
F9Q, and 812
101118 102117
Remove the exhaust bracket nuts (4) . Remove the (6) silencer rubber mounting bush bolt.
Note: vehicle.
Mark the position of the exhaust rubber mounting

bush supports on the vehicle body with a pen.
102479
Remove the catalytic converter stay mounting bolts
(7) .
102116
Remove the mounting bolt (5) of the exhaust pipe ru-
bber mounting bush on the body.
19B-17
EXHAUST
F9Q, and 812
10
101120 101121
Remove: Remove:
- the catalytic converter stay mountings (8) , - the engine lifting bracket,
- the catalytic converter stay. - the nuts (10) securing the catalytic converter to the
turbocharger,
- the catalytic converter from underneath the vehicle.
REFITTING
WARNING
The order for fitting the catalytic converter stays

must be observed.
9 WARNING
The gaskets must always be replaced.
Refit and tighten to torque the nuts securing the

catalytic converter to the turbocharger (30 Nm) .
Refit the catalytic converter stays observing the or-
102313 der of fitting.
Remove the engine tie-bar (9) .
19B-18
EXHAUST
F9Q, and 812
Refitting the stay at the timing end Refitting the stay at the flywheel end
14
15
13
11
12
101120 102479
Refit the stay, finger tightening nut (11) and bolt (12) Refit the catalytic converter stay mountings by hand
, (without tightening fully). (without tightening fully) and in the correct tightening
Tighten to torque and in order: order.
- the stay nut (30 Nm) (11) , Tighten to torque and in order the stay mounting
- the stay mounting bolt (44 Nm) (12) . nuts and bolts (21 Nm) .
Note:
pipe.
Tighten to torque:
- the exhaust bracket studs (7 Nm) ,
- the exhaust bracket nuts (21 Nm) ,
- the bolt securing the engine tie-bar to the engi-

ne (180 Nm) ,
- the bolt securing the engine tie-bar to the sub-

frame (105 Nm) ,
- the bolt securing the exhaust pipe bracket to

the body (21 Nm) ,

dy.
19B-19
EXHAUST
F9Q, and 812
nal.
WARNING

(4 Nm) .
19B-20
EXHAUST
K9K, and 722 or 728 or 732
Tightening torquesm
turbocharger outlet 7 Nm 1
studs

lytic converter to the tur- 2
bocharger
bolts securing the ups- 44 Nm

tream stay to the engine
bolts securing the 21 Nm

downstream stay to the
gearbox 104343
Remove:
bolt securing the ups- 25 Nm
tream stay to the cataly- - the scuttle panel grilles (see MR 371 Bodywork,
tic converter 55A, Exterior protection, Scuttle panel grille ).
downstream stay to the - the air filter access panel,
catalytic converter
exhaust pipe bracket to
the body 3
catalytic converter out- 7 Nm
let exhaust bracket
studs
ball joint bracket bolts 21 Nm

with their springs

bolts
104246
REMOVAL Remove:
Put the vehicle on a two-post lift. - the scuttle panel mounting bolts (3) ,
Disconnect the battery, starting with the negative - the scuttle panel partition.
terminal. Remove the engine undertray.
19B-21
EXHAUST
K9K, and 722 or 728 or 732
7
4
6 5
102076 102116
Remove: Remove the mounting bolt (7) from the exhaust pipe
- the exhaust bracket mountings (4) , rubber mounting bush on the body.
- the catalytic converter downstream stay mounting

(5) . Note:
Loosen the other stay mountings on the gearbox. Mark the position of the exhaust rubber mounting
Remove the catalytic converter downstream stay (6) bush supports on the vehicle body with a pen.
.
102117
Remove the silencer rubber mounting bush moun-

ting bolt (8) .

vehicle.
19B-22
EXHAUST
K9K, and 722 or 728 or 732
REFITTING
WARNING
Always replace:
- the catalytic converter seals,
- the turbocharger - catalytic converter bracket
studs.
Tighten to torque the turbocharger outlet studs (7

Nm) .
10 Fit the catalytic converter.

- the upstream stay bolts on the engine,
9 - the upstream stay bolts on the catalytic converter,
102077
- the downstream stay bolts on the gearbox,
Remove: - the downstream stay bolts on the catalytic conver-

ter,
- the catalytic converter upstream stay mounting
bolts, - the catalytic converter - turbocharger mounting
- the catalytic converter upstream stay (9) , nuts.
- the nuts (10) securing the catalytic converter to the Tighten to torque and in order:
turbocharger, - the nuts securing the catalytic converter to the
- the catalytic converter. turbocharger (26 Nm) ,
- the bolts securing the upstream stay to the en-
gine (44 Nm) ,
- the bolts securing the downstream stay to the

gearbox (21 Nm) ,
- the bolt securing the upstream stay to the cata-
lytic converter (25 Nm) ,
- the bolt securing the downstream stay to the

catalytic converter (21 Nm) ,
- the bolt securing the exhaust pipe bracket to
the body (21 Nm) ,
Note:
pipe.
K9K, and 722 or 728

Tighten to torque:
- the catalytic converter outlet exhaust bracket
studs (7 Nm) ,
19B-23
EXHAUST
K9K, and 722 or 728 or 732
K9K, and 732

their springs (21 Nm) .

dy.
WARNING

nal.
WARNING

(4 Nm) .
19B-24
EXHAUST

gen sensors.
Tightening torquesm
oxygen sensor 45 Nm
exhaust bracket moun- 21 Nm

ting nuts 1
bolts
REMOVAL
101793
Remove:
- the mounting nuts (1) from the exhaust bracket,
terminal.
REFITTING
770 or 771
Remove the downstream oxygen sensor. WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must be
Cut the exhaust pipe (see 19B, Exhausts, General positioned so that they cannot come into contact
information ). with the underbody.
Refit the downstream oxygen sensor.

Tighten to torque the oxygen sensor (45 Nm) using
the (Mot. 1495-01).
Refit and tighten to torque if necessary the exhaust
bracket studs (7 Nm) .
Fit:
- the catalytic converter,
- the sleeve (see 19B, Exhausts, General informa-
tion ).
19B-25
EXHAUST
WARNING
Always replace:
- the exhaust bracket seal,
- all the disconnected air inlet plastic pipes.
Tighten to torque the exhaust bracket mounting

nuts (21 Nm) .
Tighten the sleeve while easing the exhaust pipe to
ensure alignment.
Reconnect the oxygen sensor.
dy.
nal.
WARNING

(4 Nm) .
19B-26
EXHAUST
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool
safety belt ting equipment, Underbody lift ).

Tightening torquesm Removal - Refitting ).
Remove:
studs on the turbochar- 14.5 Nm
ger - the engine protectors,
bolts securing the cata- 21 Nm - the scuttle panel grille (see MR 371 Bodywork,
lytic converter mounting 55A, Exterior protection, Scuttle panel grille ).
clamp to the cylinder
block
the catalytic converter 19.5 Nm

studs

lytic converter to the tur-
bocharger
catalytic converter half- 21 Nm

clamp mounting bolts
bolt securing the stay to 8 Nm

the catalytic converter
nuts securing the stay 21 Nm 104343

to the cylinder block Remove:
nuts securing the stay 21 Nm - the air filter access panel mounting bolts (1) ,
to the catalytic converter
bolts of the ball joint 21 Nm
bracket with springs
silencer rubber moun- 21 Nm

ting bush mounting bolt
exhaust pipe rubber 21 Nm

mounting bush moun-
ting bolt
IMPORTANT
104246
Remove:
19B-27
EXHAUST
M9R, and 700
- the nuts (7) securing the stay on the cylinder block,
- the catalytic converter stay,
- the catalytic converter studs using a roller-type
stud removal tool.
114986
Remove:

turbocharger,
114991
Remove the bolts from the ball joint bracket (8) with
their springs.
114771
Remove:
ting, Rear suspended engine mounting: Remo-
val - Refitting ),
- the catalytic converter stay mounting bolt (5) ,

- the catalytic converter stay mounting nuts (6) ,
19B-28
EXHAUST
M9R, and 700
102116 114985
Remove:
- the mounting bolt (11) from the gearbox controls
retaining bracket,
- the gearbox controls retaining bracket.

CONCERNED
102117
Note:
Mark the position of the exhaust rubber mounting
bush supports on the vehicle body with a pen.
Remove:
- the exhaust pipe rubber mounting bush mounting 114980
bolt (9) , Remove:
- The silencer rubber mounting bush mounting bolt - the catalytic converter half-clamp mounting bolts
(10) . (12) ,
Remove the exhaust pipe. - the catalytic converter half-clamps (13) .
19B-29
EXHAUST
M9R, and 700
Remove the catalytic converter at the timing end. REFITTING
Fit the catalytic converter using a safety belt to the
lifting eye on the timing end. I - REFITTING PREPARATION OPERATION
Remove the seal from the ball joint 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,
- on the turbocharger,
Refit the new studs onto the turbocharger using a
Tighten to torque the studs on the turbocharger
(14.5 Nm) .
Fit the new catalytic converter mounting clamps onto
the cylinder block.
Finger tighten the bolts securing the catalytic con-
verter mounting clamp to the cylinder block until con-
tact is made.
114981
Tighten to torque the bolts securing the catalytic
Remove: converter mounting clamp to the cylinder block
(21 Nm) .
- the catalytic converter mounting clamp mounting
bolts (14) ,
- the catalytic converter mounting clamps.

Remove the safety belt.
Move the engine towards the front of the vehicle.
114843
Remove the catalytic converter.
19B-30
EXHAUST
M9R, and 700
II - REFITTING OPERATION FOR PART - the catalytic converter half-clamp mounting
CONCERNED bolts (21 Nm) ,
- the bolt securing the stay to the catalytic con-
verter (8 Nm) ,
- the nuts securing the stay to the cylinder block
(21 Nm) ,
- the nuts securing the stay to the catalytic con-
verter (21 Nm) .
Refit:
- the gearbox controls retaining bracket,
- the mounting bolt for the gearbox controls retaining
bracket.

mounting, Rear suspended engine mounting:
Tighten to torque the lower engine tie-bar (see 19D,
114844
mounting: Tightening torque ).
Move the engine towards the front of the vehicle.
Refit the new seal to the ball joint bracket.
Fit:
Fit the exhaust pipe.
- the new seal between the turbocharger and the ca-
Refit:
talytic converter,
- the exhaust pipe rubber mounting bush mounting
- the catalytic converter. bolt, aligning the marks,
Refit the catalytic converter onto the turbocharger. - the silencer rubber mounting bush mounting bolt,
Fit: aligning the marks,
- the ball joint bracket bolts with springs.
- the new catalytic converter nuts onto the turbochar-
ger, Tighten to torque:
- the new catalytic converter half-clamps. - the bolts of the ball joint bracket with springs
(21 Nm) ,
Refit the new studs onto the catalytic converter
using a roller-type stud removal tool. - the silencer rubber mounting bush mounting
bolt (21 Nm) ,
Tighten to torque the catalytic converter studs
(19.5 Nm) . - the exhaust pipe rubber mounting bush moun-
ting bolt (21 Nm) .
Refit:
Refit:
- the catalytic converter half-clamp mounting bolts,
- the catalytic converter stay,
- the catalytic converter stay mounting bolt, - the scuttle panel partition mounting bolts,
- the stay mounting nuts onto the catalytic converter, - the air filter access panel,
- the stay mounting nuts onto the cylinder block. - the air filter access panel mounting bolts,
Tighten to torque: - the scuttle panel grille (see MR 371 Bodywork,
- the nuts securing the catalytic converter to the
turbocharger (21 Nm) , - the engine protectors.
19B-31
EXHAUST
M9R, and 700
19B-32
EXHAUST
Expansion chamber: Removal - Refitting 19B
REFITTING
Tightening torquesm Fit:
- the expansion chamber,
rubber mounting sup- 8 Nm
port bolt on the expan- - the sleeve (see 19B, Exhaust, General Vehicle
sion chamber Information ).
rubber mounting sup- 21 Nm

port bolt on the body WARNING
Cut the new expansion chamber pipe (see 19B,
Exhaust, General Vehicle Information ).
REMOVAL
Tighten to torque:
- the rubber mounting support bolt on the expan-
sion chamber (8 Nm) ,
Cut the exhaust pipe (see 19B, Exhaust, General
- the rubber mounting support bolt on the body
Vehicle Information ).
(21 Nm) .
Tighten the sleeve, while easing the exhaust pipe to
ensure the correct alignment of the pipe.
1 Make sure that there is no contact with the underbo-
dy.
WARNING
- Any damaged heat shields must be replaced.
- Do not reuse an old sleeve.
- The « sleeve bolts and tightening nuts » must
101818 be positioned so that they cannot come into
Remove: contact with the underbody.
- the mounting bolts (1) securing the expansion

chamber to the rubber mounting support,
- the expansion chamber.
Note:
If the rubber mountings are damaged, mark the
position of the support on the body, then replace
the « support/rubber mounting » assembly.
19B-33
EXHAUST
Silencer: Removal - Refitting 19B
Tighten to torque:
Tightening torquesm - the rubber mounting support bolt on the silen-

cer (8 Nm) ,
rubber mounting sup- 8 Nm - the rubber mounting support bolt on the body
port bolt on the silencer (21 Nm) .
rubber mounting sup- 21 Nm Tighten the sleeve, while easing the exhaust pipe to
port bolt on the body ensure the correct alignment of the pipe. 19B, Ex-
haust, General Vehicle Information ).
REMOVAL in place and properly secured.
Put the vehicle on a two-post lift. Make sure that there is no contact with the underbo-
Cut the exhaust pipe (see 19B, Exhaust, General dy.
Vehicle Information ).
WARNING
- Any damaged heat shields must be replaced.
- Do not reuse an old sleeve.
- The « sleeve tightening nut and bolts » must be
positioned so that they cannot come into con-
1 tact with the underbody.
101817
Remove:
- the silencer mounting bolts (1) on the rubber moun-
ting support,
- the silencer.
Note:
If the rubber mountings are damaged, mark the
position of the support on the body, then replace
the « support / rubber mounting assembly » .
REFITTING
Fit:
- the silencer,
- the sleeve (see 19B, Exhaust, General Vehicle
Information ).
19B-34
EXHAUST
Particle filter: Function 19B
F9Q, and 804
the particle filter clogging level depends on the user's
driving style:
Equipment required
- during an average trip (mixed cycle type and mo-
diagnostic tool torway of more than 15 min ), the particle filter auto-
matically burns the particles without the customer
noticing (apart from some white smoke): this is
I - SAFETY ADVICE « spontaneous regeneration » ,
- when the operating temperature is not high enough to
Due to the dangers of high temperatures, be sure to trigger spontaneous regeneration, clogging increases
observe the following instructions: until it reaches 35 g (min) ; an acceleration request to
trigger spontaneous regeneration is then sent to the
- Never open or separate the pressure measurement driver via an instrument panel warning light; the same
circuit, except at unions on the exhaust line (only the happens if several attempts to regenerate have failed.
supplier can ensure that the pressure measurement
circuit is correctly sealed), - 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 polluting 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 permanently continuously eva-

luates the level of clogging of the particle filter using the
pressure difference upstream and downstream of the
particle filter. When it is loaded, the two temperature
values inform the injection computer that the tempera-
ture conditions are high enough (approximately 600˚C
) to trigger regeneration.
Regeneration consists of burning the particles held in

the particle filter: to do this, the injection goes over to
« delayed injection » mode and the fuel not burned in
the combustion chambers burns the residues contai-
ned in the particle filter cells.
19B-35
EXHAUST
Particle filter: Parts description 19B
F9Q, and 804
107038
(1) Connection hose

(2) Particle filter
(3) Rubber mounting
(4) Particle filter pressure sensor
(5) Upstream pressure measure-
ment tapping
(6) Downstream pressure measure-
ment tapping
(7) Upstream particle filter tempera-
ture sensor
(8) Downstream particle filter tem-
perature sensor
19B-36
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
Equipment required
diagnostic tool
nut securing the rubber 25 Nm
mounting bush support
on the particle filter

between the connection
hose and the catalytic 2
pre-converter
rubber mounting bush 25 Nm

nuts on the sub-frame
exhaust sleeve nut 25 Nm

106673
adapter 44 Nm
Remove the downstream pressure pipe (1) from its
downstream pressure 21 Nm adapter (2) bolted to the exhaust pipe.
measurement tapping
on its adapter
WARNING
connection clip bolt 25 Nm When the pressure measurement tapping is
between the silencer removed, the adapter must be held (2) with a
and the particle filter lock wrench.
exhaust flange nuts 21 Nm

between the connection WARNING
hose and the catalytic
The pressure measurement circuit must never be
pre-converter
opened except at the adapters on the exhaust
nuts mounting the rub- 25 Nm pipe.
ber mounting bush sup-
port on the sub-frame
REMOVAL
terminal.
Make a cut in the exhaust pipe, behind the particle
filter (see 19B, Exhaust, General information ).
19B-37
EXHAUST
F9Q, and 804
3
5
111881 111882
Remove the heat shield mounting clip (3) . Disconnect the particle filter pressure sensor con-
nector (4) .
Move the heat shield to one side slightly.
Remove the retaining clip (5) from the wiring har-
Unpick:
ness on the particle filter pressure sensor mounting.
- the downstream pressure measurement tapping
heat shield,
- the downstream temperature sensor wiring har-
ness.
Pass the downstream pressure measurement tap-
ping into the engine compartment whilst leaving the
pressure sensor complete.
B
A
6
111885
Disconnect the upstream and downstream tempera-
ture sensor offset connectors (6) .
Unpick the upstream and downstream temperature
sensor offset connectors (6) .
19B-38
EXHAUST
F9Q, and 804
7
111885
Remove:
- the mounting bolt (7) from the particle filter pressu-
re sensor mounting.
- the particle filter pressure sensor assembly (8) and
its mounting.
19B-39
EXHAUST
F9Q, and 804
10
107038
Remove: REFITTING
- the mounting nuts (9) on the exhaust flange
between the connection hose and the catalytic pre-
converter, WARNING
- the sub-frame rubber mounting bolts (10) ,
Always replace:
- the particle filter.
- the seal between the hose and particle filter,
Once the particle filter has been removed, remove:
- the seal between the hose and the catalytic pre-
- the rubber mounting, converter,
- the upstream and downstream temperature sen- - any adapter on the exhaust line that has been
sors from their adapters on the exhaust line (see removed,
19B, Exhaust, Particle filter temperature sen-
sor: Removal - Refitting ).
WARNING
- the upstream pressure measurement tapping at its
adapter on the exhaust pipe (see 19B, Exhaust, Always clean the bearing surfaces of the connec-
Particle filter pressure sensor: Removal - Refit- tion hose - par ticle filter flanges thoroughly.
ting ).
Once the particle filter has been removed, refit:
- the connection hose (see 19B, Exhaust, Connec-
tion hose: Removal - Refitting ). - the connection hose and its new seals (see 19B,
Exhaust, Connection hose: Removal - Refitting
).
19B-40
EXHAUST
F9Q, and 804
- the upstream and downstream temperature sen-
sors at their adapters on the exhaust line (see 19B,
Exhaust, Particle filter temperature sensors:
adapter on the exhaust line (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit-
ting ).
- the rubber mounting on the particle filter.
Torque tighten the nut securing the rubber moun-
ting bush support on the particle filter (25 Nm) .
Place the pressure sensor and its mounting in the
engine compartment before fitting the particle filter. 12
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
information ), applying a mastic seal. WARNING
Tighten to torque the exhaust sleeve nut (25 Nm) Always replace any adapter (12) that has been
at the same time as making sure that the exhaust removed from the exhaust line.
pipe is correctly aligned.
If it has been replaced, tighten to torque the adapter
(44 Nm) .
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-41
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 the whole of the pressure
measurement tapping on its adapter (21 Nm) bol-
measurement tapping has no low points (siphon)
ted to the exhaust pipe.
susceptible to 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 on the sub-frame (25 Nm) .
WARNING

dy.

nal.
19B-42
EXHAUST
F9Q, and 804
WARNING

puter.
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. Select:
- 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-43
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
F9Q, and 804
Equipment required Tightening torquesm

diagnostic tool adapter, if it has been 44 Nm
replaced
upstream pressure 21 Nm
measurement tapping
on its union screwed
into 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 - Refitting ).
19B-44
EXHAUST
F9Q, and 804
2
3
4
6
106670 111885
Remove the upstream pressure measurement tap- Remove:
ping (1) from its adapter (2) screwed into the ex-
- the mounting nut (3) from the particle filter pressure
haust pipe.
sensor mounting (4) ,
- the particle filter pressure sensor:
WARNING
When the pressure measurement tapping (1) is
removed from its adapter, the adapter (2) must WARNING
be held with a lock wrench. Never separate the pressure measurement tap-
pings (5) from the particle filter pressure sensor
(6) . Replace the « sensor-pipes-end pieces » as
WARNING a unit, supplied assembled by the Parts Depart-
The pressure measurement circuit must never be ment (see 19B, Exhaust, Particle filter: Func-
opened except at the adapters on the exhaust tion ).
pipe.
19B-45
EXHAUST
F9Q, and 804
REFITTING
106673
WARNING
Always replace any adapter (7) that has been
removed from the exhaust pipe.
Tighten to torque the adapter, if it has been repla-

ced (44 Nm) .
Coat the upstream pressure measurement tapping
threads with ANTI-SEIZE high temperature grease.
WARNING
the threading.
19B-46
EXHAUST
F9Q, and 804
106672
Fit the rigid part of the upstream pressure measure- tool to clear any faults stored by the injection com-
ment tapping then position it so that it is parallel (± puter.
3˚) to the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measure-
ment tapping on its union screwed into the ex-
haust pipe (21 Nm) .
Refit the particle filter (see 19B, Exhaust, Particle
filter: Removal - Refitting ).
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).
19B-47
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
F9Q, and 804
Equipment required Tightening torquesm

diagnostic tool adapter, if it has been 44 Nm
replaced
upstream particle filter 30 Nm

temperature sensor
downstream particle fil- 30 Nm

ter temperature sensor
107038
(A) Upstream particle filter temperature sensor.
(B) Downstream particle filter temperature sensor.
I - (A) UPSTREAM PARTICLE FILTER

TEMPERATURE SENSOR
1 - Removal
Remove the particle filter (see 19B, Exhaust, Parti-
cle filter: Removal - Refitting ).
19B-48
EXHAUST
F9Q, and 804
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
2 II - (B) DOWNSTREAM PARTICLE FILTER

TEMPERATURE SENSOR
1 - Removal
terminal.
106671
Remove the upstream particle filter temperature

sensor (1) from its adapter (2) screwed into 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.
3
2 - Refitting
WARNING
111882
Disconnect the downstream particle filter temperatu-
re sensor offset connector (3) .
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 there is no contact with the wiring harness,
19B-49
EXHAUST
F9Q, and 804
2 - Refitting
WARNING

B ced (44 Nm) .
A Coat the threads on the downstream particle filter
temperature sensor with ANTI-SEIZE high-tempera-
3 ture grease.
WARNING
the threading.
Tighten to torque the downstream particle filter

temperature sensor (30 Nm) .
111885 Check:
Unclip the downstream particle filter temperature - that 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.
5
WARNING

puter.
106671
Remove the downstream particle filter temperature

sensor (4) from its adapter (5) screwed into 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-50
EXHAUST
Connecting hose: Removal - Refitting 19B
F9Q, and 804
adapter on the exhaust pipe (see 19B, Exhaust,
Tightening torquesm Particle filter pressure sensor: Removal - Refit-
ting ).
Tighten to torque the exhaust bracket nuts (21
Nm) between the connection hose and the particle
REMOVAL filter.
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 ).

adapter on the exhaust pipe (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit-
ting ).
Remove:
- the nuts from the exhaust between the connection

hose and the particle filter,
- the connection hose.
REFITTING
WARNING
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 flanges between the connection hose and
the catalytic pre-converter,
- 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-51
EXHAUST
Particle filter: Cleaning 19B
F9Q, and 803 or 804
I - INSTRUCTIONS FOR CARRYING OUT FORCED
Special tooling required REGENERATION OF THE PARTICLE FILTER
(76 mm diameter). Precautions to be taken during forced regeneration
of the particle filter
Mot. 1018 Sump plug tool.
Two additional equipment kits for workshop exhaust
gas extractors are available (see 2005 garage equi-
Equipment required pment catalogue ), both are approved for use at the
high temperatures produced during forced regene-
kit for particle filter
ration of a particle filter, for example.
kit for twin exhaust These two kits approved for particle filter regenera-
tion are:
diagnostic tool
- the kit for particle filter for use with vehicles
equipped with a single exhaust pipe on the silen-
Tightening torquesm cer,
- the kit for twin exhaust for use with vehicles
engine drain plug 20 Nm
equipped with a twin exhaust pipe on the silencer.
rubber mounting bush 21 Nm
on the body
IMPORTANT
rubber mounting bush 8 Nm During forced regeneration of the particle filter,
on the connector pipe the temperature of the exhaust pipe rises signifi-
cantly.
Always use one of these kits approved for use at
the high temperatures generated during forced
regeneration, whether this is being carried out in
Note:
the workshop with an exhaust gas extractor or
Forced regeneration can only be carried out after outside the workshop.
the « SERVICE » warning light comes on along
Ensure that when in use, the kit is not touching
with the message « REGENERATE PARTICLE
the rear bumper when carrying out forced rege-
FILTER» or the orange « CHECK EMISSION
neration of the particle filter.
CONTROL » warning light (see Driver's Hand-
book for vehicle concerned ).
19B-52
EXHAUST
F9Q, and 803 or 804
Twin exhaust pipe kit special features II - PROCEDURE FOR FORCED REGENERATION
OF THE PARTICLE FILTER USING THE CLIP
DIAGNOSTIC TOOL
Connect the diagnostic tool to the vehicle.
IMPORTANT
During forced regeneration of the particle filter,
the temperature of the exhaust pipe rises signifi-
cantly.
Always use one of these kits approved for use at
the high temperatures generated during forced
regeneration, whether this is being carried out in
the workshop with an exhaust gas extractor or
outside the workshop.
Ensure that when in use the is not touching the
rear bumper when carrying out forced regenera-
tion of the particle filter.
116224
WARNING
To prevent engine racing, check the engine oil
Note: level using the dipstick before running the forced
regeneration command.
Ensure, when using a kit for twin exhaust (1)
on a single exit exhaust system: The engine oil level must be between the
« MIN » and « MAX » marks on the dipstick.
- that an exhaust gas extractor is fitted to holes
(2) and (3) if forced regeneration is being car- For the particle filter forced regeneration procedure,
ried out in the workshop, see MR 372 Fault finding, 13B, Diesel injection,
Fault finding - Interpretation of commands, Parti-
- that hoses (2) and (3) are positioned to direct
cle filter regeneration .
the hot exhaust gases away from another vehi-
cle or a person, if the operation is being carried
out outside the workshop. Note:
If required, the forced regeneration procedure
may be stopped by pressing the engine Start but-
ton twice in succession.
Note:
Strong odours and thick smoke are to be expec-
ted during forced regeneration of the particle fil-
ter.
When forced regeneration of the particle filter is

complete, use the diagnostic tool to:
- deal with the present faults,
- clear the stored faults.
19B-53
EXHAUST
F9Q, and 803 or 804
Position the vehicle on a two-post lift (see MR 370 Refit the filler cap.
Mechanics, 02A, Lifting equipment, Towing and
Wait for 10 minutes .
lifting ).
Check the oil level using the dipstick.
IMPORTANT Top up, if necessary.
Allow the engine to cool before draining the oil.
Remove the oil filter using the (Mot. 1329) for F9Q Note:
engines. The engine oil level must be between the
Coat the new oil filter sealing ring with engine oil. « MIN » and « MAX » marks on the dipstick.
Tighten the oil filter until the seal makes contact with
the engine.
Note:
Tighten the new oil filter manually 3/4 of a turn.
After each particle filter forced regeneration,
Wipe away any excess oil. always replace the exhaust system connector
Remove: pipe rubber mounting bush.
- the engine oil filler cap,

- the sump drain plug using the (Mot. 1018) or an 8
mm square male drive drain plug socket .
Allow all the engine oil to flow into a drain tray.
Rubber-lipped seal
102116
Remove:
- the bolt (4) mounting the exhaust system connector

pipe rubber mounting bush on the body,
- the bolts (5) mounting the exhaust system connec-
tor pipe rubber mounting bush on the connector pi-
pe.
113765
Fit the new exhaust system connector pipe rubber
Refit the new seal (no direction of fitting for rubber- mounting bush.
lipped seals).
Tighten to torque:
Tighten to torque the engine drain plug (20 Nm) .
- the bolt mounting the rubber mounting bush on
Clean any traces of the drained oil from the sump.
the body (21 Nm) ,
- the bolts mounting the rubber mounting bush on
Refill the engine oil. the connector pipe (8 Nm) .
19B-54
RESERVOIR
Draining the fuel tank 19C
K4J – K4M – F4R

K4M
fuel pressure.
2
IMPORTANT

- refrain from smoking or bringing red hot objects 3
1
union,
DRAINING THE FUEL TANK
F4R or K4J
101803
Disconnect the fuel inlet union (1) .
2 Fit in place a (3) « T » (Mot. 1311-08) union.
Fit onto the « T » union outlet a pipe (2) long enough

to drain the pump into a container.
WARNING
The ignition must be switched off during this ope-
ration.
Remove the Protection and Switching Unit cover.
1
101496
Fit in place, the (3) « T » union from the kit (Mot.
1311-08).
19C-1
RESERVOIR
K4J – K4M – F4R
102502 102501
Put the electrical connector (4) to one side, without Plug the brown connector terminal (5) into the + bat-
disconnecting it. tery feed to run the petrol pump.
Let the petrol flow out until it flows intermittently.
Disconnect the + battery feed from the terminal (5) .
5
Note:
It is also possible to use the pneumatic siphoning
pump for draining the fuel tank (see the Equip-
ment catalogue) at the fuel supply outlet of the
dipstick.
102503
Disconnect the Protection and Switching Unit brown
connector (5) .
19C-2
RESERVOIR
K9K – F9Q – M9R
Equipment required
petrol or diesel tank drain pneumatic siphoning 2

pump
IMPORTANT

- beware of fuel splashes when disconnecting the 1
union, 104617
- protect sensitive areas from fuel outflow. Remove:
- the clips (1) ,
DRAINING THE FUEL TANK
- the trim (2) .
99641
104618
Disconnect the battery, starting with the negative Remove the seat mountings (3) .
terminal.
Take out the carpet.
Note:
Since diesel vehicles are not fitted with an electri-
cal fuel pump, the petrol or diesel tank drain
pneumatic siphoning pump must be used to
drain the tank.
Remove the rear seats (see MR 371 Bodywork,

76A, Rear seat runners and frames, Second row
complete rear seat ).
19C-3
RESERVOIR
K9K – F9Q – M9R
104214 104203
Remove the soundproofing pads (4) . Disconnect the tuner-amplifier (6) (if fitted to the ve-
hicle).
7
104620
Remove the panel (5) .
104204
Remove:
- the tuner-amplifier unit mounting bolts (7) ,
- the tuner-amplifier unit assembly.
19C-4
RESERVOIR
K9K – F9Q – M9R
Make preparations for fuel outflow.
Connect the suction pipe of the petrol or diesel
tank drain pneumatic siphoning pump in place of
the diesel supply quick-release union (11) .
Place the return pipe of the siphoning pump into a
8 container.
Run the petrol or diesel tank drain pneumatic si-
phoning pump.
Let the fuel flow out until it flows intermittently.
nal.
WARNING
104545
Remove the inspection flap blanking cover (8) .
10
11
105006
Disconnect:
- the electrical connectors (9) ,
- the quick-release diesel return union (10) and the
diesel supply union (11) .
19C-5
RESERVOIR
Fuel tank: Removal - Refitting 19C
Equipment required F4R or K4J or K4M
component jack Disconnect the petrol vapour absorber (see 14A,

Emission control, Fuel vapour absorber ).
Unclip the petrol vapour absorber pipes.
Tightening torquesm
Disconnect the connectors from the « Pump-sender
fuel tank mounting bolts 21 Nm unit » assembly (see 19C, Tank, Pump/sender/fil-
ter ).
bolt
IMPORTANT
During this operation, be sure to:

1
- refrain from smoking or bringing hot objects close
to the work area,
union,
REMOVAL
2
Drain the tank (see 19C, Tank, Draining the fuel
tank ).
Put the vehicle on a two-post lift. 3
terminal.
Remove: 102465
Remove:
- the reservoir and heat shield (1) mounting bolts,
- the exhaust clamp - manifold mounting nuts,
- the heat shield mounting clips (2) ,
- the expansion chamber - body mounting bolt,
- the heat shield (3) .
- the silencer or intermediate tube rubber mounting
support connecting bolts,
- the exhaust pipe from the sub-frame and the rear
axle.
Disconnect the headlight height regulator sensor wi-
ring (depending on the equipment level).
Disconnect the headlight height regulator sensor lin-
kage (depending on the equipment level).
19C-6
RESERVOIR
102467 102466
Remove the mounting clips (4) from the fuel and bra- Remove the tank mounting bolts (6) .
ke pipes.
Unclip:
- the fuel pipe unions from the catalytic converter,
- the fuel pipe clips.
Move the hoses aside.
102459
Remove the tank by turning it around the exhaust pi-
pe.
Take care not to damage the brake pipes and the
5 parking brake cable.
Remove the « pump/sender/filter » assembly (see
102468 19C, Tank, Pump/sender/filter ) for petrol engines
Remove the tank - neck connection hose clips (5) . or the gauge (see 19c, Tank, Sender unit ) for die-
sel engines.
Fit the component jack under the reservoir.
19C-7
RESERVOIR
REFITTING
Refit the « pump/sender/filter » assembly (see 19C,
Tank, Pump/sender/filter ) for petrol engines or the
gauge (see 19c, Tank, Sender unit ) for diesel engi-
nes.
Reshape the heat shield.
Take care not to bring the heat shield into contact
with the tank.
The tank hose securing clips must always be repla-
ced.
Tighten to torque the fuel tank mounting bolts
(21 Nm) .
Check that the fuel pipe unions click into place.
nal.
WARNING
Tighten to torque the battery cover mounting bolt

(4 Nm) .
19C-8
RESERVOIR
Fuel tank: Description 19C
F9Q or K9K or M9R
1
8
2
2
9 2
10
5
2 5 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 fuel suction assembly
19C-9
RESERVOIR
F9Q or K9K or M9R
2 8
13036-1
No. Description
1 Breather
2 Overfill prevention ball
19C-10
RESERVOIR
F9Q or K9K or M9R
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 diesel fuel has a sealed type cap.
19C-11
RESERVOIR
F4R or K4J or K4M
3
1
11
2 8
2
9
2
12 10
13 7
5
5 6
2
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 vehicle roll-over leak prevention valve
12 Anti-backflow pipe (degassing - filling)
13 Petrol suction assembly
19C-12
RESERVOIR
F4R or K4J or K4M
2
10
13036
No. Description
1 Connection to petrol vapour absorber
2 Overfill prevention ball
19C-13
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-14
RESERVOIR
Filler neck: Removal - Refitting 19C
Tightening torquesm

bolt 3
IMPORTANT
During this operation, be sure to:

- refrain from smoking or bringing hot objects near
the working area,
union,
REMOVAL
Drain the tank (see 19C, Tank, Draining the fuel 102469
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) ,
- the filler neck.
1
REFITTING
102468
Always replace the filler pipe tightening clips with
Disconnect the anti-return pipe (1) . new ones.
Remove the filler pipe clips (2) .
nal.
WARNING
19C-15
RESERVOIR
Filler neck: Removal - Refitting 19C
Tighten to torque the battery cover mounting bolt
(4 Nm) .
19C-16
RESERVOIR
Sender unit: Removal - Refitting 19C
K9K – F9Q – M9R
Mot. 1397 Universal petrol tank

gauge nut wrench.
Tightening torquesm
3
bolts
IMPORTANT
During this operation, it is essential to: 104618
- refrain from smoking or bringing red hot objects Remove the seat mountings (3) .
near the working area, Take out the carpet.
unions,
REMOVAL
terminal.
2 4
104214
Remove the soundproofing pads (4) .
1
104617
Remove:
- the clips (1) ,
- the trim (2) .
19C-17
RESERVOIR
K9K – F9Q – M9R
5 7
104620
104204
Remove:
- the tuner-amplifier unit mounting bolts (7) ,
- the tuner-amplifier unit assembly.
6
8
104203
Disconnect the tuner-amplifier (6) (if fitted to the ve-
hicle).
104545
Remove the inspection flap blanking cover (8) .
19C-18
RESERVOIR
K9K – F9Q – M9R
10
105006 104547
Disconnect: Remove the nut from the sender using the (Mot.
1397) (11) .
- the electrical connector (9) ,
Remove the sender unit, being careful with the float.
- the quick-release unions (10) .
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 370 Mechanical systems, 13B, Diesel injec-
been removed to prevent any deformation of the
tion: Cleanliness guidelines ).
fuel tank.
19C-19
RESERVOIR
K9K – F9Q – M9R
REFITTING
102470
Replace the O-ring seal.
Refit the sender unit by aligning mark (12) on the
sender with mark (13) on the tank.
Position the nut (15) .
Tighten the nut (15) until mark (14) on the nut is ali-
gned with mark (13) on the tank and mark (12) on
the sender.
Connect the battery starting with the positive termi-
nal (see MR 370 Mechanical systems, 80A, Batte-
ry: Removal - Refitting ).
(4 Nm) .
19C-20
RESERVOIR
Petrol filter: General information 19C
102299
The fuel filter is located in the fuel tank; it is integrated
into the « pump-sender-filter » assembly and cannot
be removed.
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-21
RESERVOIR
Pump-sender unit-filter: Removal - Refitting 19C
F4R or K4J or K4M
Mot. 1397 Universal petrol tank

gauge nut wrench.
Tightening torquesm

bolts
IMPORTANT
During this operation: 104618
- refrain from smoking or bringing red hot objects Remove the seat mountings (3) .
close to the working area, Move the carpet to one side.
union,
REMOVAL
terminal.
2
4
104214
Remove the soundproofing (4) .
1
104617
Remove:
- the clips (1) ,
- the trim (2) .
19C-22
RESERVOIR
F4R or K4J or K4M
5 7
104620
104204
Remove:
- the mounting bolts (7) from the receiver unit,
- the receiver unit assembly.
6
8
104203
Disconnect the receiver (6) (if fitted to the vehicle).
104545
Remove the access flap blanking cover (8) .
19C-23
RESERVOIR
F4R or K4J or K4M
10
104546 104547
Disconnect: Remove the nut from the « pump/sender/filter » as-
sembly using tool (Mot. 1397) (11) .
- the electrical connectors (9) ,
Remove the « pump/sender/filter » assembly, being
- the quick-release union (10) .
careful of the float.
Prepare for fuel outflow.
WARNING
Refit the « pump/sender/filter » assembly nut as
soon as the « pump/sender/filter » assembly is
removed to prevent any deformation of the tank
19C-24
RESERVOIR
F4R or K4J or K4M
REFITTING
102470
Replace the O-ring seal.
Refit the « pump/sender/filter » assembly, aligning
mark (12) on the « pump/sender/filter » assembly
with mark (13) on the tank.
Position the nut (15) .
Tighten the nut (15) until mark (14) on the nut is ali-
gned with mark (13) on the tank and with mark (12)
on the « pump/sender/filter » assembly.
Connect the battery starting with the positive termi-
nal (see MR 370 Mechanical systems, 80A, Batte-
ry: Removal - Refitting ).
(4 Nm) .
19C-25
RESERVOIR
Fuel level sensor: Checking 19C
Checking the gauge sender unit
Value Capacity Height H (in

between ter- mm) +/- 6 mm
minals A1
and B1 (in
Ω) +/- 10 Ω
20 Full tank upper stop
95 Tank 3/4 full 150
106 (170) Tank 1/2 full 111
245 Tank 1/4 full 72
290 Reserve 40
320 Tank empty lower stop
MEASURING THE 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-26
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
M9R, and 700
114631
Mark Description Tightening tor-

que (Nm)
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(3) Lower engine tie-bar support mounting bolts 62
(4) Bolt mounting the upper engine tie-bar onto the body 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolts mounting the right-hand suspended mounting support on the body 62
(7) Bolts mounting the right-hand suspended mounting support on the engine 62
(8) Bolts 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) Nut mounting the left-hand rubber pad on the gearbox mounting 62
(11) Bolts mounting the left-hand rubber pad on the body mounting 62
(12) Acoustic mass mounting bolt 21
19D-1
ENGINE MOUNTING
Suspended engine mounting 19D
K4J, and 730 – K4M, and 782
7
4
6
1 3
103235
Tightening torques (in Nm)
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
19D-2
ENGINE MOUNTING
F4R, and 770 or 776
12 10
7 6
11
5
3
4 8
2
1
103244
(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
F9Q, and 804 or 812
6
7 12
11 10
5
3
4 8
103237
Tightening torque (in Nm)
(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-4
ENGINE MOUNTING
K9K, and 722 or 728
103236
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 21 for M8 bolts

62 for M10
bolts
(8) 62
(9) 180
(10) 62
19D-5
ENGINE MOUNTING
K4M, and 761
9
8
4
6
7
1 6
3
5
103274
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 21 for M8 bolts

62 for M10
bolts
(7) 62
(8) 180
(9) 62
19D-6
ENGINE MOUNTING
F4R, and 771
6 12
7 11
10
9
5
3
9
4
8
1
2
1
103275
(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-7
ENGINE MOUNTING
K9K, and 732
7
8
10
9 12
10
4 11
6
3
9
112652
(1) 62
(2) 21
(3) 62
(4) 105
(5) 115
(6) 62
(7) 105
(8) 180
(9) 62
(10) 62
(11) 62
(12) 62
19D-8
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
M9R, and 700

gearbox assembly.
Tightening torquesm

mounting bolts

mounting bolts
side reinforcement 21 Nm
mounting bolts
REMOVAL
101212
I - REMOVAL PREPARATION OPERATION Remove:
Position the vehicle on a two-post lift (see 02A, Lif- - the left-hand side reinforcement mounting bolts,
- the left-hand side reinforcement (1) ,
Remove:
- the engine protectors, Exterior protection, Front bumper: Removal -
- the battery (see 80A, Battery, Battery: Removal - Refitting ).
Refitting ),
- the front left-hand wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting),
- the left-hand wheel arch liner.
114933
19D-9
ENGINE MOUNTING
M9R, and 700
102365
Remove:

112658
Remove: unit: Removal - Refitting ).

(3) ,
116580
115585

cessories unit.
Remove:
- the clips (6) ,

116581
Position the (Mot. 1390) on the gearbox on the rub-
Disconnect the screen washer pipes. ber pads (9) and (10) .
19D-10
ENGINE MOUNTING
M9R, and 700
CONCERNED
114656
115208
Remove the left-hand suspended engine mounting
nut (11) .
114633
Mark the left-hand suspended mounting in relation

to the bodywork.
115321 Loosen the left-hand suspended mounting rubber
Remove: pad mounting nuts (13) .
- the mounting bolts (12) from the gearbox left-hand Remove:
suspended engine mounting,
- the gearbox suspended engine mounting. - the bolts (14) and (15) mounting the left-hand sus-
pended engine mounting on the body,
- the mounting bolt (16) for the retaining strut

between the battery tray mounting and the left-
hand suspended mounting,
19D-11
ENGINE MOUNTING
M9R, and 700
- the left-hand body suspended mounting fitted with Refit the mounting nut to the left-hand suspended
the rubber pad. engine mounting.
Tighten to torque:
REFITTING - the mounting nut on the left-hand suspended
mounting (see 19D, Engine mounting, Suspen-
I - REFITTING OPERATION FOR PART ded engine mounting: Tightening torque ),
CONCERNED
- the mounting nuts on the left-hand suspended
Refit the left-hand body suspended mounting fitted mounting rubber pad (see 19D, Engine mounting,
with the rubber pad. Suspended engine mounting: Tightening tor-
que ), aligning the marks.
Finger tighten the mounting bolts for the left-hand
suspended mounting on the body. Refit the retaining strut mounting bolt between the
battery tray bracket and the left-hand suspended
mounting.
Refit:
unit: Removal - Refitting ),
Screw on without tightening:
Tighten to torque:
Nm) ,
114633 - the front end panel upper mounting bolts (21
Tighten to torque the mounting bolts (17) for the left- Nm) .
hand suspended mounting on the body (see 19D,
Engine mounting, Suspended engine mounting:
Tightening torque ). Connect the screen washer pipes.
Tighten the bolt (18) mounting the left-hand suspen- Refit the clips.
ded mounting on the body. The torque given is only
an example (see 19D, Engine mounting, Suspen-
ded engine mounting: Tightening torque ). Connect the engine accessories unit connectors.
Refit the left-hand suspended mounting to the gear- Refit:
box.
Screw on the bolts mounting the left-hand suspen-
ded mounting on the gearbox without tightening. - the engine accessories unit mounting bolts,
Tighten to torque the bolts (19) mounting the left- - the front bumper (see MR 371, Bodywork, 55A,
hand suspended mounting on the gearbox (see Exterior protection, Front bumper: Removal -
19D, Engine mounting, Suspended engine Refitting ),
mounting: Tightening torque ). - the left-hand side reinforcement,
Tighten the bolt (20) mounting the left-hand suspen-
- the left-hand side reinforcement mounting bolts.
ded mounting on the gearbox. The torque given is
only an example (see 19D, Engine mounting, Sus- Tighten to torque the side reinforcement moun-
pended engine mounting: Tightening torque ). ting bolts (21 Nm) .
19D-12
ENGINE MOUNTING
M9R, and 700
Refit:
- the left-hand wheel arch liner,
- the front left-hand wheel (see 35A, Wheels and ty-
res, Wheel: Removal - Refitting),
Refitting ),
- Adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon bulbs, Xenon headlight: Ad-
justment ),
- Adjust the headlights (see 80B, Headlights,
19D-13
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting 19D
M9R, and 700
REMOVAL

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

CONCERNED
114632
Remove the lower engine tie-bar:
- by pulling it back (3) then lifting it (4) to detach it
from its support,
- by pivoting it (5) to the right.
REFITTING

114650 CONCERNED
Remove:
Refit:
- the lower engine tie-bar mounting bolt (1) from the
sub-frame,
- the lower engine tie-bar mounting bolt onto the
- the lower engine tie-bar mounting bolt (2) from the
support,
support.
- the lower engine tie-bar mounting bolt onto the
sub-frame.
Tighten to torque the lower engine tie-bar bolts (see
mounting: Tightening torque ).
19D-14

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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

JANUARY 2006 Edition Anglaise

© Renault s.a.s. 2006

19A COOLING SYSTEM

19D ENGINE MOUNTING

X84, and J84

JANUARY 2006 Edition Anglaise

© Renault s.a.s. 2006

10A ENGINE AND LOWER ENGINE ASSEMBLY 12A FUEL MIXTURE

Engine identification 10A-1 Specifications 12A-1

Oil consumption Check 10A-3 Air inlet 12A-12

Oil filter: Removal - Refitting 10A-4 Air resonator: Removal -

Oil level sensor: Removal - Air filter: Removal - Refitting 12A-24

Engine/gearbox assembly: Air inlet duct: Removal -

Sump: Removal - Refitting 10A-99 Inlet manifold: Removal -

Exhaust manifold: Removal -

Tightening the cylinder head 11A-110

Cylinder head gasket :

Crankshaft seal at timing end Turbocharging pressure

Cylinder head: Removal - Pressure regulator: Checking 12B-5

12B TURBOCHARGING 13B DIESEL INJECTION

Turbocharger: Removal - High pressure pipe:

Intercooler: Removal - Diesel injector: check 13B-69

High pressure pump:

Diesel injector: Removal -

Injector rail - Injectors: High-pressure pipe between

Fuel flow actuator: Removal -

Specifications 13B-1 Fuel pressure regulator:

Centralised coolant Accelerator pedal sensor

Computer configuration 13B-64

13B DIESEL INJECTION 14A ANTIPOLLUTION

Accelerator pedal Exhaust gas recirculation

Diesel injection computer: Exhaust gas recirculation

16A STARTING - LOAD

Pre-postheating control 13C-9 Starter: Removal - Refitting 16A-28

Alternator pulley: Removal -

Petrol vapour rebreathing:

Fuel vapour recirculation Coils Removal - Refitting 17A-1

Oil vapour rebreathing 14A-6 Fuel injection parts

17B PETROL INJECTION 17C LPG INJECTION

Throttle valve: Operating 17B-25 LPG injector: Check 17C-29

Special notes on the system LPG computer: Removal -

Conditions for carrying out

Combustion misfire fault 19A COOLING SYSTEM

LPG tank: Draining 17C-8 Cooling radiator: Removal -

LPG expansion valve outlet 19B EXHAUST

LPG injection rail: Removal - Catalytic pre-converter:

LPG injector: Removal - Catalytic converter: Removal

19B EXHAUST 19D ENGINE MOUNTING

Silencer: Removal - Refitting 19B-34 Left-hand suspended engine

Particle filter pressure

Particle filter temperature

Connecting hose: Removal -

Particle filter: Cleaning 19B-52

Draining the fuel tank 19C-1

Fuel tank: Removal -