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Mr364megane1 PDF
Mr364megane1 PDF
12B TURBOCHARGING
13C PREHEATING
14A ANTIPOLLUTION
17A IGNITION
"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."
19B EXHAUST
19C RESERVOIR
"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."
Mégane II - Section 1
Contents
Page
10A ENGINE AND LOWER ENGINE ASSEMBLY 11A TOP AND FRONT OF ENGINE
Alternator: General
13C PREHEATING information 16A-1
Alternator: Removal -
Pre/postheating unit: Refitting 16A-2
Removal - Refitting 13C-1
Alternator pulley: Removal -
Heater plugs Removal - Refitting 16A-20
Refitting 13C-2
Starter: Identification 16A-24
Pre-postheating control 13C-11
Starter: Removal - Refitting 16A-25
14A ANTIPOLLUTION
17A IGNITION
Petrol vapour rebreathing:
Operation 14A-1 Coils Removal - Refitting 17A-1
Specifications 19A-2
Checking 19A-3
Diagram 19A-4
Contents
19C RESERVOIR
Pump-sender unit-filter:
Removal - Refitting 19C-20
Suspended engine
mounting: Tightening torque 19D-9
Right-hand suspended
engine mounting: Removal -
Refitting 19D-14
XM0B 730
XM0H
K4J 1390 79.5 70 10/1
XM1A
XM08 732
XM0C 760
XM0J K4M 761 1598 79.5 80.5 9.8/1
XM1B
XM05 770
XM0U 771
9.8/1
XM1M F4R 1998 82.7 93
XM1N
XM0F 722
XM0T
XM02 729
10A-1
ENGINE AND LOWER ENGINE ASSEMBLY
Engine oil: Draining - Refilling 10A
M9R, and 700
Copper seal
Tightening torquesm
drain plug 44 Nm
I - OIL SERVICE
Remove the oil filler plug and the dipstick.
113764
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ). Refit the new seal on the plug, positioning the groo-
ve (2) towards the plug.
Remove the engine undertray.
Tighten to torque the drain plug ( 44 Nm ) .
II - FILLING
WARNING
Always check the oil level using the dipstick.
Do not exceed the maximum level on the dipstick
(as this could damage the engine).
Correct the engine oil level if necessary before
delivering the vehicle to the customer.
114651
Remove the drain plug (1) .
Let the oil run into a drain tray.
10A-2
ENGINE AND LOWER ENGINE ASSEMBLY
Oil consumption Check 10A
PROCEDURE FOR MEASURING OIL
CONSUMPTION
Note:
The operation should be carried out with the
engine warm after the fan unit has started opera-
ting.
Wait two minutes for all of the oil to flow into the oil
sump.
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
3 - Topping up
Note:
The operation should be carried out with the
engine warm after the fan assembly has started
operating.
Wait two minutes for all of the oil to flow into the oil
sump.
10A-3
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
III - FINAL OPERATION
Special tooling required
Top up the engine oil.
Mot. 1329 76 mm diameter oil fil-
Wipe any oil run-off with a cloth.
ter removing tool
Refit the engine undertray.
REMOVAL
111850
REFITTING
10A-4
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
F4R, and 770 or 771 or 776
Tightening torquesm
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
Remove the engine undertray.
111852
Position the (Mot. 1329) (2) on the oil filter.
Remove the oil filter.
REFITTING
Lubricate the oil filter seal with new engine oil.
Tighten the oil filter until it comes into contact with
the oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
1 Refit the air conditioning compressor stay.
Tighten to torque the air conditioning compressor
stay mounting bolts ( 44 Nm ) .
Top up the engine oil.
Wipe any oil run-off with a cloth.
111851
Refit the engine undertray.
Remove:
- the mounting bolts (1) from the air conditioning
compressor stay.
- the air conditioning compressor stay.
10A-5
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
K4M, and 760 or 761 – K4J, and 730 or 732
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
Remove the engine undertray.
110385
Position tool (Mot. 1329) (1) on the oil filter.
Remove the oil filter.
REFITTING
Apply new engine oil to the oil filter seal.
Tighten the oil filter until it comes into contact with
the oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
Top up the engine oil.
Refit the engine undertray.
10A-6
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
M9R, and 700
Tightening torquesm
cover 25 Nm
REMOVAL
114779
Remove the filter element - cover assembly.
114653
Loosen the cover (1) slightly.
Let the engine oil flow out before removing the filter
element - cover assembly.
113320
Remove:
- the filter element (2) from the cover (3) ,
- the O-ring (4) from the cover (3) .
10A-7
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
M9R, and 700
114780
Refit:
113869
- the new filter element (6) in the cover (7) ,
Position the new O-ring (5) correctly on the cover. - the filter element - cover assembly.
Apply new engine oil to the O-ring. Tighten to torque the cover ( 25 Nm ) .
10A-8
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter: Removal - Refitting 10A
F9Q
REFITTING
Special tooling required
Remove:
115078
10A-9
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
REMOVAL
Special tooling required
Tightening torquesm
front end panel lower 44 Nm - the mounting bolts (1) from the Protection and
Switching Unit,
mounting bolts
- the Protection and Switching Unit cover.
10A-10
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
102504 102365
Disconnect the connectors (2) from the Protection Remove:
and Switching Unit.
- front end panel mounting bolts (7) ,
Unfasten the bonnet opening cable (3) .
- the front end panel,
Remove:
- the air inlet scoop.
- the clips (4) ,
Drain the engine cooling system (see 19A, Cooling,
- the front end panel upper mounting bolts (5) , Engine cooling system: Draining-refilling ).
Disconnect the screen washer tubes.
102473
114933 Loosen the clip (8) from the intercooler upstream ho-
se.
Unclip the air inlet scoop.
Disconnect the intercooler upstream hose.
10A-11
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
114649 112661
Remove the bolt (9) mounting the intercooler downs- Disconnect:
tream duct on the cooling radiator.
- the cooling radiator top and bottom hose using
Loosen: (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the clip (10) on the intercooler downstream duct on - the fan unit resistor connector (11) ,
the intercooler,
- the fan unit connector.
- the intercooler downstream duct clip on the damper
Unclip the wiring harness from the fan unit.
valve.
Move the downstream duct away from the intercoo-
ler.
10A-12
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
109537 114929
Disconnect: Disconnect the hose (15) from the oil cooler coolant
outlet union.
- the hoses from the expansion bottle on the cooling
radiator side (12) , Remove:
- the pressure switch connector on the condenser - the oil pressure sensor using the (Mot. 1495-01) ,
lower air conditioning pipe (13) .
- the mounting bolts (16) from the coolant inlet union,
Unpick the wiring harness from the pressure switch
- the coolant inlet union.
connector on the fan unit.
Disconnect, using the (Mot. 1202-01) or (Mot. 1202-
Remove the air conditioning pipes from the conden-
02) or (Mot. 1448) :
ser (14) .
- the hose (17) from the coolant inlet union on the
union,
Note:
- the hose (18) from the cylinder block coolant inlet
Plugs must be fitted to the hoses and the expan- pipe,
sion valve to prevent moisture from entering the
system. Remove the hose from the coolant inlet union.
10A-13
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
114928
Remove:
- the mounting bolts (19) from the oil cooler, 114928
10A-14
ENGINE AND LOWER ENGINE ASSEMBLY
Exchanger: Removal - Refitting 10A
M9R, and 700
II - FINAL OPERATION Tighten to torque the intercooler upstream hose
clip ( 5.5 Nm ) .
Connect, using the (Mot. 1202-01) or (Mot. 1202-
02) or (Mot. 1448) :
Refit:
- the coolant inlet union hose on the cylinder block,
- the air inlet scoop,
- the coolant inlet pipe hose on the union,
- the coolant outlet union hose to the oil cooler. - the front end panel,
Refit:
- the clips,
- the coolant inlet union,
- the front end panel mounting bolts.
- the coolant inlet union mounting bolts,
- the oil pressure sensor. Tighten to torque:
Tighten to torque:
- the front end panel upper mounting bolts ( 21
- the coolant inlet union mounting bolts ( 24 Nm ) Nm ) ,
,
- using (Mot. 1495-01) the oil pressure sensor ( 44 - the front end panel lower mounting bolts ( 44
Nm ) . Nm ) .
Refit the cooling assembly. Connect the Protection and Switching Unit connec-
Refit the air conditioning pipes to the condenser. tors.
Attach the pressure switch connector wiring harness
Clip the bonnet opening cable.
to the fan unit.
Connect, using the (Mot. 1202-01) or (Mot. 1202- Disconnect the screen washer tubes.
02) or (Mot. 1448) :
Refit:
- the expansion bottle hoses on the cooling radiator
side, - the Protection and Switching Unit cover,
- the cooling radiator top and bottom hose.
- the Protection and Switching Unit cover mounting
Connect:
bolts,
- the pressure switch connector on the condenser
lower air conditioning pipe, - the oil filter (see 10A, Engine and peripherals, Oil
filter: Removal - Refitting ).
- the fan unit connector,
- the fan unit resistor connector, - the engine undertray.
Clip the fan unit wiring harness into place.
Refit:
Refit:
- the engine protectors,
- the intercooler downstream duct clip to the inter-
cooler,
- the front bumper (see MR365 Bodywork, 55A Ex-
- the intercooler downstream duct clip on the damper terior protection, Front bumper ).
valve.
Tighten to torque: Refill:
- the intercooler downstream duct clip on the in- - the coolant circuit using the filling station (see
tercooler ( 5.5 Nm ) , 62A, Air conditioning, Maintenance ),
- the intercooler downstream duct clip on the
damper valve ( 5.5 Nm ) . - the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
Tighten the bolt mounting the intercooler downs-
tream duct on the cooling radiator. Connect the battery (see 80A, Battery, Battery: Re-
Connect the intercooler upstream hose. moval - Refitting ).
10A-15
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pressure 10A
Connect the battery (see 80A, Battery, Battery: Re-
Special tooling required moval - Refitting ).
Mot. 836-05 Oil pressure gauge kit Start the vehicle.
Carry out the check.
I - ADAPTERS FOR USE WITH VARIOUS ENGINES Check the values.
87363
Position the (Mot. 836-05) with the appropriate adap-
ters.
10A-16
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pressure sensor: Removal - Refitting 10A
M9R, and 700
- the engine accessories unit cover.
Special tooling required
Tightening torquesm
114933
Unclip the air inlet scoop (6) .
112658
Remove:
- the engine accessories unit cover mounting bolts
(1) ,
10A-17
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pressure sensor: Removal - Refitting 10A
M9R, and 700
102365
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
115022
II - OPERATION FOR REMOVAL OF PART
CONCERNED
115021
Remove the oil pressure sensor using the (Mot.
114061 1495-01) (1) .
Disconnect the oil pressure sensor connector (8) .
Note:
Be careful not to damage the air conditioning
compressor connector.
10A-18
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pressure sensor: Removal - Refitting 10A
M9R, and 700
REFITTING
II - FINAL OPERATION
Refit:
- the front end panel,
- the upper mounting bolts of the front end panel,
- the lower mounting bolts of the front end panel.
Tighten to torque:
- the front end panel upper mounting bolts ( 21
Nm ) ,
- the front end panel lower mounting bolts ( 44
Nm ) .
Clip the air inlet scoop into place.
Connect the screen washer pipes.
Position the bonnet opening cable.
Connect the engine accessories unit connectors.
Refit:
- the clips,
- the engine accessories unit cover,
- the engine accessories unit cover mounting bolts,
- the front bumper (see MR 365 Bodywork, 55A Ex-
terior protection, Front bumper ),
- the engine undertray,
- the engine protectors.
10A-19
ENGINE AND LOWER ENGINE ASSEMBLY
Oil level sensor: Removal - Refitting 10A
M9R, and 700
II - FINAL OPERATION
Tightening torquesm Refit the heat insulating material around the oil level
sensor.
oil level sensor 25 Nm Refit the front right-hand wheel.
front right-hand wheel 110 Nm Tighten to torque the front right-hand wheel ( 110
Nm ) .
REMOVAL
114932
Disconnect the oil level sensor (1) .
Remove the oil level sensor.
REFITTING
10A-20
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
Equipment required
safety belt
Tightening torquesm
REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ).
Remove:
- the dipstick,
10A-21
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
Apply the product to the section to be cleaned: wait
approximately ten minutes, then remove the residue
using a wooden spatula.
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
(engine, radiator, etc.).
102008
Remove:
Remove:
CA or CAREG
Remove:
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-
solve any seal still adhering.
10A-22
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
I - FIRST FITTING
20167
20170
Refit the oil splash plate onto the cylinder block.
5
Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positio-
5 ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent deformation of the
clutch housing.
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVE
SEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE SEALANT at
(5) which are 7 mm in diameter , at the joint
between the crankshaft closure panel and the cy-
linder block.
10A-23
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
6 7 8 9 10 11 12 13 14
15
16
5 4 3 2 1 20 19 18 17
20171
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-
ning.
Tighten to torque and in order the sump mounting
bolts ( 14 Nm ) .
Check that all the sump mounting bolts are tighte-
ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
bolts ( 44 Nm ) .
10A-24
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
II - SECOND FITTING bolts ( 44 Nm ) .
CA or CAREG
Refit the bolt mounting the sump on the multifunction
support.
Tighten to torque the bolt mounting the sump on
the multifunction support ( 21 Nm ) .
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts ( 110 Nm ) .
- the battery cover bolts ( 4 Nm ) .
108881
Proceed in the reverse order to removal.
15
16
5 4 3 2 1 20 19 18 17
20171
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-
ning.
Tighten to torque and in order the sump mounting
bolts ( 14 Nm ) .
Check that all the sump mounting bolts are tighte-
ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
10A-25
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F9Q, and 800 or 804 or 808
Equipment required
safety belt
Tightening torquesm
REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting 101212
equipment, Underbody lift ). Remove the half sub-frame side reinforcements (1) .
Disconnect the battery (see 80A, Battery, Battery: Attach the cooling assembly to the upper cross
Removal - Refitting ). member using a safety belt .
Remove the engine undertray.
Drain the engine oil (see 05A, Draining - Filling, Note:
Engine ). When positioning the safety belt , be careful not
Remove: to:
10A-26
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F9Q, and 800 or 804 or 808
Apply the product to the section to be cleaned: wait
approximately ten minutes, then remove the residue
using a wooden spatula.
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
(engine, radiator, etc.).
Note:
2
There are two fitting procedures for preparing the
cylinder block gasket face when refitting:
102008
- the first fitting procedure is used if SILICONE
Remove: ADHESIVE SEALANT has been used to seal
the crankshaft closure panel,
- the mounting nuts from the half sub-frame,
- the second fitting is used if a seal is used for the
- the mounting bolts from the half sub-frame,
crankshaft closure panel sealing.
- the half sub-frame (2) .
Remove:
- the engine tie-bar,
- the sump mountings,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-
solve any seal still adhering.
10A-27
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F9Q, and 800 or 804 or 808
I - FIRST FITTING II - SECOND FITTING
A A
B B
15159 15159
Apply a bead of SILICONE ADHESIVE SEALANT : Apply a bead of SILICONE ADHESIVE SEALANT
at (A) , on the joint between the crankshaft closure
- at (A) , both sides of bearing No.1,
panel and the cylinder block.
- at (B) , the joint between the cylinder block and the
crankshaft closure panel.
Note
Refit the sump fitted with a new seal.
Do not cut the two crankshaft closure panel seal
tabs which sit higher than the cylinder block gas-
ket face (B) .
10A-28
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F9Q, and 800 or 804 or 808
III - REFITTING (FOR THE FIRST AND SECOND
FITTINGS)
2 3 4 5 6 7 8 9
10
1
11
22
12
21 13
20 19 18 17 16 15 14
15195
Stage 1:
- Stage 2:
Tighten to torque:
10A-29
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
REMOVAL
Equipment required
I - REMOVAL PREPARATION OPERATION
safety belt
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ).
Tightening torquesm Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
sump mounting bolts 14 NM
Remove:
sump mounting bolts 14 NM
- the engine covers,
are tightened to torque
- the dipstick,
sump mounting bolts 44 NM
- the engine undertray.
sump mounting bolts 14 NM Remove:
sump mounting bolts 14 NM - the front bumper (see MR 365 Bodywork, 55A Ex-
are tightened to torque terior protection, Front bumper ),
10A-30
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
101212 102008
Remove the half sub-frame side reinforcements (1) . Remove:
Attach the cooling assembly to the upper cross - the mounting nuts from the half sub-frame,
member using a safety belt .
- the mounting bolts from the half sub-frame,
Note: - the half sub-frame (2) .
When positioning the safety belt , be careful not
to:
K9K, and 732
- pinch the cooling hoses,
Remove:
- strap the half sub-frame.
- the lower engine tie-bar mounting bolts,
Move the diesel drain pipe away from the injection - the lower engine tie-bar support lower mounting
rail protector. bolts.
Remove:
10A-31
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
CA or CAREG
Remove the mounting bolt from the sump on the
multifunction support.
REFITTING
3
I - REFITTING PREPARATION OPERATION
20167
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
4
(engine, radiator, etc.).
20166
Apply the product to the section to be cleaned: wait
Apply:
approximately ten minutes, then remove the residue
using a wooden spatula. - four beads at (3) and (4) of SILICONE ADHESIVE
SEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE at (5) which
are, 7 mm in diameter , at the joint between the
crankshaft closure panel and the cylinder block.
10A-32
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
II - REFITTING OPERATION FOR PART
CONCERNED
6 7 8 9 10 11 12 13 14
1 - FIRST FITTING
15
6
16
7
5 4 3 2 1 20 19 18 17
20171
Refit the oil sump with a new seal.
Fit:
10A-33
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
2 - SECOND FITTING bolts ( 44 NM ) .
CA or CAREG
Refit:
10A-34
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
K9K, and 722 or 728 or 729 or 732
Refit:
Tighten to torque:
Refit:
Refit:
Refit:
- the dipstick,
10A-35
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm
101212
REMOVAL
Remove:
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ). - the half sub-frame side reinforcement mounting
bolts,
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ). - the side reinforcements (1) .
Remove the engine undertray. Attach the cooling assembly to the upper cross
member using the safety belt .
Drain the engine oil (see 05A, Draining - Filling,
Engine ).
Note:
Remove:
When positioning the safety belt , be careful not
- the engine covers,
to:
- the dipstick,
- pinch the cooling hoses,
- the front wheels,
- strap the half sub-frame.
- the wheel arch liners.
10A-36
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F4R, and 770 or 771 or 776
B
2
102008 15159
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-
solve any seal still adhering.
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
(engine, radiator, etc.).
10A-37
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
F4R, and 770 or 771 or 776
2 3 4 5 6 7 8 9
10
1
11
22
12
21
13
20 19 18 17 16 15 14
15195
Stage 1:
• Tighten to torque and in order, bolts (8) , (15) , (4)
, (19) , (11) , (12) ( 18 Nm ).
- Stage 2:
• Tighten to torque and in order, bolts (10) , (13) ,
(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18)
, (3) , (20) , (2) , (21) , (1) and (22) ( 15 Nm ).
Refit the lower engine tie-bar (see 19D, Engine
mounting, Suspended engine mounting ).
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts (F4R 776) ( 130 Nm ) ,
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Proceed in the reverse order to removal.
Top up the engine oil (see 05A, Draining - Filling,
Engine ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
10A-38
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
M9R, and 700
Tightening torquesm
REMOVAL
102008
Remove:
I - REMOVAL PREPARATION OPERATION
- the lower mounting bolts (1) from the side reinfor-
Position the vehicle on a lift (see 02A, Lifting equi-
cements,
pment, Underbody lift ).
- the half sub-frame (2) .
Disconnect the battery (see 80A, Battery, Battery :
Removal - Refitting ). Drain the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ).
Remove:
- the engine protectors.
- the dipstick,
- the front wheels,
- the front wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365 Bodywork, 55A Ex-
terior protection, Front bumper ).
10A-39
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART Check that the base plate is not scratched.
CONCERNED
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could cause damage to
cer tain components (engine, radiator, etc.).
WARNING
The sealing surfaces must be clean, dry and free
from grease (avoid finger marks).
REFITTING
114410
10A-40
ENGINE AND LOWER ENGINE ASSEMBLY
Sump: Removal - Refitting 10A
M9R, and 700
III - FINAL OPERATION
Refit:
- the half sub-frame,
- the half sub-frame mounting bolts,
- the half sub-frame mounting nuts.
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) .
Refit the side reinforcement lower mounting bolts.
Tighten to torque the side reinforcement lower
mounting bolts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365 Bodywork, 55A Ex-
terior protection, Front bumper ),
- the engine undertray,
- the front wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery, B attery :
Removal - Refitting ).
Fill up the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ).
Refit:
- the dipstick,
- the engine protectors.
10A-41
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pump: Removal - Refitting 10A
Connect the battery, starting with the positive termi-
nal.
Tightening torquesm
23224
Remove:
REFITTING
Proceed in the reverse order to removal.
10A-42
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pump: Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
REMOVAL
Remove:
REFITTING
10A-43
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pump: Removal - Refitting 10A
M9R, and 700
III - FINAL OPERATION
113156
Replace the oil strainer O-ring.
Fit the strainer to the oil pump and finger tighten the
two mounting bolts in the following tightening order -.
Tighten the strainer mounting bolts ( 10 Nm ) in
the following tightening order -.
Remove:
- the sump (see 10A, Engine and peripherals,
Sump: Removal - Refitting .
- the engine undertray.
Fill up the engine oil (see 10A, Engine and periphe-
rals, Engine oil: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Start the engine and wait until the engine oil warning
light goes out.
Check the engine oil level.
Refit the engine undertray.
10A-44
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
multifunction support 44 Nm
mounting bolts
multifunction support 21 Nm
mounting bolt on the
sump
REMOVAL
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ).
Remove the engine protectors.
Disconnect the battery (see 80A, Battery, Battery :
Removal - Refitting ).
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray, 102265
Remove:
- the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper: Removal - - the multifunction support mounting bolts (1) ,
Refitting ),
- the bolt (2) mounting the multifunction support on
- the accessories belt (see 11A, Top and front of the sump,
engine, Accessories belt: Removal - Refitting ),
- the multifunction support.
- the alternator (see 16A, Starting-Charging, Alter-
nator: Removal - Refitting ).
10A-45
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
REFITTING
CHAUFO
CA or CAREG
111057
Remove: 102265
10A-46
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K4J, and 730 or 732 – K4M, and 760 or 761
CHAUFO
111057
Refit:
Refit:
10A-47
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K9K, and 722 or 724 or 728 or 729 or 732
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
multifunction support 44 Nm
mounting bolts
REMOVAL
10A-48
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
I - REFITTING OPERATION FOR PART
CONCERNED
CA or CAREG
111057
Remove:
- the multifunction support mounting bolts (3) ,
- the multifunction support. 102265
Refit:
- the multifunction support,
- the multifunction support mounting bolts.
Tighten to torque and in order:
- the multifunction support mounting bolt on the
sump ( 21 Nm ) .
- the multifunction support mounting bolts ( 44
Nm ) ,
10A-49
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
K9K, and 722 or 724 or 728 or 729 or 732
CHAUFO
111057
Refit:
II - FINAL OPERATION
Refit:
10A-50
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
Equipment required
filling station
Tightening torquesm
multifunction support 44 Nm
mounting bolts
REMOVAL 109537
Place the vehicle on a two-post lift (see 02A, Lifting Disconnect:
equipment, Underbody lift ).
- the air conditioning compressor connector,
Drain the coolant circuit using the filling station
- the pressure switch connector (1) .
(see 62A, Air conditioning, Maintenance ).
Remove:
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ). - the air conditioning compressor pipe (2) ,
Remove the alternator (see 16A, Starting - Char- - the air conditioning pipe between the compressor
ging, Alternator ). and the dehydration canister (3) .
Note:
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
Remove:
- the air conditioning compressor mounting bolts,
- the air conditioning compressor.
10A-51
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
104337
Remove:
- the multifunction support mounting bolts (4) ,
- the multifunction support.
REFITTING
Refit the multifunction support.
Tighten to torque:
- the multifunction support mounting bolts ( 44
Nm ) ,
- the air conditioning compressor mounting
bolts ( 25 Nm ) .
- the air conditioning compressor strut mounting
bolts ( 44 Nm )
Refit the alternator (see 16A, Starting - Charging,
Alternator ).
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
Fill the coolant circuit using the filling station (62A,
Air conditioning, Maintenance).
10A-52
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
multifunction support 44 Nm
mounting bolts
REMOVAL
114862
Remove:
- the multifunction support mounting bolts (3) ,
- the multifunction support.
114861
10A-53
ENGINE AND LOWER ENGINE ASSEMBLY
Multifunction support: Removal - Refitting 10A
M9R, and 700
REFITTING
114862
II - FINAL OPERATION
10A-54
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
REMOVAL
Special tooling required
Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1202-01 Clip pliers for cooling ting equipment, Underbody lift ).
system hose clips
(large model)
IMPORTANT
Mot. 1202-02 Pliers for small hose During this operation, secure the vehicle to the
clips lift with a safety belt , to avoid any imbalance.
Mot. 1448 Remote operation clip Remove:
pliers for cooling sys-
tem hose clips - the engine covers,
- the front wheels,
Equipment required
- the right and left-hand wheel arch liners,
safety belt - the engine undertray.
filling station Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-
hydraulic crane
box ),
load positioner - the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:
Tightening torquesm Removal - Refitting ).
101212
Remove:
- the battery (see 80A, Battery, Battery: Removal -
Refitting ),
10A-55
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper ).
2
4 5
7
102504
Disconnect the two connectors (2) .
101795
Unclip the front bonnet opening cable (3) .
Remove: Disconnect:
- the clip (4) ,
- the petrol inlet pipe from the injector rail (7) ,
- the fastening (5) .
- the radiator top hose, using the (Mot. 1202-01) or
Disconnect the screen washer tubes. (Mot. 1202-02) or (Mot. 1448) .
102365 11
Remove:
- the front end panel mounting bolts (6) , 8 9
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
10
109537
10A-56
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
CA or CAREG
Disconnect the pressostat connector on the lower air
conditioning pipe on the condenser (9) .
Remove:
- the air conditioning pipes from the condenser (10) .
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister (11)
13
, 14
Note:
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
101822
Remove the cooling assembly.
Disconnect the computer connectors (13) .
Remove the battery tray mounting bolts (14) .
Remove:
- the battery tray,
- the computer mounting.
12
15
101807
Remove the air filter outlet duct (12) .
104553
Remove the air filter unit (15) .
10A-57
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
17
101978 101812
Disconnect the wiring harness connectors from the Remove the brake servo pipe (17) .
relay board.
19
18
16
104240
111051 Disconnect:
Disconnect the earth strap on the body.
- the hoses (18) and (19) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
10A-58
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
22
B
C
21
A
101743 103409
Remove:
Unclip the lever cables on the gearbox:
- the multifunction switch cable ball joint (21) ,
- grip the gearbox control at (A) ,
- the multifunction switch cable (22) by unlocking the
- pull the pin at (B) , sleeve stop.
- raise the gearbox control at (C) .
20
101699
10A-59
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
24
23
102008
Remove:
101740 - the front left-hand driveshaft (see 29A, Drives-
Pull out clip (23) . hafts, Front left-hand driveshaft ),
Disconnect the hydraulic clutch supply pipes. - the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the exhaust downpipe mountings,
Note:
- the lower engine tie-bar,
Plug the pipes to prevent fluid from escaping.
- the half sub-frame (24) .
Position the hydraulic crane fitted with a load posi-
tioner or a chain.
10A-60
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
101866
Mark the suspended engine mounting in relation to
the body.
103273
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 3784A, Petrol engine - 4 cy-
linders - K4, 10A, Engine and peripherals, Nor-
mal replacement ).
10A-61
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4M, and 760 or 761
Tighten to torque: Tighten to torque the battery cover bolts ( 4 Nm ) .
CA or CAREG
IMPORTANT
Correctly attach the brake hose and the sensor
wiring for the ABS system.
Do not twist the brake hose.
10A-62
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler:
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
pliers for cooling sys-
tem hose clips - refit the clip in the same recess in the event that
the hoses are not replaced,
Equipment required - it is essential to replace the hoses and/or the inter-
cooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak
filling station or come undone.
hydraulic crane
half sub-frame rear 321 Nm - the right and left-hand wheel arch liners,
mounting bolt
- the engine undertray.
battery cover bolts 4 Nm
Drain:
CA or CAREG
10A-63
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
1 102365
Remove:
9 7
3
104338
2 Remove:
102504
WARNING
Disconnect the connectors (2) .
Follow the cleanliness guidelines closely (see
Unclip the bonnet release cable (3) . 13B, Diesel injection, Cleanliness guidelines
).
Remove:
Be aware of the residual pressure and the quan-
- the clip (4) , tity of diesel fuel in the pipes.
Disconnect the screen washer tubes. Fit plugs into the openings.
10A-64
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
CA or CAREG
Disconnect the pressostat connector on the lower air
conditioning pipe from the condenser (12) .
Remove:
- the air conditioning pipes from the condenser (13) .
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister (14)
.
10 Note:
14
15
11 12
102473
13 Disconnect the air duct from the intercooler (15) .
Remove the cooling assembly.
109537
Disconnect the hoses from the expansion bottle on
the cooling radiator side (11) .
10A-65
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
16
20
19
102500 104245
Remove the air filter outlet duct (16) . Remove:
17
18
21
101822
Disconnect the computer connectors (17) . 22
Remove:
- the battery tray mounting bolts (18) ,
- the battery tray,
- the computer mounting.
104340
Remove:
10A-66
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
23
24 A
104322 101743
Remove the brake servo pipe (23) from the vacuum Unclip the lever cables on the gearbox:
pump.
- clip the gearbox control at (A) ,
Disconnect the heater radiator top hose (24) on the
- pull the pin at (B) ,
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) . - raise the gearbox control at (C) .
25
101699
Remove the gearbox controls (25) .
10A-67
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
26
27
102513 102008
Press the clip (26) . Remove:
Disconnect the supply pipes. - the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
Remove the clutch hydraulic control at the bulkhead.
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ),
Note:
- the exhaust downpipe mountings,
Plug the pipes to prevent fluid from escaping.
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (27) .
Position the hydraulic crane fitted with a load posi-
tioner or a chain.
10A-68
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
REFITTING
To replace the engine (see Technical Note 3652A,
High pressure diesel engine - Common Rail 4 cy-
linder cast iron, 10A, Engine and peripherals,
Normal replacement ).
Position the « engine and gearbox assembly » in the
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ) in accordance
with the marks,
- the suspended gearbox mounting (see 19D, Engi-
ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting )
- the upper engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting ),
102742
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ).
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm
),
- the front end panel lower mounting bolt ( 44 Nm
),
- the wheel mounting bolt ( 110 Nm ) ,
- the half sub-frame front mounting bolt ( 105 Nm
),
- the half sub-frame rear mounting bolt ( 321 Nm
).
Add the brake fluid to the brake fluid reservoir.
102419
IMPORTANT
Mark the suspended engine mounting in relation to
Correctly attach the brake hose and the sensor
the body.
wiring for the ABS system.
Remove: Do not twist the brake hose.
- the lower engine tie-bar,
Perform the following operations:
- the upper engine tie-bar. - bleed the clutch (see 37A, Mechanical compo-
nent controls): bleed the clutch circuit
- the suspended engine mounting,
- fill up the gearbox oil (see 05A, Draining-Refilling,
- the gearbox suspended mounting, Gearbox ),
Rotate the « engine and gearbox » assembly in or- - fill up the engine oil (see 05A, Draining-Refilling,
der to remove it. Engine ),
10A-69
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 800 or 808
- fill up the coolant (see 19A, Cooling, Cooling sys-
tem: Draining-refilling ).
CA or CAREG
Fill the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ).
Note:
Always initialise the xenon bulb system (if fitted
to the vehicle; see 80C, Xenon bulbs, Xenon
headlight: Adjustment ).
10A-70
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler:
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
pliers for cooling sys-
tem hose clips - refit the clip in the same recess in the event that
the hoses are not replaced,
Equipment required - it is essential to replace the hoses and/or the inter-
cooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak
filling station or come undone.
hydraulic crane
half sub-frame rear 21 Nm - the right and left-hand wheel arch liners,
mounting bolt
- the engine undertray.
battery cover bolts 4 Nm
Drain:
CA or CAREG
10A-71
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
1 102365
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
101212 Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
Remove:
5
4
102504
Remove:
10A-72
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
9
106275
7
102514
Remove:
- the fuel supply pipe (7)
- the fuel return pipe (8) .
WARNING
Follow the cleanliness guidelines closely (see
13B, Diesel injection, Cleanliness guidelines
).
10
Be aware of the residual pressure and the quan-
tity of diesel fuel in the pipes.
10A-73
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
16
15
14
11 12
13
109537 101822
Disconnect the hoses from the expansion bottle on Disconnect the computer connectors (15) .
the cooling radiator side (11) .
Remove the battery tray mounting bolts (16) .
Remove:
CA or CAREG
- the battery tray,
Disconnect the pressostat connector on the lower air
conditioning pipe on the condenser (12) . - the computer mounting.
Remove:
K9K, and 728
- the air conditioning pipes on the condenser (13) ,
Move the turbocharger pressure regulation solenoid
- the air conditioning pipe between the air conditio-
valve to one side.
ning compressor and the dehydration canister (14)
,
Note: Disconnect:
Plugs must be fitted to the hoses and the expan- - the air filter outlet duct,
sion valve to prevent moisture from entering the
- the flow meter connector (if fitted to the vehicle).
system.
10A-74
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
18
19
17
104553 104340
Remove the air filter unit (17) Disconnect:
- the pre-postheating unit (18) ,
- the earth strap on the body (19) .
20
101978 21
Disconnect the wiring harness connectors from the
relay board.
102263
Remove the brake servo pipe (20) .
Disconnect the heater radiator hoses from the scutt-
le panel (21) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
10A-75
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
B
22
A
C
102264 A
Disconnect the heater radiator hoses from the scutt-
le panel (2 2) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
101743
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
23
101699
Remove the gearbox controls (23) . 24
101701
Remove the clutch hydraulic control (24) .
10A-76
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
25
102008 101866
Remove:
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the half sub-frame (25) .
Position the hydraulic crane fitted with a load posi-
tioner or a chain.
102112
Remove:
10A-77
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 722 or 728
REFITTING
To replace the engine (see Technical Note 6006A, CA or CAREG
High pressure diesel engine « Common Rail » - 4
Fill the refrigerant circuit using the filling station
cylinder cast iron, 10A, Engine and peripherals, (see 62A Air conditioning, Maintenance ).
Normal replacement ).
Position the « engine and gearbox assembly » in the
vehicle.
Connect the battery (see 80A, Battery, Battery: Re-
Refit:
moval - Refitting ).
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ),
Note:
- the suspended gearbox mounting (see 19D, Engi-
Always initialise the xenon bulb system (if fitted
ne mounting, Suspended mounting ),
to the vehicle; see 80C, Xenon bulbs, Xenon
- the lower engine tie-bar (see 19D, Engine moun- headlight: Adjustment ).
ting, Suspended mounting ),
Bleed the cooling circuit (see 19A, Cooling, Coo-
- the front right-hand driveshaft (see 29A, Drives- ling circuit: Bleeding ).
hafts, Front right-hand driveshaft ),
Tighten to torque the battery cover bolts ( 4 Nm ) .
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm
),
- the front end panel lower mounting bolt ( 44 Nm
),
- the wheel mounting bolts ( 110 Nm ) ,
- the half sub-frame front mounting bolt ( 165 Nm
),
- the half sub-frame rear mounting bolt ( 21 Nm ) .
Add the brake fluid to the brake fluid reservoir.
IMPORTANT
Correctly attach the brake hose and the sensor
wiring for the ABS system.
Do not twist the brake hose.
10A-78
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
rounded bracket bolts 21 Nm - the front bumper (see MR 365, Bodywork, 55A,
with their spring Exterior protection, Front bumper ),
Drain:
half sub-frame rear 21 Nm
mounting nuts - the gearbox (see 05A, Draining-Refilling, Gear-
box ),
half sub-frame front 105 Nm
- the refrigerant circuit using the filling station (see
mounting bolts
62A, Air conditioning, Maintenance ).
intercooler upstream 5.5 Nm
hose
intercooler downs- 8 Nm
tream pipe on the air
inlet valve
10A-79
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
112658 112659
- the Protection and Switching Unit cover. - the mounting nut (8) from the wiring harness.
Move the wiring harness to one side.
Remove the battery tray.
102504
Remove:
10A-80
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
102365
Remove:
- the mounting bolts from the lower front end panel
(10) ,
- the front end panel.
115019
Drain the engine cooling system (see 19A, Cooling,
Remove the air inlet duct (12) .
Cooling system: Draining-refilling ).
115020
114659
Remove the air filter unit.
Remove the air resonator (11) .
10A-81
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
102473
Loosen the intercooler upstream hose clip (13) .
Disconnect the intercooler upstream hose.
112661
Disconnect:
- the fan unit resistor connector (14) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.
10A-82
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
Remove the cooling assembly.
Disconnect:
- the fuel supply pipe,
- the fuel return pipe from the diesel filter,
- the fuel return pipe.
WARNING
Follow the cleanliness guidelines closely (see
13B, Diesel injection, Cleanliness guidelines:
Precautions during repair ).
Watch out for diesel fuel splashing when discon-
necting the supply union.
115023
Remove the bolt (1 5) mounting the intercooler
downstream pipe on the cooling radiator.
Loosen:
- the clip (16) securing the intercooler downstream
pipe on the intercooler,
- the clip securing the intercooler downstream pipe
on the air inlet valve.
Move aside the intercooler downstream pipe on the
intercooler.
Disconnect:
- the cooling radiator top and bottom hoses using the
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- the hoses from the expansion bottle on the cooling
104340
radiator side (17) ,
Disconnect:
- the pressostat connector on the condenser lower
air conditioning pipe (18) . - the pre-postheating unit connector (21) ,
Release the wiring harness from the pressostat con- - the earth strap on the body (22) .
nector on the fan unit.
Remove:
- the air conditioning pipes from the condenser (19) .
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister (20)
.
Note:
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
10A-83
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
115003 101743
Remove the clutch hydraulic control pipe at the bulk- Unclip the lever cables on the gearbox:
head (23) .
- grip the gearbox control at (A) ,
Remove the brake assistance pipe from the vacuum
pump. - pull the pin at (B) ,
102008
Remove:
- the side reinforcement mounting bolts (25) ,
- the side reinforcements,
10A-84
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
- the half sub-frame.
114650
Remove:
- the rear mounting (28) (see 19D, Engine moun-
ting, Rear mounting: Removal and Refitting )
114991
10A-85
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114989
Position the (Mot. 1390) . REFITTING
Remove:
- the right-hand suspended mounting (see 19D, En- I - REFITTING OPERATION FOR PART
gine mounting, Right-hand suspended moun- CONCERNED
ting: Removal - Refitting ). Position:
- the mounting nut on the left-hand suspended - the right-hand suspended mounting in its housing,
mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ). - the « Engine and gearbox » assembly in the vehi-
cle.
Rotate the « engine and gearbox » assembly in or-
der to remove it. Refit:
- the right-hand suspended mounting (see 19D, En-
gine mounting, Right-hand suspended moun-
ting: Removal - Refitting ).
- the mounting nut on the left-hand suspended
mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ).
10A-86
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
II - FINAL OPERATION pe,
Refit: - the intercooler upstream hose,
- the rear mounting (see 19D, Engine mounting, - the intercooler downstream pipe.
Rear mounting: Removal - Refitting ).
Tighten to torque:
- the front right-hand driveshaft (see 29A, Drives-
- the intercooler upstream hose ( 5.5 Nm ) ,
hafts, Front right-hand driveshaft ),
- the intercooler downstream pipe ( 5.5 Nm ) ,
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ), - the intercooler downstream pipe on the air inlet
valve ( 8 Nm ) .
- the rounded bracket bolts with their spring.
Refit:
Tighten to torque the rounded bracket bolts with
their spring ( 21 Nm ) . - the air conditioning pipes to the condenser.
Refit: - the air conditioning pipe between the air conditio-
- the half sub-frame, ning compressor and the dehydration canister.
Tighten to torque:
- the half sub-frame mounting bolts,
- the air conditioning pipes on the condenser ( 8
- the half sub-frame mounting nuts.
Nm ) ,
Tighten to torque:
- the air conditioning pipe between the air condi-
- the half sub-frame rear mounting nuts ( 21 Nm ) tioning compressor and the dehydration canis-
, ter ( 8 Nm ) .
- the half sub-frame front mounting bolts ( 105 Secure the wiring harness to the pressostat connec-
Nm ) . tor on the fan unit.
Refit: Connect
- the gearbox controls, - the hoses from the expansion bottle on the cooling
radiator side,
- the fuse box,
- the pressostat connector on the condenser lower
- the relay box,
air conditioning pipe.
- the earth strap on the body,
- the fan unit resistor connector,
Connect:
- the fan unit connector.
- the pre-postheating unit connector,
Clip the fan unit wiring harness into place.
- the brake servo pipe from the vacuum pump,
Refit:
- the clutch hydraulic control pipe at the bulkhead,
- the Protection and Switching Unit mounting bolt,
- the heater radiator hose from the scuttle panel out-
- the air inlet duct,
let,
- the air resonator,
- the heater radiator hose from the scuttle panel out-
let using the (Mot. 1202-01) or (Mot. 1202-02) or - the front end panel,
(Mot. 1448) ,
- the front end panel lower mounting bolts,
- the fuel supply pipe,
- the front end panel upper mounting bolts,
- the fuel return pipe on the diesel filter,
- the clips.
- the fuel return pipe.
Tighten to torque:
Refit the cooling assembly.
- the front end panel upper mounting bolts ( 21
Connect: Nm ) ,
- the cooling radiator top and bottom hoses using the - the front end panel lower mounting bolts ( 44
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) , Nm ) .
- the mounting bolt to the intercooler downstream pi- Clip on the air inlet scoop.
10A-87
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
M9R, and 700
Refit:
- the battery tray, the injection computer and its
mounting,
- the battery tray mounting bolts,
Connect
- the computer connectors,
- the Protection and Switching Unit connectors.
Refit:
- the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper ),
10A-88
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler (F4R 776):
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
pliers for cooling sys-
tem hose clips - refit the clip in the same recess if the hoses are
not replaced,
Equipment required - it is essential to replace the hoses and/or the inter-
cooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak
filling station or come undone.
hydraulic crane
CA or CAREG
10A-89
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
1
102365
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
101212 Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
Remove:
- the battery (see 80A, Battery, Battery: Removal - F4R, and 770 or 771
Refitting ).
2 7
4 5
102504 101795
Disconnect the connectors (2) . Disconnect the fuel supply pipe (7) from the injector
rail.
Unclip the bonnet opening cable (3) .
Remove:
10A-90
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
10
13 11
12
8
106271
Disconnect:
- the injector rail (8) from the fuel supply pipe
109536
- the cooling radiator top hose using the (Mot. 1202-
Disconnect:
01) or (Mot. 1202-02) or (Mot. 1448) ,
- the fan unit connectors. - the turbocharging pressure sensor connector (10) ,
Unclip the wiring harness from the fan unit. - the air temperature sensor connector (11) ,
9
106275
Disconnect the intercooler hose (9) . 14
101807
10A-91
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
19 20
18
16
15
17
109537 101822
Disconnect the hoses from the cooling radiator ex- Disconnect the computer connectors (19) .
pansion bottle (15) .
Remove the battery tray mounting bolts (20) .
Remove the battery tray.
CA or CAREG
Disconnect the pressostat connector on the lower air
conditioning pipe from the condenser (16) .
Remove:
- the air conditioning pipes from the condenser (17) .
- the air conditioning pipe between the compressor
and the dehydration canister (18) .
Note:
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
10A-92
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
25
21
106280
106278
Remove the computer and its mounting (25) .
24
22
23
106632
104553
Move the fuel vapour recirculation solenoid valve to
Remove the air filter unit.
one side (21) .
10A-93
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
27
101978
Disconnect the wiring harness connectors from the
relay board. 101812
Remove the brake servo pipe (27) .
Disconnect the downstream oxygen sensor connec-
tor.
26
28
111051
Disconnect the earth strap (26) .
106787
Remove the brake servo pipe (28) .
10A-94
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
29
30
A
104240 101743
Disconnect hoses (29) and (30) using the (Mot. Unclip the two gear lever cables on the gearbox:
1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- grip the gearbox control at (A) ,
F4R, and 770 or 776
- pull the pin at (B) ,
33
31
101699 32
Remove the control cables from the gearbox (31) .
103409
Remove:
10A-95
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
- the multifunction switch cable (33) by loosening the
sleeve stop.
34
102008
Remove:
33
- 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 ),
101740
- the exhaust downpipe mountings,
Place a cloth under the master cylinder.
- the lower engine tie-bar,
Remove the clip (33) from the union on the master
cylinder return. - the upper engine tie-bar.
Disconnect the pipes from the slave cylinder. - the half sub-frame (34) .
Fit plugs into the openings. Position the hydraulic crane fitted with a load posi-
tioner or a chain.
Withdraw the slave cylinder feed pipes.
10A-96
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
102742
Mark the suspended engine mounting in relation to
the body.
103273
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 6027A, Petrol engine - 4 cy-
linders - F4, 10A, Engine and peripherals, Nor-
mal replacement ).
Refit:
Remove the suspended gearbox mounting. - the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting ),
10A-97
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F4R, and 770 or 771 or 776
- the front left-hand driveshaft (see 29A, Drives- Tighten to torque the battery cover mounting bolts
hafts, Front left-hand driveshaft ). ( 4 Nm ) .
Proceed in the reverse order to removal.
Tighten to torque: Note:
Be sure to initialise the xenon bulb system (if fit-
- the front end panel upper mounting bolt ( 21 Nm
ted to the vehicle) see 80C, Xenon bulbs,
),
Xenon headlights: Adjustment ).
- the front end panel lower mounting bolt ( 44 Nm
), Adjust the headlights (see 80B, Headlights,
Halogen headlights: Adjustment ).
- the wheel bolts ( 110 Nm ) ,
- the wheel bolt (F4R 776) ( 130 Nm ) ,
IMPORTANT
Correctly attach the flexible brake pipe and ABS
sensor wiring.
Do not twist the brake hoses.
CA or CAREG
Fill the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ).
10A-98
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler:
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
pliers for cooling sys-
tem hose clips - refit the clip in the same recess if the hoses are
not replaced,
Equipment required - it is essential to replace the hoses and/or the inter-
cooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak
filling station or come undone.
hydraulic crane
CA or CAREG
10A-99
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
1
102365
Remove:
- front end panel mounting bolts (6) ,
- the front end panel.
101212 Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
Remove:
4 5
102504
Remove:
10A-100
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
106275
7
8
102514
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
WARNING
Follow the cleanliness guidelines closely (see
10
13B, Diesel injection, Cleanliness guidelines
).
Be aware of the residual pressure and the quan-
tity of diesel fuel in the pipes.
10A-101
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
14
15
11
12
101807
Remove the air filter outlet duct (15) .
13
109537
Disconnect the hoses from the cooling radiator ex-
pansion bottle (11) .
CA or CAREG
Disconnect the pressostat connector on the lower air 16
conditioning pipe from the condenser (12) .
17
Remove:
- the air conditioning hoses from the condenser (13)
,
- the air conditioning hose between the air conditio-
ning compressor and the dehydration canister (14)
.
101822
Note:
Disconnect the computer connectors (16) .
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the Remove the battery tray mounting bolts (17) .
system.
Move the turbocharger pressure solenoid valve to
one side.
Remove:
Remove the cooling radiator assemblies. - the battery tray,
- the computer and its support.
Disconnect the flowmeter connector (if fitted to the
vehicle).
10A-102
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
104245 104553
- the relay,
- the fuse box,
20
21
18
103409
Remove:
19
- the multifunction switch cable ball joint (20) ,
10A-103
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
22
23
25
26
110681 103749
Disconnect: Remove:
- the pre-postheating unit (22) , - the exhaust mounting nuts (25) ,
- the automatic transmission computer connector - the lower engine tie-bar (26) .
(23) .
24
103413
Open the gearbox computer wiring harness moun-
ting bracket (24) .
10A-104
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
27
102008 102114
Remove:
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-
hafts, Front left-hand driveshaft ),
- the half sub-frame (27) .
Position the hydraulic crane fitted with a load posi-
tioner .
103273
Remove:
10A-105
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 729, and DP0
REFITTING
To replace the engine (see Technical Note 6006A, CA or CAREG
High pressure diesel engine « Common Rail » - 4
Fill the refrigerant circuit using the filling station
cylinder cast iron, 10A, Engine and peripherals, (see 62A Air conditioning, Maintenance ).
Normal replacement ).
- the front left-hand driveshaft (see 29A, Drives- Adjust the headlights (see 80B, Headlights,
hafts, Front left-hand driveshaft ). Halogen headlights: Adjustment ).
Proceed in the reverse order to removal.
Tighten to torque:
IMPORTANT
Correctly attach the flexible brake pipe and ABS
sensor wiring.
Do not twist the brake hoses.
10A-106
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
REMOVAL
Special tooling required
Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1202-01 Clip pliers for cooling ting equipment, Underbody lift ).
system hose clips
(large model)
IMPORTANT
Mot. 1202-02 Pliers for small hose During this operation, secure the vehicle to the
clips lift with a safety belt , to avoid any imbalance.
Mot. 1448 Remote operation clip Remove:
pliers for cooling sys-
tem hose clips - the engine covers,
- the front wheels,
Equipment required
- the right-hand and left-hand wheel arch liners,
safety belt - the engine undertray.
filling station Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-
hydraulic crane
box ),
load positioner - the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:
Tightening torquesm Removal - Refitting ).
101212
Remove:
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
10A-107
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper ).
7
2
5
4 101802
Disconnect the fuel supply union (7) .
Disconnect:
102504
- the cooling radiator top hose using the (Mot. 1202-
Disconnect the connectors (2) .
01) or (Mot. 1202-02) or (Mot. 1448) .
Unclip the bonnet opening cable (3) .
- the fan unit connectors,
Remove:
Unclip the wiring harness from the fan unit.
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
11
6
8 9
10
102365
Remove:
109537
- front end panel mounting bolts (6) , Disconnect the hoses from the cooling radiator ex-
- the front end panel. pansion bottle (8) .
Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining-refilling ).
10A-108
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
CA or CAREG
Disconnect the pressostat connector on the lower air
conditioning pipe from the condenser (9) .
Remove:
- the air conditioning pipes from the condenser (10) .
- the air conditioning pipe between the compressor
13
and the dehydration canister (11) . 14
Note:
Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
101103
Remove:
- the air resonator mounting bolt (12) ,
- the air resonator.
101978
Disconnect the wiring harness connectors from the
relay board.
10A-109
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
17 18
15
111051 104240
Disconnect the earth strap from the body.
Disconnect:
16 B
C
101812 A
Remove the brake servo pipe (16) .
101743
10A-110
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
19 21
101699 102008
Remove the gearbox controls (19) . Remove:
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the half sub-frame (21) .
Position the hydraulic crane fitted with a load posi-
tioner or a chain.
20
101740
Pull out clip (20) .
Disconnect the hydraulic clutch supply pipes.
Note:
Plug the pipes to prevent fluid from escaping.
10A-111
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 3784A, Petrol engine - 4 cy-
linders - K4, 10A, Engine and peripherals, Nor-
mal replacement ).
Position the « engine and gearbox assembly » in the
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engi-
ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting ),
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ),
Remove the « engine and gearbox assembly » . Do not twist the brake hose.
10A-112
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K4J, and 730 or 732
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Blee-
ding the cooling circuit: ).
CA or CAREG
Fill the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ).
Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the xenon bulb system (see
80C, Xenon bulbs, Xenon headlights: ).
Adjustment ).
10A-113
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler:
(large model) - detach the hose, using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose - do not use a degreaser, brake cleaning product, or
clips any other product,
- clean the intercooler bearing face and the hose
Mot. 1448 Remote operation clip
using a dry, lint-free cloth,
pliers for cooling sys-
tem hose clips - refit the clip in the same recess if the hoses are
not replaced,
Mot. 1390 Support for removing
and refitting the - it is essential to replace the hoses and/or the inter-
engine and gearbox cooler if they are damaged.
assembly If this procedure is not followed the hoses may leak
or come undone.
Equipment required
Tightening torquesm
IMPORTANT
front end panel upper 21 Nm During this operation, strap the vehicle to the lift
mounting bolt using a safety belt , to avoid any imbalance.
CA or CAREG
Drain the refrigerant circuit using the filling station
(see 62A, Air conditioning, Maintenance ).
10A-114
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
Remove:
- the battery (see 80A, Battery, Battery: Removal - CA or CAREG
Refitting ).
Disconnect the pressostat connector from the lower
- the scuttle panel grille (see MR 371 Bodywork, air conditioning pipe on the condenser.
55A, Exterior protection, Scuttle panel grille ). Remove:
- the two air conditioning pipes from the condenser,
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister.
2
Note:
1 Plugs must be fitted to the hoses and the expan-
sion valve to prevent moisture from entering the
system.
4
3
Remove:
- the clip (3) ,
6
- the fastening (4) .
102365
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
101212
Remove:
- the half sub-frame side reinforcements (5) ,
- the front bumper (see MR 371, Bodywork, 55A,
Exterior protection, Front bumper ).
10A-115
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
7
10
104338 106275
Remove: Disconnect.
- the fuel supply pipe (7) , Disconnect:
- the fuel return pipe (8) . - the intercooler hose (10)
- the cooling radiator top hose using the (Mot. 1202-
WARNING 01) or (Mot. 1202-02) or (Mot. 1448) .
Follow the cleanliness guidelines closely (see - the fan unit connectors,
13B, Diesel injection, Cleanliness guidelines
- the hoses from the expansion bottle on the cooling
).
radiator side.
Watch out for diesel fuel splashing when discon-
Unclip the wiring harness from the fan unit.
necting the supply union.
11
102473
Disconnect the duct (11) .
10A-116
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
12
13
17
16
102500 104245
Disconnect the connector (12) . Remove:
Remove the air filter outlet duct (13) . - the Protection and Switching Unit mounting bolt,
14
15
19
18
101822
Disconnect the computer connectors (14) .
Remove:
- the battery tray mounting bolts (15) ,
- the battery tray,
104340
- the computer mounting.
Remove:
10A-117
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
20
23
21
104322 101740
Remove the brake servo pipe (20) from the vacuum Pull the clip (23) from the clutch pipes.
pump.
Disconnect the hydraulic clutch supply pipes.
Disconnect the heater radiator hoses (21) from the
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) . Note:
Plug the pipes to prevent fluid from escaping.
24
22
104085
Remove the gearbox controls (2 2) , using a
102008
screwdriver.
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-118
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (24) .
111879
102742
111880
Position the (Mot. 1390) .
102419
Remove:
10A-119
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 804
IMPORTANT
Correctly attach the flexible brake pipe and ABS
sensor wiring.
Do not twist the brake hoses.
10A-120
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
Mot. 1202-01 Clip pliers for cooling Procedure for removing the air inlet duct on the
system hose clips intercooler (there is a danger of leakage and dislo-
(large model) cation if this procedure is not complied with):
- detach the hose using the (Car. 1363) ,
Mot. 1202-02 Pliers for small hose
clips - do not use a degreaser, brake cleaning product, or
any other product,
Mot. 1448 Remote operation clip
- clean the bearing face on the intercooler and on
pliers for cooling sys-
the hose with a dry, lint-free cloth,
tem hose clips
- always replace the clip with a new one,
Mot. 1390 Support for removing
and refitting the - replace the new clip in the same position if the
engine and gearbox hose is not replaced,
assembly - it is essential to replace the hose and/or the inter-
cooler if they are damaged,
Equipment required
half sub-frame front 105 Nm Position the vehicle on a two-post lift (see 02A, Lif-
mounting bolt ting equipment, Underbody lift ).
Drain:
CA or CAREG
10A-121
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
102504
Remove:
101212
- the relay plate cover.
102365
Remove:
10A-122
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
106275
112656
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
WARNING
- Follow the cleanliness guidelines closely.
- Beware of diesel fuel splashing when discon-
necting the supply unions.
112661
Disconnect:
- the hoses from the intercooler (9) ,
- the radiator top hose, using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) .
- the fan unit resistor connector (10) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.
10A-123
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
109537 101822
Disconnect the hoses from the cooling radiator ex- Disconnect the computer connectors (15) .
pansion bottle (11) .
Unclip:
- the wiring harness from the battery negative termi-
CA or CAREG nal,
Disconnect the pressostat connector from the lower - the wiring harness.
air conditioning pipe on the condenser. (12)
Remove:
Remove:
- the battery tray mounting bolts (16) ,
- the air conditioning pipes from the condenser (13) .
- the battery tray with the computer and its support.
- the air conditioning pipe between the air conditio-
ning compressor and the dehydration canister (14) Move the turbocharger pressure solenoid valve to
. one side.
Disconnect:
Note: - the connector from the flowmeter,
Plugs must be fitted to the hoses and the expan- - the air duct between the air filter unit and the turbo-
sion valve to prevent moisture from entering the charger.
system.
10A-124
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
112657
101978
Disconnect the wiring harness connectors from the
relay board.
104553
Loosen the air filter unit upstream air duct retaining
tabs slightly (17) .
Remove:
- the air filter unit upstream air duct,
- the air filter unit (18) .
104340
Disconnect:
- the pre-postheating unit connector (19) ,
- the earth strap from the body (20) .
10A-125
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
112946 101743
Remove the brake servo pipe (21) from the vacuum Remove the gearbox controls.
pump.
Disconnect: WARNING
- the heating radiator hose from the scuttle panel Do not touch the gearbox control slides.
(22) using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) ,
- the heating radiator hose (23) using the (Mot.
1202-01) or (Mot. 1202-02) or (Mot. 1448) .
101740
Pull clip (24) .
Disconnect the clutch hydraulic control.
Remove:
- the lower engine tie-bar,
- the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ),
10A-126
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the half sub-frame.
112814
112813
Position the (Mot. 1390) .
10A-127
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
Rotate the engine and gearbox assembly in order to
remove it.
Remove the engine and gearbox assembly.
REFITTING
10A-128
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
Connect:
- the earth strap on the body, Refit the fan unit wiring harness.
10A-129
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
K9K, and 732
CA or CAREG
Fill the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ).
10A-130
ENGINE AND LOWER ENGINE ASSEMBLY
Engine speed and position sensor: Removal - Refitting 10A
M9R, and 700
IV - FINAL OPERATION
REMOVAL
114979
10A-131
ENGINE AND LOWER ENGINE ASSEMBLY
Crankshaft seal at timing end Removal - Refitting 10A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
REMOVAL
Remove:
101212
Remove:
10A-132
ENGINE AND LOWER ENGINE ASSEMBLY
Crankshaft seal at timing end Removal - Refitting 10A
M9R, and 700
114850
113656
Position the sealing ring notches opposite the not-
ches in the timing cover.
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
114851
Engage the sealing ring notches in the timing cover
notches.
Tighten the sealing ring by hand using the tool sup-
plied in the new gasket spare parts kit.
10A-133
ENGINE AND LOWER ENGINE ASSEMBLY
Crankshaft seal at timing end Removal - Refitting 10A
M9R, and 700
114852
Using tool supplied in the new gasket spare parts kit
tighten to torque the crankshaft timing end sea-
ling ring ( 47 Nm ) .
10A-134
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, and
K9K, and 722 or 728 or 729 or 732, and CA or CAREG
Tightening torquesm
IMPORTANT
Wear protective gloves during every operation.
1
WARNING
Never turn the engine in the opposite direction to its
normal operation.
101212
Remove the right-hand side reinforcement (1) .
WARNING
It is imperative to replace the accessories belt and
the tensioning rollers.
WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft and the accesso-
ries pulley.
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove:
- the engine covers,
101878
- the front right-hand wheel,
Turn the accessories belt auto tensioner clockwise
- the front right-hand wheel arch liner. using a 16 mm spanner.
Remove:
- the accessories belt,
- the tensioning roller.
11A-1
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, and
K9K, and 722 or 728 or 729 or 732, and CA or CAREG
REFITTING
Use a brush to remove any deposits from the
crankshaft pulley V-grooves.
Refit the tensioning roller.
Tighten to torque the tensioning roller mounting
bolt ( 40 Nm ) .
22
106000
WARNING
The accessories belt has five teeth, but the air
conditioning compressor pulley has six grooves.
When fitting the accessories belt, it is essential to
check that the groove (2) remains free.
11A-2
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, and
CHAUFO
- the front right-hand wheel,
Special tooling required
- the front right-hand wheel arch liner.
Mot. 1638 Accessories belt ten-
sioning tool
Tightening torquesm
IMPORTANT 101212
Wear protective gloves during the operation. Remove the side reinforcement (1) .
Loosen the tensioning roller bracket mounting bolts.
Remove:
WARNING
- the accessories belt,
Never turn the engine in the opposite direction to its
normal operation. - the tensioning roller.
REFITTING
WARNING Use a brush to remove any deposits from the
It is imperative to replace the accessories belt and crankshaft pulley V-grooves.
the tensioning rollers.
WARNING
- The two Torx mounting bolts of the tensioning
WARNING roller must be replaced by M8 x 20 bolts (part
number 77 03 002 059 ).
Do not run the engine without the accessories belt
to avoid damaging the crankshaft and the accesso- Refit the accessories belt.
ries pulley.
Refit the tensioning roller fitted with new bolts.
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Remove:
- the engine covers,
11A-3
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, and
CHAUFO
20845
WARNING
The accessories belt has five teeth, but the pul-
leys have six grooves. It is essential to check that
21861
groove (2) remains free when the belt is fitted.
Tension the accessories belt using the (Mot. 1638)
by tightening nut (3) (with the two tensioning roller
mounting bolts loosened).
Check (4) and using the (Mot. 1505) or the (Mot.
1715) , that the accessories belt tension is between
223 and 245 Hz .
It is essential to turn the engine through two revolu-
tions to position the accessories belt correctly.
Check that the accessories belt tension is between
223 and 245 Hz at the measuring point (4) . If not,
readjust the tension.
Tighten to torque the tensioning roller mounting
bolt ( 35 Nm ) .
Proceed in the reverse order to removal
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
11A-4
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
Tightening torquesm
IMPORTANT
Wear gloves throughout the operation. 1
WARNING
Never turn the engine in the opposite direction to its
normal operation.
101212
WARNING
It is imperative to replace the accessories belt and
the tensioning rollers.
WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft and the accesso-
ries pulley.
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove:
- the engine covers, 104339
- the front right-hand wheel, Turn the accessories belt auto tensioning roller anti-
clockwise using a 16 mm spanner.
- the front right-hand wheel arch liner.
Remove:
REFITTING
Use a brush to remove any deposits from the
crankshaft pulley V-grooves.
11A-5
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
Tighten to torque the tensioning roller mounting
bolt ( 50 Nm ) .
Rotate the crankshaft twice to position the accesso-
ries belt correctly.
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover bolts ( 4 Nm ) .
11A-6
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
M9R, and 700
- the right-hand side reinforcement from the half sub-
Special tooling required frame cross member (1) .
Mot. 1770 Crankshaft pulley loc-
king tool II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
REMOVAL
Remove the engine undertray. Place a 3 mm Allen key in the tensioning roller hole
(2) .
Move accessories belt tensioning pulley clockwise
until the Allen key is fully inserted.
Remove the accessories belt.
101212
Remove:
- the front right-hand wheel,
- the front right-hand wheel arch liner;
- the right-hand side reinforcement mounting bolts
on the half sub-frame cross member,
11A-7
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
M9R, and 700
114856 114849
Remove: Remove:
- the tensioning roller mounting bolts (3) , - the crankshaft accessories pulley mounting bolt
using the (Mot. 1770) (1) ,
- the tensioning roller.
- the washer,
- the crankshaft accessories pulley.
114857
Remove:
- the fixed roller mounting bolt plastic cover (4) ,
- the fixed roller mounting bolts (5) ,
- the fixed roller (6) .
11A-8
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
M9R, and 700
11A-9
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
M9R, and 700
III - FINAL OPERATION
Refit:
- the right-hand side reinforcement from the half sub-
frame cross member.
- the right-hand side reinforcement mounting bolts
on the half sub-frame cross member,
- the front right-hand wheel arch liner;
- the front right-hand wheel.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
11A-10
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
11A-11
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
WARNING
When replacing the belt, be sure to replace the ten-
sioning rollers and fixed rollers.
Note:
The timing belt procedure is the same for engines
with or without camshaft dephasers
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif- 102450
ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove:
- the engine undertray,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
102451
Position the (Mot. 1453) and the (Mot. 1453-01) with
retaining straps.
11A-12
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
101866 101103
Mark the suspended engine mounting in relation to Remove:
the body.
- the air resonator mounting,
Remove:
- the air resonator,
- the « engine and suspended engine mounting »
assembly,
- the lower engine tie-bar.
WARNING
Do not damage the air conditioning pipe.
14491
11A-13
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
ADJUSTING THE TIMING
14490
14491-1 Check that the camshaft grooves are horizontal and
Position the camshaft grooves (2) almost horizontal- offset downwards.
ly and offset downwards, turning the crankshaft in its
normal operating direction (timing end clockwise).
Screw in the TDC setting pin (3) (Mot. 1489) .
14487
Remove:
- the crankshaft accessories pulley (4) , locking the
14489 flywheel with a screwdriver,
Turn the crankshaft in its operating direction (timing
- the upper timing cover (5) ,
end clockwise), until the crankshaft comes into con-
tact with TDC setting pin. - the lower timing cover (6) .
11A-14
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
REFITTING - PROCEDURE 1
7 WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the fixed
roller.
WARNING
101872
Undo the nut (7) on the tensioning roller to slacken Be sure to degrease:
the timing belt.
- the end of the crankshaft (timing end),
Remove:
- the timing sprocket bore and contact surfaces,
- the fixed roller (8) using the (Mot. 1368) ,
- the contact surfaces of the crankshaft and
- the timing belt, taking care not to drop the cranks- accessories pulley.
haft sprocket,
This is to avoid timing slippage.
- the timing sprocket,
This slippage causes engine damage.
- the tensioning roller.
14490
11A-15
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
111337 14489
Fit the (Mot. 1496) with the (Mot. 1750) (9) .
108875
11A-16
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
2 - REFITTING
14487-2
108879 Tighten to torque the fixed roller mounting bolt (
Refit the tensioning roller by positioning the tensio- 45 Nm ) using the (Mot. 1368) .
ning roller lug in rib (12) .
3 - BELT TENSION
14487-3
Refit: 103263
- the crankshaft timing sprocket (13) , Using a 6 mm Allen key, bring the adjustable index
(15) opposite the notch (16) , by turning the eccen-
- the timing belt,
tric (17) clockwise.
- the fixed roller (14) .
11A-17
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
Tighten to torque the tensioning roller mounting 4 - CHECKING THE TIMING AND TENSION
nut ( 27 Nm ) .
103263
11A-18
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
II - PROCEDURE FOR ENGINES FITTED WITH
TIMING COVER WITH FLAP
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the fixed
roller.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
14490 - the timing sprocket bore and contact surfaces,
Fit the camshaft adjusting tool (Mot. 1496) without - the contact surfaces of the crankshaft and
forcing (the camshaft grooves must be horizontal accessories pulley.
and below the centre line).
This is to avoid timing slippage.
This slippage causes engine damage.
WARNING
The timing adjustment and tensioning operation
must be repeated if the camshaft setting tool
does not engage.
14490
Set the camshaft grooves horizontally and below the
centre line by turning the camshafts with the (Mot.
799-01) , if necessary.
11A-19
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
111337 14489
Fit the (Mot. 1496) with the (Mot. 1750) (21) .
108875
11A-20
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
2 - REFITTING 3 - TIMING BELT TENSION
108879
103263
Refit the tensioning roller by positioning the tensio-
ning roller lug in rib (24) . Bring the adjustable index (26) opposite the notch
(27) , by turning the eccentric (28) clockwise using a
Refit the crankshaft timing sprocket. 6 mm Allen key.
Tighten to torque the tensioning roller mounting
nut ( 27 Nm ) .
14487-3
Refit:
109054
- the timing belt, Refit the lower timing cover.
11A-21
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
Rotate the crankshaft twice in a clockwise direction,
on the timing end, before aligning the markings (on
the camshaft dephaser) already made by the opera-
tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
Move the crankshaft slowly and smoothly to rest on
the TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
109055
109052
Remove:
11A-22
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
4 - CHECKING THE TIMING AND TENSION
103263
11A-23
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
REFITTING -PROCEDURE 2
WARNING
If the stud is loosened with the nut (see NT
3887A, Replacing camshaft pulley studs K9 -
K4, 11A, Top and front of engine, Camshaft ).
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the fixed
roller.
14490
WARNING
Fit (without forcing) the camshaft setting tool (Mot.
1496) (the camshaft grooves must be horizontal and Be sure to degrease:
offset towards the bottom). - the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
109052
11A-24
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
14490 111337
Fit the (Mot. 1496) with the (Mot. 1750) (34) .
103261
Position the camshaft grooves horizontally and off- 111336
set downwards, by turning the camshafts with the
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
(Mot. 1496) if necessary.
end of the camshafts
Remove the old camshaft pulley nuts and replace
them with new ones (without tightening the nuts: 0.5
to 1 mm play between nuts and pulleys).
11A-25
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
II - REFITTING
14489
108879
Refit the tensioning roller by positioning the tensio-
ning roller lug in groove (38) .
14487-1
Check that the crankshaft is in contact with the TDC
setting pin (Mot. 1489) (35) (crankshaft groove (36)
should be at the top). 14487-3
Position the RENAULT badge (37) etched on the Refit:
camshaft pulley spokes vertically at the top.
- the timing sprocket (39) ,
- the timing belt on the camshaft pulleys (without mo-
ving the camshaft pulleys).
11A-26
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
III - BELT TENSION
101876
Fit the camshaft pulley locking tool (Mot. 1490-01) 103263
(40) (use the timing cover mountings to mount the Using a 6 mm Allen key, bring the adjustable index
tool). (42) in line with the notch (43) , by turning the eccen-
tric (44) clockwise.
Tighten to torque the tensioning roller mounting
nut ( 27 Nm ) .
Remove camshaft pulley locking tool (Mot. 1490-01)
.
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pul-
leys. In addition, from time to time, press the
camshaft pulleys against the camshafts.
14487-3
Refit the fixed roller (41) .
Tighten to torque the fixed roller mounting bolt (
45 Nm ) using the (Mot. 1368) .
Refit the crankshaft accessories pulley (without tigh-
tening the bolt, 2 to 3 mm play between bolt and pul-
ley).
11A-27
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
103263 14489
Remove:
screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
11A-28
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4J, and 730 or 732
Check the tensioning roller indexes are aligned; if REFITTING
not readjust the tension by loosening the tensioning
roller eccentric by a single turn. Refit the TDC setting pin plug, applying a drop of
JOINT SILICONE ADHERENT onto the thread hole.
Correctly align the adjustable index with the fixed in-
Tighten to torque the TDC setting pin plug ( 20 Nm
dex or the notch (depending on the type of tensio-
).
ning roller).
Refit the lower timing cover.
Tighten to torque the tensioning roller mounting
nut ( 27 Nm ) . Refit the upper timing cover.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
15103-1
Refit:
Fit the camshaft adjusting tool (Mot. 1496) without - new inlet camshaft sealing plugs (Mot. 1487) ,
forcing (the camshaft grooves must be horizontal - new exhaust camshaft sealing plugs (Mot. 1488) .
and offset downwards).
Proceed in the reverse order to removal.
Remove the TDC setting pin. - the battery cover mounting bolts ( 4 Nm ) .
11A-29
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
REMOVAL
Special tooling required
Position the vehicle on a two-post lift (see 02A, Lif-
Mot. 1453 Multiple-adjusting ting equipment, Underbody lift ).
engine mounting sup-
port with retaining Disconnect the battery (see 80A, Battery, Battery:
straps Removal - Refitting ).
Remove the accessories belt (see 11A, Top and
Mot. 1453-01 Additional winder nut front of engine, Accessories belt: Removal - Re-
on engine lift support fitting ).
Mot. 1453
Tightening torquesm
WARNING
Never turn the engine in the opposite direction to its
normal operation.
102451
Position the (Mot. 1453) and (Mot. 1453-01) with re-
taining straps.
11A-30
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
102115
102114
WARNING
Do not damage the air conditioning pipe.
11A-31
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19654
Remove the upper timing cover by unclipping the
tabs (3) .
11A-32
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19654-1
Remove:
- the cylinder marking sensor on the high pressure
pump (4) ,
- the plastic bolt (6) .
Unclip the tabs (5) .
Remove the lower timing cover.
11A-33
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19654-2
Remove the cylinder head suspended mounting. Positioning the timing at the adjustment point
7 8
19702
19650
Rotate the crankshaft clockwise (timing end) to posi-
Remove the TDC setting pin plug. tion the hole (8) in the camshaft pulley partially in
line with the hole (9) in the cylinder head.
11A-34
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19650-1 19655
Screw in the TDC setting pin (1) (Mot. 1489) . Insert the pin (2) (Mot. 1430) in the camshaft pulley
and cylinder head holes.
Remove:
- the pin (Mot. 1430) ,
- the TDC setting pin (Mot. 1489) .
14489-1
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft comes in contact with the TDC
setting pin (Mot. 1489) .
11A-35
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19656
Remove the crankshaft accessories pulley, locking
the flywheel with a screwdriver.
11A-36
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
10
19656-1
Undo the tensioning roller bolt (10) to slacken the ti- REFITTING
ming belt.
Remove:
WARNING
- the timing belt (take care not to drop the crankshaft
sprocket), It is imperative to replace the timing belt, the ten-
sioning roller and the accessories pulley bolt.
- the timing sprocket,
- the tensioning roller.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft accesso-
ries pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
11A-37
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19710
Refit the crankshaft timing sprocket.
11A-38
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
I - ADJUSTING THE TIMING
2 14
13
12
11
15
19656-2
Note:
Check that the tensioning roller lug (11) is cor-
rectly positioned in the groove (12) .
14489
11A-39
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
16
19657 19658
Fit the new timing belt, aligning the marks on the belt Position the tensioning roller adjustable index (16)
with those on the camshaft sprockets and the high opposite the lug using a 6 mm Allen key, turning it
pressure pump. anticlockwise.
Tighten to torque the tensioning roller bolt ( 25 Nm
Note: ).
19 belt tooth spaces between the camshaft Refit the crankshaft accessories pulley.
sprocket and pump marks. Tighten to torque and angle (crankshaft in contact
with the TDC setting pin):
- crankshaft accessories pulley M12 mounting
bolt ( 60 Nm + 100˚ ± 10˚ ) ,
- crankshaft accessories pulley M14 mounting
bolt ( 120 Nm + 95˚ ± 15˚ ) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
11A-40
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19
20
18
17
19702 19655
Rotate the crankshaft clockwise through two revolu- Check:
tions (timing end).
- that the timing pin (Mot. 1430) engages properly in
Before the camshaft pulley hole (17) comes in line the camshaft and cylinder head holes,
with the cylinder head hole (18) , screw the TDC set-
- that there are 19 belt tooth spaces between the
ting pin (Mot. 1489) into the cylinder block.
camshaft sprocket mark (19) and the high pressure
Bring the crankshaft slowly and smoothly into con- pump sprocket mark (20) .
tact with the pin.
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
11A-41
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
21
23
111083 111082
23
24
111081 111081
Loosen the tensioning roller bolt by no more than Loosen the tensioning roller bolt by no more than
one turn, holding it with a 6 mm Allen key. one turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index (21) , turning Gradually align the adjustable index (23) , turning
the Allen key anticlockwise, to the middle of the timi- the key clockwise, to the middle of the timing window
ng window (22) . (24) .
11A-42
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
II - REFITTING
Tighten to torque the tensioning roller mounting
bolt ( 25 Nm ) .
Refit the TDC setting pin plug, applying JOINT SILI-
CONE ADHERENT to the thread hole.
Tighten to torque the TDC setting pin plug ( 20 Nm
).
19654-2
Refit the cylinder head suspended mounting.
Tighten to torque the cylinder head suspended
mounting bolts ( 21 Nm ) .
11A-43
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19654-1
25
26
19659
Refit the lower timing cover, positioning the tab (25)
in the lower timing cover aperture (26) .
11A-44
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 722 or 728 or 729
19654
Refit:
- the upper timing cover,
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ) in accordance
with the marks,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
.
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
11A-45
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
Tightening torquesm
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Remove:
- the engine undertray,
- the accessories belt (see 11A, Cylinder head, Ac-
cessories belt: Removal - Refitting ).
11A-46
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
102420 15102
Remove:
Remove:
- the upper engine tie-bar.
- the TDC setting pin plug.
- the lower engine tie-bar.
Mark the position of the suspended engine mounting - the flywheel guard cover plate.
in relation to the body.
Slacken the bolt (1)
Remove the suspended engine mounting.
WARNING
Do not damage the air conditioning pipes (if fitted
to the vehicle).
104739
Remove:
11A-47
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
ADJUSTING THE TIMING
104326
104329 Undo the tensioning roller mounting nut (3) to slac-
Rotate the crankshaft clockwise (timing end); bring ken the tensioning roller.
the camshaft pulley mark to half a tooth before the
Remove the timing belt.
mark on the guard.
REFITTING
WARNING
Replace the timing belt, the tensioning roller, the
crankshaft accessories pulley and bolt.
104330
When the mark on the camshaft pulley is half a tooth
before the mark on the guard, press in the TDC set-
ting pin (Mot. 1054) until the crankshaft is timed.
11A-48
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
104336 104327
Refit the tensioning roller, taking care to position it Fit the new timing belt, aligning the marks on the belt
correctly on the locating pin (4) . with those on the crankshaft, camshaft and high
pressure pump sprockets (count 28 belt tooth spa-
ces between the mark on the camshaft sprocket and
the mark on the high pressure pump sprocket).
6 6 Press the tensioning roller against the belt by tighte-
ning the bolt (8) on the tensioning roller mounting.
Note:
16187
Note:
The crankshaft groove (5) must be in the middle
of the two ribs (6) on the crankshaft guard plate.
The crankshaft timing sprocket mark (7) should
be offset one tooth to the left of the vertical axis
of the engine.
11A-49
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
16563 104332
Pretension the timing belt between the crankshaft ti-
ming sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of
(11 Nm) .
104331
Mount the timing belt pretensioning tool (Mot. 1543)
fitted with the cover (Mot. 1705) (9) on the cranks-
haft accessories pulley bolt.
11A-50
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F9Q, and 800 or 804 or 808
10
104333 105435
Position the sensor of the (Mot. 1505) o r (Mot.
Remove the crankshaft accessories pulley bolt.
1715) between the crankshaft sprocket and the ten-
sioning roller.
Refit the crankshaft accessories pulley, without se-
Tension the belt to obtain the recommended value parating its two component parts.
90 ± 3 Hz by turning the bolt (10) .
Tighten to torque and angle the crankshaft acces-
Tighten to torque the tensioning roller mounting
sories pulley mounting bolt ( 40 Nm + 110˚ ± 10˚ )
nut (10 Nm) .
.
Turn the crankshaft through two revolutions.
Refit:
Reposition the TDC setting pin (Mot. 1054) .
Position the timing at its setting point (start pressing - the suspended engine mounting (see 19D, Engine
on the pin half a tooth before alignment of the cams- mounting, Suspended mounting ),
haft pulley mark and the cover plate mark, to avoid
going into a camshaft balancing hole). - the upper engine tie-bar (see 19D, Engine moun-
ting, Suspended mounting ),
Remove the TDC setting pin (Mot. 1054) .
Refit the TDC setting pin plug, applying a drop of - the lower engine tie-bar (see 19D, Engine moun-
RHODORSEAL 5661 onto the thread. ting, Suspended mounting ),
Tighten to torque the TDC setting pin plug ( 20 Nm
). - the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
Apply a pretensioning force between the crankshaft
timing sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of
11 Nm . To refit, proceed in the reverse order to removal.
Place the sensor of the (Mot. 1505) between the
Connect the battery (see 80A, Battery, Battery: Re-
crankshaft sprocket and the tensioning roller.
moval - Refitting ).
Check that the tension value is 80 ± 5 Hz ; if not, rea-
djust. Tighten to torque:
Tighten to torque the tensioning roller mounting
- the wheel bolts ( 110 Nm ) ,
nut ( 45 Nm ) .
Remove the (Mot. 1543) . - the battery cover bolts ( 4 Nm ) .
11A-51
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
Mot. 1054 TDC setting pin exhaust camshaft pul- (30 Nm)
ley nut
Mot. 1509 Camshaft sprocket
locking tool inlet camshaft depha- 100 Nm
ser mounting bolt
Mot. 1509-01 Conversion kit for Mot.
1509 camshaft pulley depha- 25 Nm
ser blanking cover
Mot. 799-01 Timing gear wheel
immobiliser exhaust camshaft pul- 86˚ ± 6˚
ley nut
Mot. 1496 Camshaft setting tool
toothed sprocket nuts 80 Nm
Mot. 1487 Tool for refitting cams-
haft covers (57 mm inlet and exhaust cams- 86˚ ± 6˚
diameter) haft pulley nuts
11A-52
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
WARNING
Never turn the engine in the opposite direction to its
normal operation.
WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.
WARNING 102450
On the F4R engine, it is essential to fit the cranks-
haft sprocket with the integral key.
WARNING
WARNING
When replacing the belt, it is imperative to replace
the tensioning roller and the fixed roller.
REMOVAL 102451
Position the vehicle on a two-post lift (see 02A, Lif- Position the (Mot. 1453) and (Mot. 1453-01) with re-
ting equipment, Underbody lift ). taining straps.
11A-53
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
102365
1 Remove:
- the front end panel mounting bolts (6) ,
- the front end panel,
106077 - the front right-hand driveshaft (see 29A, Drives-
hafts, Front right-hand driveshaft ).
Remove:
- the radiator cross member right-hand side reinfor-
cement (1) ,
- the lower engine tie-bar.
3
2 105432
Position the (Mot. 1672) with retaining straps.
5
4
102504
11A-54
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
- the connector on the lifting bracket.
102742
106278
Note:
Remove the fuel vapour recirculation solenoid valve
Be careful not to bend the air conditioning pipe. (9) .
101807
Remove:
11A-55
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
10
11
106632 15105
Remove the camshaft sealing plugs.
Loosen the nut (10) .
Pull the mounting bracket away from the electric I - ADJUSTING THE TIMING
coolant pump.
15106
Rotate the engine clockwise (timing end) so that the
camshaft grooves are offset below the centre line
and almost horizontal, as shown in the drawing.
Insert the TDC setting pin (Mot. 1054) so that it is
12 between the balancing hole and the crankshaft set-
ting groove.
15102
11A-56
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
Correct position
15163-2 15163-1
Turn the engine slightly in the same direction,
pushing in the TDC setting pin (Mot. 1054) until the Incorrect position
setting point is reached.
15163
15106-1
Remove the TDC setting pin (Mot. 1054) .
11A-57
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
106519
15303
Remove:
- the flywheel guard,
- the crankshaft pulley, locking the flywheel with a
screwdriver.
Refit the TDC setting pin (Mot. 1054) .
11A-58
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
13
14
18433
Remove:
- the upper timing cover (13) ,
- the lower timing cover (14) .
11A-59
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
15
106338
16
17
104719
11A-60
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
- the lower timing cover (17) .
18
19
18433-2
Slacken the timing belt by loosening the tensioning
roller nut (18) .
WARNING
Remove:
Never turn the engine in the opposite direction to
- the fixed roller (19) , its normal operation.
- the timing belt,
- the crankshaft timing sprocket.
WARNING
When replacing the timing belt, it is imperative to
replace the tensioning roller and the fixed roller.
WARNING
A belt which has been removed MUST be repla-
ced.
11A-61
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
II - ADJUSTING THE TIMING
20
104703
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces
(20) ,
- the contact surfaces of the crankshaft accesso-
ries pulley,
This is to prevent slippage between the timing
gear and the crankshaft.
This slippage causes engine damage.
WARNING
Never turn the engine in the opposite direction to
its normal operation.
WARNING
In this case, the old camshaft pulley nuts must be
removed in order to correctly set the belt tension.
11A-62
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
15815-3
Check that the camshaft dephaser wheel is correctly
locked (no rotation of the wheel to the left or to the
right).
11A-63
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
26 25
22
27
21
16019 16019-3
Position the (Mot. 1509) with sprocket (Mot. 1509- Tighten the bolt and the shouldered nut (25) .
01) .
Bring the toothed sprockets of the (Mot. 1509) into
Position the spacer (21) of the (Mot. 1509-01) on the contact with the camshaft pulleys.
stud (22) .
Tighten the toothed sprocket nuts ( 80 Nm ) (26) .
Remove:
24
- the inlet camshaft dephaser blanking cover (27) ,
- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
23
- the camshaft pulleys.
Loosen the stud with the nut (see NT 3884A, Repla-
cing F4 camshaft pulley studs, Top and front of
engine, Camshaft ).
16019-1
Fit the upper bolt (23) , positioning the spacer (24)
(Mot. 1509-01) between the tool and the rocker co-
ver (do not tighten the bolt).
11A-64
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
Refit the degreased camshaft pulleys with the old
mountings.
F4R, and 776
Tighten to torque the old mountings (15 Nm max.)
using the (Mot. 799-01) .
WARNING
104711
Install the (Mot. 1509) with its toothed sprocket
(Mot. 1509-01) .
Tighten the bolt and the shouldered nut (28) .
Bring the toothed sprockets into contact with the
camshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (29) .
Remove:
- the camshaft pulley nuts,
- the (Mot. 1509) , 15106-1
- the camshaft pulleys. Position the grooves offset horizontally below the
centre-line as shown above by turning the cams-
Loosen the stud with the nut (see NT 3884A, Repla-
hafts using the (Mot. 799-01) .
cing F4 camshaft pulley studs, Top and front of
engine, Camshaft ).
11A-65
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
31
30
15104 15114
Position the (Mot. 1496) , attaching it to the end of
the camshafts. Correct position
15163-1
WARNING
Check that the crankshaft is correctly centered.
The crankshaft groove (30) must be between the
two ribs (31) .
11A-66
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
33
32
15201
34
15815-1
Refit:
- the timing sprocket,
- the timing belt,
- the fixed roller (34) .
Tighten to torque the fixed roller mounting bolt (
50 Nm ) .
11A-67
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
III - ADJUSTING THE TENSION
37
38
35
39
36
15256
104728
11A-68
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
42
40
41
21877
Make a pencil mark (42) between the camshaft pul-
104711
leys and the camshaft bearing cap.
Position the (Mot. 1509) for locking the camshaft Remove the following tools:
pulley. - TDC setting pin (Mot. 1054) ,
Tighten the bolt and the shouldered nut (40) . - camshaft setting tool (Mot. 1496) .
Bring the toothed sprocket nuts into contact with the Rotate the crankshaft clockwise through two revolu-
camshaft pulleys. tions (timing end).
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (40) ,
- the old inlet and exhaust camshaft pulley nuts (
(30 Nm) ) (41) ,
Remove the (Mot. 1509) fitted with the (Mot. 1509-
01) .
11A-69
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
IV - CHECKING THE TIMING AND THE TENSION
15104
Position the camshaft adjustment tool (Mot. 1496) .
15163-2
Before the end of the second revolution (i.e. half a
tooth before alignment of the marks made previously
by the operator), insert the crankshaft TDC setting
pin (Mot. 1054) (so that it is between the balancing
hole and the timing hole).
15163-1
Bring the timing to its adjustment point.
11A-70
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
43 45
44
46
104728 104711
Position the (Mot. 1509) with the toothed sprockets Position the (Mot. 1509) for locking the camshaft
(Mot. 1509-01) for locking the camshaft pulleys. pulley.
Tighten the bolt and the shouldered nut (43) . Tighten the bolt and the shouldered nut (45) .
Offer up the toothed sprocket nuts against the cams- Offer up the toothed sprocket nuts against the cams-
haft pulleys. haft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (44) . Tighten the toothed sprocket nuts ( 80 Nm ) (46) .
Loosen: Loosen:
- the old inlet camshaft dephaser pulley mounting - the old inlet camshaft pulley nut,
bolt,
- the old exhaust camshaft pulley nut.
- the old exhaust camshaft pulley nut.
Remove the (Mot. 1509) for locking the camshaft
Remove the (Mot. 1509) with the sprocket (Mot. pulley.
1509-01) for locking the camshaft pulleys.
11A-71
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
49
47
48
15256
Align mark (47) with mark (48) by loosening the ten-
sioning roller nut by up to one turn, while holding it in
position with a 6 mm (49) Allen key.
Final tighten the tensioning roller nut ( 28 Nm ) .
11A-72
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
Remove the following tools:
50
51
104728
11A-73
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
54
55
52
53
104711
Position the camshaft locking tool (Mot. 1509) , tor-
que tightening the nuts ( 80 Nm ) (54) .
104711
Tighten the bolt and the shouldered nut (55) .
Position the (Mot. 1509) for locking the camshaft
pulley. Remove the old camshaft pulley nuts and replace
them with new ones.
Tighten the bolt and the shouldered nut (52) .
Tighten to torque and angle the inlet and exhaust
Bring the toothed sprocket nuts into contact with the camshaft pulley nuts ( 30 Nm + 86˚ ± 6˚ ) .
camshaft pulleys.
Remove the following tools:
Tighten the toothed sprocket nuts ( 80 Nm ) (53) .
- (Mot. 1496) ,
Remove:
- camshaft pulley locking tool (Mot. 1509) .
- the old inlet camshaft pulley nut, - the TDC setting pin (Mot. 1054) .
- the old exhaust camshaft pulley nut. Rotate the crankshaft clockwise through two revolu-
tions.
Refit a new nut onto the inlet and exhaust camshaft
pulley.
11A-74
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
2 - Checking the timing
56
57
15104
WARNING
It is imperative to replace the crankshaft acces-
sories pulley and bolt.
58
15106-1
11A-75
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
F4R, and 770 or 771 or 776
15303 15103-1
Lock the flywheel using a large screwdriver. Refit:
Tighten to torque and angle the crankshaft acces- - the new sealing plugs:
sories pulley bolt ( 40 Nm + 110˚ ± 10˚ ) .
• on the inlet camshaft (Mot. 1487) ,
• on the exhaust camshaft (Mot. 1448) ,
WARNING
- the right-hand suspended mounting (see 19D, En-
To avoid damaging the crankshaft accessories
gine mounting, Suspended mounting ) in accor-
pulley, do not start the engine without the acces-
dance with the marks.
sories belt.
Proceed in the reverse order to removal.
Refit:
Tighten to torque:
- the crankshaft accessories belt (see 11A, Top and
front of engine, Accessories belt ), - the M6 lower timing cover bolts ( 80 Nm ) ,
- the TDC setting pin plug, applying a drop of RHO- - the M8 lower timing cover bolts ( 20 Nm ) ,
DORSEAL 5661 to the thread hole. - the M8 upper timing cover bolts ( 18 Nm ) ,
- the M10 upper timing cover bolts ( 38 Nm ) ,
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
11A-76
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
Tightening torquesm
11A-77
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
102450
101866
Mark the suspended engine mounting in relation to
the body.
Remove:
- the « engine/suspended engine mounting » as-
sembly,
- the lower engine tie-bar.
WARNING
Do not damage the air conditioning pipe.
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) and the 2
retaining straps.
101807
Remove:
- the air filter outlet duct (1) ,
- the throttle valve (2) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
11A-78
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
ADJUSTING THE TIMING
4
3
14491
Pierce the centre of the plugs on the end of the 14491-1
camshaft using a screwdriver. Position the camshaft grooves (5) almost horizontal-
ly and offset towards the bottom while turning the
Remove:
crankshaft in its operating direction (clockwise timi-
- the sealing plugs at the camshaft end with a ng end).
screwdriver,
Screw in the TDC setting pin (4) (Mot. 1489) .
- the TDC setting pin plug (3) .
14489
Turn the crankshaft in its operating direction (timing
end clockwise), until the crankshaft comes into con-
tact with TDC setting pin.
11A-79
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
10
9
14490 101872
Check that the camshaft grooves are horizontal and Undo the tensioning roller bolt (9) to slacken the timi-
offset downwards. ng belt.
Remove:
- the pulley (10) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the cranks-
haft sprocket,
7 - the timing sprocket,
- the tensioning roller.
14487
Remove:
- the crankshaft accessories pulley (6) , locking the
flywheel with a screwdriver,
- the upper timing cover (7) ,
- the lower timing cover (8) .
11A-80
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
REFITTING - PROCEDURE 1
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the pul-
ley.
WARNING
111336
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
end of the camshafts
11A-81
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
103269
Check that the mark (12) on the dephaser is vertical
and pointing upwards.
Make a mark (13) with a pencil between the depha-
ser wheel and the rocker cover.
11A-82
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
14489 14487-3
Check: Refit:
- that the crankshaft is correctly in contact with the - the timing sprocket (18) ,
TDC setting pin (Mot. 1489) (15) with the cranks- - the timing belt,
haft groove (14) facing upwards,
- the pulley (17) .
- that the inlet camshaft dephaser wheel is correctly
locked (wheel does not rotate right or left). Tighten to torque the pulley mounting bolt (45 Nm)
using (Mot. 1368) .
.
3 - BELT TENSION
2 - REFITTING
103263
108879 Using a 6 mm Allen key, bring the adjustable index
Refit the tensioning roller by positioning the tensio- marker (19) opposite the notch (20) , by turning the
ning roller lug in the groove (16) . eccentric (21) clockwise.
11A-83
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
Tighten to torque the tensioning roller mounting
nut (7 Nm)
Remove:
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
103263
11A-84
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
103267
Tighten to torque the timing tensioning roller nut Check that the timing pulley index markers are cor-
(27 Nm) (25) . rectly positioned before checking the timing setting.
Check that the dephaser mark (26) is aligned with Screw the TDC setting pin (Mot. 1489) into the cylin-
the mark (27) . der block.
Move the crankshaft slowly and smoothly until it is
resting against the pin.
4 - CHECKING THE TIMING AND TENSION
Fit the camshaft adjusting the (Mot. 1496) without
forcing (the camshaft grooves must be horizontal
a - Checking the tension and below the centre line).
Rotate the crankshaft through two clockwise revolu-
tions (timing end) before aligning the marks (on the WARNING
camshaft dephaser).
If the tool cannot be engaged, readjust the timing
Screw in the TDC setting pin (Mot. 1489) . and the tension.
11A-85
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
II - PROCEDURE FOR AN ENGINE FITTED WITH A
TIMING COVER WITH A FLAP
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the pul-
ley.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces, 111337
- the accessories pulley contact surfaces, Fit the (Mot. 1496) with (Mot. 1750) (28) .
111336
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
end of the camshafts
11A-86
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
103269
Check that the mark (29) on the dephaser is vertical
and pointing upwards.
Make a mark (30) with a pencil between the depha-
ser wheel and the rocker cover.
11A-87
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
14489 14487-3
Check: Refit:
- that the crankshaft is correctly in contact with the - the timing sprocket (35) ,
TDC setting pin (Mot. 1489) (32) with the cranks- - the timing belt,
haft groove (48) facing upwards,
- the pulley (34) .
- that the inlet camshaft dephaser wheel is correctly
locked (wheel does not rotate right or left).
.
2 - REFITTING
14487-2
Tighten to torque the pulley mounting bolt (45 Nm)
using (Mot. 1368) .
108879
Refit the tensioning roller by positioning the tensio-
ning roller lug in the groove (33) .
11A-88
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
3 - BELT TENSION
109055
103263 Refit the crankshaft accessories pulley.
Move the adjustable index marker (36) opposite the
Tighten to torque and angle the crankshaft acces-
notch (37) , by turning the eccentric (38) clockwise
sories pulley bolt (40 Nm + 145˚ ± 15˚) .
using a 6 mm Allen key.
109054
Refit the lower timing cover.
11A-89
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
109052 109051
Remove the timing flap from the lower timing cover.
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the TDC setting pin (Mot. 1489) .
Rotate the crankshaft twice in a clockwise direction,
on the timing end, before aligning the markings (on
the camshaft dephaser) already made by the opera-
tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
Move the crankshaft slowly and smoothly to press
against the TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
103263
11A-90
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
4 - CHECKING THE TIMING AND TENSION
Tighten to torque the timing tensioning roller nut ( Position (without forcing) the camshaft timing tool
27 Nm ) .
(Mot. 1496) (the camshaft end grooves must be ho-
rizontal and offset towards the bottom).
b - Checking the timing
Check that the index marker and the timing tensio-
ning roller notch are correctly positioned before WARNING
checking the timing. The timing adjustment and tensioning operation
must be repeated if the camshaft setting tool
Screw the TDC setting pin (Mot. 1489) into the cylin-
does not engage.
der block.
Move the crankshaft slowly and smoothly to press
against the TDC setting pin.
109052
11A-91
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
REFITTING -PROCEDURE 2
WARNING
If the stud is loosened with the nut (see Techni-
cal Note 3887A, Replacement of K9 -K4 cams-
haft pulley studs, 11A, Top and front of
engine, Camshaft ).
WARNING
Replace the timing belt, the crankshaft accesso-
ries pulley bolt, the tensioning roller and the pul-
ley.
14490
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the accessories pulley contact surfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-
ces.
This is to avoid timing slippage.
This slippage causes engine damage.
103261
Position the camshaft grooves horizontally and off-
set downwards, by turning the camshafts using the
(Mot. 1496) if necessary.
11A-92
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
111337
Fit the (Mot. 1496) with (Mot. 1750) (44) .
111336
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
end of the camshafts
11A-93
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
14489
103269
Check that the crankshaft is in contact with the TDC
setting pin (Mot. 1489) (45) (crankshaft groove (46)
should be at the top).
11A-94
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
111338 111340
Fit the camshaft dephaser into a vice with jaws. Check that the dephaser hub is mechanically secu-
red correctly using a tubular hexagon box spanner
(the hub must not be able to rotate towards the left or
right).
Refit:
- the exhaust camshaft pulley with a new nut,
- the inlet camshaft dephaser with a new bolt.
Position:
- the RENAULT logo (47) engraved on the camshaft
pulley spokes vertically at the top,
- the dephaser marking (48) vertically and at the top.
Make a mark (49) with a pencil between the depha-
ser wheel and the rocker cover.
111339
Fit a bolt in the dephaser hub.
11A-95
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
II - REFITTING
103265
108879 Fit the camshaft pulley locking tool (Mot. 1490-01)
When refitting the tensioning roller, ensure that the (52) (use the timing cover mountings to fit the tool).
tensioning roller lug fits correctly into the groove (50)
.
14487-3
Refit the pulley (53) .
14487-3
Tighten to torque the pulley mounting bolt ( 45 Nm
Refit:
) using the (Mot. 1368) .
- the timing sprocket (51) ,
Refit the crankshaft accessories pulley (without tigh-
- the timing belt on the camshaft pulleys (without mo- tening the bolt, leaving 2 to 3 mm play between bolt
ving the camshaft pulleys). and pulley).
11A-96
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
III - BELT TENSION
103263
103263 Check that the adjustable index marker (57) is ali-
Using a 6 mm Allen key, bring the adjustable index gned with the fixed index marker (58) .
marker (54) opposite the notch (55) , by turning the
Loosen the tensioning roller nut by up to one turn,
eccentric (56) clockwise.
holding the adjustable index with a 6 mm Allen key.
Tighten to torque the tensioning roller mounting
Gradually move the adjustable index marker (57)
nut (7 Nm).
opposite the notch (58) , turning the eccentric (59) in
Remove the camshaft pulley immobilising tool (Mot. a clockwise direction.
1490-01) .
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pul-
leys. In addition, from time to time, press the
camshaft pulleys against the camshafts.
11A-97
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
103268
Tighten to torque the tensioning roller mounting
nut (27 Nm) .
Check that:
- the RENAULT logo (60) engraved on the camshaft
pulley spokes is positioned vertically at the top,
- the dephaser mark (61) is aligned with the mark
(62) already made by the operator.
14839
Fit the camshaft pulley immobilising tool (Mot. 1490-
01) .
11A-98
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
14489 103265
- (Mot. 1496) ,
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
11A-99
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 730 or 732
2 - Checking the timing
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
15103-1
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended engine mounting ),
- the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended engine mounting ),
- the accessories belt (see 11A, Top and front of
engine, Accessories belt ),
- the new inlet camshaft sealing plugs (Mot. 1487) ,
14490
- the new exhaust camshaft sealing plugs (Mot.
Fit the camshaft adjusting tool (Mot. 1496) without 1488) .
forcing (the camshaft grooves must be horizontal
Proceed in the reverse order to removal.
and offset downwards).
Connect the battery, starting with the positive termi-
nal.
WARNING
If the tool cannot be engaged, readjust the timing WARNING
and the tension.
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
11A-100
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
I - PRECAUTIONS FOR REPAIR
Special tooling required
11A-101
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
IV - REMOVAL
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) with the
retaining straps.
Remove:
- the exhaust ball joint bracket mounting bolts,
- the lower engine tie-bar mounting bolts.
Detach the manual priming pump.
WARNING
Be careful not to damage the air conditioning
pipes.
11A-102
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
112998
113927
112989
Undo the cylinder head suspended mounting bolts.
Twist the timing belt slightly (to remove the cylinder
head suspended mounting).
Remove the cylinder head suspended mounting (6) .
112990
Remove:
11A-103
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
19650 19650-1
Remove the TDC pin plug (7) using a torx socket Screw in the TDC setting pin (10) (Mot. 1489) .
(14).
14489
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft is pressed against the TDC set-
ting pin.
107270
Turn the crankshaft to position the hole (8) of the
camshaft pulley almost opposite the hole (9) in the
cylinder head.
11A-104
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
109049 109046
Undo the tensioning roller bolt (12) to slacken the ti-
Engage the pin (11) (Mot. 1430) in the camshaft
ming belt.
pulley and cylinder head holes.
Remove:
Remove:
- the timing belt,
- the timing pin from the camshaft pulley (Mot. 1430) - the timing tensioning roller.
,
107260
11A-105
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
V - REFITTING - the mark on the high-pressure pump (16) is offset
by one tooth to the right of the vertical axis (17) ,
1 - REFITTING PART CONCERNED - the crankshaft is in contact with the TDC setting pin
(Mot. 1489) (crankshaft timing sprocket collet (18)
at the top).
109042
14489
109043
Place the tensioning roller lug (13) in the cylinder Remove one bolt from the camshaft pulley wheel.
head groove (14) . Loosen the two other camshaft pulley wheel bolts
(19) by one turn.
Engage the pin (15) (Mot. 1430) in the holes of the
camshaft pulley and cylinder head, turning the
camshaft using an 18 mm offset spanner if necessa-
ry.
Check that:
11A-106
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
109044
Fit the timing belt, starting with the crankshaft sproc-
ket, aligning the marks on the belt with those on the
crankshaft sprockets, the camshaft and the high-
pressure pump. There should be 19 tooth spaces
between the sprocket marks and 51 tooth spaces
between the crankshaft sprockets and the high pres-
sure pump.
11A-107
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
19658
Position the tensioning roller adjustable index mar-
ker (20) opposite the lug (21) using a 6 mm Allen
key, turning it anti-clockwise.
Tighten to torque the tensioning roller bolt (27
Nm) .
109047
Check that the camshaft pulley hub bolts are not ful-
ly up against the camshaft pulley wheel.
11A-108
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
109045
Refit camshaft pulley wheel bolt (22) .
Tighten to torque the camshaft pulley wheel bolts
( 14 Nm ) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the timing pin from the camshaft pulley (Mot. 1430)
,
107272
Tighten the old crankshaft accessories pulley bolt fit-
ted with a spacer (23) (which does not cover the timi-
ng sprocket mark) onto the crankshaft.
11A-109
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
107270 109048
Rotate the crankshaft twice in a clockwise direction If the (Mot. 1430) does not engage:
(timing end) before the camshaft pulley hole (24) is
loosen the camshaft pulley wheel bolts by one turn,
opposite the cylinder head hole (25) .
Turn the camshaft pulley hub using an offset span-
Screw the TDC setting pin (Mot. 1489) into the cylin-
ner to facilitate setting of the camshaft pulley hub.
der block.
Do not retighten the camshaft pulley wheel bolts.
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
109049
Set the camshaft pulley using the (Mot. 1430) .
11A-110
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
109045
Check that the crankshaft timing sprocket collet (26)
is positioned vertically facing upwards.
Note:
After two turns, the tensioning roller markers may
be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-111
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
a - First position b - Second position
111083 111082
111081
111081
Loosen the tensioning roller bolt by a maximum of
one turn, holding the tensioning roller using a 6 MM Loosen the tensioning roller bolt by a maximum of
Allen key. one turn, holding the tensioning roller using a 6 MM
Allen key.
Gradually align the adjustable index marker (27) to
the middle of the timing window (28) , turning the key Gradually align the adjustable index marker (29) to
anti-clockwise. the middle of the timing window (30) , turning the key
clockwise.
Tighten to torque:
11A-112
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
Rotate the crankshaft twice in a clockwise direction
(timing end) before the camshaft pulley hole is oppo-
site the cylinder head hole.
Screw the TDC setting pin (Mot. 1489) into the cylin-
der block.
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
107260
Refit the accessories crankshaft pulley with a new
bolt.
Tighten to torque and angle (crankshaft in contact
with the TDC setting pin) the crankshaft pulley M14
bolt ( 120 Nm + 95˚ ± 15˚ )
Remove the following tools:
- TDC setting pin (Mot. 1489) ,
- timing pin from camshaft pulley (Mot. 1430) .
11A-113
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
112989 112990
Refit the cylinder head suspended mounting (31) .
Tighten to torque the cylinder head suspended
mounting bolts ( 21 Nm )
19659
Refit:
- the lower timing cover (32) , positioning the tab (33)
in the hole (34) in the inner timing cover,
- the timing cover plastic bolt (35) .
11A-114
TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K, and 732
112990 113927
Refit the upper timing cover (36) Refit the right-hand suspended mounting support
(see 19D, Engine mounting, Right-hand suspen-
ded engine mounting: Removal - Refitting ).
Refit:
Refit:
11A-115
TOP AND FRONT OF ENGINE
Timing chain: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removing the timing chain requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
Removal - Refitting ).
To remove the timing chain (see Technical Note
6017A, M9R diesel engine ).
REFITTING
To refit the timing chain (see Technical Note
6017A, M9R diesel engine ).
Refit the engine and gearbox assembly (see 10A,
Engine and peripherals, Engine and gearbox as-
sembly: Removal - Refitting ).
11A-116
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Tightening torquesm
11A-117
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Move the fuel supply pipe aside.
1
3
105432
1
Set up the engine stand (1) (Mot. 1672)
Remove the (Mot. 1453) and (Mot. 1453-01) .
2
18699
101876
11A-118
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Move the bracket/wiring harness assembly aside.
5
9
6
10
7
8
104240
18666 Disconnect the connector (9) from the injectors
Disconnect:
Unfasten the clip (10) .
- the ignition coil connectors (5) ,
Move the wiring harness to one side.
- the air temperature sensor connector (6) ,
Remove:
- the inlet manifold pressure sensor connector (7) ,
- the ignition coils,
- the fuel vapour recirculation solenoid valve pipe (8)
- the plugs,
,
- the air filter unit (see 12A, Fuel mixture, Air filter
- the catalytic converter upstream oxygen sensor
unit: Removal - Refitting ).
connector.
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting ).
11A-119
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
12
15
11
18706 18431
Remove: Remove:
- the lifting bracket (11) , - the oil separator mounting bolts (15) ,
- the inlet manifold mounting bolts (12) - the oil separator.
- the inlet manifold.
13
16
16
14
103256
101793 Remove:
Remove: - the rocker cover mounting bolts,
- the catalytic converter/gearbox stay mounting bolts - detach the rocker cover vertically, tapping the lugs
(13) , (16) with a copper hammer.
- the catalytic converter/gearbox stay
- the exhaust pipe mounting nuts (14) . WARNING
Detach the exhaust pipe. Do not damage the aluminium surfaces.
11A-120
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
14498
Remove the inlet and exhaust camshafts.
11A-121
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Apply the product to the section to be cleaned; Wait
approximately ten minutes, then remove the residue
using a wooden spatula.
17
WARNING
18 Do not allow this product to drip onto the pain-
twork.
Clean the cylinder head carefully to prevent
foreign bodies from entering the oil supply and
return pipes.
Failure to follow this guideline could lead to bloc-
kage of the oilways, resulting in rapid and serious
damage to the engine.
To prevent any risk of unpriming the hydraulic For the cylinder head stripping procedure (see
tappets make sure that they are vertical. Technical Note 3784A, K4 4-cylinder petrol engi-
ne, 10A, Engine and peripherals, Rebuilding the
Remove: cylinder head) .
Position the pistons at mid-stroke to prevent any
- the cylinder head mounting bolts,
contact with the valves when refitting the camshafts.
- the cylinder head. Be sure to degrease:
Mount the cylinder head on the cylinder head moun- - the cylinder head combustion face,
ting (Mot. 1573) .
- the cylinder block combustion face.
Remove the cylinder head gasket from the cylinder
block.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
11A-122
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
20 19
21
14689 14499
Check that the centring dowel is present (19) on the Reprime the hydraulic tappets (hydraulic tappets
cylinder block. may empty after a long down time).
Fit the (Mot. 104) (20) onto the cylinder block. To check if repriming is necessary, press the top of
the tappet (21) with your thumb.
REFITTING If the tappet piston depresses:
Fit the new cylinder head gasket. - immerse the tappets in a container full of diesel
fuel,
Refit the cylinder head.
- refit the hydraulic tappets.
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket: Refit:
Removal - Refitting ). - the valve rockers,
Tighten the cylinder head (see 11A, Top and front - the camshafts, oiling the bearings.
of engine, Tightening the cylinder head ).
11A-123
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
I - CAMSHAFT MARKINGS
Inlet camshaft
101880
Position the groove (22) on the end of the camshaft
horizontally (groove below the centre line of the
camshaft).
The cams (23) for cylinder 1 must be located to the
right of the vertical axis (24) , flywheel end view.
11A-124
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
Exhaust camshaft
101881
Position groove (25) horizontally on the end of the
camshaft (groove below the centre line of the cams-
haft).
The cams (26) for cylinder 1 must be located to the
left of the vertical axis (27) , flywheel end view.
11A-125
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
28
15106-1 14517
Position the camshaft grooves horizontally and off- Using a stipple roller, apply LOCTITE 518 to the
set downwards. camshaft rocker cover gasket face until it turns red-
dish.
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could damage certain components (engine,
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-126
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
II - TIGHTENING PROCEDURE
14497
Tighten to torque and in order:
- rocker cover mounting bolts 22, 23, 20, 13 , 8
Nm ,
- rocker cover mounting bolts 1 to 12, 14 to 19,
21 to 24 (12 Nm) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order rocker cover moun-
ting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-127
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
3
2
6 8
4
5 1
7
101869 18431
Refit the oil separator.
11A-128
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
29
106443
On the four ignition coils, apply a bead (2 9) of
FLUORINATED GREASE 82 00168 855 2 mm in
diameter to the inner circumference of the high-ten-
sion cap.
Refit the plugs.
Tighten to torque the plugs ( 25 to 30 Nm ) using
the plug spanner set (Ele. 1382) .
Refit the coils.
Tighten to torque:
- the coil mounting bolts (if the holes are already
threaded) ( 12 Nm ) ,
- the coil mounting bolts (if the holes are not
threaded) ( 15 Nm ) ,
Always replace all the inlet manifold seals.
11A-129
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
14497-1
Tighten to torque and in order the inlet manifold
mounting bolts ( 9 Nm ) .
Refit: 30
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting ).
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting ).
20256
The first type of elastomer seal is fitted with a spring
(30) with a lip seal (31) in the shape of a « V »
11A-130
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
1 - Fitting the first seal type to the inlet camshaft
34
33
32
35
20257
The second type of elastomer seal is fitted with a flat 14892
lip seal (32) and a protector (33) (which also assists Fit the seals using the (Mot. 1491) (34) and the old
in fitting the seal to the engine). nuts (35) .
Note:
Both seal versions can be fitted on the same
engine. They are not interchangeable. It is
essential to use the same version when replacing
an old seal, except when one or more camshafts
are replaced.
11A-131
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
2 - Fitting the seal to the exhaust camshaft
38
36 37
105531
18687
WARNING
It is very important to hold the protector (3 6)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (37) in order to prevent any oil
leaks once the seal is fitted to the engine.
38
21687
Screw the stud of (38) the (Mot. 1632) onto the
camshaft.
11A-132
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
21687-1 21687-3
Fit the protector, with a seal, to the camshaft. Screw in the collar nut until the cover comes into
contact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of en-
gine, Timing belt: Removal - Refitting ).
39
40 WARNING
Follow the second procedure in the timing belt
refitting procedure.
21687-2
Fit cover (39) and the collar nut (40) of the (Mot.
1632) .
11A-133
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4J, and 730 or 732
15103-1
Refit:
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
- new inlet camshaft sealing plugs using the (Mot.
1487) ,
- new exhaust camshaft sealing plugs using the
(Mot. 1488) ,
Proceed in the reverse order to removal.
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Bleed the cooling circuit (see 16A, Cooling, Coo-
ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
11A-134
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
Mot. 1202-02 Pliers for small hose Procedure for removing the air inlet duct (K9K 728
clips and 729):
- make a mark on the inlet duct between the stain-
Mot. 1448 Remote operation clip less steel pipe and the hose,
pliers for cooling sys-
tem hose clips - detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, or
Equipment required any other product,
diagnostic tool - clean the stainless steel pipe and the hose with a
dry, lint-free cloth,
cylinder head testing tool - refit the clip in the same recess in the event that
the hoses are not replaced,
angular tightening wrench
- rotate the clip around its axis to make torque tigh-
tening easier,
Tightening torquesm
- it is essential to replace the hose and/or the stain-
rocker cover mounting 10 Nm less steel pipe in the event of damage.
bolts There is a risk of leaks or dislodging if this proce-
dure is not followed.
turbocharger oil return 9 Nm
pipe
11A-135
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif- K9K, and 722
ting equipment, Underbody lift ).
Remove: 4 3
1
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ). 5
Remove: 2
- the battery,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining-refilling ).
102081
Disconnect:
- the air temperature and pressure sensor connector
(1) ,
- the exhaust gas recirculation valve control connec-
tor (2) ,
- the air hoses (3) ,
- the air hose (4) ,
- the turbocharging pressure regulation valve rubber
pipe,
- the air sleeve from the air filter unit,
105432 - the oil vapour rebreathing pipe from the rocker co-
ver.
Fit the engine stand (Mot. 1672) .
Remove the air resonator unit mounting stay (5) .
Remove the (Mot. 1453) and (Mot. 1453-01) .
11A-136
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
6
9
8
7
110325
Pull out the clip.
110326
Disconnect:
11
- the air temperature and pressure sensor connector
(6) ,
- the exhaust gas regulation valve control connector
(7) ,
12
- the engine speed and position sensor connector
(8) , 10
- the air hose (9) ,
- the rubber hose from the turbocharging pressure
control valve.
110322
Make a mark on the inlet duct between the stainless
steel pipe and the hose (10) .
Undo the bolt (11) .
Remove the air duct (12) .
11A-137
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
17
18
13
16
14
15
102086 102263
Disconnect: Disconnect:
- the injector connectors, - the water unit hoses (16) using the (Mot. 1202-01)
or (Mot. 1202-02) or (Mot. 1448) ,
- the heater plug connectors,
- the brake servo vacuum pipe (17) on the vacuum
- the rail pressure sensor connectors,
pump side,
- the diesel fuel supply pipe from the pump,
- the coolant temperature sensor connector on the
- the diesel return pipe from the pump, water unit.
- the fuel temperature sensor (13) , - the radiator top hose from the cylinder head water
outlet using the (Mot. 1202-01) or (Mot. 1202-02)
- the fuel flow actuator connector (14) .
or (Mot. 1448) .
Remove the wiring and diesel return pipe support
Unclip the heater radiator hose (18) .
(15) .
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
11A-138
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
21
19
104175 19711
Disconnect the turbocharger oil return pipe (19) . Remove:
- the rocker cover mounting bolts (21) ,
- the rocker cover.
22
20
22
19712
Remove:
19710 - the cylinder head mounting bolts (22) ,
Remove the inner timing cover (20) . - the cylinder head.
11A-139
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
I - CLEANING Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
Clean the cylinder head.
the cylinder head.
IMPORTANT
WARNING
Do not scratch the aluminium gasket faces.
The sealing surfaces must be clean, dry and free
During the operation, wear: from grease (avoid finger marks).
- goggles, Refit the cylinder head.
- gloves. Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head ) using
Clean the gasket faces with DÉCAPJOINT to dissol-
the angular tightening wrench .
ve the section of the gasket which is still attached.
Apply the product to the section to be cleaned; wait
approximately ten minutes, then remove the residue WARNING
using a wooden spatula. The sealing surfaces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Please make sure, during this operation, that no WARNING
foreign bodies enter the oilways (galleries in both Applying excess sealant could cause it to be
the cylinder block and the cylinder head). squeezed out when parts are tightened. The pro-
duct-fluid mix may damage some components
(engine, radiator).
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply galle- 23
ries.
Failure to follow this advice could lead to the pipe
blocking, quickly damaging the camshaft.
23
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feeler
gauge.
The maximum bow is 0.05 mm .
23
WARNING 19712-1
No regrinding of the cylinder head is permitted. Fit the new rocker cover gasket.
Test the cylinder head to detect any possible cracks Apply beads (23) of SILICONE ADHESIVE SEAL 2
using the cylinder head testing tool . mm in diameter.
For the cylinder head stripping procedure (see
Technical Note 6006A, 4 cast iron cylinder High
Pressure Common Rail Diesel Engine, 10A, En-
gine and peripherals, Rebuilding the cylinder
head ).
REFITTING
Proceed in the reverse order to removal.
Fit the new cylinder head gasket, centred by two
dowels.
11A-140
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 722 or 728 or 729
Tighten to torque the intercooler hose clip ( 5.5
Nm ) .
5 1
Refit:
6 3 - the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ).
2 - the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
7
- the accessories belt (see 11A, Top and front of
4 engine, Accessories belt: Removal - Refitting ).
Fill the cooling circuit (see 19D, Cooling, Cooling
circuit: Draining-refilling ).
8
Reprime the diesel circuit (see 13B, Fuel supply,
Diesel fuel supply circuit ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-
ling circuit: Bleeding ).
19711
Tighten to torque the battery cover bolts ( 4 Nm ) .
Refit the rocker cover.
Tighten to torque and in order the rocker cover
mounting bolts ( 10 Nm ) .
Reconnect the turbocharger oil return pipe, fitted
with new seals.
Tighten to torque the turbocharger oil return pipe
( 9 Nm ) .
19709
Reconnect:
- the oil vapour rebreather pipe,
- the new turbocharger air sleeves.
11A-141
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 800 or 808
oil supply pipe bolt on 22.5 Nm - the front bumper (see MR 365 Bodywork, 55A,
the turbocharger Exterior protection, Front bumper ).
IMPORTANT
11A-142
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 800 or 808
1 9 8
5
4
7
18983
Remove the vacuum tank mounting bolts (7) .
6
Disconnect:
- the turbocharger pressure regulation solenoid val-
ve pipes,
105511
- the engine damping device solenoid valve connec-
Disconnect:
tor (8) ,
- the air filter outlet duct (1) ,
- the camshaft sensor connector (9) .
- the air duct (2) towards the turbocharger,
Remove the vacuum tank.
- the oil vapour rebreathing pipe (3) ,
- the engine damping device valve pipe (4) .
Remove:
- the air duct (5) from the inlet manifold,
- the oil vapour rebreathing canister (6) .
11A-143
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 800 or 808
10
11
11
18
12
13
12
14
16
15 17
105512 104323
Disconnect: Disconnect:
- the exhaust gas recirculation solenoid valve con- - the cylinder head outlet water unit hoses using the
nector (10) , (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the injector connectors (11) , - the connector (18) from the coolant temperature
sensor.
- the heater plug connectors (12) ,
- the rail pressure sensor connector (13) ,
- the high-pressure pump pressure regulator con-
nector (14) ,
- the diesel return temperature sensor connector
(15) ,
- the diesel filter connector,
- the diesel fuel supply pipe (16) ,
- the diesel return pipe (17) .
Insert the blanking plugs.
19
Move the wiring harnesses to one side.
102348
Remove the three high-pressure pump support
mounting bolts (19) .
11A-144
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 800 or 808
21
23
22
20
18997 16189
Remove: Remove the cylinder head mounting bolts (23) .
- the catalytic converter (20) (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ). WARNING
- the oil supply pipe (21) , When removing the cylinder head, take care not
to cause any damage to its gasket face as it pas-
- the oil return pipe mountings (22) on the turbochar-
ses the turbocharger above it.
ger.
Remove the cylinder head. This operation requires
two people.
I - CLEANING
Clean the cylinder head.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
11A-145
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 800 or 808
Apply the product to the section to be cleaned; wait Tighten to torque:
approximately ten minutes, then remove the residue
- the oil supply pipe bolt on the turbocharger (
using a wooden spatula.
22.5 Nm ) ,
- the oil supply pipe bolt on the cylinder block (
WARNING 22.5 Nm ) ,
To prevent any foreign bodies from entering the - the oil return pipe bolts ( 12 Nm ) .
oil pipes (pipes in both the cylinder block and
cylinder head). Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ).
WARNING
- the timing belt (see 11A, Top and front of engine,
Protect the oilway to prevent any foreign bodies Timing belt: Removal - Refitting ).
from entering the cylinder head oil supply galle-
ries. - the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
Failure to follow this advice could block the oil
supply pipes, causing rapid camshaft damage. Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining-refilling ).
Reprime the diesel circuit (see 13A, Fuel supply,
WARNING Diesel fuel supply circuit ).
The cylinder head bolts must be replaced each Connect the battery (see 80A, Battery, Battery: Re-
time they are removed and must not be oiled moval - Refitting ).
before being fitted.
Bleed the cooling circuit (see 19A, Cooling, Coo-
ling circuit: Bleeding ).
II - CHECKING THE GASKET FACE Tighten to torque the battery cover bolts ( 4 Nm ) .
Check for gasket face bow using a ruler and a feeler
gauge.
WARNING
No regrinding of the cylinder head is permitted.
REFITTING
Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head.
11A-146
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
Mot. 1509-01 Conversion kit for Mot. coils (if holes not threa- 15 Nm
1509 ded)
Tightening torquesm
11A-147
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
16019-4 16019-4
Fit the (Mot. 1509) with the gear (Mot. 1509-01) .
Remove:
Tighten the collar nut (1) and the bolt (2) , then bring
the gears of (Mot. 1509) into contact with the cams- - the exhaust camshaft pulley nut,
haft pulleys while torque tightening the nuts (80
Nm) (3) . - the inlet camshaft dephaser mounting bolt,
Remove the inlet camshaft dephaser blanking cover
Loosen the nut stud if necessary (see Technical
using a 14 mm Allen key.
Note 3887A, Replacement of F4 camshaft pulley
studs, 11A, Top and front of engine, Camshaft ).
18699
11A-148
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
5
8
12 11 10
6
14889 18666
Disconnect:
- the ignition coil connectors (8) ,
7 - the air temperature sensor connector (9) ,
- the camshaft dephaser connector (10) ,
- the inlet manifold pressure sensor connector (11) ,
- the fuel vapour recirculation solenoid valve pipe
(12) ,
- the injector connectors,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Move the wiring harness to one side.
Remove:
- the ignition coils,
- the plugs,
Disconnect:
11A-149
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
17
18
13
14
102939 102940
Remove: Remove:
- the lifting bracket (13) at the timing end, - the oil separator mounting bolts.
- the oil separator (17) ,
- the inlet manifold mounting bolts (14) ,
- the lifting bracket at the flywheel end (18) .
- the inlet manifold.
15
16
101793
Remove:
11A-150
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
19
19
102941
Remove the rocker cover bolts.
Remove the rocker cover vertically, tapping the lugs
(19) with a copper hammer.
WARNING
Do not damage the aluminium surfaces.
11A-151
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
20
15151
Remove the inlet and exhaust camshafts (20)
11A-152
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
21
22
14499
Remove:
- the valve rockers (21) ,
- the hydraulic tappets (22) .
Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
11A-153
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
15153
Remove:
- the cylinder head bolts, WARNING
- the cylinder head. To prevent any foreign bodies from entering the
oil pipes (pipes in the cylinder block and cylinder
Mount the cylinder head on the cylinder head moun-
head).
ting (Mot. 1573) .
Remove the cylinder head gasket from the cylinder
block II - CHECKING THE GASKET FACE
IMPORTANT
Do not scratch the aluminium gasket faces. WARNING
During the operation, wear: No regrinding of the cylinder head is permitted.
- goggles, Test the cylinder head to detect any cracks using the
- gloves. cylinder head testing tool (see Technical Note
3783A, F4 4-cylinder petrol engine, 10A, Engine
Clean the gasket faces with DÉCAPJOINT to dissol- and peripherals, Rebuilding the cylinder head)
ve any sections where the seal is still attached. for the cylinder head stripping procedure.
Apply the product to the section to be cleaned; Wait Position the pistons at mid-stroke to prevent any
for approximately ten minutes, then remove it using contact with the valves when the camshafts are
a wooden spatula. being refitted.
11A-154
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
Be sure to degrease:
REFITTING
Fit the new cylinder head gasket.
24 25
23 15152
The camshafts are identified by the pulley moun-
tings.
Detailed view of the pulley mountings:
- (24) : exhaust camshaft,
- (25) : inlet camshaft.
14499
Refit:
11A-155
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
26
15106-1 14517
Position the camshaft grooves as shown in the dia- Using a stipple roller, apply LOCTITE 518 to the
gram. camshaft rocker cover gasket face until it is reddish
in colour.
WARNING
The gasket faces must be clean, dry and free Note:
from grease (avoid finger marks). Using a cloth, remove the LOCTITE 518 from
(26) the camshaft rocker cover bearings.
WARNING
Do not apply oil to the sealing face of the cams-
haft bearing cap cover.
11A-156
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
14497
Tighten to torque and in order:
- rocker cover bolts 22, 23, 20, 13 ( (8 Nm) ) ,
- rocker cover bolts 1 to 12, 14 to 19, 21 to 24 (
(12 Nm) ) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order mounting bolts 22,
23, 20, 13 (12 Nm) .
11A-157
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
102738 102729
Refit the oil separator.
11A-158
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
27
106443
On the four ignition coils, apply a bead (2 7) of
FLUORINATED GREASE 82 00 169 855 2 mm in
diameter to the lower circumference of the high-ten-
sion cap.
11A-159
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 770 or 771
102939 15103-1
Refit the plugs. Refit:
Tighten to torque the plugs ( 25 to 30 Nm ) . - the new sealing plugs:
Refit the coils. • on the inlet camshaft (Mot. 1487) ,
Tighten to torque: • on the exhaust camshaft (Mot. 1488) ,
- the coils (if holes already threaded) ( 12 Nm ) , - the right-hand suspended engine mounting (see
19D, Engine mounting, Suspended engine
- the coils (if holes not threaded) ( 15 Nm ) .
mounting ).
Refit the inlet manifold with its new gasket.
Proceed in the reverse order to removal.
Tighten to torque and in order the inlet manifold ( 9
Fill the cooling circuit (see 19A, Cooling, Cooling
Nm ) .
circuit: Draining-refilling ).
Refit the camshaft offset timer solenoid valve, with a
Connect the battery (see 80A, Battery, Battery: Re-
new seal.
moval - Refitting ).
Replace the camshaft seals.
Bleed the cooling circuit (see 19A, Cooling, Coo-
- use the (Mot. 1517) for the inlet camshaft seal. ling circuit: Bleeding ).
- use the (Mot. 1512) for the exhaust camshaft seal. Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
Refit:
- the timing belt (it is essential to follow the procedu-
re (see 11A, Top and front of engine, Timing
belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
11A-160
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
Equipment required Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining-refilling ).
cylinder head testing tool
Tightening torquesm
11A-161
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
105432
Set up the engine stand (1) (Mot. 1672) .
Remove the (Mot. 1453) and (Mot. 1669) .
1
14889
102735
Disconnect:
11A-162
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
- the catalytic converter upstream oxygen sensor
connector.
5
10
4
11
7 6
8
18666
Disconnect:
104240
- the ignition coil connectors (4) , Disconnect the connector (10) from the injectors
- the air temperature sensor connector (5) , Unfasten the clip (11) .
- the camshaft dephaser solenoid valve connector Move the wiring harness to one side.
(6) ,
Remove:
- the inlet manifold pressure sensor connector (7) ,
- the ignition coils,
- the fuel vapour recirculation solenoid valve pipe (8)
, - the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
101809
Disconnect:
- the camshaft position sensor connector (9) ,
11A-163
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
12
14
13
15
103272 101793
Remove: Remove:
- the lifting bracket (12) , - the catalytic converter-gearbox stay mounting bolts
(14) ,
- the inlet manifold mounting bolts (13) ,
- the catalytic converter/gearbox strut,
- the inlet manifold.
- the exhaust pipe mounting nuts (15) .
Move the exhaust pipe aside.
Remove the camshaft pulleys using the (Mot. 1490-
01) .
11A-164
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
16
18
17
18
103255 103256
Remove:
Remove:
WARNING
- the oil separator mounting bolts (17) ,
Do not damage the aluminium surfaces.
- the oil separator.
103258
Remove the inlet and exhaust camshafts.
11A-165
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
Apply the product to the section to be cleaned; Wait
approximately ten minutes, then remove the residue
using a wooden spatula.
19
WARNING
Do not allow this product to drip onto the pain-
20
twork.
Clean the cylinder head carefully to prevent
foreign bodies from entering the oil supply and
return pipes.
Failure to follow this guideline could lead to bloc-
kage of the oilways, resulting in rapid and serious
damage to the engine.
To prevent any risk of unpriming the hydraulic For the cylinder head stripping procedure (see
tappets make sure that they are vertical. Technical Note 3784A, K4 4-cylinder petrol engi-
ne, 10A, Engine and peripherals, Rebuilding the
Remove: cylinder head) .
Position the pistons at mid-stroke to prevent any
- the cylinder head mounting bolts,
contact with the valves when refitting the camshafts.
- the cylinder head. Be sure to degrease:
Mount the cylinder head on the cylinder head moun- - the cylinder head combustion face,
ting (Mot. 1573) .
- the cylinder block combustion face.
Remove the cylinder head gasket from the cylinder
block.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
11A-166
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
22 21 23
14689 14499
Check that the centring dowel is present (21) on the Reprime the hydraulic tappets (hydraulic tappets
cylinder block. may empty after a long down time).
Fit the (Mot. 104) (22) on the cylinder block. To check if repriming is necessary, press the top of
the tappet (23) with your thumb.
REFITTING If the tappet piston depresses:
Fit the new cylinder head gasket. - immerse the tappets in a container full of diesel
fuel,
Refit the cylinder head.
- refit the hydraulic tappets.
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket: Refit:
Removal - Refitting ). - the valve rockers,
Tighten the cylinder head (see 11A, Top and front - the camshafts, oiling the bearings.
of engine, Tightening the cylinder head ).
11A-167
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
I - CAMSHAFT MARKINGS
26 27
Inlet camshaft
24
28
29
103685
Position the pin (26) of the (Mot. 1669) against the
102507
bottom of the groove by loosening bolt (27) .
Mount the (Mot. 1669) on the rocker cover, correctly
(24) The inlet camshaft is fitted with positioning the pin (28) in the rocker cover hole (29) .
the camshaft sensor target.
Exhaust camshaft
25
30
103684
Fit the rocker cover tool (Mot. 1669) using the bolts
102506
(30) .
11A-168
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
32
35
31 34
103687 103686
Tighten the bolt (31) until the pin (32) is hard up Turn the bolt (34) until the pin (35) is hard up against
against the bottom of the groove. the bottom of the groove.
Remove the (Mot. 1669) from the rocker cover.
33
103688
Position the bolt of the (Mot. 1669) in place of the
original bolt at (33) to hold the tappet in the com-
pressed position.
11A-169
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
36
15106-1 14517
Position the camshaft grooves horizontally and off- Using a stipple roller, apply LOCTITE 518 to the
set downwards. camshaft rocker cover gasket face until it turns red-
dish.
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could damage certain components (engine,
radiator).
11A-170
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
II - TIGHTENING PROCEDURE
14497
Tighten to torque and in order:
- rocker cover mounting bolts 22, 23, 20, 13 (8
Nm) ,
- rocker cover mounting bolts 1 to 12, 14 to 19,
21 to 24 (12 Nm) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order rocker cover moun-
ting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-171
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
10 1 9
4
5
8
3
2
6
101820
WARNING
Excess sealant could be squeezed out when the 37
parts are tightened. A mixture of sealant and fluid
could damage certain components (engine,
radiator).
16016
Refit:
11A-172
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
38
106443
11A-173
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
3 8
39 7
103257 103272
Refit the plugs. Tighten to torque and in order the inlet manifold
mounting bolts ( 9 Nm ) .
Tighten to torque the plugs ( 25 to 30 Nm ) using
the plug spanner set (Ele. 1382) .
III - REPLACING THE CAMSHAFT SEALS
Refit the coils.
Tighten to torque
- the coil mounting bolts (if holes already threa-
ded) ( 12 Nm ) ,
- the coil mounting bolts (if holes not threaded) (
15 Nm )
.
Refit the cylinder reference sensor (39) with a new
seal.
Tighten to torque the camshaft position sensor
mounting bolt ( 10 Nm ) . 41
40
Always replace all the inlet manifold seals.
20257
The elastomer seal on these engines is fitted with a
flat lip seal (40) and a protector (41) (also assists in
fitting the seal to the engine).
11A-174
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
1 - Fitting the seal to the exhaust camshaft
44
42 43
105531
18687
WARNING
It is very important to hold the protector (4 2)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (43) in order to prevent any oil
leaks once the seal is fitted to the engine.
44
21687
Screw the stud (44) of the (Mot. 1632) onto the
camshaft.
11A-175
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
21687-1 21687-3
Fit the protector, with a seal, to the camshaft. Screw in the collar nut until the cover comes into
contact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
45 WARNING
46 It is very important to hold the protector when
handling the seal, as this type of seal is very fra-
gile. In order to prevent any oil leaks once the
seal is fitted to the engine, it is strictly forbidden
to touch the elastomer seal.
21687-2
Fit the cover (45) and the collar nut (46) of the (Mot.
1632) .
11A-176
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
47
48
105531
105532
Fit the protector (47) , with a seal, to the camshaft.
Push the centre of the protector to force the seal into
its housing.
48
105534
Screw the stud (48) of the (Mot. 1632) onto the
camshaft.
105533
Remove the seal protector, taking care not to drop
the seal.
11A-177
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K4M, and 760 or 761
49
50
105535 15103-1
Fit the cover (49) and the collar nut (50) of the (Mot. Refit:
1632) .
- the accessories belt (see Top and front of engine,
Screw in the collar nut until the cover comes into Accessories belt: Removal - Refitting ).
contact with the cylinder head.
- new inlet camshaft sealing plugs using the (Mot.
Remove the nut, cover, protector and threaded rod. 1487) ,
- new exhaust camshaft sealing plugs using the
IV - REFITTING (Mot. 1488) ,
Refit the timing belt (see 11A, Top and front of en- Proceed in the reverse order to removal.
gine, Timing belt: Removal and Refitting )
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining - refilling ).
WARNING Connect the battery (see 80A, Battery, Battery: Re-
Follow the second procedure in the timing belt moval - refitting ).
refitting procedure.
Bleed the cooling circuit (see 19A, Cooling, Coo-
ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
11A-178
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F4R, and 776
WARNING
Removing and refitting the turbocharger requires
careful application of the repair procedures to
ensure the system is properly sealed.
FAILURE TO COMPLY WITH THESE INSTRUC-
TIONS MAY HAVE SERIOUS SAFETY-RELATED
CONSEQUENCES FOR THE DRIVER.
11A-179
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
Disconnect the battery, starting with the negative
Special tooling required terminal.
Mot. 1202-01 Clip pliers for cooling Drain the cooling circuit through the cooling radiator
system hose clips using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
(large model) 1448) .
11A-180
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
105432
Fit the engine support with (Mot. 1672) .
Remove (Mot. 1453) and (Mot. 1453-01) .
111887
111888
Disconnect:
- the oil vapour rebreathing pipe (4)
- the air inlet duct (see 12A, Fuel mixture, Air inta-
ke: Removal - Refitting ) (5) .
- the turbocharging pressure connector (7) ,
- the throttle valve connector (8) ,
- the turbocharging pressure solenoid valve connec-
tor (9) ,
- the flowmeter connector (10)
- the rail pressure sensor connector (11) ,
- the diesel pressure regulator connector (12) .
Remove:
- the injector rail protector (13) (see 13B, Diesel in-
jection, Injector rail protector ).
11A-181
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
111889
Disconnect:
- the diesel return temperature sensor connector,
- the high-pressure pump pressure regulator con-
nector,
111886
- the heater plug connectors (21) ,
Disconnect:
- the diesel return pipe (22) ,
- the vacuum pipe (14) from the vacuum pump,
- the diesel fuel supply pipe.
- the air filter outlet duct (15) , Remove the starter (see 16A, Starting-Charging,
Starter: Removal - Refitting .
- the exhaust gas recirculation connector (16) ,
Remove:
- the coolant temperature sensor (17) ,
- the turbocharger air duct,
- the turbocharger vacuum pipes (18) . - the turbocharger oil return pipe
- the coolant hoses.
- the turbocharger oil supply pipe.
Disconnect the scuttle panel hoses from the cylinder
head outlet.
111965
Disconnect:
11A-182
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
111861
102348
Remove:
- the high-pressure pump rear mounting bolts (23) ,
- the windscreen wiper mounting,
- the bonnet,
- the cylinder head mounting bolts.
WARNING
When removing the cylinder head, take care not
to cause any damage to its gasket face as it pas-
ses the turbocharger above it.
11A-183
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
I - CLEANING Refit the cylinder head with a new cylinder head gas-
ket.
Clean the cylinder head.
Refit new cylinder head bolts.
Tighten the cylinder head (see 11A, Top and front
IMPORTANT
of engine, tightening the cylinder head) using a
Do not scratch the aluminium gasket faces.
angular tightening wrench .
Wear protective goggles.
Refit the catalytic converter (see 19B, Exhaust, Ca-
Wear gloves during the operation. talytic converter ).
Clean the gasket faces with DECAPJOINT clea- Refit the timing belt (see 11A, Top and front of en-
ning product to dissolve the part of the gasket gine, Timing belt ).
which is stuck to the sump and cylinder cover. Refit the accessories belt (see 11A, Top and front
Apply the product to the section to be cleaned; of engine, Accessories belt ).
Wait approximately ten minutes, then remove the
Fill and bleed the cooling circuit (see 19A, Cooling,
residue using a wooden spatula. Bleeding the cooling circuit .
Reprime the diesel circuit (see 13B, Fuel supply,
WARNING Diesel supply circuit ).
To prevent any foreign bodies from entering the Connect the battery, starting with the positive termi-
oil pipes (pipes in both the cylinder block and nal.
cylinder head).
WARNING
WARNING carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply pipes.
Tighten to torque the battery cover mounting
Failure to follow this instruction could lead to the bolts. ( 4 Nm . )
pipes becoming blocked, causing rapid camshaft
damage.
WARNING
No regrinding is permitted.
REFITTING
Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head.
Degrease the gasket faces.
11A-184
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
Drain the engine cooling circuit (see 19A, Cooling,
Special tooling required Cooling circuit: Draining-refilling ).
Mot. 1672 Lower engine support
WARNING
Mot. 1453 Multiple-adjusting
engine mounting sup- Fit plugs in the openings.
port with retaining
Always respect the repair precautions (see 13B,
straps
Diesel injection, Diesel injection: Precautions
Mot. 1453-01 Additional winder nut during repair ).
on engine lift support Remove:
Mot. 1453
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Equipment required
- the engine covers,
diagnostic tool
- the battery tray,
cylinder head testing equipment - the lower engine tie-bar (see 19D, Engine moun-
ting, Suspended engine mounting: Removal -
angular tightening wrench Refitting ).
Remove the catalytic pre-converter (see 19B, Ex-
Tightening torquesm haust, Catalytic Pre-converter: Removal - Refit-
ting ).
battery cover mounting 4 Nm
Remove:
bolts
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting) ,
REMOVING - REFITTING - the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
IMPORTANT
11A-185
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
7 6 13
11
1 4
2 15
5 12
3
14
111887 111886
Disconnect:
111888
Disconnect: 16
17
- the oil vapour rebreathing pipe (1) ,
- the air inlet duct (see 12A, Fuel mixture, Air inlet:
Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the throttle valve connector (5) ,
- the turbocharging pressure solenoid valve connec-
tor (6) , 111965
11A-186
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
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-187
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
I - CLEANING
IMPORTANT
Do not scratch the aluminium sealing surfaces.
During the operation, wear:
21
- goggles,
- gloves.
21 WARNING
To prevent any foreign bodies from entering the
oil pipes (pipes in both the cylinder block and
cylinder head).
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply galle-
ries.
Failure to follow this instruction could lead to the
pipes becoming blocked, causing rapid camshaft
damage.
111863
Remove the mounting bolts (21) from the exhaust
gas recirculation pipe. II - CHECKING THE GASKET FACE
Remove the mounting clip from the exhaust gas re- Check for gasket face bow using a ruler and a feeler
circulation pipe. gauge.
Remove the cylinder head mounting bolts.
The maximum bow is 0.05 mm .
Remove the cylinder head.
WARNING
No regrinding is permitted.
11A-188
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
F9Q, and 804
REFITTING
Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head.
Degrease the gasket faces.
Refit the cylinder head with a new cylinder head gas-
ket.
Refit new cylinder head bolts.
Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head) using a
angular tightening wrench .
Refit the catalytic pre-converter (see 19B, Exhaust,
Catalytic Pre-converter: Removal - Refitting ).
Refit the timing belt (see 11A, Top and front of en-
gine, Timing belt: Removal - Refitting ).
Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting
).
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining-refilling ).
Reprime the diesel circuit (see 13B, Fuel supply,
Diesel fuel supply circuit ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-
ling circuit: Bleeding ).
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
11A-189
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
Ele. 1552 Tool for removing rear Before starting work on the vehicle, obtain:
screen wiper arm - a new plug kit ( PART NO. 77 01 476 857) ,
Mot. 1672 Lower engine support - some cleaning cloths ( PART NO. 77 11 211 707) ,
- cleaning product ( PART NO. 77 11 24 188) .
Mot. 1453 Multiple-adjusting
engine mounting sup-
port with retaining
straps
IMPORTANT
Mot. 1453-01 Additional winder nut
on engine lift support Before carrying out any work on the injection sys-
Mot. 1453 tem, check using the diagnostic tool :
- that the injection rail is not under pressure,
Mot. 1202-01 Clip pliers for cooling
system hose clips - that the fuel temperature is not too high.
(large model) It is essential to respect the safety and cleanliness
advice given in this document whenever work is
Mot. 1202-02 Pliers for small hose
carried out on this system (see 13B, Diesel injec-
clips
tion, Cleanliness guidelines).
Mot. 1448 Remote operation clip
pliers for cooling sys-
tem hose clips
WARNING
Equipment required Procedure for removing the air inlet duct (risk of
leaking and dislodging if this procedure is not res-
diagnostic tool
pected):
hydraulic crane - detach the hose using the (Car. 1363) ,
load positioner - do not use degreaser, brake cleaning agents, or
any other products,
cylinder head testing tool
- clean the bearing face on the intercooler with a
angular tightening wrench dry, lint-free cloth,
- always replace the clip with a new one,
Tightening torquesm - place the clip in the same position if the hose is
not replaced,
rocker cover mounting 10 Nm
- it is essential to replace the hose and/or the rigid
bolts
pipe in the event of damage.
alternator mounting 21 Nm
bolts
REMOVAL
hose clip on the stain- 5.5 Nm
less steel pipe
I - REMOVAL PREPARATION OPERATION
turbocharger oil return 9 Nm
pipe Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
battery cover bolts 4 Nm
Remove the engine covers.
11A-190
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
Remove the engine undertray. - the front bumper (see MR365, Bodywork, 55A,
Exterior protection, Front bumper ).
102101
104175
102100
Remove:
Remove:
102267
- the accessories belt (see 11A, Top and front of Remove:
engine, Accessories belt ),
- the alternator upper mounting bolt (26) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt ), - the alternator lower mounting bolt (27) ,
11A-191
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
112815
19710
Remove:
- the inner timing cover mounting bolts (6) ,
- the inner timing cover.
102473
Disconnect the air inlet pressure sensor connector
(7) .
Loosen the clips (8) and (9) .
19626
Remove the air inlet duct (10) .
Fit the engine stand (Mot. 1672) .
Remove the (Mot. 1453) fitted with the (Mot. 1453-
01) .
11A-192
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
112811 112992
Unclip the injection rail protector cover (14) .
Pull out the clip.
Remove:
- the injection rail protector cover,
- the injection rail protector cover mounting bolt and
mounting nut (15) ,
- the dipstick,
- the dipstick guide tube mounting bolts (16) .
Remove the dipstick guide tube.
112991
Remove:
112993
- the mounting bolt (12) from the stainless steel pipe,
Disconnect:
- the stainless steel pipe (13) . - the heater plug connectors (17) ,
11A-193
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
- the injector connectors (18) ,
112656
112994 Clean the fuel return and supply pipe unions (see
Disconnect: 13A, Diesel injection, Repair precautions ).
- the connector (19) from the damper valve,
- the cylinder reference sensor connector (20) , WARNING
- the pressure regulation solenoid valve connector Do not blast compressed air once the fuel circuit
(21) , is open, otherwise impurities may enter the sys-
tem. Use wipes if necessary.
- the flow regulation solenoid valve connector (22) ,
- the diesel temperature sensor connector (23) ,
Note:
- the rail pressure sensor connector.
Make preparations for fuel outflow. Clean with
Unclip the wiring harness retaining clip (24) .
new wipes.
Remove the wiring harness clip mounting nut (25) .
Disconnect:
Remove the wiring harness.
- the fuel supply pipe (28) ,
Tilt the alternator against the radiator assembly.
- the fuel return pipe (29) .
Fit plugs.
11A-194
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
112996
113475
Remove:
112997
Disconnect:
- the damper valve (see 12A, Damper valve: Re- - the turbocharging pressure regulation solenoid val-
moval - Refitting . ve hose on the pressure regulation valve side.
11A-195
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
REFITTING
I - CLEANING
IMPORTANT
Do not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
- the cylinder head using a hydraulic crane fitted No regrinding of the cylinder head is permitted.
with a load positioner .
For the cylinder head stripping procedure see Tech-
nical Note 6006A, 4-cylinder cast iron High Pres-
sure Common Rail Diesel Engine, 10A, Engine
and peripherals, Rebuilding the cylinder head . .
11A-196
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
III - REFITTING OPERATION FOR PART
CONCERNED
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING Refit:
The gasket faces must be clean, dry and free - the air inlet duct between the air filter unit outlet
from grease (avoid finger marks). and the turbocharger inlet,
- the oil vapour rebreathing pipe;
11A-197
TOP AND FRONT OF ENGINE
Cylinder head gasket : Removal - Refitting 11A
K9K, and 732
Refit: Connect:
- the injection rail protector cover mounting bracket, - the air pressure sensor,
- the injection rail protector cover retaining bracket - the exhaust gas recirculation solenoid valve con-
mounting bolts, nector.
Remove the blanking plugs. Fit the (Mot. 1453) with the (Mot. 1453-01) .
Connect: Remove the (Mot. 1672) .
- the fuel supply pipe, Refit:
- the fuel return pipe. - the inner timing cover,
Torque tighten the alternator mounting bolts ( 21 - the alternator upper mounting bolt,
Nm ) . - the alternator lower mounting bolt,
Connect:
- the turbocharger oil return pipe.
- the rail pressure sensor connector, Tighten to torque the turbocharger oil return pipe
- the diesel fuel temperature sensor connector. ( 9 Nm ) .
- the pressure regulation solenoid valve connector, - the catalytic converter (see 19B, Exhaust, Cataly-
tic converter ),
- the cylinder reference sensor,
- the timing belt (see 11A, Top and front of engine,
- the connector on the damper valve, Timing belt ),
- the heater plugs connector, - the accessories belt (see 11A, Top and front of
- the injector connectors, engine, Accessories belt ),
Position the wiring harness. - the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper ),
Refit the mounting nut of the wiring harness clip.
- the engine undertray,
Clip the retaining clip of the wiring harness.
- the battery,
Refit:
Fill and bleed the cooling circuit (see 19A, Cooling,
- the dipstick guide tube mounting bolts to the injec- Bleeding the cooling circuit ).
tion rail protector cover support,
Reconnect the battery (see 80A, Battery, Removal
- the diesel anti-splash device cover, - Refitting ).
- the injection rail protector cover bolt and nuts, Refit the engine covers.
Clip on the injection rail protector cover. Tighten to torque the battery cover bolts ( 4 Nm ) .
Refit:
- the clip to the stainless steel pipe,
- the stainless steel pipe between the intercooler
hose and the turbocharger, aligning the marks,
- the pipe between the intercooler and the damper
valve.
Tighten to torque the hose clip on the stainless
steel pipe ( 5.5 Nm )
Clip the stainless steel pipe to the turbocharger.
Refit the air duct between the damper valve and the
intercooler
Tighten the clips.
11A-198
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
K4J, and 730 or 732 – K4M, and 760 or 761
CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
14500
WARNING WARNING
Reuse the bolts if the length under the head The gasket faces must be clean, dry and free
does not exceed 117.7 mm (otherwise replace from grease (avoid finger marks).
all the bolts with new ones).
Tighten to torque and in order the cylinder head
In order to ensure that the bolts are correctly mounting bolts ( 20 Nm ) .
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes. Check that all of the cylinder head mounting bolts
are tightened to the correct torque of 20 Nm .
Do not oil the new bolts. The bolts must be oiled
if reused. Angle-tighten in order the cylinder head mounting
bolts ( 240˚ ± 6˚ ) .
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-199
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
K9K, and 722 or 728 or 729
Tightening torquesm
8 4 1 5 9
7 3 2 6 10
19712
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Always replace all of the cylinder head bolts with
new ones after removal.
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil that
may be in the cylinder head mounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-200
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
F9Q, and 800 or 804 or 808
CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
9 5 1 4 8
16189
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Systematically replace all cylinder head bolts
after removal.
To ensure correct tightening, use a syringe to
remove any oil that may be in the cylinder head
mounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-201
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
F4R, and 770 or 771 or 776
CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
1 10
6
4
2
8
3
7
15153
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
11A-202
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
F4R, and 770 or 771 or 776
Step 2
Angle-tighten in order the cylinder head mounting
bolts ( 100˚ ± 6˚ )
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-203
TOP AND FRONT OF ENGINE
Tightening the cylinder head 11A
K9K, and 732
CYLINDER HEAD TIGHTENING PROCEDURE
Equipment required
Tightening torquesm
19712
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Always replace all of the cylinder head bolts with
new ones after removal.
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-204
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
M9R, and 700
REMOVAL
Removing the cylinder head requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
Removal - Refitting ).
To remove the cylinder head (see Technical Note
6017A, M9R Diesel engine ).
REFITTING
To refit the cylinder head (see Technical Note
6017A, M9R Diesel engine ).
Refit the engine and gearbox assembly (see 10A,
Engine and peripherals, Engine and gearbox as-
sembly: Removal - Refitting ).
11A-205
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Engine
Gear-
Vehicle Type Suffix Bore Stroke Cubic Compression
box capacity
(mm) (mm) ratio
(cc)
ND0 770
XM0U 9.8/1
DP0 F4R 771 82.7 93 1,998
(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 2,500 rpm for approxi-
mately 30 seconds . (4)at 2,000 rpm CO should be a maximum of 0.3 %
(2)octane rating 91 unleaded compatible
Negative temperature coefficient air tem- 10,454 2,174 to 857 to 326 to 143 à 112 to
perature sensor (resistance in Ω) to 8,623 1,928 763 292 127 98
12A-1
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
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
12A-2
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
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
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
12A-4
FUEL MIXTURE
Specifications 12A
F4R, and 770 or 771 or 776
Camshaft dephaser solenoid AISIN (F4R 770 and It is controlled by the opening cyclic ratio.
valve 771)
Resistance: 7.2 ± 0.5 Ω to 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth
12A-5
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 – K4M, and 760 or 761
Equipment required
diagnostic tool
Engine
Gear-
Vehicle Type Suffix Bore Stroke Cubic Compression
box capacity
(mm) (mm) ratio
(cc)
730
XM0B JH3 K4J 79.5 70 1390
732
10 / 1
JH3 760
XM0C K4M 79.5 80.5 1,598
DP0 761
(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 2,500 rpm for approxi-
mately 30 seconds . (4)at 2,000 rpm CO should be a maximum of 0.3 %
(2)octane rating 91 unleaded compatible
Negative temperature coefficient air tem- 10,454 2,174 to 857 to 326 to 143 à 112 to
perature sensor (resistance in Ω) to 8,623 1,928 763 292 127 98
12A-6
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 – K4M, and 760 or 761
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
12A-7
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 – K4M, and 760 or 761
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
Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-
vious table)
12A-8
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 – K4M, and 760 or 761
Coolant temperature sensor JAEGER ELTH Negative temperature coefficient thermistor (see pre-
vious table)
or SILEA
K4J
K4M
12A-9
FUEL MIXTURE
Specifications 12A
K4J, and 730 or 732 – K4M, and 760 or 761
K4M
Camshaft dephaser solenoid valve DELPHI It is controlled by the opening cyclic ratio.
Resistance: 7.2 ± 0.5 Ω to 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth
12A-10
FUEL MIXTURE
Air inlet 12A
K4J, and 730 or 732
Diagram of the air inlet circuit
102071
12A-11
FUEL MIXTURE
Air inlet 12A
K4M, and 760 or 761
5 4
6
2
3
7
2
101190
12A-12
FUEL MIXTURE
Air inlet 12A
K9K, and 722
4
5
3 7
2
8
102070
12A-13
FUEL MIXTURE
Air inlet 12A
F9Q, and 800
3 5
4
102482
12A-14
FUEL MIXTURE
Air inlet 12A
F4R, and 770 or 771
4
5
3
2
2
102744
12A-15
FUEL MIXTURE
Air inlet 12A
F4R, and 776
4
6
2
5
1
107841
12A-16
FUEL MIXTURE
Air inlet 12A
K9K, and 728 or 729
4 3 7
5
2
1
110316
12A-17
FUEL MIXTURE
Air inlet 12A
F9Q, and 804
Diagram of the air inlet circuit
112269
12A-18
FUEL MIXTURE
Air inlet 12A
K9K, and 732
8 5 3
6
4
1
112302
12A-19
FUEL MIXTURE
Air inlet 12A
F9Q, and 808
Diagram of the air inlet circuit
114617
12A-20
FUEL MIXTURE
Air inlet 12A
M9R, and 700
Diagram of the air inlet circuit
114472
12A-21
FUEL MIXTURE
Air resonator: Removal - Refitting 12A
M9R, and 700
114659
Remove the air resonator (3) starting with the end
115726
piece side of the duct that is upstream of the air filter.
REFITTING
II - FINAL OPERATION
Refit the left-hand headlight.
Tighten:
115725 - the left-hand headlight upper mounting bolt,
Remove:
- the left-hand headlight lower mounting bolt.
- the left-hand headlight upper mounting bolt (1) ,
Disconnect the left-hand headlight connectors.
- the left-hand headlight lower mounting bolt (2) .
Refit the front bumper (see MR 365, Bodywork,
Disconnect the left-hand headlight connectors. 55A, Exterior protection, Front bumper ).
Remove the left-hand headlight. Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
12A-22
FUEL MIXTURE
Air filter: Replacement 12A
K4J, and 730 or 732
REPLACING THE FILTER ELEMENT
2
1
101104
101103 Disconnect brake servo vacuum pipe (2) from the in-
Remove: let manifold.
- the air resonator mounting bolt (1) ,
- the air resonator housing. WARNING
Do not damage the vacuum outlet on the inlet
manifold. If it is broken the inlet manifold will
need to be replaced.
Remove:
- the two air filter cover mounting bolts (3) ,
- the filter element.
12A-23
FUEL MIXTURE
Air filter: Replacement 12A
F4R, and 770 or 771 or 776 – F9Q, and 800 or 804 or 808 – K4M, and 760 or 761 – K9K, and 722 or 728 or 729 or
732
Tightening torquesm
2
battery cover mounting 4 Nm
bolts
106276
1
Remove:
- the cover (2) ,
- the filter element.
.
106277 REFITTING
Remove the mounting bolts (1) from the air filter co- Tighten to torque the battery cover mounting bolts
ver. ( 4 Nm ) .
12A-24
FUEL MIXTURE
Air filter: Removal - Refitting 12A
F4R or F9Q or K4M or K9K or M9R
REMOVAL REFITTING
II - FINAL OPERATION
Tighten the air filter unit mounting bolts.
106277
Remove the mounting bolts (1) from the air filter co-
ver.
106276
Remove:
- the cover (2) ,
- the air filter.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4J, and 730 or 732
Tightening torquesm
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
102101
Unclip the trim (3) .
2
1
4
102100
Remove:
- the seal (1) , 102105
Remove wiper arms (4) using tool (Ele. 1294-01) .
- the plastic rivets (2) .
Remove the scuttle panel grille.
12A-26
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4J, and 730 or 732
5 8
101487 101104
Remove: Disconnect brake servo vacuum pipe (7) from the in-
let manifold.
- the bulkhead soundproofing mountings (5) ,
- the bulkhead soundproofing material.
WARNING
Do not damage the vacuum outlet on the inlet
manifold. If it is damaged, the inlet manifold will
need to be replaced.
Remove:
- air filter cover mounting bolts (8) ,
- the filter element.
101103
Remove:
- the air resonator mounting bolt (6) ,
- the air resonator.
12A-27
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4J, and 730 or 732
REFITTING
Replace:
- the throttle valve seal each time it is removed using
grease to make fitting easier,
- the plastic rivets and clips every time they are re-
moved.
9
Proceed in the reverse order to removal.
Torque tighten the air filter unit mounting bolts ( 9
Nm ) .
Connect the battery, starting with the positive termi-
nal.
10
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
11
101488
Remove:
- air filter mounting bolts (11) ,
- the air filter unit.
12A-28
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
M9R, and 700
Tightening torquesm
102504
Disconnect the connectors (2) .
Unpick the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) .
12A-29
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
M9R, and 700
112659 104555
Disconnect the injection computer connectors (6) . Move the turbocharger regulation solenoid valve
(10) to one side.
Remove:
Remove the air duct between the air filter unit and
- the battery tray mounting bolts (7) ,
the turbocharger.
- the wiring harness mounting nut (8) .
Move the electric wiring harness to one side.
Unpick the battery negative terminal wiring harness
(9) .
Remove the battery tray and the injection computer.
114933
Unclip the air inlet scoop (11) .
12A-30
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
102365
Remove:
- the lower front end panel mounting bolts (12) .
- the front end panel.
115019
Remove the air inlet duct (14) .
114659
Remove the air resonator (13) .
115020
Remove the air filter unit (15)
12A-31
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
M9R, and 700
II - FINAL OPERATION
Refit:
Tighten to torque:
I - REFITTING OPERATION FOR PART Refit the battery tray and the computer.
CONCERNED
Tighten to torque the battery tray mounting bolts (
Refit the air flowmeter onto the air filter unit. 21 Nm ) .
Tighten to torque the air flowmeter mounting bolts Refit the wiring harness mounting nut.
( 4 Nm ) using the (Mot. 1608) .
Tighten to torque the wiring harness mounting nut
Refit the air filter unit.
( 8 Nm ) .
Connect:
Refit:
12A-32
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4M, and 760 or 761 – F4R, and 770 or 771 or 776
Tightening torquesm
101811
Remove the injection computer (4) and its mounting.
2
1
6
3
101822 5
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
101737
- the wiring harness strap (3) .
Remove:
Unclip the wiring harnesses from the battery tray.
- the air inlet sleeve (5) ,
Remove the battery tray.
- the air ducts (6) ,
- the air filter unit.
12A-33
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K4M, and 760 or 761 – F4R, and 770 or 771 or 776
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (
21 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12A-34
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K9K, and 722 or 728 or 729
Tightening torquesm
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
Remove the battery (see 80A, Battery: Removal -
Refitting ).
101811
Remove the injection computer (4) and its mounting.
101822
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
101737
- the wiring harness strap (3) .
Remove:
Unclip the wiring harnesses from the battery tray.
- the air inlet sleeve (5) ,
Remove the battery tray.
- the air ducts (6) ,
- the air filter unit.
12A-35
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K9K, and 722 or 728 or 729
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (
21 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12A-36
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
F9Q, and 800 or 804 or 808 – K9K, and 732
Tightening torquesm
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
Remove the battery (see 80A, Battery: Removal -
Refitting ).
101811
Remove the injection computer (4) and its mounting.
101822
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
101737
- the wiring harness strap (3) .
Remove:
Unclip the wiring harnesses from the battery tray.
- the air inlet sleeve (5) ,
Remove the battery tray.
- the air ducts (6) ,
- the air filter unit.
12A-37
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
F9Q, and 800 or 804 or 808 – K9K, and 732
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (
21 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12A-38
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
M9R, and 700
Tightening torquesm
REMOVAL
Loosen:
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ). - the air inlet duct clip (3) on the air filter unit side,
114846
Unclip:
12A-39
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
M9R, and 700
- the air flowmeter (5) .
REFITTING
Note:
Be sure not to damage the air flowmeter seal.
Replace the seal if necessary.
II - FINAL OPERATION
Refit the air filter unit - turbocharger air inlet duct.
Tighten to torque:
- the air inlet duct clip on the air filter unit side (
5.5 Nm ) ,
- the air inlet duct clip on the turbocharger side (
5.5 Nm ) .
Clip:
- the oil vapour rebreathing duct onto the air filter unit
- turbocharger air inlet duct,
- the turbocharger regulation solenoid valve hose
onto the air filter unit - turbocharger air inlet duct,
Refit the turbocharger regulation solenoid valve onto
the air filter unit.
Connect:
- the air flowmeter connector,
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
12A-40
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
K9K, and 732
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
REMOVAL
112810
Disconnect:
- the connector (4) from the damper flap,
- the vacuum pipe from the brake servo.
Remove:
- the damper flap mounting nuts (5) ,
- the damper flap,
- the damper flap seal.
112815 REFITTING
Disconnect the air inlet pressure sensor connector
(1) .
I - REFITTING OPERATION FOR PART
Loosen the clip and (2) and move the air inlet duct CONCERNED
(3) to one side.
Refit:
- the damper flap with a new seal,
- the damper flap mounting nuts.
Tighten to torque the damper flap mounting nuts (
12 Nm ) .
Connect:
- the vacuum pipe from the brake servo,
- the connector to the damper flap.
II - FINAL OPERATION
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
12A-41
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
K9K, and 732
Refit the engine covers.
12A-42
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
F9Q, and 804
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
Replace the seal.
damper flap mounting 8 Nm
bolts Tighten to torque the damper flap mounting bolts
( 8 Nm ) .
battery cover mounting 4 Nm
bolts Connect the battery, starting with the positive termi-
nal.
REMOVAL WARNING
Remove the engine covers. Carry out the necessary programming (see 80A,
Disconnect the battery, starting with the negative Battery: Removal - Refitting ).
terminal.
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
111887
Loosen the air inlet hose clip (1) .
Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the connector (2) from the damper flap,
- the turbocharging pressure sensor connector (3) .
Remove the damper flap.
12A-43
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
M9R, and 700
Tightening torquesm
REMOVAL
Remove:
12A-44
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
M9R, and 700
112659 115701
Disconnect the injection computer connectors (6) . Disconnect the turbocharger pressure sensor con-
nector (11) .
Remove:
Remove the turbocharger pressure sensor mounting
- the battery tray mounting bolts (7) , nut (12) on the damper flap strut.
102365
Remove:
- the lower front end panel mounting bolts (13) .
- the front end panel.
114933
12A-45
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114649
114406
Disconnect the damper flap connector (17) .
Remove:
- the mounting bolts (18) from the damper flap retai-
ning strut on the inlet manifold,
- the mounting bolts (19) from the damper flap retai-
ning strut on the exhaust gas recirculation solenoid
valve,
- the damper flap,
- the seal between the damper flap and the exhaust
gas recirculation solenoid valve
REFITTING
115702 Replace the seal between the damper flap and the
exhaust gas recirculation solenoid valve.
Remove the mounting bolt (14) from the intercooler
duct (downstream) on the cooling radiator.
Loosen:
- the downstream intercooler duct clip (15) on the in-
tercooler,
- the downstream intercooler duct clip (16) on the
damper flap.
Remove the downstream intercooler duct.
12A-46
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
M9R, and 700
II - REFITTING OPERATION FOR PART
CONCERNED
Finger tighten until contact:
- the damper flap retaining strut mounting bolts on
the inlet manifold,
- the damper flap retaining strut mounting bolts on
the exhaust gas recirculation solenoid valve,
Tighten to torque:
- the damper flap retaining strut mounting bolts
on the inlet manifold ( 12 Nm ) ,
- the damper flap retaining strut mounting bolts
on the exhaust gas recirculation solenoid valve
( 12 Nm ) .
12A-47
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
M9R, and 700
III - FINAL OPERATION - the engine undertray,
Refit: - the engine protectors,
- the downstream intercooler duct clip onto the inter- - the battery (see 80A, Battery, Battery: Removal -
cooler and the damper flap, Refitting ).
- the downstream intercooler duct mounting bolt Carry out programming by following command sce-
onto the cooling radiator. nario SC036 if replacing or removing - refitting the
damper flap (see MR 366 Fault finding, 13B, Fault
Tighten to torque: finding - Interpretation of commands ) and (see
- the downstream intercooler duct clip on the in- MR 366 Fault finding, 13B, Fault finding - Repla-
tercooler ( 5.5 Nm ) , cement of components ).
12A-48
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
F9Q, and 800 or 808
Tightening torquesm
REMOVAL
101892
1
4
101893
Disconnect:
- the battery, starting with the negative terminal,
5
- the turbocharging pressure sensor (1) .
101884
Remove:
12A-49
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
F9Q, and 800 or 808
REFITTING
8
7
101884
Replace the seal.
Refit the inlet duct.
Tighten to torque in order:
- the inlet duct mounting bolts ( 8 Nm ) ,
- the inlet duct nut ( 21 Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-50
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
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:
111887
Disconnect:
Remove:
12A-51
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
K4J, and 730 or 732
Tightening torquesm
REMOVAL
Disconnect the battery, starting with the negative
terminal.
Remove:
101794
- the air filter unit (see 12A, Fuel mixture, Air filter
unit ), Remove:
- the plenum chamber mounting bolts,
- the throttle valve (see 12A, Fuel mixture, Throttle
valve ). - the plenum chamber.
REFITTING
Always replace all of the seals.
Proceed in the reverse order to removal.
1 2
101100
Disconnect:
12A-52
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
K4J, and 730 or 732
7
5
4
3
101794
Tighten to torque and in order the plenum chamber
mounting bolts ( 9 Nm )
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air unit bolts ( 9 Nm ) ,
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting
12A-53
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
F4R, and 770 or 771 – K4M, and 760 or 761
Tightening torquesm
REMOVAL
4
2
1
102735
Disconnect:
- throttle valve connector (2) ,
- brake servo vacuum pipe (3) to the inlet manifold.
101807
Note:
Disconnect the battery, starting with the negative Do not damage the vacuum outlet on the inlet
terminal. manifold. If it is damaged, the inlet manifold will
need to be replaced.
Remove:
- the engine covers, Disconnect fuel vapour recirculation pipe (4) to the
throttle valve.
- air duct (1) .
12A-54
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
F4R, and 770 or 771 – K4M, and 760 or 761
ON THE WORKBENCH
Remove the throttle valve.
7 REFITTING
Always replace all of the seals with new ones.
Proceed in the reverse order to removal.
7
6
5
8
6
5 2
5
101795 1
Disconnect electrical wiring harness (5) . 3
Pull the electric wiring harness to one side.
IMPORTANT
102726
Be careful of petrol splashing when disconnec-
ting the supply pipe union from the injector rail. Tighten to torque and in order the inlet manifold
bolts ( 9 Nm ) .
Unclip fuel vapour recirculation pipe (7) from the in- Tighten to torque the motorised throttle valve
let manifold. bolts ( 13 Nm ) , tightening each bolt evenly.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
102726
12A-55
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
F4R, and 776
Tightening torquesm
REMOVAL
Disconnect the battery, starting with the negative
terminal.
106633
Remove:
- motorised throttle valve mounting bolts (4) ,
2 - the motorised throttle valve.
1
5
7
106270
106787
Disconnect:
- turbocharging pressure sensor connector (5) ,
- vacuum pipe (6) from the brake servo,
- oil vapour recirculation pipe (7) .
106272
12A-56
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
F4R, and 776
106271 106337
106337
REFITTING
WARNING
Be sure to replace all the sealing joints with new
ones when they are removed.
12A-57
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4J, and 730 or 732
Tightening torquesm
IMPORTANT
Be careful of petrol splashing when disconnec-
ting the supply pipe union from the injector rail.
WARNING 7
Protect the alternator against fuel spills from the 5
rail or supply duct.
6
101493
Remove the two injection rail bolts (5)
Pull the injection rail gently towards yourself to re-
move it.
Remove:
1
- nut (6) securing the electrical wiring harness,
- oil gauge well (7) .
101801
12A-58
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4J, and 730 or 732
REFITTING
9 10
12 16
11
8 15
19
13 17
101792 20 18 14
Remove the injector holder shim mounting bolts. 101792
Secure:
Tighten to torque:
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-59
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4M, and 760 or 761
Tightening torquesm
bolts 7 to 14 on the 21 Nm
injector holder shim
1
suspended mounting 44 Nm
bolt
REMOVAL
Disconnect the battery, starting with the negative
terminal.
101810
Remove the inlet manifold (see 12A, Fuel mixture, Disconnect injectors (1) .
Inlet manifold ).
Move the wiring harness to one side.
Remove:
IMPORTANT
Be careful of petrol splashing when disconnec- - injector rail mounting bolts (2) ,
ting the supply pipe union from the injector rail. - the injector rail, pulling it carefully towards you.
WARNING
3
Protect the alternator against fuel spills from the
rail or supply duct.
102303
Remove injector mounting plate mounting bolts (3) .
12A-60
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4M, and 760 or 761
REFITTING 4 Nm ) .
5 6
13 9
10
14
7 11
12 8
102303
The injector holder shim seal must always be repla-
ced.
Insert all the mounting bolts.
Secure:
- the injector holder shim against the upper timing
cover, by tightening bolt (3) by hand,
- the injector holder shim against the engine suspen-
ded mounting by tightening bolt (4) by hand.
Tighten to torque in order:
- bolts 5 and 6 on the injector holder shim ( 25
Nm ) ,
- bolts 7 to 14 on the injector holder shim (
21 Nm ) .
Tighten to torque:
- the suspended mounting bolt ( 44 Nm ) ,
- the upper timing cover bolt ( 44 Nm ) .
Refit the inlet manifold (see 12A, Fuel mixture, Inlet
manifold ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-61
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
F4R, and 770 or 771
Tightening torquesm
bolts 9 to 16 on the 21 Nm
injector holder shim 2
suspended mounting 44 Nm
bolt 6
IMPORTANT
Be careful of petrol splashing when disconnec- 4
ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from the
rail or supply duct.
102730
Remove:
- injector rail mounting bolts (4) ,
- the injector rail, pulling it carefully towards you.
101801
12A-62
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
F4R, and 770 or 771
REFITTING
8 12
7
11
15
16 13
10 9
101792 5 14
Remove the injector holder shim mounting bolts. 101792
Secure:
Tighten to torque:
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-63
FUEL MIXTURE
Manifolds: Removal - Refitting 12A
F9Q, and 800 or 808
Tightening torquesm 6
8
Manifold mounting stud 8 Nm
REMOVAL
102478
Disconnect the battery, starting with the negative
terminal. Disconnect the exhaust gas recirculation solenoid
valve.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ), Remove:
- the turbocharger (See 12B, Turbocharging, Tur- - the exhaust gas recirculation solenoid valve (6) ,
bocharger ).
- the exhaust gas recirculation pipe (7)
- the manifolds.
REFITTING
- on the manifolds,
102486
- the exhaust gas recirculation solenoid valve,
Disconnect:
- on the air inlet duct.
- the air inlet pipe from the damper (1) ,
- the engine stop solenoid valve (2) connector. Tighten to torque:
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-64
FUEL MIXTURE
Manifolds: Removal - Refitting 12A
F9Q, and 804
Tightening torquesm
manifold mounting 8 Nm
studs
REMOVAL
Disconnect the battery, starting with the negative
terminal.
Position the vehicle on a lift.
Remove:
- the injector rail protector (see 13B, Diesel injec-
tion, Injector rail protector: Removal - Refitting
). 111872
Disconnect the exhaust gas temperature before tur-
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
bocharger sensor (1) .
- the exhaust gas recirculation unit (see 14A, Emis-
Remove:
sion control, Exhaust gas recirculation unit ),
- the manifold mounting nuts
- the exhaust gas recirculation pipe,
- the exhaust manifold (2) .
- the catalytic pre-converter (see 19B, Exhaust, Ca-
talytic pre-converter: Removal - Refitting ).
- the starter motor (see 16A, Starting-charging,
Starter motor: Removal - Refitting ).
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting ).
111873
Remove the inlet manifold (3) .
12A-65
FUEL MIXTURE
Manifolds: Removal - Refitting 12A
F9Q, and 804
REFITTING
Proceed in the reverse order to removal.
Replace the manifold gaskets.
Refit the manifolds.
Tighten to torque:
- the manifold mounting studs ( 8 Nm ) ,
- the manifold mounting nuts ( 28 Nm ) ,
Refit:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
- the exhaust gas recirculation solenoid valve (see
14A, Emission control, Exhaust gas recircula-
tion unit ),
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger ).
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12A-66
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
Tightening torquesm
exhaust manifold 30 Nm
mounting nuts
12A-67
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
114990 112658
Loosen the air inlet duct clip (5) on the air flowmeter
Remove:
side.
Remove: - the Protection and Switching Unit cover mounting
bolts (7) ,
- the air inlet duct on the air flowmeter side,
- the front bumper (see MR 365, Bodywork, 55A, - the Protection and Switching Unit cover.
Exterior protection, Front bumper ).
102504
12A-68
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
- the EGR duct heat shield mounting bolt (14) on the
cylinder head,
- the EGR duct mounting bolts (15) on the cylinder
head.
102365
Remove:
113311
113280
113281
Remove:
113295
- the gasket between the EGR cooler and the EGR
Remove: duct,
- the EGR duct heat shield mounting bolt (13) on the - the gasket between the EGR duct and the exhaust
exhaust manifold, manifold.
12A-69
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
113279
113279
Remove: Note:
- the exhaust manifold mounting nuts, Check that the manifold gasket is positioned cor-
rectly.
- the exhaust manifold spacers,
The tab must be positioned as (18) .
- the exhaust manifold,
- the exhaust manifold gasket. Refit the new seal on the exhaust manifold.
113279
12A-70
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
M9R, and 700
III - FINAL OPERATION Connect the Protection and Switching Unit connec-
tors.
Refit:
- the new gasket between the EGR duct and the ex- Refit:
haust manifold,
- the Protection and Switching Unit cover,
- the new gasket between the EGR cooler and the
EGR duct. - the Protection and Switching Unit cover mounting
bolts,
Finger tighten until contact:
- the front bumper (see MR 365, Bodywork, 55A,
- the EGR duct mounting bolts on the exhaust mani-
Exterior protection, Front bumper ),
fold,
- the EGR duct mounting bolts on the EGR cooler, - the air inlet duct to the air flowmeter,
- the EGR duct mounting bolts on the cylinder head. - the air inlet duct clip on the air flowmeter side.
Tighten to torque:
Tighten to torque the air inlet duct clip ( 5.5 Nm ) .
- the EGR duct mounting bolts on the EGR cooler
( 30 Nm ) , Refit the battery tray with the injection computer
mounting.
- the EGR duct mounting bolts on the exhaust
manifold ( 30 Nm ) , Fit the computer connector wiring harness.
- the EGR duct mounting bolt on the cylinder Refit:
head ( 10 Nm ) .
Fit the heat shield. - the wiring harness mounting nut,
- the EGR duct heat shield mounting bolt to the cylin- Tighten to torque the battery tray mounting bolts (
der head, 21 Nm ) .
- the EGR duct heat shield mounting bolt to the ex-
Fit:
haust manifold.
Tighten to torque: - the turbocharger regulation solenoid valve wiring
harness,
- the EGR duct heat shield mounting bolt on the
cylinder head ( 10 Nm ) , - the battery negative terminal connector wiring har-
ness,
- the EGR duct heat shield mounting bolt on the
exhaust manifold ( 10 Nm ) . - the injection computer connector wiring harness.
Refit:
Connect:
- the front end panel,
- the turbocharger regulation solenoid valve connec-
- the upper mounting bolts of the front end panel, tor,
- the lower mounting bolts of the front end panel.
- the air flowmeter connector,
Tighten to torque:
- the injection computer connectors.
- the lower mounting bolts of the front end panel
( 44 Nm ) , Refit:
- the upper mounting bolts of the front end panel
- the turbocharger (see 12B, Turbocharging, Tur-
( 21 Nm ) .
bocharger: Removal - Refitting ).
Clip on the air inlet scoop.
- the catalytic converter (see 19B, Exhaust, Cataly-
Connect the screen washer pipes. tic converter: Removal - Refitting ).
Refit the clips.
- the battery (see 80A, Battery, Battery: Removal -
Fit the bonnet opening cable. Refitting ).
12A-71
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 722 or 728 or 729
- the exhaust gas recirculation unit,
Special tooling required
- the manifold mounting nuts (5) ,
Mot. 1567 Remote operation
- the manifold.
pliers for EGR clips
Tightening torquesm
exhaust manifold 26 Nm
mounting nuts
lifting eye 21 Nm
REMOVAL
Put the vehicle on a two-post lift.
4 2
3
1
5
102074
Remove:
- the lifting eye (2) ,
12A-72
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 722 or 728 or 729
REFITTING
8
4
2
6 7
3
1
5
20848-1
Replace the manifold gasket. Refit the turbocharger (see 12B, Turbocharging,
Turbocharger ).
Tighten to torque the exhaust manifold studs ( 9
Nm ) . Connect the battery, starting with the positive termi-
nal.
Refit the manifold.
Tighten to torque and in order the exhaust manifold
mounting nuts ( 26 Nm ) . WARNING
Carry out the necessary programming (see 80A,
Fit:
Battery: Removal - Refitting ).
- the exhaust gas recirculation unit,
Tighten to torque the battery cover mounting bolts
- the new exhaust gas recirculation unit tube, ( 4 Nm ) .
- the new clips on the new exhaust gas recirculation
unit tube.
Tighten the new clips using the (Mot. 1567) .
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolts ( 21 Nm ) ,
- the air inlet metal tube mounting bolts ( 21 Nm )
,
- the lifting eye ( 21 Nm ) .
Proceed in the reverse order to removal.
12A-73
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K4J, and 730 or 732 – K4M, and 760 or 761
Tightening torquesm
manifold nuts. 23 ± 3 Nm
oxygen sensors 45 Nm
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
K4J
Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit ). 3
2
K4M
Remove the inlet manifold (see 12A, Fuel mixture,
Inlet manifold ).
101793
Remove:
Note:
Mark with a pen the position of the exhaust
silentbloc supports on the vehicle body.
12A-74
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K4J, and 730 or 732 – K4M, and 760 or 761
7
4
7
102116 101798
Remove mounting bolt (4) from the exhaust pipe si- Remove oxygen sensor (6) using tool (Mot. 1495-
lentbloc supports on the body. 01) .
Remove upper heat shield (7) from the exhaust ma-
nifold.
102117
Remove mounting bolt (5) from the silencer silent-
bloc bracket on the body. 101797
Withdraw the exhaust pipe towards the rear of the Remove:
vehicle.
- the nine exhaust manifold securing nuts,
- the exhaust manifold.
12A-75
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K4J, and 730 or 732 – K4M, and 760 or 761
ON THE WORKBENCH
8
2
3
5
9
7
1
4
6
101797
101502 Proceed in the reverse order to removal.
Remove the lower heat shield.
Tighten to torque and in order:
- the manifold nuts. ( 23 ± 3 Nm ) ,
REFITTING
- the heat shield bolts ( 10 Nm ) ,
Always replace:
- the oxygen sensors ( 45 Nm ) ,
- the manifold gaskets,
- the mounting bolts for the exhaust pipe brac-
- the exhaust bracket gaskets, kets to the body ( 21 Nm ) ,
- the manifold nuts. - the bolt on the inlet manifold strut ( 8 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-76
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
F4R, and 770 or 771
Tightening torquesm
manifold nuts 18 Nm
2
heat shield bolts 10 Nm
oxygen sensors 45 Nm
3
REMOVAL Note:
Position the vehicle on a two-post lift. Mark with a pen the position of the exhaust
silentbloc supports on the vehicle body.
Disconnect the battery, starting with the negative
terminal.
1
4
102116
101501
Remove mounting bolt (4) from the exhaust pipe si-
Disconnect downstream oxygen sensor (1) . lentbloc supports on the body.
12A-77
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
F4R, and 770 or 771
102117 101797
Remove mounting bolt (5) from the silencer silent- Remove:
bloc bracket on the body.
- the exhaust manifold mounting nuts,
Withdraw the exhaust pipe towards the rear of the
- the exhaust manifold.
vehicle.
ON THE WORKBENCH
7
101798
Remove oxygen sensor (6) using tool (Mot. 1495-
01) . 101502
Remove upper heat shield (7) from the exhaust ma- Remove the lower heat shield.
nifold.
REFITTING
Always replace:
- the manifold gaskets,
12A-78
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
F4R, and 770 or 771
- the exhaust bracket gaskets,
- the manifold nuts.
8
2
3
5
9
7
1
4
6
101797
Proceed in the reverse order to removal.
Tighten to torque and in order:
- the manifold nuts ( 18 Nm ) ,
- the heat shield bolts ( 10 Nm ) ,
- the oxygen sensors ( 45 Nm ) ,
- the mounting bolts for the exhaust pipe brac-
kets to the body ( 21 Nm ) ,
- the bolt on the exhaust manifold strut on the
gearbox ( 21 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-79
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
F4R, and 776
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
exhaust manifold 20 Nm
mounting nuts WARNING
21936
Remove:
- the exhaust manifold mounting nuts,
- the exhaust manifold.
12A-80
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
F4R, and 776
2
6
5
1
3 7 8
4
21936
Tighten to torque and in order the exhaust manifold
mounting nuts ( 20 Nm ) .
Refit:
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger ).
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
WARNING
Strict adherence to the repair procedures is
required for the removal and refitting of the turbo-
charger in order to seal the system FAILURE TO
COMPLY WITH THESE INSTRUCTIONS MAY
HAVE SERIOUS SAFETY-RELATED CONSE-
QUENCES .
12A-81
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 732
Tightening torquesm
exhaust manifold 9 Nm
mounting studs
exhaust manifold 26 Nm
mounting nuts
REMOVAL
12A-82
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 732
113558
Loosen the mounting bolts (7) on the EGR unit by a
few turns.
Move the EGR unit to one side without removing it.
113475
II - REMOVAL OF PART CONCERNED
Remove the mounting bolts (4) from the injection rail
cover mounting bracket.
113561
Remove:
113842
Remove: - the mounting nuts (8) from the exhaust manifold,
- the clip (5) from the EGR rigid pipe using the (Mot. - the exhaust manifold.
1567) ,
- the mounting bolts (6) from the exhaust gas recir- REFITTING
culation pipe,
- the exhaust gas inlet pipe . I - REFITTING PREPARATION OPERATION
Always clean the joint faces thoroughly.
12A-83
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 732
II - REFITTING OPERATION FOR PART
CONCERNED
20848-1
Tighten to torque and in order the exhaust manifold Fit the new snap-on clip.
mounting studs ( 9 Nm ) .
Position the new exhaust manifold gasket. WARNING
Refit: Ensure that you do not constrain the exhaust gas
recirculation rigid pipe before fitting the snap-on
- the exhaust manifold, clip.
- the exhaust manifold mounting nuts.
Tighten the bolts of the exhaust gas recirculation ri-
Tighten to torque the exhaust manifold mounting gid pipe on the manifold until they make contact.
nuts ( 26 Nm ) .
Adjust the exhaust gas recirculation rigid pipe in re-
lation to the cooler support.
III - FINAL OPERATION Lock the snap-on clip of the exhaust gas recircula-
Fit the exhaust gas recirculation unit. tion rigid pipe using the (Mot. 1567) .
Torque tighten the exhaust gas recirculation unit Tighten to torque the exhaust gas recirculation ri-
mounting bolts ( 25 Nm ) . gid pipe mounting bolts ( 35 Nm ) .
Refit: Refit:
- the lifting eye mounting bolts on the timing end,
- the new exhaust gas recirculation rigid pipe with a
new seal, - the timing end lifting eye,
- the mounting bolts on the exhaust gas recirculation - the injection rail protector cover retaining bracket
pipe, mounting bolts,
12A-84
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
K9K, and 732
- the inlet throttle valve mounting bolt,
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting ).
- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ).
- the engine undertray.
Connect the damper valve connector.
Refit the air inlet duct between the intercooler and
the inlet throttle valve on the inlet throttle valve.
Tighten the clip on the air inlet duct.
Connect the air inlet pressure sensor connector.
Connect the battery (see 80A, Battery: Removal -
Refitting ).
Refit the engine covers.
12A-85
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4J, and 730 or 732
Equipment required
diagnostic tool
Tightening torquesm
1
101800
Remove:
2 - mounting bolts (4) ,
- the throttle valve.
101489
Disconnect the battery, starting with the negative
terminal.
Remove air filter unit (1) (see 12A, Fuel mixture,
Air filter unit ).
Disconnect:
- throttle valve connector (2) ,
- fuel vapour recirculation pipe (3) on the control so-
lenoid valve.
12A-86
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4J, and 730 or 732
REFITTING
Proceed in the reverse order to removal.
Replace the throttle valve seal each time it is remo-
ved (use grease to make it easier to fit).
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air filter unit bolts ( 9 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-87
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
F9Q, and 800 or 808
Tightening torquesm
REMOVAL
2
101892
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-88
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4M, and 760 or 761
Equipment required
diagnostic tool 4
Tightening torquesm
REMOVAL 2
4
102735
Disconnect:
1 - throttle valve connector (2) ,
- fuel vapour recirculation pipe (3) on the control so-
lenoid valve.
Remove:
- the four throttle valve mounting bolts (4) ,
- the throttle valve.
101807
Disconnect the battery, starting with the negative
terminal.
Remove air duct (1) .
12A-89
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
K4M, and 760 or 761
REFITTING
Replace the throttle valve seal with a new one each
time it is removed.
Proceed in the reverse order to removal.
Tighten to torque the throttle valve mounting bolts
( 13 Nm ) , tightening them evenly.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
12A-90
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Tightening torquesm
REMOVAL
2 4
1
106270
Remove the engine covers.
Remove air duct (1) .
Remove fuel vapour recirculation pipe (2) . 101807
Disconnect the motorised throttle valve connector. Disconnect the battery, starting with the negative
terminal.
Remove air duct (4) .
12A-91
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
F4R, and 770 or 771 or 776
REFITTING
Replace the throttle valve seal each time it is remo-
ved.
7
Proceed in the reverse order to removal.
Tighten to torque the throttle valve mounting bolts
(F4R 776) ( 10 Nm ) , tightening them evenly.
Tighten to torque the throttle valve mounting bolts
6 ( 13 Nm ) , tightening them evenly.
Connect the battery, starting with the positive termi-
nal.
WARNING
7 Carry out the necessary programming (see 80A,
5 Battery: Removal - refitting ).
- the four throttle valve mounting bolts (7) , Using the diagnostic tool « CLIP » , check that the
programming has been performed correctly ET051
- the throttle valve. « Throttle stop programming » .
12A-92
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
F9Q, and 804
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
Replace the seal.
throttle valve mounting 8 Nm
bolts Torque tighten the throttle valve mounting bolts (
8 Nm ) .
battery cover mounting 4 Nm
bolts Connect the battery, starting with the positive termi-
nal.
REMOVAL WARNING
Remove the engine covers. Carry out the necessary programming (see 80A,
Disconnect the battery, starting with the negative Battery: Removal - Refitting ).
terminal.
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
3
2
1
111887
Undo the air inlet hose clip (1) .
Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the throttle valve connector (2) ,
- the turbocharging pressure sensor connector (3) .
Remove the throttle valve.
12A-93
FUEL MIXTURE
Throttle valve: Cleaning 12A
F4R or K4J or K4M
Equipment required
diagnostic tool
WARNING
Wear protective goggles and gloves during the ope-
ration. Be sure to work in a clean environment so
as not to allow any contamination of the throttle
valve.
106901
WARNING
Do not apply cleaning agent, part number 77 11
171 437 , to the outside of the valve, in the spring
housing or on the connector.
106899
Remove the external O-ring seals from the throttle
valve.
Note:
The Renault carburettor cleaning agent, part
number 77 11 171 437 can damage the seals.
106900
12A-94
FUEL MIXTURE
Throttle valve: Cleaning 12A
F4R or K4J or K4M
106902
WARNING
It is essential to replace the throttle valve O-ring
seals.
Note:
If the throttle valve is dropped or receives any
other impact, it will need to be replaced.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12A-95
FUEL MIXTURE
Engine stop device 12A
F9Q, and 800 or 808
I - OBJECTIVE
The system is intended to stop the engine quickly after
the ignition is switched off. 4
II - DESCRIPTION
102486
The system consists of:
- a diaphragm (1) acting on the throttle,
- a throttle (2) ,
- a solenoid valve (3) ,
- a vacuum (4) .
1
III - OPERATING PRINCIPLE
When the ignition is switched off, the solenoid valve
101892
connects the vacuum and the diaphragm.
The diaphragm is submitted to the vacuum; this closes
the air inlet flap.
2 The engine can no longer take in air and stops running
immediately.
101894
12A-96
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F9Q
Instructions that must be followed when turbochargers - Replace the turbocharger upstream duct (see dia-
are replaced due to mechanical damage: gram)
- damage to the bearing system, - Clean the turbocharger ducts
- broken shaft,
- Drain the engine oil
- compressor wheel rubbing against the turbocharger
casing, - Replace the oil filter
- broken compressor wheel. - Replace the oil return and supply pipes and their
Damage of the kind listed above can lead to impurities seals
entering the circuits to which the turbocharger is con-
nected.
I - INSTRUCTIONS FOR THE AIR CIRCUIT
FOR THE AIR CIRCUIT:
- Consequences:
Diagram of the air circuit
• swarf and metal objects in the ducts upstream and
downstream of the turbocharger, 6 2
A
• large volumes of oil in the air circuit (collected in the
intercooler).
- Risks (after replacing the turbocharger):
• metal objects found in the compressor wheel (des- 7
truction of turbocharger),
• engine racing (oil sucked up in the intercooler).
FOR THE LUBRICATION CIRCUIT:
5
- Consequences: B
1
• swarf found in the engine oil circuit, 4
• circulation of swarf within the circuit. C
3
- Risks (after replacing the turbocharger):
• premature wear on the bearing system (destruction
of turbocharger).
112666
12B-1
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F9Q
11
110738 112772
Damage to the compressor wheel results in metal ob- For ducts comprising several components:
jects entering the air duct (A) between the air filter and
- mark the duct (11) so that you can identify where
the turbocharger.
each component should be positioned when refitting,
Replace the air duct (A) between the air filter and the
- separate all the duct components.
turbocharger.
Check that there are no metal objects inside the flow-
meter (7) .
112770
Clean the removed ducts one by one using a cleaning
spray:
- brush as much of the duct interior as possible (only
use brushes with plastic bristles),
- wash the duct with plenty of cleaning liquid,
- let the cleaned duct drain by standing it up vertically
and then start cleaning the next duct.
12B-2
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F9Q
112771 102480
Dry the ducts one by one using a compressed air spray
gun.
For ducts comprising several components:
- assemble the components in the correct order using
the markings (11) that you have previously made.
Refit:
- the turbocharger pressure sensor (4) for section (C) ,
if the duct is fitted with one.
- the air circuit duct (between the turbocharger and the
intercooler) for section (B) ,
- the air circuit duct (between the intercooler and the in-
let manifold) for section (C) ,
Refit the new intercooler (3) , if the vehicle is fitted with
one (refer to the Workshop Repair Manual of the vehi-
cle affected 12B, Turbocharging, Intercooler ,).
WARNING
Always replace all seals that have been removed.
12B-3
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F9Q
WARNING
12B-4
TURBOCHARGING
Turbocharging: Precautions for repair 12B
M9R, and 700
WARNING
With a marker, mark the position of the exhaust rub-
ber mounting bush supports on the bodywork.
WARNING
- Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation.
- Check that the turbocharger oil return pipe is not
completely or partially blocked by scale. Check
that it is not leaking; if it is, replace it.
12B-5
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728 or 729
diagnostic tool
6 3
1
Tightening torquesm
turbocharger mounting 7 Nm
studs on the turbochar-
ger 2
turbocharger mounting 7 Nm
studs on the exhaust
manifold
turbocharger mounting 26 Nm
nuts on the exhaust
manifold 4
5
turbocharger oil inlet 22.5 Nm
pipe union on the cylin-
der head
exhaust gas recircula- 12 Nm - the exhaust gas recirculation solenoid valve (4) ,
tion solenoid valve heat - the turbocharging duct (5) on the turbocharger,
shield mounting bolts
- the pipe (6) from the turbocharging pressure regu-
battery cover mounting 4 Nm lation valve on the air duct.
bolts
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
12B-6
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728 or 729
10
11
110326
Disconnect:
110325 - the turbocharging pressure sensor connector (9) ,
Pull out the clip. - the exhaust gas recirculation solenoid valve mani-
fold (10) ,
- the turbocharging duct (11) on the turbocharger,
- the pipe from the turbocharging pressure regula-
8 tion valve on the turbocharging pressure regulation
solenoid valve.
110323
Undo bolt (7) .
Remove the air duct (8) .
12B-7
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728 or 729
14
12
13
102076 102116
Remove: Remove mounting bolt (14) from the exhaust pipe
rubber mounting bush support on the body.
- the exhaust flange mountings (12) ,
- the stay mounting (13) on the catalytic converter.
Loosen the other stay mountings on the gearbox.
Remove stay (13) . 15
Note:
Mark the position of the exhaust rubber mounting
bush supports on the vehicle body with a pen.
102117
Remove mounting bolt (15) from the silencer rubber
mounting bush support on the body.
Withdraw the exhaust pipe towards the rear of the
vehicle.
12B-8
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728 or 729
22
20
17
21
16
102077 102079
Remove: Remove:
- the catalytic converter stay (16) , - the oil supply pipe (20) ,
- the four mounting nuts (17) securing the catalytic - the oil return pipe (21) ,
converter to the turbocharger,
- the two upper mounting nuts (22) from the turbo-
- the catalytic converter. charger,
- the lower mounting nut from below,
- the turbocharger.
19 18
102119
Remove:
- the bracket (18) ,
- the exhaust gas recirculation solenoid valve heat
shield (19) .
12B-9
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 722 or 728 or 729
WARNING
WARNING Carry out the necessary programming (see 80A,
Check that the intercooler is not full of oil. If this Battery: Removal - Refitting ).
is the case, remove it, rinse with a cleaning agent
and then let it dry. Before starting, disconnect the 4 injectors (starting
the engine is prohibited).
Run the starter motor until the oil pressure warning
WARNING light goes out (wait for a few seconds).
Switch off the ignition.
Always replace:
Reconnect the 4 injector connectors.
- all the O-rings and both copper seals on the tur-
bocharger oil inlet duct, Start the engine.
- the exhaust flange seal. Let the engine idle then depress the accelerator se-
veral times with no load.
- any damaged heat shield.
Switch off the ignition.
Tighten to torque:
Make sure that there are no oil leaks.
- the turbocharger mounting studs on the turbo-
charger ( 7 Nm ) , Connect the diagnostic tool and clear the stored
faults.
- the turbocharger mounting studs on the ex-
Make sure that all the exhaust pipe heat shields are
haust manifold ( 7 Nm ) .
in place and properly secured.
Position the turbocharger on the exhaust manifold.
Make sure that there is no contact with the underbo-
Tighten to torque the turbocharger mounting nuts dy.
on the exhaust manifold ( 26 Nm ) .
Tighten to torque the battery cover mounting bolts
Apply LOCTITE FRENTANCH to the threads of the ( 4 Nm ) .
turbocharger oil inlet pipe union on the cylinder
head.
Position the turbocharger oil supply pipe on the tur-
bocharger and on the cylinder head, applying new
seals in the process.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cy-
linder head ( 22.5 Nm ) ,
- the turbocharger oil inlet duct socketed bolt on
the turbocharger ( 22.5 Nm ) .
Position the turbocharger oil return pipe on the tur-
bocharger and on the cylinder block, applying new
seals in the process.
Torque tighten the turbocharger oil return pipe
mounting bolts on the turbocharger ( 12 Nm )
12B-10
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 800
Tightening torquesm
turbocharger mounting 8 Nm
studs
turbocharger mounting 26 Nm
nuts
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
102480
Remove:
- the turbocharger.
12B-11
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 800
REFITTING
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.
check that the sealing is perfect; if not, replace it.
12B-12
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 800
made previously.
Make sure that there is no contact with the underbo-
dy.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
114467
Always replace the end piece seal on the union (5) ,
if the end piece has been removed.
Tighten to torque:
- the turbocharger mounting studs ( 8 Nm ) ,
- the turbocharger union end piece ( 26 Nm ) , if
the studs have been removed.
Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts
( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply pipe
nuts,
- screw on (without tightening) the oil supply pipe
mounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- the oil supply pipe mounting nuts ( 22.5 Nm ) ,
- the oil supply pipe mounting bolt on the cylin-
der block ( 12 Nm ) ,
- the turbocharger oil return pipe mounting bolts
( 12 Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter: Removal - Refitting ).
Proceed in the reverse order to removal.
Make sure that all the exhaust pipe heat shields are
in place and properly secured.
Refit the exhaust pipe, aligning it with the marks
12B-13
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F4R, and 776
Equipment required
1
diagnostic tool
Tightening torquesm
turbocharger cooling 12 Nm 3
2 4
duct bolts (initial torque)
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) .
REMOVAL
Note:
To loosen the turbocharger mounting nuts on the
exhaust manifold, spray some releasing agent
onto the nuts while they are still warm, just
21928
before removal.
Fit hose clamps and remove the turbocharger coo-
Disconnect the battery, starting with the negative ling hoses (5) .
terminal.
Removal of the turbocharger requires the engine to
be removed (see 10A, Engine and peripherals,
Engine - Gearbox ).
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter ).
12B-14
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F4R, and 776
21929 21931
Remove:
Remove:
- the heat shield bolt (6) ,
- the turbocharger oil return pipe mounting bolts (8) ,
- the engine cover mounting and the turbocharger
strut (7) , - the turbocharger oil return pipe (10) ,
- the turbocharger - intercooler air pipe.
- the turbocharger oil supply pipe (9) .
21930
21933
Remove the starter motor heat shield.
Remove:
- the turbocharger.
12B-15
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F4R, and 776
REFITTING
The turbocharger mounting nuts and studs must be
replaced along with the seals.
WARNING
Ensure that no impurities enter the turbine or
compressor during the refitting operation.
If there has been a fault in the turbocharger,
check that the intercooler is not full of oil. If this is
the case, remove it, rinse with a cleaning agent
and then let it dry.
Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
15
21931
16
22809
On the workbench, refit and tighten to torque:
- the two bolts of the oil return pipe towards the
cylinder block ( 12 Nm ) (13) ,
- the oil return pipe bolt (14) .
17
Pre-tighten the turbocharger cooling duct bolts
(initial torque) ( 12 Nm ) (15) ,
Tighten to torque the turbocharger cooling duct
bolts ( 27 Nm ) .
106273
Tighten:
12B-16
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F4R, and 776
All removed seals must be replaced including those
on the cooling pipe as well as the intercooler - turbo-
18 charger air pipe.
Fill and bleed the cooling circuit (see 19A, Cooling,
Filling - Bleeding ).
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
18 Battery: Removal - Refitting ).
WARNING
- Before starting the engine, connect the dia-
gnostic tool and lock the injection system.
- Run the starter motor until the oil pressure war-
ning light goes out (wait a few seconds) then
21933 unlock the injection system.
- Start the engine then accelerate with no load
several times.
- Switch off the ignition and check that there are
no oil leaks.
- Run the engine at idle speed until the engine
cooling fan starts up:
- Accelerate several times with no load then per-
form a road test.
- Clear the faults using the diagnostic tool .
- Switch off the ignition and check that there are
no oil leaks.
21931
Tighten to torque:
12B-17
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 804
Equipment required
diagnostic tool
Tightening torquesm
turbocharger mounting 37 Nm
nuts
oil supply pipe moun- 25 Nm - the battery tray mounting bolts (1) ,
ting bolt on the housing - the nut (2) ,
turbocharger oil return 12 Nm - the battery tray.
pipe
Bleed the cooling system (see 19A, Cooling, Coo-
battery cover mounting 4 Nm ling system: Draining - filling ).
bolts Remove the catalytic pre-converter (see 19B, Ex-
haust, Catalytic Pre-converter: Removal - Refit-
ting ).
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
Remove the battery.
12B-18
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 804
111866 111869
Remove, using the (Mot. 1448) : Remove the duct between the turbocharger and the
air filter.
- the « hose - rigid pipe assembly » (3) . between
the EGR cooler (4) and the water outlet unit, Disconnect the turbocharger (7) vacuum pipe.
- the « hose - rigid pipe assembly » (5) between the
EGR coolant and the heater matrix hose.
Disconnect the upper cooling hose on the turbochar-
ger.
111860
111865
Remove the air duct (6) from the turbocharger.
Remove the turbocharger oil return pipe (8) .
12B-19
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 804
111868 111870
Remove the starter motor (see 16A, Starting-Char- Remove the turbocharger oil supply pipe (10) .
ging, Starter motor: Removal - Refitting ).
111871
111867 Remove the turbocharger mounting nuts (11) .
Remove the heat shield (9) .
12B-20
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 804
REFITTING
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.
Tighten to torque:
- the turbocharger mounting nuts ( 37 Nm ) ,
- the turbocharger oil supply pipe hollow moun-
ting bolts ( 22.5 Nm ) ,
- the oil supply pipe hollow mounting bolt on the
housing ( 44 Nm ) ,
- the oil supply pipe mounting bolt on the hou-
sing ( 25 Nm ) ,
- the turbocharger oil return pipe ( 12 Nm ) .
Refit:
- the starter motor (see 16A, Starting-charging,
112458 Starter motor: Removal - Refitting ).
Remove the turbocharger (12) . - the catalytic pre-converter (see 19B, Catalytic
pre-converter: Removal - Refitting ).
12B-21
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 804
Make sure that all the exhaust pipe heat shields are
in place and properly secured.
Make sure that there is no contact with the underbo-
dy.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
12B-22
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 732
Tightening torquesm
turbocharger mounting 9 Nm
studs
turbocharger mounting 26 Nm
nuts
112991
REMOVAL
Loosen the mounting bolt (1) on the air inlet rigid
duct.
I - REMOVAL PREPARATION OPERATION
Move the air inlet rigid duct to one side (see (2) .
Put the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ).
112816
Disconnect:
12B-23
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 732
REFITTING
WARNING
Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation.
Check that the turbocharger oil return pipe is not
completely or partially blocked by scale. Check
that there are no leaks. If there are, replace the
part.
WARNING
Check that the intercooler is not full of oil. If it is,
remove and rinse it with the cleaning agent, then
let it drip dry.
102079
Remove:
WARNING
- the bolt (6) mounting the oil inlet pipe on the turbo-
Replace any damaged heat shield.
charger,
- the bolt mounting the oil inlet pipe on the cylinder
head,
- the oil supply pipe ,
- the oil return pipe mounting bolts,
- the oil return pipes (5) ,
- the upper mounting nuts (7) from the turbocharger,
- the lower mounting nut from the turbocharger,
- the turbocharger.
12B-24
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 732
II - REFITTING OPERATION FOR PART Refit the catalytic converter (see 19B, Exhaust, Ca-
CONCERNED talytic converter: Removal - Refitting ).
Tighten to torque the turbocharger mounting nuts Refit the air inlet rigid duct mounting bolt.
( 26 Nm ) . Connect:
Refit: - the air inlet duct on the turbocharger,
- the new oil inlet pipe, - the oil vapour rebreathing pipe.
- the oil inlet pipe mounting bolt on the turbocharger Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -
- the bolt mounting the oil inlet pipe on the cylinder
Refitting ).
head.
Refit the engine covers.
Tighten to torque:
Refit:
Refit:
Connect:
12B-25
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 808
Disconnect the battery, starting with the negative
Special tooling required terminal.
Mot. 1566 Wrench for removing
high-pressure pipes
Tightening torquesm
turbocharger mounting 8 Nm
studs
turbocharger mounting 26 Nm
nuts
turbocharger mounting 26 Nm
nuts
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
12B-26
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 808
I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION
(TURBOCHARGER SIDE)
104421
Disconnect the turbocharger air inlet and outlet pi-
pes (3) . 114207
Remove:
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ). - the mounting bolt (4) from the oil supply pipe,
- the hollow mounting bolt (5) from the oil supply pipe
Note: union on the turbocharger.
During factory fitting, 2 types of oil supply pipe Loosen the union (6) on the cylinder block.
can be fitted to the turbocharger. Remove the oil supply pipe by passing it through the
The way in which a turbocharger is removed turbocharger wheels.
depends on the type of pipe. Remove:
- the oil return pipe mounting bolts,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger.
12B-27
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 808
II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
114467
In the event that the oil supply pipe is replaced:
104417
- remove the oil supply union end piece (9) . This
Remove the bolt (7) mounting the oil supply pipe to
step prepares the turbocharger for the supply pipe
the cylinder block.
to be refitted with the hollow bolt union.
Undo the oil supply pipe unions on:
- the cylinder block, REFITTING
- the turbocharger (8) using the (Mot. 1566) .
Remove the turbocharger oil supply pipe.
Note:
Remove:
During factory fitting, 2 types of oil supply pipe
- the oil return pipe mounting bolts, can be fitted to the turbocharger.
- the oil return pipe, The way in which a turbocharger is refitted
depends on the type of pipe.
- the turbocharger bracket mounting nuts,
- the turbocharger.
WARNING
Ensure that no impurities enter the turbine or
Note:
compressor during the refitting operation.
There is only one supply pipe part number
Check that the turbocharger oil return pipe is not
available as a replacement part. Only the oil sup-
completely or partially blocked by scale.
ply pipe with a hollow bolt union is available.
Also check that it is perfectly sealed. If not,
replace it.
12B-28
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 808
- the turbocharger seals. II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT
UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mounting
studs ( 8 Nm ) .
Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts
( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply union
mounting nut on the cylinder block,
- screw on (without tightening) the supply pipe hol-
low mounting bolt,
- screw on (without tightening) the oil supply pipe
mounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
114467
- the hollow mounting bolt on the turbocharger
oil supply pipe ( 22.5 Nm ) , Always replace the end piece seal on the union (10)
, if the end piece has been removed.
- the nut mounting the oil supply pipe on the cy-
linder block ( 22.5 Nm ) , Tighten to torque:
- the bolt mounting the oil supply pipe on the cy- - the turbocharger mounting studs ( 8 Nm ) ,
linder block ( 25 Nm ) - the turbocharger union end piece ( 26 Nm ) , if it
- the turbocharger oil return pipe mounting bolts has been removed.
( 12 Nm ) . Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts
( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply pipe
mounting nuts,
- screw on (without tightening) the oil supply pipe
mounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- using the tool, the oil supply pipe mounting nut
on the turbocharger side ( 22.5 Nm ) ,
- the oil supply pipe mounting nut on the cylinder
block ( 22.5 Nm ) ,
- the turbocharger oil return pipe mounting bolts
( 12 Nm )
12B-29
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 808
To refit, proceed in the reverse order to removal.
Make sure that all the exhaust pipe heat shields are
in place and properly secured.
Refit the exhaust pipe, aligning it with the marks
made previously.
Make sure that there is no contact with the underbo-
dy.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
12B-30
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
REMOVAL
Equipment required
I - REMOVAL PREPARATION OPERATION
roller-type stud removal tool
Put the vehicle on a two-post lift (see 02A, Lifting
tweezers equipment, Underbody lift ).
turbocharger strut 25 Nm
mounting bolt on the
flywheel end
turbocharger transverse 25 Nm
mounting bolt
turbocharger strut 25 Nm
mounting bolt on the
timing side 114982
IMPORTANT
Wear protective gloves during the operation.
12B-31
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
113282
Rotate the air duct retaining clip (7) on the turbo-
charger.
113277
Remove the lower mounting nuts (4) from the turbo-
charger.
114846 113155
Disconnect: Remove the mounting bolts (8) for the air duct on the
inlet manifold.
- the hose (5) from the turbocharging pressure regu-
lator on the control diaphragm, Move to one side the air duct towards the intercoo-
ler.
- the oil vapour rebreathing hose (6) on the oil sepa-
rator.
Loosen the air duct clip on the turbocharger side.
Disconnect the air inlet duct on the turbocharger si-
de.
12B-32
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
II - OPERATION FOR REMOVAL OF PART - the turbocharger strut.
CONCERNED
REFITTING
115068
Remove the air inlet duct seal at the turbocharger
outlet using a tweezers .
114471
Remove:
- the mounting bolts (11) from the turbocharger strut,
12B-33
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
115069
Refit the new seal to the turbocharger air inlet duct.
Note:
Check that the turbocharger air inlet duct seal
(12) is fitted in the correct direction.
12B-34
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
II - REFITTING OPERATION FOR PART - the new upper mounting nut on the turbocharger,
CONCERNED
- the new lower mounting nuts on the turbocharger.
Tighten to torque:
- the lower mounting nuts on the turbocharger (
28 Nm ) ,
- the upper mounting nut on the turbocharger (
28 Nm ) .
Undo the turbocharger strut mounting bolt on the ti-
ming end (13) .
Tighten to torque:
- the turbocharger transverse mounting bolt ( 25
Nm ) ,
- the turbocharger strut mounting bolt on the ti-
ming side ( 25 Nm ) (13) .
WARNING
Do not tighten the bolt too quickly to prevent the
turbocharger strut from rotating.
12B-35
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
M9R, and 700
- the hollow bolt securing the oil pipe on the cy-
linder block ( 16 Nm ) (16) ,
- the bolt mounting the oil pipe on the cylinder
block ( 25 Nm ) (17) .
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter: Removal - Refitting ).
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
WARNING
Disconnect the injection rail pressure regulator
connector (disables engine starting).
Run the starter motor until the oil pressure war-
ning light goes out (do this for a few seconds).
Switch off the ignition.
Connect the injection rail pressure regulator con-
nector.
114982
Start the engine.
Lubricate the new turbocharger oil pipe O-ring on
the cylinder block side. Let the engine idle then depress the accelerator
several times under no load.
Switch off the ignition.
WARNING
Check for the gasket between the turbocharger Make sure that there are no oil leaks.
and the turbocharger oil pipe. Connect the diagnostic tool and clear the sto-
red faults.
Remove the protective plug from the oil supply union
on the cylinder block side.
Fit the turbocharger oil pipe, first positioning it in the
cylinder block (14) .
WARNING
Do not rotate the turbocharger oil pipe O-ring on
the cylinder block side when inserting.
After fitting, check that the turbocharger oil pipe
O-ring, on the cylinder block side, has not come
out of its housing.
Check for two copper seals on the oil supply
union on the cylinder block side.
Finger tighten:
- the bolts (15) mounting the oil pipe on the turbo-
charger,
- the oil pipe hollow bolt (16) on the cylinder block,
- the bolts (17) mounting the oil pipe on the cylinder
block.
Tighten to torque:
- the bolts mounting the oil pipe on the turbo-
charger ( 10 Nm ) (15) ,
12B-36
TURBOCHARGING
Pressure regulator: Checking 12B
K9K, and 722 or 724 or 728 or 729 or 732
1 - Check
21869
Remove the turbocharger (see 12B, Turbochar-
ging, Turbocharger ).
Note:
The check cannot be carried out with the turbo-
charger in place.
21869 Use a magnetic holder fitted with a dial gauge loca-
Remove the turbocharger (see 12B, Turbochar- ted at the end of the regulation valve rod (as far as
ging, Turbocharger ). possible on the rod shaft).
Gradually apply pressure to the regulation valve
using the pressure and vacuum pump.
Note:
The check cannot be carried out with the turbo-
4 - Value
charger in place.
For a vacuum value of 0.6 bar , the rod movement
Use a magnetic holder fitted with a dial gauge loca- must be 7 mm ± 0.5 .
ted at the end of the regulation valve rod (as far as
possible on the rod shaft).
Gradually apply pressure to the regulation valve
using the pressure and vacuum pump.
2 - Value
For a pressure value of 1.4 bar , the rod movement
must be 4.3 mm .
12B-37
TURBOCHARGING
Pressure regulator: Checking 12B
K9K, and 722 or 724 or 728 or 729 or 732
5 - Check
110748
Remove the turbocharger (see 12B, Turbochar-
ging, Turbocharger ).
Note:
The check cannot be carried out with the turbo-
charger in place.
6 - Value
For a vacuum value of 0.5 bar , the rod movement
must be 1.7 mm .
12B-38
TURBOCHARGING
Pressure regulator: Checking 12B
F9Q, and 800 or 808
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
1 - CHECKING
21869
Note:
The turbocharger cannot be tested in situ.
2 - Value
12B-39
TURBOCHARGING
Pressure regulator: Checking 12B
F4R, and 776
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
1 - CHECKING
22807
Note:
The turbocharger cannot be tested in situ.
2 - Value
12B-40
TURBOCHARGING
Pressure regulator: Checking 12B
F9Q, and 804
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.
1 - Checking
21869
Remove the turbocharger (see 12B, Turbochar-
ging, Turbocharger ).
Note:
The check cannot be carried out with the turbo-
charger in place.
2 - Value
Test points:
- For a pressure value of 200 mbar , the rod move-
ment should be between 2 and 4 mm .
- for a pressure value of 550 mbar , the rod move-
ment should be between 8 and 11 mm. .
12B-41
TURBOCHARGING
Pressure regulator: Checking 12B
M9R, and 700
WARNING
The turbocharging pressure regulator rod must not
be adjusted.
1 - Check
21869
Remove the turbocharger (see 12B, Turbochar-
ging, Turbocharger: Removal - Refitting ).
Note:
The check cannot be carried out with the turbo-
charger in place.
2 - Value
Test points:
- For a vacuum value of 250 mbar , the rod move-
ment should be between 3 and 6 mm .
- for a vacuum value greater than 600 mbar , the rod
should not move.
12B-42
TURBOCHARGING
Turbocharging pressure regulation valve 12B
F9Q, and 800 or 808
The turbocharging pressure regulation valve is open in
the rest position. The engine operates as normally as-
WARNING pirated.
If the turbocharger solenoid valve is removed, it is The solenoid valve, closed in the rest position, is sup-
essential to mark the supply and return pipes on plied after the engine is started following a delay which
the solenoid valve. varies according to the coolant temperature.
103128
Shaft Description
X Time in seconds
102480
Y Coolant temperature in ˚C
101889
12B-43
TURBOCHARGING
Turbocharging pressure regulation valve 12B
F4R, and 776
21927
Pressure regulation valve diaphragm (1) is controlled
by a solenoid valve (2) , which is in turn controlled by
the injection computer.
The pressure adjustment valve is closed at rest posi-
tion. 107010
12B-44
TURBOCHARGING
Turbocharging pressure regulation valve 12B
K9K, and 728 or 732
The turbocharging pressure regulation solenoid valve
is closed in the rest position; it is powered once the en-
gine is started and a delay according to the coolant
temperature.
WARNING
When removing the turbocharging pressure regula-
tion solenoid valve, it is essential to mark the supply
and return pipes on the solenoid valve.
114184
114185
12B-45
TURBOCHARGING
Intercooler: Removal - Refitting 12B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
REMOVAL
Special tooling required
WARNING
12B-46
TURBOCHARGING
Intercooler: Removal - Refitting 12B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
102504
114933
12B-47
TURBOCHARGING
Intercooler: Removal - Refitting 12B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
102474
Loosen the intercooler downstream duct clip (11) on
114649
the intercooler.
Remove the intercooler downstream duct mounting Move the intercooler downstream duct away from
bolt (9) on the cooling radiator. the intercooler.
WARNING
If there has been a fault in the turbocharger,
check that the intercooler is not full of oil.
In this is the case:
- remove the intercooler.
- rinse the intercooler with a cleaning agent,
- allow the intercooler to drain.
12B-48
TURBOCHARGING
Intercooler: Removal - Refitting 12B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
II - REFITTING OPERATION FOR PART Clip on the bonnet opening cable.
CONCERNED
Refit:
Connect:
- the intercooler upstream hose, - the battery tray,
- the intercooler downstream duct onto the intercoo- - the battery tray mounting bolts,
ler.
Tighten to torque: - the wiring harness mounting nut on the battery tray.
Refit the intercooler downstream duct mounting bolt Clip on the battery terminal wiring harness.
onto the cooling radiator.
Connect:
Tighten to torque the intercooler downstream duct
clip on the damper valve ( 5.5 Nm ) .
- the screen washer pipes,
Note:
You must initialise the xenon bulb system (if fitted
to the vehicle).
12B-49
TURBOCHARGING
Intercooler: Removal - Refitting 12B
B84 or C84, and F4R, and 774
Tightening torquesm
REMOVAL
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove:
- the front bumper,
- the headlights.
102474
102476
Remove the air deflectors (1) .
102473
Disconnect the inlet (2) and outlet (3) ducts from the
intercooler.
12B-50
TURBOCHARGING
Intercooler: Removal - Refitting 12B
B84 or C84, and F4R, and 774
102475
Lift the intercooler upwards to release it from the
mounting brackets (4) .
REFITTING
Check that the intercooler is not full of oil.
If it is, it must be rinsed with a cleaning agent and
then left to drain properly.
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
12B-51
FUEL SUPPLY
Petrol supply circuit 13A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
5
2
4
3
19310
The fuel system does not have a return.
The fuel pressure does not vary with engine load.
The circuit comprises:
- a rail (1) without a union to return pipes and without a
supply pressure regulator,
- a single pipe (2) coming from the tank,
- from a supply assembly « pump - dipstick - fuel filter »
fitted with a pressure regulator (3) , pump (4) and fuel
filter (5) (all located in the reservoir),
- a fuel vapour recirculation tank (6) .
13A-1
FUEL SUPPLY
Diesel fuel supply circuit 13A
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
Operating diagram of the diesel fuel supply circuit
102847
- an injection computer.
IMPORTANT
Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
13A-2
FUEL SUPPLY
Diesel fuel supply circuit 13A
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
WARNING
Removing the flow regulator solenoid valve and the
pressure regulating solenoid valve from the high-
pressure pump is prohibited. SIEMENS .
13A-3
FUEL SUPPLY
Diesel fuel supply circuit 13A
F9Q, and 800
1 2 3 4 5 7 6
100821
The circuit comprises:
- a priming bulb (1) (located in the engine compart-
WARNING
ment),
Dismantling the interior of a high-pressure pump or
- a fuel filter (2) that may be fitted with a water detection the injectors is prohibited.
sensor,
- a high-pressure regulator (3) mounted on the pump,
- a high-pressure pump (4) ,
- an injection rail (5) fitted with a diesel pressure sensor
and a pressure limiter (6) ,
- four solenoid injectors (7) ,
- various sensors,
- an injection computer.
IMPORTANT
It is strictly forbidden to uncouple a high-pressure
pipe union when the engine is running.
13A-4
FUEL SUPPLY
Diesel fuel supply circuit 13A
F9Q, and 800 or 804 or 808
Operating diagram of the diesel fuel supply circuit
102307
• a fuel heater, Outside the warranty period for the pump, only the
pump pressure regulator can be replaced.
• a water detection sensor (4) , depending on the ver-
sion, During the pump warranty period, the high-pressure
pump should be completely replaced if the pressure
- a high-pressure pump (5) consisting of: regulator fails.
• a mechanical low-pressure pump,
• a pressure regulator, (6)
- an injector rail (7) fitted with a pressure regulator (8) ,
- four solenoid injectors (9) ,
- a diesel fuel temperature sensor (10) for the diesel re-
turn circuit,
- an injection computer.
IMPORTANT
Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
13A-5
FUEL SUPPLY
Petrol filter: General information 13A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
102299
The fuel filter is located in the fuel tank; it is built into
the « pump-sender-filter » assembly and cannot be re-
moved.
WARNING
The « pump-sender-filter » assembly must be repla-
ced if one of the components is faulty.
13A-6
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 722 or 728 or 729
Tightening torquesm
WARNING
Follow the cleanliness instructions closely (see
13B, Diesel injection, Cleanliness guidelines ).
The cartridge assembly must be replaced (the die-
sel filter is contained in a non-removable cartridge).
REMOVAL
Disconnect the battery, starting with the negative
terminal.
101539
Remove:
WARNING
Keep the pipe unions away from contaminated
areas.
REFITTING
Take the blanking plugs off the fuel supply pipes.
13A-7
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 722 or 728 or 729
102124
Prime the fuel system with the priming pump (3)
(automatic degassing).
Proceed in the reverse order to removal.
Tighten to torque the wheel bolts ( 110 Nm ) .
21749
Connect the battery, starting with the positive termi-
nal.
Regularly bleed out the water in the diesel filter
via the bleed plug (4) .
WARNING
Carry out the necessary programming (see 80A, Some vehicles have a sensor for detecting water
Battery: Removal - Refitting ). in the diesel fuel (5) , located on the filter. If water
is detected in the circuit, the injection fault war-
ning light on the instrument panel comes on.
13A-8
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
F9Q, and 800 or 804 or 808
Tightening torquesm
IMPORTANT
WARNING 101539
- Protect sensitive areas from fuel leakage.
Remove:
- Strictly observe the cleanliness guidelines.
- the front right-hand wheel,
The diesel filter is located behind the right-hand headli- - the wheel arch liner mounting bolts (1) ,
ght. It is contained in a removable cartridge. This car-
tridge has a built-in diesel fuel heater, comprising a - the wheel arch liner clips using an unclipping tool,
resistor and temperature switch. - the wheel arch liner (2) .
Note:
Remove the diesel filter assembly to remove the
cartridge.
REMOVAL
Disconnect the battery, starting with the negative
terminal.
104560
Unclip the diesel filter from its mounting by pushing it
upwards.
13A-9
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
F9Q, and 800 or 804 or 808
102477 19317
Disconnect the diesel heater connector (3) from the
Mark the position of the diesel filter cover in relation
diesel heater.
to the bowl (6) .
WARNING Remove the mounting bolt (7) from the cover on the
Keep the pipe unions away from contaminated bowl.
areas.
Open the diesel filter and replace:
Disconnect from the diesel filter:
- the filter element,
- the pipe (4) coming from the tank,
- the engine supply pipe (5) . - the seal,
WARNING
Align the marking on the cover, fitted with blan-
king plugs, with the marking on the bowl.
13A-10
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
F9Q, and 800 or 804 or 808
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting water
in the diesel fuel, located in the diesel filter. If
water is detected in the circuit, the injection fault
warning light on the instrument panel comes on.
19317
102124
Reprime the supply circuit:
- Turn the air bleed screw (8) 360 degrees,
- operate the manual priming pump (9) until the fuel
runs without air bubbles,
- retighten the bleed screw (8) ,
- operate the manual priming pump (9) one last time.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13A-11
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 724 or 732 – M9R, and 700
- the front right-hand wheel arch liner (1) .
Tightening torquesm
II - OPERATION FOR REMOVAL OF PART
wheel bolts 110 Nm CONCERNED
WARNING
Note:
Make sure you have a new diesel filter before ope-
ning the fuel circuit.
REMOVAL
114559
Remove the diesel filter from its mounting on the
I - REMOVAL PREPARATION OPERATION
body by pushing the « filter - metal strap » assembly
Place the vehicle on a two-post lift (see 02A, Lifting upwards.
equipment, Underbody lift ).
Disconnect all the fuel pipe unions on the diesel fil-
Disconnect the battery (see 80A, Battery, Battery: ter.
Removal - Refitting ).
Note:
Make preparations for the fuel outflow.
WARNING
Prevent the hose unions from coming into con-
tact with a polluted environment.
Note:
Only use wipes part number 77 11 211 707 to
clean the filter and pipes once the fuel circuit is
opened.
REFITTING
13A-12
FUEL SUPPLY
Diesel filter: Removal - Refitting 13A
K9K, and 724 or 732 – M9R, and 700
Refit the « filter - metal strap » assembly on its
mounting on the body.
Note:
Check that the filter is correctly positioned and
secure in its mounting by shaking it: the filter
must not move.
If necessary, remove the filter and gently
squeeze the metal strap retaining bracket on its
mounting.
II - FINAL OPERATION
102124
Refit:
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting water
in the diesel fuel, located at the bottom of the fil-
ter. If water is detected in the circuit, a fault war-
ning light on the instrument panel comes on.
13A-13
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
K4M, and 760 or 761
Tightening torquesm
REMOVAL
Disconnect the battery, starting with the negative
terminal.
Remove:
101810
- the engine covers, Disconnect injector electrical harness (1) .
- the inlet manifold (see 12A, Fuel mixture, Inlet Remove:
manifold ).
- the two injector rail mounting bolts (2) ,
- the injector rail, pulling it carefully towards you.
IMPORTANT
Be careful of petrol splashing when disconnec-
ting the supply pipe union from the injector rail. ON THE WORKBENCH
WARNING
Protect the alternator against fuel spills from the
rail or supply duct.
4 3
101816
Remove:
- injector clips (3) ,
- injectors (4) .
13A-14
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
K4M, and 760 or 761
REFITTING
WARNING
The O-rings and the injector mounting clips must
always be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
13A-15
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
B84 or C84 or G84, and K4J, and 730 or 732
Tightening torquesm
REMOVAL Disconnect:
Disconnect the battery, starting with the negative - fuel supply pipe (2)
terminal.
- injector and pinking sensor electrical harness (3) .
Remove the engine covers.
IMPORTANT
Be careful of petrol splashing when disconnec-
ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from the
rail or supply duct.
101801
Remove mounting nuts (1) from the injection rail pro-
tector.
Move the wiring harness to one side.
101493
Remove:
- the two injector rail mounting bolts (4) ,
- the injector rail, pulling it carefully towards you.
13A-16
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
B84 or C84 or G84, and K4J, and 730 or 732
ON THE WORKBENCH
6
5
101492
Remove:
- injector clips (5) ,
- injectors (6) .
REFITTING
WARNING
The O-rings and the injector mounting clips must
always be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
13A-17
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
F4R, and 770 or 771 or 776
Tightening torquesm 3
injector rail mounting 9 Nm
bolts
REMOVAL Disconnect:
Disconnect the battery, starting with the negative - fuel supply pipe (2) ,
terminal. - injector and pinking sensor electrical harness (3) .
Remove the engine covers.
4
6
1
5
101801
Remove the two injection rail guard mounting nuts 106787
(1) .
Disconnect:
Move the wiring harness to one side.
- turbocharging pressure sensor connector (4)
- the vacuum pipe from brake servo (5) ,
- oil vapour recirculation pipe (6) .
13A-18
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting 13A
F4R, and 770 or 771 or 776
ON THE WORKBENCH
106271
10
Disconnect fuel supply pipe (7) from the injector rail. 9
102737
IMPORTANT
Remove:
Be careful of petrol splashing out when discon-
necting the fuel supply union. - injector clips (9) ,
- injectors (10) .
WARNING
REFITTING
Protect sensitive areas from fuel spillage.
WARNING
The O-rings and the injector mounting clips must
always be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Remove:
13A-19
FUEL SUPPLY
Electric fuel: Checking 13A
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
IMPORTANT
101803
Disconnect the petrol inlet pipe from the injection
rail.
1 Connect:
2 - pipe (1) fitted with a pressure gauge and located in
test kit (Mot. 1311-01) , to the « T » union of tool
(Mot. 1311-08) (2) ,
- the « T » union to the rail,
- petrol inlet pipe (3) to the « T » union.
3 Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the igni-
101496 tion off.
Disconnect the petrol inlet pipe from the injection
rail. Remove the Protection and Switching Unit cover.
13A-20
FUEL SUPPLY
Electric fuel: Checking 13A
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
4
5
1
12
102502 102501
Place the electrical connector (4) to one side without Connect terminal (5) of the brown connector to the
disconnecting it. battery positive feed
Note:
The flow reading should be between 80 and 120
l/h .
102503
Disconnect the brown connector (5) from the Protec-
tion and Switching Unit.
13A-21
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
Vehicle type Type Suffix Idling Maximum Maximum Homologa- Legal maxi-
speed unladen laden tion value mum (m -1)
(m-1)
XM02 729
13B-1
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Engine speed and position sensor MGI Var iable reluctance sensor
Resistance: 760 Ω (K9K 722)
Resistance: 680 Ω (K9K 724,
728, 729)
2-track connector
- A: + signal
- B: - signal
13B-2
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
13B-3
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
Turbocharging air temperature BOSCH / LDF6T 20-250 Pressure sensor with a negative
and pressure sensor temperature coefficient thermistor
Supply voltage: + 5 V
Resistance:
- 20376 ± 1110.5 Ω at - 25˚C
- 15614 ± 829 Ω at - 20˚C
- 9426 ± 475 Ω at - 10˚C
- 5887 ± 281.5 Ω at 0˚C
- 3791 ± 172.5 Ω at 10˚C
- 2511 ± 109 Ω at 20˚C
- 1715.5 ± 71 Ω at 30˚C
- 1200 ± 47 Ω at 40˚C
- 851 ± 32 Ω at 50˚C
- 612 ± 22 Ω at 60˚C
- 446 ± 15 Ω at 70˚C
- 330 ± 11 Ω at 80˚C
4-track connector:
- 1: earth
- 2: air temperature sensor signal
- 3: + 5 V supply
- 4: pressure sensor signal
13B-4
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
13B-5
DIESEL INJECTION
Specifications 13B
K9K, and 722 or 728 or 729
13B-6
DIESEL INJECTION
Specifications 13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
Engine
Vehicles Gearbox
Type Suffix Bore Stroke Cubic capa- Compres-
(mm) (mm) city (cc) sion ratio
XM0G 800
XM1G ND0 F9Q 80 93 1870 19:1
XM00 808
High pressure pump BOSCH CP3 Pressure from 250 to 1,350 bar
13B-7
DIESEL INJECTION
Specifications 13B
F9Q, and 800 or 808
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)
13B-9
DIESEL INJECTION
Specifications 13B
F9Q, and 804
13B-10
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
Equipment required
diagnostic tool
Flow regulation solenoid valve SIEMENS VDO Integrated in the high pressure
pump
Cannot be removed
Supply voltage: + 12 V
13B-11
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
Pressure regulation solenoid valve SIEMENS VDO Integrated in the high pressure
pump
Cannot be removed
Supply voltage: + 12 V
Engine speed and position sensor SIEMENS VDO Variable reluctance sensor
Resistance: 680 Ω ± 6.8 at 20˚C
2-track connector
- 1: + signal
- 2: - signal
13B-12
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
13B-13
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
Exhaust gas recirculation solenoid PIERBURG Integrated in the exhaust gas recir-
valve position potentiometer culation solenoid valve
Supply voltage: + 5 V
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: not used
- 5: potentiometer signal
- 6: solenoid valve earth
13B-14
DIESEL INJECTION
Diesel injection: Specifications 13B
K9K, and 732
Air inlet flowmeter SIEMENS VDO Air flowmeter with integrated air
temperature sensor
6-track connector:
- 1: air temperature signal
- 2: earth
- 3: Not used
- 4: + 12 V supply
- 5: supply: + 5 V
- 6: air flow signal
13B-15
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
I - RISKS LINKED TO CONTAMINATION 2 - Blanking plugs
The high pressure direct injection system is highly sen- The blanking plugs are used to cap the fuel circuit once
sitive to contamination. The risks caused by contami- it is opened and to therefore prevent contaminants
nation are: from entering.
- damage to or destruction of the high pressure injec- A set of blanking plugs should be used once only and
tion system, used plugs must be discarded after use: once used,
the plugs are soiled and cleaning them is not sufficient
- a component seizing, to make them reusable.
- a component not being properly sealed. Unused plugs must also be discarded and not used
again for any other operation on an injection system.
All After-Sales operations must be performed under
very clean conditions. Having carried out an operation Blanking plug set part number:
in good conditions means that no impurities (particles a
few microns in size) have penetrated the system during - F9Q: 77 01 208 229
dismantling. - K9K ( DELPHI injection): 77 01 206 804
The cleanliness principle must be applied from the filter - K9K ( SIEMENS injection): 77 01 476 857
to the injectors.
- M9R: 77 01 209 062
What are the sources of contamination?
13B-16
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
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: they both have the same end
each removal and which are mentioned in the work result and neither is preferred over the other.
procedures specific to each vehicle (see the relevant
Workshop Repair Manual).
1 - Using the injector cleaning agent
3) Wear safety goggles fitted with side shields to pre-
vent the cleaning product from splashing the eyes. Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
4) Wear latex safety gloves to avoid prolonged contact the relevant Workshop Repair Manual).
with the skin.
Protect sections which are sensitive to fuel leaks.
Reseal the bag hermetically using adhesive tape, for Open the circuit at the unions and immediately fit the
example, even if the bag must be opened shortly afte- relevant blanking plugs.
rwards: ambient atmosphere can be a source of pollu-
tion.
WARNING
After opening the fuel circuit, the use of brushes, clea-
ning agents, air blow guns, rifle-type brushes or stan- Do not blast with compressed air once the fuel cir-
dard cloths is strictly prohibited: These items are likely cuit is open, otherwise impurities may enter the sys-
to allow impurities to enter the system. tem. Use cleaning cloths only, if necessar y.
13B-17
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
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.
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
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
V - INSTRUCTIONS FOR FITTING THE PLUGS
13B-19
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
part no. 77 01 206 804
13B-20
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
20977
13B-21
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B-22
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
part no. 77 01 476 857
13B-23
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
113430
13B-24
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B-25
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
part no. 77 01 208 229
13B-26
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
104561
13B-27
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B-28
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
part no. 77 01 209 062
13B-29
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
113737
13B-30
DIESEL INJECTION
Description 13B
F9Q, and 800 or 808
The high pressure direct injection system is intended to
deliver a specific volume of diesel fuel to the engine at
a specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a pressure regulator mounted on the pump,
- a high pressure pump,
- an injection rail fitted with a diesel fuel pressure sen-
sor and a pressure limiter,
- four solenoid injectors,
- various sensors,
- an injection computer.
13B-31
DIESEL INJECTION
Description 13B
K9K, and 722 or 728 or 729
The high pressure direct injection system is intended to
deliver a specific volume of diesel fuel to the engine at
a specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a high pressure pump combined with a low pressure
pump (transfer pump),
- a pressure regulator mounted on the pump,
- a spherical injection rail,
- a pressure sensor incorporated into the rail,
- four solenoid injectors,
- a diesel fuel temperature sensor,
- a coolant temperature sensor,
- a turbocharging air temperature and pressure sensor,
- a cylinder marking sensor,
- an engine speed sensor,
- an accelerometer,
- an exhaust gas recirculation solenoid valve,
- an accelerator pedal potentiometer,
- an atmospheric pressure sensor,
- an injection computer.
13B-32
DIESEL INJECTION
Operation 13B
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
- the needle stroke (determined by a constant for an in-
jector type),
Equipment required
- the nominal hydraulic flow of the injector (specific to
diagnostic tool each injector),
- the high pressure rail pressure regulated by the com-
puter.
IMPORTANT
The computer manages:
Before carrying out any work on the injection circuit,
- idle speed regulation,
check using the diagnostic tool :
- that the rail is not pressurised, - the exhaust gas flow reinjected into the inlet,
- that the fuel temperature is not too high. - the fuel supply (timing, flow and rail pressure),
Every time work is carried out, be sure to follow the - the fan assembly actuation request (function: centra-
safety and cleanliness advice specified in this docu- lised coolant temperature management),
ment.
- the air conditioning,
Loosening a high pressure pipe union when the
- the cruise control-speed limiter function,
engine is running is strictly prohibited.
- the pre/postheating actuation.
The « common rail » high pressure injection system
operates in sequential mode (based on the multipoint The high pressure pump is supplied at low pressure by
injection principle for petrol engines). a mechanical low pressure pump (transfer pump).
Through its pre-injection process, this injection system The high pressure pump supplies the rail which is pres-
can provide: sure-controlled:
- a reduction in the amount of pollutant gases and par- - for discharge by the injector valves.
ticles,
Drops in pressure may also be compensated for.
- a high engine torque at low engine speeds. The fuel flow actuator allows the high pressure pump to
The high pressure pump generates the high pressure supply the exact volume of diesel fuel required to main-
transmitted to the injection rail. The actuator on the tain the pressure in the rail. This feature allows heat
high pressure pump controls the volume of diesel fuel generation to be minimised and engine output to be im-
supplied according to the demand determined by the proved.
injection computer. The rail supplies each injector To discharge the rail, the injection valves are controlled
through a steel pipe. by small electrical pulses:
The computer: - short enough not to open the injector (passing throu-
- determines the injection pressure value necessary for gh the return circuit from the injectors),
the engine to operate correctly and then operates the - long enough to open the valves and discharge the
fuel flow actuator. It checks that the pressure value is rail.
correct by analysing the value transmitted by the
pressure sensor located on the rail, The injection computer actuates the fan assembly and
the coolant temperature warning light on the instru-
- determines the injection time necessary to deliver the ment panel (function: centralised coolant temperature
right volume of diesel fuel and the moment when in- management).
jection should be started,
The various vehicle computers communicate via multi-
- electrically actuates each injector individually after plex links. The fault warning lights on the instrument
determining these two values. panel are therefore activated via the multiplex network.
The flow injected into the engine is determined accor- In the event of an impact, the function that cuts off the
ding to: diesel fuel supply circuit is managed by the airbag
- the duration of injector actuation, computer. It gives the command via the multiplex
network to the injection computer to lock the injection
- the injector opening and closing speed, locking relay control.
13B-33
DIESEL INJECTION
Operation 13B
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
Unlocking is only enabled after the ignition is switched
off for 10 seconds . This operation causes the fault
warning light to come on for longer than usual when WARNING
switching on the ignition. The warning light will not re- - The engine must not be run with diesel fuel contai-
turn to normal operation until the fault has been cleared ning more than 10% diester or petrol, even in
using the diagnostic tool . minute quantities.
The vehicle speed signal is transmitted to the instru- - Dismantling the interior of the high pressure pump
ment panel by the ABS computer or the gearbox (vehi- and the injectors is prohibited. Only the fuel flow
cle without ABS system) via the multiplex network. actuator, the diesel fuel temperature sensor and
the Venturi tube can be replaced.
Some vehicles have a sensor for detecting water in the
- It is prohibited to remove the pressure sensor from
diesel fuel, which is located in the filter. If there is water
the injection rail as this could cause contamination
present in the diesel fuel, the orange injection warning
of the circuit. If the pressure sensor is faulty,
light comes on.
replace the assembly consisting of the pressure
Automatic configuration for cruise control - speed limi- sensor, rail, and the five high pressure pipes.
ter operation and for air conditioning operation. - It is strictly prohibited to remove any injection
pump pulley bearing the number 070 575. If the
Injection computer actuating the air conditioning com- pump is being replaced also replace the pulley.
pressor clutch via the UPC.
- Supplying any system component directly with the
A new electronics casing called the « UPC » has been + 12 V is prohibited.
added to the vehicles wiring diagram.
- Ultrasonic decarbonisation and cleaning are prohi-
bited.
The UPC supplies the following with power:
- Never start the engine unless the battery is pro-
- the air conditioning compressor, perly connected.
- the fan assembly, - Never turn the engine against its operating direc-
tion.
- the electrical heating resistors.
Reprime the circuit using the priming pump.
The UPC is located in the engine compartment near
the battery. It contributes to the protection of certain
electrical components.
IMPORTANT
In this capacity, it comprises: The engine should not be run with diesel fuel con-
taining more than 10% diester.
- fuses,
13B-34
DIESEL INJECTION
Operation 13B
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
When the high pressure pump, injectors and high pres-
sure supply, outlet and return unions are removed or
repaired, all apertures should be capped with suitable
new blanking covers to prevent contamination.
WARNING
Any pipe removed must be replaced.
WARNING
Dismantling the interior of the pump is prohibited.
The fuel return pipe fitted to the injectors must be
replaced when removed.
The diesel fuel temperature sensor cannot be
removed. It is part of the fuel return rail.
Loosening a high pressure pipe union when the
engine is running is prohibited.
13B-35
DIESEL INJECTION
Location of components 13B
K9K, and 722
102072
13B-36
DIESEL INJECTION
Location of components 13B
K9K, and 722
101105 102084
102085
102082
13B-37
DIESEL INJECTION
Location of components 13B
K9K, and 722
19654-1
13B-38
DIESEL INJECTION
Location of components 13B
K9K, and 722
20796 102125
102121
102204
(36) Diesel filter
13B-39
DIESEL INJECTION
Location of components 13B
K9K, and 722
102124
102077
(39) Turbocharger
(40) Catalytic converter
102128
13B-40
DIESEL INJECTION
Location of components 13B
F9Q, and 800 or 808
101883
(16) Turbocharging pressure sensor
(1) Diesel filter
(17) Diesel temperature sensor (fuel
(2) Manual priming pump return)
(3) Cylinder reference sensor (18) High pressure pump
(4) Rail pressure sensor (19) Diesel pressure regulator
(5) Solenoid injectors
(6) Engine stop system vacuum
reserve
(7) Engine stop system solenoid
valve
(8) Exhaust gas recirculation sole-
noid valve (F9Q 800)
(9) Turbocharger regulation sole-
noid valve
(10) Flowmeter with air temperature
sensor
(11) Injection computer
(12) Protection and Switching Unit
(13) Engine stop valve diaphragm
(14) Engine stop valve
(15) Pressure limiter (on injection
rail)
13B-41
DIESEL INJECTION
Location of components 13B
F9Q, and 800 or 808
18297-1
102485
13B-42
DIESEL INJECTION
Location of components 13B
F9Q, and 800 or 808
28
31
16181 101891
29
32
30
102479 101889
13B-43
DIESEL INJECTION
Location of components 13B
F9Q, and 800 or 808
33 38
34
101892 101886
35
37
36
39
102486
13B-44
DIESEL INJECTION
Location of components 13B
F9Q, and 800 or 808
40
102352
102204
13B-45
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
106343
(17) High pressure pump
(1) Pr iming pump
(18) Turbocharging pressure sole-
(2) Cylinder reference sensor noid valve
(3) Turbocharger
(4) Exhaust gas recirculation sole-
noid valve
(5) Injector
(6) Turbocharging air temperature
and pressure sensor
(7) Injection computer
(8) Air filter unit
(9) UPC
(10) Coolant temperature sensor
(11) Engine speed and position sen-
sor
(12) Rail pressure sensor
(13) Spherical injection rail
(14) Accelerometer
(15) Diesel fuel temperature sensor
(16) Diesel fuel flow actuator
101811
13B-46
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
101105 102084
102085
110327
13B-47
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
110319
101889
13B-48
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
19654-1
102204
20796
(36) Accelerator pedal potentiometer
13B-49
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
102124
102125
102128
104954
13B-50
DIESEL INJECTION
Location of components 13B
K9K, and 728 or 729
102077
(41) Turbocharger
(42) Catalytic converter
13B-51
DIESEL INJECTION
Location of components 13B
F9Q, and 804
101883
13B-52
DIESEL INJECTION
Location of components 13B
F9Q, and 804
18297-1
102485
13B-53
DIESEL INJECTION
Location of components 13B
F9Q, and 804
16181 101891
111864 101889
13B-54
DIESEL INJECTION
Location of components 13B
F9Q, and 804
111856 102121
102204
101886
(33) Accelerator pedal potentiometer
13B-55
DIESEL INJECTION
Location of components 13B
K9K, and 732
114186
13B-56
DIESEL INJECTION
Location of components 13B
K9K, and 732
101105 112994
111748
13B-57
DIESEL INJECTION
Location of components 13B
K9K, and 732
114348
102204
13B-58
DIESEL INJECTION
Location of components 13B
K9K, and 732
102124
102125
113840
114559
13B-59
DIESEL INJECTION
Location of components 13B
K9K, and 732
114185
13B-60
DIESEL INJECTION
Immobiliser function 13B
K9K, and 722 or 728 or 729 – F9Q, and 800 or 804 or 808
These vehicles are fitted with an engine immobiliser
system, controlled by a RENAULT card random rolling
code recognition system, which requires a special pro-
cedure for replacing the computer.
REPLACEMENT
For the removal/refitting procedure, (see 13B, Die-
sel injection, Diesel injection computer ).
For the engine immobiliser functions (see 82A, En-
gine immobiliser, Operation ).
Injection computers are supplied without a code, but
they can all be programmed with one.
When replacing the computer, program it with the
vehicle code, then check that the engine immobiliser
function is operational.
Switch on the ignition for a few seconds without star-
ting the engine.
Switch off the ignition.
Note:
The immobiliser function operates after roughly
10 seconds (the red immobiliser warning light
blinks on the instrument panel).
WARNING
- The injection computer retains the immobiliser
code for life.
- The system has no security code.
- Running tests with computers borrowed from
the Parts Department or from another vehicle
which must then be returned is prohibited.
- These computers are permanently coded.
13B-61
DIESEL INJECTION
Injection warning light 13B
K9K, and 722 or 728 or 729 or 732
If there is a serious injection fault (level 2), the red en-
gine symbol and the word « Stop » appears (only on in-
Note: formation display), with the message « Injection
faulty » , followed by the « Stop » warning light and
For vehicles fitted with K9K 732 engines (see MR
buzzer.
370 Mechanics, Scénic II ).
The faults relate to:
Vehicles fitted with the Delphi DDCR high-pressure
diesel fuel system use fault warning symbols and text - with delayed stop: the fuel flow actuator (loop discre-
warning messages, depending on the level of severity pancy and overpressure),
of the faults detected, to inform the customer and de- - with immediate stop:
termine the correct fault finding procedure.
• the engine speed sensor,
The injection computer controls the illumination of war-
• the diesel flow actuator,
ning lights and message displays on the instrument pa-
nel. The fault warning lights come on: • the rail pressure sensor,
- during the preheating phase, • the supply to all the injectors,
- if there is an injection fault, • the sensor supply voltage,
- if the engine is overheating. • an internal computer fault.
The warning signals are sent to the instrument panel If the engine overheats, the engine temperature fault
via the multiplex network. symbol appears with the message «Engine
overheating » (only on information display) followed by
the « Stop » warning light and buzzer. If this happens,
WARNING LIGHT ACTIVATION PRINCIPLE.
the vehicle will stop immediately.
During the starting phase (press the « Start » button,
the orange preheating symbol is lit during the prehea- « On Board Diagnostic » excess pollution orange
ting phase, then goes out) (see 13C, Preheating, Pre- warning light
postheating control ).
The orange warning light, represented by an engine,
In the event of an injection fault (level 1), the message comes on for approximately 5 seconds then goes out.
« Check injection» is displayed and then the It is never displayed when the engine is running (not
« Service » warning light comes on. This means a re- operational).
duced level of operation and a limited safety level.
Repairs should be carried out as soon as possible.
These faults are associated with:
- the engine immobiliser,
- a C2l (individual injector correction) coding error,
- an injector,
- the injector controls,
- the diesel fuel supply (injector leak, etc.),
- an engine speed sensor target fault,
- the injection locking relay,
- the exhaust gas recirculation solenoid valve or posi-
tion sensor,
- the accelerator pedal potentiometer (gangs 1 and 2),
- the accelerator pedal potentiometer supply,
- the turbocharging pressure sensor (in the event of
overpressure),
- water in the diesel fuel or a water detection sensor
fault (if fitted on vehicle.
13B-62
DIESEL INJECTION
Injection warning light 13B
F9Q, and 800 or 804 or 808
Vehicles fitted with the Bosch EDC16 high pressure - an injector fault,
diesel fuel system use fault warning symbols and text
- a rail pressure sensor fault,
warning messages, depending on the level of severity
of the faults detected, to inform the customer and de- - a rail pressure regulator fault.
termine the correct fault finding procedure.
If the engine overheats, the engine coolant temperatu-
The injection computer controls the illumination of war- re fault symbol appears with the message « Engine
ning lights and message displays on the instrument pa- overheating » (only on information display) followed by
nel. The fault warning lights and error messages are the « Stop » warning light and buzzer. In this case the
visible: vehicle must be stopped immediately.
- during the preheating phase,
« On Board Diagnostic » excess pollution orange
- if there is an injection fault, warning light
- if the engine is overheating. The orange engine symbol comes on when the ignition
The warning signals are sent to the instrument panel is switched on for around 5 seconds then goes out. It
via the multiplex network. is never displayed when the engine is running (not ope-
rational).
WARNING LIGHT PRINCIPLE
During the starting phase (press on the « Start » but-
ton, the orange preheating symbol is lit during the pre-
heating phase then it goes out) (see 13C, Preheating,
Pre-postheating control ).
In the event of an injection fault (level 1), the message
« Check injection» is displayed and then the
« Service » warning light comes on. This means a re-
duced level of operation and a limited safety level.
These faults are associated with:
- an internal computer fault,
- an immobiliser system fault,
- a speed synchronisation fault,
- an accelerator pedal potentiometer fault,
- an air flowmeter fault,
- a speed sensor fault (see ABS system),
- an EGR solenoid valve fault,
- a fault in the turbocharging pressure regulation sole-
noid valve,
- a fault in the main relay of the Protection and Swit-
ching Unit,
- an injector fault,
- an injector flow correction fault (IMA),
- a sensor power feed fault.
If there is a serious injection fault (level 2), the red en-
gine symbol and the word « Stop » appears (only on in-
formation display), with the message « Injection
faulty » , followed by the « Stop » warning light and
buzzer.
These faults are associated with:
- an internal computer fault,
13B-63
DIESEL INJECTION
Injection / air conditioning programming 13B
K9K, and 722 or 728 or 729
Note: Note:
For vehicles fitted with engine concerned (see MR The value of parameter ( PR044 ) « power absor-
370 Mechanics, Scénic II ). bed by the air conditioning compressor » is never 0,
whatever the status of the air conditioning compres-
The air conditioning management is shared between sor. The minimum reading is approximately 250 W .
several computers that communicate via the multiplex
The air conditioning compressor is of the « variable
network.
displacement » type.
It is of the « cold loop » type.
- authorising engine cooling fan control in accordance The operation of the air conditioning compressor is in-
with vehicle speed and circuit pressure, hibited for 1 second after the engine has started.
13B-64
DIESEL INJECTION
Injection / air conditioning programming 13B
K9K, and 722 or 728 or 729
7 - Engine overspeed timed protection Output conditions:
programming
- engine speed above 3500 rpm ,
The air conditioning compressor is disengaged if the
- and vehicle speed greater than 90 mph (150 km/h)
engine speed is above 4500 rpm for more than 3 se- (by way of information).
conds .
To reduce the heating time, fit air heating resistors Output conditions:
known as « passenger compartment heating - engine speed greater than 2500 rpm ,
resistors » in the passenger compartment heating cir-
cuit. - or vehicle speed greater than 3.6 mph (6 km/h)
- or a gear is engaged.
The UCH determines the need to actuate the heating
resistors, according to the user's request.
4 - Stalling prevention programming
The injection computer determines:
When the engine speed falls below 760 rpm , opera-
- the number of heating resistors supplied (power con- tion of passenger compartment heating resistors is in-
trol limitation) depending on the alternator charge, terrupted. When engine speed rises above 750 rpm ,
- whether resistor operation should be disabled, accor- the passenger compartment heating resistors are re-
ding to engine speed, load and vehicle speed. enabled.
Input conditions:
- engine speed less than 3000 rpm ,
- and vehicle speed less than 78 mph (130 km/h) .
13B-65
DIESEL INJECTION
Injection / air conditioning programming 13B
F9Q, and 800 or 804 or 808
The air conditioning management is shared between It is re-engaged if the engine speed exceeds 780 rpm .
several computers that communicate via the multiplex
network.
II - PASSENGER COMPARTMENT HEATING
When the air conditioning is switched on, the air condi- RESISTORS OPERATION PROGRAMMING
tioning control panel requests authorisation to engage
During certain operating phases, the injection compu-
the compressor clutch.
ter disables the heating resistors.
The injection computer authorises or inhibits the com-
pressor clutch, and controls the fan assembly via the
1 - Engine start programming
UPC.
The heating resistors are disabled while the heater
When the air conditioning function is selected, the plugs are in operation.
idling speed is not altered.
When the engine starts, the heating resistor supply is
The signals used for the air conditioning function are authorised after a delay that depends on the engine
transmitted via:
coolant temperature.
- track A A4 « CAN HIGH » multiplex connection,
- track A A3 « CAN LOW » multiplex connection. Engine coolant tem- Delay
This compressor is the variable output type. perature
(s)
(˚C +/- 1)
I - AIR CONDITIONING COMPRESSOR OPERATION
PROGRAMMING - 30 30
4 - Anti-stalling function
The air conditioning compressor is disengaged if the
engine speed is below 750 rpm .
13B-66
DIESEL INJECTION
Idling speed 13B
K9K, and 722 or 728 or 729 or 732
II - IDLE SPEED CORRECTION IN THE EVENT OF
AN ACCELERATOR PEDAL POTENTIOMETER
Note: FAULT
For vehicles fitted with K9K 732 engines (see MR - If one of the two accelerator pedal potentiometer
370 Mechanics, Scénic II ). tracks is faulty, the injection computer forces an idle
speed of 1300 rpm . This defect mode limits perfor-
The injection computer calculates the idling speed nee- mance. The « Check injection » message lights up,
ded to maintain it at the recommended level and to followed by the « Service » warning light.
compensate for any variation in the mechanical or - If the accelerator pedal potentiometer is jammed, no
electrical torque as a function of: longer supplied, or is no longer sending an output si-
gnal, the injection computer imposes an idle speed of
- the coolant temperature,
1300 rpm . This defect mode limits performance. The
- the battery voltage, « Check injection » message lights up, followed by
the « Service » warning light.
- the gear selected,
- If there is inconsistency between the accelerator pe-
- the electrical consumers (climate control, fan unit, dal potentiometer signal and the brake switch signal,
passenger compartment heating electrical resistors, the injection computer imposes an idle speed of 1300
etc.), rpm .
103122
13B-67
DIESEL INJECTION
Idling speed 13B
B84 or C84 or S84, and F9Q, and 800 or 804
I - IDLE SPEED CORRECTION ACCORDING TO
COOLANT TEMPERATURE
103129
13B-68
DIESEL INJECTION
Centralised coolant temperature management 13B
K9K, and 722 or 728 or 729 or 732
Note:
For vehicles fitted with K9K 732 engines (see MR
370 Mechanics, Scénic II ).
The fan will operate at high speed under the low speed
operating conditions if low speed is faulty.
13B-69
DIESEL INJECTION
Centralised coolant temperature management 13B
F9Q, and 800 or 804 or 808
The coolant temperature sensor (injection and coolant
temperature indicator on the instrument panel) is a 3-
track sensor:
- 2 tracks for the coolant temperature signal to the com-
puter (tracks B E1 and B K3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be con-
trolled by the injection computer. It consists of a single
temperature sensor serving injection, the engine coo-
ling fan, the temperature indicator and the instrument
panel engine coolant temperature warning light.
The request to operate the engine cooling fan is made
by the injection computer through the multiplex
network.
13B-70
DIESEL INJECTION
Computer configuration 13B
K9K, and 722 or 728 or 729 or 732
PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
Equipment required
Before programming, reprogramming or replacing
diagnostic tool
the computer, save to the diagnostic tool the fol-
The system can be programmed and reprogrammed lowing data:
via the diagnostic socket using the diagnostic tool .
- the C2I parameters (individual injector correction),
WARNING
- The injection computer retains the immobiliser
code for life.
- The system has no security code.
- Running tests with computers borrowed from
the Parts Department or from another vehicle
which must then be returned is prohibited.
- The computers are permanently coded.
Note:
If commands SC001 and SC003 are not run or
cannot be run following programming, repro-
gramming or replacement of the computer, the
C2I of each injector must be written manually,
reading the C2Is on the injectors (see 13B, Die-
sel Injection, Injectors: Configuration ).
13B-71
DIESEL INJECTION
Computer configuration 13B
F9Q, and 800 or 808
• using the diagnostic tool , ensure that the com-
puter has not detected any faults relating to the in-
Equipment required
jector codes and that the instrument panel
diagnostic tool warning light is off.
WARNING
- Connect the diagnostic tool (to the mains or the
cigarette lighter).
- Check the condition of the battery.
- Connect a battery charger (the engine cooling
fans are automatically activated for the entire
duration of the computer (re)programming ).
- Keep to the engine coolant temperature guidelines
supplied in the diagnostic tool before carrying
out any (re)programming.
PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
13B-72
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-
sel fuel leakage.
Note:
The diagnostic tool can be used for testing the
high pressure circuit with the engine running.
This command can be used for finding a leak due
to an incorrectly fitted or tightened union. This
command only works if the engine coolant tem-
perature is above 60˚C . The fault finding proce-
dure will not reveal small leaks due to incorrect
tightening.
WARNING
Do not leave anything in the engine bay during
the test phase (significant vibration).
Note:
The engine automatically runs a cycle of four
accelerations and decelerations to lower the rail
pressure.
13B-73
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K, and 732
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-
sel fuel leakage.
112811
Pull out the clip.
112815
Disconnect the air inlet pressure sensor connector
(1) .
Loosen the clip and (2) move the air inlet duct aside
(3) .
112991
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
13B-74
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K, and 732
Run command AC029 « high pressure circuit sea-
ling test » , in the « LPG/fuel circuit » tab.
WARNING
Do not leave anything in the engine bay during
the test phase (significant vibration).
Note:
The engine automatically runs a cycle of four
accelerations and decelerations to lower the rail
pressure.
Disconnect:
112992
- the battery (see 80A, Battery, Battery: Removal -
Unclip the injection rail protector cover (6) . Refitting ).
Loosen the clip and move the air inlet duct aside.
- the mounting nut and bolt (7) from the injection rail
protector cover, Pull out the stainless steel pipe clip.
- the injection rail protector cover, Remove the air inlet duct.
Refit the clip onto the stainless steel pipe if necessa- Refit:
ry.
- the injection rail protector cover,
Clip the stainless steel pipe to turbocharger.
- the injection rail protector cover mounting nut and
Refit the air inlet duct on the damper valve. bolt,
13B-75
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
« pump-rail » high- 38 Nm
pressure pipe nuts
1
« rail-injectors » high- 38 Nm
pressure pipe nuts
IMPORTANT
13B-76
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
102362
4 7
6
9 8
102361
- the injectors,
13B-77
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
10
15
14
13 12 11
102360
Carefully disconnect:
- the diesel return pipe (10) connecting the injectors
to the high-pressure injection pump,
- the spherical injector rail pressure sensor (11) ,
- the accelerometer (12) ,
- the oil level sensor (13) ,
- the timing cover cylinder marking sensor (14) .
Shift the electrical harness to one side.
Remove filler neck (15) located on the spherical in-
jector rail.
WARNING
- Be sure to hold the intermediate injector union
(18) in place with a spanner when loosening the
high-pressure pipes.
- Do not damage injector leak return nozzle (19) .
13B-78
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
Note:
Loosen the nuts pipe by pipe.
17
20
16
20803
19 20803
Remove high-pressure pipes (20) one by one.
Fit blanking plugs into the openings.
18
19724
Loosen:
13B-79
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
WARNING
When tightening the high-pressure pipes, it is
essential to support the injector central union
(18) .
Note:
20960 The order of fitting the injector rail pipes is not
impor tant.
WARNING
- Before fitting a new high-pressure pipe, lightly
lubricate the nut threads with the oil from the
applicator provided in the new parts kit.
- Be careful not to allow oil into the high-pressure
pipe.
- Do not lubricate high-pressure pipes supplied
without an applicator, as these high-pressure
pipes are self-lubricating.
WARNING
Do not remove the caps from each component
until the last moment.
13B-80
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
III - REFITTING THE « PUMP - RAIL » HIGH
PRESSURE PIPE AND THE « RAIL - INJECTOR »
HIGH PRESSURE PIPES
Tighten to torque the rail mounting nuts ( 28 Nm ) .
WARNING
- Do not touch the high-pressure pipes with the
spanner when tightening.
- Be sure to hold the injector central union in
place with a spanner when tightening.
13B-81
DIESEL INJECTION
High pressure pipe: Replacement 13B
K9K, and 722 or 728 or 729 or 732
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
WARNING
- pump end,
- rail end.
- injectors end,
- rail end.
Note:
Tighten each pipe fully before moving on to the
next pipe.
13B-82
DIESEL INJECTION
Diesel injector: check 13B
K9K, and 722 or 728 or 729
Command AC029 « High pressure circuit sealing
test » in the « Fuel/LPG » tab also enables the lea-
kage rate of each injector to be checked in order to
determine an internal leak in one or several injec-
tors. This test only works when the engine tempera-
ture is greater than 60˚C .
Switch off the ignition.
Disconnect the return pipes of the four injectors.
Connect the four transparent hoses with an internal
diameter of 4 mm and a length of 50 cm in the place
of the return pipes.
Immerse these hoses into four graduated measuring
cylinders (or use the measuring tool found in the
« capped rail » kit).
Start the engine.
Allow the engine to run for 2 minutes at idle speed.
Run command AC029 « High pressure circuit sea-
ling test » in the « Fuel/LPG » tab. The engine will
automatically carry out a cycle of four accelerations /
decelerations to increase the pressure in the rail and
check whether there are internal leaks on the injec-
tors' return circuit.
When the cycle is complete, the test must be run
again, to obtain a correct reading of the flow of each
injector.
After two cycles the flow of each injector should be
35 ml .
Replace the faulty injector.
IMPORTANT
Never leave a tool or other object on the side of
the engine housing during the four cycles (signifi-
cant vibration).
13B-83
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
Mot. 1367 Engine support tool for Tighten to torque 38 Nm the « pump-rail » and
replacing cylinder « injection rail » high pressure pipes with the fol-
head lowing part numbers:
- 77 01 207 025 ,
Mot. 1606 High pressure pump-
pulley retaining tool - 77 01 207 026 ,
- 77 01 207 027 ,
Mot. 1525 Extractor for timing
gear with tapered hub - 77 01 207 028 ,
- 77 01 207 029 .
Mot. 1525-02 Adaptor claws for Mot.
1525 for high pressure pipes with other part numbers,
tighten to a torque of 24 Nm .
Equipment required
diagnostic tool
IMPORTANT
Tightening torquesm Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
high pressure injection 21 Nm • that the injection rail is not under pressure,
pump mounting bolts
• that the fuel temperature is not too high.
high pressure injection 55 Nm
- It is essential to respect the safety and cleanliness
pump pulley mounting
advice given in this document whenever work is
nut
carried out on this system.
rail mounting nuts 28 ± 3 Nm - Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
union at the rail end 24 Nm
13B-84
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
21265
21265
Remove the engine covers.
13B-85
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
5
7 5
8 6
4
102361
110323
Undo the bolt (2) .
Remove the air duct (3) .
102362
13B-86
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
102360 102083
Disconnect: Remove the (16) « pump-rail » high pressure pipe
(see 13B, Diesel injection, High pressure pipe:
- the fuel return pipe connecting the injectors to the
Replacing ).
pump (10) ,
Slacken the rail mounting nuts (15) by a few turns.
- the rail pressure sensor (11) ,
Loosen the nut at the pump end, then the nut at the
- the accelerator (12) ,
rail end.
- the oil level sensor (13) ,
Slide the nut down the tube, keeping the olive in con-
- the cylinder reference sensor (14) on the timing co- tact with the taper.
ver.
Plug the openings on the injection circuit.
Unclamp the electrical harness and move it to one
side.
Remove the channel located on the spherical injec-
tion rail.
19626
Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .
13B-87
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
- the tie-bar and make a mark.
102114
Remove:
- the right-hand suspended mounting support and
cover,
19654
13B-88
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
102115
Remove the engine tie-bar mounting bolts (18) on
the gearbox and sub-frame. 103749
Raise the engine a few centimetres for access to the Remove the mounting bolts securing (19) the engine
suspended mounting attachments on the cylinder tie-bar on the gearbox and on the engine sub-frame.
head and the high pressure pump pulley.
Raise the engine a few centimetres for access to the
suspended mounting attachments on the cylinder
WARNING head and the high pressure pump pulley.
Do not dislodge the right-hand driveshaft when
lifting the engine. WARNING
Do not dislodge the right-hand driveshaft when
lifting the engine.
13B-89
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
19654-1
Remove:
- the cylinder reference sensor (20) ,
- the plastic bolt (21) ,
Unclip the three tabs (22) .
Remove the lower timing cover.
13B-90
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
19654-2
23167
Position the engine at Top Dead Centre. The cams-
haft pulley hole (24) should be opposite the cylinder
head hole (25) .
13B-91
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
23168 23169
Position the (Mot. 1606) (3) . Fit the (Mot. 1525) (4) fitted with the (Mot. 1525-02)
.
If necessary, turn the engine slowly to adjust the po-
sition of the locking tool on the pump pulley teeth.
Remove the high pressure pump pulley nut (26) , WARNING
holding the pulley with an open-jawed spanner. Ensure that the tool pushrod is correctly oriented
and is pressing against the high pressure pump
shaft.
13B-92
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
Before fitting the new high pressure pipe, lightly lu-
bricate the union threads with the oil from the appli-
cator provided in the new parts kit.
WARNING
Some pipes are supplied with applicator and
some without.
The pipes supplied without applicator are self-
lubricating pipes.
102085
Remove:
- the high pressure pump,
- the high pressure pump extractor tool.
REFITTING
WARNING
Do not remove the blanking plugs from each
component until the last moment.
WARNING
Always replace all high pressure pipes removed.
13B-93
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 722 or 728 or 729
If replacing the high pressure pump, reprime the die-
sel circuit using the diagnostic tool .
Note:
For VDiag numbers earlier than VDiag 48 , it is essential
that the injection computer is reprogrammed.
If the reprogramming is not carried out, do not apply the
procedure detailed below but prime the fuel circuit using
the priming bulb.
WARNING
Never start the engine until the pump has been reprimed.
Also comply with the operation instructions provided to
prevent the high pressure pump from being damaged
internally, due to running with no load and no diesel lubri-
cation.
WARNING
13B-94
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 800 or 808
Mot. 1525-03 Adapter claws for Mot. - that the fuel temperature is not too high.
1525 (for 33-tooth pul- Loosening a high-pressure pipe union when the
ley) engine is running is strictly prohibited.
Mot. 1746 Offset spanner for
tightening high pres-
sure pump pipe WARNING
Mot. 1566 Wrench for removing Ensure that any high-pressure pipe removed is
high-pressure pipes replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high-pressure pump
and the injectors is prohibited.
Tightening torquesm
It is essential to read the repair precautions (see 13A,
high-pressure pump 30 Nm Diesel injection, Repair precautions ).
mounting bolts on the
pump supports REMOVAL
high-pressure pump 50 Nm Put the vehicle on a two-post lift.
pulley nut
Disconnect the battery, starting with the negative
high-pressure pump 20 Nm + 80˚ terminal.
support mounting bolts Remove:
on the cylinder head
- the accessories belt (see 11A, Top and front of
high-pressure pump 44 Nm engine, Accessories belt ),
rear support mounting - the timing belt (see 11A, Top and front of engine,
bolts on the cylinder Timing belt ).
block
- the injector rail protector (see 13B, Diesel injec-
injector rail mounting 22 Nm tion, Injector rail protector: Removal - Refitting
bolts ), if fitted to the vehicle.
pump-rail high-pressure 29 Nm
pipe nut on the pump
side
pump-rail high-pressure 25 Nm
pipe nut on the rail side
13B-95
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 800 or 808
102352 102353
- the diesel fuel heater from the diesel filter, Plug the openings.
102348
Remove the two mounting bolts (3) from the high-
pressure pump on the high-pressure pump rear sup-
port.
102351
13B-96
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 800 or 808
102350 102894
Remove: Fit the pulley extractor (Mot. 1525) (2) with claws
- the three mounting bolts (4) from the high-pressure (Mot. 1525-03) for pulleys with thirty-three teeth.
pump front support, Remove the pulley by tightening the pulley extractor
- the high-pressure pump, with the high-pressure thrust bolt (6) .
pump support.
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.
1668) .
102893
Position the (Mot. 1668) (1) .
102345
Remove the nut (5) from the high-pressure pump
Remove:
pulley.
- the three mounting bolts (7) from the high-pressure
pump,
13B-97
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 800 or 808
- the high-pressure pump mounting bolts on the - Do not lubricate high-pressure pipes supplied
pump supports ( 30 Nm ) , without an applicator, as these high-pressure
pipes are self-lubricating.
- the high-pressure pump pulley nut ( 50 Nm ) by
immobilising the pulley with (Mot. 1668) .
WARNING
Do not remove the plugs from each component
until the last moment.
13B-98
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 800 or 808
Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt ),
- the accessories belt (see 11A, Top and front of
engine, Accessories belts ).
For versions with injector rail protector covers:
- Refit the air inlet duct (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting ).
Note:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting ).
WARNING
13B-99
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 804
Mot. 1525-03 Adapter claws for Mot. - that the fuel temperature is not too high.
1525 (for 33-tooth pul- Loosening a high-pressure pipe union when the
ley) engine is running is strictly prohibited.
Mot. 1746 Offset spanner for
tightening high pres-
sure pump pipe WARNING
Mot. 1566 Wrench for removing Ensure that any high-pressure pipe removed is
high-pressure pipes replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high-pressure pump
and the injectors is prohibited.
Tightening torquesm
It is essential to read the repair precautions (see 13A,
high-pressure pump 30 Nm Diesel injection, Repair precautions ).
mounting bolts on the
pump supports REMOVAL
high-pressure pump 50 Nm Put the vehicle on a two-post lift.
pulley nut
Disconnect the battery, starting with the negative
high-pressure pump 20 Nm + 80˚ terminal.
support mounting bolts Remove:
on the cylinder head
- the accessories belt (see 11A, Top and front of
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
mounting bolts on the
rear pump support
pump-rail high-pressure 29 Nm
pipe nut on the pump
side
pump-rail high-pressure 25 Nm
pipe nut on the rail side
13B-100
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 804
111888
Remove the injector rail protector (see 13B, Diesel
injection, Injector rail protector: Removal - Refit-
ting ).
Disconnect:
102353
- the diesel fuel heater from the diesel filter,
Remove the pump - rail high-pressure pipe (3) .
- the heater plugs,
Plug the openings.
- the pressure regulator (1) ,
102348
102351
Remove the bolts mounting the high-pressure pump
Disconnect the diesel supply and return pipes (2) .
to the high-pressure pump rear support.
Plug the openings.
Remove the diesel pipes retaining clip.
13B-101
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 804
102350 102894
Remove: Set the pulley extractor (Mot. 1525) in place; fitted
- the bolts (5) mounting the high-pressure pump with claws (Mot. 1525-03) (8) for pulleys with thirty-
front support, three teeth.
- the high-pressure pump, with the high-pressure Remove the pulley by tightening the pulley extractor
pump support. thrust bolt (9) .
102893
Position the (Mot. 1668) (6) .
Remove the nut (7) from the high-pressure pump 102345
pulley.
Remove:
13B-102
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 804
WARNING
Do not remove the plugs from each component
until the last moment.
13B-103
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
F9Q, and 804
Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt ),
- the accessories belt (see 11A, Top and front of
engine, Accessories belts ),
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ).
Note:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting ).
WARNING
13B-104
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 732
WARNING
WARNING
112811
Pull the clip
Remove the air inlet duct mounting bolt.
Move the air inlet duct to one side.
Remove:
- the rigid air duct between the intercooler hose and
the turbocharger,
13B-105
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 732
- the injector rail protector cover
Disconnect:
- the heater plug connectors,
- the injector connectors,
- the rail pressure sensor connector,
- the fuel flow actuator connector,
- the fuel temperature sensor connector.
Clean (see 13B, Diesel injection, Repair precau-
tions ):
- the fuel return pipe connecting the injectors,
- the fuel inlet pipe.
111748
Disconnect:
Remove:
- the fuel return pipe connecting the injectors to the
high-pressure pump, - the mounting bolts (3) from the dipstick guide on
the mounting of the diesel anti-splash device.
- the fuel inlet pipe.
- the bolt (4) and mounting nuts (5) from the injector
Note: rail protector cover support.
Make preparations for the fuel outflow, Move the wiring harness to one side.
Clean with new wipes. Unpick the drain pipe on the injector rail protector
cover support.
WARNING
When loosening the union of the high-pressure
pipe on the high-pressure pump, the interme-
diate nut must be secured on the high-pressure
pump using a lock wrench.
13B-106
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 732
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Remove:
WARNING
If the high-pressure pump is to be reused, keep it
in a sealed plastic bag all the time it is discon-
nected.
WARNING Note:
When replacing a high-pressure pump, retain the The high-pressure pump pulley can also be
high-pressure pump pulley and refit on the new immobilised using the (Mot. 855) .
pump.
Fit (Mot. 1768) on the high-pressure pump pulley
then extract the pulley.
Hold the high-pressure pump in a vice, using the
lower securing point on the pulley side.
WARNING
Ensure that you do not mark the high-pressure
pulley when extracting it using the tool.
You must replace any damaged high-pressure
pump pulleys.
REFITTING
WARNING
- Remove the blanking plugs only before recon-
necting the fuel circuit pipes
- The plugs are single-use. Do not reuse them
and throw away the complete kit after opening.
111743
13B-107
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 732
I - REFITTING OPERATION FOR PART
CONCERNED
WARNING
When replacing an injector rail, only remove it
from its packaging just before it is refitted.
Note:
If the new parts kit does not contain an applica-
tor, lubrication of the pipe threads will be unne-
cessary (as they are self-lubricating pipes).
13B-108
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K, and 732
II - FINAL OPERATION
Refit: WARNING
- the injector rail protector cover support,
Confirm that there are no diesel fuel leaks:
- the injector rail protector cover support mounting - Check the tightness after repair (see 13B, Die-
nuts and bolt, sel injection, High-pressure pipe: test ),
- the dipstick guide, - run the engine at idle speed,
- the dipstick guide mounting bolts. - accelerate several times at no load,
- Check that there are no diesel fuel leaks
Note: Using diagnostic tool , check that there are no sto-
Ensure that the injector rail protector support red faults. Clear them if necessary.
mounting bolt does not fall under the high-pres-
sure pump.
Connect:
- the drain pipe to the injector rail protector cover
support
Refit:
13B-109
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
M9R, and 700
REMOVAL
Special tooling required
diagnostic tool Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
Tightening torquesm
- that the fuel temperature is not too high.
high-pressure pump 25 Nm
mounting bolts Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
high-pressure pipe 32 Nm
union on the high-pres-
sure pump WARNING
Obtain a set of special high-pressure injection
high-pressure pipe 32 Nm circuit plugs.
union on the injector rail
Ensure that any high-pressure pipe removed is
high-pressure pipe 10 Nm replaced.
retaining bracket moun-
ting bolts on the bea- Position the vehicle on the two-post lift (see 02A,
ring cap casing Lifting equipment, Underbody lift ).
Remove:
13B-110
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
M9R, and 700
REFITTING
WARNING
Do not remove the blanking plugs from each
component until the last moment.
WARNING
Do not apply pressure to the high-pressure pump
gear teeth.
WARNING
Check that the high-pressure pump is in contact
with the cylinder head before positioning the
bolts.
13B-111
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
M9R, and 700
III - FINAL OPERATION
Remove the « wiring harness and fuel pipe » as- Confirm that there is no diesel fuel leak:
sembly.
- run the engine at idle speed,
- accelerate several times at no load,
WARNING - carry out a road test,
Do not lubricate high-pressure pipes supplied
- switch off the ignition,
without an applicator, as these high-pressure
pipes are self-lubricating. - check that there is no diesel fuel escaping.
Do not allow oil into the high-pressure pipe.
Tighten to torque:
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting ).
13B-112
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728 or 729
Equipment required
WARNING
diagnostic tool
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206
Tightening torquesm 804 ),
WARNING
13B-113
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728 or 729
109463 109467
Disconnect the injector diesel return pipe (2) . Disconnect the high-pressure pump electrical con-
nectors (3) .
Fit plugs into the openings.
Remove the mounting bolts from the neck (4) fixed
to the spherical injector rail.
Pull the electric wiring harness to one side with the
neck on the side.
Loosen the injector rail mounting nuts by several
turns.
Remove the clips connecting the high-pressure pi-
pes.
Clean the high-pressure pipe (see 13B, Diesel in-
jection, Diesel injection: Precautions during re-
pair ).
Remove the « injector-rail » high-pressure pipe con-
cerned.
13B-114
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728 or 729
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
WARNING
Do not remove the plugs from each component
until the last moment.
109462
Note: 19724
an injector corresponds to a cylinder. Using cloths (part no.: 77 11 211 707 ) soaked in
fresh solvent, clean:
Pull off the compression washer.
- the injector wells,
I - CLEANING THE INJECTORS Use a new cloth to dry components that have been
cleaned.
13B-115
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 722 or 728 or 729
III - FINAL OPERATION If removing the four injectors, torque tighten the rail
mounting nuts ( 28 Nm ) .
- rail end.
- injectors end,
- rail end.
Note:
Tighten a pipe fully before moving on to the next
pipe.
20960
Refit the neck on the injector rail.
Insert the high-pressure pipe olive in the injector Refit the engine undertray.
high-pressure inlet taper.
Program the alphanumeric code (C2I) for the repla-
Insert the high-pressure pipe olive into the rail high-
ced injector(s) using diagnostic tool (see 13B, Die-
pressure conical outlet.
sel injection, Injectors: configuration ).
Finger tighten the high-pressure pipe nuts, starting
with the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts. WARNING
13B-116
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
F9Q, and 800 or 804 or 808
For versions without injector rail protectors:
Special tooling required
- remove the inlet duct (see 12A, Fuel mixture, Air
Mot. 1566 Wrench for removing inlet duct: Removal - Refitting ), if necessary.
high-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
IMPORTANT
WARNING
Opening the injectors is prohibited.
REMOVAL
Remove the engine covers.
13B-117
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
F9Q, and 800 or 804 or 808
18297-1
Disconnect the injector connector.
Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the return rail.
Fit blanking plugs into the openings.
13B-118
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
F9Q, and 800 or 804 or 808
REFITTING
WARNING
WARNING
II - REFITTING THE INJECTOR
The injector filter rod must not be removed.
WARNING
WARNING
Do not remove the protective caps from each
When loosening the injector pipe unions (2) on
component until the last moment.
the injectors, be sure to hold the filter rod retai-
ning nuts (3) with a lock wrench.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector bracket mounting bolt,
- the injector and its bracket,
- the compressor washer.
13B-119
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
F9Q, and 800 or 804 or 808
1326
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.
WARNING
Do not fit high-pressure pipes without mountings.
WARNING
Always replace any high-pressure pipe removed
with a new one.
WARNING
Always hold the filter rod mounting nuts on the
injector holder with a lock wrench when tighte-
ning.
13B-120
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
F9Q, and 800 or 804 or 808
18297-1
Refit the return rail (5) . Program the alphanumeric code (IMA) for the injec-
tor(s) replaced using the diagnostic tool (see MR
Do not remove the injector clip.
366 Fault finding, 13B, Diesel injection, Fault fin-
Press the injector clip. ding - Replacement of components ).
Push the return rail end piece vertically.
Throw away the plug set upon completion of the WARNING
operation.
Confirm that there is no diesel fuel leak:
To refit, proceed in the reverse order to removal.
- Run the engine at idle speed.
Refit the air inlet duct (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting ), if removed. - Accelerate several times at no load.
- Switch off the ignition.
Note: - Check that there is no diesel fuel escaping.
For versions with injector rail protector covers: Tighten to torque the battery cover mounting bolts
- Refit the inlet duct without refitting the injector ( 4 Nm ) .
rail protector or replacing the duct seal.
For versions with injector rail protector covers:
Connect the battery, starting with the positive termi- - Remove the air inlet duct,
nal.
- Refit the injector rail protector (see 13B, Diesel in-
jection, Injector rail protector: Removal - Refit-
WARNING ting ).
Carry out the necessary programming (see 80A, - Refit the inlet duct (see 12A, Fuel mixture, Air in-
Battery: Removal - Refitting ). let duct: Removal - Refitting ).
13B-121
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
WARNING
WARNING
13B-122
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
112811 112992
Pull out the clip. Unclip injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector rail
protector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
Protect the alternator from fuel outflow.
Clean (see 13B, Repair precautions ). :
- the high-pressure pipes between the injector rail
and the injectors,
- the fuel return connectors of the injectors.
112991
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
13B-123
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
- the nut of the high-pressure pipe between the injec-
tor rail and the injector on the injector end,
Note:
Make preparations for the fuel outflow. Clean with
new wipes.
114075
111749
WARNING
Ensure that the clip is not fully removed from its
housing to prevent it from being twisted when
touching the rocker cover.
1327
WARNING
When the high-pressure pipe unions (10) on the
injector holder are loosened, it is imperative to
hold the filter rod retaining nut (11) with a lock
wrench.
111751
Remove:
Extract the fuel return connector from the injector
- the nut of the high-pressure pipe between the injec- while pushing the lower bracket of the retaining clip
tor rail and the injector on the rail end, downwards.
13B-124
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
Fit the correct blanking plug.
Remove the fuel return pipe from the injector.
114010
Note:
If the injector is jammed in its well and does not
come out, turn the injector at the flat support sur-
111746
faces of the injector bracket using a 13 mm open
Remove: end wrench.
- the injector bracket mounting bolt (13) ,
Fit the appropriate blanking plug on the injector's no-
- the injector bracket, se.
- the spacer between the cylinder head and the in-
jector bracket, WARNING
- the injector, If it is to be reused, keep the injector(s) in a sea-
- the compression washer located at the bottom of led plastic bag until required.
the injector well in the cylinder head.
WARNING
Ensure that no impurities enter into the cylinder
via the injector well in the cylinder head: plug the
orifice using a clean cloth.
Note:
This procedure only applies if removing all the
injectors and, after having removed them all, in
preparation for refitting them.
13B-125
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
112993 112994
Disconnect: Disconnect:
- the injector connector (14) , - the connector (16) from the damper valve,
- the heater plugs connector (15) . - the cylinder marking sensor connector (17) ,
- the pressure regulation solenoid valve connector
(18) ,
- the flow regulation solenoid valve connector (19) ,
- the diesel temperature sensor connector (20) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (21) .
Remove the wiring harness clip mounting nut (22) .
Move the electric wiring harness to one side.
13B-126
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
- the injector rail protector support.
Undo the injector rail mounting nuts by a few turns
(the injector rail should be loose).
REFITTING
WARNING
Clean the fuel supply and return pipe unions (see Leave the injectors to soak in cleaner fluid.
13B, Repair Precautions ). Clean using new wipes.
Disconnect:
- the fuel supply pipe (23) , WARNING
- the fuel return pipe (24) . Only remove the blanking plugs immediately
before connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;
Note: dispose of the whole set after use.
Make preparations for the fuel outflo w. Clean with
new wipes. Remove the injector from its plastic bag.
13B-127
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
Tighten to torque the injector bracket mounting Remove the blanking plugs.
bolt ( 30 Nm ) .
Push the retaining clip of the fuel return connector
Remove the blanking plugs. on the injector to the front of the vehicle in order to
Fit the new high-pressure pipe(s) between the injec- place it in its initial position.
tor rail and the injector.
Clip on the fuel return connector of the injector.
Note:
WARNING
If the new pipes kit does not contain an applica-
tor, lubrication of the pipe threads will be unne- Check the condition of the seal on the fuel return
cessary (as they are self-lubricating pipes). connector of the injector.
Change the diesel return rail if one of its compo-
Finger tighten the high-pressure pipe nuts, starting nents is damaged.
with the one at the injector rail side.
- the mounting nuts and bolt of the injector rail pro- - the injector rail protector cover mounting nut and
tector support. bolt,
Clip the diesel evacuation pipe. Clip injector rail protector cover.
Remove the blanking plugs.
Refit:
Connect:
- the clip on the stainless steel pipe if necessary,
- the fuel supply pipe,
- the stainless steel pipe on the hose, aligning the
- fuel return pipe.
markings,
Fit the wiring harness.
- the air inlet duct clip between the turbocharger and
Refit the mounting nut of the wiring harness clip. the intercooler.
Clip on the retaining clip of the wiring harness.
Tighten the air inlet duct clip ( 5.5 Nm ) .
Connect:
Clip the stainless steel pipe to turbocharger.
- the rail pressure sensor connector,
- the diesel fuel temperature sensor connector, Refit:
- the connector of the flow regulation solenoid valve, - the stainless steel pipe mounting bolt,
- the connector of the pressure regulation solenoid - the air inlet duct on the damper valve.
valve,
- the cylinder marking sensor connector, Tighten the clip.
- the heater plugs connector, - the connector of the air inlet pressure sensor,
- the injectors' connector.
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
2 - All types
Reprime the fuel circuit with the manual priming
Tighten to torque the high-pressure pipe nuts ( 24 pump.
Nm ) using (Mot. 1566) or (Mot. 1746) and starting
at the injector rail end. Refit the engine covers.
13B-128
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K, and 732
Using the diagnostic tool , clear any faults stored
by the injection computer, before restarting the engi-
ne.
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B, Die-
sel injection, High-pressure pipe: Check ),
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check for leaks and for diesel fuel outflow.
13B-129
DIESEL INJECTION
Injectors: Configuration 13B
K9K, and 722 or 728 or 729 or 732
REPLACING THE INJECTORS
Note:
The C2I (individual injector correction) parameters
are a factory calibration carried out on each injector
to adjust the flow of each injector precisely, taking
into account differences in manufacture.
Note:
Only after replacing all four injectors at once, reset
the injector programming adaptives using the
RZ004 « Pressure regulation adaptives » .
13B-130
DIESEL INJECTION
Injectors: Configuration 13B
F9Q, and 800 or 808
• reconfigure the computer for the equipment (air con-
ditioning),
Equipment required
• make sure, using the diagnostic tool CLIP, that the
diagnostic tool computer has not detected any faults relating to the
injector codes and that the instrument panel warning
light is off.
INJECTORS
A 6-character « alphanumeric » code known as the
IMA (Injector Flow Correction) is marked on the injec-
tors. This code is specific to each injector, and takes
into account manufacturing dispersion and specifies
the flow of the injector.
When one or more injectors is replaced, the code of the
new injector(s) must be programmed into the compu-
ter. If this operation is not carried out then the engine
speed will be limited to 1800 rpm .
Follow the procedure described below:
13B-131
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
REMOVAL
Special tooling required
Mot. 1746 Offset spanner for Switch off the ignition and wait 30 seconds before
tightening high pres- starting work on the injection system.
sure pump pipe
Remove the engine covers.
Tightening torquesm
WARNING
- cleaning product (part no. 77 11 224 188) . Disconnect the air inlet pressure sensor connector
(1) .
Loosen the clip (2) and move the air inlet duct aside
WARNING (3) .
IMPORTANT
Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanliness
advice given in this document whenever work is
carried out on this system (see 13B, Diesel injec-
tion, cleanliness guidelines ).
112811
13B-132
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
Move the dipstick pipe to one side.
112991
Remove:
- the stainless steel pipe mounting bolt (4) ,
- the stainless steel pipe (5) .
1327
WARNING
When the high-pressure pipe unions (9) on the
injector holder are loosened, it is imperative to
hold the filter rod retaining nut (10) with a lock
wrench.
Remove:
13B-133
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
Removing the four high-pressure pipes
Note:
This procedure only applies if removing all the
high-pressure pipes and, after having removed
them all, in preparation for refitting them.
112994
Disconnect:
- the connector (13) from the damper valve,
- the cylinder marking sensor connector (14) ,
- the pressure regulation solenoid valve connector
(15) ,
112993 - the flow regulation solenoid valve connector (16) ,
Disconnect:
- the diesel temperature sensor connector (17) ,
- the injector connector (11) ,
- the rail pressure sensor connector.
- the heater plugs connector (12) .
Unclip the wiring harness retaining clip (18) .
Remove the wiring harness clip mounting nut (19) .
Move the electric wiring harness to one side.
13B-134
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
111748
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support bolt and mounting
nuts (22) ,
112656
- the injector rail protector support,
Protect the alternator from fuel outflow.
- the fuel supply and return pipes.
Clean the fuel supply and return pipes unions (see
13B, Repair Precautions ). Clean the unions (see 13B, Repair precautions ):
Disconnect: - of the fuel return pipe on the high-pressure pump
and injector rail,
- the fuel inlet pipe (20) ,
- on the high-pressure pipe between the high-pres-
- the fuel return pipe (21) .
sure pump and the injector rail,
Note:
REFITTING
Make preparations for the fuel outflo w. Clean with
new wipes.
I - REFITTING PREPARATION OPERATION
Fit blanking plugs,
WARNING
Only remove the blanking plugs immediately
before connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;
dispose of the whole set after use.
13B-135
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 732
II - REFITTING OPERATION FOR PART III - FINAL OPERATION
CONCERNED
Refit:
Fit the new high-pressure pipe between the injector
rail and the injector. - the dipstick tube mounting bolts.
If the new pipes kit does not contain an applica- - the injector rail protector cover,
tor, lubrication of the pipe threads will be unne-
cessary (as they are self-lubricating pipes). - the injector rail protector cover mounting nut and
bolt,
Finger tighten the high-pressure pipe nuts, starting
with the one at the injector rail side. Clip injector rail protector cover.
Refit: Refit:
- the injector rail protector support,
- the stainless steel pipe mounting bolt,
- the mounting nuts and bolt of the injector rail pro-
tector support. - the air inlet duct on the damper valve.
Clip the diesel evacuation pipe.
Tighten the clamp.
Remove the blanking plugs.
Connect:
Connect:
- the fuel supply pipe, - the connector of the air inlet pressure sensor,
- fuel return pipe. - the battery (see 80A, Battery, Battery: Removal -
Fit the wiring harness. Refitting ).
Refit the mounting nut of the wiring harness clip. Reprime the fuel circuit with the manual priming
Clip the retaining clip of the wiring harness into pla- pump.
ce.
Refit the engine covers.
Connect:
Using the diagnostic tool , clear any faults stored
- the rail pressure sensor connector,
by the injection computer, before restarting the engi-
- the diesel fuel temperature sensor connector, ne.
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoid WARNING
valve, Confirm that there is no diesel fuel leak:
- the cylinder marking sensor connector, - Check the tightness after repair (see 13B, Die-
- the connector on the damper valve, sel injection, High-pressure pipe: Check ),
13B-136
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 722 or 724 or 728 or 729
Equipment required
WARNING
diagnostic tool
Tighten to torque 38 Nm the « pump-rail » and
« injector-rail » high-pressure pipes with one of the
following part numbers:
Tightening torquesm
- 77 01 207 025 ,
injector rail mounting 28 Nm
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 torque 24 Nm .
nuts of the neck on the 21 Nm
rail
REMOVAL
WARNING
13B-137
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 722 or 724 or 728 or 729
109473
102362
109470
Remove the dipstick mounting bolts (5) .
Place the dipstick to one side.
Remove the injector rail protector cover (6) .
109466
- the injectors.
13B-138
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 722 or 724 or 728 or 729
REFITTING
109467
Disconnect the high-pressure pump electrical con-
nectors (9) .
Remove the mounting bolts from the neck (10) fixed 20960
to the spherical injector rail.
Move the electric wiring harness and neck to the
side as shown by the arrow. WARNING
Before fitting a new high-pressure pipe, lightly
Loosen the injector rail mounting nuts by several
turns. lubricate the nut threads with oil from the applica-
tor provided in the new part.
Remove the clips connecting the high-pressure pi-
pes. Be careful not to allow oil into the high-pressure
pipe.
13B-139
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K, and 722 or 724 or 728 or 729
Insert the high-pressure pipe olive in the rail high- Fit the turbocharger air duct.
pressure outlet taper.
Lock the air duct between the turbocharger and the
Finger tighten the high-pressure pipe nuts, starting intercooler air inlet pipe.
with the nut at the injector end.
Tighten the bolt of the air duct on the rocker cover.
Slightly pretighten the high-pressure pipe nuts.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
Note: Prime the diesel circuit using the priming pump.
The assembly order of the « injector-rail » high-
pressure pipes is not important. WARNING
Fit the new clip provided with the new high-pressure
Confirm that there is no diesel fuel leak:
pipe.
- check the seal after repair,
If replacing the four high-pressure pipes, torque tigh-
ten the injector rail mounting nuts ( 28 Nm ) . - let the engine run at idle speed until the engine
cooling fan starts to operate,
Tighten to torque and in order the « pump-rail »
high-pressure pipe nuts ( 24 Nm ) : - accelerate several times at no load,
Note:
Tighten a pipe fully before moving on to the next
pipe.
13B-140
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
M9R, and 700
- the oil separator (see 13B, Diesel injection, Oil
Special tooling required separator: Removal - Refitting ).
Mot. 1566 Wrench for removing
high-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
« rail-injector » high- 32 Nm
pressure pipe mounting
nuts
WARNING
Obtain the special high-pressure injection circuit
plug kit.
Always replace any high-pressure pipe or high-
pressure pipe clip removed with a new one.
REMOVAL
Remove:
13B-141
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
M9R, and 700
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
Fit:
- the high-pressure pipe olive in the injector taper,
- the high-pressure pipe olive into the injector rail
outlet taper.
Finger tighten until contact the high-pressure pipe
nuts, starting with the nut at the injector rail side.
Tighten to torque and in order, using (Mot. 1566) ,
the « rail-injector » high-pressure pipe mounting
nuts ( 32 Nm ) :
- on the injectors,
- on the injector rail.
113134
III - FINAL OPERATION
Using (Mot. 1566) , loosen: Refit:
- the high-pressure nut at the injector end, - the diesel return pipe,
- the bolt mounting the diesel return pipe on the roc-
- the high-pressure pipe nut at the injector rail end.
ker cover
Drive the mobile section of the diesel return pipe into
Note: the injectors.
Loosen the nuts pipe by pipe. Tighten to torque the diesel return pipe mounting
bolt on the rocker cover ( 10 Nm ) .
Move the nuts along the tube, keeping the olive in Connect the quick-release union to the diesel return
contact with the taper. pipe.
WARNING
Do not lubricate the high-pressure pipes supplied
without an applicator, these high-pressure pipes
are self-lubricated.
Do not allow oil into the high-pressure pipe.
WARNING
Do not remove the blanking plugs from each
component until the last moment.
13B-142
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728 or 729
13B-143
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728 or 729
109466 109467
Disconnect the injector connectors (1) and the hea- Disconnect:
ter plugs (2) .
- the connectors (4) for the flow actuator and the die-
sel fuel temperature sensor,
- the spherical rail pressure sensor (5) .
Move the electric wiring harness and channel to the
side as shown by the arrow.
Remove the mountings from the channel (6) fixed on
the spherical rail.
Protect the alternator from fuel outflow.
Clean the high-pressure pipes (see 13B, Diesel in-
jection, Diesel injection: Precautions during re-
pair ).
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Use wipes if necessary.
102362
Remove the diesel fuel splash plate (3) .
13B-144
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728 or 729
II - OPERATION FOR REMOVAL OF PART
CONCERNED
20803
Remove the clips between the high-pressure pipes.
20803
Loosen the nuts securing the high-pressure pipes
between the injector rail and the injector. Remove:
Remove the four high-pressure pipes and discard.
- the injector rail mounting nuts (8) ,
WARNING
If an injector rail is being replaced, only remove
the new one from its original packaging when it is
about to be fitted.
13B-145
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 722 or 728 or 729
II - REFITTING OPERATION FOR PART Reprime the fuel circuit.
CONCERNED
Connect the battery (see 80A, Battery, Battery: Re-
Fit the injector rail. moval - Refitting ).
Tighten the injector rail mounting bolts (the injector Confirm that there is no diesel fuel leak:
rail should be loose).
- check the seal after repair (see 13B, Diesel injec-
tion, Diesel injection: Repair precautions ),
III - FINAL OPERATION
- let the engine run at idle speed until the engine
Remove the blanking plugs from: cooling fan starts to operate,
- the high-pressure pump, - accelerate several times at no load,
- the injector rail fuel inlet opening. - check for leaks and for diesel fuel outflow.
Fit a new high-pressure pipe between the injector Use diagnostic tool to check for stored faults. Clear
rail and the high-pressure pump. them if necessary.
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unneces-
sary (as they are self-lubricating pipes).
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unneces-
sary (as they are self-lubricating pipes).
13B-146
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
Tightening torquesm
IMPORTANT
REMOVAL
Disconnect the battery, starting with the positive ter-
minal.
Remove:
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ).
13B-147
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 800 or 808
18297-1
Note:
The diesel temperature sensor is an integral part
of the fuel return pipe; these two components are
connected and cannot be removed separately.
13B-148
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 800 or 808
REFITTING
Position the injector rail.
WARNING
Do not remove the protective caps from each
6 component until the last moment.
7
Always replace any high-pressure pipe removed
with a new one.
13B-149
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 800 or 808
18297-1
For versions with injector rail protector covers: - check that there is no diesel fuel escaping.
- Refit the air inlet duct (see 12A, Fuel mixture, Air Tighten to torque the battery cover mounting bolts
inlet duct: Removal - Refitting ). ( 4 Nm ) .
For versions with injector rail protector covers:
Note: - Remove the air inlet duct,
Refit the inlet duct without refitting the injector rail - Refit the injector rail protector (see 13B, Diesel in-
protector or refitting the duct seal. jection, Injector rail protector: Removal - Refit-
ting ), if fitted to the vehicle,
Connect the battery, starting with the positive termi-
nal. - Refit the air inlet duct (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting ).
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13B-150
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 804
Equipment required
diagnostic tool
3
Tightening torquesm
111965
injector rail mounting 25 Nm Disconnect:
bolts
- the injector connectors (1) ,
nuts on the injector side 25 Nm - the cylinder marking sensor connector (2) ,
and the nut on the injec-
tor pump side - the fuel return pipe.
Plug the openings.
nuts on the rail side 29 Nm
Do not remove the injector clip.
battery cover mounting 4 Nm
Press the injector clip.
bolts
Pull the return rail end piece vertically.
Remove the diesel return pipe (3) .
IMPORTANT
Plug the openings.
Before carrying out any work on the injection sys-
tem, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
REMOVAL
Disconnect the battery, starting with the negative
terminal.
Remove:
- the engine covers,
- the injector rail protector (see 13B, Diesel injec-
tion, Injector rail protector: Removal - Refitting
).
13B-151
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 804
REFITTING
4 Position the injector rail.
WARNING
Do not remove the protective caps from each
component until the last moment.
Always replace any high-pressure pipe removed
with a new one.
5
Tighten the injector rail bolts, leaving clearance
between the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
- screw, by hand, the high-pressure pipe nuts onto
the pump and injector side,
- screw, by hand, the high-pressure pipe nuts onto
the rail side.
Tighten to torque using (Mot. 1566) or (Mot. 1746) :
1327
- the injector rail mounting bolts ( 25 Nm )
Remove the high-pressure diesel pipes using (Mot. - the nuts on the injector side and the nut on the
1566) or (Mot. 1746) . injector pump side ( 25 Nm )
- the nuts on the rail side ( 29 Nm )
WARNING
When loosening the injector pipe unions (4) on WARNING
the injectors, be sure to hold the filter rod retai- Do not put high-pressure pipes under stress.
ning nuts (5) with a lock wrench.
Do not touch the high-pressure pipes with the
spanner when tightening them.
Plug the openings.
Always hold the filter rod retaining nuts on the
Remove the oil separator. injector holder when tightening.
111859
Remove:
13B-152
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
F9Q, and 804
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 ).
111965
Note:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting ).
WARNING
13B-153
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
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
112815
13B-154
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
112811 112992
Pull out the clip. Unclip injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector rail
protector cover,
- the injector rail protector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
112991
Remove the stainless steel pipe mounting bolt (4)
Move the air inlet duct to one side.
112993
Disconnect:
- the injector connector (9) ,
13B-155
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
- the heater plugs connector (10) .
112656
112994 Protect the alternator from fuel outflow.
Disconnect:
Clean (see 13B, Repair precautions ):
- the connector (11) from the damper valve,
- the fuel supply pipe (18) ,
- the cylinder marking sensor connector (12) ,
- the fuel return pipe (19) .
- the pressure regulation solenoid valve connector
Disconnect:
(13) ,
- the fuel supply pipe (18) ,
- the flow regulation solenoid valve connector (14) ,
- the fuel return pipe (19) .
- the diesel temperature sensor connector (15) ,
- the rail pressure sensor connector.
Make preparations for the fuel outflow. Clean with
Unclip the wiring harness retaining clip (16) . new wipes.
Remove the wiring harness clip mounting nut (17) .
Fit blanking plugs,
Move the electric wiring harness to one side.
13B-156
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
111748
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support mounting bolt and
mounting nuts,
1327
- the injector rail protector support.
Clean (see 13B, Repair precautions ):
WARNING
- the high-pressure pipes between the injector rail
When loosening the high-pressure pipe unions
and the injectors,
(21) on the injector holder, it is essential to hold
- the high-pressure pipes (19) between the high- the filter rod mounting nut (22) with a lock
pressure pump and the injector rail. wrench.
Remove:
- the nuts from the four high-pressure pipes between
the injector rail and the injector on the rail end,
- the nuts from the four high-pressure pipes between
the injector rail and the injector on the injector end,
Remove the four high-pressure pipes and dispose of
them in a bin.
Note:
Make preparations for the fuel outflow. Clean with
new wipes.
13B-157
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
Remove the high-pressure pipe between the high- REFITTING
pressure pump and the injector rail and dispose of it
in a bin.
I - REFITTING PREPARATION OPERATION
WARNING
When loosening the connector of the high-pres- WARNING
sure pipe, the intermediate nut must be secured
Only remove the blanking plugs immediately
on the pump using a lock wrench.
before connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;
Note: dispose of the whole set after use.
Make preparations for fuel outflow. Clean with
Take the injector rail out of its plastic bag.
new wipes.
Note:
If the new pipes kit does not contain an applica-
tor, lubrication of the pipe threads will be unne-
cessary (as they are self-lubricating pipes).
- 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.
If the new pipes kit does not contain an applica-
tor, lubrication of the nut threads will be unneces-
sar y (as they are self-lubricating pipes).
13B-158
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K, and 732
Tighten to torque: - the injector rail protector cover mounting nut and
bolt,
- the high-pressure pipe nuts between the injec-
tor rail and the injectors ( 24 Nm ) using (Mot.
Clip injector rail protector cover.
1566) or (Mot. 1746) starting with the rail end.
- the high-pressure pipe nuts between the injec- Refit:
tor rail and the high-pressure pump ( 24 Nm )
using (Mot. 1566) or (Mot. 1746) starting with the - the clip on the stainless steel pipe if necessary,
high-pressure pump end.
- the stainless steel pipe on the hose, aligning the
markings,
III - FINAL OPERATION
Refit: - the clamp of the air inlet duct between the turbo-
charger and the intercooler.
- the injector rail protector support,
Tighten the air inlet duct clip ( 5.5 Nm ) .
- the mounting nuts and bolt of the injector rail pro-
tector support.
Clip the stainless steel pipe to turbocharger.
Refit:
Note:
Ensure that the injector rail protector support - the stainless steel pipe mounting bolt,
mounting bolt does not fall under the high-pres-
sure pump. - the air inlet duct on the damper valve.
- the rail pressure sensor connector, Using the diagnostic tool , clear any faults stored
by the injection computer, before restarting the engi-
- the diesel fuel temperature sensor connector,
ne.
- the connector of the flow control solenoid valve,
- the connector of the pressure control solenoid val-
WARNING
ve,
Confirm that there is no diesel fuel leak:
- the cylinder marking sensor connector,
- Check the tightness after repair (see 13B, Die-
- the connector on the damper valve, sel injection, High-pressure pipe: Check ),
- the heater plugs connector, - run the engine at idle speed,
- the injectors' connector. - accelerate several times at no load,
Refit: - switch off the ignition,
- the dipstick tube mounting bolts. - check for leaks and for diesel fuel outflow.
- the dipstick,
Using diagnostic tool , check that there are no sto-
- the injector rail protector cover, red faults; clear if necessary.
13B-159
DIESEL INJECTION
Rail pressure sensor 13B
K9K, and 722 or 724 or 728 or 729 or 732
102086
Pressure sensor (1) cannot be removed from the sphe-
rical injector rail.
In the event of a pressure sensor fault, the « rail pres-
sure sensor and high-pressure pipe » assembly must
be replaced (see 13B, Diesel injection, Injector rail ).
13B-160
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
F9Q, and 800
Equipment required
diagnostic tool
Tightening torquesm
IMPORTANT
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- All high-pressure pipes must be replaced and any
removed high-pressure pipe clips.
13B-161
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
F9Q, and 800
REMOVAL
18297-5
Disconnect:
- the battery, starting with the negative terminal.
- the pressure sensor.
Unscrew the pressure sensor.
13B-162
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
F9Q, and 800
REFITTING
Replace the seal.
Screw in the sensor.
Tighten the pressure sensor to torque ( 3.5 daNm
+/- 0.5 ) .
Connect the connector.
WARNING
Connect the battery; carry out the necessary pro-
gramming (see (see 8, Electrical equipment) ).
WARNING
13B-163
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
1
Tightening torquesm
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Always replace any high pressure pipe and high
pressure pipe clips removed with new ones.
REMOVAL
102362
Remove the engine covers.
Remove diesel splash plate (2) .
13B-164
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 722
5 7
4
102514 102315
Disconnect: Remove the high-pressure pipe (6) on injector no. 4
(see 13B, Diesel injection, High pressure pipes:
- the heater plugs,
Replacement ).
- the injector connectors (3) from cylinders no. 3 and
Cap the openings.
no. 4,
Undo bracket bolts (7) .
- the pump electrical connectors (4) ,
Withdraw the fuel flow actuator (by hand using small
- the supply and return pipes (5) .
successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
13B-165
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 722
REFITTING
WARNING
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
13B-166
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 728 or 729
Equipment required
diagnostic tool
Tightening torquesm
Note:
For vehicles with a K9K 732 engine (see MR 370
Mechanical, Scénic II ).
110325
Pull the clip.
IMPORTANT
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Always replace any high-pressure pipe or high-
pressure pipe clip removed with a new one. 110323
Undo bolt (1) .
REMOVAL Remove air duct (2) .
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
13B-167
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 728 or 729
102362 102315
Remove the diesel splash plate (3) . Remove the high-pressure pipe (7) from injector no.
4 (see 13B, Diesel injection, High-pressure pi-
pes: Replacing ).
Fit plugs into the openings.
Undo bracket bolts (8) .
4
Withdraw the fuel flow actuator (by hand using small
successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
6
5
102514
Disconnect:
- the heater plugs,
- the injector connectors (6) from cylinders n˚3 and
n˚4,
- the pump electrical connectors (4) ,
- the supply and return pipes (5) .
13B-168
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K, and 728 or 729
REFITTING
WARNING
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13B-169
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 722 or 728 or 729
IMPORTANT
Do not leave any object (tools or other) on the
side of the engine housing during the entire ope-
ration.
Position the tools so that they do not fall during
the « engine running » phase of the test.
13B-170
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 732
112811
Pull out the clip.
112815
Disconnect the air inlet pressure sensor connector
(1) .
Loosen the clip and (2) move the air inlet duct aside
(3) .
112991
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
13B-171
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 732
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
IMPORTANT
Do not leave any object (tools or other) on the
side of the engine housing during the entire ope-
ration.
Position the tools so that they do not fall during
the « engine running » phase of the test.
Remove: Loosen the clip and move the air inlet duct aside.
- the mounting nut and bolt (7) from the injector rail Pull out the clip from the stainless steel pipe.
protector cover,
Move the air inlet duct to one side.
- the injector rail protector cover, Remove:
- the dipstick, - the dipstick,
- the dipstick tube mounting bolts (8) . - the dipstick tube mounting bolts.
Move the dipstick tube to one side. Move the dipstick tube to one side.
Disconnect the four fuel return pipes of the four in- Disconnect the four transparent pipes from (Mot.
jectors (see 13B, Diesel injector fuel return rail: 1771) .
Removal - Refitting ).
Refit:
Connect the transparent hoses of (Mot. 1771) to the
injectors instead of the injector fuel return pipes. - the dipstick tube mounting bolts.
Fit the correct blanking plug to the injector fuel return - the dipstick,
connectors. - the injector rail protector cover,
Insert these hoses in the four graduated measuring - the injector rail protector cover mounting nut and
cylinders of the (Mot. 1711) . bolt,
Refit: Clip injector rail protector cover.
- the dipstick tube mounting bolts. Refit the clip onto the stainless steel pipe if necessa-
- the dipstick. ry.
Clip the stainless steel pipe to turbocharger.
Refit the clip onto the stainless steel pipe if necessa-
ry. Refit:
Clip the stainless steel pipe to turbocharger. - the stainless steel pipe mounting bolt,
Refit the air inlet duct on the damper valve. - the air inlet duct on the damper valve.
Tighten the clamp. Tighten the clamp.
13B-172
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K, and 732
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Reprime the fuel circuit with the manual priming
pump.
Refit the engine covers.
13B-173
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
Tightening torquesm
regulator bolts 6 Nm
IMPORTANT
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Be sure to replace any high pressure pipe and
high pressure pipe clips that have been removed.
13B-174
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 800 or 808
REMOVAL
18297-1
Disconnect the battery, starting with the negative
terminal.
Blow the area with compressed air to clean impuri-
ties away from the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
- fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not use
any tool for leverage).
13B-175
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 800 or 808
REFITTING
Clean the fuel pressure regulator bearing face on WARNING
the high pressure pump, taking care not to introduce
any impurities. Confirm that there is no diesel fuel leakage:
- let the engine run at idle speed until the engine
Wipe the fuel pressure regulator bearing face on the
cooling fan starts up,
high pressure pump, taking care not to introduce any
impurities. - accelerate several times at no load,
Note:
Lubrication is very important to avoid external
leakage.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
13B-176
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 804
REMOVAL
Equipment required
diagnostic tool
Tightening torquesm
regulator bolts 6 Nm
IMPORTANT
1
Before carrying out any work on the injection circuit,
check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high. 111887
- It is essential to respect the safety and cleanliness Disconnect the battery, starting with the negative
advice given in this document whenever work is terminal.
carried out on this system. Blow compressed air into the area to clean dirt from
- Loosening a high-pressure pipe union when the around the fuel pressure regulator.
engine is running is strictly prohibited. Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
WARNING
- Obtain the special high-pressure injection cap kit. - fuel pressure regulator bolts (1) ,
- Be sure to replace any high-pressure pipe remo- - the fuel pressure regulator manually (do not use
ved. any tool for leverage).
13B-177
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
F9Q, and 804
REFITTING
Clean the fuel pressure regulator bearing face on WARNING
the high-pressure pump, taking care not to introduce
any impurities. Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the engine
Wipe the fuel pressure regulator bearing face on the
cooling fan starts to operate,
high-pressure pump, taking care not to introduce
any impurities. - accelerate several times at no load,
Connect the battery, starting with the positive termi- - carry out a road test,
nal. - switch off the ignition,
Flush the fuel pressure regulator housing in the - check that there is no diesel fuel escaping.
high-pressure pump, with the ignition on for a few
seconds.
Note:
Lubrication is very important to avoid external
leaks.
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting ).
13B-178
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 722
Equipment required
WARNING
diagnostic tool
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206
Tightening torquesm 804 ),
WARNING
- Obtain a set of special high-pressure injection cir- 102120
cuit plugs.
Disconnect air aspiration hose (1) .
- Always replace any high-pressure pipe and high-
pressure pipe clips that have been removed.
WARNING
13B-179
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 722
REFITTING
2 WARNING
Do not remove the blanking plugs from each
component until the last moment.
3
Lubricate the O-ring with the lubricant from the appli-
cator supplied with the new part.
WARNING
Do not damage the O-ring when refitting.
102317
13B-180
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 728 or 729
Equipment required
WARNING
diagnostic tool
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206
Tightening torquesm 804 ),
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Always replace any high-pressure pipe and high-
pressure pipe clips that have been removed.
110325
WARNING Pull the clip.
13B-181
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 728 or 729
2 5
110323 102317
Unscrew bolt (1) Clean the sensor (see 13B, Diesel injection, Diesel
Remove the air duct (2) . injection: Precautions during repair ).
3 REFITTING
4
WARNING
Do not remove the blanking plugs from each
component until the last moment.
WARNING
Do not damage the O-ring when refitting.
102514
Disconnect: Fit the diesel fuel temperature sensor.
- the heater plugs from cylinders n˚ 3 and 4, Tighten to torque the diesel temperature sensor (
- the injectors (3) on cylinders 3 and 4, 15 Nm ) .
- the fuel temperature sensor connector (4) . Reconnect the electrical connector.
13B-182
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 728 or 729
Check the sealing after repair (see 13B, Diesel in-
jection, High-pressure pipe: Check sealing ).
WARNING
13B-183
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 732
111747
The diesel temperature sensor (1) is attached to the
diesel injector fuel return rail.
Replace the diesel injector fuel return rail and diesel
temperature sensor assembly if there is a diesel tem-
perature sensor fault (see 13B, Diesel injection, Die-
sel injector fuel return rail: Removal - Refitting ).
13B-184
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 724
REMOVAL
Equipment required
I - REMOVAL PREPARATION OPERATION
diagnostic tool
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
IMPORTANT
WARNING
13B-185
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 724
109470 109465
Remove: Remove the high pressure pump protectors (8) and
- the dipstick, (9)
102514
Note:
Make preparations for fuel outflow. Clean with
new cloths.
13B-186
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 724
REFITTING
Note:
Do not lubricate the diesel temperature sensor
seals with grease or used diesel. Use the appli-
cator supplied with the kit.
WARNING
Do not damage the O-ring when refitting.
Do not remove the blanking plugs from each
component until the last moment.
102514
Disconnect the diesel temperature sensor connector
(11) . II - REFITTING PART CONCERNED
Connect:
Refit:
13B-187
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting 13B
K9K, and 724
Check the sealing after repair (see 13B, Diesel in-
jection, High pressure pipe: check ).
WARNING
13B-188
DIESEL INJECTION
Accelerometer: Removal - Refitting 13B
K9K, and 722 or 728 or 729
REFITTING
Special tooling required
Proceed in the reverse order to removal.
Emb. 1596 2 4 mm socket for
removing/refitting Tighten to torque the accelerometer ( 20 Nm )
clutch master cylinder using tool low torque wrench .
Connect the battery, starting with the positive termi-
Equipment required nal.
REMOVAL
102086
Disconnect the accelerometer connector (1) .
Remove the accelerometer using tool (Emb. 1596) .
13B-189
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 722
Equipment required
diagnostic tool
Tightening torquesm
102120
IMPORTANT Disconnect:
- the battery, starting with the negative terminal,
Before carrying out any work on the injection circuit,
check using the diagnostic tool CLIP: - the intake duct (1) .
• that the injection rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanliness
advice whenever work is carried out on this sys-
tem.
- Loosening a high pressure pipe union when the 2
engine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Always replace any high pressure pipe and high
pressure pipe clips removed with new ones.
REMOVAL
Remove the engine covers. 102514
Disconnect the fuel supply and return pipes (2) .
13B-190
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 722
REFITTING
WARNING
Do not remove the blanking plugs from any com-
3 ponent until the last moment.
13B-191
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 728 or 729
Equipment required
diagnostic tool
Tightening torquesm
IMPORTANT
1
WARNING
- Obtain a set of special high-pressure injection cir-
cuit plugs.
- Be sure to replace any high-pressure pipe and
high-pressure pipe clips that have been removed.
REMOVAL
Remove the engine covers.
110323
Undo bolt (1) .
Remove the air duct (2) .
13B-192
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K, and 728 or 729
REFITTING
WARNING
Do not remove the blanking plugs from each
3 component until the last moment.
102514 WARNING
Disconnect the fuel supply and return pipes (3) . Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
102316
Disconnect the return pipe (4) connecting the injec-
tor to the pump.
Remove:
- the Venturi mounting bolt (5) ,
- the Venturi.
13B-193
DIESEL INJECTION
Accelerator pedal potentiometer: General information 13B
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
The accelerator pedal potentiometer is incorporated in
the accelerator pedal. If it is replaced, the accelerator
pedal must also be replaced.
There are two types of pedal: with or without a kic-
kdown point.
Vehicles fitted with cruise control / speed limiter have
an accelerator pedal with a kickdown point at the end
of their travel ( « kick-down » ).
This kickdown point makes it possible to exit the speed
limiter function if the driver has to increase speed.
WARNING
A pedal fitted with a kickdown point may be fitted in
place of a pedal without a kickdown point. However,
fitting a pedal without a kickdown point in place of a
pedal with a kickdown point is prohibited.
13B-194
DIESEL INJECTION
Accelerator pedal potentiometer: Removal - Refitting 13B
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
REFITTING
Tightening torquesm Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
battery cover mounting 4 Nm
nal.
bolt
WARNING
REMOVAL
carry out the necessary programming (see 80A,
Disconnect: Battery: Removal - refitting ).
- the battery, starting with the negative terminal,
- the accelerator pedal connector.
Note:
A fault on the accelerator pedal position potentio-
meter results in changes in the idle speed or
engine operation (see 13B, Diesel injection,
Idle speed ).
102204
Remove:
- pedal mounting bolts (1) ,
- the pedal.
13B-195
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 722 or 728 or 729 – F9Q, and 800 or 808
Equipment required
diagnostic tool
Tightening torquesm
1
battery tray mounting 21 Nm 2
bolts
Note:
When programming, reprogramming or replacing a
computer, it is necessary to program the C2I para- 3
meters (individual injector correction) and the
engine parameters into the new computer using the
diagnostic tool RENAULT CLIP tool. 101822
Disconnect the injection computer connectors (1) .
There are two procedures for doing this (see 13B, Die-
sel Injection, Injectors: Configuration and pro- Remove:
gramming ):
- the battery tray mounting bolts (2) ,
- an automatic procedure which can be used if it is pos-
- the wiring harness bracket (3) .
sible to read the information contained in the old com-
puter, Detach the wiring harnesses from the battery tray.
- a manual procedure for when it is not possible to read Remove the battery tray.
the information contained in the old computer.
REMOVAL
Remove the engine covers. 4
Disconnect the battery, starting with the negative
terminal.
Remove the battery.
101811
Remove the injection computer and its support (4) .
13B-196
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 722 or 728 or 729 – F9Q, and 800 or 808
REFITTING
101890
Remove: 101887
- the computer mounting bolts (5) ,
Proceed in the reverse order to removal.
- the computer.
Tighten to torque the battery tray mounting bolts (
21 Nm ) .
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13B-197
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700
Tightening torquesm
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.
Unclip:
I - REMOVAL PREPARATION OPERATION - the wiring harness (2) from the battery negative ter-
Remove the engine covers. minal,
Remove the battery (see 80A, Battery, Battery: Re- - the wiring harness.
moval - Refitting ).
Remove:
Remove:
- the computer mounting nuts,
- the computer from its support.
REFITTING
Refit:
- the computer on its support,
- the computer mounting nuts.
13B-198
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700
II - FINAL OPERATION
Refit the mounting bolt to the computer support.
Tighten to torque the mounting bolt on the compu-
ter support ( 21 Nm ) .
Refit the upper mounting bolt to the computer sup-
port.
Clip on:
- the wiring harness to the battery negative terminal,
- the wiring harness.
Connect the computer connectors.
Refit:
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
- the engine covers.
13B-199
PREHEATING
Pre/postheating unit: Removal - Refitting 13C
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732 – M9R, and 700
Tightening torquesm
Note:
It is located behind the front left-hand wheel arch
liner.
REMOVAL
Disconnect the battery, starting with the negative
terminal.
102125
Disconnect the pre-postheating unit connector.
Remove:
- the pre-postheating unit mounting bolt,
- the pre-postheating unit.
REFITTING
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
101823 Battery: Removal - Refitting ).
Remove:
Tighten to torque:
- the front left-hand wheel,
- the battery cover mounting bolts ( 4 Nm ) ,
- the front left-hand wheel arch liner.
- the wheel bolts ( 110 Nm ) .
.
13C-1
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 722
Tightening torquesm
heater plugs 15 Nm
REMOVAL
15762
Remove the engine covers.
Disconnect the electrical connector from the heater
Disconnect the battery, starting with the negative plugs.
terminal. Clean around the outside of the heater plugs with a
compressed air gun to prevent contamination of the
cylinders.
Undo then remove the plugs using a 10 mm diame-
ter long radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
WARNING
Ensure that no foreign bodies enter the cylinder
during this operation.
REFITTING
102120 Proceed in the reverse order to removal.
Disconnect the air duct. Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13C-2
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 728 or 729
Tightening torquesm
heater plugs 15 Nm
110323
110325
Pull the clip.
15762
WARNING
Ensure that no foreign bodies enter the cylinder
during this operation.
13C-3
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 728 or 729
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13C-4
PREHEATING
Heater plugs Removal - Refitting 13C
F9Q, and 800 or 804 or 808
Tightening torquesm
heater plugs 15 Nm
REMOVAL
15762
Remove the engine covers.
Disconnect the electrical connector from the heater
Disconnect the battery, starting with the negative plugs.
terminal.
Clean around the outside of the heater plugs with a
compressed air gun to prevent contamination of the
F9Q, and 804 cylinders.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
13C-5
PREHEATING
Heater plugs Removal - Refitting 13C
F9Q, and 804
UD replaced with 11,05,08,02-01,37-001,016 on 08/
06/2005
13C-6
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 732
Tightening torquesm
heater plugs 15 Nm
WARNING
- detach the hose using the (Car. 1363) , Disconnect the air inlet pressure sensor connector
(1) .
- do not use a degreaser, brake cleaning product, or
any other product, Loosen the clip (2) and move the air inlet duct aside
(3) .
- clean the bearing face on the intercooler and on
the hose with a dry, lint-free cloth,
- always replace the clip with a new one,
- place the clip in the same position if the hose is
not replaced,
- always replace the hose and/or the intercooler if
damaged.
REMOVAL
112811
Pull out the clip.
13C-7
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 732
- the injection rail protector cover,
- the dipstick,
- the dipstick pipe mounting bolts (9) .
Move the dipstick pipe to one side.
112991
Make a marking (4) on the air inlet duct between the
stainless steel pipe and the hose.
Detach the hose from the stainless steel pipe.
Remove:
- the mounting bolt (5) from the stainless steel pipe,
- the stainless steel pipe (6) .
112993
Note:
Do not pull on the plug cable.
WARNING
Ensure that no foreign bodies enter the cylinder
during this operation.
112992
REFITTING
Unclip the injection rail protector cover (7) .
Remove: I - REFITTING OPERATION FOR PART
CONCERNED
- the mounting nut and bolt (8) from the injection rail
protector cover, Refit the heater plugs using the hose.
13C-8
PREHEATING
Heater plugs Removal - Refitting 13C
K9K, and 732
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the connector to the heater plugs.
II - FINAL OPERATION
Refit:
- the mounting bolts to the dipstick pipe,
- the dipstick,
- the injection rail protector cover,
- the injection rail protector mounting bolt and moun-
ting nut.
Clip on the injection rail protector cover.
Refit:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning the
marking,
Clip the stainless steel pipes onto the turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -
Refitting ).
Refit the engine covers.
13C-9
PREHEATING
Heater plugs Removal - Refitting 13C
M9R, and 700
REFITTING
Equipment required
I - REFITTING OPERATION FOR PART
socket wrench for removing/refitting preheating CONCERNED
plugs
Refit the heater plugs.
Tightening torquesm
WARNING
heater plugs 16.5 Nm Ensure that no foreign bodies enter the cylinder
during this operation.
13C-10
PREHEATING
Pre-postheating control 13C
F9Q, and 800 or 808
The pre/post heating function is controlled by the injec-
tion computer.
a - Variable preheating
The duration the indicator light is lit and of the supply to
the heater plugs depends on the coolant temperature
and the battery voltage.
101188
X: Time in seconds
Y: Coolant temperature in ˚C
101189
X: Time in seconds
Y: Coolant temperature in ˚C
In all cases the preheating warning light should light up
for more than 12 seconds .
b - Fixed preheating
After the warning light goes out the plugs remain sup-
plied for a fixed period of 10 seconds .
2 - Starting
The plugs continue to be supplied while the starter is
being activated.
13C-11
PREHEATING
Pre-postheating control 13C
K9K, and 722 or 728 or 729 or 732
The pre-postheating function is controlled by the injec- At idling speed with no depression of the accelerator
tion computer. pedal.
1 - Ignition on « preheating »
a - Variable preheating
The time taken for the warning light to come on and for
supply to the heater plugs depends on the coolant tem-
perature and the battery voltage.
103124
X: Time in seconds
Y: Coolant temperature in ˚C
103123
X: Time in seconds
Y: Coolant temperature in ˚C
Whatever the situation, the heater plug warning light
cannot remain lit for more than 12 seconds (except in
the event of a coolant temperature sensor fault).
b - Fixed preheating
After the warning light goes out, the heater plugs conti-
nue to be supplied for a fixed period of 5 seconds .
2 - Starting
The plugs remain supplied while the starter motor is
being activated.
13C-12
ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
I - OPERATING DIAGRAM OF THE CIRCUIT
2 6 1
8
3
4
106679
10
11
12
102734
102724
(9) Fuel vapour absorber
(7) Fuel vapour absorber bleed (10) Fuel vapour recirculation coming
solenoid valve from the tank
14A-1
ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
WARNING
The breather should not be blocked during normal
engine operation.
II - OPERATING PRINCIPLE
The tank is vented by means of the fuel vapour absor-
ber.
Fuel vapour is trapped by the active charcoal contai-
ned in the absorber as it passes through.
Fuel vapour trapped in the absorber is eliminated and
burnt by the engine.
To do this, connect the fuel vapour absorber and the in-
let manifold via the solenoid valve. This solenoid valve
is located on the shock absorber cup.
The principle behind the solenoid valve is to open a
passage of variable size (according to the opening cy-
clic ratio signal sent by the injection computer).
The variation in the passage opened for fuel vapour in
the solenoid valve results from the balance between
the magnetic field created by the supply to the winding
and the return spring force attempting to close the so-
lenoid valve.
14A-2
ANTIPOLLUTION
Fuel vapour recirculation circuit: check 14A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
I - CHECKING THE OPERATION OF THE FUEL II - FUEL VAPOUR ABSORBER BLEEDING
VAPOUR ABSORBER BLEED CONDITIONS
The fuel vapour absorber bleed solenoid valve is
controlled by track C-E1 of the computer if:
Note:
- the coolant temperature is above 55˚C ,
A fault with this system may result in rough idling
or the engine stalling. - the air temperature is above 10˚C ,
- the engine is not at idle speed,
- a given load threshold is reached,
- the throttle potentiometer is not in the « no load »
6 1 position.
2
During « on board diagnostic » fault finding, fuel va-
pour absorber bleeding is not authorised.
3
4
106679
14A-3
ANTIPOLLUTION
Fuel vapour canister: Removal - Refitting 14A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
The absorber is located on the fuel tank under the ve-
hicle.
REMOVAL
3 4
102734
Disconnect:
- pipe (2) bringing the fuel vapour from the tank,
102483
- pipe (3) taking the fuel vapours to the solenoid val-
ve,
Release absorber (1) from the fuel tank retaining
notch by pushing it in the direction of the arrow. - breather pipe (4) .
Remove the absorber.
REFITTING
Proceed in the reverse order to removal.
14A-4
ANTIPOLLUTION
Fuel vapour canister:Checking 14A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14A-5
ANTIPOLLUTION
Oil vapour rebreathing 14A
B84 or C84 or S84, and K4J, and 730 or 732
I - LOCATION OF COMPONENTS
101495
(1) Oil vapour breather port (2) Oil vapour recovery plate loca-
ted on the cylinder head cover
(3) Sized port
3
101499
101869
14A-6
ANTIPOLLUTION
Oil vapour rebreathing 14A
B84 or C84 or S84, and K4J, and 730 or 732
For information on removing oil vapour recovery plate (3) Air unit
(2) , (see 11A, Top and front of engine, Tightening
the cylinder head ). (4) Motorised throttle valve
(5) Inlet manifold
II - OPERATING DIAGRAM (6) Air inlet
(7) Sized port
A: At low loads, small quantities of oil vapour are
sucked back in via sized opening (7). III - CHECKING
To ensure the antipollution system works properly, the
oil vapour rebreathing circuit must be kept clean and in
7 4 3
good condition.
5
6
101956
3
7 4
5 6
101957
(1) Engine
(2) Oil vapour recovery plate
14A-7
ANTIPOLLUTION
Oil vapour rebreathing 14A
K4M, and 760 or 761
I - LOCATION OF COMPONENTS
102305
3
4
101820
14A-8
ANTIPOLLUTION
Oil vapour rebreathing 14A
K4M, and 760 or 761
II - OPERATING DIAGRAM (5) Air inlet
(6) Sized opening
A: At low loads, the oil vapours are rebreathed in
small quantities through the sized opening (6) III - CHECKING
4 6 3 To ensure the antipollution system works properly, the
oil vapour rebreathing circuit must be kept clean and in
good condition.
5
102308
4 6 3
102309
(1) Engine
(2) Oil vapour recovery plate
(3) Motorised throttle
(4) Inlet manifold
14A-9
ANTIPOLLUTION
Oil vapour rebreathing 14A
K9K, and 722 or 728 or 729 or 732
I - PRESENTATION OF THE CIRCUIT B : Under medium or high load, the pressure in the air
inlet duct pulls the valve diaphragm, the oil vapours are
rebreathed in small quantities via a sized opening.
1
II - CHECK
2
To ensure the correct operation of the anti-pollution
system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
3
4 6 5
20965
1
2
6
4 5
20965-1
14A-10
ANTIPOLLUTION
Oil vapour rebreathing 14A
F9Q, and 800 or 808
I - CIRCUIT PRESENTATION
1
3
2
4
5
2
6
3
100054
100053
(1) Oil vapour rebreathing pipe con-
(1) Engine nected to the intake pipes
(2) Oil separator (2) Cylinder block outlet oil vapour
(3) Air filter unit rebreathing pipe
II - CHECK
To ensure the correct operation of the anti-pollution
system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
14A-11
ANTIPOLLUTION
Oil vapour rebreathing 14A
F4R, and 770 or 771 or 776
I - PRESENTATION OF COMPONENTS
102723
(1) Oil vapour breather pipe (3) Oil vapour recovery plate on the
(2) Oil vapour recirculation valve cylinder head cover
102729
14A-12
ANTIPOLLUTION
Oil vapour rebreathing 14A
F4R, and 770 or 771 or 776
B A
106629
106588
Oil vapour recovery plate located on the rocker cover
14A-13
ANTIPOLLUTION
Oil vapour rebreathing 14A
F4R, and 770 or 771 or 776
For removal, (see 11A, Top and front of engine, Cy-
linder head gasket ).
102738
5
9
10
102745
14A-14
ANTIPOLLUTION
Oil vapour rebreathing 14A
F4R, and 770 or 771 or 776
III - CHECKING
To ensure the antipollution system works properly, the
oil vapour rebreathing circuit must be kept clean and in
good condition.
14A-15
ANTIPOLLUTION
Oil vapour rebreathing 14A
F9Q, and 804
I - THE CIRCUIT
100054
100053
(1) Oil vapour rebreathing pipe con-
(1) Engine nected to the inlet pipes
(2) Oil separator (2) Cylinder block outlet oil vapour
(3) Air filter unit rebreathing pipe
II - CHECK
To ensure the antipollution system works properly, the
oil vapour rebreathing circuit must be kept clean and in
good condition.
14A-16
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
K9K, and 722 or 728 or 729
I - THE CIRCUIT
Note:
5 3
A The position of the exhaust gas recirculation sole-
noid valve is a determining factor in the calculation
of the quantity of air admitted by the engine.
IV - OPERATING CONDITIONS
4
The following parameters determine actuation of the
1 exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
7 6 - atmospheric pressure,
- accelerator pedal position,
8 - diesel injected,
- engine speed.
102364
Operating point for checking the exhaust gas
(1) Engine recirculation solenoid valve
(2) Air filter unit The exhaust gas recirculation solenoid valve is actua-
ted if:
(3) Plenum chamber
(4) Exhaust manifold - the air temperature is between -30˚C and 67 ˚C , in-
clusive,
(5) Exhaust gas recirculation unit
with solenoid valve - or the coolant temperature is between 0˚C and 127˚C
inclusive,
(6) Turbocharger
(7) Injection computer - the engine speed is above 500 rpm ,
(8) Intercooler - the diesel fuel injection flow is between 10 and 31
(A) Air inlet mg/stroke inclusive,
(B) Exhaust gas outlet - the atmospheric pressure is above 421 mbar .
If so, the diagnostic tool indicates an exhaust gas recir-
II - PURPOSE OF THE EXHAUST GAS culation solenoid valve position opening cylinder ratio
RECIRCULATION SYSTEM value equal to 4 and 60% .
Exhaust gas recirculation is used to reduce the nitro- Exhaust gas recirculation is cut off if:
gen oxide (NOx) content of the exhaust gases. - the battery voltage is below 9 V ,
The computer regulates the passage of gases by ac- - the engine speed is below 500 rpm ,
tuating a solenoid valve.
- the mapping (engine speed - load) exceeds a thres-
hold,
III - OPERATING PRINCIPLE
- the air conditioning compressor is actuated.
The solenoid valve is controlled by an opening cyclic
ratio signal issued by the injection computer. The ope- The exhaust gas recirculation solenoid valve is not
ning cyclic ratio signal modulates the opening of the supplied after starting for 2 seconds .
solenoid valve, and consequently the quantity of ex- The exhaust gas recirculation solenoid valve is no lon-
haust gas directed back to the inlet manifold.
ger supplied if there is a fault on:
The computer runs a constant test to keep track of the
- the exhaust gas recirculation solenoid valve,
position of the exhaust gas recirculation solenoid val-
ve. - the turbocharging pressure sensor,
14A-17
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
K9K, and 722 or 728 or 729
15761
Track Description
1 Solenoid supply
3 Not used
14A-18
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
F9Q, and 800 or 808
I - THE CIRCUIT
9 7
5
4 8
10
3
11
2
1
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 inlet IV - OPERATING CONDITIONS
(9) Exhaust gas outlet The following parameters determine activation of the
(10) Intercooler inlet exhaust gas recirculation solenoid valve:
(11) Intercooler outlet - coolant temperature,
- the air temperature,
II - PURPOSE OF THE EXHAUST GAS - atmospheric pressure,
RECIRCULATION SYSTEM
- the injection flow,
Exhaust gas recirculation is used to reduce the nitro-
gen oxide (NOx) content of the exhaust gases. - the engine speed.
Exhaust gas recirculation is cut off if:
The injection computer allows gas to pass by actuating
a solenoid valve. - the battery voltage is below 9 V ,
14A-19
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
F9Q, and 800 or 808
- If the engine speed is above 2,950 rpm when the pe-
dal is released (low pedal value),
Note:
There is no exhaust gas recirculation at altitude (>
1,200m).
15761
Track Description
1 Solenoid supply
2 Sensor feed
4 Sensor earth
5 Solenoid earth
6 Sensor output
103127
X Time in seconds
Y Coolant temperature in ˚C
14A-20
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
F9Q, and 804
I - DIAGRAM
114451
(1) Engine
(2) Exhaust gas cooler
(3) Exhaust gas recirculation unit
(4) Inlet manifold
(5) Exhaust manifold
(6) Turbocharger
14A-21
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
K9K, and 732
I - THE CIRCUIT
Note:
The position of the exhaust gas recirculation sole-
noid valve is a determining factor in the calculation
of the quantity of air admitted by the engine.
IV - OPERATING CONDITIONS
The following parameters determine actuation of the
exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- accelerator pedal position,
- diesel injected,
- engine speed.
102364
(1) Engine
(2) Air filter unit
(3) Plenum chamber
(4) Exhaust manifold
(5) Exhaust gas recirculation unit
with solenoid valve
(6) Turbocharger
(7) Injection computer
(8) Intercooler
(A) Air inlet
(B) Exhaust gas outlet
14A-22
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
K9K, and 722
Tightening torquesm
REMOVAL
Disconnect the battery, starting with the negative
terminal. 4
102119
1 Disconnect:
- turbocharging pressure regulation valve pipe (3)
from the air duct,
- air inlet pipe (4) on the exhaust gas recirculation
unit.
Remove:
- bracket (5) ,
102120
Remove: - engine lifting eye (6) ,
14A-23
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
K9K, and 722
8
10
102074
Remove:
- exhaust gas recirculation solenoid valve heat
shield (8) ,
- exhaust gas recirculation pipe (9) ,
REFITTING
Replace the exhaust gas recirculation tube complete
with new clips.
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolt ( 21 Nm ) ,
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
14A-24
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
K9K, and 728 or 729 or 732
REMOVAL
Disconnect the battery, starting with the negative 3
terminal.
102126
Disconnect the wiring harness (3) .
Move the wiring harness to one side.
110325
Pull the clip.
14A-25
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
K9K, and 728 or 729 or 732
REFITTING
Replace the exhaust gas recirculation tube complete
6 4
with new clips.
7
Tighten the new clips using (Mot. 1567) .
Replace the O-rings on the metal air inlet tube.
Tighten to torque:
5
- the exhaust gas recirculation unit mounting
bolts ( 21 Nm ) ,
- the metal inlet air tube mounting bolts ( 21 Nm )
8 ,
- the lifting eye (timing end) ( 21 Nm ) ,
102119 - the exhaust gas recirculation solenoid valve
heat shield mounting bolts ( 12 Nm ) .
Disconnect:
Proceed in the reverse order to removal.
- the turbocharging pressure regulation valve pipe
Connect the battery, starting with the positive termi-
(4) from the air duct,
nal.
- the air inlet pipe (5) on the exhaust gas recircula-
tion unit.
WARNING
Remove: Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
- the bracket (6) ,
Tighten to torque the front engine cover mounting
- the engine lifting eye (7) , bolts ( 4 Nm ) .
11
9
10
102074
Remove:
14A-26
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
F9Q, and 804
Tightening torquesm
REMOVAL
Disconnect the battery, starting with the negative
terminal.
Remove the battery.
Remove the air duct (see 12A, Fuel mixture, Inlet
duct: Removal - Refitting ).
111964
111861
Remove the mounting bolts (1) from the exhaust gas
recirculation pipe.
113177
WARNING
Never remove the exhaust gas recirculation sole-
noid valve from the unit.
REFITTING
Proceed in the reverse order to removal.
14A-27
ANTIPOLLUTION
Exhaust gas recirculation unit 14A
F9Q, and 804
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolts ( 25 Nm ) ,
- the exhaust gas recirculation pipe mounting
bolts ( 18 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
14A-28
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
Note:
For vehicles fitted with the K9K 732 engine (see
Workshop Repair Manual 370 Mechanics, Scé-
nic II ).
REMOVAL
Remove:
- the heat shield,
- the exhaust gas recirculation solenoid valve moun-
ting bolts,
- the exhaust gas rebreathing solenoid valve by uns-
crewing it gradually,
- the exhaust gas recirculation solenoid valve by gra-
dually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve seal with a new one
14A-29
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
F9Q, and 800 or 808
Tightening torquesm
REMOVAL
Remove:
- the inlet and exhaust manifolds (see 12A, Fuel
mixture, Manifold ),
- the bolts securing the exhaust gas recirculation so-
lenoid valve,
- the exhaust gas recirculation solenoid valve by gra-
dually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve gasket with a new one
14A-30
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
Equipment required
diagnostic tool
Tightening torquesm
bolt mounting the 25 Nm Disconnect the connector (2) from the oil vapour re-
exhaust gas cooler sup- circulation solenoid valve.
ports on the cylinder
head
coolant circulation 10 Nm
cover mounting bolts
REMOVAL
14A-31
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
112991 113475
Remove the mounting bolt (3) from the stainless Remove the mounting bolts (7) from the injection rail
steel pipe. protector cover mounting bracket.
Move the air inlet duct (4) to one side.
112815
Disconnect the connector (5) from the air inlet pres-
sure sensor.
Loosen the clip (6) and move the air inlet duct aside.
Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting ).
14A-32
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
- the air inlet metal tube (11) ,
- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ).
- the mounting bolts from the exhaust gas inlet pipe
(12) ,
- the mounting bolts from the exhaust gas recircula-
tion unit assembly (13) ,
- the exhaust gas recirculation unit assembly.
114341
112329
Remove:
14A-33
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
REFITTING
WARNING
Take care not to damage the bearing faces to
prevent any risk of coolant leaks.
WARNING
WARNING
Ensure that the seals between the cooler and its
two supports are correctly positioned to avoid
any coolant leaks.
14A-34
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 732
Refit: Tighten:
- the new rigid exhaust gas recirculation pipe with a - the bolts mounting the rail protector mounting brac-
new seal, ket on the exhaust gas cooler assembly,
- the new exhaust gas recirculation pipe mounting - the nut mounting the rail protector on the mounting
bolts, bracket.
Refit the damper valve (see 12A, Fuel mixture,
Fit the new snap-fit clamp.
Damper valve: Removal - Refitting ).
Connect the air inlet pressure sensor connector.
WARNING
Refit the clip on the air inlet duct if necessary.
Ensure that you do not squeeze the exhaust gas
inlet pipe before fitting the snap-fit clamp. Position the air inlet duct.
Clip the air inlet duct onto the turbocharger.
Tighten the rigid exhaust gas recirculation pipe
mounting bolts until they make contact. Refit the air inlet duct mounting bolt.
Tighten the air inlet duct bolt.
Adjust the rigid exhaust gas recirculation pipe in re-
lation to the cooler support on the timing end. Connect the exhaust gas recirculation solenoid val-
ve connector.
Lock the snap-fit clamp of the rigid exhaust gas re-
circulation pipe using the (Mot. 1567) . Refit the oil vapour rebreathing pipe.
Tighten to torque the mounting bolts of the rigid Connect the battery (see 80A, Battery: Removal -
exhaust gas recirculation pipe ( 35 Nm ) ). Refitting).
Bleed the coolant (see 19A, Cooling, Cooling cir-
cuit: Bleeding ).
III - FINAL OPERATIONS
Refit:
Refit:
- the engine undertray,
- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter: Removal - Refitting ). - the engine covers.
Clear any faults stored by the computer using the
- the coolant circulation cover diagnostic tool .
- the coolant circulation cover mounting bolts
WARNING
Ensure that the water inlet and outlet hoses of
the exhaust gas cooler are correctly aligned so
that they do not bend.
Refit:
14A-35
ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting 14A
K9K, and 732
For removing and refitting the supports for the exhaust
gas recirculation (see 14A, Emission control, Ex-
haust gas cooler: Removal - Refitting ).
14A-36
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting 14A
K9K, and 732
REFITTING
Special tooling required
14A-37
STARTING - LOAD
Alternator: General information 16A
F4R or F9Q or K4J or K4M or K9K or M9R
I - OPERATION
Engine Alternator Current
These vehicles are fitted with an alternator with internal strength
ventilation and incorporated regulator, plus a warning
light on the instrument panel, which operates as fol- VALEO : TG11 C018
lows:
VALEO : TG11 C040 110 A
- when the ignition is switched on, the warning light co-
mes on, VALEO : TG11 C049
- when the engine starts, the warning light goes out,
VALEO : SG12 B078
- if the warning light comes on while the engine is run-
ning, this indicates a « charge » fault. VALEO : SG12 B081
125 A
F9Q
VALEO : SG15 B092
II - IDENTIFICATION
VALEO : SG15 B098
16A-1
STARTING - LOAD
Alternator: Removal - Refitting 16A
K9K, and 722 or 724 or 728 or 729 or 732
Fit the cooling assembly to the upper cross member
using the safety belt .
Equipment required
safety belt
Tightening torquesm
alternator mounting 21 Nm
bolts
Remove:
REMOVAL
- the side stiffener mounting bolts,
REMOVAL PREPARATION OPERATION
- the side reinforcements (1) .
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
102008
Note:
Remove:
When fitting the safety strap, take care:
- not to crush the cooling hoses, - the half sub-frame mounting nuts and bolts (2) ,
- not to strap up the half sub-frame. - the half sub-frame.
16A-2
STARTING - LOAD
Alternator: Removal - Refitting 16A
K9K, and 722 or 724 or 728 or 729 or 732
CA or CAREG
19703
109537
Note:
Disconnect:
Take care not to constrain the compressor air
- the pressostat connector (3) , conditioning pipes during this operation.
- the air conditioning compressor connector (4) ,
Remove the air conditioning compressor mounting
Move the electric wiring harness to one side. bolts (5) .
Remove the air conditioning compressor and attach
it using a safety belt .
16A-3
STARTING - LOAD
Alternator: Removal - Refitting 16A
K9K, and 722 or 724 or 728 or 729 or 732
OPERATION FOR REMOVAL OF PART
CONCERNED
CHAUFO
19703
111079
Remove:
WARNING
- the free pulley support mounting bolts (6) ,
Do not damage the cooling unit vanes (radiator,
- the idler pulley support. condenser, etc.) during handling.
Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator mounting bolts (7) ,
- the alternator.
16A-4
STARTING - LOAD
Alternator: Removal - Refitting 16A
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
I - REFITTING PREPARATION OPERATION
Refit:
- the free pulley support,
- the free pulley support mounting bolts.
Tighten to torque the free pulley support moun-
ting bolts ( 21 Nm ) .
16A-5
STARTING - LOAD
Alternator: Removal - Refitting 16A
F4R, and 770 or 771 or 776
Tightening torquesm
alternator mounting 25 Nm
bolts
REMOVAL
Position the vehicle on a two-post lift. 1
Disconnect the battery, starting with the negative
terminal.
101212
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)
at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pi-
pes.
16A-6
STARTING - LOAD
Alternator: Removal - Refitting 16A
F4R, and 770 or 771 or 776
3
2
5 7
4
102504
104342
Remove:
- intercooler air duct (7) ,
- the accessories belt tension wheel.
6
102365
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the front end panel,
- the accessories belt (See 11A, Top and front of
engine, Accessories belt ).
Disconnect the alternator electrical connections.
16A-7
STARTING - LOAD
Alternator: Removal - Refitting 16A
F4R, and 770 or 771 or 776
REFITTING
19703
Remove: 18987
- the alternator mounting bolts (8) , Refit the rings (9) using pliers or a vice to facilitate fit-
ting.
- the alternator using a screwdriver.
WARNING
WARNING
When replacing the belt, be sure to replace the
Do not force it against the air conditioning hose: tension wheels and idler pulleys.
there is a risk of refrigerant fluid escaping.
Torque tighten the alternator mounting bolts ( 25
Nm ) .
Note: Replace the accessories belt.
To facilitate removal of the alternator, shift the Tension the accessories belt (see 11A, Top and
cooling assembly gently forward (be careful not front of engine, Accessories belt ).
to deform the condenser pipes).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
16A-8
STARTING - LOAD
Alternator: Removal - Refitting 16A
F9Q, and 800 or 804 or 808
Tightening torquesm
alternator mounting 25 Nm
bolts
1
102365
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
101212 - the mounting (5) ,
Remove: - the front end panel mounting bolts (6) ,
- the engine covers, - the front end panel,
- the front wheels, - the accessories belt (see 11A, Top and front of
engine, Accessories belt ).
- the wheel arch liners,
- the half sub-frame side reinforcement (1) , Disconnect the alternator electrical connections.
- the bumper (see MR 365 Bodywork, 55A, Exte- Remove the accessories belt tensioning roller.
rior protection, Front bumper ).
Disconnect the screen washer pipes.
16A-9
STARTING - LOAD
Alternator: Removal - Refitting 16A
F9Q, and 800 or 804 or 808
REFITTING
19703
Remove: 18987
- the alternator mountings (7) , Refit the rings (8) using a vice to facilitate fitting.
To facilitate removal of the alternator, shift the coo- Torque tighten the alternator mounting bolts ( 25
ling assembly forward gently (be careful not to da- Nm ) .
mage the condenser pipes). Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt ).
Proceed in the reverse order to removal.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
16A-10
STARTING - LOAD
Alternator: Removal - Refitting 16A
K4J, and 730 or 732 – K4M, and 760 or 761
Tightening torquesm
alternator mounting 21 Nm
bolts
REMOVAL
Position the vehicle on a two-post lift.
101212
Disconnect the battery, starting with the negative Remove:
terminal.
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)
at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pi-
pes.
16A-11
STARTING - LOAD
Alternator: Removal - Refitting 16A
K4J, and 730 or 732 – K4M, and 760 or 761
3 7
2
5
4
102504
19703
Remove:
- the alternator mounting bolts (7) ,
6
- the alternator using a screwdriver.
WARNING
Do not force it against the air conditioning hose:
there is a risk of refrigerant fluid escaping.
102365
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) . Note:
16A-12
STARTING - LOAD
Alternator: Removal - Refitting 16A
K4J, and 730 or 732 – K4M, and 760 or 761
REFITTING
18987
WARNING
When replacing the belt, be sure to replace the
tension wheels and idler pulleys.
Tighten to torque:
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Tighten to torque:
16A-13
STARTING - LOAD
Alternator: Removal - Refitting 16A
B84 or C84, and F4R, and 774
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal -
Tightening torquesm Refitting ).
alternator mounting 25 Nm
bolts
REMOVAL
Note:
The tensioning roller and the inertia reel must be
102504
replaced when the accessories belt is replaced.
102365
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the mounting (5) ,
- the impact cross member mounting bolt (6) ,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
106077 Disconnect the alternator electrical connections.
Remove: Remove the accessories belt tensioning roller.
16A-14
STARTING - LOAD
Alternator: Removal - Refitting 16A
B84 or C84, and F4R, and 774
19703 18987
Remove: Refit the rings (8) using pliers or a vice to facilitate fit-
ting.
- the alternator mountings (7) ,
Refit:
- the alternator using a screwdriver.
- the alternator,
To ease alternator removal, slightly move the coo-
ling system toward the front (be careful not to bend - the alternator mounting bolts.
the condenser pipes).
Tighten to torque the alternator mounting bolts (
25 Nm ) .
REFITTING Refit the new accessories belt.
Refit the accessories belt (see 11A, Top and front
WARNING of engine, Accessories belt: Removal - Refitting
).
The belt must be replaced with a new one if it
has been removed. Tighten to torque the wheel mounting bolts ( 130
Nm ) .
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting .
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
16A-15
STARTING - LOAD
Alternator: Removal - Refitting 16A
M9R, and 700
Tightening torquesm
alternator mounting 25 Nm
bolts
turbocharger pressure 8 Nm
sensor mounting nut
114855
Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting ).
16A-16
STARTING - LOAD
Alternator: Removal - Refitting 16A
M9R, and 700
102504
Disconnect the connectors (4) from the Protection
and Switching Unit.
Unfasten the bonnet opening cable (5) .
Remove:
114933
Unclip the air inlet scoop (2) . - the clip (6) ,
- the front end panel upper mounting bolt (7) .
Disconnect the screen washer tubes.
102365
Remove:
- the front end panel lower mounting bolts (8) ,
112658
Remove the Protection and Switching Unit cover - the front end panel.
mounting bolts (3) . Remove the « cooling radiator - condenser -
intercooler » assembly from its housing and push it
forwards.
16A-17
STARTING - LOAD
Alternator: Removal - Refitting 16A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114409
114859
114649 Remove the alternator mounting bolts (14) .
Remove: Remove the alternator.
- the air inlet duct clip (10) from the intercooler,
- the air inlet clip mounting bolt (11) from the conden-
ser,
- the air inlet duct.
16A-18
STARTING - LOAD
Alternator: Removal - Refitting 16A
M9R, and 700
Tighten to torque:
- the air inlet hose clip on the damper valve ( 5.5
Nm ) ,
- the air inlet hose clip on the intercooler ( 5.5 Nm
).
Tighten the air inlet clip mounting bolt on the con-
denser.
- the positive terminal mounting nut ( 8 Nm ) . - the front end panel lower mounting bolts ( 44
Nm ) .
Connect the alternator electrical connector.
Clip:
- the bonnet opening cable,
16A-19
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and CA
Tightening torquesm
alternator decoupling 80 Nm
pulley
essential equipment
110266
- tool box for removing and refitting the alternator pulley Hold the alternator in a vice.
(Mot. 1732)
II - OPERATION FOR REMOVAL OF PART
CONCERNED
110276
16A-20
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and CA
110268 110270
Fit the drive (2) from the tool box for removing and Hold the hexagon socket (6) using an open-jawed
refitting the alternator pulley (Mot. 1732) (correspon- spanner (7) .
ding to the alternator mark) into the hexagon socket
Loosen the decoupling pulley (8) using a ratchet (9)
(3) .
(turning the ratchet clockwise).
Remove the decoupling pulley.
110269
Position the drive adapter (4) in socket (5) .
16A-21
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and CA
REFITTING
110269
Fit:
110266
- the hexagon socket (10) in the alternator,
Screw the new decoupling pulley onto the alternator - the drive (11) (corresponding to the socket in the
rotor. alternator rotor),
- the drive adapter (12) onto the drive (11) .
Note:
Check that the torque wrench is capable of tigh-
tening in an anticlockwise direction.
16A-22
STARTING - LOAD
Alternator pulley: Removal - Refitting 16A
K4J or K4M or K9K, and CA
110266
Tighten to torque the alternator decoupling pulley
( 80 Nm ) using a torque wrench.
II - FINAL OPERATION
Refit the alternator to the vehicle (see 16A, Starting
- Charging, Alternator: Removal - Refitting ).
16A-23
STARTING - LOAD
Starter: Identification 16A
Engine Starter motor
K9K MITSUBISHI
16A-24
STARTING - LOAD
Starter: Removal - Refitting 16A
F4R, and 770 or 771
REFITTING
Tightening torquesm
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
101482
Check that the centring dowel (1) is in place.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Tighten to torque:
14853 - the starter mounting bolts ( 38 Nm ) ,
Remove the engine covers.
- the battery cover mounting bolts ( 4 Nm ) .
Disconnect:
- the oil level sensor connector,
- the starter connections,
Remove:
- the starter motor mounting bolts,
- the starter motor.
16A-25
STARTING - LOAD
Starter: Removal - Refitting 16A
F9Q, and 800 or 808
Tightening torquesm
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove:
- the engine covers,
3
- the front right wheel, 5
- the battery,
- the battery tray, 101120
- the air hose between the air filter and turbocharger Remove:
duct, - the bracket (3) ,
- the catalytic converter (4) mounting plate on the
gearbox,
- the catalytic converter (5) (see 19B, Exhaust, Ca-
talytic converter ).
Disconnect the starter motor electrical connections.
1 2
102421
Remove:
- the air hose (1) and gently separate the hose (2) ,
- the engine tie-bar.
102427
Remove:
- the starter motor mounting bolts (6) ,
- the starter motor.
16A-26
STARTING - LOAD
Starter: Removal - Refitting 16A
F9Q, and 800 or 808
REFITTING
Check that the centring dowel is in place.
Proceed in the reverse order to removal.
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter ).
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the engine cover mounting bolts ( 4 Nm ) .
16A-27
STARTING - LOAD
Starter: Removal - Refitting 16A
K9K, and 722
Tightening torquesm
REMOVAL 4
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal. 5
Remove:
- the engine covers,
- the front right-hand wheel.
102268
Remove:
- the starter mountings (4) ,
- the starter (5) .
REFITTING
Check that the centring dowel is in place.
2 Proceed in the reverse order to removal.
Tighten to torque the starter mounting bolts ( 44
Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter ).
Connect the battery, starting with the positive termi-
nal.
1
3
WARNING
104175
carry out the necessary programming (see 80A,
Remove: Battery: Removal - refitting ).
- the catalytic converter stay (1) ,
Tighten to torque:
- catalytic converter stay (2) on the gearbox,
- the wheel bolts ( 110 Nm ) ,
- the catalytic converter (3) (see 19B, Exhaust, Ca-
talytic converter ). - the battery cover mounting bolts ( 4 Nm ) .
16A-28
STARTING - LOAD
Starter: Removal - Refitting 16A
K4J, and 730 or 732 – K4M, and 760 or 761
REFITTING
Tightening torquesm
REMOVAL
Put the vehicle on a two-post lift.
1
Disconnect the battery, starting with the negative
terminal.
101482
Check that the centring dowel (1) is in place.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removing - refitting ).
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
14853 - the battery cover mounting bolts ( 4 Nm ) .
Remove:
Disconnect:
Remove:
16A-29
STARTING - LOAD
Starter: Removal - Refitting 16A
F4R, and 776
Tightening torquesm
REMOVAL
The engine needs to be removed if the starter motor
is being replaced (see 10A, Engine and periphe-
rals, Engine - gearbox ).
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter ). 21921
Remove:
- the starter mountings (3) ,
- the starter motor.
2 1
106249
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
16A-30
STARTING - LOAD
Starter: Removal - Refitting 16A
F4R, and 776
REFITTING
21935
Check that the centring dowel (4) is in place.
Proceed in the reverse order to removal.
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
- the the catalytic converter downstream strut
nut ( 21 Nm ) ,
- the heat shield mounting bolts ( 8.5 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
16A-31
STARTING - LOAD
Starter: Removal - Refitting 16A
K9K, and 728 or 729
Tightening torquesm
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove the engine covers. 106203
Disconnect the gearbox earth.
106201
Disconnect the oil level sensor.
106205
Disconnect:
- the starter electrical connections (1)
- the rail pressure sensor (2) .
16A-32
STARTING - LOAD
Starter: Removal - Refitting 16A
K9K, and 728 or 729
106191
Remove:
- the starter mountings,
- the starter motor.
REFITTING
Check that the centring dowel is in place.
Proceed in the reverse order to removal.
Tighten to torque the starter mounting bolts ( 44
Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal - refitting ).
16A-33
STARTING - LOAD
Starter: Removal - Refitting 16A
F9Q, and 804
Tightening torquesm
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove: 111865
- the engine covers, Remove the turbocharger oil return pipe (2) .
- the front right-hand wheel,
- the battery,
- the battery tray,
- the air hose between the air filter and turbocharger
duct,
Remove the catalytic pre-converter. (see 19B; Ex-
haust, Catalytic pre-converter: Removal - Refit-
ting ).
111868
REFITTING
Check that the centring dowel is in place.
Tighten to torque the starter motor mounting bolts
( 44 Nm ) .
16A-34
STARTING - LOAD
Starter: Removal - Refitting 16A
F9Q, and 804
Proceed in the reverse order to removal.
Replace the turbocharger oil return pipe seals.
Tighten to torque the turbocharger oil return pipe
mounting bolts ( 12 Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter ).
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
16A-35
STARTING - LOAD
Starter: Removal - Refitting 16A
M9R, and 700
Equipment required
filling station
Tightening torquesm
solenoid excitation 5 Nm
mounting nut
front end panel upper 21 Nm - the Protection and Switching Unit cover mounting
mounting bolts bolts (1) ,
front end panel lower 44 Nm - the Protection and Switching Unit cover.
mounting bolts
REMOVAL
- the battery (see 80A, Battery, Battery: Removal - Unfasten the bonnet opening cable (3) .
Refitting ).
Remove:
- the engine undertray,
- the front bumper (see MR365, Bodywork, 55A, - the clips (4) ,
Exterior protection, Front bumper ).
- the front end panel upper mounting bolts (5) ,
Drain the coolant circuit using the filling station
(see 62A, Air conditioning, Maintenance ). Disconnect the screen washer tubes.
16A-36
STARTING - LOAD
Starter: Removal - Refitting 16A
M9R, and 700
102365
Remove:
Remove:
114649
Loosen:
16A-37
STARTING - LOAD
Starter: Removal - Refitting 16A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
109537
Remove the air dehydration canister conditioning
pipe mounting bolt (14) from the air conditioning 114628
compressor. Remove:
- the mounting nut (15) from the starter base,
Note: - the mounting nut (16) from the solenoid excitation.
Plugs must be fitted to the pipe and the compres-
sor to prevent moisture from entering the system.
114998
Remove the earth wire mounting bolt (17) on the
starter.
Move the starter motor wiring harness to one side.
16A-38
STARTING - LOAD
Starter: Removal - Refitting 16A
M9R, and 700
113312
Remove:
REFITTING
Refit:
Tighten to torque:
16A-39
STARTING - LOAD
Starter: Removal - Refitting 16A
M9R, and 700
II - FINAL OPERATION - the injection computer connectors.
Refit: Refit:
- the air dehydration canister conditioning pipe onto - the clips,
the air conditioning compressor,
- the Protection and Switching Unit cover mounting
- the air dehydration canister conditioning pipe bolts,
mounting bolt onto the air conditioning compressor
- the front bumper (see MR365, Bodywork, 55A,
(see 62A, Air conditioning, Compressor: Remo-
Exterior protection, Front bumper ),
val - Refitting ).
- the engine undertray,
Fit the cooling assembly.
- the engine protectors,
Refit:
- the battery (see 80A, Battery, Battery: Removal -
- the intercooler downstream duct onto the intercoo-
Refitting ).
ler and damper valve,
Fill the coolant circuit using the filling station (see
- the intercooler downstream duct mounting bolt
62A, Air conditioning, Maintenance ).
onto the cooling radiator.
Tighten to torque:
- the intercooler downstream duct clip on the in-
tercooler ( 5.5 Nm ) ,
- the intercooler downstream duct clip on the
damper valve ( 5.5 Nm ) .
Refit:
- the front end panel,
- the front end panel mounting bolts.
Tighten to torque:
- the front end panel upper mounting bolts ( 21
Nm ) ,
- the front end panel lower mounting bolts ( 44
Nm ) ,
Clip:
- the air inlet scoop,
- the bonnet opening cable.
Refit:
- the battery tray,
- the battery tray mounting bolts,
- the wiring harness mounting nut onto the battery
tray.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut on the battery
tray ( 8 Nm )
Clip the battery - terminal wiring harness.
Connect:
- the screen washer pipes,
- the Protection and Switching Unit connectors,
16A-40
STARTING - LOAD
Starter: Removal - Refitting 16A
K9K, and 732
Tightening torquesm
REMOVAL
113863
106201
Disconnect:
- the oil pressure sensor connector (1) ,
- the oil level sensor connector (2) .
Unclip the diesel fuel drain pipe.
16A-41
STARTING - LOAD
Starter: Removal - Refitting 16A
K9K, and 732
REFITTING
II - OPERATION FOR REMOVAL OF PART Connect the battery (see 80A, Battery: Removal -
CONCERNED Refitting ).
Refit the engine cover.
106191
Remove:
16A-42
STARTING - LOAD
Starter: Removal - Refitting 16A
B84 or C84, and F4R, and 774
Tightening torquesm
starter mountings 38 Nm
catalytic converter 44 Nm
downstream stay nut
REMOVAL
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Removal of the starter requires the engine to be re-
moved (see 10A, Engine and peripherals, Gear-
box - motor assembly: Removal - Refitting ).
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
21921
Remove:
- the starter mountings (3) ,
- the starter motor.
106249
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
16A-43
STARTING - LOAD
Starter: Removal - Refitting 16A
B84 or C84, and F4R, and 774
REFITTING
21935
Check that the centring dowel (4) is in place.
Proceed in the reverse order to removal.
Tighten to torque:
- the starter mountings ( 38 Nm ) ,
- the catalytic converter downstream stay nut (
44 Nm ) ,
- the heat shield mountings ( 8.5 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting ).
16A-44
IGNITION
Coils Removal - Refitting 17A
F4R, and 770 or 771 – K4J, and 730 or 732 – K4M, and 760 or 761
REMOVAL
Tightening torquesm
101490
Remove the engine covers.
Disconnect:
- the battery starting with the negative terminal.
14851
- the connectors (1) from the ignition coils.
There are four ignition coils secured directly onto the
spark plugs by bolts on the cylinder head cover.
WARNING
The coils are in series in pairs by the injection com-
puter: Damaged connectors must be replaced.
- track C M4 for cylinders 1 and 4, Remove the coil mounting screws (2) .
- track C M3 for cylinders 2 and 3.
REFITTING
To refit, proceed in the reverse order of removal.
If necessary, replace the coil O-rings.
Tighten the ignition coil mounting screws to tor-
que ( 1.5 daNm ) .
WARNING
Connect the battery; carry out the necessary pro-
gramming ( (see 80A, Battery) ).
17A-1
IGNITION
Coils Removal - Refitting 17A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
REMOVAL
Tightening torquesm
101490
Remove the engine covers.
Disconnect:
- the battery, starting with the negative terminal,
14851
- the ignition coil connectors (1) .
There are four ignition coils, and they are mounted
directly onto the spark plug by a bolt on the rocker Remove the coil mounting bolts (2) .
cover.
The coils are supplied in series two by two by the in-
jection computer:
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
17A-2
IGNITION
Coils Removal - Refitting 17A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
106589
Remove the coil mounting bolts (3) .
WARNING
Be sure to replace any damaged connectors.
REFITTING
Proceed in the reverse order to removal.
17A-3
IGNITION
Coils Removal - Refitting 17A
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
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 ) ,
- the battery cover mounting bolts ( 4 Nm ) .
17A-4
IGNITION
Spark plugs 17A
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
Tightening torque
Spark plugs
25 to 30 Nm
Remove:
- the ignition coils (see 17A, Ignition, Coils ),
- the spark plugs.
EYQUEM RFN58LZ
K4J and K4M
CHAMPION RC87YCL
17A-5
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
1 2 3 4 5 6
10 9 8 7
101099
17B-1
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
11 12 13 14 15 17 18
16
22 21 20 19
101804
17B-2
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
27
25
29
25
30
24
28
101493 101101
101800
31
(26) Motorised throttle valve 32
101498
17B-3
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
41
34 42
34
33
39
101809
35 36
43
38
38
37
101796
17B-4
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
44
46
102144
47
45
102204
101105
17B-5
PETROL INJECTION
Location of components 17B
K4J, and 730 or 732 – K4M, and 760 or 761
48 51
101798 102483
49
50
101501
17B-6
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
1 2 3 4 5 6 7
11 10 9 8
102722
17B-7
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
12 23 13 14 15
22 21 20 19 18 17 16
106078
106280
17B-8
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
32
26
27
28
25
31
102732
36
36
30
35
30
102724
17B-9
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
37
39
40
102735
42
38
41
106269
17B-10
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
43 46
45
106787
106633
48
47
44
106279
17B-11
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
49 51
101105 102483
(49) Protection and Switching Unit (51) Fuel vapour recirculation absor-
ber
50
52
102204
101798
17B-12
PETROL INJECTION
Location of components 17B
F4R, and 770 or 771 or 776
56
53
54
101501 106253
55
106244
17B-13
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
F4R, and 770 or 771 – K4M, and 760 or 761 – K4J, and 730 or 732
II - DOWNSTREAM OXYGEN SENSOR
Special tooling required
Tightening torquesm
oxygen sensor 45 Nm
REMOVAL
101501
Remove lambda sensor. (2)
REFITTING
1
Proceed in the reverse order to removal.
Tighten to torque the oxygen sensor ( 45 Nm )
using a 24 mm fork socket for the downstream sen-
sor and tool (Mot. 1495-01) for the upstream oxygen
sensor.
101798
Remove lambda sensor (1) using the tool (Mot.
1495-01) .
17B-14
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
F4R, and 776
II - DOWNSTREAM OXYGEN SENSOR
Special tooling required
Tightening torquesm
oxygen sensors 34 Nm
2
REMOVAL
21926
Remove:
- the engine undertray,
- the oxygen sensor (2) using (Mot. 1495-01) .
REFITTING
Proceed in the reverse order to removal.
106244
Tighten to torque the oxygen sensors ( 34 Nm )
Remove the front engine cover. using tool (Mot. 1495-01) .
Disconnect the oxygen sensor.
Remove the oxygen sensor (1) using the tool (Mot.
1495-01) .
17B-15
PETROL INJECTION
Accelerator pedal potentiometer: Removal - Refitting 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
- the pedal.
Tightening torquesm
REFITTING
battery cover mounting 4 Nm Proceed in the reverse order to removal.
bolts
Connect the battery, starting with the positive termi-
The accelerator pedal potentiometer is incorporated in nal.
the accelerator pedal. If it is replaced, the accelerator
pedal must also be replaced.
WARNING
There are two types of pedal: with or without a resis-
Carry out the necessary programming (see 80A,
tance point .
Battery: Removal - refitting ).
Vehicles equipped with cruise control/speed limiter
have an accelerator pedal with a point of resistance at
the end of their travel (kickdown) Note:
This kickdown point is used for exiting the speed limiter A fault on the accelerator pedal position potentio-
function if the driver has to increase his speed. meter results in changes in the idle speed or
engine operation (see 17B, Petrol injection, Idle
speed correction ).
WARNING
Torque tighten the battery cover mounting bolts (
A pedal fitted with a kickdown point may be fitted in
4 Nm ) .
place of a pedal without a kickdown point. Fitting a
pedal without a resistance point in place of a pedal
with a resistance point is not permitted.
REMOVAL
102204
Disconnect:
- the battery, starting with the negative terminal,
- the accelerator pedal connector.
Remove:
- pedal mounting bolts ,
17B-16
PETROL INJECTION
Position and speed sensor 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
diagnostic tool
102485
Program with the engine flywheel target after repla-
cing speed and position sensor (1) or the engine
flywheel
102144
Program the engine flywheel target, after replacing
In third gear, accelerate twice in succession to 4000
speed and position sensor (1) or the engine
rpm , then decelerate to power take-up speed.
flywheel.
Power take-up speed is the moment when, during
deceleration under no load with the injection cut out,
the computer authorises injection again.
Use the diagnostic tool to check that programming
has been carried out correctly ET089: « Program
engine flywheel target » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is working correctly.
17B-17
PETROL INJECTION
Position and speed sensor 17B
F4R, and 771 – K4M, and 761
Equipment required
diagnostic tool
102144
Program the engine flywheel target, after replacing
speed and position sensor (1) or the engine
flywheel.
In third gear, accelerate twice in succession to 4000
rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, during
deceleration under no load with the injection cut out,
the computer authorises injection again.
Note:
Do not shift the gear lever to « D »
17B-18
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
diagnostic tool
Tightening torquesm
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negative
terminal.
4
K4M, and 760 or 761 – K4J, and 730 or 732
101822
Remove the battery.
Disconnect the injection computer connectors (2) .
Remove:
1 - the battery tray (3) mounting bolts,
- the electrical wiring harness (4) .
Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
102107
Disconnect the injection computer connectors (1) .
Remove:
- the bolts securing the computer to the mounting,
- the computer.
17B-19
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (
21 Nm ) .
Connect the battery, starting with the positive termi-
nal.
WARNING
5
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
Note:
When the ignition is switched on, the motorised
throttle valve should go through a cycle of pro-
gramming for its minimum and maximum posi-
tions.
101811
Use the diagnostic tool to check that this program-
Remove the injection computer (5) and its mounting. ming has been completed correctly ET051: Throttle
stop programming .
Perform flywheel target programming during a road
test.
In third gear, accelerate twice in succession to 4000
rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, during
deceleration under no load with the injection cut out,
the computer authorises injection again.
Use the diagnostic tool to check that programming
has been carried out correctly ET089: « Program
engine flywheel target » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is functioning correctly.
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
101890
Remove the four computer mounting bolts.
17B-20
PETROL INJECTION
Special notes 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
SPECIAL NOTES FOR MULTIPOINT INJECTION 6 - Idle speed (warm engine)
SAGEM « S3000 »
Nominal idle speed
1 - 128-track computer
Engine Engine speed (rpm)
It is marked SAGEM and is a type « S3000 » FLASH K4J 730 / 750 +/- 50
EEPROM controlling the injection and ignition. 732
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 F4R 771
F4R 776
Without cylinder n˚1 marking sensor on the camshaft
Therefore, engine phasing is carried out by software The idle speed is corrected depending on:
using the TDC sensor. Starting the engine in semi-se-
- the engine coolant temperature,
quential mode (for engine phasing) then entering
phased sequential mode. - the battery voltage,
- the air conditioning,
With cylinder n˚1 marking sensor on the camshaft The- 7 - Maximum speed
refore, engine phasing (cylinder n˚1 recognition) is car-
ried out using the cylinder marking sensor signal. a - Engine overspeed protection, cold engine
Starting the engine in semi-sequential mode (for engi-
ne phasing) then entering phased sequential mode.
K4J, and 730 or 732
When the coolant temperature is below 60˚C or for 10
seconds after starting, the cut-off value is 5800 rpm .
17B-21
PETROL INJECTION
Special notes 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
b - Engine overspeed protection, warm engine 11 - Operation of the fuel pump
Once the engine is warm, the cut-off returns to its nor- The request is made by the injection computer. It recei-
mal value: ves its power supply from the Protection and Switching
Unit.
13 - Oxygen sensor
Use of two oxygen sensors located upstream and
F4R, and 770 or 771 or 776 downstream of the catalytic converter.
The cut-off speed is 6000 rpm whichever gear is enga-
ged (manual gearbox), and 6300 rpm (automatic gear- 14 - Throttle valve
box).
Correction of the air flow and the idle speed is carried
out by the motorised throttle valve.
17B-22
PETROL INJECTION
Special notes 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17 - Accelerator pedal
Replacement of the accelerator pedal poses no parti-
cular problems.
The computer adopts the value read when the ignition
was switched on as the no load position reference va-
lue.
A twin-track potentiometer is used to inform the com-
puter of the accelerator pedal position. It has two tracks
with different resistance values. The first track supplies
a voltage of ( 0 to 5 V ) which is double the second
track ( 0 to 2.5 V ). The comparison between the two
provides a check on the consistency of the signal sup-
plied.
18 - Idle speed
It is increased by a maximum of 160 rpm if the battery
voltage is below 12.7 V .
If a manifold pressure sensor fault is present or stored,
the idle speed setpoint is:
- 896 rpm (K4J and K4M engines),
- 1024 rpm (F4R engine).
17B-23
PETROL INJECTION
Injection warning light 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
The S 3000 injection system manages the lighting of 5 - When a fault causing excessive exhaust gas
three warning lights and the display of warning messa- pollution levels is detected
ges according to the severity of the faults detected,
The « on board diagnostic » indicator light depicting an
with the aim of informing the customer and directing
engine lights up:
fault finding.
- « flashing » in the event of a fault which might cause
The injection computer controls the lighting of warning destruction of the catalytic converter (destructive mis-
lights and message displays on the instrument panel. fires). If this happens, the vehicle will stop immedia-
These warning lights are lit during the starting phase, in tely.
the event of an injection fault or engine overheating.
- « continuously » in the event that depollution stan-
The signals to light up the warning lights reach the ins- dards have not been adhered to (polluting engine
trument panel via the multiplex network. misfires, catalytic converter fault, oxygen sensor fault,
inconsistency between the oxygen sensors and fuel
vapour absorber fault).
WARNING LIGHT OPERATING PRINCIPLE
- the computer,
17B-24
PETROL INJECTION
Immobiliser function 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
This vehicle is equipped with an immobiliser which re-
quires a specific procedure for replacing the computer.
WARNING
- The injection computer retains its immobiliser
code for life.
- The system has no security code.
- It is forbidden to perform tests with computers
borrowed from the Parts Department or from
another vehicle which must then be returned.
- These computers are permanently coded.
17B-25
PETROL INJECTION
Injection - air conditioning programming 17B
F4R, and 770 or 771 or 776
I - INJECTION COMPUTER - AIR CONDITIONING II - COMPRESSOR FUNCTION PROGRAMMING
COMPUTER CONNECTION
In certain operating phases, the injection computer di-
Climate control is managed by several computers. sables the air conditioning compressor.
The injection computer is responsible for:
1 - Performance return programming for hill starts
- managing the request for cold air in response to pas-
senger compartment controls and the circuit pressure To facilitate starting on a hill, operation of the air condi-
level. tioning compressor is prevented for 20 seconds .
- determining the power absorbed by the air conditio-
ning compressor based on the pressure of the circuit, 2 - Maximum engine speed protection
programming
- authorising the fan assembly control according to ve-
hicle speed and circuit pressure. Operation of the air conditioning compressor is preven-
ted if:
- authorising or disables the compressor clutch.
- the instantaneous engine speed is above 6300 rpm ,
When climate control is activated, the climate control
panel requests authorisation for air conditioning com- - the constant engine speed is above 5760 rpm for
pressor operation. more than 10 seconds .
The request to run the fan assembly and compressor is Exit conditions:
made by the injection computer via the multiplex
- for a time of 10 seconds ,
network. This request depends on the air conditioning
but also on the coolant temperature and vehicle speed. - « and » certain conditions of the coolant temperature
centralised management function.
The engine cooling fan and the compressor are sup-
plied by the Protection and Switching Unit.
The data used for the function is exchanged via the
multiplex network:
- Track A A4 « CAN HIGH » multiplex connection,
- Track A A3 « CAN LOW » multiplex connection.
The injection computer also receives the refrigerant
pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
WARNING
The value of parameter PR044: « power absorbed
by the AC compressor » is never 0 , irrespective
of the status of the compressor. The minimum value
reading is approximately 250 to 300 W .
17B-26
PETROL INJECTION
Injection - air conditioning programming 17B
K4J, and 730 or 732
I - INJECTION COMPUTER - AIR CONDITIONING II - COMPRESSOR FUNCTION PROGRAMMING
COMPUTER CONNECTION
In certain operating phases, the injection computer di-
Climate control is managed by several computers. sables the air conditioning compressor.
The injection computer is responsible for:
1 - Performance return programming for hill starts
- managing the request for cold air in response to pas-
senger compartment controls and the circuit pressure To facilitate starting on a hill, operation of the air condi-
level. tioning compressor is prevented for 10 seconds .
- determining the power absorbed by the air conditio-
ning compressor based on the pressure value of the 2 - Maximum engine speed protection
circuit, programming
- authorising the fan assembly control according to ve- The compressor does not work if:
hicle speed and circuit pressure.
- the instantaneous engine speed is above 6688 rpm ,
- authorising or disables the compressor clutch.
- the constant engine speed is above 6112 rpm for
When climate control is activated, the climate control more than 10 seconds .
panel requests authorisation for air conditioning com-
pressor operation.
3 - Thermal protection programming
The injection computer authorises or prevents:
The compressor does not work if the coolant tempera-
- air conditioning compressor operation, ture is above 119˚C at high speed and high load.
- fan assembly operation, Entry conditions:
- an accelerated idle speed. - engine speed greater than 6496 rpm ,
This speed depends on the power absorbed by the - « and » inlet manifold pressure below 1046 mbar .
compressor:
Exit conditions:
- 850 rpm .
- engine speed below 6496 rpm ,
The request to run the fan assembly and compressor is
made by the injection computer via the multiplex - « and » coolant temperature below 119˚C ,
network. This request depends on the air conditioning - « and » inlet manifold pressure below 1046 mbar .
but also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup- 4 - Performance return programming
plied by the Protection and Switching Unit.
The compressor is prevented from operating for 5 se-
The data used for the function is exchanged via the conds .
multiplex network:
Entry conditions:
- Track A A4 « CAN HIGH » multiplex connection,
- throttle fully open,
- Track A A3 « CAN LOW » multiplex connection.
- « and » engine speed below 2016 rpm ,
The injection computer also receives the refrigerant
pressure sensor signal on tracks: - « and » engine speed below 10 mph (16 km/h) .
- B J3 refrigerant pressure sensor signal, Exit conditions:
- B J2 refrigerant pressure sensor + 5 V supply, - throttle not fully open,
- B K2 refrigerant pressure sensor earth. - « or » for a time of 5 seconds ,
The compressor is of variable displacement type. - « or » engine speed at or above 2048 rpm ,
- « or » vehicle speed greater than 16 mph (26 km/h) .
WARNING
The value of parameter PR044: « power absorbed 5 - Performance return programming for hill starts
by the AC compressor » is never 0 , irrespective To facilitate hill-starting, under certain load and engine
of the status of the compressor. The minimum value operating conditions, operation of the air conditioning
reading is approximately 250 to 300 W . compressor is prevented for 5 seconds .
17B-27
PETROL INJECTION
Injection - air conditioning programming 17B
K4J, and 730 or 732
6 - Maximum engine speed protection
programming
The air conditioning compressor does not work if the
engine speed is above 6496 rpm .
17B-28
PETROL INJECTION
Injection - air conditioning programming 17B
K4M, and 760 or 761
I - INJECTION COMPUTER - AIR CONDITIONING II - COMPRESSOR FUNCTION PROGRAMMING
COMPUTER CONNECTION
In certain operating phases, the injection computer di-
Climate control is managed by several computers. sables the air conditioning compressor.
The injection computer is responsible for:
1 - Engine start programming
- managing the request for cold air in response to pas-
senger compartment controls and the circuit pressure The compressor is prevented from operating for 10 se-
level. conds after engine start.
- determining the power absorbed by the air conditio-
ning compressor based on the pressure value of the 2 - Performance return programming
circuit,
The compressor is prevented from operating for 5 se-
- authorising the fan assembly control according to ve- conds .
hicle speed and circuit pressure.
Entry conditions:
- authorising or disables the compressor clutch.
- throttle fully open,
When climate control is activated, the climate control
- « and » engine speed below 2016 rpm ,
panel requests authorisation for air conditioning com-
pressor operation. - « and » engine speed below 10 mph (16 km/h) .
The injection computer authorises or prevents: Exit conditions:
- air conditioning compressor operation, - throttle not fully open,
- fan assembly operation, - « or » for a time of 5 seconds ,
- an accelerated idle speed. - « or » engine speed at or above 2048 rpm ,
This speed depends on the power absorbed by the - « or » vehicle speed greater than 16 mph (26 km/h) .
compressor:
- 850 rpm . 3 - Performance return programming for hill starts
The request to run the fan assembly and compressor is To facilitate hill-starting, under certain load and engine
made by the injection computer via the multiplex operating conditions, operation of the air conditioning
network. This request depends on the air conditioning compressor is prevented for 5 seconds .
but also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup- 4 - Maximum engine speed protection
plied by the Protection and Switching Unit. programming
The data used for the function is exchanged via the The air conditioning compressor does not work if the
multiplex network: engine speed is above 6496 rpm .
- Track A A4 « CAN HIGH » multiplex connection,
5 - Thermal protection programming
- Track A A3 « CAN LOW » multiplex connection.
The air conditioning compressor does not work if the
The injection computer also receives the refrigerant coolant temperature is above 119˚C at high speed and
pressure sensor signal on tracks: high load.
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
WARNING
The value of parameter PR044: « power absorbed
by the AC compressor » is never 0 , irrespective
of the status of the compressor. The minimum value
reading is approximately 250 to 300 W .
17B-29
PETROL INJECTION
Throttle valve: Operating 17B
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
I - THROTTLE BODY ding to the position of the accelerator. Therefore, the
maximum engine speed under full load or in neutral is
The throttle valve ensures that idle speed regulation 2500 rpm .
and engine air intake modulation are performed cor-
rectly. It is composed of an electric motor and two
throttle position potentiometers. 4 - Pedal information mode
If the signal from the inlet manifold vacuum is lost, ope-
When the engine is idling, the throttle position is regu-
lated according to the idle speed setpoint. This setpoint ning of the throttle is directly proportional to pressure
takes into account the major power consumers (air on the accelerator pedal.
conditioning) and operating conditions (air temperature
and coolant temperature).
Note:
When the driver depresses the accelerator pedal, his Each of these modes results in the injection fault
request is translated into an angle of throttle opening. warning light on the instrument panel lighting up.
However, to improve driving pleasure, the throttle ope-
ning is not directly proportional to the driver’s request.
There are four types of defect mode for the throttle val-
ve.
17B-30
PETROL INJECTION
Idle speed correction 17B
F4R, and 770 or 771 or 776
I - IDLE SPEED CORRECTION ACCORDING TO
COOLANT TEMPERATURE
- 20 1072
20 976 (1)
40 896
80 752
100 752
120 848
Note:
If the engine is started when the coolant tempera-
ture is between 15˚C and 30˚C and, as a result, the
engine speed remains at idle speed, the engine
speed will decrease progressively. This drop in
engine speed is due to an antipollution function
when the engine is started (oxygen sensor heating
resistors starting).
17B-31
PETROL INJECTION
Idle speed correction 17B
K4J, and 730 or 732
I - IDLE SPEED CORRECTION ACCORDING TO
COOLANT TEMPERATURE
- 20 1152
20 1008 (1)
40 960
80 752
100 752
120 896
Note:
If the engine is started when the coolant tempera-
ture is between 15˚C and 30˚C and, as a result, the
engine speed remains at idle speed, the engine
speed will decrease progressively. This drop in
engine speed is due to an antipollution function
when the engine is started (oxygen sensor heating
resistors starting).
17B-32
PETROL INJECTION
Idle speed correction 17B
K4M, and 760 or 761
I - IDLE SPEED CORRECTION ACCORDING TO
COOLANT TEMPERATURE
- 20 1150
20 944 (1)
40 850
80 700
100 700
120 752
Note:
If the engine is started when the coolant tempera-
ture is between 15˚C and 30˚C and, as a result, the
engine speed remains at idle speed, the engine
speed will decrease progressively. This drop in
engine speed is due to an antipollution function
when the engine is started (oxygen sensor heating
resistors starting).
17B-33
PETROL INJECTION
Adaptive idle speed correction 17B
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
I - ADAPTIVE IDLE SPEED CORRECTION
WARNING
Principle After the computer memory has been cleared, it is
imperative to start the engine, stop it, then leave it
In normal warm-engine operating conditions, the idle
running at idle speed so that the adaptive correction
speed OCR PR091 varies between a high and low va-
can recalibrate itself correctly.
lue to obtain the nominal idle speed.
• 750 rpm
• 6 % < or = X < or = 22 %
17B-34
PETROL INJECTION
Richness regulation 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761
III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: « downstream oxygen
diagnostic tool
sensor voltage » on the diagnostic tool
An engine operating with the S 3000 computer is fitted The value read represents the voltage supplied to the
with two oxygen sensors called the upstream sensor computer by the oxygen sensor located upstream of
and the downstream sensor after their position on the the catalytic converter, expressed in millivolts.
catalytic converter.
The function of this sensor is to locate faults on the ca-
talytic converter and to perform a second, more preci-
I - SENSOR HEATING se, check on the richness. This second richness check
is called the « slow regulation loop » . This function is
Oxygen sensor heating is controlled by the computer if
activated only after the engine has been operating for a
all of the following conditions are met:
certain time.
- the inlet manifold pressure is below a threshold which
When the engine is « looped » (when the computer
depends on a function table of the engine speed,
corrects the richness according to the two sensors, the
- the road speed is below ( 84 mph (135 km/h) , engine is said to be « looped » ), the voltage should be
in the region of 600 mV (except at idle speed when it
- after a certain mapped engine operating time which may be difficult to stabilise). When the vehicle is dece-
depends on the engine's top dead centre (excluding lerating, the voltage should be approximately 100 mV .
no load operation) and the coolant temperature.
II - UPSTREAM SENSOR VOLTAGE The richness correction value read on the diagnostic
tool i n p a r a m e t e r PR 138: «RICHNESS
CORRECTION » represents the average of the rich-
Reading parameter PR098: « upstream oxygen ness corrections applied by the computer depending
sensor voltage » on the diagnostic tool on the richness of the fuel mixture as determined by
the oxygen sensor located upstream of the catalytic
The value read represents the voltage supplied to the converter (the oxygen sensor in fact analyses the oxy-
computer by the oxygen sensor located upstream of gen content of the exhaust gas).
the catalytic converter. It is expressed in millivolts. With
a « looped engine » (when the engine corrects the rich- The centre point of the correction value is 50% and the
ness according to the two sensors, the engine is said to end value 0 to 100% .
be « looped » ); the voltage should oscillate quickly
between two values: - value less than 50% : request for decrease in rich-
ness,
- 100 mV and 450 mV for a lean mixture,
- value above 50% : request for increase in richness.
- 450 mV and 900 mV for a rich mixture.
17B-35
PETROL INJECTION
Richness regulation 17B
F4R, and 770 or 771 or 776 – K4M, and 760 or 761
2 - Non-loop mode
In mixture regulation mode, the phases of operation
during which the computer ignores the value of the vol-
tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
17B-36
PETROL INJECTION
Richness regulation 17B
K4J, and 730 or 732
III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: « downstream oxygen
diagnostic tool sensor voltage » on the diagnostic tool
An engine operating with the S 3000 computer is fitted The value read represents the voltage supplied to the
with two oxygen sensors called the upstream sensor computer by the oxygen sensor located upstream of
and the downstream sensor after their position on the the catalytic converter, expressed in millivolts.
catalytic converter.
The function of this sensor is to locate faults on the ca-
talytic converter and to perform a second, more preci-
I - SENSOR HEATING se, check on the richness. This second richness check
is called the « slow regulation loop » . This function is
Oxygen sensor heating is controlled by the computer if activated only after the engine has been operating for a
all of the following conditions are met: certain time.
- the inlet manifold pressure is below a threshold which When the engine is « looped » (when the computer
depends on a function table of the engine speed, corrects the richness according to the two sensors, the
engine is said to be « looped » ), the voltage should be
- the speed is below ( 84 mph (135 km/h) , in the region of 600 mV (except at idle speed when it
may be difficult to stabilise). When the vehicle is dece-
- after a certain mapped engine operating time which lerating, the voltage should be approximately 100 mV .
depends on the engine's top dead centre (excluding
no load operation) and the coolant temperature.
- 450 mV and 900 mV for a rich mixture. V - ENTERING RICHNESS REGULATION MODE
1 - Loop mode
Note:
The smaller the difference between the minimum The start of richness regulation is effective following a
and maximum values, the poorer the signal from period which depends on the engine coolant tempera-
the sensor. ture when the engine is started. At 20˚C , the start of
the richness loop is effective after approximately 8 se-
If the difference is small, check the sensor heater. conds .
17B-37
PETROL INJECTION
Richness regulation 17B
K4J, and 730 or 732
2 - Non-loop mode
In mixture regulation mode, the phases of operation
during which the computer ignores the value of the vol-
tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
17B-38
PETROL INJECTION
Adaptive richness correction 17B
K4J, and 730 or 732 – K4M, and 760 or 761
I - PRINCIPLE Pressure zones which must be passed through
during the test
In looping phase, the richness regulation corrects the
injection time to obtain fuel dosing as close as possible There are five pressure zones to scan during road tes-
to a richness of 1. Richness correction value PR138 is ting. These zones are defined by the following calibra-
tions:
close to 50% , with stop values of 0 and 100% .
If the coolant temperature is above 90˚C while idling for II - INTERPRETING VALUES OBTAINED FROM A
more than 10 minutes (K4M engine) and 1 minute ROAD TEST
(K4J engine), the adaptives are fixed until the end of
In the event of a lack of fuel (injectors clogged, pressu-
idling.
re and fuel flow too low, etc), the richness regulation in-
creases to obtain a richness as close as possible to 1
Programming conditions for adaptive richness and the richness adaptive corrections increase until the
correction richness correction is again fluctuating around 50% .
If there is an excess of fuel, the logic is inverted.
- Warm engine: coolant temperature above 80˚C ,
17B-39
PETROL INJECTION
Adaptive richness correction 17B
F4R, and 770 or 771 or 776
I - PRINCIPLE Pressure zones which must be passed through
during the test
In looping phase, the richness regulation corrects the
There are five pressure zones to scan during road tes-
injection time to obtain fuel dosing as close as possible
ting. These zones are defined by the following calibra-
to a richness of 1. Richness correction value PR138 is
tions:
close to 50% , with stop values of 0 and 100% .
If the coolant temperature is above 80˚C while idling for II - INTERPRETING VALUES OBTAINED FROM A
more than 1 minute , the adaptives are fixed until the ROAD TEST
end of idling. In the event of a lack of fuel (injectors clogged, pressu-
re and fuel flow too low, etc), the richness regulation in-
creases to obtain a richness as close as possible to 1
Programming conditions for adaptive richness and the richness adaptive corrections increase until the
correction richness correction is again fluctuating around 50% .
- Warm engine: coolant temperature above 80˚C , If there is an excess of fuel, the logic is inverted.
17B-40
PETROL INJECTION
Central coolant temperature management 17B
The fan assembly is controlled by the injection compu-
ter.
I - ANTI-PERCOLATION FUNCTION
17B-41
PETROL INJECTION
Camshaft dephaser: Description 17B
F4R, and 770 or 771 – K4M, and 760 or 761
I - SPECIAL NOTES The supply by a variable opening cyclic ratio signal
(amplitude 12 V , frequency 250 Hz ) enables oil to be
distributed to the mechanism and the dephaser angle
F4R, and 770 or 771 – K4M, and 760 or 761 to be adjusted.
15200
102943
The higher the engine speed, the later the inlet valves 101814
must be closed. The camshaft dephaser control solenoid valve is con-
trolled if the following conditions are met:
17B-42
PETROL INJECTION
Camshaft dephaser: Description 17B
F4R, and 770 or 771 – K4M, and 760 or 761
- coolant temperature between 10 and 120˚C ,
WARNING
A solenoid valve jammed open causes an unstable
idle speed, manifold pressure which is too high at
idle speed and significant engine operating noise.
102736
At rest, the solenoid valve is in the closed position. It
authorises the flow of oil to control the dephaser when
the following conditions are met:
- no speed sensor fault,
3
- no camshaft position sensor fault,
- no injection system faults,
- after the engine has started,
- outside idling speed,
- battery voltage > 11.4 V ,
- coolant temperature above 30˚C ,
- engine speed between 1,500 and 4,300 rpm ,
- charge > 87% (approximately 900 mbar ).
102732
WARNING
From 1,500 to 4,300 rpm , the computer supplies the A solenoid valve which is blocked open leads to an
solenoid valve. unstable idle speed and too high a pressure in the
manifold at idling speed.
Above 4,300 rpm , the solenoid valve is not supplied.
The position of the mechanism improves filling at high
speeds. In this position, a locking piston locks the me-
chanism.
17B-43
PETROL INJECTION
Fault finding warning light activation conditions (when driving) 17B
I - FAULTS CAUSING ACTIVATION OF THE
ONBOARD DIAGNOSTIC WARNING LIGHT
Note:
1 - Electrical fault The fault may not be re-detected:
Continuous illumination of the light after several conse- - if the fault is fleeting in nature,
cutive detections of a fault (depending on the compo- - due to the driving style of the customer, which may
nent). not always cover all of the fault detection condi-
tions.
2 - Combustion misfiring that could destroy the
catalytic converter
Immediate illumination and flashing of the warning li-
ght.
WARNING
17B-44
PETROL INJECTION
Conditions for carrying out fault finding (when driving) 17B
I - CONDITIONS FOR ENTERING FAULT FINDING Power take-up speed is the moment when, during de-
MODE celeration under no load and the injection cut out, the
computer authorises injection again.
If, when the ignition is switched on and when driving,
the air temperature read by the temperature sensor is
not between -7.5˚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 (see 17A, Petrol injec-
the manifold pressure is greater than 273 mbar (altitu- tion, Adaptive richness correction ).
de of about 2500 metres), OBD is not authorised until
the ignition is switched on again.
In order for the On Board Diagnostic system to function
correctly, there must be no electrical fault in the injec-
tion system, even if the OBD warning light does not
come on.
II - TEST PROCEDURE
Before performing the tests, carry out the following in
the sequence shown:
- repair all electrical faults,
17B-45
PETROL INJECTION
Combustion misfire fault finding 17B
IV - CONDITIONS FOR DETECTION
Equipment required Check that programming has been correctly carried
out.
diagnostic tool
Check that the prerequisites for switching on the igni-
The purpose of detecting misfiring is to detect any mal- tion and for detecting misfiring correspond.
functions which could cause hydrocarbon pollutant Detection is carried out as soon as the coolant tempe-
emissions to exceed the OBD limit, or cause damage rature is above 7.5˚C , in three operating ranges
to the catalytic converter. between idle speed and 4,500 rpm .
The pollutant misfiring test can also be carried out by
Note: maintaining the engine at idle speed with all the power
consumers on for 10 minutes .
- In comparison to the Sagem 2000 injection,
Sagem 3000 has the following functions:
• injection cut-off to cylinders causing misfiring, WARNING
At the end of this test, it is essential that the ignition
• appearance of a fault indicating non-conformity
is not switched off before the result is read on the
of the flywheel target.
diagnostic tool. Switching the ignition off will lead to
- If distortion of the target is too marked, the compu- the results being misinterpreted.
ter cannot implement an adjustment that is suffi-
cient to detect misfiring correctly.
V - REPAIR CONFIRMATION
Using the tool diagnostic tool , check:
I - THE FAULT FINDING SYSTEM CAN DETECT:
- clogging or flooding of a spark plug,
ET 057 Misfiring on cylinder 1 No
- clogging of the injectors or an injector flow fault,
ET 058 Misfiring on cylinder 2 No
- incorrect operation of the supply system (pressure re-
gulator, fuel pump, etc.), ET 059 Misfiring on cylinder 3 No
- a faulty connection in the petrol or injection circuits
ET 060 Misfiring on cylinder 4 No
(coil secondary, etc.).
Following this test, if the diagnostic tool has indicated
II - MEASUREMENT OF ENGINE MISFIRINGS misfiring faults DF065 , DF059 , DF060 , DF061 , or
DF062 , refer to the appropriate fault finding procedure
Fault finding is performed by measuring the instanta- for the symptom concerned.
neous variations in engine rotation speed.
If a drop in torque is detected, this is an indication of
misfiring. Misfiring results in a drop in engine torque
below a predetermined threshold.
This fault finding is practically continuous while the car
is being driven. If it is not carried out, or if a fault is de-
tected, all other OBD fault finding (catalytic converter
and upstream oxygen sensor) will be prevented.
17B-46
PETROL INJECTION
Catalytic converter fault finding 17B
The purpose of catalytic converter fault finding is to de- III - REPAIR CONFIRMATION
tect a fault which could cause hydrocarbon pollutant
If after the test, the diagnostic tool has detected a cata-
emissions to exceed the OBD limit.
lytic converter fault DF110: « Catalytic converter »
The catalytic converter's capacity to store oxygen is in- refer to the fault finding procedure for this fault.
dicative of its condition. As the catalytic converter
ages, its capacity to store oxygen reduces along with
its ability to treat pollutant gases.
- no electrical faults,
- no misfiring detected,
II - FAULT DETECTION
2 - If it needs replacing
WARNING
At the end of this test, it is essential that the ignition
is not switched off before the result is read on the
diagnostic tool. Switching off the ignition will lead to
the results being misinterpreted.
17B-47
PETROL INJECTION
Oxygen sensor fault finding 17B
Equipment required
WARNING
diagnostic tool At the end of this test, it is essential that the ignition
is not switched off before the result is read on the
The purpose of fault finding on the upstream oxygen diagnostic tool. Switching off the ignition will lead to
sensor is to detect faults that would cause emissions of the results being misinterpreted.
hydrocarbon, carbon monoxide or nitrogen oxide to ex-
ceed the OBD limit. It is carried out by measuring and
comparing periods of upstream oxygen sensor vibra- V - REPAIR CONFIRMATION
tion. If, after the test, the diagnostic tool has detected an
upstream oxygen sensor fault DF092: « Upstream
I - POSSIBLE CAUSES OF FAULTS oxygen sensor circuit » refer to the fault finding pro-
cedure for this fault.
There are possible types of fault in the upstream oxy-
gen sensor:
- 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-48
PETROL INJECTION
Speed limiter: Operating principle 17B
Entry conditions:
- switch in speed limiter position,
- 19 mph (30 km/h) minimum, 125 mph (200 km/h)
maximum (guideline only),
- « + » , « - » or « R » buttons pressed.
Exit conditions:
- accelerator depressed firmly (beyond the safety resis-
tance point),
- switch in the « off » position,
- « 0 » button depressed,
- injection computer intervention (fault or overspeed),
Note:
If the warning light on the instrument panel flashes,
it informs to the driver that the cruising speed can-
not be maintained.
17B-49
COOLING SYSTEM
General information 19A
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drive
IMPORTANT
belt,
The circuits are designed to be pressurised; take
care at high temperatures (risk of serious scalding). - that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
Never remove the valve from the expansion bottle air.
while the engine is hot.
Vehicles in the current range have cooling circuits with
Similarly, take care when working under the bonnet, the following basic specifications:
as the radiator fan(s) may start up unexpectedly.
- Pressurised sealed circuit (expansion bottle valve),
Do not open the bleed valve(s) while the engine is
running.
Note:
Summary of expansion bottle valve ratings.
WARNING
Expansion bottle valve with:
The coolant helps to keep the engine running pro-
perly (heat exchange). • a yellow hand: 1.4 bar
The system does not operate using pure water. • a white hand: 1.6 bar
• a grey hand: 1.8 bar
WARNING
When carrying out a repair that requires a the cir-
cuit to be completely drained, it is essential to flush
the circuit with clean water, blow compressed air
through the circuit to eliminate water, fill and drain
the circuit and then measure the effective protec-
tion.
The criteria to be met are:
- Protection down to - 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.
For any further information, refer to the Workshop
Repair Manual of the vehicle concerned.
19A-1
COOLING SYSTEM
Specifications 19A
Grade and quantity of coolant
730
K4J 6
732
760 6
K4M
761 6.5
722 5.3
800 7.2
808 7.2
Thermostat
K4J 89 99 ± 2
K4M 89 99 ± 2
K9K 89 99 ± 2
F9Q 89 99 ± 2
F4R 89 99 ± 2
M9R 89 99 ± 2
19A-2
COOLING SYSTEM
Checking 19A
I - RECOMMENDATIONS FOR REPAIR II - CHECKING THE CIRCUIT SEALING
IMPORTANT Note:
The circuits are designed to be pressurised; take The expansion bottle valve must be replaced if
care at high temperatures (risk of serious scal- coolant is leaking from the valve.
ding).
Never remove the valve from the expansion
Checking the cooling system and the expansion
bottle while the engine is hot.
bottle valve
Similarly, take care when working under the bon-
net, as the radiator fan(s) may start up unexpec-
tedly.
Do not open the bleed valve(s) while the engine
is running.
107138
Note:
For any further information, refer to the Works-
hop Repair Manual of the vehicle concerned.
19A-3
COOLING SYSTEM
Diagram 19A
K4J, and 730 or 732 – K4M, and 760 or 761
9
3
5 9
1
4
6
7
10
2
8
105003
(1) Engine
(2) Cooling radiator
(3) Heating radiator
(4) Expansion tank
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Automatic gearbox coolant-oil
intercooler (if fitted to the vehi-
cle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-4
COOLING SYSTEM
Diagram 19A
K9K, and 722 or 728 or 729
9
7
1
5
4 8
10
11
110741
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 11 mm choke (K9K 722)
(8) 9 mm by-pass choke (K9K 728 /
729)
(9) Bleed screws
(10) Coolant-engine oil intercooler
(11) Coolant-oil intercooler (K9K
729)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-5
COOLING SYSTEM
Diagram 19A
F9Q, and 800 or 808
9
3
9
7
5 1
4
10
8
2
102269
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 9 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-6
COOLING SYSTEM
Diagram 19A
F4R, and 770 or 771
9
3
9
10 1
4 5
7
6
2
11
102740
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8.3 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
(11) Automatic gearbox coolant-oil
intercooler (if fitted to the vehi-
cle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-7
COOLING SYSTEM
Diagram 19A
F4R, and 776
9
12 3
1 11
5
4
6 9 8
10
13
106628
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Water-oil intercooler
(11) Thermostat mounting
(12) Turbocharger
(13) Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-8
COOLING SYSTEM
Diagram 19A
F9Q, and 804
12 9
11 7 3
1
5
4
6
9 13
10
14
112266
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Water-oil intercooler
(11) Cylinder head coolant outlet unit
(12) Turbocharger
(13) Exhaust gas cooler
(14) Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEM
Diagram 19A
K9K, and 732
7
7
3
9
5 1 7
112268
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) Bleed screws
(8) Water-oil intercooler
(9) Exhaust gas cooler
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-10
COOLING SYSTEM
Diagram 19A
M9R, and 700
114452
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) Choke
(8) Choke
(9) Bleed screws
(10) Water-oil heat exchanger
(11) Exhaust gas recirculation sole-
noid valve
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-11
COOLING SYSTEM
Cooling circuit: Draining - Refilling 19A
Special tooling required WARNING
When carrying out a repair that requires a complete
Car. 1363 Trim removal lever change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
Mot. 1202-01 Clip pliers for hose clips (large
drive out the water, fill and bleed the circuit and
model)
then measure the effective protection.
Mot. 1202-02 Clip pliers for hose clips (small The parameters to be observed are:
model)
- Protection down to - 25˚C ± 2 for cold and tempe-
Mot. 1448 Remote operation pliers for coo- rate climates,
ling system hose clips - Protection down to - 40 ˚C ± 2 for very cold clima-
tes.
Mot. 1700 Cooling system filling and dia-
gnostic tool
Note:
IMPORTANT Before carrying out any operation, protect electrical
The circuits are designed to be pressurised; take equipment using plastic bags.
care at high temperatures (risk of serious burns).
Never remove the cap from the expansion bottle
while the engine is hot. Note:
Similarly, take care when working under the bonnet, The engine must be switched off and the air condi-
as the radiator fan(s) may start up unexpectedly. tioning system deactivated to prevent the engine
Do not open the bleed valve(s) while the engine is cooling fans operating as soon as the engine is
running. started.
DRAINING
WARNING
Use the following tools:
The coolant helps to keep the engine running pro-
perly (heat exchange). - (Car. 1363) ,
The system does not operate using pure water. - (Mot. 1202-01) ,
- (Mot. 1202-02) ,
CLEANING
For cleaning (see 19A, Cooling, Cooling system:
cleaning).
FILLING
Use GLACEOL RX (TYPE D) coolant.
19A-12
COOLING SYSTEM
Cooling circuit: Draining - Refilling 19A
Refill the cooling system using the cooling system
diagnostic and filling tool (Mot. 1700) . For guidance
on the use of this tool see Technical Note 3857A,
Using the cooling system diagnostic and filling
tool .
Fill up the expansion bottle until the coolant over-
flows.
Refit the expansion bottle cap.
Bleed the circuit (see 19A, Cooling system, Coo-
ling circuit: Bleeding, page 19A-15) .
19A-13
COOLING SYSTEM
Engine cooling circuit: Cleaning 19A
IMPORTANT
The circuits are designed to be pressurised; take
care at high temperatures (risk of serious burns).
Do not remove the cap from the expansion bottle
while the engine is hot.
Similarly, take care when working under the bonnet,
as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine is
running.
WARNING
Drain the fluid with the engine warm.
Flushing and refilling should be carried out with a
warm or cold engine.
Never flush a hot engine (risk of serious thermal
shock).
Note:
In some cases it will be necessary to disconnect
the radiator top hose to correctly flush the engine
cooling radiator.
19A-14
COOLING SYSTEM
Cooling circuit: Bleeding 19A
BLEEDING
IMPORTANT
Do not open the bleed screw(s) while the engine
is running or hot.
Do not open the expansion bottle while the
engine is running or hot (above 50˚C ).
Adjust the level, if necessary.
Retighten the expansion bottle cap while the
engine is hot.
Using approved equipment, measure the degree
of coolant protection.
Check for any leaks.
Make sure the passenger compartment heating
is working properly.
19A-15
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
Disconnect the battery, starting with the negative
Special tooling required terminal.
Car. 1363 Trim removal lever Remove:
REMOVAL
1
WARNING
102504
Procedure for removing the air inlet duct on the Disconnect the two connectors (1) .
intercooler: Unclip the bonnet opening cable (2) .
- risk of leaks and of coming loose if this proce- Remove:
dure is not adhered to.
- the clip (3) ,
- detach the hose using tool (Car. 1363) ,
- the mounting (4) .
- do not use degreaser, brake cleaner, or any
other product, Disconnect the windscreen washer pipes.
19A-16
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
F4R, and 776 – F9Q, and 800 or 804 or 808 – K9K,
and 722 or 728 or 729 or 732
102365
Remove the cross member (5) . 6
Drain the cooling circuit through the radiator bottom
hose.
Disconnect:
- the radiator top hose,
- the expansion bottle hoses on the radiator,
- the fan unit connector. 102473
102474
Disconnect the intercooler inlet ducts (6) and outlet
ducts (7) .
Remove the intercooler.
19A-17
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
Separate the condenser from the radiator. Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
WARNING - the wheel mounting bolts ( 110 Nm ) .
Be careful not to damage the air conditioning
piping.
Note
Remove the radiator.
Be sure to initialise the xenon bulb system (if fit-
Separate the fan unit from the radiator. ted on vehicle; see 80C, Xenon bulbs, Xenon
headlight: Adjustment ).
REFITTING
Proceed in the reverse order to removal.
WARNING
Ensure that the fins of the cooling unit (radiator,
condenser) are not damaged when moved.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19A-18
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
K9K, and 732
front end panel upper 21 Nm Disconnect the connectors (1) from the relay board,
mounting bolts
Unclip the bonnet opening cable (2) ,
front end panel lower 44 Nm Remove:
mounting bolts
- the clip (3) ,
wheel bolts 110 Nm - the mounting (4) .
Disconnect the screen washer pipes.
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal
- fitting ).
Remove:
- the engine covers,
- the front wheels,
- the engine undertray,
- the right and left-hand wheel arch liners,
- the front bumper (see MR 371 Bodywork, 55A,
Exterior protection, Front bumper ). 102365
Remove:
- the front end panel bolts (5) ,
- the front end panel.
Drain the cooling system via the radiator bottom ho-
se, using tool (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
19A-19
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
K9K, and 732
102473 109537
102474 112661
Disconnect the ducts (6) and (7) from the intercoo- Disconnect:
ler.
- the cooling radiator top hose,
Remove the intercooler.
- the expansion bottle hoses (8) ,
- the fan unit resistor connector (9) .
- the fan unit connector
19A-20
COOLING SYSTEM
Cooling radiator: Removal - Refitting 19A
K9K, and 732
Connect:
Separate the condenser from the cooling radiator. - the fan unit connectors;
- the fan unit resistor connector,
WARNING Refit the intercooler.
Be careful not to damage the air conditioning Connect the intercooler ducts.
piping.
Refit the front end panel.
Tighten to torque:
- the front end panel upper mounting bolts ( 21
Nm )
II - OPERATION FOR REMOVAL OF PART
CONCERNED - the front end panel lower mounting bolts ( 44
Nm )
Remove the radiator assembly from the fan unit.
Clip the bonnet opening cable
Separate the cooling radiator from the fan unit.
Reconnect:
19A-21
COOLING SYSTEM
Water pump: Removal - Refitting 19A
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
REFITTING
Tightening torquesm
102422
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
19A-22
COOLING SYSTEM
Water pump: Removal - Refitting 19A
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
102422
Tighten to torque and in order the water pump
mounting bolts ( 9 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
Fill the cooling system (see 19A, Cooling, Draining
- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -
Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-
ding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheel
mounting bolts ( 110 Nm ) .
19A-23
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K4J, and 730 or 732 – K4M, and 760 or 761
Tightening torquesm
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Remove
- the engine covers, 14505
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. The pro-
duct-fluid mix may cause damage to some com-
ponents (engine, radiator, etc.).
19A-24
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K4J, and 730 or 732 – K4M, and 760 or 761
10063
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm
to 1 mm wide.
19A-25
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K4J, and 730 or 732 – K4M, and 760 or 761
Refit:
1 6 7 - the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheel
mounting bolts ( 110 Nm ) .
4
5 2 8
14505
Note:
Apply one to two drops of LOCTITE FRENE-
TANCH to the mounting bolts (1) and (4) of the
water pump.
Refit:
- the water pump,
- the water pump mounting bolts.
Pretighten the water pump M6 mounting bolts to 8
Nm and the water pump M8 mounting bolts to 8
Nm .
Tighten to torque and in order:
- the water pump M8 mounting bolt ( 22 Nm ) ,
- the water pump M6 mounting bolts ( 10 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
19A-26
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
- the accessories belt (see 11A, Top and front of Tilt the alternator forward.
engine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
102266
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
19A-27
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 722 or 728 or 729 or 732
1 2
4 4
102262 102262
Remove:
- the water pump mounting bolts (4) , WARNING
- the water pump. The sealing surfaces must be clean, dry and free
from grease (avoid finger marks).
REFITTING
Note:
19A-28
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 722 or 728 or 729 or 732
102266
Refit:
- the inner timing cover (5) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt ),
- the accessories belt (see 11A, Top and front of
engine, Accessories belt ).
Fill the cooling system (see 19A, Cooling, Draining
- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -
Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-
ding the cooling system ).
Refit:
- the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque:
- the front right-hand wheel mounting bolts ( 110
Nm )
19A-29
COOLING SYSTEM
Water pump: Removal - Refitting 19A
F4R, and 770 or 771 or 776
REFITTING
Tightening torquesm
102422
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
19A-30
COOLING SYSTEM
Water pump: Removal - Refitting 19A
F4R, and 770 or 771 or 776
4 1
3
2
102422
Tighten to torque and in order the water pump
mounting bolts ( 9 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ).
Fill the cooling system (see 19A, Cooling, Draining
- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -
Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-
ding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheel
mounting bolts ( 110 Nm ) .
19A-31
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 732
Tightening torquesm
102266
Remove:
- the inner timing cover mounting bolts,
- the timing cover.
19A-32
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 732
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED
WARNING
The water pump seal every time the water pump
is removed.
Note:
Apply one or two drops of LOCTITE FRENE-
TANCH to the water pump mounting bolts.
102262
Remove:
- the water pump mounting bolts
- the water pump.
III - CLEANING
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Clean the gasket faces with DECAPJOINT to 102262
dissolve the part of the gasket still present. Refit:
Apply the product to the part to be cleaned, wait - the water pump,
approximately 10 minutes, then remove residue
- the water pump mounting bolts.
using a wooden spatula.
Tighten to torque and in order the water pump
mounting bolts ( 11 Nm ) .
19A-33
COOLING SYSTEM
Water pump: Removal - Refitting 19A
K9K, and 732
II - FINAL OPERATION
102266
Refit:
- the alternator,
WARNING
Carry out the necessary programming.
Tighten to torque:
19A-34
COOLING SYSTEM
Water pump: Removal - Refitting 19A
M9R, and 700
REMOVAL
Special tooling required
IMPORTANT
The circuits are designed to be pressurised, so
be careful at high temperatures (risk of serious
burns).
Do not remove the cap from the expansion bottle
while the engine is hot.
When working under the bonnet, be aware that
the radiator cooling fan(s) may start without war-
ning.
Do not open the bleed screw(s) with the engine
running.
Remove:
- the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- the engine undertray.
19A-35
COOLING SYSTEM
Water pump: Removal - Refitting 19A
M9R, and 700
101212 114933
112658
Remove the Protection and Switching Unit cover
mounting bolts (3) .
114855
Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting ).
19A-36
COOLING SYSTEM
Water pump: Removal - Refitting 19A
M9R, and 700
102504 102365
Disconnect the connectors (4) . Remove:
Unfasten the bonnet opening cable (5) . - the front end panel mounting bolts (8) ,
Remove: - the front end panel.
- the clip (6) , Remove the « Cooling radiator - condenser -
intercooler » assembly from its housing and move it
- the mounting (7) .
forwards.
Disconnect the screen washer tubes.
Fit the (Mot. 1390) on two pads.
Drain the cooling system (see 19A, Cooling, Coo-
Undo
ling system: Draining - Filling ).
- the right-hand suspended mounting support moun-
ting bolts,
- the upper engine tie-bar mounting bolts.
Remove the upper engine tie-bar.
19A-37
COOLING SYSTEM
Water pump: Removal - Refitting 19A
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
114858
Remove:
- the water pump pulley mounting bolts (11) ,
- the water pump pulley (12) .
114863
At the same time, turn the (Mot. 1390) forwards, lif-
ting the right-hand suspended engine mounting (9)
and bring the compressor pulley (10) level.
19A-38
COOLING SYSTEM
Water pump: Removal - Refitting 19A
M9R, and 700
Tighten to torque and in order the water pump
mounting bolts ( 25 Nm ) .
II - FINAL OPERATION
Position
Refit:
Tighten to torque:
Remove: Clip:
Refit:
I - REFITTING OPERATION FOR PART
CONCERNED - the front bumper (see MR 365 Bodywork, 55A Ex-
terior protection, Front bumper ),
The water pump seal must be replaced.
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting )
WARNING - the rear suspended engine mounting (see 19D,
Clean the pump shaft cooling hole on the cylin- Engine mounting, Rear suspended engine
der block. mounting: Removal - Refitting ).
Check that the water pump is supported by the cylin- Disconnect the battery (see 80A, Battery, Battery:
der block before tightening the bolts. Removal - Refitting ).
19A-39
COOLING SYSTEM
Plenum chamber: Removal - Refitting 19A
M9R, and 700
REMOVAL
Special tooling required
Tightening torquesm
112659
WARNING
Disconnect the injection computer connectors (1) .
When carrying out a repair that requires a complete
change, it is essential to flush the circuit with clean Remove:
water, blast compressed air through the circuit to - the battery tray mounting bolts (2) ,
drive out the water, fill and bleed the circuit and
then measure the effective protection. - the wiring harness mounting nut (3) .
The parameters to be observed are: Move the wiring harness to one side.
- protection down to -25˚C ±2 for cold and tempe- Unpick the wiring harness (4) from the battery - ter-
rate countries, minal.
- protection up to -40˚C ±2 for countries with extre- Remove the battery tray.
mely cold climates. Drain the cooling system via the radiator bottom
hose using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) (see 19A, Cooling, Cooling system:
Draining - Filling).
IMPORTANT
The circuits are designed to be pressurised, so be
careful at high temperatures (risk of serious burns).
Do not remove the cap from the expansion bottle
while the engine is hot.
During an operation under the bonnet, be aware
that one (or several) of the radiator cooling fan(s)
may operate unexpectedly.
Do not open the bleed screw(s) with the engine run-
ning.
19A-40
COOLING SYSTEM
Plenum chamber: Removal - Refitting 19A
M9R, and 700
114934 113291
Disconnect the coolant temperature sensor connec- Remove:
tor (5) .
- the coolant outlet unit mounting bolts,
- the coolant outlet unit.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
REFITTING
WARNING
The seal faces must be clean, dry and free from
grease (avoid finger marks).
19A-41
COOLING SYSTEM
Plenum chamber: Removal - Refitting 19A
M9R, and 700
113291
Remove:
Tighten to torque:
19A-42
EXHAUST
General information 19B
Special tooling required
F4R, and 776
Mot. 1199-01 35/50 mm diameter
and 50/95 mm diame-
ter exhaust pipe cut-
ting tool. Complete
assembly in kit.
WARNING
Any damaged heat shields must be replaced.
The sealing between the exhaust manifold and the
catalytic converter must be perfect. 109581
All seals removed must be replaced.
Take care not to damage the catalytic converter
during removal and refitting.
- correctly position the After-Sales sleeve. Before cutting the pipe between the catalytic converter
and the expansion chamber, remove the protective
plate.
2 - Identifying the cut zone
Two punch marks on the exhaust pipe indicate the
area to be cut (see 19B, Exhaust, General informa-
tion on exhausts ).
19B-1
EXHAUST
General information 19B
Cut zone 1
D
P1
P2
80 mm
101504 100649
101503
102118
Turn the cutting tool with the handle while gripping the
pipe.
19B-2
EXHAUST
General information 19B
4 - Special notes on the replacement part Cut zone 1
60 mm
101960
WARNING
When replacing the middle section of the exhaust
pipe (pipe on diesel version, expansion chamber on 101501
petrol versions), the replacement part needs to be
shortened by 60 mm . Cut zone 2
101500
19B-3
EXHAUST
General information 19B
WARNING
Do not reuse a used bracket.
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must be
positioned so that they cannot come into contact
with the underbody.
Any damaged heat shields must be replaced.
19B-4
EXHAUST
Pipe assembly 19B
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
112063
112062
19B-5
EXHAUST
Pipe assembly 19B
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
112061
19B-6
EXHAUST
Pipe assembly 19B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
112060
112059
19B-7
EXHAUST
Pipe assembly 19B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
2
2
112059 112058
19B-8
EXHAUST
Pipe assembly 19B
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
19B-9
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F4R, and 776
Tightening torquesm
Remove the engine in order to remove the catalytic - the upper bracket (3) and upstream stays (4) ,
pre-converter (see 10A, Engine and peripherals, En- - the catalytic converter/gearbox stay mounting (5) ,
gine - gearbox ).
- the catalytic converter mounting nuts, (6) on the
turbocharger,
REMOVAL
- the catalytic converter.
Remove the oxygen sensor on the workbench.
REFITTING
Refit the oxygen sensors.
WARNING
1 Be sure to replace all the exhaust flange and tur-
bocharger sealing joints.
19B-10
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F4R, and 776
- the upper bracket mounting bolt (on the ex-
haust manifold) ( 8.5 Nm ) ,
- the upper bracket mounting bolt (on the cataly-
tic converter) ( 8.5 Nm ) ,
- the catalytic converter nuts (on the turbochar-
ger) ( 40 Nm ) ,
- the oxygen sensors ( 34 Nm ) ,
- the exhaust flange studs ( 8.5 Nm ) .
Proceed in the reverse order to removal.
19B-11
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F9Q, and 804
- the exhaust mounting bolts,
catalytic pre-converter 30 Nm
upstream stay moun-
ting nuts on the cataly-
tic pre-converter
catalytic pre-converter 50 Nm
gearbox-side downs-
tream stay mounting
bolts on the engine
catalytic pre-converter 50 Nm
gearbox-side downs-
tream stay mounting 1
bolts on the catalytic
pre-converter
catalytic pre-converter 50 Nm
timing-end downstream 111864
stay mounting bolts on
Remove:
the engine
- the catalytic pre-converter lower stay mounting
catalytic pre-converter 30 Nm bolts (1)
timing-end downstream
stay mounting nuts on - the catalytic pre-converter lower stay.
the catalytic pre-conver-
ter
catalytic pre-converter 7 Nm
outlet exhaust flange
studs
Remove:
19B-12
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F9Q, and 804
111862
Remove:
- the catalytic pre-converter upper stay mounting
bolts (2) ,
- the catalytic pre-converter upper stay,
- the turbocharger and catalytic pre-converter moun-
ting clip bolt (3) ,
- the catalytic pre-converter.
19B-13
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
F9Q, and 804
- the connector clip between the turbocharger - the catalytic pre-converter gearbox-side
and the catalytic pre-converter. downstream stay mounting bolts on the engine
( 50 Nm ) ,
On the workbench, refit the gearbox-side downs-
tream stay to the catalytic pre-converter. - the catalytic pre-converter gearbox-side
downstream stay mounting bolts on the cataly-
Tighten the gearbox-side downstream stay moun- tic pre-converter ( 50 Nm ) ,
ting bolts on the catalytic pre-converter so that they
make contact. - the catalytic pre-converter timing-end downs-
Fit the catalytic pre-converter to the engine. tream stay mounting bolts on the engine ( 50
Nm ) ,
Tighten the gearbox-side downstream stay moun-
ting bolts on the engine so that they make contact. - the catalytic pre-converter timing-end downs-
tream stay mounting nuts on the catalytic pre-
Refit: converter ( 30 Nm ) .
- the connector clip between the turbocharger and
the catalytic pre-converter,
Note:
- the catalytic pre-converter upstream stay.
Make sure there is no contact between the cata-
Pretighten in order: lytic pre-converter and the turbocharger oil return
- the catalytic pre-converter upstream stay mounting pipe.
nuts on the engine,
Tighten to torque:
- the catalytic pre-converter upstream stay mounting
nuts on the catalytic pre-converter, - the catalytic pre-converter outlet exhaust flan-
ge studs ( 7 Nm ) .
Loosen then tighten in order and until they make
contact: - the exhaust flange nuts ( 21 Nm ) ,
- the catalytic pre-converter gearbox-side downs-
tream stay mounting bolts on the engine, Proceed in the reverse order to removal.
- the catalytic pre-converter gearbox-side downs- Make sure that there is no contact with the underbo-
tream stay mounting bolts on the catalytic pre-con- dy.
verter.
Refit the catalytic pre-converter downstream stay on
WARNING
the timing end.
Any damaged heat shields must be replaced.
Pretighten in order:
- the catalytic pre-converter timing-end downstream Connect the battery, starting with the positive termi-
stay mounting bolts on the engine, nal.
Tighten to torque:
tighten to torque the battery cover mounting bolts
- the connector clip between the turbocharger ( 4 Nm ) .
19B-14
EXHAUST
Catalytic converter: Removal - Refitting 19B
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
Tightening torquesm
oxygen sensor 45 Nm
REMOVAL
Put the vehicle on a two-post lift. 101793
Disconnect the battery, starting with the negative Remove:
terminal.
- the exhaust bracket mounting nuts (1) ,
Remove the engine undertray.
- the catalytic converter.
19B-15
EXHAUST
Catalytic converter: Removal - Refitting 19B
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
REFITTING
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must be
positioned so that they cannot come into contact
with the underbody.
Any damaged heat shields must be replaced.
Fit:
- the catalytic converter,
WARNING
Always replace:
- the exhaust bracket seal.
- all the disconnected air inlet plastic pipes.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19B-16
EXHAUST
Catalytic converter: Removal - Refitting 19B
F9Q, and 800 or 808
Tightening torquesm
REMOVAL 2
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove:
- the front right-hand wheel,
- the engine undertray.
102116
Remove the mounting bolt (2) from the exhaust pipe
rubber mounting bush on the body.
19B-17
EXHAUST
Catalytic converter: Removal - Refitting 19B
F9Q, and 800 or 808
102117 101120
Remove the (3) silencer rubber mounting bush bolt. Remove:
Withdraw the exhaust pipe towards the rear of the - the catalytic converter stay mounting bolts (5) (timi-
vehicle. ng end),
- the catalytic converter stay (timing end).
102479
Remove the catalytic converter stay mounting bolts 102313
(4) (flywheel end).
Remove the engine tie-bar (6) .
19B-18
EXHAUST
Catalytic converter: Removal - Refitting 19B
F9Q, and 800 or 808
8 9
101121 101120
Remove: Tighten to torque and in order:
- the engine lifting bracket, - the catalytic converter stay nut (timing end) ( 30
Nm ) (8) ,
- the nuts (7) securing the catalytic converter to the
turbocharger, - the catalytic converter stay mounting bolt (timi-
ng end) ( 44 Nm ) (9) .
- the catalytic converter from underneath the vehicle.
REFITTING
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must be
positioned so that they cannot come into contact
with the underbody.
Any damaged heat shields must be replaced.
WARNING
The gaskets must always be replaced.
Pretighten in order:
- the catalytic converter stay mounting bolts (timing
end),
- the stay mounting bolts (flywheel end),
- the catalytic converter nuts on the turbocharger,
Tighten to torque the nuts mounting the catalytic
converter onto the turbocharger ( 30 Nm ) .
19B-19
EXHAUST
Catalytic converter: Removal - Refitting 19B
F9Q, and 800 or 808
10
102479
Tighten to torque and in order the catalytic conver-
ter stay mounting nut (flywheel end) ( 21 Nm )
(10) .
Note:
Make sure there is no contact between the cata-
lytic conver ter and the turbocharger oil return
pipe.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19B-20
EXHAUST
Catalytic converter: Removal - Refitting 19B
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
turbocharger outlet 7 Nm
studs
catalytic converter 26 Nm
mounting nuts on the 1
turbocharger
d ownstream stay 21 Nm
mounting bolts on the 2
gearbox 3
upstream stay moun- 25 Nm
ting bolt on the catalytic
converter
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
19B-21
EXHAUST
Catalytic converter: Removal - Refitting 19B
K9K, and 722 or 728 or 729 or 732
102116 102077
Remove the mounting bolt (4) from the exhaust pipe Remove:
rubber mounting bush on the body. - the catalytic converter upstream stay mounting
bolts,
Mark with a pen the position of the exhaust rub- - the catalytic converter mounting nuts on the turbo-
ber mounting bush supports on the vehicle body. charger (7) ,
- the catalytic converter.
102117
19B-22
EXHAUST
Catalytic converter: Removal - Refitting 19B
K9K, and 722 or 728 or 729 or 732
WARNING
- the catalytic converter seal, Tighten to torque the ball joint bracket bolts with
their springs ( 21 Nm ) .
- the turbocharger - catalytic converter bracket
studs. Proceed in the reverse order to removal.
Note:
Make sure there is no contact between the cata-
lytic conver ter and the turbocharger oil return
pipe.
Tighten to torque:
19B-23
EXHAUST
Catalytic converter: Removal - Refitting 19B
M9R, and 700
REMOVAL
Equipment required
I - REMOVAL PREPARATION OPERATION
roller-type stud removal tool
Place the vehicle on a two-post lift (see 02A, Lifting
safety belt equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting ).
Tightening torquesm
Remove:
studs on the turbochar- 14.5 Nm
- the engine protectors,
ger
- the scuttle panel grille (see MR 365 Bodywork,
catalytic converter 21 Nm 55A, Exterior protection, Scuttle panel grille ),
mounting clamp moun-
ting bolts on the cylinder - the acoustic protection clips on the scuttle panel
block partition,
- the acoustic protection.
catalytic converter 21 Nm
mounting nuts on the
turbocharger
19B-24
EXHAUST
Catalytic converter: Removal - Refitting 19B
M9R, and 700
114771 114991
Remove: Remove the bolts from the ball-jointed bracket (5)
with springs.
- the lower engine tie-bar (see 19D, Engine moun-
ting, rear suspended engine mounting: Remo-
val - Refitting ).
- the catalytic converter stay mounting bolt (2) ,
- the catalytic converter stay mounting nuts (3) ,
- the nuts (4) mounting the stay on the cylinder
block,
- the catalytic converter stay,
- the catalytic converter studs using a roller-type
stud removal tool .
19B-25
EXHAUST
Catalytic converter: Removal - Refitting 19B
M9R, and 700
II - OPERATION FOR REMOVAL OF PART
CONCERNED
102116
114980
Remove:
- the catalytic converter half-clamp mounting bolts
(8) ,
- the catalytic converter half-clamps (9) .
Remove the catalytic converter, timing end.
Fit the catalytic converter using a safety belt to the
lifting eye on the timing end.
102117
Note:
Mark with a pen the position of the exhaust rub-
ber mounting bush supports on the vehicle body.
Remove:
- the exhaust pipe rubber mounting bush mounting
bolt (6) ,
- The silencer rubber mounting bush mounting bolt
(7) .
Detach the exhaust pipe.
19B-26
EXHAUST
Catalytic converter: Removal - Refitting 19B
M9R, and 700
REFITTING
114843
Remove the catalytic converter.
19B-27
EXHAUST
Catalytic converter: Removal - Refitting 19B
M9R, and 700
II - REFITTING OPERATION FOR PART - the stay mounting bolt on the catalytic conver-
CONCERNED ter ( 8 Nm ) ,
114844 Refit:
Move the engine towards the front of the vehicle. - the exhaust pipe rubber mounting bush mounting
Fit: bolt, aligning the marks,
- the new seal between the turbocharger and the ca- - the silencer rubber mounting bush mounting bolt,
talytic converter, aligning the marks,
- the stay mounting nuts on the catalytic converter, - the acoustic protection clips on the scuttle panel
partition,
- the stay mounting nuts on the cylinder block.
- the scuttle panel grille (see MR 365 Bodywork,
Tighten to torque:
55A, Exterior protection, Scuttle panel grille ),
- the catalytic converter mounting nuts on the
turbocharger ( 21 Nm ) , - the engine protectors.
- the catalytic converter half-clamp mounting Connect the battery (see 80A, Battery, Battery: Re-
bolts ( 21 Nm ) , moval - Refitting ).
19B-28
EXHAUST
Expansion chamber: Removal - Refitting 19B
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
REFITTING
Tightening torquesm
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » assem-
bly must be positioned so that it cannot come
into contact with the underbody.
Any damaged heat shields must be replaced.
101818
Remove:
- the bolts (1) securing the expansion chamber to the
rubber mounting bush support,
- the expansion chamber.
Note:
If the rubber mounting bushes are damaged,
mark the position of the support on the
bodywork, then replace the « support / rubber
mounting bush assembly » .
19B-29
EXHAUST
Silencer: Removal - Refitting 19B
REFITTING
Tightening torquesm Fit:
- the silencer,
bolts securing the rub- 8 Nm
ber mounting bush on - the sleeve (see 19B, Exhausts, General informa-
the silencer tion ).
Position the vehicle on a two-post lift. Tighten the sleeve, while easing in the exhaust pipe
to ensure the correct alignment of the pipe.
Cut the exhaust pipe (see 19B, Exhausts, General
information ). Make sure that all the exhaust pipe heat shields are
in place and properly secured.
Make sure that there is no contact with the underbo-
dy.
WARNING
Do not reuse an old sleeve.
101817
Remove:
- the silencer mounting bolts (1) on the rubber moun-
ting bush support,
- the the silencer.
Note:
If the rubber mounting bushes are damaged:
- mark the position of the mounting on the vehicle
body,
- replace the « support / rubber mounting bush
fitting assembly » .
19B-30
EXHAUST
Particle filter: Function 19B
F9Q, and 804
The extent to which the particle filter is clogged de-
pends on the user's driving style:
Equipment required
- during an average trip (combined cycle and motorway
diagnostic tool of more than 15 minutes ), the particle filter automa-
tically burns the particles without being noticed by the
customer (apart from some white smoke): this is
I - SAFETY ADVICE « spontaneous regeneration » ,
- if the operating temperature is not high enough to trig-
Due to the dangers of high temperatures, be sure to ger spontaneous regeneration, clogging increases
observe the following instructions: until it exceeds 35 g ; an acceleration request to trig-
ger spontaneous regeneration is then sent to the dri-
- never open or separate the pressure tapping circuit, ver via an instrument panel warning light; the same
except at the level of the unions on the exhaust pipe happens if several attempts to regenerate have failed.
(only the supplier can guarantee pressure tapping cir-
cuit sealing), - if these conditions are still not met and clogging rea-
ches 45 g (min) . « Static regeneration » , using dia-
gnostic tool must be performed in the workshop (
- Position the pressure pipes correctly. If the pipes are
« SERVICE » warning light comes on and the
not positioned correctly, their flexible sections may be
« CHECK ANTIPOLLUTION» message appears:
twisted which will create low points and this may re- (see 19B, Exhaust, Particle filter: Cleaning ).
sult in the pipes rupturing when fluid freezes and ex-
pands.
IMPORTANT
Do not park and run the engine in a place where
combustible substances and materials such as
grass or leaves can come into contact with the hot
exhaust system.
II - OPERATING PRINCIPLE
19B-31
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm
downstream pressure 21 Nm
measurement tapping
on its adapter
19B-32
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
111881 111885
Remove the heat shield (3) mounting clip then move
Disconnect the upstream and downstream tempera-
it aside slightly
ture sensor offset connectors (6) .
Unpick the downstream pressure measurement tap-
ping and also the downstream temperature sensor Unpick the upstream and downstream temperature
cabling from the heat shield. sensor offset connectors (6) .
Pass the downstream pressure measurement tap-
ping into the engine compartment whilst leaving the
pressure sensor complete.
111885
Remove:
111882
- the bolt (7) securing the filter particle pressure sen-
Disconnect the particle filter pressure sensor con-
sor mounting located in the engine compartment.
nector (4) located in the engine compartment.
Remove the retaining clip (5) from the cabling on the - the particle filter pressure sensor assembly (8) and
particle filter pressure sensor mounting. its mounting.
19B-33
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
107038
Remove: REFITTING
- the nuts (9) on the exhaust flange between the con-
nection hose and the catalytic pre-converter,
WARNING
- the sub-frame rubber mounting bush bolts (10) ,
- the particle filter. Always replace:
Remove the particle filter assembly: - the seal between the hose and particle filter,
- the rubber mounting bush, - the seal between the hose and the catalytic pre-
converter,
- the upstream and downstream temperature sen-
sors from their adapters on the exhaust line (see - any adapter on the exhaust pipe that has been
19B, Exhaust, Particle filter temperature sen- loosened,
sor: Removal - Refitting ).
- the upstream pressure measurement tapping at its
WARNING
adapter on the exhaust pipe (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit- Always clean the bearing surfaces of the connec-
ting ). tion hose - par ticle filter flanges thoroughly.
- the connection hose (see 19B, Exhaust, Connec- With particle filter removed, refit:
tion hose: Removal - Refitting ).
- the connection hose and its new seals (see 19B,
Exhaust, Connection hose: Removal - Refitting
).
19B-34
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
- the upstream and downstream temperature sen-
sors on their adapters on the exhaust pipe (see
19B, Exhaust, Particle filter temperature sen-
sors: Removal - Refitting ).
- the upstream pressure measurement tapping at its
adapter on the exhaust line (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refit-
ting ).
- the rubber mounting bush on the particle filter.
Torque tighten the rubber mounting bush support
mounting nut on the particle filter ( 25 Nm ) .
Place the pressure sensor and its mounting in the
engine compartment before fitting the particle filter.
Tighten to torque:
- the exhaust bracket nuts between the connec-
tion hose and the catalytic pre-converter ( 21
Nm ) .
- the rubber mounting bush nuts on the sub-fra-
106673
me ( 25 Nm ) .
Fit the exhaust sleeve (see 19B, Exhaust : General
Vehicle Information ) by applying sealing mastic for WARNING
the exhaust. All the adapters on the exhaust pipe (12) must be
Tighten to torque the exhaust sleeve nut ( 25 Nm ) replaced.
at the same time as making sure that the exhaust
pipe is correctly aligned.
WARNING
When fitting the particle filter, be sure to pass the
downstream pressure measurement tapping
behind the heat shield.
WARNING
Make sure that the grease does not flow beyond
the threading.
19B-35
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
106672
Fit the rigid part of the downstream pressure measu-
rement tapping then position it so that it is parallel (
±3˚ ) to the exhaust pipe longitudinal axis. WARNING
Make sure, after tightening the pressure measu-
Tighten to torque the downstream pressure
rement tappings, that this pressure measurement
measurement tapping on its adapter ( 21 Nm )
tapping has no low points (siphon) susceptible to
bolted to the exhaust pipe.
water accumulation.
Proceed in the reverse order to removal.
To do this:
Tighten to torque:
- check that the rigid sections of the pressure
- the connection clip bolt between the silencer pipes are correctly positioned in relation to the
and the particle filter ( 25 Nm ) , exhaust pipe longitudinal axis,
- the exhaust flange nuts between the connec- - at the retaining clips, manipulate the pressure
tion hose and the catalytic pre-converter ( 21 measurement tappings on the heat shield (turn
Nm ) , the tapping in the clip so as to avoid the low
points).
- the nuts mounting the rubber mounting bush
support onto the sub-frame ( 25 Nm ) .
WARNING
Any damaged heat shields must be replaced.
19B-36
EXHAUST
Particle filter: Removal - Refitting 19B
F9Q, and 804
WARNING
Connect the battery, starting with the positive ter-
minal. carry out the necessary programming (see
80A, Battery: Removal - Refitting ).
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.
Note:
This command is only carried out after replacing
the particle filter.
19B-37
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm
upstream pressure 21 Nm
measurement tapping
on its union bolted onto
the exhaust pipe
107038
(A) Particle filter pressure sensor.
(B) Upstream pressure measurement tapping end
piece.
(C) Downstream pressure measurement tapping
end piece.
REMOVAL
Remove the particle filter (see 19B, Exhaust, Parti-
cle filter: Removal and Refitting ).
19B-38
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
F9Q, and 804
3
2 4
6
106670 111885
Remove the upstream pressure pipe (1) from its in- Remove:
termediary adapter (2) bolted to the exhaust pipe.
- the mounting nut (3) from the particle filter pressure
sensor mounting (4) ,
WARNING - the particle filter pressure sensor:
When removing the pressure measurement tap-
ping (1) from its adapter it is essential to open
the adapter (2) with a lock wrench. WARNING
Never separate the pressure measurement tap-
pings (5) from the particle filter pressure sensor
WARNING (6) ; replace the « sensor - pipes - end pieces »
The pressure measurement circuit must never be assembly if necessary, this is supplied assem-
opened except at the level of the adapters on the bled by the Parts Department (see Particle
exhaust pipe. filter : repair precautions, Safety instructions
).
19B-39
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
F9Q, and 804
REFITTING
106673
WARNING
Each exhaust pipe intermediary adapter (7) that
is removed must be replaced.
WARNING
Make sure that the grease does not flow beyond
the threading.
19B-40
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
F9Q, and 804
106672
Fit the rigid part of the upstream pressure measure- be stored by the injection computer before restarting
ment tapping then position it so that it is parallel ( ± the engine.
3˚ ) with the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measure-
ment tapping on its union bolted onto the ex-
haust pipe ( 21 Nm ) .
Refit the particle filter (see 19B, Exhaust, Particle
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-41
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
F9Q, and 804
Tightening torquesm
Equipment required
adapter, if it has been 44 Nm
diagnostic tool replaced
107038
(A) Upstream particle filter temperature sensor I - (A) UPSTREAM PARTICLE FILTER
TEMPERATURE SENSOR
(B) Downstream particle filter temperature sensor
1 - Removal
Remove the particle filter (see 19B, Exhaust, Parti-
cle filter: Removal - Refitting ).
19B-42
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
F9Q, and 804
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
Refit the particle filter (see 19B, Exhaust, Particle
filter: Removal - Refitting ).
1 - Removal
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove the engine undertray.
106671
WARNING
When the upstream particle filter temperature
sensor (1) is removed, the adapter must be held
(2) with a lock-wrench.
2 - Refitting
WARNING
111882
Always replace any adapter (2) that has been
removed from the exhaust pipe. Disconnect the downstream particle filter temperatu-
re sensor offset connector (3) .
Tighten to torque the adapter, if it has been repla-
ced ( 44 Nm ) .
Coat the threads on the upstream particle filter tem-
perature sensor with ANTI-SEIZE high temperature
grease.
WARNING
Make sure that the grease does not flow beyond
the threading.
Check that:
- that there is no contact with the wiring harness,
19B-43
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
F9Q, and 804
2 - Refitting
WARNING
Always replace any adapter (3) that has been
removed from the exhaust pipe.
WARNING
Make sure that the grease does not flow beyond
the threading.
Unpick the downstream particle filter temperature - there is no contact with the wiring harness,
sensor offset connector (3) from its mounting. - the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal
WARNING
Carry out the necessary programming (see sec-
tion 80A, Battery: Removing - Refitting ).
106671
WARNING
When the downstream particle filter temperature
sensor (4) is removed, the adapter must be held
(5) with a lock wrench.
19B-44
EXHAUST
Connecting hose: Removal - Refitting 19B
F9Q, and 804
- the upstream pressure measurement tapping at its
adapter on the exhaust pipe (see 19B, Exhaust,
Tightening torquesm Particle filter pressure sensor: Removal - Refit-
ting ).
exhaust flange nuts 21 Nm
Tighten to torque the exhaust flange nuts ( 21 Nm
) between the connection hose and the particle filter.
REMOVAL Refit the particle filter (see 19B, Exhaust, Particle
filter: Removal - Refitting ).
Remove:
Remove:
REFITTING
WARNING
Always replace:
- the flange seal between the connection hose
and the catalytic pre-converter,
- the flange seal between the connection hose
and particle filter,
WARNING
Refit:
19B-45
EXHAUST
Particle filter: Cleaning 19B
F9Q, and 804
PROCEDURE FOR FORCED REGENERATION OF Follow this procedure:
THE PARTICLE FILTER USING THE CLIP
- run command SC017 or VP040 ,
DIAGNOSTIC TOOL
- during regeneration, the engine speed will be held
at 1500 rpm , and the engine noise changes (de-
Command SC017: REGENERATION OF THE
layed injection),
PARTICLE FILTER
- the exhaust fumes rise in temperature and burn the
soot retained in the particle filter,
Note: - the command lasts for approximately 30 minutes ,
Only run this command under the following con- - when the engine speed returns to idle speed the
ditions: command has terminated,
- fault DF308 Particle filter clogged , or DF312 - check the quantity of soot contained in the particle
Number of regenerations exceeded , or filter PR383 < 10 .
DF383 Particle filter regeneration impossible
present,
Note:
- soot weight in the particle filter greater than
45 g . Be prepared for strong odours and thick smoke
during particle filter regeneration.
Note:
If necessary, regeneration can be stopped by
pressing the engine start button twice in succes-
sion.
19B-46
EXHAUST
Particle filter: Cleaning 19B
F9Q
For the particle filter forced regeneration procedure,
Special tooling required see MR 366 or MR 372 Fault finding, 13B, Diesel
injection, Fault finding, Interpretation of com-
Mot. 1329 76 mm diameter oil fil-
mands, Particle filter regeneration .
ter removing tool
WARNING
To prevent engine racing, check the engine oil
level using the dipstick before running the forced
regeneration command.
The engine oil level must be between the
« MIN » and « MAX » marks on the dipstick.
19B-47
EXHAUST
Particle filter: Cleaning 19B
F9Q
Rubber-lipped seal For the connector pipe and rear silencer rubber
mounting bushes, tighten to torque:
- the mounting bolt of the rubber mounting bushes
on the body ( 21 Nm ) ,
- the mounting bolts of the rubber mounting bush
on the connector pipe ( 8 Nm ) ,
- the mounting bolts of the rubber mounting bush
on the rear silencer ( 8 Nm ) ,
113765
Refit the drain plug with its new seal (no fitting direc-
tion).
Tighten to torque the engine drain plug ( 20 Nm ) .
Clean any traces of the drained oil from the sump.
Refit the engine undertray.
Refill the engine oil.
Refit the filler plug.
Wait for 10 minutes .
Check the oil level using the dipstick.
Top up if necessary.
Note:
The engine oil level must be between the
« MIN » and « MAX » marks on the dipstick.
19B-48
RESERVOIR
Draining the fuel tank 19C
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
DRAINING THE FUEL TANK
Special tooling required
Mot. 1311-08 Union for measuring K4J, and 730 or 732 – F4R, and 770 or 771 or 776
fuel pressure
WARNING
2
During this operation, it is essential to:
- refrain from smoking or bringing red hot objects 3
close to the work area,
- guard against petrol splashes caused by the resi-
dual pressure in the pipes,
- protect sensitive areas from fuel outflow.
WARNING
The ignition must be switched off during this opera-
tion. 1
101496
Disconnect the fuel inlet union (1) .
Position and fit a (3) « T » (Mot. 1311-08) union.
Fit a pipe (2) long enough to carry the fuel into a con-
tainer to the « T » -union outlet.
19C-1
RESERVOIR
Draining the fuel tank 19C
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
102502
Place the electrical connector (4) to one side without
101803
disconnecting it.
102503
Disconnect the brown connector (6) from the Protec-
tion and Switching Unit.
19C-2
RESERVOIR
Draining the fuel tank 19C
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
12 1
102501
Connect terminal (5) of the brown connector to a +
battery supply to operate the fuel pump.
Let the petrol flow out until it comes intermittently.
Disconnect the + battery supply from terminal (5) .
Note:
It is also possible to use the pneumatic siphoning
Pump tool for draining the fuel tank (see catalo-
gue entitled Equipment) , to be adapted on the
union at « T » (Mot. 1311-08) .
19C-3
RESERVOIR
Draining the fuel tank 19C
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
Equipment required
IMPORTANT
99641
Disconnect the battery, starting with the negative 2
terminal.
Note:
Since diesel vehicles are not fitted with an electri-
cal fuel pump, the petrol or diesel tank drain
pneumatic siphoning pump tool must be used
to drain the tank. 102461
Lift up the cushion from the rear bench seat (see Remove:
Workshop repair Manual 365 Bodywork, 76A,
- the closure panel mounting bolts (1) ,
Rear seat mountings and runners, Complete
seat base ). - the closure panel,
- the inspection flap blanking cover (2) .
19C-4
RESERVOIR
Draining the fuel tank 19C
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
4 3
102462
Disconnect:
- the fuel tank sender connector (3) ,
- the body height sensor connector (4) (if fitted),
- union (5) .
Make preparations for the fuel outflow.
Connect the rubber suction pipe of the petrol or die-
sel tank drain pneumatic siphoning pump to the
diesel fuel supply quick-release union, and the si-
phoning pump's backflow pipe to the container (5) .
Run the petrol or diesel tank drain pneumatic si-
phoning pump .
Let the fuel flow out until it comes intermittently.
Drain the tank.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19C-5
RESERVOIR
Fuel tank: Description 19C
F4R or K4J or K4M
2 11
2
8
9
10
2
12
13 7
5
5
2 6
102487
No. Description
1 Tank
2 Mounting holes
3 Filler neck
11 Overfill prevention valve and leak prevention valve in case of vehicle roll-over
19C-6
RESERVOIR
Fuel tank: Description 19C
F4R or K4J or K4M
3
4
2 10
13036
No. Description
19C-7
RESERVOIR
Fuel tank: Description 19C
F4R or K4J or K4M
No. Description
4 Restriction 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.
4 - Filler neck
The filler neck for unleaded petrol has the following:
- a smaller diameter filling opening (restriction valve).
Leaded petrol damages the toxic fume filter system:
catalytic converter and oxygen sensor,
19C-8
RESERVOIR
Fuel tank: Description 19C
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
8 1
2
2
4
9 2
10
5
2 6
110881
No. Description
1 Tank
2 Mounting holes
3 Filler neck
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
19C-9
RESERVOIR
Fuel tank: Description 19C
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
2
8
13036-1
No. Description
19C-10
RESERVOIR
Fuel tank: Description 19C
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
No. Description
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
2 - Filler neck
The filler neck for unleaded fuel has a leaktight cap.
19C-11
RESERVOIR
Fuel tank: Removal - Refitting 19C
Equipment required F4R or K4J or K4M
component jack Remove the petrol vapour absorber (see 14A, Anti-
pollution, Petrol vapour absorber ).
Unclip the petrol vapour absorber pipes.
Tightening torquesm
Disconnect the connectors on the « Pump-Sender-
wheel bolt 110 Nm Filter » assembly (see 19C, Fuel tank, Pump-Sen-
der-Filter ).
fuel tank mounting 21 Nm
IMPORTANT
1
During this operation, be sure to:
- refrain from smoking or bringing red-hot objects
near the working area,
- watch out for fuel splashes when disconnecting
the union,
- protect sensitive areas from fuel outflow.
2
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining 3
the fuel tank ).
Remove the « pump-sender-filter » assembly (see
19C, Fuel tank, Pump-sender-filter ) for petrol en-
102465
gines or the sender (see 19C, Fuel tank, Sender )
for diesel engines. Remove:
Put the vehicle on a two-post lift. - the mounting bolts (1) from the fuel tank and the
heat shield,
Disconnect the battery, starting with the negative
terminal. - the heat shield mounting clips (2) ,
19C-12
RESERVOIR
Fuel tank: Removal - Refitting 19C
102467 102466
Remove mounting clips (4) from the brake and fuel Position the component jack under the tank.
pipes. Remove the fuel tank mounting bolts (6) .
Unclip:
Lower the fuel tank.
- the fuel pipe unions at the catalytic converter,
- the clips from the fuel pipes.
102459
5
Remove the tank by turning it around the exhaust pi-
102468 pe.
Remove fuel tank filler neck hose connection clips Take care not to damage the brake pipes or the par-
(5) . king brake cable.
Move the hoses to one side.
19C-13
RESERVOIR
Fuel tank: Removal - Refitting 19C
REFITTING
Reshape the heat shield.
Take care not to bring the heat shield into contact
with the fuel tank.
The tank hose securing clips must always be repla-
ced.
Proceed in the reverse order to removal.
Tighten to torque:
- the wheel bolt ( 110 Nm ) ,
- the fuel tank mounting ( 21 Nm ) .
Check that the fuel pipe unions click into place.
Refit the « pump-sender-filter » assembly (see 19C,
Fuel tank, Pump-sender-filter ) for petrol engines
or the sender (see 19C, Fuel tank, Sender ) for die-
sel engines.
Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19C-14
RESERVOIR
Filler neck: Removal - Refitting 19C
Tightening torquesm
3
IMPORTANT
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining 102469
the fuel tank ). Remove the filler neck mounting bolts (3) .
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
4
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch liner.
104559
Remove:
102468
REFITTING
Disconnect the anti-backflow pipe (1) . Always replace the clips with new ones.
Remove filler pipe clips (2) . Proceed in the reverse order to removal.
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
19C-15
RESERVOIR
Filler neck: Removal - Refitting 19C
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
19C-16
RESERVOIR
Sender unit: Removal - Refitting 19C
F9Q or K9K or M9R
Tightening torquesm
IMPORTANT
Disconnect the battery, starting with the negative - the blanking cover (2) on the inspection flap.
terminal.
Lift up the rear bench seat base (see MR 365 Bo-
dywork, 76A, Rear seat runners and frames,
Complete seat base ).
Remove the carpet retaining clip.
Move the carpet to one side.
19C-17
RESERVOIR
Sender unit: Removal - Refitting 19C
F9Q or K9K or M9R
104546 104547
Disconnect: Remove the nut from the sender using tool (Mot.
1397) (5) .
- electrical connectors (3) ,
Remove the sender unit, being careful with the float.
- quick-release union(s) (4) .
Prepare for fuel outflow.
WARNING
Fit the correct blanking plugs into the unions (see
Refit the sender nut as soon as the sender has
MR 364 Mégane, 13B, Injection: Cleanliness gui-
been removed to prevent any deformation of the
delines ).
fuel tank.
19C-18
RESERVOIR
Sender unit: Removal - Refitting 19C
F9Q or K9K or M9R
REFITTING
102470
Replace the O-ring seal.
Refit the sender unit by aligning mark (6) on the sen-
der with mark (7) on the tank.
Position nut (9) .
Tighten the nut (9) until mark (8) on the nut is aligned
with mark (7) on the tank and mark (6) on the sen-
der.
Proceed in the reverse order to removal.
Connect the battery starting with the positive termi-
nal (see MR 364 Mégane, 80A, Battery: Removal -
Refitting ).
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
19C-19
RESERVOIR
Pump-sender unit-filter: Removal - Refitting 19C
K4M – F4R – K4J
Tightening torquesm
2
IMPORTANT
104546
Disconnect:
19C-20
RESERVOIR
Pump-sender unit-filter: Removal - Refitting 19C
K4M – F4R – K4J
REFITTING
104547
Remove the nut from the pump/sender/filter assem- 102470
bly using tool (Mot. 1397) (5) . Replace the O-ring seal.
Remove the pump/sender/filter assembly, being ca- Refit the pump/sender/filter assembly, aligning mark
reful not to damage the float. (6) on the pump/sender/filter assembly with mark (7)
on the tank.
WARNING Position the nut (9) .
Refit the pump/sender/filter assembly nut as Tighten the nut (9) until the mark (8) on the nut is ali-
soon as the pump/sender/filter assembly has gned with mark (7) on the tank and mark (6) on the
been removed to prevent any deformation of the pump/sender/filter assembly.
fuel tank.
Proceed in the reverse order to removal.
Connect the battery starting with the positive termi-
nal (see MR 364 Mechanical systems, 80A, Batte-
ry: Removal - Refitting ).
Tighten to torque the battery cover mounting bolts
( 4 Nm ) .
19C-21
RESERVOIR
Petrol filter: General information 19C
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
102299
The fuel filter is located in the fuel tank; it is built into
the « pump-sender-filter » assembly and cannot be re-
moved.
WARNING
The « pump-sender-filter » assembly must be repla-
ced if one of the components is faulty.
19C-22
RESERVOIR
Fuel level sensor: Checking 19C
Checking the sender unit
Spare 290 40
MEASURING HEIGHT H
Place the removed sender on a flat surface.
H is the height measured between the float pin and
the working plane.
Note:
All these values are given as a guide.
19C-23
ENGINE MOUNTING
Suspended engine mounting 19D
K4J, and 730 or 732 – K4M, and 760, and JR5
6
4 5
1 3
103235
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
19D-1
ENGINE MOUNTING
Suspended engine mounting 19D
K9K, and 722 or 728
10
9
4
8
7
6
1 3
7
2
103236
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 21
(8) 62
(9) 180
(10) 62
19D-2
ENGINE MOUNTING
Suspended engine mounting 19D
F9Q, and 800 or 804 or 808
6 12
7
11
10
5
9
3 4
103237
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(10) 62
(11) 180
(12) 62
19D-3
ENGINE MOUNTING
Suspended engine mounting 19D
K4M, and 761
4 6
9
8
3
1
8
5
2
103274
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
(9) 62
19D-4
ENGINE MOUNTING
Suspended engine mounting 19D
F4R, and 770 or 771 or 776
12
7 6
11
9 10
3
9
4
8
2
1
103275
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-5
ENGINE MOUNTING
Suspended engine mounting 19D
F4R, and 770 or 771 or 776
7 6 12
11
9
10
9
5
3
13 8
4
103244
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-6
ENGINE MOUNTING
Suspended engine mounting 19D
K9K, and 729, and DP0
7
9
8
4
5 6
7
3
1
110743
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 62
(8) 62
(9) 62
19D-7
ENGINE MOUNTING
Suspended engine mounting 19D
K9K, and 732
113926
Tightening torques (in Nm)
(1) 62
(2) 62
(3) 105
(4) 115
(5) 62
(6) 180
(7) 105
(8) 62
(9) 105
(10) 62
(11) 62
19D-8
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
K9K, and 732
113926
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(3) Bolt mounting the lower engine tie-bar onto its support 62
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 62
(9) Bolt mounting the left-hand suspended mounting support on the body 62
(11) Left-hand rubber pad mounting bolts on the body mounting 105
19D-9
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
M9R, and 700
114630
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 105
(9) Bolt mounting the left-hand suspended mounting support on the body 62
19D-10
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
B84 or C84, and F4R, and 774
106075
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 62
(10) 21
(11) 105
(12) 180
(13) 62
19D-11
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
Tightening torquesm
left-hand suspended 62 Nm
mounting bolts on the
gearbox
left-hand suspended 62 Nm
mounting bolts on the
body
I - REMOVAL PREPARATION OPERATION - the wiring harness from the battery tray.
Place the vehicle on a two-post lift (see 02A, Lifting
Remove:
equipment, Underbody lift ).
Remove: - the battery tray mounting bolts (2) ,
- the engine undertray,
- the battery tray with the computer and its support.
- the scuttle panel grille (see MR365 Bodywork,
55A, Exterior protection, Scuttle panel grille ),
- the battery (see 80A, Battery: Removal - Refit-
ting ).
102450
19D-12
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
II - OPERATION FOR REMOVAL OF PART Tighten to torque the left-hand suspended moun-
CONCERNED ting bolts on the body ( 62 Nm ) .
Refit the left-hand rubber pad.
Refit the left-hand rubber pad mounting nut onto the
gearbox mounting and the left-hand rubber pad
mounting bolts onto the body mounting.
Tighten to torque:
- the left-hand rubber pad mounting bolts on the
body mounting ( 105 Nm ) ,
- the left-hand rubber pad mounting nut on the
gearbox mounting ( 62 Nm ) .
II - FINAL OPERATION
Remove the (Mot. 1453) .
Refit:
- the battery tray with the engine management com-
puter and its support,
- the battery tray mounting bolts.
112655
Clip:
Remove:
- the battery negative terminal wiring harness,
- the left-hand rubber pad mounting nut (3) on the - the wiring harness onto the battery tray.
gearbox mounting,
Connect the engine management computer connec-
- the left-hand rubber pad mounting bolts (4) on the tors.
body mounting,
Refit:
- the rubber pad,
- the scuttle panel grille (see MR 365, 55A, Exterior
- the bolts (5) mounting the left-hand suspended protection, Scuttle panel grille ),
mounting on the body,
- the engine undertray,
- the left-hand suspended mounting on the body,
Connect the battery (see 80A, Battery: Removal -
- the bolts (6) mounting the left-hand suspended Refitting ).
mounting on the gearbox.
- the gearbox left-hand suspended mounting.
REFITTING
19D-13
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
Tightening torquesm
REMOVAL
113927
Remove:
19D-14
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
K9K, and 732
- the bolts (4) mounting the suspended mounting on
the engine,
- the suspended mounting.
REFITTING
II - FINAL OPERATION
Remove the (Mot. 1453)
Refit the scuttle panel grille (see MR 365, Bo-
dywork, 55A, Exterior protection, Scuttle panel
grille ).
Connect the battery (see 80A, Battery: Removal -
Refitting).
19D-15
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting 19D
K9K, and 732
REFITTING
Tightening torquesm
I - REFITTING PREPARATION OPERATION
bolt mounting the 180 Nm Refit:
engine tie-bar on its
support - the bolt mounting the engine tie-bar on its support
bolt mounting the 105 Nm - the bolt mounting the engine tie-bar on the sub-fra-
engine tie-bar on the me
sub-frame Tighten to torque:
- the bolt mounting the engine tie-bar on its sup-
port ( 180 Nm ) ,
REMOVAL
- the bolt mounting the engine tie-bar on the sub-
frame ( 105 Nm ) .
I - REMOVAL PREPARATION OPERATION
II - FINAL OPERATION
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ). Refit the engine undertray.
Disconnect the battery (see 80A, Battery: Removal Connect the battery (see 80A, Battery: Removal -
Refitting ).
- Refitting ).
112653
Remove:
19D-16
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting 19D
M9R, and 700
Tightening torquesm
REMOVAL
II - FINAL OPERATION
Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -
Refitting ).
114650
Remove:
19D-17