MR423THALIA1

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

X35
JANUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

19A COOLING
19B EXHAUST
19C TANK
19D ENGINE MOUNTING
X35
JANUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

SYMBOL - THALIA - Section 1ContentsPage
SYMBOL - THALIA - Section 1
Contents
Page
ENGINE AND CYLINDER BLOCK

10A 11A TOP AND FRONT OF ENGINE
ASSEMBLY
Engine/gearbox assembly: Accessories belt: Removal -
Removal - Refitting 10A-1 Refitting 11A-1
Engine oil: Draining - Crankshaft accessories

Refilling 10A-49 pulley: Removal - Refitting 11A-15
Oil filter: Removal - Refitting 10A-57 Timing belt: Removal -

Refitting 11A-28
Oil filter unit: Removal -
Refitting Rocker cover: Removal -
Refitting 11A-61
Crankshaft seal at timing end
Removal - Refitting 10A-65 Cylinder head: Removal -
Refitting 11A-76
Crankshaft seal at gearbox
end : Removal - Refitting 10A-74 Camshaft: Removal -
Refitting 11A-105
Sump: Removal - Refitting 10A-83
Camshaft seal at timing end:
Conrod bearing shell: Removal - Refitting 11A-120
Removal - Refitting 10A-102
Oil decanter: Removal -
Exchanger: Removal - Refitting 11A-140
Refitting 10A-110
Oil pressure sensor:

12A FUEL MIXTURE
Oil level sensor: Removal -
Refitting 10A-126
Air filter: Removal - Refitting 12A-1
Oil pump: Removal -
Air filter unit: Removal -
Refitting 10A-127
Refitting 12A-5
Oil pressure: Check 10A-136
Air resonator: Removal -
Multifunction support: Refitting 12A-12
Air flowmeter: Removal -
Flywheel: Removal - Refitting 10A-155 Refitting 12A-13
Drive plate: Removal - Throttle valve: Removal -

Refitting 10A-164 Refitting 12A-15
Contents
12A FUEL MIXTURE 13B DIESEL INJECTION
Throttle valve: Cleaning 12A-22 High pressure pump:

Removal - Refitting 13B-18
Inlet manifold: Removal -
Refitting 12A-24 Fuel flow actuator: Removal -
Refitting 13B-25
Injector holder shim:
Removal - Refitting 12A-42 Venturi: Removal - Refitting 13B-27
Exhaust manifold: Removal - High pressure pipe:

Refitting 12A-46 Checking 13B-29
High-pressure pipe between

the pump and rail: Removal -
Refitting 13B-31
12B TURBOCHARGING
High-pressure pipe between
Turbocharger: Removal - the rail and injector: Removal
Refitting 12B-1 - Refitting 13B-35
Turbocharger oil pipe: Injector rail: Removal -

Removal - Refitting 12B-7 Refitting 13B-39
Intercooler: Removal - Rail pressure sensor:

Refitting 12B-12 Removal - Refitting 13B-43
Fuel temperature sensor:

13A FUEL SUPPLY Leak flow from injectors:

Check 13B-46
Fuel circuit: Operating Diesel injector: Removal -
diagram 13A-1 Refitting 13B-48
Fuel filter : Removal - Accelerometer: Removal -
Refitting 13A-2 Refitting 13B-51
Fuel pressure: check 13A-6
Fuel flow: check 13A-10

13C PREHEATING
Pre/postheating unit:
13B DIESEL INJECTION Removal - Refitting 13C-1
Diesel injection: Precautions Heater plugs Removal -

for repair 13B-1 Refitting 13C-2
Diesel injection: List and

location of components 13B-8
Diesel injection computer: 14A ANTIPOLLUTION

Fuel vapour recirculation
Camshaft position sensor: circuit: Operating diagram 14A-1
Fuel vapour canister:
Crankshaft position sensor: Removal - Refitting 14A-2
Contents
14A ANTIPOLLUTION 17B PETROL INJECTION
Exhaust gas recirculation Pinking sensor: Removal -

solenoid valve: Removal - Refitting 17B-24
Refitting 14A-4
Crankshaft position sensor:
Intercooler: Removal - Removal - Refitting 17B-27
Refitting 14A-9
Injector rail - Injectors:
Exhaust gas recirculation Removal - Refitting 17B-32
mounting: Removal -
Refitting 14A-11
Exhaust gas recirculation

assembly: Removal - 19A COOLING
Refitting 14A-12
Engine cooling circuit:
Exhaust gas recirculation Specifications 19A-1
rigid pipe: Removal -
Refitting 14A-19 Engine cooling circuit: check 19A-2
Engine cooling circuit: List

and location of components 19A-4
16A STARTING - CHARGING Cooling circuit: Draining -

Refilling 19A-7
Alternator: Removal - Cooling radiator: Removal -
Refitting 16A-1 Refitting 19A-11
Starter: Removal - Refitting 16A-12 Water pump: Removal -
Alternator pulley: Removal - Refitting 19A-26
Refitting 16A-23 Thermostat: Removal -
Refitting 19A-39
Plenum chamber: Removal -

17A IGNITION Refitting 19A-45
Water pump inlet pipe:

Coils Removal - Refitting 17A-1 Removal - Refitting 19A-55
Spark plugs: Removal - Engine cooling fan assembly:
Refitting 17A-7 Removal - Refitting 19A-61
Thermoplunger unit:
17B PETROL INJECTION Expansion bottle: Removal -
Refitting 19A-72
Fuel injection: List and
location of components 17B-1 Coolant temperature sensor:
Oxygen sensors: Removal -
Refitting 17B-12
Throttle body potentiometer:

Petrol injection computer:

Contents
19B EXHAUST
Exhaust: Parts and

consumables for the repair
work 19B-1
Exhaust: Precautions for

repair 19B-5
Catalytic converter: Removal

- Refitting 19B-9
Expansion chamber:
Connector pipe: Removal -

Refitting 19B-27
Silencer: Removal - Refitting 19B-29
19C TANK
Fuel tank: Draining 19C-1
Fuel tank: Removal -

Refitting 19C-6
Filler neck: Removal -

Refitting 19C-11
Fuel level sensor module:

Removal - Refitting 19C-13
Additional fuel circuit petrol

pump: Removal - Refitting 19C-17
Additional fuel circuit

reservoir: Removal - Refitting 19C-19
19D ENGINE MOUNTING
Left-hand suspended engine

mounting: Removal -
Refitting 19D-1
Right-hand suspended
engine mounting: Removal -
Refitting 19D-16
Lower engine tie-bar:

Removal - Refitting 19D-26
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine/gearbox assembly: Removal - Refitting 10A
D4F
- the petrol injection computer (see 17B, Petrol in-
Essential special tooling jection, Petrol injection computer: Removal -
Refitting, page 17B-21) ,
Mot. 1448 Long nose pliers for hose
clips. - the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
Mot. 1390 Support for removing/refitting
the engine - gearbox assem- - the air filter unit (see 12A, Fuel mixture, Air filter
bly. unit: Removal - Refitting, page 12A-5) ,
- the front wheels (see Wheel: Removal - Refitting)
Essential equipment (35A, Wheels and tyres),
- the front wheel arch liners (see Front wheel arch
refrigerant charging station
liner: Removal - Refitting) (55A, Exterior protec-
tion),
Tightening torquesm - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
earth cable bolts on the 21 N.m
manual gearbox a Attach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
earth cable bolts on the 8 N.m a Remove:
vehicle body
- the engine tie-bar (see 19D, Engine mounting,
connecting pipe bracket 8 N.m Lower engine tie-bar: Removal - Refitting, page
bolt for the 19D-26) ,
« compressor - interme-
- the front left-hand wheel driveshaft (see Front left-
diate pipe »
hand wheel driveshaft: Removal - Refitting)
connecting pipe bracket 8 N.m (29A, Driveshafts),
bolt for the - the front right-hand wheel driveshaft (see Front ri-
« compressor - ght-hand wheel driveshaft: Removal - Refitting)
condenser » (29A, Driveshafts),
- the front axle subframe (see Front axle sub-fra-
REMOVAL me: Removal - Refitting) (31A, Front axle compo-
nents),
- the catalytic converter (see 19B, Exhaust, Cataly-
I - REMOVAL PREPARATION OPERATION
tic converter: Removal - Refitting, page 19B-9) .
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the engine undertray bolts,
- the engine undertray.
a Drain:
- the gearbox (see Manual gearbox oil: Draining -
Refilling) (21A, Manual gearbox),
- the cooling system (see 19A, Cooling, Cooling
circuit: Draining - Refilling, page 19A-7) ,
- the refrigerant circuit using a refrigerant charging
station (see Coolant circuit Draining - Refilling)
(62A, Air conditioning).
a Remove:
- the battery (see Battery : Removal - Refitting)
(80A, Battery),
10A-1
D4F
132667 133000
a Remove the gaiter (1) from the gearbox control rod. a Undo the power-assisted steering high pressure
pipe nut (2) .
a Remove the nut from the gearbox control rod.
a Remove the nut (3) from the power-assisted stee-
a Remove the gearbox control rod.
ring high pressure pipe bracket.
a Disconnect the connector (4) from the pressure sen-
sor of the power-assisted steering high pressure pi-
pe.
a Remove the power-assisted steering high pressure
pipe.
a Remove the seal from the power-assisted steering
high pressure pipe.
a Fit blanking plugs on:
- the power-assisted steering high pressure pipe,
- the power-assisted steering pump.
10A-2
D4F
132656 132679
a Remove from the compressor: a Use the tool (Mot. 1448) to separate the clip (7) from
the cooling radiator top hose on the coolant outlet
- the bolt (5 ) for the « intermediate pipe -
unit.
compressor » connecting pipe bracket,
a Disconnect the cooling radiator top hose from the
- the bolt (6) for the « compressor - condenser »
coolant outlet unit.
connecting pipe bracket.
a Disconnect from the compressor:
- the « compressor - intermediate pipe » connecting
pipe,
- the « compressor - condenser » connecting pipe.
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
a Fit blanking plugs.
132679
a Disconnect the quick-release unions (8) from the
heater matrix.
10A-3
D4F
132818 132664
a Remove the clip (9) on the coolant pump inlet pipe a Disconnect:
hose using the tool (Mot. 1448).
- the brake servo pipe union (10) on the inlet mani-
a Disconnect the hose from the coolant pump inlet pi- fold,
pe.
- the fuel vapour rebreather pipe union (11) on the
inlet manifold,
- the fuel supply pipe union from the injector rail.
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.

- the fuel supply pipe to the injector rail,
- the injector rail.
10A-4
D4F
133008 133001
a Move the brake fluid level sensor wiring (12) away a Unclip the fuel vapour absorber wiring (17) from the
from the power-assisted steering pump reservoir. vehicle body.
a Unclip the power-assisted steering pump reservoir a Remove the fuel vapour absorber wiring.
(13) by:
- pressing on the lugs (14) ,
- pushing upwards (15) .
132515
a Disconnect the fuel vapour absorber connector (16)
.
10A-5
D4F
133003 133004
a Disconnect the connector (19) from the accelerator

pedal cable potentiometer.
a Unclip the potentiometer connector (20) from the

support of the accelerator pedal cable potentiometer
connector.
a Move the potentiometer wiring away from the sup-

port of the accelerator pedal cable potentiometer
connector.
133002
a Remove the earth wire bolts (18) on the vehicle bo-
dy.
132996
a Disconnect the connector (21) from the fan of the

engine cooling fan assembly.
10A-6
D4F
133005 133006
a Disconnect: a Remove the engine compartment connection unit
relays.
- the engine cooling fan assembly resistor connector
(22) , a Disconnect the engine wiring from the engine inter-
connection unit.
- the connector (23) from the pressure sensor of the
air conditioning circuit.
132985
133007 a Unclip the engine wiring (25) from the left-hand sus-
pended mounting.
a Remove the engine compartment connection unit
cover (24) . a Move aside the engine wiring.
10A-7
D4F
132988 132989
a Remove the power-assisted steering pipe bracket a Unclip the clutch cable (28) from the sleeve stop.
bolts (26) .
a Remove the clutch cable (29) from the slave cylinder
a Remove the power-assisted steering pipe from the of the clutch thrust bearing.
manual gearbox.
a Move the clutch cable away from the manual gear-
box.
II - OPERATION FOR REMOVAL OF PART

CONCERNED
17765
132995
a Support the engine and gearbox assembly on (Mot.
a Remove the earth wire bolts (27) on the manual 1390).
gearbox.
a Remove the earth wires from the manual gearbox.
10A-8
D4F
132983 132659
a Remove: a Mark the position of the suspended mounting on the
body.
- the nut (30) from the suspended engine mounting
rubber pad shaft on the gearbox. a Remove:
- the nuts (31) from the suspended engine mounting - the bolt (32) from the rubber pad on the right-hand
rubber pad on the gearbox, suspended engine mounting,
- the suspended engine mounting rubber pad from - the bolts (33) of the right-hand suspended engine
the gearbox. mounting cover,
- the right-hand suspended engine mounting.
a Lift the vehicle to remove the "engine and gearbox"
assembly.
Note:
Check no component obstructs the movement of
the body around the engine - gearbox assembly.
REFITTING
I - REFITTING PREPARATION OPERATION

a For standard replacement (see Standard replace-
ment) (Technical Note 6023A, 10A, Engine and pe-
ripherals).
10A-9
D4F
a parts always to be replaced: refrigerant pipe seal a Refit:
(30,02,02,52).
- the relays of the engine compartment connection
unit,
WARNING - the cover to the engine compartment connection
Do not remove the blanking plugs from each unit.
component until the last moment. a Connect:
Also, do not remove the components from their - the fan connector of the engine cooling fan assem-
packaging until they are to be fitted to the vehi- bly,
cle.
- the engine cooling fan assembly resistor connec-
tor,
WARNING - the connector of the air conditioning circuit pressu-
In order to avoid any refrigerant leaks, do not re sensor.
damage (deform, twist, etc.) the pipe. a Fit the wiring of the accelerator pedal cable potentio-
meter in place.
a Clip the connector of the accelerator pedal cable po-
WARNING
tentiometer onto the support of the accelerator pedal
To avoid any leaks, check that the pipe surface is cable potentiometer.
sound before positioning the new seal. The sur-
face must be clean and scratch free. a Connect the connector to the accelerator pedal ca-
ble potentiometer.
a Refit the earth cable to the vehicle body.
II - REFITTING OPERATION FOR PART
CONCERNED a Torque tighten the earth cable bolts on the vehicle
body (8 N.m).
a Position the "engine and gearbox" assembly in the
body. a Fit the fuel vapour absorber wiring in place.
a Clip the fuel vapour absorber wiring onto the vehicle
a Refit the right-hand suspended engine mounting in
body.
the position marked at the time of the removal.
a Connect the connector to the fuel vapour absorber.
a Remove the (Mot. 1390).
a Fit:
III - FINAL OPERATION - the power-assisted steering pump reservoir,

- the brake fluid level sensor wiring of the power-as-
a Fit the clutch cable.
sisted steering pump reservoir.
a Refit the clutch cable to the slave cylinder of the a Remove the blanking plugs from:
clutch thrust bearing.
- the fuel supply pipe on the injector rail,
a Clip the clutch cable onto the sleeve stop.
a Refit the earth wires to the manual gearbox.
a Disconnect:
a Tighten the earth cable bolts on the manual gear- - the fuel supply pipe union on the injector rail,
box (21 N.m).
- the petrol vapour rebreather pipe union on the inta-
a Fit: ke distributor,
- the power-assisted steering pipe to the manual - the brake servo pipe union on the intake distributor.
gearbox,
a Connect the coolant pump inlet pipe hose to the coo-
- the engine wiring. lant pump inlet pipe.
a Clip the engine wiring onto the left-hand suspended a Using the tool (Mot. 1448), fit the coolant pump inlet
engine mounting. pipe hose clip onto the coolant pump inlet pipe.
a Connect:
a Connect the engine wiring to the engine intercon-
nection unit. - the quick-release unions of the heater matrix,
10A-10
D4F
- the cooling radiator top hose to the coolant outlet - the front left-hand wheel driveshaft (see Front left-
unit. hand wheel driveshaft: Removal - Refitting)
a Use the tool (Mot. 1448) to fit the clip of the cooling (29A, Driveshafts),
radiator top hose onto the coolant outlet unit.
a Remove the blanking plugs from the air conditioning Lower engine tie-bar: Removal - Refitting, page
circuit components. 19D-26) .
a Lubricate the new seals with air conditioning oil (see
Air conditioning: Parts and consumables for the a Detach the « engine cooling radiator - condenser »
repair work) (62A, Air conditioning) to make fitting assembly from the front upper cross member.
easier.
a Refit:
a Fit new seals to:
- the front bumper (see Front bumper: Removal -
pipe, Refitting) (55A, Exterior protection),
- the « compressor - condenser » connecting pipe. - the front wheel arch liners (see Front wheel arch
a Connect the following to the compressor: liner: Removal - Refitting) (55A, Exterior protec-
tion),
pipe, - the front wheels (see Wheel: Removal - Refitting)
- the « compressor - condenser » connecting pipe. (35A, Wheels and tyres),
a Tighten to torque: - the air filter unit (see 12A, Fuel mixture, Air filter
- the connecting pipe bracket bolt for the unit: Removal - Refitting, page 12A-5) ,
« compressor - intermediate pipe » (8 N.m),
- the battery tray (see Battery tray: Removal - Re-
- the connecting pipe bracket bolt for the fitting) (80A, Battery),
« compressor - condenser » (8 N.m).
a Remove the blanking plugs: - the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
- from the power-assisted steering high pressure pi-
pe,
- from the power-assisted steering pump. - the battery (see Battery : Removal - Refitting)
(80A, Battery).
a Refit the seal on the power-assisted steering high
pressure pipe. a Perform the following operations:
a Fit the power-assisted steering high pressure pipe.
- fill the gearbox (see Manual gearbox oil: Draining
a Connect the connector to the pressure sensor of the
- Refilling) (21A, Manual gearbox).
power-assisted steering high pressure pipe.
a Fit the gearbox control rod. - fill and bleed the cooling circuit (see 19A, Cooling,
Cooling circuit: Draining - Refilling, page 19A-7)
a Refit the nut for the gearbox control rod.
,
a Fit the gaiter to the gearbox control rod.
- fill the refrigerant circuit using a refrigerant char-
a Refit:
ging station (see Coolant circuit Draining - Re-
- the catalytic converter (see 19B, Exhaust, Cataly- filling) (62A, Air conditioning).
tic converter: Removal - Refitting, page 19B-9) ,
- fill the power-assisted steering circuit.
me: Removal - Refitting) (31A, Front axle compo- a Bleed the power-assisted steering circuit (see
nents),
Power-assisted steering circuit: Bleeding) (36B,
- the front right-hand wheel driveshaft (see Front ri- Power-assisted steering).
ght-hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts), a Refit the engine undertray.
10A-11
K7J or K7M
a Disconnect the air intake sleeve on the side mem-
Essential special tooling ber.
clips.
Ms. 583 Hose clamp pliers.

the engine - gearbox assem-
bly.
Essential equipment
Tightening torquesm
earth wiring bolts 21 N.m
WARNING
To prevent impurities from entering the circuit, place 133726
protective plugs on all fuel circuit components a Disconnect the connector (1) from the fuel vapour
exposed to the open air. absorber solenoid valve.
WARNING
In order to avoid any refrigerant leaks, do not
damage (deform, twist, etc.) the pipe.
IMPORTANT
Wear protective gloves during the operation.
REMOVAL

133715
IMPORTANT
To prevent the vehicle from falling, lash it to the a Unclip the wiring from the vehicle body at (2) .
vehicle lift using a strap. a Move aside the wiring.
a Remove:
- the battery (see Battery: Removal - Refitting)

(80A, Battery),
fitting) (80A, Battery).
10A-12
K7J or K7M
132834 133724
a Disconnect the fuel return pipe (3) . a Disconnect the fuel supply pipe (5) from the injector
rail.
a Insert the blanking plugs.
a Disconnect the brake servo pipe on the inlet mani-
fold.
133152
a Remove the engine wiring bolt (4) .
133723
a Unclip:
- the accelerator cable ball joint (6) on the inlet mani-
fold,
- the accelerator cable sleeve stop (7) from the lifting
ring.
a Unclip the clutch cable.
10A-13
K7J or K7M
a Remove the gearbox sleeve stop.
133030
107934
a Remove the gear selection linkage protection (9) .
a Remove the earth wiring bolts (8) .
a Remove the gear selection linkage nut.
a Move the earth wiring to one side.
a Remove: a Move aside the gear selection linkage.
- the engine undertray bolts, a Attach the gear selection linkage to the vehicle body.
- the engine undertray, a Remove:
(35A, Wheels and tyres).
Lower engine tie-bar: Removal - Refitting, page
19D-26) ,
- the engine tie-bar mounting bolts on the gearbox,
- the engine tie-bar mounting on the gearbox.
a Drain:
- the engine oil if necessary (see 10A, Engine and

cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-49) ,


circuit: Draining - Refilling, page 19A-7) .
AIR CONDITIONING or CLIMATE CONTROL
a Drain the refrigerant circuit using a refrigerant char-

ging station (see Coolant circuit Draining - Refil-
ling) (62A, Air conditioning).
10A-14
K7J or K7M
133720 133016
a Unclip the coolant outlet unit cooling hose from the a Unclip the engine wiring from the multifunction sup-
power-assisted steering pump hose at (10) . port at (12) .
a Remove the clip (11) from the cooling hose using the
tool (Mot. 1448). a Fit the tool (Ms. 583) onto the power-assisted stee-
ring pump low pressure pipe (13) .
a Disconnect the cooling hose from the coolant outlet
unit.
a Remove the expansion bottle cooling hose clips
using the tool (Mot. 1448).
a Disconnect:
- the expansion bottle cooling hoses,
- the cooling hoses from the heater matrix.
a Remove the bolt from the compressor - expansion
valve connecting pipe bracket.
a Disconnect the expansion valve - compressor con-
necting pipe.
a Remove the bolt from the compressor - condenser
connecting pipe bracket.
a Uncouple the compressor - condenser connecting
pipe.
133026
a Remove the clip (14) from the power-assisted stee-

ring pump low pressure pipe using the tool (Mot.
1448).
a Disconnect the low pressure hose from the power-

assisted steering pump.
10A-15
K7J or K7M
a Remove:
- the left-hand driveshaft (see Front left-hand
wheel driveshaft: Removal - Refitting) (29A, Dri-
veshafts),
- the right-hand driveshaft (see Front right-hand
veshafts).
133031
a Remove the mountings (16) from the exhaust flan-
ge.
a Separate the expansion chamber from the catalytic
converter.
a Remove the exhaust bracket sealing ring.
107933 a Unclip the subframe tie rod protections.

a Disconnect the connector (15) from the reversing
sensor.
10A-16
K7J or K7M
133030 133709
a Remove the nut (18) from the high pressure pipe on
the steering rack.
133033
a Remove the mountings (17) from the pipe protec-
tors.
a Slightly separate the pipe protectors.
a Remove the front axle subframe (see Front axle
sub-frame: Removal - Refitting) (31A, Front axle
components).
10A-17
K7J or K7M
133711 133710
a Unclip the engine wiring on the gearbox suspended
engine mounting pad support at (21) .
133721
a Remove the cover from the engine compartment
connection unit. 133018
a Unclip the relays and fuses (19) from the engine a Unclip the wiring from the upstream oxygen sensor
compartment connection unit. at (22) .
a Disconnect the connector (20) from the engine com- a Disconnect the upstream oxygen sensor connector.
partment connection unit.
10A-18
K7J or K7M
133529
133026
a Remove:
- the bolt (26) from the connecting pipe support on

the front panel,
- the bolt (27) from the connecting pipe support on
the side member.

CONCERNED
132837
a Disconnect the fan assembly connector (23) .
a Unclip the fan assembly wiring.
a Disconnect:
- the heating resistor connector (24) ,
- the connector (25) on the pressure switch.
a Move aside the engine wiring.
133725
a Mark the positions of the suspended engine moun-

tings on the body.
a Support the « engine - gearbox » assembly on engi-
ne marks using the (Mot. 1390).
a Remove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand suspen-
ded engine mounting: Removal - Refitting, page
19D-16) .
10A-19
K7J or K7M
a Move aside the engine wiring. II - REFITTING OPERATION FOR PART
CONCERNED
a Fit:
- the « engine and gearbox » assembly,
- the engine wiring.
a Refit:
- the suspended engine mounting rubber pad on the
gearbox,
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-16) .
III - FINAL OPERATION

a Refit:
- the bolt for the connecting pipe support on the front
panel,
133285 - the bolt for the connecting pipe support on the side
a Remove the nut (28) from the gearbox suspended member.
engine mounting pad. a Connect:
a Detach the suspended engine mounting rubber pad - the heating resistor connector,
shaft from the gearbox.
- the pressure switch connector,
a Remove:
- the motor-driven fan assembly connector.
- the nuts (29) from the suspended engine mounting
a Clip the fan assembly wiring.
rubber pad on the gearbox,
a Connect the upstream oxygen sensor connector.
- the suspended engine mounting rubber pad from
the gearbox. a Clip:
a Lift the vehicle to remove the « engine-gearbox » - the upstream oxygen sensor wiring,
assembly. - the engine wiring onto the gearbox suspended en-
gine mounting pad support.
Note: a Connect the engine compartment connection unit
connector.
Check that no component obstructs the move-
ment of the body around the «engine - a Clip on the fuses and relays of the engine compart-
gearbox » assembly. ment connection unit.
a Refit the engine compartment connection unit cover.
REFITTING a Remove the blanking plugs.
a Refit:
I - REFITTING PREPARATION OPERATION - the nut for the high pressure pipe on the steering
a Always replace the exhaust flange sealing ring. rack,
a parts always to be replaced: refrigerant pipe seal
me: Removal - Refitting) (31A, Front axle compo-
(30,02,02,52).
nents).
a For standard replacement (see Engine: Standard
a Fit the pipe protectors.
replacement) (Technical Note 6010A, 10A, Engine
and peripherals). a Refit the mountings of the pipe protectors.
10A-20
K7J or K7M
a Clip on the subframe tie rod protections. a Connect:
a Fit: - the cooling hoses to the heater matrix,
- the new ring onto the exhaust flange, - the cooling hoses to the expansion bottle.
- the expansion chamber to the catalytic converter. a Fit the cooling hose clips on the expansion bottle
a Refit the exhaust flange mountings.
a Connect the cooling hose to the coolant outlet unit.
a Connect the reversing sensor connector.
a Fit the cooling hose clip using the tool (Mot. 1448).
a Refit:
a Clip the cooling hose of the coolant outlet unit to the
- the left-hand driveshaft (see Front left-hand power-assisted steering pump hose.
a Refit:
veshafts),
- the engine tie-bar mounting support on the gear-
- the right-hand driveshaft (see Front right-hand box,
veshafts). - the engine tie-bar (see 19D, Engine mounting,
a Remove the blanking plugs. 19D-26) .
a Connect the low pressure pipe hose to the power- a Detach the gear selection linkage from the vehicle
assisted steering pump. body.
a Fit the clip onto the power-assisted steering pump a Fit the gear selection linkage.
low pressure pipe using the tool (Mot. 1448).
a Refit the gear selection linkage nut.
a Remove the tool (Ms. 583) from the power-assisted
steering pump low pressure pipe. a Fit the gear selection linkage protection.
a Refit:
a Clip the engine wiring onto the multifunction support.
(35A, Wheels and tyres),
WARNING
Do not remove the blanking plugs from each
component until the last moment. a Fit the earth wiring.
Also, do not remove the components from their a Torque tighten the earth wiring bolts (21 N.m)
packaging until they are to be fitted to the vehi-
a Fit the sleeve stop onto the gearbox.
cle.
a Attach the clutch cable.
a Clip:
WARNING
To avoid any leaks, check that the pipe surface is - the accelerator cable sleeve stop to the lifting ring,
sound before positioning the new seal. The sur- - the accelerator cable ball joint onto the inlet mani-
face must be clean and scratch free. fold.
a Remove the blanking plugs. a Connect the brake servo pipe to the inlet manifold.
a It is recommended to lubricate the new seals with air a Remove the blanking plugs.
conditioning oil to make fitting easier (see Air condi- a Connect the fuel supply pipe to the injector rail.
tioning: Parts and consumables for the repair
work) (62A, Air conditioning). a Refit the engine wiring bolt.
a Fit new seals to the air conditioning connecting pi- a Connect the fuel return pipe.
pes. a Fit the wiring.
a Connect: a Clip the wiring onto the body.
- the compressor-condenser connecting pipe, a Connect:
- the expansion valve - compressor connecting pipe. - the fuel vapour absorber solenoid valve connector,
10A-21
K7J or K7M
- the intake sleeve onto the side member.
a Refit:
(80A, Battery).
a Refill:
- the engine oil if necessary (see 10A, Engine and
Refilling, page 10A-49) ,

a Fill the refrigerant circuit using a refrigerant char-
10A-22
K9K
Essential special tooling

clips.

bly.
Tightening torquesm
earth cable bolt on the 44 N.m

gearbox casing
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion. 20792
a Unclip the air filter air inlet pipe from the air filter unit
by pressing the pins (1) .
IMPORTANT
Wear protective gloves during the operation. Note:
Be careful not to damage the pins (1) .
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for repair, page 13B-1) .
REMOVAL

a Remove:
- the engine cover,
(80A, Battery),
10A-23
K9K
101743 112946
a Disconnect the brake servo pipe union (3) from the
vacuum pump.
133120
a Unclip the manual gearbox control cables (2) by:
- pinching the manual gearbox control (A) , 134561
a Unclip the engine compartment connection unit co-
- pulling the manual gearbox control pin (B) ,
ver (4) .
- lifting the manual gearbox control (C) out of the ma-
nual gearbox control support.
a Move aside the manual gearbox control cables.
10A-24
K9K
134562 134564
a Unclip the engine wiring at (8) from the left-hand
a Unclip:
suspended engine mounting support on the vehicle
body.
- the support for each relay (5) from the engine com-
partment connection unit,
- the support for each fuse (6) from the engine com-
134565
a Disconnect the engine cooling fan assembly con-
nector (9) .
a Unclip the engine cooling fan assembly wiring from
134563 the « engine cooling fan assembly - cooling
radiator » assembly.
a Unclip the connector (7) from the engine compart-
ment connection unit.
a Disconnect the connector (7) from the engine com-

10A-25
K9K
- the diesel fuel return pipe union (13) .
a Fit a blanking plug to:
- the high pressure pump opening,
- the openings of the venturi,
- the fuel supply pipe opening,
- the diesel fuel return pipe opening.
a Unclip the fuel pipes from the lower timing cover.
a Remove:
tion),
- the engine undertray,
134566 - the front bumper (see Front bumper: Removal -
a Unclip the fuel pipes (11) from the wiring channel Refitting) (55A, Exterior protection).
(10) . a Drain:
- the manual gearbox (see Manual gearbox: Remo-
val - Refitting) (21A, Manual gearbox).
a Clean the cooling system (see 19A, Cooling, Coo-
ling circuit: Draining - Refilling, page 19A-7) .
a Remove:
(29A, Driveshafts),
- the front right-hand wheel driveshaft (see Front ri-
(29A, Driveshafts),
nents).
134567
a Clean the fuel supply pipe union and the diesel fuel
return pipe union (see 13B, Diesel injection, Diesel
injection: Precautions for repair, page 13B-1) .
WARNING
a Disconnect the high pressure pump from:

- the fuel supply pipe union (12) ,
10A-26
K9K
133122 134568
a Remove the bolts (14) from the exhaust flange, fitted a Fit the tool (Ms. 583) onto the power-assisted stee-
with their spring. ring low pressure pipe.
IMPORTANT
To avoid any risk of damaging the systems, apply
the safety and cleanliness instructions and ope-
ration recommendations before carrying out the
repair (see Steering: Precautions for repair)
(36A, Steering assembly).
a Use the tool (Mot. 1448) to separate the clip (15) for
the power-assisted steering low pressure pipe from
the power-assisted steering pump.
a Disconnect the power-assisted steering low pressu-
re pipe from the power-assisted steering pump.
a Loosen the nut (16) for the power-assisted steering
high pressure pipe on the power-assisted steering
pump.
pipe bolt (17) from the power-assisted steering
pump.
10A-27
K9K
134691 133124
a Remove: a Disconnect the connector (21) from the reverse gear

switch.
- the power-assisted steering high pressure pipe bolt a Unclip the reverse gear switch cable from the fifth
(18) from the engine wiring support, gear housing.
- the power-assisted steering high pressure pipe bolt
(19) from the gearbox.
133125
a Remove the earth cable bolt (22) from the gearbox
housing.
134688

pipe bolt (20) from the left-hand suspended engine
mounting on the gearbox.
a Move aside the power-assisted steering high pres-

sure pipe.
10A-28
K9K
134569 134572
a Use the tool (Mot. 1448) to separate the expansion
bottle bottom cooling hose clip (23) from the expan-
sion bottle.
a Disconnect the expansion bottle bottom cooling
hose from the expansion bottle.
a Unclip the bottom cooling hose from the expansion
bottle at (24) .
a Use the tool (Mot. 1448) to separate the expansion
bottle top cooling hose clip (25) from the coolant out-
let unit.
a Disconnect the expansion bottle top cooling hose
from the coolant outlet unit.
a Use the tool (Mot. 1448) to separate the cooling ra-
diator top cooling hose clip (26) from the coolant out-
let unit.
a Disconnect the cooling radiator top cooling hose
134570
a Disconnect the cooling hoses (27) from the heater
matrix by:
- pressing on the tabs (A) of the heater matrix coo-
ling hoses,
- pulling the heater matrix cooling hoses towards (B)
.
10A-29
K9K
133130 133123
a Disconnect the union (28) from the clutch master cy- a
linder supply pipe.
Note:
a Fit blanking plugs to the openings of the:
To make it easier to disconnect the clutch control
- clutch master cylinder supply pipe union, pipe, ensure that it is extracted along the pipe
- the brake fluid reservoir union. line.
a Disconnect the clutch control pipe from the clutch

thrust bearing by:
- pressing on the clutch thrust bearing clip (A) ,
- by pulling the clutch control pipe towards (B) .
133121
a Unclip the clutch control pipe from the left-hand sus-
pended gearbox mounting bracket at (29) .
10A-30
K9K
CONCERNED
110317
134571
a Remove the nut (30) from the shaft of the left-hand

suspended engine mounting.
110318
a Position the (Mot. 1390).
132930
a Remove the nut (31) from the right-hand suspended

engine mounting pad.
a Lift the engine slightly until the right-hand suspen-
ded engine mounting cover detaches from the right-
hand suspended mounting pad.
a Remove:
- the bolts (32) from the right-hand suspended engi-
ne mounting cover,
- the right-hand suspended engine mounting cover,
10A-31
K9K
- the « engine and gearbox » assembly. a Remove the blanking plugs from the openings of
the:
REFITTING - clutch master cylinder supply pipe union,
- the brake fluid reservoir union.
a Connect:
- the clutch master cylinder supply pipe union,

- the heater matrix cooling hoses,
- the cooling radiator top hose to the coolant outlet
unit.
a Fit the expansion bottle top cooling hose clip to the
coolant outlet unit using the tool (Mot. 1448).
a Connect the expansion bottle bottom cooling hose to

the expansion bottle.
a Fit the expansion bottle bottom cooling hose clip to
the expansion bottle using the tool (Mot. 1448).
109399 a Clip on the expansion bottle bottom cooling hose.

a Always replace: a Torque tighten the earth cable bolt on the gearbox
casing (44 N.m).
- the exhaust flange sealing ring,
- the differential output seals (see Differential out- a Connect the reverse gear switch connector.
put seal: Removal - Refitting) (21A, Manual gear- a Clip the reverse gear switch cable onto the fifth gear
box). housing.
CONCERNED a Refit:
a Refit: - the power-assisted steering high pressure pipe bolt
onto the support on the gearbox left-hand suspen-
- the « engine and gearbox » assembly,
ded engine mounting,
- the right-hand suspended engine mounting cover on the gearbox,
bolts.
a Lower the engine so that the right-hand suspended on the engine wiring bracket.
engine mounting cover is in contact with the right-
hand suspended engine mounting pad. a Tighten the power-assisted steering high pressure
pipe nut on the power-assisted steering pump.
a Refit:
a Refit the power-assisted steering high pressure pipe
- the right-hand suspended engine mounting pad
bolt onto the power-assisted steering pump.
nut,
- the left-hand suspended engine mounting shaft a Connect the power-assisted steering low pressure
pipe to the power-assisted steering pump.
nut.
a Remove the tool (Mot. 1390). a Fit the clip for the power-assisted steering low pres-
sure pipe to the power-assisted steering pump using
the tool (Mot. 1448).
a Connect the clutch control pipe to the clutch thrust steering low pressure pipe.
bearing.
a Refit:
a Clip the clutch control pipe onto the support on the
gearbox left-hand suspended engine mounting. - the exhaust flange bolts fitted with their spring,
10A-32
K9K
- the front axle subframe (see Front axle sub-fra- a Connect the brake servo pipe union to the vacuum
me: Removal - Refitting) (31A, Front axle compo- pump.
nents),
a Fit the manual gearbox control cables.
a Clip the manual gearbox control cables:
(29A, Driveshafts), - onto the manual gearbox control cable support,
- the front left-hand wheel driveshaft (see Front left- - onto the manual gearbox control selector.
hand wheel driveshaft: Removal - Refitting) a Clip the air filter air inlet pipe onto the air filter unit.
(29A, Driveshafts),
a Refit:
Refitting) (55A, Exterior protection), - the battery tray (see Battery tray: Removal - Re-
liner: Removal - Refitting) (55A, Exterior protec- - the battery (see Battery : Removal - Refitting)
tion), (80A, Battery),
- the front wheels (see Wheel: Removal - Refitting) - the engine cover.
(35A, Wheels and tyres). a Perform the following operations:
a Clip the fuel pipes onto the lower timing cover. - fill the cooling system (see 19A, Cooling, Cooling
a Remove the blanking plug from:
- fill the manual gearbox with oil (see Manual gear-
- the diesel fuel return pipe opening, box: Removal - Refitting) (21A, Manual gearbox),
- the fuel supply pipe opening, - bleed the clutch circuit (see Clutch circuit: Remo-
- the opening of the venturi, val - Refitting) (37A, Mechanical component con-
trols),
- the high pressure pump opening.
- bleed the cooling circuit (see 19A, Cooling, Coo-
a Connect to the high pressure pump: ling circuit: Draining - Refilling, page 19A-7) ,
- the fuel supply pipe union, - bleed the power-assisted steering circuit (see
Power-assisted steering circuit: Bleeding)
- the diesel fuel return pipe union.
(36B, Power-assisted steering).
a Clip the fuel pipes onto the engine wiring channel.
a Refit the engine undertray.
a Connect the engine cooling fan assembly connector.
a Clip:
- the wiring for the engine cooling fan assembly onto
the « engine cooling fan assembly - radiator » as-
sembly,
- the engine wiring to the left-hand suspended engi-
ne mounting on the vehicle body.
a Connect the connector of the engine compartment
connection unit.
a Clip:
- the connector of the engine compartment connec-
tion unit,
- the support for each of the engine compartment
connection unit fuses,
- the support for each of the engine compartment
connection unit relays.
a Clip on the engine compartment connection unit co-
ver.
10A-33
K4J, and DP0
Essential special tooling station (see Coolant circuit Draining - Refilling)
clips.
a Remove:
- the air resonator (see 12A, Fuel mixture, Air reso-
Mot. 1390 Support for removing/refitting nator: Removal - Refitting, page 12A-12) ,
bly. - the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-5) ,
Essential equipment
refrigerant charging station (80A, Battery),
safety strap(s) - the automatic transmission computer (see Auto-

matic transmission computer: Removal - Refit-
ting) (23A, Automatic transmission),
Tightening torquesm
earth cable bolt to the 21 N.m
automatic gearbox
connecting pipe bracket 8 N.m
bolt for the - the battery tray (see Battery tray: Removal - Re-
« compressor-interme- fitting) (80A, Battery),
diate pipe »
connecting pipe bracket 8 N.m (35A, Wheels and tyres),
bolt for the
« compressor- - the front wheel arch liners (see Front wheel arch
condenser » liner: Removal - Refitting) (55A, Exterior protec-
tion),
earth cable bolt on the 8 N.m
vehicle body - the front bumper (see Front bumper: Removal -
exhaust bracket nuts 21 N.m
a Attach the « cooling radiator - condenser » assem-
bly to the front upper cross member using a safety
REMOVAL strap(s).
a Remove:
a Position the vehicle on a two-post lift (see Vehicle: - the engine tie-bar (see 19D, Engine mounting,
Towing and lifting) (02A, Lifting equipment). Lower engine tie-bar: Removal - Refitting, page
19D-26) ,
a Remove:
- the engine undertray. (29A, Driveshafts),
a Drain: - the front left-hand wheel driveshaft (see Front left-

(29A, Driveshafts),
- the automatic transmission (see Automatic gear- - the front axle subframe (see Front axle sub-fra-
box oil: Draining - Refilling) (23A, Automatic me: Removal - Refitting) (31A, Front axle compo-
transmission), nents).
10A-34
K4J, and DP0
101793 116660
a Remove the nuts (1) from the exhaust bracket. a Disconnect the accelerator cable (4) .
a Separate the catalytic converter from the exhaust a Unclip the accelerator cable (5) from the inlet mani-
manifold. fold.
a Remove the exhaust bracket seal.
133500
132767 a Disconnect the quick-release unions (6) from the

heater matrix hoses.
a Unclip:
- the power-assisted steering low pressure pipe (2) ,
- the cooling degassing hose (3) .
10A-35
K4J, and DP0
- the cooling radiator top hose.
133057
a Remove: 133498
a Using the tool (Mot. 1448), separate the clip (11)
- the bolt (7) from the power-assisted steering low
from the expansion bottle hose.
pressure pipe,
a Disconnect the expansion bottle hose.
- the nuts (8) from the injector rail protector,
- the injector rail protector.
133496
a Disconnect the engine cooling fan assembly resistor
132769 connector (12) .
a Remove using the (Mot. 1448) :
- the cooling degassing hose clip (9) ,
- the cooling radiator top hose clip (10) .
a Disconnect:
- the cooling degassing hose,
10A-36
K4J, and DP0
133497 133492
a Disconnect the connector (13) from the fan of the a Disconnect the fuel vapour absorber connector (15)
engine cooling fan assembly. .
133495 133490
a Disconnect the connector (14) from the air conditio- a Disconnect the connector (16) from the power-assis-
ning circuit pressure sensor. ted steering pressure sensor.
10A-37
K4J, and DP0
133002 133506
a Remove the bolt (17) from the earth cable on the ve- a Unclip the relays of the engine compartment con-
hicle body. nection unit.
a Move aside the relays of the engine compartment
connection unit.
133507
a Remove the cover (18) from the engine compart-
ment connection unit. 133504
a Disconnect the connector (19) from the engine wi-
ring.
10A-38
K4J, and DP0
133505 133499
a Unclip the engine wiring (20) from the left-hand sus- a
pended mounting.
WARNING
a Move aside the engine wiring.
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
a Remove the air conditioning pipe bracket bolts (21)

on the air conditioning compressor.
a Disconnect the air conditioning pipes from the air
conditioning compressor.
a Fit blanking plugs.
10A-39
K4J, and DP0
110245 133491
a Unclip the automatic gearbox control cable. a Using the tool (Mot. 1448), remove the clip (23) from
the power-assisted steering low pressure pipe.
a Move the automatic gearbox control cable to one si-
de.
WARNING
a Disconnect the power-assisted steering low pressu-

re pipe.
132816
a Fit the tool (Ms. 583) (22) on the power-assisted
steering low pressure pipe.
10A-40
K4J, and DP0
132817 133487
a Remove:
- the bolt (24) from the power-assisted steering high
pressure pipe,
- the union (25) from the power-assisted steering
high pressure pipe.
133486
a Remove:
- the bolts (26) from the power-assisted steering
high pressure pipe,
- the bolt (27) from the earth cable on the automatic
gearbox.
10A-41
K4J, and DP0
CONCERNED
132686
a Unclip the downstream oxygen sensor connector
(28) . 133485
a Support the engine and gearbox assembly on (Mot.
a Disconnect the downstream oxygen sensor connec-
1390).
tor.
a Remove the right-hand suspended engine mounting
19D-16) .
133493
a Unclip the fuel supply pipe (29) .
a Disconnect the fuel supply pipe union (30) .
10A-42
K4J, and DP0
a Parts always to be replaced:
- the refrigerant pipe seals,
- the exhaust flange seal.
WARNING
component until the last moment.
Also, do not remove the components from their
cle.
WARNING
WARNING
133484 To avoid any leaks, check that the pipe surface is
a Remove the nut (31) from the suspended engine sound before positioning the new seal. The sur-
mounting rubber pad shaft on the gearbox. face must be clean and scratch free.
Note: II - REFITTING OPERATION FOR PART

CONCERNED
Check that no component obstructs the move-
ment of the body around the engine - gearbox a Position the "engine and gearbox" assembly in the
assembly. body.
a Lift the vehicle to remove the "engine and gearbox" a Refit the nut of the suspended engine mounting rub-
assembly. ber pad shaft on the gearbox.
a Refit the right-hand suspended engine mounting
REFITTING
19D-16) .
a For service engine replacements (see Standard re-
placement) (Technical Note 6023A, 10A, Engine
and peripherals).
a Remove the blanking plugs from the fuel supply pi-
pes.
a Connect the fuel supply pipe union.
a Clip on the fuel supply pipe.
a Connect the downstream oxygen sensor connector.
a Clip the downstream oxygen sensor connector.
a Refit the earth cable bolt to the automatic gearbox.
a Torque tighten the earth cable bolt to the automa-
tic gearbox (21 N.m).
a Remove:
- the blanking plug from the power-assisted steering
pump,
10A-43
K4J, and DP0
- the blanking plug from the power-assisted steering - the engine cooling fan assembly resistor connec-
high pressure pipe union. tor,
a Refit: - the hose on the expansion bottle.
- the bolts for the power-assisted steering high pres- a Use the tool (Mot. 1448) to fit the expansion bottle
sure pipes, hose clip in place.
- the power-assisted steering high pressure pipe a Connect:
union to the power-assisted steering pump.
- the cooling radiator top hose to the coolant outlet
a Connect the power-assisted steering low pressure unit,
pipe to the power-assisted steering pump.
- the cooling degassing hose to the coolant outlet
a Use the tool (Mot. 1448) to fit the clip of the power- unit.
assisted steering low pressure pipe.
a Using the (Mot. 1448), fit:
steering low pressure pipe. - the cooling radiator top hose clip to the coolant out-
let unit,
a Clip on the automatic gearbox control cable.
a Remove the blanking plugs from the air conditioning - the cooling degassing hose clip to the coolant out-
pipes. let unit.
a Fit new seals on the air conditioning pipes. a Refit:
a Lubricate the new seals with air conditioning oil (see - the injector rail protector,
Air conditioning: Parts and consumables for the - the bolt of the power-assisted steering low pressu-
repair work) (62A, Air conditioning) to make fitting re pipe.
easier.
a Connect the quick-release unions of the heater ma-
a Fit the air conditioning pipes onto the air conditioning trix hoses.
compressor.
a Clip the accelerator cable onto the inlet manifold.
a Tighten to torque:
- the connecting pipe bracket bolt for the a Connect the accelerator cable to the throttle valve.
« compressor-intermediate pipe » (8 N.m), a Refit a new exhaust bracket seal.
- the connecting pipe bracket bolt for the a Fit the catalytic converter on the exhaust manifold.
« compressor-condenser » (8 N.m).
a Torque tighten the exhaust bracket nuts (21 N.m).
a Clip the engine wiring onto the left-hand suspended
mounting. a Refit:
a Connect the engine wiring connector. - the front axle subframe (see Front axle sub-fra-
a Clip the relays onto the engine compartment con-
nents),
nection unit.
a Refit the engine compartment connection unit cover.
a Fit the earth cable on the vehicle body. (29A, Driveshafts),
a Torque tighten the earth cable bolt on the vehicle - the front right-hand wheel driveshaft (see Front ri-
body (8 N.m). ght-hand wheel driveshaft: Removal - Refitting)
a Connect: (29A, Driveshafts),
- the power-assisted steering pressure sensor con- - the engine tie-bar (see 19D, Engine mounting,
nector, Lower engine tie-bar: Removal - Refitting, page
19D-26) .
- the fuel vapour absorber connector,
a Remove the safety strap(s).
- the air conditioning circuit pressure sensor connec-
tor, a Refit:
- the fan connector of the engine cooling fan assem- - the front bumper (see Front bumper: Removal -
bly, Refitting) (55A, Exterior protection),
10A-44
K4J, and DP0
tion),
- the automatic transmission computer (see Auto-
(80A, Battery),
- the air filter unit (see 12A, Fuel mixture, Air filter
nator: Removal - Refitting, page 12A-12) .
a Perform the following operations:
- fill and bleed the cooling circuit (see 19A, Cooling,
,
filling) (62A, Air conditioning).
- bleed the power-assisted steering circuit (see
(36B, Power-assisted steering),
- fill the automatic gearbox (see Automatic gearbox
oil: Draining - Refilling) (23A, Automatic gear-
box).
10A-45
K9K
IMPORTANT
tion.
IMPORTANT
IMPORTANT
20792
a Unclip the air filter unit air inlet pipe from the air filter
REMOVAL unit by pressing on the pins (1) .
REMOVAL PREPARATION OPERATION

Note:
a Position the vehicle on a two-post lift (see Vehicle)
(02A, Lifting equipment). Be careful not to damage the pins (1) .
a Remove:
- the engine cover,
(80A, Battery).
10A-46
K9K
101743 112946
a Disconnect the brake servo pipe union (3) from the
vacuum pump.
133120
a Unclip the manual gear selector cables (2) by:
- pinching the manual gear selector (A) , 134561
a Unclip the engine compartment connection unit co-
- pulling the manual gear selector pin (B) ,
ver (4) .
- lifting the manual gear selector (C) from the manual
gear selector mounting.
a Move aside the manual gear selector cables.
10A-47
K9K
134562 134564
a Unclip:
suspended engine mounting support.
- the support for each relay (5) from the engine com-
partment connection unit,
- the support for each fuse (6) from the engine com-
134565
nector (9) .
134563
a Unclip the connector (7) from the engine compart-

ment connection unit.
a Disconnect the connector (7) from the engine com-

10A-48
Engine oil: Draining - Refilling 10A
D4F
I - OIL SERVICE
Mot. 1018 Sump plug tool. Towing and lifting) (02A, Lifting equipment).
Essential equipment
oil recovery container
Tightening torquesm
drain plug 20 Nm
Average oil capacity

(test with dipstick) (l)
Engine
Oil c h a n ge Oil change with
without filter filter replace-
replacement ment
D4F 3.8 4
132923
IMPORTANT a Remove:
Wear leaktight gloves (Nitrile type) for this opera- - the engine cover,
tion.
- the filler cap (1) ,
- the dipstick (2) ,
WARNING
Always check the oil level using the dipstick. - the engine undertray.
Do not exceed the maximum level on the dipstick

(could destroy the engine).
Correct the engine oil level if necessary before deli-
vering the vehicle to the customer.
Note:
When topping up the engine oil, always leave at
least 10 minutes before checking the level with a
dipstick.
PARTS AND INGREDIENTS FOR THE

REPAIRWORK
a parts always to be replaced: Engine oil sump
drain plug seal (10,03,01,04)
a Consumable:
- engine oil (see Engine oil: Specifications) (Tech-
nical Note 6013A, 04A, Lubricants).
10A-49
D4F
132670 113764
a Place the oil recovery container under the engine. a Refit:
a Remove: - a new seal (4) on the sump drain plug,
- the drain plug (3) from the engine oil sump using - the drain plug on the sump.
the (Mot. 1018),
a Torque tighten the drain plug (20 Nm).
- the engine oil sump drain plug seal.
a Clean the traces of oil around the drain plug so that
a Let the engine oil run. any possible leaks can be detected.
a Remove the oil recovery container.
II - FILLING
a Fill the engine with oil, observing the recommended
amount.
a Wait at least 10 minutes.
a Check the oil level using the dipstick.
a Adjust the engine oil level if necessary.
a Refit:
- the filler cap,
- the dipstick,
- the engine cover,
10A-50
K7J or K7M
II - OIL SERVICE
Essential equipment
Tightening torquesm
engine oil drain plug 20 N.m

(adjust with dipstick) (l)
Engine Draining Oil change

plus oil fil-
ter replace-
ment
K7J/K7M 3.3 3.4
133157
a Remove:
IMPORTANT - the engine oil filler cap (1) ,

Wear leaktight gloves (Nitrile type) for this opera- - the dipstick (2) ,
tion.
WARNING
Always check the oil level using the dipstick.
Note:
dipstick.
I - PARTS AND CONSUMABLES FOR THE REPAIR

drain plug seal (10,03,01,04).
a Consumable:
10A-51
K7J or K7M
any possible leaks can be detected.
III - FILLING
amount.
a Refit:
- the engine oil filler cap,
- the dipstick,
133024
a Place a oil recovery container under the engine.

a Remove:
- the sump drain plug (3) using the tool (Mot. 1018),
- the sump drain plug seal.
a Let the engine oil run.
113765
a Refit:
- a new seal onto the engine oil drain plug,
- the engine oil drain plug on the sump.
a Torque tighten the engine oil drain plug (20 N.m).
10A-52
K4J or K4M
I - DRAINING
Essential equipment
Tightening torquesm
drain plug 20 N.m
Average oil capacity (adjust with

dipstick) (l)
Engine
Oil c h a n ge Oil change with
without filter filter replace-
replacement ment
K4J/K4M 4.7 4.8
133058
IMPORTANT
a Remove the filler plug (1) .
tion.
WARNING
Note:
dipstick.
PARTS AND INGREDIENTS FOR THE 133513
REPAIRWORK a Remove:
a parts always to be replaced: Engine oil sump - the dipstick (2) ,
a Consumable:
nical Note 6013A, 04A, Lubricants). a Place a oil recovery container under the engine.
10A-53
K4J or K4M
II - FILLING
amount.
a Refit:
- the filler cap,
- the dipstick,
132892
a Remove:
- the sump drain plug (3) using the tool (Mot. 1018).
- the sump drain plug seal.
a Let the engine oil run.
113764
a Refit:
- a new seal (4) on the sump drain plug,
- the drain plug on the sump.
a Torque tighten the drain plug (20 N.m).
any possible leaks can be detected.
10A-54
K9K
I - PRECAUTIONS FOR REPAIR
Mot. 1018 Sump plug tool.
Essential equipment
oil draining wrench
8 mm square drain plug socket
Tightening torquesm
the drain plug 20 N.m

(test with dipstick) (l)
Engine Suffix Oil change Oil change 113765

without fil- with filter
ter replace- replacement a There is no direction of fitting for a seal fitted with a
ment rubber lip.
700
IMPORTANT
K9K 718 4.4 4.5 Wear leaktight gloves (Nitrile type) for this opera-
tion.
740
WARNING
Correct the engine oil level if necessary before
delivering the vehicle to the customer.
Note:
dipstick.
II - PARTS AND CONSUMABLES FOR THE REPAIR

WORK

drain plug seal (10,03,01,04).
a Consumable:

10A-55
K9K
III - OIL SERVICE
135088
a Remove the drain plug (3) from the engine oil sump
using the (Mot. 1018) or a oil draining wrench.
135087
a Let the engine oil flow out.
a Remove:
- the engine oil filler cap (1) , a Remove the drain plug seal.
- the dipstick (2) , a Refit the new seal to the drain plug.
a Torque tighten the drain plug (20 N.m) using a oil
- the engine undertray. draining wrench and a 8 mm square drain plug
socket.
a Place the oil recovery container under the engine.
a Wipe the oil drips around the drain plug using a
cloth.
IV - FILLING
a Position the vehicle back on the ground.
a Fill the engine with oil, observing the correct quantity

of oil as recommended by the manufacturer.
a Top up the engine oil level if necessary.
a Refit:
- the engine oil filler cap,
- the dipstick.
10A-56
Oil filter: Removal - Refitting 10A
D4F
Essential special tooling CONCERNED
Mot. 1330 Oil filter removing tool (66
mm diameter).
Essential equipment
IMPORTANT
tion.
WARNING
vering the vehicle to the customer. 132698
a Remove the oil filter using the (Mot. 1330) (1) .
Note: REFITTING
least 10 minutes before checking the level with a I - REFITTING PREPARATION OPERATION
dipstick.
a Use SURFACE CLEANER (see Vehicle: Parts
When removing the oil filter, check that the oil filter and ingredients for the repairwork) (04B, Consu-
seal is not still stuck to the cylinder block or oil filter mables - Products) to clean and degrease the oil
mounting. pump joint face.
REMOVAL WARNING
The joint faces must be clean, dry and free from
grease (avoid finger marks).
a Position the vehicle on a two-post lift (see Vehicle: a parts always to be replaced: Oil filter (10,05,05,
Towing and lifting) (02A, Lifting equipment). 03).
a Remove: a Lubricate the new oil filter seal with new engine oil.
CONCERNED
a Place the oil recovery container under the engine.
a Fit a new oil filter.
a Tighten the oil filter until it makes contact.
a Tighten the oil filter by 3/4 of a turn.

a Wipe any oil run-off with a cloth.
10A-57
D4F
a Top up the engine oil with oil recommended by the
manufacturer (see Engine oil: Specifications)
(Technical Note 6013A, 04A, Lubricants).
a Start the engine and wait until the oil pressure war-
ning light goes out on the instrument panel.
a Check for leaks from the oil filter.
10A-58
K9K
mm diameter).
Essential equipment
IMPORTANT
tion.
WARNING 97160
Note:
dipstick.
REMOVAL

132607
a Remove:
a Remove the oil filter (1) using (Mot. 1329) (2) .
REFITTING
a Fit a oil recovery container under the engine.
a parts always to be replaced: Oil filter (10,05,05,

03).
a Lubricate the new oil filter seal with new engine oil.

CONCERNED
a Manually refit a new oil filter until the oil filter seal co-
mes into contact with the oil filter support.
10A-59
K9K
a Tighten the oil filter 3/4 of a turn manually or using

a Start the engine and leave it running for approxima-
tely 30 seconds.
a Check there are no leaks from the oil filter.
Note:
The engine oil level must be between the “mini-
mum” and “maximum” marks on the dipstick.
10A-60
K4J or K4M
mm diameter).
Essential equipment
IMPORTANT
tion.
WARNING
a Remove the oil filter using the (Mot. 1329) (1) .
Note: REFITTING
dipstick.
When removing the oil filter, check that the oil filter and ingredients for the repairwork) (04B, Consu-
seal does not remain attached to the cylinder block mables - Products) to clean and degrease the cylin-
or oil filter support. der block joint face.
REMOVAL WARNING
To ensure proper sealing, the joint faces must be
I - REMOVAL PREPARATION OPERATION clean, dry and not greasy (avoid any finger
marks).
Towing and lifting) (02A, Lifting equipment). a parts always to be replaced: Oil filter (10,05,05,
a Remove: 03).
- the engine undertray bolts, a Lubricate the new oil filter seal with new engine oil.

a Fit a oil recovery container under the engine. CONCERNED

10A-61
K4J or K4M
(Technical Note 6013A, 04B, Lubricants).
10A-62
K7J or K7M
mm diameter).
Essential equipment
IMPORTANT
tion.
WARNING
a Remove the oil filter using the (Mot. 1329).
Note: REFITTING
dipstick.
a Using SURFACE CLEANER (see Vehicle: Parts
and ingredients for the repairwork) (04B, Consu-
REMOVAL mables - Products), clean and degrease the cylinder
block joint faces.

WARNING
Towing and lifting) (02A, Lifting equipment). To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
a Remove: ger marks).
- the engine undertray. 03).
a Place the oil recovery container under the engine. a Lubricate the new oil filter seal with new engine oil.

CONCERNED

a Remove the oil recovery tray.
10A-63
K7J or K7M
10A-64
Crankshaft seal at timing end Removal - Refitting 10A
D4F
Mot. 1374 Oil pump seal removal tool.
Mot. 1626 Tool for fitting PTFE cranks-

haft seal, timing end.
REMOVAL

a Disconnect the battery (see Battery: Removal - Re-
a Remove:
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection), 18645-1
- the engine undertray bolts, a Fit the tool (Mot. 1374) to extract the crankshaft seal
at the timing end.
a Tighten the nut (Mot. 1374) of tool (1) .
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-15) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-28) ,
- the timing sprocket.
18645-2
a Tighten the bolt (2) of the (Mot. 1374).
a Remove the crankshaft timing end seal.
10A-65
D4F
REFITTING
a Always replace the crankshaft seal at the timing end.

mables - Products) to clean and degrease:
- the mating face of the crankshaft seal at the timing

end,
- the cylinder block seal housing.
WARNING
20784
a Fit the threaded rod (5) of the (Mot. 1626) into the
CONCERNED
crankshaft.
18687 20782
a Refit the crankshaft seal at the timing end using the a Fit the protector equipped with the crankshaft timing
tool (Mot. 1626). end seal to the crankshaft, taking care not to touch
the crankshaft seal at the timing end.
Note:
This type of seal is extremely fragile.
Only touch the protective part (3) when handling
the gasket. It is strictly forbidden to touch the
seal (4) ; this is to prevent any oil leaks once the
oil seal is fitted to the engine.
10A-66
D4F
20783 20780
a Fit the cover (6) and the collar nut (7) of the (Mot. a Tighten the shouldered nut of the tool (Mot. 1626)
1626). until the cover of the tool (Mot. 1626) comes into
contact with the crankshaft closure panel.
20781
a Screw on the shouldered nut of the tool (Mot. 1626)
20779
until the cover of the tool (Mot. 1626) comes into
contact with the spacer. a Remove:
- the nut from the (Mot. 1626),
- the cover from the (Mot. 1626),
- the protector from the crankshaft seal at the timing

end,
- the threaded rod of the (Mot. 1626).
10A-67
D4F
a Refit:
- the timing sprocket,
page 11A-1) ,
terior protection),
Refitting) (35A, Wheels and tyres).
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
a Bleed the power-assisted steering circuit (see
Power-assisted steering).
10A-68
K7J or K7M
REFITTING
Mot. 1385 Crankshaft oil seal fitting tool I - REFITTING PREPARATION OPERATION
(timing end) (35 x 47 x 7)
a parts always to be replaced: Crankshaft seal on
timing end (10,03,03,04)
WARNING and ingredients for the repairwork) (04B, Consu-
To prevent impurities from entering the circuit, place
protective plugs on all fuel circuit components - the crankshaft seal mating face,
exposed to the open air.
IMPORTANT WARNING
Wear protective gloves during the operation. To ensure proper sealing, the gasket surfaces
ger marks).
REMOVAL
I - REMOVAL PREPARATION OPERATION CONCERNED

a Remove:
(80A, Battery),


terior protection),
19D-26) ,

14523
page 11A-1) , a Refit:
- the timing belt (see 11A, Top and front of engine, - a new crankshaft seal at the timing end, using the
Timing belt: Removal - Refitting, page 11A-28) . tool (Mot. 1385),
- the crankshaft timing sprocket.

CONCERNED
a Remove:
a Refit:
- the crankshaft timing sprocket,
- the crankshaft seal on the timing side. Timing belt: Removal - Refitting, page 11A-28) ,
10A-69
K7J or K7M
page 11A-1) ,
19D-26) ,
terior protection),
(80A, Battery).
10A-70
K4J or K4M

bly.
Mot. 1385 Crankshaft oil seal fitting tool

(timing end) (35 x 47 x 7)
Tightening torquesm
REMOVAL

Towing and lifting) (02A, Lifting equipment). 101793
a Remove: a Remove the nuts (1) from the exhaust bracket.
- the air resonator (see 12A, Fuel mixture, Air reso- a Separate the catalytic converter from the exhaust
nator: Removal - Refitting, page 12A-12) , manifold.
- the engine undertray bolts, a Position the (Mot. 1390) under the engine.
- the engine undertray, a Remove:
- the front bumper (see Front bumper: Removal - - the right-hand suspended engine mounting (see
Refitting) (55A, Exterior protection), 19D, Engine mounting, Right-hand suspended
- the right-hand headlight (see Front headlight: Re- engine mounting: Removal - Refitting, page
moval - Refitting) (80B, Headlights), 19D-16) ,
- the front right-hand wheel (see Wheel: Removal - - the accessories belt (see 11A, Top and front of
Refitting) (35A, Wheels and tyres), engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
wheel arch liner: Removal - Refitting) (55A, Ex- - the crankshaft accessories pulley (see 11A, Top
terior protection), and front of engine, Crankshaft accessories
- the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting, - the timing belt (see 11A, Top and front of engine,
page 19D-26) . Timing belt: Removal - Refitting, page 11A-28) .
10A-71
K4J or K4M
II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
14487-5 14523
a Remove the crankshaft seal (2) . a Refit a new seal using the tool (Mot. 1385).
REFITTING III - FINAL OPERATION

a Refit:
mables - Products) to clean and degrease: - the crankshaft accessories pulley (see 11A, Top
- the crankshaft seal mating face,
WARNING page 11A-1) ,
To ensure proper sealing, the gasket surfaces - the right-hand suspended engine mounting (see
must be clean, dry and not greasy (avoid any fin- 19D, Engine mounting, Right-hand suspended
ger marks). engine mounting: Removal - Refitting, page
19D-16) .
a Always replace the crankshaft seal.
a Remove the tool (Mot. 1390).
a Fit the catalytic converter on the exhaust manifold.
a Refit:
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) ,
terior protection),
10A-72
K4J or K4M
- the right-hand headlight (see Front headlight: Re-
moval - Refitting) (80B, Headlights),
Refitting) (55A, Exterior protection),
10A-73
Crankshaft seal at gearbox end : Removal - Refitting 10A
D4F
Essential special tooling val - Refitting) (21A, Manual gearbox),
Mot. 1625 Tool for fitting PTFE cranks- - the « pressure plate - disc » assembly (see Me-
haft seal, flywheel end. chanism / Disk: Removal - Refitting) (20A,
Clutch),
REMOVAL - the flywheel (see 10A, Engine and cylinder block

assembly, Flywheel: Removal - Refitting, page
10A-155) (20A, Clutch).
a Position the vehicle on a two-post lift (see Vehicle: II - OPERATION FOR REMOVAL OF PART
Towing and lifting) (02A, Lifting equipment). CONCERNED
a Remove:
(80A, Battery),
- the starter (see 16A, Starting - Charging, Starter:
Removal - Refitting, page 16A-12) ,
tion),
18644-2
ting, Lower engine tie-bar: Removal - Refitting, a Remove the crankshaft seal (1) at the gearbox end
page 19D-26) . using a screwdriver.
a Drain the manual gearbox (see Manual gearbox

oil: Draining - Refilling) (21A, Manual gearbox). Note:
a Remove: Take care not to damage the crankshaft mating

face.
(29A, Driveshafts), REFITTING
ght-hand wheel driveshaft: Removal - Refitting) I - REFITTING PREPARATION OPERATION
(29A, Driveshafts),
a Always replace the crankshaft seal at the gearbox
- the front axle subframe (see Front axle sub-fra- end.
nents),
- the windscreen wiper arms (see Windscreen wi-
per arm: Removal - Refitting) (85A, Wiping -
Washing),
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
10A-74
D4F
- the crankshaft seal mating face,
WARNING

CONCERNED
20773
a Fit the centring device of the tool (Mot. 1625) onto
the crankshaft.
a Tighten the bolts (4) on the centring device of the
(Mot. 1625).
18687
a Refit the crankshaft seal at the gearbox end, using
Note:
This type of seal is extremely fragile.
Only touch the protective part (2) when handling
the gasket. It is strictly forbidden to touch the
seal (3) ; this is to prevent any oil leaks once the
oil seal is fitted to the engine.
20774
a Fit the protector equipped with the crankshaft seal
(gearbox end) onto the centring device of the tool
(Mot. 1625), taking care not to touch the crankshaft
seal at the gearbox end.
10A-75
D4F
20775 20778
a Fit the cover (5) of tool (Mot. 1625) and the nut (6) of a Remove:
tool (Mot. 1625) (with the thread of the nut towards
the outside of the engine). - the nut from the (Mot. 1625),
- the protector for the crankshaft seal at the gearbox
end,
- the centring device of the (Mot. 1625).

a Refit:
- the flywheel (see 10A, Engine and cylinder block
10A-155) (20A, Clutch),
- the « pressure plate - disc » assembly (see Me-
chanism / Disk: Removal - Refitting) (20A,
Clutch),
val - Refitting) (21A, Manual gearbox),
20776 Removal - Refitting) (56A, Exterior equipment),
a Tighten the nut of tool (Mot. 1625) until the cover of - the windscreen wiper arms (see Windscreen wi-
the tool (Mot. 1625) comes into contact with the cy- per arm: Removal - Refitting) (85A, Wiping -
linder block. Washing),
nents),
(29A, Driveshafts),
10A-76
D4F
(29A, Driveshafts).
a Fill the manual gearbox (see Manual gearbox oil:
Draining - Refilling) (21A, Manual gearbox).
a Refit:
page 19D-26) ,
tion),
(80A, Battery).
10A-77
K4J or K4M
Essential special tooling liner: Removal - Refitting) (55A, Exterior protec-
tion),
Mot. 1129-01 Crankshaft oil seal fitting tool
(flywheel end) (80 x 100 x 8 - the front bumper (see Front bumper: Removal -
seal). Refitting) (55A, Exterior protection).
a Attach the « cooling radiator - condenser » assem-
Essential equipment bly to the front upper cross member using a safety
strap(s).
a Remove:
safety strap(s)
REMOVAL 19D-26) ,
(29A, Driveshafts),
a Position the vehicle on a two-post lift (see Vehicle: - the front left-hand wheel driveshaft (see Front left-
Towing and lifting) (02A, Lifting equipment). hand wheel driveshaft: Removal - Refitting)
a Remove: (29A, Driveshafts),
- the engine undertray. nents).
a Drain: - the « engine and gearbox » assembly (see 10A,

Engine and cylinder block assembly, Engine/
- the cooling system (see 19A, Cooling, Cooling gearbox assembly: Removal - Refitting, page
circuit: Draining - Refilling, page 19A-7) , 10A-1) ,
- the automatic transmission (see Automatic gear- - the automatic transmission (see Automatic gear-
box oil: Draining - Refilling) (23A, Automatic box: Removal - Refitting) (23A, Automatic trans-
transmission), mission),
- the refrigerant circuit using a refrigerant charging - the drive plate (see 10A, Engine and cylinder
station (see Coolant circuit Draining - Refilling) block assembly, Drive plate: Removal - Refit-
(62A, Air conditioning). ting, page 10A-164) .
a Remove:

nator: Removal - Refitting, page 12A-12) ,
(80A, Battery),


10A-78
K4J or K4M
CONCERNED CONCERNED
132380
118581
a Refit a new crankshaft seal at the gearbox end,
a Remove the crankshaft seal (1) at the gearbox end
using the tool (Mot. 1129-01) (2) .
using a screwdriver.

Note: a Refit:
Take care not to damage the mating face of the
- the drive plate (see 10A, Engine and cylinder
crankshaft seal.
block assembly, Drive plate: Removal - Refit-
ting, page 10A-164) ,
REFITTING - the automatic transmission (see Automatic gear-

box: Removal - Refitting) (23A, Automatic trans-
mission),
I - REFITTING PREPARATION OPERATION - the « engine and gearbox » assembly (see 10A,
a Always replace the crankshaft seal at the gearbox
gearbox assembly: Removal - Refitting, page
end.
10A-1) ,
a Use SURFACE CLEANER (see Vehicle: Parts - the front axle subframe (see Front axle sub-fra-
and ingredients for the repairwork) (04B, Consu- me: Removal - Refitting) (31A, Front axle compo-
mables - Products) to clean and degrease: nents),
- the mating face of the crankshaft seal on the - the front left-hand wheel driveshaft (see Front left-
crankshaft at the gearbox end, hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
- the housing of the crankshaft seal on the cylinder
block at the gearbox end.
(29A, Driveshafts),
WARNING - the engine tie-bar (see 19D, Engine mounting,
To ensure proper sealing, the gasket surfaces Lower engine tie-bar: Removal - Refitting, page
must be clean, dry and not greasy (avoid any fin- 19D-26) .
ger marks). a Remove the safety strap(s).
10A-79
K4J or K4M
a Refit:
tion),
(80A, Battery),
,
- fill the automatic gearbox (see Automatic gearbox
oil: Draining - Refilling) (23A, Automatic gear-
box).
10A-80
K7J or K7M
Essential special tooling per arm: Removal - Refitting) (85A, Wiping -
Washing),
Mot. 1129-01 Crankshaft oil seal fitting tool
(flywheel end) (80 x 100 x 8
seal).
REMOVAL - the left-hand suspended engine mounting (see

19D, Engine mounting, Left-hand suspended
19D-1) ,
Towing and lifting) (02A, Lifting equipment). - the manual gearbox (see Manual gearbox: Remo-
IMPORTANT - the « pressure plate - disc » assembly (see Me-

To prevent the vehicle from falling, lash it to the chanism / Disk: Removal - Refitting) (20A,
vehicle lift using a strap. Clutch),
a Remove: - the flywheel (see 10A, Engine and cylinder block

10A-155) .
a Drain the gearbox (see Manual gearbox oil: Drai-
ning - Refilling) (21A, Manual gearbox).
CONCERNED
a Remove:
(80A, Battery),
- the TDC sensor (see 1 7 B , Petrol injection,
Crankshaft position sensor: Removal - Refit-
ting, page 17B-27) ,
19D-26) ,
(29A, Driveshafts),
(29A, Driveshafts), 118581
- the catalytic converter (see 19B, Exhaust, Cataly- a Remove the crankshaft seal (1) at the gearbox end
tic converter: Removal - Refitting, page 19B-9) , using a screwdriver.
nents), Note:
- the starter (see 16A, Starting - Charging, Starter: Take care not to damage the mating face of the
Removal - Refitting, page 16A-12) , crankshaft seal.
10A-81
K7J or K7M
REFITTING - the « pressure plate - disc » assembly (see Me-

Clutch),
a parts always to be replaced: Crankshaft seal on
gearbox end (10,03,03,05).
a Use SURFACE CLEANER (see Vehicle: Parts - the left-hand suspended engine mounting (see
and ingredients for the repairwork) (04B, Consu- 19D, Engine mounting, Left-hand suspended
mables - Products) to clean and degrease: engine mounting: Removal - Refitting, page
19D-1) ,
- the mating face of the crankshaft seal on the
crankshaft at the gearbox end, - the scuttle panel grille (see Scuttle panel grille:
- the housing of the crankshaft seal on the cylinder
block at the gearbox end.
WARNING Washing),
To ensure proper sealing, the gasket surfaces
ger marks).
nents),
CONCERNED

(29A, Driveshafts),

(29A, Driveshafts),

19D-26) ,


14522
a Refit a new crankshaft seal to the crankshaft at the - the battery tray (see Battery tray: Removal - Re-
gearbox end, using the tool (Mot. 1129-01) (2) . fitting) (80A, Battery),

III - FINAL OPERATION (80A, Battery).
a Refit:
a Fill the gearbox (see Manual gearbox oil: Draining
- the flywheel (see 10A, Engine and cylinder block - Refilling) (21A, Manual gearbox).
10A-155) , a Refit the engine undertray.
10A-82
Sump: Removal - Refitting 10A
D4F
Mot. 1716 Removes housing with sili-

cone seals.
Tightening torquesm
sump bolts 6 N.m
IMPORTANT
tion.
REMOVAL

132920
Towing and lifting) (02A, Lifting equipment). a Detach the sump using the (Mot. 1716) (1) .
a Remove: a Remove the sump.

- the engine undertray. Note:
a Drain the engine oil (see 10A, Engine and cylinder Note the quantity of oil in the sump.
block assembly, Engine oil: Draining - Refilling,
page 10A-49) .
REFITTING
CONCERNED I - REFITTING PREPARATION OPERATION
a Apply SUPER CLEANING AGENT FOR JOINT FA-

CES (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) to:
- the sump joint face if it is to be reused,
- the cylinder block gasket face.
a Leave for approximately ten minutes.
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
18643
a a Remove the residue using a wooden spatula.
Note: a Use an ABRASIVE PAD to thoroughly clean:

Prepare for the engine oil to drain out. - the sump joint face in case of reuse,
a Remove the sump bolts. - the cylinder block joint face.
10A-83
D4F
WARNING
a Check that the sump is not:

18643
- scratched,
a Finger tighten the sump bolts until they make con-
tact.
- deformed.
a Torque tighten in order the sump bolts (6 N.m).
If this is the case, replace the sump.
a Check that the base plate is not scratched.
a Fill up the engine oil (see 10A, Engine and cylinder
page 10A-49) .
110432
a Apply a bead of SILICONE ADHESIVE SEALANT

(see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products) with an ap-
proximate diameter of 5 mm at a distance of
approximately 8 mm from the inner edge of the
sump to ensure correct sealing.

CONCERNED
a Refit the sump.
10A-84
K7J or K7M
Essential special tooling (35A, Wheels and tyres).
Tav. 1233-01 Set of tooling for operations
on drivetrain subframe.
Essential equipment
safety strap(s)
Tightening torquesm
sump bolts (initial tor- 8 N.m

que)
connecting bolts « for 8 N.m

the engine - gearbox »
(initial torque)
sump bolts 14 N.m
connecting bolts for the 44 N.m

« engine - gearbox »
133030
front axle subframe rear 105 N.m
a Remove the protection (1) from the gear control rod.
bolts
a Remove the nut from the gear control rod.
front axle subframe front 62 N.m
bolts a Remove the gear control rod.
a Attach the gear control rod to the vehicle body.
steering box bolts 50 N.m
a Unclip the protections from the subframe tie rods.
steering box nuts 50 N.m
a Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-9) .
REMOVAL

a Remove:

a Drain the engine oil (see 10A, Engine and cylinder

page 10A-49) .
a Remove:

19D-26) ,
10A-85
K7J or K7M
133287 133025
a Remove:
- the bolts (2) from the catalytic converter support,
- the catalytic converter support.
a Attach:
- the « cooling radiator - condenser - fan assembly »

to the front panel using a safety strap(s),
- the power-assisted steering box to the vehicle body

using a safety strap(s).
133033
a Remove the bolts (5) from the underbody protectors.
a Separate the underbody protectors (6) .
133995
a Remove:
- the power-assisted steering box bolts (3) ,
- the power-assisted steering box nuts (4) .
a Move the power-assisted steering box aside.
10A-86
K7J or K7M
CONCERNED
133996
a Remove the bolt (7) from each front axle subframe
tie rod. 133287
107792
134828
a Remove:
a One by one, remove the front axle subframe bolts
and replace them in turn with one of the threaded - the « engine-gearbox » connecting bolts (8) ,
rods of the tool (Tav. 1233-01).
- the sump bolts,
a Lower the front axle subframe by gradually loose-
- the sump.
ning the nuts of the tool (Tav. 1233-01).
10A-87
K7J or K7M
REFITTING

a parts always to be replaced: engine oil sump
seal (10,03,01,09).
a parts always to be replaced: Front sub-frame
bolt (13,02,02,03).
WARNING
a risk of leaks.
WARNING
ger marks).
20166
a Clean the cylinder block joint face using SUPER
CLEANING AGENT FOR JOINT FACES (see Ve-
hicle: Parts and consumables for repair) (04B,
Consumables - Products).
and consumables for repair) (04B, Consumables -
Products) to degrease:
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
20167
a Use MASTIXO (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
Products) to apply:
- four beads (A) with a diameter of 5 mm,
- two drops (B) with a diameter of 5 mm at the inter-
section of the crankshaft closure panel and the cy-
linder block.
10A-88
K7J or K7M
II - REFITTING OPERATION FOR PART a Tighten to torque:
CONCERNED
- the front axle subframe rear bolts (105 N.m),
- the front axle subframe front bolts (62 N.m).
a Refit the bolt for each front axle subframe tie rod.
a Fit the underbody protectors.
a Refit the bolts for the underbody protectors.
a Fit the steering box.
- the steering box bolts (50 N.m),
- the steering box nuts (50 N.m).
a Remove:
- the power-assisted steering box safety strap(s),
20171
- the safety strap(s) from the « cooling radiator -
condenser - fan assembly » .
a Refit:
a Refit:
- a new seal to the sump,
- the sump. - the catalytic converter support,
a Fit without tightening: - the catalytic converter (see 19B, Exhaust, Cataly-
- the sump bolts, tic converter: Removal - Refitting, page 19B-9) .
- the « engine - gearbox » connecting bolts. a Clip on the subframe tie rod protections.
a Pretighten in order and to torque the sump bolts
a Detach the gear control rod from the vehicle body.
(initial torque) (8 N.m).
a Pretighten to torque the connecting bolts « for the a Fit the gear control rod.
engine - gearbox » (initial torque) (8 N.m).
a Refit the nut to the gear control rod.
a Tighten to torque and in order:
a Fit the gear control rod protection.
- the sump bolts (14 N.m),
- the connecting bolts for the « engine - a Refit:
gearbox » (44 N.m).
a Fit the front axle subframe by gradually tightening - the engine tie-bar (see 19D, Engine mounting,
the nuts of the tool (Tav. 1233-01).
19D-26) ,
a Fit:
- the steering box, Refitting) (55A, Exterior protection),
- the « radiator - condenser - fan assembly » assem-
bly. - the engine undertray.
a One by one, remove the threaded rods of the tool a Top up the engine oil (see 10A, Engine and cylin-
(Tav. 1233-01) and replace them in turn with new der block assembly, Engine oil: Draining - Refil-
front subframe bolts. ling, page 10A-49) .
10A-89
K9K

Essential equipment
safety strap(s)
Tightening torquesm
gearbox edge bolts 44 N.m
sump bolts 14 N.m
multifunction support 25 N.m

bolt on the sump
catalytic converter ups- 50 N.m

tream strut bolt on the
cylinder block 114527
a Remove:
tream strut bolts on the - the nut (1) from the dipstick guide,
catalytic converter
- the dipstick guide,
front axle subframe rear s105 N.m - the front bumper (see Front bumper: Removal -
bolt Refitting) (55A, Exterior protection),
front axle subframe front s62 N.m - the engine undertray bolts,
bolt - the engine undertray.
steering box studs 50 N.m a Drain the engine oil (see 10A, Engine and cylinder
steering box bolts 50 N.m page 10A-49) .
IMPORTANT
tion.
REMOVAL

a Remove:
- the engine cover,
- the dipstick.
10A-90
K9K
132608 134829
a Remove: a Undo the bolt for the front axle subframe acoustic
- the lower engine tie-bar tie rod bolts (2) , mass (4) .
- the lower engine tie-bar tie rod, a Remove:
- the bolt (3) from the lower engine tie-bar tie rod, - the steering box bolts (5) ,
- the lower engine tie-bar. - the steering box bolts (6) .
a Attach: a Remove the steering box.
- the « cooling radiator - engine cooling fan
assembly » to the radiator upper cross member
using a safety strap(s),
- the steering box to the vehicle body using a safety
strap(s).
14175
a Remove the bolts (7) from each subframe - vehicle

body tie rod.
a Unclip the protection for each front axle subframe tie
rod.
10A-91
K9K
134004
134831
134828
a One by one, remove the front axle subframe bolts
(9) and replace them in turn with one of the threaded
134830 Note:
a Remove: The nuts of the tool (Tav. 1233-01) must be in
- the bolt (8) from each front axle subframe tie rod, contact with the front axle subframe.
- the bolt from the cooling radiator lower hose clip. a Lower the subframe by gradually loosening the nuts
of the tool (Tav. 1233-01).
10A-92
K9K
123838 123815
a Remove: a Remove:
- the relay bearing bracket bolt, - from the catalytic converter, the bolts (11) of the ca-
talytic converter upstream strut,
- the bolts (10) from the relay bearing,
- from the cylinder block, the bolt (12) of the catalytic
- the relay bearing.
converter upstream strut.
a Undo the bolt (13) of the catalytic converter ups-
tream strut from the cylinder block.
a Remove the catalytic converter upstream strut.

CONCERNED
a Remove the sump bolt from the multifunction sup-
port.
10A-93
K9K
a Always replace:
- the front axle subframe bolts,
- the sump seal.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
WARNING
a risk of leaks.

hicle: Parts and ingredients for the repairwork)
(04B, Consumables - Products) and an ABRASIVE
PAD.
109153
mables - Products) and CLEAN CLOTHS to de-
grease:
- the sump seal housings in case of reuse,
WARNING
ger marks).
WARNING
20171
a Remove:
- the bolts (14) from the edge of the gearbox,
- the bolts (15) from the sump,
- the sump,
- the sump seal.
REFITTING

a Clean the oil pump strainer with a cloth.
10A-94
K9K
CONCERNED
a Refit:
- a new seal on the sump,
- the sump.
a Fit without tightening:
- the gearbox edge bolts,
- the sump bolts.
a Torque tighten the gearbox edge bolts (44 N.m).
20166
20171
a Tighten to torque and in order the sump bolts (14
N.m).
a Torque tighten the multifunction support bolt on
the sump (25 N.m).
20167 a Refit the catalytic converter upstream strut.

a Apply: a Fit the catalytic converter upstream strut bolts on the
catalytic converter without tightening them.
- four beads of SILICONE ADHESIVE SEALANT
(16) (04B, Consumables - Products) with a diame- a Tighten to torque:
ter of 5 mm,
- the catalytic converter upstream strut bolt on
- two drops (17) of SILICONE ADHESIVE SEA- the cylinder block (50 N.m),
LANT (04B, Consumables - Products) with a dia-
- the catalytic converter upstream strut bolts on
meter of 5 mm at the intersection between the
the catalytic converter (26 N.m).
cylinder block and the crankshaft nose closure pa-
nel. a Tighten the bolt for the catalytic converter upstream
strut on the cylinder block.
a Refit:
- the relay bearing,
10A-95
K9K
- the relay bearing bolts,
- the relay bearing bracket bolt.
a Fit the front axle subframe using the tool (Tav. 1233-
01).
a Remove the tool (Tav. 1233-01).
- the front axle subframe rear bolt (s105 N.m),
- the front axle subframe front bolt (s62 N.m).
a Refit:
- the bolt for the cooling radiator bottom hose clip,
- the bolts for each front axle subframe tie rod.
a Clip on the protection for each front axle subframe

tie rod.
a Refit the bolts for each subframe - vehicle body tie

rod.
- the steering box studs (50 N.m),
- the steering box bolts (50 N.m).
a Tighten the bolt for the front axle subframe acoustic

mass.
a Remove:
- the safety strap(s) from the steering box,
- the safety strap(s) from the « cooling radiator - en-

gine cooling fan assembly » .
a Refit:
- the lower engine tie-bar,
- the lower engine tie-bar tie rod.

page 10A-49) .
a Refit:

- the dipstick,
- the engine cover.
10A-96
K4J or K4M
a Attach:
- the « cooling radiator - engine cooling fan
assembly » to the front panel using a safety
strap(s),
Essential equipment - the power-assisted steering box to the vehicle body

safety strap(s) using a safety strap(s).
Tightening torquesm
sump bolts 14 N.m
sump bolts on the gear- 44 N.m

box

bolt on the sump
front axle subframe rear 105 N.m

bolts
front axle subframe front 62 N.m

bolts 133995
steering box bolts 50 N.m a Remove:
steering box nuts 50 N.m - the power-assisted steering box bolts (1) ,
- the power-assisted steering box nuts (2) .

REMOVAL
a Move the power-assisted steering box to one side.

a Remove:


page 10A-49) .
a Remove:

page 19D-26) , 14175
- the front wheels (see Wheel: Removal - Refitting) a Remove the bolts (3) from each subframe - vehicle
(35A, Wheels and tyres). body tie rod.
10A-97
K4J or K4M
133996
a Remove the bolt (4) from each front axle subframe
tie rod.
13507
a One by one, remove the front axle subframe bolts a Lower the front axle subframe by gradually loose-
and replace them in turn with one of the threaded ning the nuts of the tool (Tav. 1233-01).
10A-98
K4J or K4M
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

a Always replace:
- the sump gasket,
- the front axle subframe bolts.
WARNING
a risk of leaks.

(04B, Consumables - Products).
WARNING
115584 must be clean, dry and not greasy (avoid any fin-
a Remove the bolts (5) from the gearbox sump. ger marks).

mables - Products) to degrease:
WARNING
20171
a Remove:
- the sump bolts,
- the sump,
- the sump seal.
10A-99
K4J or K4M
CONCERNED
a Refit:
- a new seal on the sump,
- the sump.
20166
20171
a Tighten to torque and in order the sump bolts (14
N.m).
a Tighten to torque the sump bolts on the gearbox
(44 N.m).
a Torque tighten the multifunction support bolt on
the sump (25 N.m).

a Fit the front axle subframe by gradually tightening
the nuts of the tool (Tav. 1233-01).
a One by one, remove the threaded rods of tool (Tav.
20167 1233-01) and replace them in turn with new front
subframe bolts.
a Apply:
- four beads (A) of MASTIXO (see Vehicle: Parts
and ingredients for the repairwork) (04B, Con- - the front axle subframe rear bolts (105 N.m),
sumables - Products) with a diameter of 5 mm, - the front axle subframe front bolts (62 N.m).
- two drops (B) of MASTIXO (see Vehicle: Parts
a Refit:
and ingredients for the repairwork) (04B, Con-
sumables - Products) with a diameter of 5 mm. - the bolt for each front axle subframe tie rod,
- the bolts for each subframe - vehicle body tie rod.
- the steering box bolts (50 N.m),
10A-100
K4J or K4M
- the steering box nuts (50 N.m).
a Remove:
- the safety strap(s) from the steering box,
- the safety strap(s) from the « cooling radiator-en-
gine cooling fan assembly » .
a Refit:
page 19D-26) ,
page 10A-49) .
10A-101
Conrod bearing shell: Removal - Refitting 10A
K9K
REMOVAL
Mot. 1914 Tool for fitting G9 con rod I - REMOVAL PREPARATION OPERATION
bearing shells
Mot. 1920 Tool for fitting F9 / K9 con rod Towing and lifting) (02A, Lifting equipment).
bearing shells a Remove the engine undertray.
a Drain the oil from the engine (see 10A, Engine and
Essential equipment
safety strap(s) Refilling, page 10A-49) .
a Remove the oil filter (see 10A, Engine and cylinder
component jack block assembly, Oil filter: Removal - Refitting,
page 10A-57) .
indelible pencil
a Remove the lower engine tie-bar (see 19D, Engine
torque wrench mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-26) .
diagnostic tool
a Strap the radiator to the vehicle using safety
strap(s).
Tightening torquesm a Remove the front axle subframe (see Front axle
sub-frame: Removal - Refitting) (31A, Front axle
con rod cap bolts 20 N.m + 45˚ ±
components).
6˚
oil pump bolts 25 N.m
IMPORTANT
repair (see Vehicle: Precautions for repair) .
IMPORTANT
tion.
123838
a Remove the relay bearing of the front right-hand
wheel driveshaft.
10A-102
K9K
140940
a
WARNING
Failure to observe the following procedure may
damage the oil pump strainer.
123834
a Disconnect the oil level sensor connector (if equip- Undo the bolts of the engine oil sump.
ped) (2) .
a Fit a component jack to support the engine oil
sump.
a Remove the bolts from the engine oil sump.
a Detach the engine oil sump, while supporting it with
the component jack.
112328
a Remove the catalytic converter upstream stay (3) .
10A-103
K9K
II - REMOVAL OPERATION FOR THE CON ROD
BEARING SHELLS NO.2
140917
a Tilt the engine oil sump forwards in order to access
the oil pump bolts. 139306
a Partially loosen the oil pump bolts 3 mm to 5 mm.
a Detach the oil pump from its position in order to re- mables - Products) to clean the big ends.
move the engine oil sump.
a Mark the position of the con rod cap in relation to the
a Remove: con rod body using a indelible pencil.
- the engine oil sump, a Position the crankshaft at Top Dead Centre.
- the engine oil sump seal,
- the oil pump.
10A-104
K9K
139300 139310
a Remove: a Fit the tie rod of the tool (Mot. 1914) on the con rod
body.
- the con rod bolts,
a Push the con rod upwards to release the con rod
- the con rod cap,
from the crankpin.
- the lower con rod bearing shell.
a Turn the crankshaft 90˚ clockwise (timing end).
Note:
If reusing the con rod bearing shells, mark the
position of the lower con rod bearing shell in rela-
tion to the con rod cap.

mables - products) to clean the bearing mating face
on the con rod cap.
10A-105
K9K
a
Note:
Always replace con rod bearing shells with a
width of 20 mm by con rod bearing shells with a
width of 18 mm.
If the set of con rod bearing shells only includes
con rod bearing shells which are 18mm wide,
only use the head of the tool (Mot. 1920) with the
marking " K9K SUP ".
Fit the head of the tool (Mot. 1920) with the marking
" K9K INF " on the threaded sleeve of the tool (Mot.
1914).
a Position the lower con rod bearing shell on the tool
(Mot. 1920).
139315
a
WARNING
damage the piston base cooling jets.
Pull the con rod - piston assembly using the tie rod of
the tool (Mot. 1914), taking care not to allow the pis-
ton to touch the piston base cooling jets.
a Remove the upper con rod bearing shell.
Note:
If reusing the con rod bearing shells, mark the
position of the upper con rod bearing shell in
relation to the con rod body.

mables - products) to clean the bearing mating face
on the con rod body.
REFITTING
I - REFITTING OPERATION FOR THE CON ROD

BEARING SHELLS ON CYLINDER NO.2
a parts always to be replaced: con rod cap bolts
(10,03,02,10)
10A-106
K9K
133814 139318
a Remove the tool head with the marking " K9K INF "
and fit the head with the marking " K9K SUP ".
a Position the upper con rod bearing shell on the tool
(Mot. 1920).
a Fit the upper con rod bearing shell on the con rod
body using the tool (Mot. 1920).
a Position the upper con rod bearing shell so that the
ends do not protrude beyond the con rod body.
a Lubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.
a Push the con rod - piston assembly back up into pla-
ce.
a Turn the crankshaft 90˚ anticlockwise.
a Lubricate the crankpin with new engine oil.
a Pull the con rod - piston assembly to position the con
rod on the crankshaft.
133815 a
a
Note:
Note: Before refitting the con rod cap, ensure that there
The contact surface between the bearing shell are no impurities (filings, cloth lint, etc.) on the
and the con rod must be dry and free of grease. con rod body or cap surfaces.
Fit the lower con rod bearing shell on the con rod Refit:
cap using the tool (Mot. 1920). - the con rod cap according to the mark made during
removal,
a Position the lower con rod bearing shell so that the
ends do not protrude beyond the con rod cap. - the new con rod bolts.
a Lubricate the surface of the con rod bearing shell a Torque and angle tighten the con rod cap bolts (20
(crankshaft end) using new engine oil. N.m + 45˚ ± 6˚).
10A-107
K9K
II - REMOVAL - REFITTING OPERATIONS FOR THE
CON ROD BEARING SHELLS ON CYLINDERS
NO.3, 1 AND 4
a Perform the same removal - refitting operations as

for the con rod bearing shells on cylinder no. 2.
Note:
For removing and refitting the con rod bearing
shells on cylinders no. 1 and no. 4, position the
pistons at Bottom Dead Centre before performing
the same removal and refitting operations as for
the con rod bearing shells on cylinder no. 2.
a parts always to be replaced: engine oil sump

seal (10,03,01,09)
20166
parts always to be replaced: Oil filter (10,05,05,
03)
parts always to be replaced: Engine oil sump

WARNING
a risk of leaks.
WARNING
ger marks).
a Use a wooden spatula or an ABRASIVE PAD to

clean the joint face of the cylinder block and engine
oil sump. 20167
a Apply SILICONE ADHESIVE SEALANT (see Vehi-
a Refit the oil pump. cle: Parts and ingredients for the repairwork) :
a Fit without tightening the oil pump bolts, while kee- - four beads with a diameter of 5 mm at (A) ,
ping a clearance of 3 mm to 5 mm.
- two drops with a diameter of 5 mm at (B) .
a Fit the engine oil sump seal. a Fit the engine oil sump while supporting it using a
component jack.
WARNING
10A-108
K9K
140918 123824
a Tilt the engine oil sump forwards in order to access a Disconnect the crankshaft position sensor (4) to pre-
the oil pump bolts. vent the engine from starting.
a Torque tighten the oil pump bolts (25 N.m) using a Refit the oil filter (see 10A, Engine and cylinder
the torque wrench PROSTEEL, part number 77 11 block assembly, Oil filter: Removal - Refitting,
226 888 starting with the 13 mm bolt. page 10A-57)
a a Fill up the engine oil (see 10A, Engine and cylinder

Note: page 10A-49) .
Check that the engine oil sump seal is definitely a Start the engine using the starter until the engine oil
in place before tightening the engine oil sump warning light goes out.
bolts.
a Connect the crankshaft position sensor.
a Refit the engine oil sump bolts. a Refit the engine undertray.
a Torque tighten in order the engine oil sump bolts a Clear the present faults using the diagnostic tool.
(see 10A, Engine and cylinder block assembly,
Sump: Removal - Refitting, page 10A-83) .
a Refit the catalytic converter upstream stay (see 19B,

Exhaust, Catalytic converter: Removal - Refit-
ting, page 19B-9) .
a Connect the connector to the oil level sensor.
a Refit the relay bearing of the front right-hand wheel
driveshaft (see Front right-hand wheel driveshaft:
Removal - Refitting) .
a Refit the front axle subframe (see Front axle sub-

frame: Removal - Refitting) (31A, Front axle com-
ponents).
a Remove the safety strap(s) from the radiator.
a Refit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-26) .
10A-109
Exchanger: Removal - Refitting 10A
K9K, and 740
Tightening torquesm
oil-water heat exchan- 39 N.m

ger bolt
oil filter support bolt 28 N.m
IMPORTANT
tion.
IMPORTANT
REMOVAL
123835
a Disconnect the oil pressure sensor connector (1) .
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery).
a Remove:
- the engine cover,
a Drain the cooling system (see 19A, Cooling, Coo-
107856
a Remove:
- the bolt (2) from the oil filter support,
- the oil filter support.
10A-110
K9K, and 740
CONCERNED
133518
a Remove the seal (3) from the oil filter support.
107857
a Remove:
- the bolt (7) from the oil-water heat exchanger,
- the oil-water heat exchanger (8) .
a Using a clean cloth, clean up any oil and coolant
runs on the cylinder block and on the oil filter sup-
port.
REFITTING

a Always replace:
- the oil-water heat exchanger seals,
- the seals of the oil filter support bolt,
- the oil filter support seal.
133609
a Remove:
- the oil filter support bolt (5) from the oil filter support
(4) ,
- the seals (6) from the oil filter support bolt.
10A-111
K9K, and 740
107306 107306
a Remove the oil-water heat exchanger seals (9) . a Refit new seals (10) and (11) on the oil-water heat
exchanger.
and ingredients for the repairwork) (04B, Consu- a Apply soapy water to the two seals (11) in contact
mables - Products) to clean and degrease: with the coolant pump inlet pipe.
- the housing of each seal in the oil-water heat ex-
changer if it is to be reused, II - REFITTING OPERATION FOR PART
CONCERNED
- the oil-water heat exchanger joint face if it is to be
reused, a Apply two drops of HIGH STRENGTH THREAD
LOCK (see Vehicle: Parts and ingredients for the
- the mating face of each seal on the coolant pump
repairwork) (04B, Consumables - Products) to the
inlet pipe,
oil-coolant heat exchanger bolt.
- the joint face on the cylinder block,
- the housing of each seal in the oil filter support bolt,
- the housing of each seal in the oil filter support.
107857
a Refit the oil-water heat exchanger (12) .
10A-112
K9K, and 740
a Torque tighten the oil-water heat exchanger bolt
(39 N.m).
133518
133609
a Refit:
- new seals (13) to the oil filter support bolt (14) ,
- the oil filter support bolt (14) to the oil filter support
(15) .
107857
a Refit:
- a new seal in the housing of the oil filter support,
- the oil filter support, positioning the lug (16) in the

hole (17) of the oil-water heat exchanger.
a Torque tighten the oil filter support bolt (28 N.m).
a Connect the oil pressure sensor connector.
a Refit the engine cover.
a Connect the battery (see Battery : Removal - Refit-

10A-113
K9K, and 740
a Fill the cooling system (see 19A, Cooling, Cooling
a Bleed the cooling system (see 19A, Cooling, Coo-
a Top up the engine oil if necessary.
Note:
The engine oil level must be between the MIN
and MAX marks on the dipstick.
a Check for oil leaks from the oil-water heat exchan-

ger.
10A-114
K9K, and 700

clips.
Tightening torquesm
oil-water heat exchan- 39 N.m

ger bolt
oil filter support bolt 28 N.m
IMPORTANT
REMOVAL 19706
a Remove:
I - REMOVAL PREPARATION OPERATION - the bolt (1) from the oil filter support,
a Position the vehicle on a two-post lift (see Vehicle: - the oil filter holder.
a Remove:
- the engine cover,
133518
a Remove the oil filter support seal (3) .
10A-115
K9K, and 700
CONCERNED
133609
a Remove:
133803
- the oil filter support bolt (5) from the oil filter support
a Fit the tool (Ms. 583) to each cooling hose (5) of the
(4) ,
oil-water heat exchanger.
- the oil filter support bolt seals (6) from the oil filter
a Separate the clip (7) of each cooling hose from the
support bolt.
oil-water heat exchanger using the tool (Mot. 1448).
a Disconnect the oil-water heat exchanger cooling ho-
ses from the of the oil-water heat exchanger.
a Remove:
- the bolt (6) from the oil-water heat exchanger,
- the oil-water heat exchanger.
a Using a clean cloth, clean up any oil and coolant
runs on the cylinder block and on the oil filter holder.
10A-116
K9K, and 700
CONCERNED
20154
a Remove the oil-water heat exchanger seal (8) .
20154
a Refit a new seal on the oil-water heat exchanger and
REFITTING position the seal of the oil-water heat exchanger (9)
behind the tabs (10) of the oil-water heat exchanger.
I - REFITTING PREPARATION OPERATION a Apply two drops of HIGH STRENGTH THREAD
a Always replace: LOCK (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) to the
- the oil-water heat exchanger seal, oil-water heat exchanger bolt.
- the seals of the oil filter support bolt, a Refit:
- the oil filter support seal. - the oil-water heat exchanger,
a Use SURFACE CLEANER (see Vehicle: Parts - the oil-water heat exchanger bolt.
mables - Products) to clean and degrease: a Torque tighten the oil-water heat exchanger bolt
(39 N.m).
- the oil-water heat exchanger seal housing if it is to
be reused, a Connect the oil-water heat exchanger cooling hoses
to the oil-water heat exchanger.
- the oil-water heat exchanger joint face if it is to be
reused, a Fit the clip of each cooling hose of the oil-water heat
exchanger to the oil-water heat exchanger using the
- the joint face on the cylinder block, tool (Mot. 1448).
- the housing of each seal in the oil filter support bolt, a Remove the tool (Ms. 583) from each cooling hose
- the housing of the seals in the oil filter support. of the oil-water heat exchanger.
10A-117
K9K, and 700
20153
a Refit: a Perform the following operations:
- new oil filter support bolt seals (11) on the oil filter - top up of the coolant level,
support bolt (12) ,
- the oil filter support bolt (12) on the oil filter support ling circuit: Draining - Refilling, page 19A-7) ,
(13) , - top up the engine oil if necessary.
- a new seal (14) in the seal housing of the oil filter
support,
Note:
- the oil filter support, positioning the lug (15) in the
hole (16) of the oil-water heat exchanger. The engine oil level must be between the « min »
and « max » marks on the dipstick.
a Torque tighten the oil filter support bolt (28 N.m).
a Check for oil leaks from the oil-water heat exchan-
ger.
10A-118
Oil pressure sensor: Removal - Refitting 10A
D4F
CONCERNED
Essential equipment
1/2" long socket (12.7 mm square drive)
Tightening torquesm
oil pressure sensor 40 N.m
REMOVAL

a Remove:
132671
133046
a Remove the bolts (1) from the brackets of the power-
assisted steering pump pipe.
a Remove the pipe from the power-assisted steering 132917
pump.
a Remove the oil pressure sensor using a 1/2" long
socket (12.7 mm square drive) (3) .
REFITTING
I - REFITTING OPERATION FOR PART

CONCERNED
a Refit the oil pressure sensor.
10A-119
D4F
a Torque tighten the oil pressure sensor (40 N.m).
II - FINAL OPERATION
a Fit the power-assisted steering pump pipe.
10A-120
K4J or K4M
Tightening torquesm
REMOVAL

a Remove:

CONCERNED
132813
a Remove the oil pressure sensor (2) .
REFITTING

CONCERNED
132812
10A-121
K7J or K7M
Tightening torquesm
REMOVAL
OPERATION FOR REMOVAL OF PART

CONCERNED
132841
a Remove the oil pressure sensor.
REFITTING
a Coat the threading of the oil pressure sensor with SI-

LICONE ADHESIVE SEALANT (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products).

CONCERNED
10A-122
K9K, and 740
Mot. 1495-01 22 mm socket for removing/
refitting oxygen sensors.
Essential equipment
diagnostic tool
Tightening torquesm
IMPORTANT
tion.
REMOVAL
123835
a Remove:
- the engine cover,
113894
a Remove the oil pressure sensor (2) using the (Mot.
1495-01).
10A-123
K9K, and 740
REFITTING

CONCERNED
a Refit the oil pressure sensor using the (Mot. 1495-
01).
a Torque tighten the oil pressure sensor (41 N.m)
using the tool (Mot. 1495-01).
a Refit:
- the engine cover.
a Connect the diagnostic tool and check for any
faults; deal with them if necessary.
10A-124
K9K, and 700

Essential equipment
diagnostic tool
Tightening torquesm
IMPORTANT
tion.
REMOVAL 134171
a Remove the oil pressure sensor (2) using the (Mot.
I - REMOVAL PREPARATION OPERATION 1495-01).
a Remove the front engine cover.

REFITTING
CONCERNED I - REFITTING OPERATION FOR PART
CONCERNED
a Refit the oil pressure sensor using the (Mot. 1495-
01).
a Torque tighten the oil pressure sensor (41 N.m)
using the tool (Mot. 1495-01).
a Connect the diagnostic tool and check for any
faults; deal with them if necessary.
134170
10A-125
Oil level sensor: Removal - Refitting 10A
K4J or K4M
Tightening torquesm
oil level sensor 25 Nm
REMOVAL

a Remove:

CONCERNED
132891
a Remove the oil level sensor (2) .
REFITTING

CONCERNED
a Refit the oil level sensor.
a Tighten to torque the oil level sensor (25 Nm).
a Connect the connector to the oil level sensor.
132890
a Disconnect the connector (1) from the oil level sen-
sor.
10A-126
Oil pump: Removal - Refitting 10A
D4F
- the sump (see 10A, Engine and cylinder block
assembly, Sump: Removal - Refitting, page
Tightening torquesm 10A-83) .

oil pump strainer bolts 9 N.m CONCERNED
REMOVAL

a Remove:

page 10A-49) .
a Remove:
132922
- the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page a Remove:
10A-57) , - the oil pump strainer bolts (1) ,
- the oil pressure sensor (see 10A, Engine and cy- - the oil pump strainer.
linder block assembly, Oil pressure sensor: Re-
moval - Refitting, page 10A-119) ,

terior protection),
page 11A-1) ,
- the crankshaft seal on the timing side (see 10A, 18646
Engine and cylinder block assembly, Cranks-
a Remove:
haft seal at timing end Removal - Refitting, page
10A-65) , - the oil pump bolts,
10A-127
D4F
- the oil pump.
18718
10275 a Apply a BEAD OF SILICONE ADHESIVE SEA-
a Remove the oil pressure supply seal (2) . LANT (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) with a
width of 1.3 mm to ensure the sealing of the oil
REFITTING pump.
I - REFITTING PREPARATION OPERATION II - REFITTING OPERATION FOR PART

a Use SUPER CLEANING AGENT FOR JOINT FA- CONCERNED
CES (see Vehicle: Parts and ingredients for the a Refit the oil pump.
repairwork) (04B, Consumables - Products) to
clean:
- the oil pump joint face if it is to be reused,
- the cylinder block joint face.
- the oil pump joint face if it is to be reused,
- the cylinder block joint face.
WARNING
a Always replace the oil pressure supply seal.
18646
a Tighten to torque and in order the oil pump bolts
(10 N.m).
a Refit the oil pump strainer.
10A-128
D4F
a Torque tighten the oil pump strainer bolts (9 N.m).

a Refit:
10A-83) ,
- the crankshaft seal on the timing side (see 10A,
Engine and cylinder block assembly, Cranks-
haft seal at timing end Removal - Refitting, page
10A-65) ,
page 11A-1) ,
terior protection),
- the oil pressure sensor (see 10A, Engine and cy-
linder block assembly, Oil pressure sensor: Re-
moval - Refitting, page 10A-119) ,
- the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
10A-57) .
a Top up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Refil-
ling, page 10A-49) .
10A-129
K9K
CONCERNED
Tightening torquesm
IMPORTANT
tion.
REMOVAL

a Remove:
- the engine cover,
Refitting) (55A, Exterior protection), 108646
- the engine undertray bolts, a Remove:
- the engine undertray. - the oil pump bolts (1) ,
a Drain the engine oil (see 10A, Engine and cylinder - the oil pump.
page 10A-49) .
REFITTING
a Remove the sump (see 10A, Engine and cylinder
block assembly, Sump: Removal - Refitting,
page 10A-83) . I - REFITTING PREPARATION OPERATION
a Check for oil pump centering rings on the cylinder
block.

CONCERNED
a Refit the oil pump.
a Torque tighten the oil pump bolts (25 N.m).

a Refit the sump (see 10A, Engine and cylinder
block assembly, Sump: Removal - Refitting,
page 10A-83) .
a Refit:
10A-130
K9K
- the engine cover.
10A-131
K7J or K7M
Tightening torquesm
REMOVAL

a Remove:
block assembly, Engine oil: Draining - Refilling, 133030
page 10A-49) . a Move aside the protective cover (1) of the gear con-
a Remove: trol rod.
- the engine tie-bar (see 19D, Engine mounting, a Remove the nut from the gear control rod.
Lower engine tie-bar: Removal - Refitting, page a Move aside the gear control rod.
19D-26) ,
a Attach the gear control rod to the vehicle body.
(35A, Wheels and tyres). a Unclip the protections from the subframe tie rods.
a Remove:
10A-83) .
10A-132
K7J or K7M
II - OPERATION FOR REMOVAL OF PART a Refit:
CONCERNED
19D-26) ,
108646
a Remove:
- the oil pump bolts (2) ,
- the oil pump.
REMOVAL

CONCERNED
a Position the oil pump pinion on the chain.

a Refit:
10A-83) ,
a Clip on the subframe tie rod protections.
a Detach the gear control rod from the vehicle body.
a Fit the gear control rod in place.
a Refit the gear control rod nut.
a Fit the gear control nut protection in place.
10A-133
K4J or K4M
CONCERNED
Tightening torquesm
REMOVAL

a Remove:
page 10A-49) .
108646
a Remove:
a Remove:
ting, Lower engine tie-bar: Removal - Refitting, - the oil pump bolts (1) ,
page 19D-26) ,
- the oil pump.
REFITTING
10A-83) . I - REFITTING PREPARATION OPERATION
a Check for oil pump centering rings on the cylinder

block.

CONCERNED

a Refit:

10A-83) ,

page 19D-26) .
10A-134
K4J or K4M
page 10A-49) .
a Refit:
10A-135
Oil pressure: Check 10A
D4F
Mot. 836-05 Oil pressure gauge kit.

WARNING
Note:
87363
dipstick.

WORK
a Always replace:
- the sump plug sealing washer (in the event of an oil
change),
- oil filter (if removed).
a Consumable:
II - CHECK
a Remove:
- the engine undertray, 132928
- the oil pressure sensor (see 10A, Engine and cy- a In place of the oil pressure sensor, fit the tool (Mot.
linder block assembly, Oil pressure sensor: Re- 836-05) (F) fitted with end pieces (E) and (C) using
moval - Refitting, page 10A-119) . the tool (Mot. 1495-01) or a 22 mm long socket.
a Start the vehicle.
a Monitor the engine oil pressure as the oil temperatu-

re rises (approximately 80˚C or the first time the en-
gine cooling fan is activated); it should not be less
than the pressure at idle speed.
a If the oil pressure is lower than the pressure at idle

speed, check that:
- the oil filter is not clogged,
10A-136
D4F
- dirt or swarf is not present in the engine oil,
- the oil pump is in good condition and being correct-
ly driven.
a D4F engine:
- idle speed: 1.5 bar,
- 3000 rpm: 3.9 bar.
a Switch off the engine.
a Remove the (Mot. 836-05) with the end pieces.
a Refit the oil pressure sensor (see 10A, Engine and
cylinder block assembly, Oil pressure sensor:
Removal - Refitting, page 10A-119) .
a Top up the oil level if necessary (see Engine oil:
Specifications) (Technical Note 6013A, 04A, Lubri-
cants).
a Start the vehicle and check that there are no oil
leaks at the oil pressure sensor.
10A-137
K7J or K7M

WARNING
Note:
87363
dipstick.

03) (in the event of removal).
drain plug seal (10,03,01,04) (in the event of an oil
change).
a Consumable:
II - CHECKING
a Remove the oil pressure sensor (see 10A, Engine
and cylinder block assembly, Oil pressure sen-
sor: Removal - Refitting, page 10A-119) .
133535
a In place of the oil pressure sensor, fit the tool (Mot.

836-05) (F) fitted with end pieces (E) and (C) using
the tool (Mot. 1495-01) or a 22 mm long socket.


speed, check that:
10A-138
K7J or K7M
ly driven.
a K7J/K7M engine:
- 3000 rpm: 3.7 bar.
cants).
10A-139
K4J or K4M
WARNING
Note:
least 10 minutes for the oil to settle before chec-
king the level with a dipstick.
87363

WORK
a Always replace:
- the sump plug sealing washer (in the event of an oil
change),
- oil filter (if removed).
a Consumable:
II - CHECK
a Remove:
- the oil pressure sensor (see 10A, Engine and cy- a Fit the end piece (C) of the tool (Mot. 836-05) in pla-
linder block assembly, Oil pressure sensor: Re- ce of the oil pressure sensor.
moval - Refitting, page 10A-119) .
10A-140
K4J or K4M
133512
a Connect the oil pressure gauge (F) of the tool (Mot.
836-05) to the end piece (C) .
a K4J/K4M engines:
- 4000 rpm: 3.1 bar.
speed, check that:
ly driven.
a Remove the tool (Mot. 836-05) assembly.
cants).
10A-141
K9K

IMPORTANT
tion.
WARNING
a In place of the oil pressure sensor, fit the tool (Mot.

836-05) (F) fitted with adapters (E) and (C) using
the tool (Mot. 1495-01) or a 22 mm long socket.
Note:
least 10 minutes before checking the level with a a Monitor the engine oil pressure as the oil temperatu-
dipstick. re rises (approximately 80˚C or the first time the en-
a parts always to be replaced: Oil filter (10,05,05, speed, check that:
03) (in the event of removal).
drain plug seal (10,03,01,04) (in the event of an oil - dirt or swarf is not present in the engine oil,
change).
a Consumable: ly driven.
- engine oil (see Engine oil: Specifications) (Tech- a Minimum oil pressure:
- at idle speed: 0.8 bar,
II - CHECKING - at 4000 rpm: 3.4 bar.

a Remove the oil pressure sensor (see 10A, Engine a Maximum oil pressure at 4000 rpm: 5.2 bar.
and cylinder block assembly, Oil pressure sen-
sor: Removal - Refitting, page 10A-119) .
10A-142
K9K
a Top up the oil with engine oil recommended by the
10A-143
Multifunction support: Removal - Refitting 10A
K9K, and 740
CONCERNED
Tightening torquesm
bolts mounting the mul- 44 N.m

tifunction support on the
cylinder block
bolt mounting the multi- 25 N.m

function support on the
sump
REMOVAL


a Remove:
120315
- the engine cover, a Remove:
- the windscreen wiper arms (see Windscreen wi- - the multifunction support bolts (1) ,
Washing), - the multifunction support.

Removal - Refitting) (56A, Exterior equipment), REFITTING
Refitting) (35A, Wheels and tyres), I - REFITTING OPERATION FOR PART
CONCERNED
terior protection),


19D-16) ,

page 11A-1) ,
- the power-assisted steering pump (see Power as-

sisted steering pump: Removal - Refitting)
- the alternator (see 16A, Starting - Charging, Al-

ternator: Removal - Refitting, page 16A-1) .
a Unclip the camshaft position sensor wiring from the 120315
multifunction support. a Refit the multifunction support.
10A-144
K9K, and 740
a Fit the multifunction support bolts without tightening
them.
- the bolts mounting the multifunction support

on the cylinder block (44 N.m),
- the bolt mounting the multifunction support on

the sump (25 N.m).
a Clip the wiring of the camshaft position sensor onto

the multifunction support.
a Refit:

ternator: Removal - Refitting, page 16A-1) ,


page 11A-1) ,

19D-16) ,

terior protection),



Washing),
- the engine cover.


10A-145
D4F
REFITTING THE ALTERNATOR

Essential equipment MOUNTING

CONCERNED
Tightening torquesm a Refit the alternator (see 16A, Starting - Charging,

Alternator: Removal - Refitting, page 16A-1) .
air conditioning com- 50 N.m
pressor mounting bolts
power-assisted steering 22 N.m a Refit:
pump support bolts
page 11A-1) ,
REMOVING THE ALTERNATOR
MOUNTING - the air filter unit (see 12A, Fuel mixture, Air filter
I - REMOVAL PREPARATION OPERATION - the engine undertray,

terior protection),
a Disconnect the battery (see Battery : Removal - - the front right-hand wheel (see Wheel: Removal -
Refitting) (80A, Battery). Refitting) (35A, Wheels and tyres).
a Remove: a Connect the battery (see Battery : Removal - Refit-
REMOVING THE AIR CONDITIONING
- the front right-hand wheel arch liner (see Front COMPRESSOR MOUNTING
terior protection),
- the engine undertray, Towing and lifting) (02A, Lifting equipment).
- the air filter unit (see 12A, Fuel mixture, Air filter a Drain the refrigerant circuit using a refrigerant char-
unit: Removal - Refitting, page 12A-5) , ging station (see Coolant circuit Draining - Refil-
page 11A-1) .
a Remove:
II - OPERATION FOR REMOVAL OF PART - the front right-hand wheel (see Wheel: Removal -
CONCERNED Refitting) (35A, Wheels and tyres),
a Remove the alternator (see 16A, Starting - Char- - the front right-hand wheel arch liner (see Front
ging, Alternator: Removal - Refitting, page 16A- wheel arch liner: Removal - Refitting) (55A, Ex-
1) . terior protection),
Note: page 11A-1) ,
The alternator mounting must be removed in - the air conditioning compressor (see Compressor:
order to remove the alternator. Removal - Refitting) (62A, Air conditioning).
10A-146
D4F
REFITTING THE AIR CONDITIONING

COMPRESSOR MOUNTING

CONCERNED
a Refit the air conditioning compressor support.
a Torque tighten the air conditioning compressor
mounting bolts (50 N.m).
a Position the alternator towards the engine cooling
fan assembly.
a Refit:
- the alternator upper bolt,
- the air conditioning compressor (see Compressor:
Removal - Refitting) (62A, Air conditioning),
132706 - the accessories belt (see 11A, Top and front of
a Remove the alternator upper bolt (1) .
page 11A-1) ,
a Rotate the alternator towards the engine cooling fan - the front right-hand wheel arch liner (see Front
assembly. wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
II - OPERATION FOR REMOVAL OF PART - the engine undertray,
CONCERNED
REMOVING THE POWER-ASSISTED

STEERING PUMP SUPPORT

a Remove:
132825 - the front right-hand wheel (see Wheel: Removal -
a Remove:
- the bolts (2) from the air conditioning compressor wheel arch liner: Removal - Refitting) (55A, Ex-
mounting, terior protection),
- the air conditioning compressor support. - the engine undertray bolts,
10A-147
D4F
- the engine undertray, - the accessories belt (see 11A, Top and front of
page 11A-1) ,
page 11A-1) , - the engine undertray,
- the power-assisted steering pump (see Power as- - the front right-hand wheel arch liner (see Front
sisted steering pump: Removal - Refitting) wheel arch liner: Removal - Refitting) (55A, Ex-
(36B, Power-assisted steering). terior protection),
II - OPERATION FOR REMOVAL OF PART Refitting) (35A, Wheels and tyres).
CONCERNED a Connect the battery (see Battery : Removal - Refit-
133043
a Remove:
- the power-assisted steering pump support bolts (3)
,
- the power-assisted steering pump support.
REFITTING THE POWER ASSISTED

STEERING PUMP SUPPORT

CONCERNED
a Refit the power-assisted steering pump mounting.
a Torque tighten the power-assisted steering pump
support bolts (22 N.m).
a Refit:
10A-148
K7J or K7M
Essential equipment
page 11A-1) ,
refrigerant charging station - the power-assisted steering pump (see Power as-
Tightening torquesm

bolt (6) on the sump (ini-
tial torque)
bolts (1), (4), (5), (3), (2) 44 N.m

of the multifunction sup-
port
bolt (6) of the multifunc- 25 N.m

tion support on the
sump
bolt (7) of the multifunc- 25 N.m

tion support on the inter-
mediate bracket
REMOVAL
I - REMOVAL PREPARATION OPERATION 133156

a Remove:
Towing and lifting) (02A, Lifting equipment). - the bolt (1) from the power-assisted steering pipe
of the multifunction support,
ging station (see Coolant circuit Draining - Refil- - the alternator (see 16A, Starting - Charging, Al-
ling) (62A, Air conditioning). ternator: Removal - Refitting, page 16A-1) ,
a Remove:
Removal - Refitting) (62A, Air conditioning).
(80A, Battery),


terior protection),


19D-26) ,
10A-149
K7J or K7M
CONCERNED

CONCERNED
133135
a Remove:
- the multifunction support bolts (2) , 133135
- the multifunction support. a Without tightening, fit the bolts (1) to (7) .
a Pretighten to torque the multifunction support bolt
(6) on the sump (initial torque) (20 N.m).
a Torque tighten in order the bolts (1), (4), (5), (3), (2)
of the multifunction support (44 N.m).
- the bolt (6) of the multifunction support on the
sump (25 N.m).
- the bolt (7) of the multifunction support on the
intermediate bracket (25 N.m).
a Refit:
- the power-assisted steering pipe bolt of the multi-
function support,
page 11A-1) ,
10A-150
K7J or K7M
19D-26) ,
terior protection),
(80A, Battery).
- the front headlight beam adjustment (see Front
headlight: Adjusting) (80B, Headlight).
10A-151
K4J or K4M

bly.
Essential equipment
Tightening torquesm

bolt on the sump (initial
torque)

bolts on the cylinder
block
multifunction support 25 N.m 101793

bolt on the sump a Remove the nuts (1) from the exhaust bracket.
exhaust bracket nuts 21 N.m a Separate the catalytic converter from the exhaust
manifold.
REMOVAL
a Position the (Mot. 1390) under the engine.
a Remove:
a Position the vehicle on a two-post lift (see Vehicle: 19D, Engine mounting, Right-hand suspended
Towing and lifting) (02A, Lifting equipment). engine mounting: Removal - Refitting, page
19D-16) ,
ging station (see Coolant circuit Draining - Refil- - the accessories belt (see 11A, Top and front of
ling) (62A, Air conditioning). engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
a Remove:
- the engine undertray bolts, sisted steering pump: Removal - Refitting)
- the front bumper (see Front bumper: Removal - ternator: Removal - Refitting, page 16A-1) ,
- the right-hand headlight (see Front headlight: Re- Removal - Refitting) (62A, Air conditioning).


terior protection),

page 19D-26) .
10A-152
K4J or K4M
CONCERNED CONCERNED
a Refit the multifunction support.
a Fit the multifunction support bolts without tightening
them.
a Pretighten the multifunction support bolt on the
sump (initial torque) (20 N.m).
- the multifunction support bolts on the cylinder
block (44 N.m),
- the multifunction support bolt on the sump (25
N.m).

a Refit:
133268 - the alternator (see 16A, Starting - Charging, Al-

page 11A-1) ,
19D-16) .
a Refit a new exhaust bracket seal.
a Position the catalytic converter on the exhaust mani-

fold.
133269
a Refit:
a Remove: - the lower engine tie-bar (see 19D, Engine moun-

- the multifunction support bolts (2) , page 19D-26) ,
- the multifunction support. - the front right-hand wheel arch liner (see Front
terior protection),
REFITTING
a Always replace the exhaust bracket seal. moval - Refitting) (80B, Headlights),
10A-153
K4J or K4M
10A-154
Flywheel: Removal - Refitting 10A
K7J or K7M
Essential special tooling me: Removal - Refitting) (31A, Front axle compo-
nents),
Mot. 582-01 Flywheel locking tool.
Tightening torquesm
flywheel bolts 25 N.m + 50˚ per arm: Removal - Refitting) (85A, Wiping -
Washing),

REMOVAL Removal - Refitting) (56A, Exterior equipment),
- the left-hand suspended engine mounting (see

I - REMOVAL PREPARATION OPERATION 19D, Engine mounting, Left-hand suspended
19D-1) ,
IMPORTANT
To prevent the vehicle from falling, lash it to the - the « pressure plate - disc » assembly (see Me-
vehicle lift using a strap. chanism / Disk: Removal - Refitting) (20A,
Clutch).
a Remove:
- the engine undertray bolts, II - OPERATION FOR REMOVAL OF PART

CONCERNED

ning - Refilling) (21A, Manual gearbox).
a Remove:

(80A, Battery),




19D-26) ,
- the front right-hand driveshaft (see Front right- 107913

hand wheel driveshaft: Removal - Refitting) a Lock the engine using the (Mot. 582-01) (1) .
(29A, Driveshafts),
a Remove:
- the front left-hand driveshaft (see Front left-hand
wheel driveshaft: Removal - Refitting) (29A, Dri- - the flywheel bolts,
veshafts),
- the flywheel,
tic converter: Removal - Refitting, page 19B-9) , - the (Mot. 582-01).
10A-155
K7J or K7M
REFITTING - the left-hand suspended engine mounting (see

I - REFITTING PREPARATION OPERATION 19D-1) ,
a Check the condition of the flywheel. - the scuttle panel grille (see Scuttle panel grille:
a parts always to be replaced: Flywheel bolts (10,
03,03,14). - the windscreen wiper arms (see Windscreen wi-
a Use SURFACE CLEANER (see Vehicle: Parts Washing),
mables - Products) to clean and degrease: - the starter (see 16A, Starting - Charging, Starter:
- the flywheel bearing face if reusing,
- the crankshaft bearing face. me: Removal - Refitting) (31A, Front axle compo-
nents),
II - REFITTING OPERATION FOR PART - the catalytic converter (see 19B, Exhaust, Cataly-
CONCERNED tic converter: Removal - Refitting, page 19B-9) ,
- the front left-hand driveshaft (see Front left-hand
veshafts),
- the front right-hand driveshaft (see Front right-
(29A, Driveshafts),
19D-26) ,
(80A, Battery).
107913
a Refit the flywheel.
a Fit the new flywheel bolts without tightening them.
a Lock the engine using the (Mot. 582-01).
a Tighten in order, to torque and to angle the flywheel

bolts (25 N.m + 50˚).

a Refit:
Clutch),
10A-156
D4F
Tightening torquesm
engine flywheel bolts 18 N.m + 110˚
REMOVAL

a Remove:
(80A, Battery),
132996
unit: Removal - Refitting, page 12A-5) , a Remove:
- the flywheel bolts (1) ,
- the starter (see 16A, Starting - Charging, Starter: - the (Mot. 582-01) (2) ,
- the flywheel.
- the front wheel arch liners (see Front wheel arch REFITTING
tion).
oil: Draining - Refilling) (21A, Manual gearbox). a Use SURFACE CLEANER (see Vehicle: Parts
a Remove: and ingredients for the repairwork) (04B, Consu-
hand wheel driveshaft: Removal - Refitting) - the flywheel bearing face if reusing,
(29A, Driveshafts),
- the front right-hand wheel driveshaft (see Front ri- - the crankshaft bearing face.
(29A, Driveshafts), a Always replace the flywheel bolts.

me: Removal - Refitting) (31A, Front axle compo- II - REFITTING OPERATION FOR PART
nents), CONCERNED
val - Refitting) (21A, Manual gearbox). a Fit the flywheel.
- the « pressure plate - disc » assembly (see Me- a Fit the new flywheel bolts without tightening them.
chanism / Disk: Removal - Refitting) (21A, Ma-
nual gearbox). a Position the (Mot. 582-01).
10A-157
D4F
(80A, Battery).
132996
a Tighten in order, to torque and to angle the engine

flywheel bolts (18 N.m + 110˚).

a Refit:
chanism / Disk: Removal - Refitting) (21A, Ma-
nual gearbox),
- the gearbox (see Manual gearbox: Removal - Re-
fitting) (21A, Manual gearbox),
nents),
(29A, Driveshafts),
(29A, Driveshafts).
Draining - Refilling) (21A, Manual gearbox).
a Refit:
tion),
10A-158
K9K
Essential special tooling ght-hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts),
Mot. 582 Flywheel locking tool.
Tightening torquesm - the front axle subframe (see Front axle sub-fra-
flywheel bolts 55 N.m
nents),

REMOVAL per arm: Removal - Refitting) (85A, Wiping -
Washing),
I - REMOVAL PREPARATION OPERATION - the scuttle panel grille (see Scuttle panel grille:
a Position the vehicle on a two-post lift (see Vehicle: Removal - Refitting) (56A, Exterior equipment),
a Remove: val - Refitting) (21A, Manual gearbox).
- the engine cover, - the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
(80A, Battery).
JB3 chanism / Disk: Removal - Refitting) (20A,
Clutch).
a Remove the catalytic converter (see 19B, Exhaust,
19B-9) . II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Remove:
- the crankshaft position sensor (see 13B, Diesel in-
jection, Crankshaft position sensor: Removal -
tion),
133056
ning - Refilling) (21A, Manual gearbox). a Remove:
a Remove: - the flywheel bolts (1) ,
- the front left-hand wheel driveshaft (see Front left- - the flywheel,
(29A, Driveshafts), - the (Mot. 582).
10A-159
K9K
REFITTING - the differential output seals (see Differential out-

put seal: Removal - Refitting) (21A, Manual gear-
box),
a Always replace the flywheel bolts. val - Refitting) (21A, Manual gearbox).
a Use SURFACE CLEANER (see Vehicle: Parts - the scuttle panel grille (see Scuttle panel grille:
and ingredients for the repairwork) (04B, Consu- Removal - Refitting) (56A, Exterior equipment),
- the thread hole of the flywheel bolts, per arm: Removal - Refitting) (85A, Wiping -
- the crankshaft bearing face, Washing),
- the flywheel bearing face at the crankshaft end, if - the front axle subframe (see Front axle sub-fra-
reusing. me: Removal - Refitting) (31A, Front axle compo-
nents),
II - REFITTING OPERATION FOR PART - the front bumper (see Front bumper: Removal -
CONCERNED Refitting) (55A, Exterior protection),
(29A, Driveshafts),
(29A, Driveshafts).
a Refit:
tion),
133056 - the battery tray (see Battery tray: Removal - Re-
a Refit: fitting) (80A, Battery),
- the flywheel, - the starter (see 16A, Starting - Charging, Starter:

- the (Mot. 582).
a Coat new flywheel bolts with FRENETANCHE (see JB3
Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products). a Remove the catalytic converter (see 19B, Exhaust,
a Tighten to torque and in order the flywheel bolts 19B-9) .
(55 N.m).

a Refit:
a Refit:
(80A, Battery),
Clutch), - the engine cover.
10A-160
K9K
a Bleed the clutch (see Clutch circuit: Removal - Re-
fitting) (37A, Mechanical component controls).
10A-161
K4J or K4M, and 5 SPEED MANUAL GBOX
Essential special tooling per arm: Removal - Refitting) (85A, Wiping -
Washing),
Tightening torquesm - the left-hand suspended engine mounting (see
flywheel bolts 25 N.m + 50˚ engine mounting: Removal - Refitting, page
19D-1) ,
REMOVAL - the manual gearbox (see Manual gearbox: Remo-

I - REMOVAL PREPARATION OPERATION - the « pressure plate - disc » assembly (see Me-
a Position the vehicle on a two-post lift (see Vehicle: Clutch).
a Remove: II - OPERATION FOR REMOVAL OF PART
- the battery (see Battery : Removal - Refitting) CONCERNED
(80A, Battery),
tion),
- the lower engine tie-bar (see 19D, Engine moun- 138917
a Remove:
page 19D-26) .
- the flywheel bolts (1) ,
oil: Draining - Refilling) (21A, Manual gearbox). - the (Mot. 582-01) (2) ,
a Remove: - the flywheel.
hand wheel driveshaft: Removal - Refitting) REFITTING
(29A, Driveshafts),
(29A, Driveshafts), a Use SURFACE CLEANER (see Vehicle: Parts
nents), - the flywheel bearing face if reusing,
10A-162
- the crankshaft bearing face. - the front axle subframe (see Front axle sub-fra-
a parts always to be replaced: Flywheel bolts (10, nents),
03,03,14).
II - REFITTING OPERATION FOR PART (29A, Driveshafts),
CONCERNED
a Fit the flywheel. ght-hand wheel driveshaft: Removal - Refitting)
(29A, Driveshafts).
a Fit the new flywheel bolts without tightening them.
a Position the (Mot. 582-01). Draining - Refilling) (21A, Manual gearbox).
a Refit:
page 19D-26) ,
- the air filter box (see 12A, Fuel mixture, Air filter
138917 (80A, Battery).
a Tighten in order, to torque and to angle the flywheel

bolts (25 N.m + 50˚).
a Refit:
Clutch),
- the gearbox (see Manual gearbox: Removal - Re-

fitting) (21A, Front axle components),
- the left-hand suspended engine mounting (see
19D-1) ,

Washing),
10A-163
Drive plate: Removal - Refitting 10A
K4J or K4M, and 4 SPEED AUTO GBOX
Essential special tooling (35A, Wheels and tyres),
Mot. 582-01 Flywheel locking tool. - the front wheel arch liners (see Front wheel arch
Essential equipment tion),
refrigerant charging station Refitting) (55A, Exterior protection).
safety strap(s) a Attach the « radiator - condenser » assembly to the
front upper cross member using a safety strap(s).
a Remove:
Tightening torquesm
drive plate bolts 55 N.m Lower engine tie-bar: Removal - Refitting, page
19D-26) ,
REMOVAL - the front right-hand wheel driveshaft (see Front ri-

(29A, Driveshafts),
a Position the vehicle on a two-post lift (see Vehicle: hand wheel driveshaft: Removal - Refitting)
Towing and lifting) (02A, Lifting equipment). (29A, Driveshafts),
a Remove: - the front axle subframe (see Front axle sub-fra-

- the engine undertray bolts, nents).
- the engine undertray. - the « engine and gearbox » assembly (see 10A,
a Drain: gearbox assembly: Removal - Refitting, page
- the cooling system (see 19A, Cooling, Cooling 10A-1) ,
circuit: Draining - Refilling, page 19A-7) , - the automatic transmission (see Automatic gear-
- the automatic transmission (see Automatic gearbox: Removal - Refitting) (23A, Automatic trans-
box oil: Draining - Refilling) (23A, Automatic mission).
transmission),
a Remove:
(80A, Battery),
10A-164
II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION
CONCERNED
a Refit:
- the automatic transmission (see Automatic gear-
box: Removal - Refitting) (23A, Automatic trans-
mission),
- the « engine and gearbox » assembly (see 10A,
gearbox assembly: Removal - Refitting, page
10A-1) ,
nents),
(29A, Driveshafts),
(29A, Driveshafts),
110226 19D-26) .
a Position the (Mot. 582-01) (1) . a Remove the safety strap(s).
a Refit:
a Remove:
- the drive plate bolts (2) , Refitting) (55A, Exterior protection),
- the drive plate, - the front wheel arch liners (see Front wheel arch
- the (Mot. 582-01). tion),
REFITTING
I - REFITTING PREPARATION OPERATION - the petrol injection computer (see 17B, Petrol in-
a Check that the drive plate is not damaged (run-out Refitting, page 17B-21) ,
tolerance of 0.2 mm on the external diameter).
II - REFITTING OPERATION FOR PART ting) (23A, Automatic transmission),
CONCERNED
(80A, Battery),
a Apply FRENETANCHE (see Vehicle: Parts and in-
gredients for the repairwork) (04B, Consumables - the air filter unit (see 12A, Fuel mixture, Air filter
- Products) to the bolts of the drive plate. unit: Removal - Refitting, page 12A-5) ,
a Refit the drive plate. - the air resonator (see 12A, Fuel mixture, Air reso-
a Position the (Mot. 582-01). a Perform the following operations:
a Torque tighten the drive plate bolts (55 N.m). - fill and bleed the cooling circuit (see 19A, Cooling,
a Remove the tool (Mot. 582-01). ,
10A-165
- fill the automatic transmission (see Automatic
gearbox oil: Draining - Refilling) (23A, Automatic
transmission).
10A-166
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K7J or K7M

bly.
Tightening torquesm
fixed roller bolt 25 N.m
tensioning roller bolts 25 N.m
new crankshaft acces- XX N.m

sories pulley bolt
IMPORTANT
133031
a Remove the bolts (1) from the exhaust bracket
between the catalytic converter and the expansion
WARNING chamber.
Do not run the engine without the accessories belt
to avoid damaging the crankshaft accessories pul- a Separate the expansion chamber from the catalytic
ley. converter.
a Lock the flywheel using a large flat-blade screwdri-
ver by inserting it at the level of the starter.
REMOVAL

a Remove:

(80A, Battery),


terior protection),

19D-26) .
11A-1
K7J or K7M
133026 133715
a Remove: a Unclip the wiring at (5) .
- the bolt (2) of the connecting pipe bracket on the a Move aside the wiring.
front panel,
- the bolt (3) of the connecting pipes bracket on the

side member.
a Unclip the connecting pipes.
a Separate the connecting pipe at the power-assisted

steering pump.
132834
a Disconnect the fuel pipe at (6) .
a Move the fuel pipe aside.
133492
a Disconnect the connector (4) from the fuel vapour

absorber solenoid valve.
11A-2
K7J or K7M
133036 133534
a Mark the positions of the suspended engine moun- a Remove:
tings on the body.
- the central nut (8) from the suspended engine
a Support the « engine - gearbox » assembly on engi- mounting rubber pad shaft on the gearbox,
ne marks using the (Mot. 1390).
rubber pad on the gearbox.
a Slightly lower the engine until the rubber pad deta-
ches from the suspended engine mounting on the
gearbox.
a Remove the rubber pad of the suspended engine
mounting from the gearbox.
a Separate the « engine - gearbox » assembly from
the gearbox side.
133528
a Remove:
- the bolts (7) from the suspended engine mounting
cover,
- the suspended engine mounting cover.
11A-3
K7J or K7M
II - OPERATION FOR REMOVAL OF PART a
CONCERNED
WARNING
Only use brushes with plastic or non-corrosive
metal (brass) bristles.
a In case of reuse, clean the crankshaft accessories

V-pulley using a brush to get rid of any deposit.

CONCERNED
a Fit a new fixed roller.
a Torque tighten the fixed roller bolt (25 N.m).
a Refit a new tensioning roller.
a Torque tighten the tensioning roller bolts (25

N.m).
a Refit the accessories crankshaft pulley with a new

bolt.
133131
a Turn the tensioning roller clockwise using a spanner. a Torque tighten the new crankshaft accessories
pulley bolt (XX N.m).
a Lock the tensioning roller using a 6 mm Allen key at
(10) .
a Remove:
- the accessories belt,
- the crankshaft accessories pulley bolt,
- the crankshaft accessories pulley,
- the tensioning roller bolts,
- the tensioning roller,
- the fixed roller bolt,
- the fixed roller.
REFITTING
a parts always to be replaced: Accessories belt 105998

(10,10,01,03).
(3) Crankshaft
a parts always to be replaced: Accessories belt
tensioning roller (10,10,01,04). (4) Air conditioning compressor
a parts always to be replaced: Accessories fixed (5) Alternator

roller (10,10,01,06). (6) Power-assisted steering pump
(7) Fixed roller
a parts always to be replaced: Crankshaft acces-
sories pulley bolts (10,03,03,10). (8) Tensioning roller
11A-4
K7J or K7M
a Fit the « engine - gearbox » assembly.
a Refit the suspended engine mounting rubber pad on

the gearbox.
a Refit the cover of the suspended engine mounting.
a Fit the fuel pipe.
a Remove the blanking plugs.
a Connect the fuel pipe.
a Fit the wiring.
a Clip the wiring into place.
a Connect the connector of the fuel vapour absorber

solenoid valve.
106001
a Fit the connecting pipe at the level of the power-as-
a Refit the new accessories belt.
sisted steering pump.
a Clip on the connecting pipes.

Note:
Make sure that the inner groove on all the pulleys a Refit:
remains free.
- the bolt of the connecting pipes bracket on the side
member,
- the bolt of the connecting pipe bracket on the front

panel.
a Remove the large flat-blade screwdriver at the level

of the starter.
a Fit the expansion chamber on the catalytic conver-

ter.
a Refit the bolts of the exhaust bracket between the

catalytic converter and the expansion chamber.
a Refit:

19D-26) ,

133134 terior protection),
a Remove the tensioning roller locking pin. - the front right-hand wheel (see Wheel: Removal -
a Rotate the engine through three revolutions to posi- Refitting) (35A, Wheels and tyres),
tion the accessories belt correctly.

(80A, Battery).
11A-5
K9K
Tightening torquesm
accessories belt tensio- 40 N.m

ning roller bolt
IMPORTANT
WARNING
to avoid damaging the crankshaft accessories pul-
ley.
REMOVAL
132916
a Remove:
Towing and lifting) (02A, Lifting equipment). - the sound insulation bolt.
a Remove:
- the sound insulation (1) .
- the engine cover,
- the windscreen wiper arms (see Windscreen wi- II - OPERATION FOR REMOVAL OF PART
per arm: Removal - Refitting) (85A, Wiping - CONCERNED
Washing),
terior protection),
19D-16) .
101878
a Rotate the accessories belt tensioning roller clockwi-

se using a 16 mm offset spanner.
a Remove the accessories belt.
11A-6
K9K
a Rotate the crankshaft clockwise through two revolu-
tions (timing end).

a Refit:
- the sound insulation,
19D-16) ,
terior protection),
123817 Removal - Refitting) (56A, Exterior equipment),
a Remove: - the windscreen wiper arms (see Windscreen wi-
- the accessories belt tensioning roller bolt (2) ,
Washing),
- the accessories belt tensioning roller from the top.
- the engine cover.
REFITTING

a
WARNING
a Clean the V-grooves of the crankshaft accessories

pulleys.
(10,10,01,03).
tensioning roller (10,10,01,04).
a parts always to be replaced: Accessories tensio-
ning roller bolt (10,10,01,09).

CONCERNED
a Refit a new accessories belt tensioning roller fitted
with a new bolt from the top.
a Torque tighten the accessories belt tensioning
roller bolt (40 N.m).
a Refit a new accessories belt.
11A-7
K4J or K4M

bly.
Tightening torquesm
tensioning roller bolts 25 N.m
IMPORTANT
101793
a Remove the nuts (1) from the exhaust bracket.
WARNING
Do not run the engine without the accessories belt a Separate the catalytic converter from the exhaust
to avoid damaging the crankshaft accessories pul- manifold.
ley. a Remove the exhaust bracket seal.
REMOVAL a Remove the right-hand suspended engine mounting
I - REMOVAL PREPARATION OPERATION 19D-16) .

a Remove:




terior protection),

page 19D-26) .
11A-8
K4J or K4M
CONCERNED

a Use a brush to remove any deposits from the
crankshaft pulley V-grooves.
(10,10,01,03)
parts always to be replaced: Accessories belt
tensioning roller (10,10,01,04)
parts always to be replaced: Accessories fixed
roller (10,10,01,06)

CONCERNED
a Refit:
- a new tensioning roller,
- a new fixed roller.
133279 a Tighten to torque:

a Turn the accessories belt tensioning roller clockwise - the fixed roller bolt (25 N.m),
using a 13 mm spanner (2) .
- the tensioning roller bolts (25 N.m).
a Remove the accessories belt.
a Refit the accessories belt, turning the tensioning rol-
ler using a 13 mm spanner.
a Rotate the crankshaft clockwise twice to balance the
accessories belt tension on every pulley.

a Refit the right-hand suspended engine mounting
19D-16) .
fold.
a Refit:
133280 - the lower engine tie-bar (see 19D, Engine moun-

a Remove: page 19D-26) ,
- the fixed roller bolt (3) , - the front right-hand wheel arch liner (see Front
- the fixed roller, wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
- the tensioning roller bolts (4) ,
- the tensioning roller. Refitting) (35A, Wheels and tyres),
11A-9
K4J or K4M
11A-10
D4F
Mot. 1715 Belt tension checking tool
(frequency indicator).
Essential equipment
forked endpiece
Tightening torquesm
alternator upper bolt 25 N.m
alternator lower bolt 50 N.m
bolt of the tensioning 37 N.m

roller
IMPORTANT 133038
Wear protective gloves during the operation. a Remove:
- the protector of the tensioning roller bolt,
- the tensioning roller bolt (1) ,
WARNING - the tensioning roller,
to avoid damaging the crankshaft accessories pul- - the fixed roller bolt (2) ,
ley. - the fixed roller,
- the "air conditioning compressor - power-assisted
steering pump" accessories belt (3) .
REMOVAL


fitting) .
a Remove:


terior protection),
11A-11
D4F
132706 133040
a Remove the lower nut (4) from the alternator. a Remove the "alternator" accessories belt (7) .
a Loosen the alternator upper bolt (5) .
REFITTING

crankshaft pulley V-grooves.
WARNING

CONCERNED
a Refit the "alternator" accessories belt.
132707
a Loosen the alternator lower bolt (6) .
11A-12
D4F
133042 133037
a Set the "alternator" accessories belt tension using a Adjust the tension of the "air conditioning compres-
the tool (Mot. 1715) (8) to a value of 260 Hz ± 5. sor - power-assisted steering pump" accessories
belt using the tool (Mot. 1715) (9) to a value of 210
Hz ± 5.
- the alternator upper bolt (25 N.m),
a Torque tighten the bolt of the tensioning roller (37
- the alternator lower bolt (50 N.m). N.m) using a torque wrench equipped with a for-
a Turn the engine three revolutions clockwise (timing ked endpiece while using an open-jawed spanner
to keep the tension of the "air conditioning compres-
end) to position the "alternator" accessories belt cor-
sor - power-assisted steering pump" accessories
rectly.
belt at a value of 210 Hz ± 5.
a Check the tension of the "alternator" accessories
belt using the tool (Mot. 1715). a Turn the engine through three revolutions clockwise
(timing end) to position the " air conditioning com-
a If the "alternator" accessories belt tension is outside pressor - power-assisted steering pump" accesso-
the permitted tolerance values, readjust it. ries belt correctly.
a Refit the fixed roller. a Check the tension of the "air conditioning compres-
a Torque tighten the fixed roller bolt (22 N.m). sor - power-assisted steering pump" accessories
belt using the tool (Mot. 1715).
a Refit:
a If the tension of the "air conditioning compressor -
- the "air conditioning compressor - power-assisted power-assisted steering pump" accessories belt is
steering pump" accessories belt, outside the permitted tolerance values, readjust it.
- the tensioning roller. a Refit the protector for the tensioning roller bolt.
a Screw in the tensioning roller bolt without tightening
it.
a Refit:
terior protection),
11A-13
D4F
ting) .
11A-14
Crankshaft accessories pulley: Removal - Refitting 11A
K7J or K7M
CONCERNED
IMPORTANT
a Refit the accessories belt (see 11A, Top and front
Wear protective gloves during the operation. of engine, Accessories belt: Removal - Refitting,
page 11A-1) .
WARNING III - FINAL OPERATION

Do not run the engine without the accessories belt a Refit:
ley. - the battery (see Battery: Removal - Refitting)
(80A, Battery),
wheel arch: Removal - Refitting) (55A, Exterior
protection),
REMOVAL
a Remove:

wheel arch: Removal - Refitting) (55A, Exterior
protection),
(80A, Battery).

CONCERNED
a Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting, page 11A-1) .
REFITTING

sories pulley bolts (10,03,03,10)
a
WARNING
a In case of reuse, clean the crankshaft accessories

V-pulley using a brush to get rid of any deposit.
11A-15
K9K
Mot. 1489 TDC locating pin.
Tightening torquesm
crankshaft accessories 120 N.m + 95˚

pulley bolt ± 15˚
TDC setting pin plug 25 N.m
REMOVAL

a Remove:
- the engine cover,
- the windscreen wiper arms (see Windscreen wi- 134832
per arm: Removal - Refitting) (85A, Wiping - a Lock the flywheel using a screwdriver (1) via a hole
Washing), on the clutch housing, at the back of the engine.
terior protection),
19D-16) ,
page 11A-1) .
132886
a Remove:
- the crankshaft accessories pulley bolt (2) ,
- the crankshaft accessories pulley.
11A-16
K9K
REFITTING

sories pulley bolts (10,03,03,10).
a If reusing the crankshaft accessories pulley, clean
the crankshaft accessories pulley V-grooves with a
brush to eliminate any deposits.
134691
a Remove the bolts (6) from the power-assisted stee-
ring high pressure pipe.
sure pipe slightly.
107272
a Refit the old bolt (3) of the crankshaft accessories
pulley fitted with a spacer (4) .
a Turn the crankshaft clockwise (timing end) using the
old bolt of the crankshaft accessories pulley, until
the collet of the crankshaft timing pinion (5) is almost
vertical and facing upwards.
123841
a Remove the TDC setting pin plug (7) .
11A-17
K9K
19650-1 14489
a Fit the tool (Mot. 1489) (8) into the cylinder block. a Turn the crankshaft clockwise (timing end) smoothly
using the bolt of the crankshaft accessories pulley,
a Remove the old bolt of the crankshaft accessories
until the crankshaft presses against the tool (Mot.
pulley fitted with its spacer.
1489) (9) .
a Torque and angle tighten the crankshaft accesso-
ries pulley bolt (120 N.m + 95˚ ± 15˚).
CONCERNED
a Refit:
- the crankshaft accessories pulley,
a Remove the (Mot. 1489) from the cylinder block.
- a new crankshaft accessories pulley bolt.
a Place a drop of SILICONE ADHESIVE SEALANT
rwork) (04B, Consumables - Products) on the
thread of the TDC setting pin plug.
a Torque tighten the TDC setting pin plug (25 N.m).
a Refit:
page 11A-1) ,
19D-16) ,
terior protection),
11A-18
K9K
Washing),
- the engine cover.
11A-19
D4F
Tightening torquesm
new bolt of the cranks- 40 N.m + 75˚ ±

haft accessories pulley 5˚
IMPORTANT
WARNING
ley.
132820
REMOVAL

a Remove:
terior protection),
- the accessories belt (see 11A, Top and front of 120407
engine, Accessories belt: Removal - Refitting, a Remove:
page 11A-1) .
- the rear suspended engine mounting bolt (1) ,
- the bolt (2) of the rear suspended engine mounting
tie-rod,
- the rear suspended engine mounting tie-rod,
- the bolts (3) of the flywheel protector,
- the flywheel protector.
11A-20
D4F
REFITTING

crankshaft accessories pulley V grooves.
WARNING


CONCERNED
a Refit the accessories crankshaft pulley with a new
bolt.
a Torque tighten the new bolt of the crankshaft ac-
120408
cessories pulley (40 N.m + 75˚ ± 5˚).
a Fit the flywheel immobiliser tool (Mot. 582-01) (4) .

CONCERNED a Remove the flywheel immobiliser tool (Mot. 582-01).
a Refit:
- the flywheel protector,
- the rear suspended engine mounting tie-rod,
page 11A-1) ,
terior protection),
132819
a Remove:
- the crankshaft accessories pulley.
11A-21
K4J or K4M
Essential special tooling Refitting) (55A, Exterior protection),
bly.
Mot. 1489 TDC locating pin. - the front right-hand wheel (see Wheel: Removal -
Mot. 1496 Tool for setting camshaft.
Mot. 1750 Addition to retaining cams- wheel arch liner: Removal - Refitting) (55A, Ex-
haft setting tool Mot. 1496 . terior protection),
Mot. 1487 Tool for removing the cams- - the lower engine tie-bar (see 19D, Engine moun-
haft covers (57 mm diame- ting, Lower engine tie-bar: Removal - Refitting,
ter). page 19D-26) .
Mot. 1488 Tool for removing the cams-

haft covers (43 mm diame-
ter).
Tightening torquesm
new crankshaft acces- 40 N.m + 145˚

sories pulley bolt
IMPORTANT
WARNING 101793
a Remove the exhaust bracket nuts.
ley.
a Separate the catalytic converter from the exhaust
manifold.
REMOVAL a Remove the exhaust bracket seal.

a Position the vehicle on a two-post lift (see Vehicle: a Remove:

a Remove: 19D, Engine mounting, Right-hand suspended
- the air resonator (see 12A, Fuel mixture, Air reso- 19D-16) ,
- the engine undertray bolts, - the accessories belt (see 11A, Top and front of
- the engine undertray, page 11A-1) .
11A-22
K4J or K4M
132767 14491
a Unclip: a Remove the lifting eye (5) .
- the power-assisted steering pipe (2) , a Pierce the centre of the plugs (6) at the camshaft
ends with a screwdriver.
- the expansion bottle hose (3) .
a Remove:
- the plugs from the camshaft ends with a screwdri-
ver,
- the TDC setting pin plug (7) .
103271
a Remove the lifting eye bolts (4) .
11A-23
K4J or K4M
14491-1 14490
a Position the camshaft grooves (8) almost horizontal- a The camshaft grooves (10) must be horizontal and
ly and offset towards the bottom turning the cranks- offset downwards.
haft in the operating direction (clockwise at timing
a Remove the TDC setting pin (Mot. 1489).
end).
a Screw in the TDC setting pin (9) (Mot. 1489).
130493
a Lock the flywheel using a screwdriver (11) .
14489
a Turn the crankshaft in its operating direction (cloc-
kwise at timing end), until the crankshaft presses
against the TDC setting pin (Mot. 1489).
11A-24
K4J or K4M
CONCERNED
108873
a Fit:
14487
- the timing tool (Mot. 1496) (13) fitted with the (Mot.
a Remove:
1750) (14) ,
- a lifting eye bolt (15) to secure the timing tool (Mot.
- the crankshaft accessories pulley. 1496) fitted with the (Mot. 1750).
REFITTING

parts always to be replaced: Crankshaft acces-
sories pulley (10,03,03,07)
parts always to be replaced: Inlet camshaft cap
(10,02,02,11)
parts always to be replaced: Exhaust camshaft
cap (10,02,02,12)
11A-25
K4J or K4M
CONCERNED
a Refit a new crankshaft accessories pulley.
a Torque and angle tighten the new crankshaft ac-
cessories pulley bolt (40 N.m + 145˚).

a Remove:
- the TDC setting pin (Mot. 1489),
- the timing tool (Mot. 1496) fitted with the (Mot.
1750).
a Refit:
- a new inlet camshaft plug using the (Mot. 1487),
- a new exhaust camshaft plug using the (Mot.
1488),
a Place a drop of SILICONE ADHESIVE SEALANT
14489 (see Vehicle: Parts and ingredients for the repai-
rwork) (04B, Consumables - Products) on the
a Screw in the TDC setting rod (Mot. 1489)
thread of the TDC setting pin plug.
a Refit the TDC setting pin plug.
Note: a Torque tighten the TDC setting pin plug (20 N.m).
Check that the crankshaft is pressing against the a Refit the lifting eye.
TDC setting pin (Mot. 1489).
a Clip:
The crankshaft groove must be upwards.
- the expansion bottle hose,
- the power-assisted steering pipe.
a Refit:
page 11A-1) ,
19D-16) .
fold.
a Refit:
130493 ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) ,
a If the crankshaft is not pressing against the TDC set-
ting pin, bring back the crankshaft by turning the - the front right-hand wheel arch liner (see Front
flywheel in its operating direction (clockwise at timi- wheel arch liner: Removal - Refitting) (55A, Ex-
ng end) using a screwdriver (16) . terior protection),
11A-26
K4J or K4M
11A-27
Timing belt: Removal - Refitting 11A
K7J or K7M
Essential special tooling Refitting) (35A, Wheels and tyres),
Mot. 1489 TDC locating pin. - the front right-hand wheel arch liner (see Front
Mot. 1501 Timing belt preloading tool. terior protection),
Mot. 1135-01 Timing belt tensioner. - the engine tie-bar (see 19D, Engine mounting,
Mot. 1715 Belt tension checking tool 19D-26) ,
(frequency indicator).
Essential equipment page 11A-1) .
indelible pencil
torque wrench
Tightening torquesm
tensioning roller nut 50 N.m
upper timing cover M10 40 N.m

bolts
upper timing cover M8 22 N.m

bolt
lower timing cover bolts 10 N.m
TDC pin plug 20 N.m
WARNING
To prevent impurities from entering the circuit, place 107359
protective plugs on all fuel circuit components a Remove the TDC pin plug (1) .
IMPORTANT
REMOVAL

a Remove:
(80A, Battery),
11A-28
K7J or K7M
132834 107498
a Disconnect the fuel pipe at (2) .
a Move the fuel pipe aside.
107499
a Remove:
- the lower timing cover (3) ,
- the upper timing cover (4) .

CONCERNED
1 - ADJUSTING THE TIMING
a Retighten the crankshaft accessories pulley bolt with

a spacer.
11A-29
K7J or K7M
2 - REMOVING THE TIMING BELT
107497
a Turn the crankshaft clockwise to bring the camshaft 107494
sprocket one tooth before the vertical axle of the
a Remove:
sprocket (top point (5) ) and the crankshaft sprocket
mark one tooth before the vertical axle of the sproc- - the nut (7) from the tensioning roller,
ket (bottom point (6) ).
- the timing belt,
a Insert TDC setting pin (Mot. 1489).
a Turn the crankshaft clockwise by pushing on TDC - the tensioning roller.
setting pin (Mot. 1489) until the crankshaft is set.
a Make marks on the covers using a indelible pencil. REFITTING
a parts always to be replaced: Timing belt (10,02,

04,02).
a parts always to be replaced: Timing belt tensio-

ning roller (10,02,04,04).

WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and bearing faces,
- the contact surfaces of the crankshaft accesso-
ries pulley.
This is to avoid timing slippage.
This slippage leads to engine damage.
11A-30
K7J or K7M
CONCERNED
a Refit the tension wheel.
107493
107494
a Fit the timing belt by aligning the belt markings with
those of the camshaft (8) and crankshaft (9) sproc-
kets.
Rolling order:
- crankshaft pulley,
- tensioning roller,
- camshaft pulley,
- water pump pulley.
PROCEDURE FOR TENSIONING THE TIMING BELT

a Position the tensioning roller against the timing belt.
a Lightly tighten the tension wheel nut.
a Remove the TDC setting pin (Mot. 1489).
16293
a Fit timing belt pretensioning tool (Mot. 1501) on the
camshaft sprocket (10) .
a Apply pretensioning torque to the timing belt section
(11) with a torque wrench set to a torque of 10 N.m.
11A-31
K7J or K7M
107492
107499
a Fit timing auxiliary belt tensioner tool (Mot. 1135-01)
(12) . a Use FRENETANCHE (see Vehicle: Parts and in-
gredients for the repairwork) (04B, Consumables
a Tighten the timing belt, pivoting the tensioning roller - Products), to coat the upper timing cover bolts.
with tool (Mot. 1135-01) in an anti-clockwise direc-
tion. a Tighten to torque:
- the upper timing cover M10 bolts (40 N.m) (13) ,
a Adjust the belt tension using the tool (Mot. 1715) to
the value of 160 Hz ± 10 (see Title has to be defi- - the upper timing cover M8 bolt (22 N.m) (14) ,
ned) (Technical Note 3786A, 10A, Engine and peri-
pherals) and (see Timing belt: Adjustment values) - the lower timing cover bolts (10 N.m).
(Technical Note 3786A, 10A, Engine and periphe- a Fit the fuel pipe.
rals).
a Torque tighten the tensioning roller nut (50 N.m).
a Connect the fuel pipe.
a Rotate the crankshaft clockwise through two revolu-
a Refit the TDC pin plug.
tions.
a Torque tighten the TDC pin plug (20 N.m).
a Set the engine at Top Dead Centre using the (Mot.
1489). a Refit:
a Remove the TDC setting pin (Mot. 1489). - the accessories belt (see 11A, Top and front of
a Refit the timing belt pretensioning torque tool (Mot. page 11A-1) ,
1501) on the camshaft sprocket
a Apply a pretensioning torque to the timing belt sec- Lower engine tie-bar: Removal - Refitting, page
tion with a torque wrench set to a torque of XX N.m. 19D-26) ,
a Remove the tool (Mot. 1501). wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
a Using the (Mot. 1715), check that the timing belt is
160 Hz ± 10. - the front right-hand wheel (see Wheel: Removal -
a If the tension value is outside tolerances, adjust it by
starting the tensioning process from the beginning. - the engine undertray,
11A-32
K7J or K7M
(80A, Battery).
11A-33
K9K
- the camshaft position sensor (see 13B, Diesel in-
Essential special tooling jection, Camshaft position sensor: Removal -
Mot. 1430 Set of 5 crankshaft and cams- engine, Accessories belt: Removal - Refitting,
haft pulley timing pins. page 11A-1) ,
Tightening torquesm pulley: Removal - Refitting, page 11A-15) .
tensioning roller bolt 27 N.m
camshaft pulley hub 14 N.m

bolts
right-hand suspended 25 N.m

engine mounting sup-
port bolts
new bolt on the cranks- 120 N.m + 95˚

haft accessories pulley ± 15˚
REMOVAL


a Remove:
- the engine cover,

Washing),



terior protection),

19D-16) ,
11A-34
K9K
19654 19654-1
134252 134690
a Unclip the upper timing cover at (1) . a Remove the lower timing cover bolt (2) .
a Remove the upper timing cover. a Unclip the lower timing cover at (3) .
a Unclip: a Remove the lower timing cover.
- the fuel supply pipe,
- the fuel return pipe,
- the camshaft position sensor wiring.
11A-35
K9K
K9K, and 740
132887
a Remove:
- the right-hand suspended engine mounting support 134691
bolts (4) , a Remove the bolts (5) from the power-assisted stee-
- the right-hand pendulum suspension support. ring high pressure pipe.
sure pipe slightly.
11A-36
K9K
CONCERNED
107270
a Turn the crankshaft clockwise (timing end) using the
123841 old crankshaft accessories pulley bolt and its spacer
a Remove the TDC setting pin plug (6) . to position the hole of the camshaft pulley hub (9) al-
most opposite the hole (10) in the cylinder head.
107272
a Refit the old crankshaft accessories pulley bolt (7) 19650-1
with a spacer (8) . a Screw tool (Mot. 1489) (11) into the cylinder block.
11A-37
K9K
14489 19656-1
a Turn the crankshaft smoothly clockwise (timing end) a Undo the timing belt tensioning roller bolt (14) .
using the old crankshaft accessories pulley bolt and
a Loosen the timing belt tensioning roller by turning
its spacer, until the crankshaft comes into contact
the eccentric cam using a 6 mm Allen key.
with the TDC setting pin (12) .
a Remove:
- the timing belt taking care not to let the crankshaft
timing sprocket fall out,
- the timing belt tensioning roller bolt,
- the timing belt tensioning roller.
REFITTING

04,02).
a parts always to be replaced: Timing belt tensio-
ning roller (10,02,04,04).
a Always replace the timing belt tensioning roller bolt.
19655
a Insert the tool (Mot. 1430) (13) into the hole of the
camshaft pulley hub and in the cylinder head hole.
11A-38
K9K
CONCERNED
14489
a Check that the crankshaft is resting against tool
107263 (Mot. 1489) by turning the crankshaft clockwise
a Refit the new timing belt tensioning roller. using the old crankshaft accessories pulley bolt and
its spacer (the timing sprocket collets must be posi-
a Fit the timing belt tensioning roller lug (15) in the cy-
tioned vertically and facing upwards (19) ).
linder head groove (16) .
a Refit a new timing belt tensioning roller bolt.
a Check that the mark on the high pressure pump (17)
is opposite the bolt head (18) .
107264
a Remove a bolt from the camshaft pulley hub.
a Loosen the other bolts (20) of the camshaft pulley
hub by one turn.
11A-39
K9K
107265 19658
a Fit a new timing belt starting with the crankshaft a Bring the timing belt tensioning roller adjustable in-
sprocket. dex (21) opposite the lug (22) using a 6 mm Allen
key, turning it anti-clockwise.
a Align the timing belt marks with the marks:
a Torque tighten the tensioning roller bolt (27 Nm).
- of the crankshaft timing sprocket,
- of the camshaft pulley,
- of the high pressure pump pulley.
Note:
There must be 19 timing belt teeth grooves
between the mark on the camshaft pulley and the
mark on the high pressure pump pulley, and 51
timing belt teeth grooves between the mark on
the crankshaft timing sprocket and the mark on
the high pressure pump pulley.
107268
a
Note:
Check that the camshaft pulley hub bolts are not
fully up against the camshaft pulley.
11A-40
K9K
107266 107270
a Refit the camshaft pulley hub bolt (23) . a Rotate the crankshaft clockwise two turns (timing
end) using the old crankshaft accessories pulley bolt
a Torque tighten the camshaft pulley hub bolts (14
and its spacer. Before the hole (24) in the camshaft
N.m).
pulley hub is opposite the hole (25) in the cylinder
a Remove: head:
- the (Mot. 1489), - screw tool (Mot. 1489) into the cylinder block,
- the (Mot. 1430). - turn the crankshaft clockwise (timing end) smoothly
using the old crankshaft accessories pulley bolt
and its spacer, until the crankshaft comes into con-
tact with the tool (Mot. 1489).
107271
a Set the camshaft pulley hub using the tool (Mot.

1430).
11A-41
K9K
First position
107269 111083
a
Note:
If the tool (Mot. 1430) does not engage:
- loosen the camshaft pulley hub bolts by one
turn,
- turn the camshaft pulley hub using an 18mm
offset wrench to set the camshaft pulley hub,
- do not retighten the camshaft pulley hub bolts.
a Loosen the camshaft pulley hub bolts by one turn.
Note:
After the two turns, the index markers of the
timing belt tensioning roller may be in two diffe-
rent positions.
Depending on the position, the rotation of the
timing belt tensioning roller eccentric differs. 111081
a Loosen the timing belt tensioning roller bolt by no
more than one turn, holding it with a 6 mm Allen key.
a Gradually align the adjustable index (26) in the mid-
dle of the timing window (27) , turning the key anti-
clockwise.
- the timing belt tensioning roller bolt (27 N.m),
- the camshaft pulley hub bolts (14 N.m).
11A-42
K9K
Second position - the (Mot. 1430).
a Rotate the crankshaft clockwise two turns (timing
end) using the old crankshaft accessories pulley bolt
and its spacer. Before the hole of the camshaft pul-
ley hub is opposite the cylinder head hole:
- screw tool (Mot. 1489) into the cylinder block,
- turn the crankshaft clockwise (timing end) smoothly
using the old crankshaft accessories pulley bolt
and its spacer, until the crankshaft comes into con-
tact with the TDC setting pin.
111082
107271
1430).
a If the tool (Mot. 1430) does not engage, repeat the
timing belt refitting operation.
111081
a Loosen the timing belt tensioning roller bolt by no

more than one turn, holding it with a 6 mm Allen key.
a Gradually align the adjustable index (28) in the mid-

dle of the timing window (29) , turning the key cloc-
kwise.
- the tensioning roller bolt (27 N.m),

- the camshaft pulley hub bolts (14 N.m).
a Remove:
- the (Mot. 1489),
11A-43
K9K
19659
107261
a Refit the right-hand suspended mounting support.
a Torque tighten in order the right-hand suspended
engine mounting support bolts (25 N.m).
19654-1
a Refit the lower timing cover, positioning the tab (30)
in the opening (31) of the inner timing cover.
a Clip on the lower timing cover.
a Refit the lower timing cover bolt (32) .
a Clip:
- the camshaft position sensor wiring,
- the fuel supply pipe.
a Refit the upper timing cover.
a Clip on the upper timing cover.
11A-44
K9K
a Remove the old crankshaft accessories pulley bolt
with its spacer.
a Refit the crankshaft accessories pulley.
a Torque tighten a new bolt on the crankshaft ac-

cessories pulley (120 N.m + 95˚ ± 15˚).
a Apply a drop of SILICONE ADHESIVE SEALANT

rwork) (04B, Consumables - Products) to the thread
of the TDC setting pin plug.
a Torque tighten the TDC setting pin plug (25 N.m).
K9K, and 740
a Refit the power-assisted steering high pressure pipe

bolts.
a Refit:

page 11A-1) ,

jection, Camshaft position sensor: Removal -

19D-16) ,

terior protection),



Washing),
- the engine cover.

11A-45
D4F
Mot. 1379 Engine support tool for opera-

tions on cylinder head.
Mot. 1054 TDC setting pin.
Tightening torquesm
lower timing cover bolt 13 N.m
interm e d i a t e timing 13 N.m

cover bolts
upper timing cover bolts 37 N.m
132828
REMOVAL a Fit the tool (Ms. 583) (1) on the low pressure supply
pipe of the power-assisted steering pump.


a Remove:


terior protection),

a Fit the tool (Ms. 583) (2) on the low pressure return
- the accessories belt (see 11A, Top and front of pipe of the power-assisted steering pump reservoir.
page 11A-1) ,

unit: Removal - Refitting, page 12A-5) .
11A-46
D4F
132829 132827
a Loosen the nut (3) on the power-assisted steering a Position the (Mot. 1379) (4) .
pump high pressure pipe.
a Move aside the power-assisted steering pump high a Mark the position of the suspended mounting on the
pressure pipe. body.
a Remove the seal from the power assisted steering

- the power assisted steering pump high pressure pi-
pe,
- the power-assisted steering pump.
132659
a Remove:

rubber pad,

cover,
- the suspended engine mounting.
11A-47
D4F
CONCERNED
1 - Adjusting the timing
109740
a Remove:
- the bolts (7) from the upper timing cover,

109737
- the timing upper housing.
a Refit the old crankshaft accessories pulley bolt.
a Turn the crankshaft clockwise (timing end). Stop a
half-tooth before the crankshaft sprocket mark is
lined up with the fixed marking.
109739
a Remove:
- the bolts (8) from the timing intermediate housing,

109735
- the timing intermediate housing,
a Remove the protector from the flywheel pin hole.
- the lower timing cover bolt (9) , a Insert the TDC setting pin (Mot. 1054) (10) .
- the lower timing cover. a Turn the crankshaft clockwise until it is stopped.
11A-48
D4F
REFITTING

04,02),
parts always to be replaced: Timing belt tensio-
ning roller (10,02,04,04),

CONCERNED
109738
a Make sure that the mark on the camshaft sprocket

and the mark on the crankshaft sprocket are aligned
with their fixed markings.
2 - Removing the timing belt
109761
a Refit the new tensioning roller, making sure:
- that the cylinder head ribbing is between the two
tensioning roller lugs,
- that the tensioning roller pin is properly positioned,
- that the tensioning roller is positioned as in the dia-
gram.
a Do not remove the pin from the new tensioning roller
before refitting the timing belt.
a Screw on the tensioning roller nut without tightening
it.
109761
a Remove:
- the nut (11) from the tensioning roller,
- the tensioning roller,
- the timing belt.
11A-49
D4F
109762 109763
a Refit the new timing belt: a Turn the tensioning roller eccentric anti-clockwise,
using a 6 mm Allen key, to bring the adjustable in-
- by lining up the crankshaft sprocket mark with the
dex level with the fixed index.
mark on the inside of the timing belt,
a Torque tighten the tensioning roller nut (25 N.m).
- by lining up the camshaft sprocket mark with the
mark on the outside of the timing belt. a Rotate the crankshaft through six revolutions in a
clockwise direction (timing end).
Procedure for tensioning timing belt a Set the timing using the TDC setting pin (Mot. 1054).
a Remove:
- the TDC setting pin (Mot. 1054),
- the tension wheel pin.
11A-50
D4F
109737 109764
a Loosen the tensioning roller nut up to one turn,
maintaining the position of the tensioning roller ec-
centric using a 6 mm Allen key.
a Turn the tensioning roller eccentric clockwise, using
a 6 mm Allen key, to bring the adjustable index to
the centre of the two fixed indexes.
a Torque tighten the tensioning roller nut (25 N.m),
maintaining the position of the eccentric using a 6
mm Allen key.
109738
a Make sure that the mark on the camshaft sprocket
and the mark on the crankshaft sprocket are aligned
with their fixed markings.
a Remove the TDC setting rod (Mot. 1054).
a Refit the protector of the flywheel pin hole.
11A-51
D4F
a Refit a new seal on the power-assisted steering
a Position the power-assisted steering pump high
pressure pipe.
a Tighten the nut on the power-assisted steering
a Remove the tool (Ms. 583) from:
- the low pressure return pipe of the power-assisted
steering pump reservoir,
- the power-assisted steering pump low pressure
supply pipe.
a Refit:
109765
a Check that the tensioning roller does not come into engine, Accessories belt: Removal - Refitting,
contact with the cylinder head. page 11A-1) ,
a If the tensioning roller is in contact with the cylinder - the front right-hand wheel arch liner (see Front
head: wheel arch liner: Removal - Refitting) (55A, Ex-
- set the engine to Top Dead Centre, terior protection),
- remove the tensioning roller and the timing belt,
- insert the tensioning roller pin,
- repeat the timing belt refitting method from the be- ting) (80A, Battery).
ginning, step by step.
- top up the power-assisted steering fluid reservoir,
a Refit:
- the lower timing cover , (36B, Power-assisted steering).
- the timing intermediate housing, a Check that the power-assisted steering fluid is not
leaking.
- the lower timing cover bolt (13 N.m),
- the intermediate timing cover bolts (13 N.m),
- the upper timing cover bolts (37 N.m).
a Refit the suspended engine mounting.
a Remove:
- the (Mot. 1379),
pump high pressure pipe,
pump.
11A-52
K4J or K4M
Essential special tooling Refitting) (35A, Wheels and tyres),
Mot. 1390 Support for removing/refitting - the front right-hand wheel arch liner (see Front
the engine - gearbox assem- wheel arch liner: Removal - Refitting) (55A, Ex-
bly. terior protection),
Mot. 1368 Tool for tightening tensioner - the lower engine tie-bar (see 19D, Engine moun-
bolt. 8 mm Torx wrench, 12.7 ting, Lower engine tie-bar: Removal - Refitting,
mm square page 19D-26) .
Mot. 1490-01 Locking and adjusting cams-

haft pulleys.
Mot. 1496 Tool for setting camshaft.
Mot. 1750 Addition to retaining cams-

haft setting tool Mot. 1496 .
Mot. 799-01 Timing gear wheel immobili-

ser.
Tightening torquesm
camshaft pulley nuts 30 N.m + 84˚

101793
upper timing cover bolts N.m a Remove the nuts (1) from the exhaust bracket.
and nuts46
exhaust bracket nuts 21 N.m manifold.
REMOVAL a Position the (Mot. 1390) under the engine.

a Remove:
I - REMOVAL PREPARATION OPERATION - the right-hand suspended engine mounting (see
19D-16) ,
a Remove: page 11A-1) .

11A-53
K4J or K4M
CONCERNED
14487
a Remove:
14487-3
a Undo the timing tension wheel nut (4) .
pulley: Removal - Refitting, page 11A-15) , a Remove:
- the lower timing cover bolts (2) , - the timing fixed roller bolt (5) using the tool (Mot.
1368),
- the lower timing cover ,
- the timing pulley,
- the upper timing cover bolts (3) ,
- the timing belt,
- the upper timing cover nuts (3) ,
- the timing tensioning roller nut,
- the timing tensioning roller,
- the crankshaft sprocket.
11A-54
K4J or K4M
CONCERNED
1 - Adjusting the timing

a
Note:
If the stud is loosened from the camshaft pulleys
(see 11A, Top and front of engine, Camshaft:
Removal - Refitting, page 11A-105) (Technical
Note 3887A, 11A, Top and front of engine).
WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and bearing faces,
101876 - the crankshaft accessories pulley bearing

faces,
a Fit the tool (Mot. 1490-01) (6) on the camshaft pul-
leys (use the bolt and nut of the upper timing cover - the camshaft ends (timing end),
to secure the tool (Mot. 1490-01)). - the camshaft sprocket bores and bearing faces.
a Loosen the camshaft pulley nuts (7) . This is to avoid timing slippage.
This slippage leads to engine damage.
a Remove the tool (Mot. 1490-01).
REFITTING

04,02)
parts always to be replaced: camshaft timing

sprocket nut (10,02,02,18)
parts always to be replaced: Timing belt tensio-

ning roller (10,02,04,04)
parts always to be replaced: Timing fixed roller

(10,02,04,05)

sories pulley (10,03,03,07)

parts always to be replaced: Inlet camshaft cap

(10,02,02,11)
parts always to be replaced: Exhaust camshaft

cap (10,02,02,12)
11A-55
K4J or K4M
14490 111337
a Fit the (Mot. 1496) with the (Mot. 1750) (8) .
103261
a Position the camshaft grooves horizontally and be-
low the centre line, by turning the camshafts with the 111336
(Mot. 1496) if necessary.
a Fit:
- the (Mot. 1496) (9) fitted with the (Mot. 1750) on

the end of the camshaft,
- a lifting eye bolt (10) to secure the tool (Mot. 1496).
a Remove the camshaft pulley nuts.
a Refit new camshaft pulley nuts without tightening

them.
11A-56
K4J or K4M
130493 14487-5
a Position the RENAULT logos (13) etched on the

camshaft pulley branches vertically and pointing
upwards.
2 - Refitting
14489
a Use a screwdriver (11) to check that the flywheel
does not turn (clockwise at the timing end), otherwi-
se bring the crankshaft back into contact with the
TDC setting pin (Mot. 1489) (12) using the screwdri-
ver; the crankshaft groove should be at the top.
108879
a Fit a new tensioning roller by positioning the tensio-

ning roller lug in the groove (14) .
a Screw on the tensioning roller nut without tightening

it.
a Refit the crankshaft sprocket.
11A-57
K4J or K4M
3 - Timing belt tension
14839-1
a Refit a new timing belt on the pulley of each cams- 103263
haft (without moving each of the camshaft pulleys). a Position the adjustable index (16) opposite the mark
(17) , by turning the eccentric (18) clockwise using a
a Fit the tool (Mot. 1490-01) (15) on the camshaft pul-
6 mm Allen key.
leys (use the bolt and nut of the upper timing cover
to secure the tool (Mot. 1490-01)). a Torque tighten the tensioning roller nut(7 N.m).
a Remove the tool (Mot. 1490-01).
Note:
Take care to tighten the timing belt between the Note:
two camshaft pulleys correctly.
Check that the camshaft pulley nuts do not touch
a Fit a new fixed roller. their respective pulley. Also, from time to time,
secure the pulley of each camshaft against its
respective camshaft.
Note:
a Rotate the timing system through six revolutions
Before torque tightening the fixed roller, always with the exhaust camshaft pulley, using the (Mot.
adjust the junior torque wrench to 25 N.m (tigh- 799-01).
ten using the tool (Mot. 1368)) to obtain a tighte-
ning torque of 50 N.m on the fixed roller bolt. The
25 N.m adjustment value is only valid for a 300
mm long torque wrench (length measured
between the square drive and the centre of the
handle); if the length of the torque wrench is dif-
ferent, a new adjustment value must be used
(see Tightening torques: General information)
(01D, Mechanical introduction).
a Torque tighten the fixed roller bolt (50 N.m) using

the tool (Mot. 1368), a junior torque wrench and a 15
mm socket.
11A-58
K4J or K4M
103263 14487-3
a Check that the adjustable index (19) is opposite the a Torque tighten the tensioning roller nut (30 N.m)
notch (20) , if this is not the case: (22) .
- loosen the timing tensioning roller nut by up to one
a Check that the RENAULT logos (23) , etched on the
turn while holding the eccentric with a 6 mm Allen
camshaft pulley stems are positioned vertically and
key,
pointing upwards.
- gradually move the adjustable index marker (19)
opposite the mark (20) turning the eccentric cam
(21) clockwise.
14839-1
a Position the tool (Mot. 1490-01) (24) (use the bolt

and the nut of the upper timing cover to secure the
tool (Mot. 1490-01)) using tool (Mot. 799-01) if ne-
cessary.
a Tighten to torque and to angle the camshaft pulley

nuts (30 N.m + 84˚).
11A-59
K4J or K4M
III - FINAL OPERATION - the front right-hand wheel (see Wheel: Removal -
14487
a Tighten to torque and in order the upper timing co-

ver bolts and nuts46 (N.m).
a Refit:
- the lower timing cover ,
page 11A-1) ,
19D-16) .
fold.
a Refit:
page 19D-26) ,
terior protection),
11A-60
Rocker cover: Removal - Refitting 11A
K9K
REMOVAL
Mot. 1453 Multiple-adjusting engine I - REMOVAL PREPARATION OPERATION

mounting support with retai-
ning straps. a Position the vehicle on a two-post lift (see Vehicle:
Mot. 1453-01 Additional winder nut on a Remove:
engine lift support Mot. 1453.
- the engine cover,
Essential equipment - the air filter unit (see 12A, Fuel mixture, Air filter
safety strap(s)
Tightening torquesm Washing),
rocker cover bolts 11 N.m Removal - Refitting) (56A, Exterior equipment).
IMPORTANT
tion.
132913
a Fit the (Mot. 1453) equipped with (Mot. 1453-01) a Remove:

and a safety strap(s).
11A-61
K9K
132608 132930
a Remove: a Remove the nut (3) from the rubber pad on the right-
hand suspended engine mounting.
- the lower engine tie-bar tie rod bolts (1) ,
a Raise the engine slightly using the tool (Mot. 1453)
- the lower engine tie-bar tie rod,
fitted with tool (Mot. 1453-01) until the right-hand
- the lower engine tie-bar stud (2) , suspended engine mounting cover is separated
from the right-hand suspended engine mounting ru-
- the lower engine tie-bar.
bber pad.
a Remove:
- the bolts (4) from the cover of the right-hand sus-
pended engine mounting on the right hand suspen-
ded engine mounting support,
- the right-hand suspended engine mounting cover.
11A-62
K9K
CONCERNED
132881
a Unclip the diesel injector fuel return rail from the roc-
ker cover at (6) .
19654
a Disconnect the oil vapour rebreathing hose from the

rocker cover (7) .
132880
a Remove:
134252
a Unclip the upper timing cover at (5) . - the rocker cover bolts (8) ,
a Remove the upper timing cover. - the rocker cover,
- the rocker cover seal.
REFITTING
a parts always to be replaced: rocker cover seal

(10,02,01,12).
11A-63
K9K
a Use SURFACE CLEANER (see Vehicle: Parts II - REFITTING OPERATION FOR PART
and ingredients for the repairwork) (04B, Consu- CONCERNED
- the rocker cover joint face on the cylinder head.
- the rocker cover seal housing in the rocker cover if
it is to be reused.
WARNING
a risk of leaks.
WARNING
squeezed out when parts are tightened. A mix- 132880
ture of sealant and fluid could damage certain a Refit:
- a new rocker cover seal.
- the rocker cover.
a Tighten to torque and in order the rocker cover

bolts (11 N.m).
a Connect the oil vapour rebreathing pipe to the rocker
cover.
a Clip the diesel injector fuel return rail onto the rocker
cover.
19712-1 a Clip on the upper timing cover.

a Apply four beads (9) of SILICONE ADHESIVE SEA- a Refit:
LANT (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) with a - the right-hand suspended engine mounting cover,
diameter of 2 mm. - the bolts on the right-hand suspended engine
mounting cover on the right hand suspended engi-
ne mounting support.
a Lower the engine using the tool (Mot. 1453) fitted

with tool (Mot. 1453-01) so that the cover of the right
hand suspended engine mounting comes into con-
tact with the rubber pad of the right-hand suspended
engine mounting.
a Refit:
- the nut of the right-hand suspended engine moun-
ting rubber pad,

11A-64
K9K
a Remove:
- the safety strap(s) from the (Mot. 1453),
- the (Mot. 1453) fitted with the (Mot. 1453-01).
a Refit:
Washing),
- the engine cover.
11A-65
K7J or K7M
REFITTING
Tightening torquesm
rocker cover bolts (ini- 2 N.m
tial torque)
(10,02,01,12).
rocker cover bolts 12 N.m
WARNING
REMOVAL any damage caused to the joint face will result in
a risk of leaks.

WARNING
a Remove:
ger marks).
- the ignition coils (see 17A, Ignition, Coils Remo- and ingredients for the repairwork) (04B, Consu-
val - Refitting, page 17A-1) . mables - Products) to degrease:
- the rocker cover joint face if it is to be re-used,
II - OPERATION FOR REMOVAL OF PART - the cylinder head joint face.
CONCERNED
II - OPERATION FOR REFITTING PART

CONCERNED
a Refit the rocker cover, fitted with a new gasket.
107771
a Disconnect the oil vapour rebreathing pipe (1) .
a Remove:
- the rocker cover bolts,
- the rocker cover,
11A-66
K7J or K7M
107771
a Pretighten to torque and in order the rocker cover
bolts (initial torque) (2 N.m).
a Torque tighten in order the rocker cover bolts (12
N.m).
a Connect the oil vapour rebreathing pipe.

a Refit:
- the ignition coils (see 17A, Ignition, Coils Remo-
val - Refitting, page 17A-1) ,
11A-67
D4F
CONCERNED
Tightening torquesm
rocker cover bolts 10 N.m
REMOVAL

a Remove:
- the inlet manifold (see 12A, Fuel mixture, Inlet
manifold: Removal - Refitting, page 12A-24) ,
- the ignition coil (see 17A, Ignition, Coils Removal
- Refitting, page 17A-1) .
110422
a Remove:
- the rocker cover bolts,
- the rocker cover,
REFITTING

a Always replace the rocker cover seal.
a Use SUPER CLEANER FOR JOINT FACES (see
rwork) (04B, Consumables - Products) to clean:
- the cylinder head joint face.
113044
a Disconnect the oil vapour rebreathing pipe (1) from
the rocker cover.
a Unclip from the rocker cover:
- the engine wiring (2) ,
11A-68
D4F
a Use SURFACE CLEANER (see Vehicle: Parts II - REFITTING OPERATION FOR PART
WARNING
a risk of leaks.
WARNING
18441
20005
a Apply a bead of SILICONE ADHESIVE SEALANT
rwork) (04B, Consumables - Products) to camshaft
bearings 1 and 5, as well as around the rear bolts of
the rocker cover to ensure that the rocker cover is
sealed.
a Refit:
- a new seal on the rocker cover,
- the rocker cover.
11A-69
D4F
110422
bolts (10 N.m).

a Connect the oil vapour rebreathing pipe onto the
rocker cover.
a Clip on the rocker cover:
- the engine wiring,
a Refit:
- Refitting, page 17A-1) ,
11A-70
K4J or K4M
Essential special tooling ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) .
bly.
Tightening torquesm
rocker cover bolts 1 to 12 N.m

13, 16 to 20, 23 to 24
rocker cover bolts 14, 14 N.m

15, 21 and 22
REMOVAL

- the air resonator (see 12A, Fuel mixture, Air reso- a Separate the catalytic converter from the exhaust
nator: Removal - Refitting, page 12A-12) , manifold.
unit: Removal - Refitting, page 12A-5) , a Position the (Mot. 1390) under the engine.
- the throttle valve (see 12A, Fuel mixture, Throttle a Remove:

valve: Removal - Refitting, page 12A-15) , - the right-hand suspended engine mounting (see
- the inlet manifold (see 12A, Fuel mixture, Inlet 19D, Engine mounting, Right-hand suspended
manifold: Removal - Refitting, page 12A-24) , engine mounting: Removal - Refitting, page
19D-16) ,
- the coils (see 17A, Ignition, Coils Removal - Re-
fitting, page 17A-1) , - the accessories belt (see 11A, Top and front of
- the oil separator (see 11A, Top and front of engi- page 11A-1) ,
ne, Oil decanter: Removal - Refitting, page 11A-
140) ,
- the engine undertray bolts, pulley: Removal - Refitting, page 11A-15) ,
- the engine undertray, - the timing belt (see 11A, Top and front of engine,
- the camshaft pulleys.

terior protection),
11A-71
K4J or K4M
CONCERNED
14497-5
a Remove the rocker cover bolts. REFITTING

a Detach the rocker cover using a screwdriver.
a Remove the rocker cover. I - REFITTING PREPARATION OPERATION
a Remove every camshaft seal (see 11A, Top and a

front of engine, Camshaft seal at timing end: Re-
WARNING
a risk of leaks.
WARNING
ger marks).
a Use SUPER CLEANING AGENT FOR JOINT FA-

clean:
11A-72
K4J or K4M
a Always replace:
- every camshaft seal,
126216
a Use a cloth to remove any RESIN ADHESIVE in the
rocker cover bearings (2) .

CONCERNED
a Refit the rocker cover.
14517
a
WARNING
a Use a stippled roller to apply RESIN ADHESIVE

rwork) (04B, Consumables - Products) to the joint
face of the rocker cover until the joint face is comple-
tely coated.
11A-73
K4J or K4M
14497
a Tighten to torque and in order: - the right-hand suspended engine mounting (see
- rocker cover bolts 1 to 13, 16 to 20, 23 to 24 (12 engine mounting: Removal - Refitting, page
N.m), 19D-16) .
- rocker cover bolts 14, 15, 21 and 22 (14 N.m). a Remove the tool (Mot. 1390).
III - FINAL OPERATION a Position the catalytic converter on the exhaust mani-
fold.
a Refit: a Torque tighten the exhaust bracket nuts (21 N.m).
- a new seal on each camshaft (see 11A, Top and a Refit:
front of engine, Camshaft seal at timing end:
- the camshaft pulleys without tightening them, page 19D-26) ,
- the timing belt (see 11A, Top and front of engine, wheel arch liner: Removal - Refitting) (55A, Ex-
Timing belt: Removal - Refitting, page 11A-28) , terior protection),
- the crankshaft accessories pulley (see 11A, Top - the front right-hand wheel (see Wheel: Removal -
and front of engine, Crankshaft accessories Refitting) (35A, Wheels and tyres),
pulley: Removal - Refitting, page 11A-15) , - the right-hand headlight (see Front headlight: Re-
engine, Accessories belt: Removal - Refitting, - the front bumper (see Front bumper: Removal -
page 11A-1) , Refitting) (55A, Exterior protection),
11A-74
K4J or K4M
- the oil separator (see 11A, Top and front of engi-
140) ,
fitting, page 17A-1) ,
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-15) ,
11A-75
Cylinder head: Removal - Refitting 11A
K9K
REMOVAL
Mot. 1448 Long nose pliers for hose I - REMOVAL PREPARATION OPERATION
clips.
Mot. 1672 Lower engine support. Towing and lifting) (02A, Lifting equipment).
Mot. 1453 Multiple-adjusting engine a Disconnect the battery (see Battery : Removal -
mounting support with retai- Refitting) (80A, Battery).
ning straps.
Mot. 1453-01 Additional winder nut on ling circuit: Draining - Refilling, page 19A-7) .
Essential equipment
a Remove:
cylinder head testing tool
- the engine cover,
cylinder head bolt tightening gauge (angular
measuring type) - the air filter unit (see 12A, Fuel mixture, Air filter

Tightening torquesm
cylinder head bolts (ini- 25 N.m - the windscreen wiper arms (see Windscreen wi-
tial torque) per arm: Removal - Refitting) (85A, Wiping -
Washing),
cylinder head bolts 270˚ ±10˚
subframe front bolts 62 N.m Removal - Refitting) (56A, Exterior equipment),
subframe rear bolts 105 N.m - the front right-hand wheel (see Wheel: Removal -
engine wiring channel 21 N.m
nut - the front right-hand wheel arch liner (see Front
dipstick guide nut 21 N.m terior protection),
rocker cover bolts 11 N.m - the engine undertray bolts,
inner timing cover bolts 9 N.m - the engine undertray.
alternator bolts 25 N.m - the right-hand suspended engine mounting (see

19D-16) ,
IMPORTANT
To avoid all risk of damage to the systems, apply - the camshaft position sensor (see 13B, Diesel in-
the safety and cleanliness instructions and opera- jection, Camshaft position sensor: Removal -
tion recommendations before carrying out any Refitting, page 13B-14) ,
tion: Precautions for repair, page 13B-1) . - the accessories belt (see 11A, Top and front of
page 11A-1) ,

IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera- pulley: Removal - Refitting, page 11A-15)
tion.
Timing belt: Removal - Refitting, page 11A-28) .
11A-76
K9K
132881
a Unclip the diesel injector fuel return rail from the roc-
ker cover at (4) .
a Disconnect the oil vapour rebreathing hose from the
rocker cover (5) .
102267
a Remove the alternator upper bolt (2) .
a Tilt the alternator forward.
132880
a Remove:
- the rocker cover bolts (6) ,
- the rocker cover,
102266
a Remove:
- the inner timing cover bolts (3) ,
- the inner timing cover.
11A-77
K9K
132878 132879
a Clean the union of the fuel supply pipe and the union a Disconnect:
of the diesel return pipe (see 13B, Diesel injection,
- all heater plug connectors (9) ,
Diesel injection: Precautions for repair, page
13B-1) . - the connector (10) from each diesel injector.
WARNING

- the diesel return pipe union (8) .
- the high pressure pump openings,
- the diesel return pipe opening.
132877
a Disconnect:
- the flow actuator connector (11) ,
- the fuel temperature sensor connector (12) .
11A-78
K9K
K9K, and 700
114527
a Remove:
- the dipstick, 24748
a Disconnect:
- the dipstick guide nut (13) ,
- the exhaust gas recirculation solenoid valve con-
- the nut (14) from the engine wiring channel, nector (16) ,
- the dipstick tube. - the connector of the air temperature sensor from
a Fit a plug on the opening of the dipstick guide in the the turbocharger air outlet pipe,
cylinder block. - the turbocharging pressure sensor connector.
a Move aside the engine wiring channel.
127902
a Disconnect the injector rail pressure sensor connec-
tor (15) .
11A-79
K9K
K9K, and 740
121867
a Disconnect the coolant temperature sensor connec-
132885
tor (20) .
a Disconnect:
K9K, and 700
nector (17) , a Unclip the engine wiring from the lifting eye on the
gearbox side.
- the connector (18) of the air temperature sensor
from the turbocharger air outlet pipe,
- the turbocharger pressure sensor connector (19) .
11A-80
K9K
K9K, and 740
132884
a Move aside from the coolant outlet unit:
132883 - the cooling radiator top hose clip (22) using the tool
a Remove the nut (21) from the heater matrix cooling (Mot. 1448),
hose bracket. - the expansion bottle top cooling hose clip (Mot.
a Remove: 1448) using the tool (23) .
- the cooling hose bracket from the heater matrix, a Disconnect:
- the engine wiring. - the brake servo pipe union (24) from the vacuum
pump,
- the cooling radiator top hose from the coolant outlet
unit,
- the expansion bottle top cooling hose from the coo-
lant outlet unit.
11A-81
K9K
K9K, and 700 K9K, and 740
20796
a Separate the thermoplunger unit cooling hose clip
(25) on the coolant outlet unit using tool (Mot. 1448).
a Disconnect the thermoplunger unit cooling hose
134709
a Separate the thermoplunger unit cooling hose clip
(26) on the coolant outlet unit cooling hose using the
tool (Mot. 1448).
a Disconnect the thermoplunger unit cooling hose
from the coolant outlet unit cooling hose.
11A-82
K9K
K9K, and 740
132882
a Position the (Mot. 1672)
a Remove the (Mot. 1453) fitted with the (Mot. 1453-

01).

CONCERNED
114341
a Separate the coolant outlet unit cooling hose clip

(27) on the cooling circuit cover using the tool (Mot.
1448).
a Disconnect the coolant outlet unit cooling hose from
the cooling circuit cover.
a Remove the turbocharger oil return pipe (see 12B,

Turbocharging, Turbocharger oil pipe: Removal
- Refitting, page 12B-7) .
19712
a Remove:
- the cylinder head bolts (30) ,
- the cylinder head,
- the cylinder head gasket.
REFITTING

134004
a parts always to be replaced: Cylinder head gas-
a Remove:
ket (10,02,01,04).
- the front bolt (28) from the front axle subframe,
- the rear bolt (29) from the front axle subframe. (10,02,01,12).
11A-83
K9K
a Always replace: 2 - Checking the gasket face
- the cylinder head bolts, a Check for gasket face bow using a ruler and a feeler
gauge.
- the front axle subframe bolts.
WARNING
IMPORTANT No regrinding of the cylinder head is permitted.
tion. a The maximum deformation is 0.05 mm.
Note:
IMPORTANT
If the cylinder head is faulty:
tion. - strip down the cylinder head (see Cylinder
head: Dismantling) (Technical Note 6006A,
10A, Engine and peripherals),
WARNING - test the cylinder head to detect any possible
Do not scrape the joint faces of the aluminium, cracks using cylinder head testing tool,
- rebuild the cylinder head (see Cylinder head:
a risk of leaks.
Dismantling) (Technical Note 6006A, 10A,
Engine and peripherals),
WARNING
The joint faces must be clean, dry and free from WARNING
grease (avoid finger marks). 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.
1 - Cleaning the cylinder head joint face
WARNING
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid dete-
rioration of the camshaft.
a Clean the joint faces of the cylinder head and cylin-

der block using the ABRASIVE PADS.

- the cylinder block gasket face,
- the cylinder head gasket face if being reused,
- the rocker cover gasket face on the cylinder head,
- the rocker cover seal housing in the rocker cover.
WARNING
11A-84
K9K
CONCERNED
K9K, and 700
a Connect the thermoplunger unit cooling hose to the
coolant outlet unit.
a Fit the thermoplunger cooling hose clip on the coo-

lant outlet unit using the tool (Mot. 1448).
K9K, and 740

a Connect the thermoplunger unit cooling hose to the
coolant outlet unit cooling hose.
a Fit the thermoplunger unit cooling hose clip on the
19712 coolant outlet unit cooling hose using the tool (Mot.
a Refit: 1448).
- a new cylinder head gasket,
- new cylinder head bolts,
- the cylinder head. a Connect:
a Tighten to torque and in order the cylinder head - the expansion bottle top cooling hose on the coo-
bolts (initial torque) (25 N.m). lant outlet unit,
a Check the tightness of the cylinder head bolts (25 - the cooling radiator top hose on the coolant outlet
N.m). unit,
a Angle tighten in order the cylinder head bolts (270˚ - the brake servo pipe union on the vacuum pump.
±10˚) using a cylinder head bolt tightening gauge a Fit:
(angular measuring type).
- the expansion bottle top cooling hose clip on the
coolant outlet unit using the tool (Mot. 1448),
- the cooling radiator top hose on the coolant outlet
a Refit the tool (Mot. 1453) fitted with tool (Mot. 1453- unit using the tool (Mot. 1448).
01).
a Remove the (Mot. 1672)
K9K, and 740
a Fit:
- the subframe front bolts (62 N.m).
- the subframe rear bolts (105 N.m).
- the heater matrix cooling hose bracket.
a Refit the turbocharger oil return pipe (see 12B, Tur-
bocharging, Turbocharger oil pipe: Removal - a Refit the nut of the heater matrix cooling hose brac-
Refitting, page 12B-7) . ket.
K9K, and 740

a Connect the coolant outlet unit cooling hose to the
cooling circuit cover. K9K, and 700
a Fit the coolant outlet unit cooling hose clip on the a Clip the engine wiring on the lifting eye, gearbox si-
cooling circuit cover using the tool (Mot. 1448). de.
11A-85
K9K
a Connect:
- the turbocharging pressure sensor connector,
- the connector of the air temperature sensor from
the turbocharger air outlet pipe,
nector.
- the injector rail pressure sensor connector.
a Fit the engine wiring channel.
a Remove the plug from the opening of the dipstick
guide in the cylinder block.
a Refit the dipstick guide.
a Tighten to torque: 19712-1
- the engine wiring channel nut (21 N.m), a Apply four beads (31) of SILICONE ADHESIVE
SEALANT (see Vehicle: Parts and ingredients
- the dipstick guide nut (21 N.m).
for the repairwork) (04B, Consumables - Pro-
a Refit the dipstick. ducts)with a diameter of 2 mm.
a Connect:
- the coolant temperature sensor connector,
- the fuel temperature sensor connector,
- the fuel flow actuator connector,
- the connector for each diesel injector,
- all heater plug connectors.
a Remove the blanking plugs from:
- the diesel return pipe opening,
- the high pressure pump openings.
a Connect to the high pressure pump: 132880
a Refit:
- the diesel return pipe union,
- the fuel supply pipe union. - a new rocker cover seal.
- the rocker cover.

bolts (11 N.m).
a Connect the oil vapour rebreathing hose onto the
rocker cover.
a Clip the diesel injector fuel return rail on the rocker
cover.
a Refit the inner timing cover.

a Tighten to torque the inner timing cover bolts (9
N.m).
a Fit the alternator in place.
a Refit the alternator upper bolt.
a Torque tighten the alternator bolts (25 N.m).
11A-86
K9K
a Refit:
page 11A-1) ,
19D-16) ,
terior protection),
Washing),
- the engine cover,
11A-87
K7J or K7M
Essential special tooling wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
clips. - the engine tie-bar (see 19D, Engine mounting,
Mot. 1489 TDC locating pin. 19D-26) .
Mot. 1851 Angular tightening tool (1/2"

drive)
Tightening torquesm
cylinder head bolts (ini- 20 N.m

tial torque)
cylinder head bolts 220˚ ± 10°°
lifting eye bolt on the 25 N.m

multifunction support
WARNING
protective plugs on all fuel circuit components
133138
a Remove:
IMPORTANT - the mountings (1) from the intake distributor rein-
Wear protective gloves during the operation. forcement strut,
- the intake distributor reinforcement strut,
REMOVAL - the accessories belt (see 11A, Top and front of

page 11A-1) ,
a Position the vehicle on a two-post lift (see Vehicle: Timing belt: Removal - Refitting, page 11A-28) ,
Towing and lifting) (02A, Lifting equipment). - the air filter unit (see 12A, Fuel mixture, Air filter
a Drain the cooling system via the bottom hose, using
the tool (Mot. 1448) (see 19A, Cooling, Cooling - the ignition coils (see 17A, Ignition, Coils Remo-
circuit: Draining - Refilling, page 19A-7) . val - Refitting, page 17A-1) .

a Remove:

(80A, Battery),

11A-88
K7J or K7M
133153 133177
a Remove the lifting eye bolts (2) on the gearbox side. a Disconnect the injector connectors (4) .
a Move aside the lifting eye on the gearbox side. a Move the injector wiring to one side.
133724 133142
a Disconnect the fuel supply (3) from the injector rail. a Disconnect:
a Insert the blanking plugs. - the connector (5) from the idle speed control motor,
- the connector (6) from the throttle valve potentio-
meter,
- the inlet air temperature sensor connector (7) ,
- the inlet air pressure sensor connector (8) ,
- the brake servo pipe from the intake distributor,
11A-89
K7J or K7M
- the petrol vapour rebreather pipe.
133290
133161
a Remove the petrol vapour rebreather pipe.
a Unclip the engine wiring (9) from the intake distribu-
tor.
a Dislodge the ball joint from the throttle valve control
cable.
a Remove the sleeve stop from the throttle valve con-
trol cable.
133720
a Unclip the coolant outlet unit hose from the power-
assisted steering hose at (10) .
a Separate the hose clips (11) , (12) and (13) on the
coolant outlet unit using the tool (Mot. 1448).
a Disconnect the coolant outlet unit hoses.
11A-90
K7J or K7M
132834 133146
a Unclip the engine wiring at (14) .
a Move the engine wiring away from the cylinder head.
133016
a Remove:
- the bolts (15) from the lifting eye on the cylinder
head, timing end,
- the bolt (16) from the lifting eye on the multifunction
support,
- the lifting eye on the timing end.
11A-91
K7J or K7M
- the rocker cover (see 11A, Top and front of engi-
ne, Rocker cover: Removal - Refitting, page
11A-61) .

CONCERNED
133133
10015
a Remove: a
- the dipstick guide lower bolt (17) , Note:
- the dipstick guide upper bolt (18) . The operation to remove the cylinder head requi-
res two people.
a Move the dipstick guide aside slightly.
a Remove:
- the cylinder head bolts,
- the cylinder head from the cylinder block,
- the cylinder head gasket from the cylinder block.
REFITTING

a parts always to be replaced: Cylinder head gas-
ket (10,02,01,04).
a parts always to be replaced: cylinder head bolts
(10,02,01,14).
133147
a Remove:
- the heat shield bolts (19) on the exhaust manifold,
- the heat shield on the exhaust manifold,
- the exhaust bracket bolts,
11A-92
K7J or K7M
a a Use SURFACE CLEANER (see Vehicle: Parts
IMPORTANT mables - Products) and CLEAN CLOTHS to de-
Wear goggles with side protectors for this opera- grease the gasket faces of the cylinder head and
tion. cylinder block.
IMPORTANT 2 - Checking the gasket face

Wear leaktight gloves (Nitrile type) for this opera- a With a ruler and set of feeler gauges, check for cylin-
tion. der head gasket face bow.
WARNING WARNING
Do not scrape the joint faces of the aluminium, No regrinding of the cylinder head is permitted.
a risk of leaks.
a The maximum deformation is 0.05 mm.
WARNING
Note:
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head. If the cylinder head is faulty:
Failure to follow this instruction could lead to the - strip down the cylinder head (see Stripping the
blocking of the oilways, resulting in a rapid dete- cylinder head) (Technical Note 6010A, 10A,
rioration of the camshaft. Engine and peripherals),
- test the cylinder head in order to detect any
possible cracks using the cylinder head test
WARNING kit (see Cylinder head testing equipment:
In order to ensure that the bolts are correctly Use) (Technical Note 6026A, 11A, Top and front
tightened, use a syringe to remove any oil which of engine),
may be in the cylinder head mounting holes. - rebuild the cylinder head (see Rebuilding the
cylinder head) (Technical Note 6010A, 10A,
Engine and peripherals).
WARNING
Do not allow this product to drip onto the pain-
twork. II - REFITTING OPERATION FOR PART
CONCERNED
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply a Remove the TDC setting pin (Mot. 1489).
pipes.
Failure to follow this advice could lead to the a Bring the pistons to mid-stroke position to prevent
blocking of the various oil inlet galleries, which any risk of contact with the valves when tightening
would quickly result in engine damage. the cylinder head.
WARNING WARNING
To ensure proper sealing, the gasket surfaces Do not oil the new bolts. Be sure to oil bolts
must be clean, dry and not greasy (avoid any fin- being reused.
ger marks).
a Fit:
1 - Cleaning the cylinder head gasket surface - a new cylinder head gasket,
a Clean the gasket surfaces of the cylinder head and - the cylinder head equipped with new bolts on the
cylinder block using a GREY ABRASIVE PAD. cylinder block.
11A-93
K7J or K7M
a Clip on the engine wiring.
a Connect the hoses to the coolant outlet unit.
a Position the hose clips on the coolant outlet unit
a Clip the coolant outlet unit hose on the power-assis-
ted steering hose.
a Fit the sleeve stop on the throttle valve control cable.
a Fit the ball joint on the throttle valve control cable.
a Clip the engine wiring onto the intake distributor.
a Fit the petrol vapour rebreather pipe.
a Connect:
- the petrol vapour rebreathing pipe,
- the brake servo pipe from the intake distributor,
- the air inlet pressure sensor connector,
107772
- connector from the inlet air temperature sensor,
a Pretighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m). - the throttle valve potentiometer connector,
a Check that all cylinder head mounting bolts are tigh- - the connector on the idle speed control motor.
tened to the correct torque 20 Nm. a Position the injector wiring.
a Tighten in order and to angle the cylinder head a Connect the injector connectors.
bolts (220˚ ± 10°°) using the tool (Mot. 1851).
a Connect the fuel supply to the injector rail.
Note:
a Refit:
Do not retighten the cylinder head bolts after
applying this procedure. - the lifting ring at the gearbox end,
- the ignition coils (see 17A, Ignition, Coils Remo-
val - Refitting, page 17A-1) ,
a Refit the rocker cover (see 11A, Top and front of
engine, Rocker cover: Removal - Refitting, page
11A-61) . - the timing belt (see 11A, Top and front of engine,
a Insert TDC setting pin (Mot. 1489).
a Turn the crankshaft clockwise by pushing on TDC
setting pin (Mot. 1489) until the crankshaft is set.
page 11A-1) ,
a Refit:
- the intake distributor reinforcement strut,
- the exhaust bracket bolts,
- the heat shield on the exhaust manifold. Lower engine tie-bar: Removal - Refitting, page
19D-26) ,
a Refit:
- the lifting eye on the timing end. terior protection),
a Torque tighten the lifting eye bolt on the multi- - the front right-hand wheel (see Wheel: Removal -
function support (25 N.m). Refitting) (35A, Wheels and tyres),
a Position the engine wiring on the cylinder head. - the engine undertray,
11A-94
K7J or K7M
(80A, Battery).
a Fill and bleed the cooling system (see 19A, Coo-
ling, Cooling circuit: Draining - Refilling, page
19A-7) .
11A-95
D4F
Tightening torquesm
cylinder head bolts (ini- 20 N.m ne, Rocker cover: Removal - Refitting, page
tial torque) 11A-61) ,
cylinder head bolts 230˚ ± 6˚ - the catalytic converter (see 19B, Exhaust, Cataly-
IMPORTANT - the water chamber (see 19A, Cooling, Plenum

Wear protective gloves during the operation. chamber: Removal - Refitting, page 19A-45) .
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED

a Remove:
IMPORTANT
tion.

a Remove:
18641
Refitting) (35A, Wheels and tyres), a Remove:
wheel arch liner: Removal - Refitting) (55A, Ex- - the cylinder head bolts,
terior protection),
engine, Accessories belt: Removal - Refitting, - the cylinder head gasket.
page 11A-1) ,
and front of engine, Crankshaft accessories REFITTING
- the air filter unit (see 12A, Fuel mixture, Air filter I - REFITTING PREPARATION OPERATION
- the timing belt (see 11A, Top and front of engine, a parts always to be replaced: cylinder head bolts
Timing belt: Removal - Refitting, page 11A-28) , (10,02,01,14).
- the inlet manifold (see 12A, Fuel mixture, Inlet parts always to be replaced: Cylinder head gas-
manifold: Removal - Refitting, page 12A-24) , ket (10,02,01,04).
11A-96
D4F
CLEANING THE CYLINDER HEAD a Check for gasket face deformation using a ruler and
a set of shims.
a
The maximum deformation is 0.05 mm.
IMPORTANT
tion. WARNING
No regrinding of the cylinder head is permitted.
IMPORTANT a Strip the cylinder head (see Cylinder head: Dis-

mantling) (Technical Note 6004A, 10A, Engine and
peripherals).
tion.
a If necessary, test the cylinder head for any cracks
with the cylinder head testing kit (see Garage equi-
WARNING pment catalogue).
Do not scrape the joint faces of the aluminium, a Rebuild the cylinder head (see Rebuilding the cy-
any damage caused to the joint face will result in linder head) (Technical Note 6004A, 10A, Engine
a risk of leaks. and peripherals).
a Position the pistons at mid-stroke.
WARNING a Check that the centring dowel is present on the cy-
To ensure proper sealing, the gasket surfaces linder block.
must be clean, dry and not greasy (avoid any fin- a Refit a new cylinder head gasket.
ger marks).

WARNING CONCERNED
Do not allow this product to drip onto the pain- a Refit:
twork.
Clean the cylinder head carefully to prevent
- new cylinder head bolts.
foreign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the WARNING
blocking of the various oil inlet galleries, which In order to ensure that the bolts are correctly
would quickly result in engine damage. tightened, use a syringe to remove any oil which
repairwork) (04B, Consumables - Products) to WARNING
clean:
Do not oil the new bolts. Be sure to oil bolts
- the cylinder head gasket face if being reused, being reused.
11A-97
D4F
page 11A-1) ,
terior protection),
18641
bolts (initial torque) (20 N.m). - fill the cooling system (see 19A, Cooling, Cooling
a Undo the cylinder head bolts.
a Pretighten to torque and in order the cylinder head ling circuit: Draining - Refilling, page 19A-7) ,
bolts (initial torque)20 N.m.
- check the level of power-assisted steering fluid in
a Check that all new cylinder head bolts are tightened the power-assisted steering fluid reservoir,
to the correct torque 20 N.m.
a Angle tighten in order the cylinder head bolts (230˚ Power-assisted steering circuit: Bleeding)
± 6˚). (36B, Power-assisted steering).
Note:
Do not retighten the cylinder head bolts after
applying this procedure.
a Refit:
- the water chamber (see 19A, Cooling, Plenum
chamber: Removal - Refitting, page 19A-45) ,

11A-61) ,

11A-98
K4J or K4M
Essential special tooling moval - Refitting) (80B, Headlights),
Mot. 1390 Support for removing/refitting - the front right-hand wheel (see Wheel: Removal -
the engine - gearbox assem- Refitting) (35A, Wheels and tyres),
bly.
Mot. 1448 Long nose pliers for hose wheel arch liner: Removal - Refitting) (55A, Ex-
clips. terior protection),
Mot. 1202-01 Pliers for large hose clips. - the lower engine tie-bar (see 19D, Engine moun-
Mot. 1202-02 Pliers for small hose clips. page 19D-26) .
Tightening torquesm
cylinder head bolts (ini- 20 N.m

tial torque)
cylinder head bolts 240˚ ± 6˚
REMOVAL

a Drain the cooling system (see 19A, Cooling, Coo- 101793
ling circuit: Draining - Refilling, page 19A-7) . a Remove the nuts (1) from the exhaust bracket.
a Remove:
- the air resonator (see 12A, Fuel mixture, Air reso- manifold.
a Remove:
unit: Removal - Refitting, page 12A-5) , - the exhaust bracket gasket,
- the throttle valve (see 12A, Fuel mixture, Throttle - the bolt (2) from the exhaust manifold stay.
manifold: Removal - Refitting, page 12A-24) , a Remove:
- the coils (see 17A, Ignition, Coils Removal - Re- - the right-hand suspended engine mounting (see
fitting, page 17A-1) , 19D, Engine mounting, Right-hand suspended
- the oil separator (see 11A, Top and front of engi- 19D-16) ,
140) , - the accessories belt (see 11A, Top and front of
- the engine undertray bolts, page 11A-1) ,
- the front bumper (see Front bumper: Removal - and front of engine, Crankshaft accessories
Refitting) (55A, Exterior protection), pulley: Removal - Refitting, page 11A-15) ,
11A-99
K4J or K4M
- the camshaft pulleys,
11A-61) ,
- every camshaft seal (see 11A, Top and front of
engine, Camshaft seal at timing end: Removal -
Refitting, page 11A-120) ,
- the camshafts (see 11A, Top and front of engine,
Camshaft: Removal - Refitting, page 11A-105) ,
- the injector rail (see 17B, Petrol injection, Injec-
tor rail - Injectors: Removal - Refitting, page
17B-32) .
111465
a Unclip the upstream oxygen sensor connector (5) .
a Disconnect the upstream oxygen sensor connector.
132954
a Remove:
- the power-assisted steering pump strut bolts (3) ,
- the power-assisted steering pump strut (4) .
132764
tor (6) .
11A-100
K4J or K4M

CONCERNED
132770
a Separate the clip (7) on the heater matrix hose using
tool (Mot. 1448) or (Mot. 1202-01) or (Mot. 1202-
02).
a Disconnect the heater matrix hose from the coolant 103259
outlet unit. a Remove:
REFITTING

a Always replace:
- the exhaust bracket gasket,
132769
a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) remove:
- the clip (8) from the expansion bottle hose,
a Disconnect from the water chamber:
11A-101
K4J or K4M
CLEANING THE CYLINDER HEAD a Use a ruler and a set of feeler gauges to check the
gasket face deformation (the maximum deformation
a
is 0.05 mm).
IMPORTANT
tion. WARNING
No regrinding of the cylinder head is permitted.
IMPORTANT a Strip the cylinder head (see Cylinder head: Dis-

Wear leaktight gloves (Nitrile type) for this opera- mantling) (Technical Note 6023A, 10A, Engine and
tion. peripherals).
a Test the cylinder head for possible cracks using the

cylinder head test kit (see Garage Equipment Cata-
WARNING
logue).
any damage caused to the joint face will result in a Rebuild the cylinder head (see Cylinder head: Re-
a risk of leaks. fitting) (Technical Note 6023A, 10A, Engine and pe-
ripherals).
WARNING
ger marks).
WARNING
Do not allow this product to drip onto the pain-
twork.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.

clean: 128611
- the cylinder head gasket face if being reused, a Position the pistons at mid-stroke.
- the cylinder block gasket face. a Check that the centring dowel (10) is on the cylinder
a Use SURFACE CLEANER (see Vehicle: Parts block.
mables - Products) to degrease: a Refit the new cylinder head seal on the cylinder
block.
CONCERNED
a Refit:
- new cylinder head bolts.
11A-102
K4J or K4M
- the heater matrix hose clip.
a Connect:
- the upstream oxygen sensor connector.
a Clip on the upstream oxygen sensor connector.
a Refit:
- the power-assisted steering pump strut,
- the injector rail (see 17B, Petrol injection, Injec-
tor rail - Injectors: Removal - Refitting, page
17B-32) ,
- the camshafts (see 11A, Top and front of engine,
Camshaft: Removal - Refitting, page 11A-105) ,
- every camshaft seal (see 11A, Top and front of
engine, Camshaft seal at timing end: Removal -
103259 - the rocker cover (see 11A, Top and front of engi-
a 11A-61) ,
WARNING - the camshaft pulleys without tightening them,
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
WARNING pulley: Removal - Refitting, page 11A-15) ,
Do not oil the new bolts. Be sure to oil bolts - the accessories belt (see 11A, Top and front of
being reused. engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
a Fit the cylinder head bolts in order without tightening
them. - the right-hand suspended engine mounting (see
bolts (initial torque) (20 N.m).
19D-16) .
a Check that all of the cylinder head bolts are tighte-
ned to the correct torque (20 Nm). a Remove the tool (Mot. 1390).
a Angle tighten in order the cylinder head bolts (240˚ a Refit a new exhaust bracket seal.
± 6˚). a Position the catalytic converter on the exhaust mani-
fold.
III - FINAL OPERATION a Torque tighten the exhaust bracket nuts (21 N.m).
a Connect to the water chamber: a Refit:
- the cooling radiator top hose, - the lower engine tie-bar (see 19D, Engine moun-
- the expansion bottle hose, ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) ,
- the heater matrix hose.
1202-02) fit:
terior protection),
- the cooling radiator top hose clip,
- the clip of the expansion bottle hose, Refitting) (35A, Wheels and tyres),
11A-103
K4J or K4M
140) ,
19A-7) .
11A-104
Camshaft: Removal - Refitting 11A
K9K
Tightening torquesm
- the camshaft seal (see 11A, Top and front of en-
bolts of the camshaft 10 N.m gine, Camshaft seal at timing end: Removal -
bearings Refitting, page 11A-120) ,
rocker cover bolts 11 N.m - the air filter unit (see 12A, Fuel mixture, Air filter
IMPORTANT - the vacuum pump (see Vacuum pump: Removal

Wear leaktight gloves (Nitrile type) for this opera- - Refitting) (37A, Mechanical component controls).
tion.
REMOVAL

a Remove:
- the engine cover,
132881
per arm: Removal - Refitting) (85A, Wiping - a Unclip the diesel injector fuel return rail from the roc-
Washing), ker cover at (1) .
Removal - Refitting) (56A, Exterior equipment), a Disconnect the oil vapour rebreathing hose (2) from
the rocker cover.
terior protection),
19D-16) ,
132880
- the accessories belt (see 11A, Top and front of a Remove:

page 11A-1) , - the rocker cover bolts (3) ,
- the crankshaft accessories pulley (see 11A, Top - the rocker cover,
pulley: Removal - Refitting, page 11A-15) , - the rocker cover seal.
11A-105
K9K
II - OPERATION FOR REMOVAL OF PART a Use SURFACE CLEANER (see Vehicle: Parts
CONCERNED and ingredients for the repairwork) (04B, Consu-
- the bearing faces of the camshaft bearings on the

cylinder head,
- the bearing faces of the camshaft bearings on the

camshaft bearings,
- the rocker cover seal housing in the rocker cover,
- the rocker cover joint face on the cylinder head.
WARNING
132889
a a risk of leaks.
Note:
Mark the position of the camshaft bearings. WARNING
a Remove:
- the camshaft bearings bolts (4) , ture of sealant and fluid could damage certain
- the camshaft bearings.
20064-1
132888
a Remove the camshaft (5) . a Apply four beads (6) of RESIN ADHESIVE (see Ve-
(04B, Consumables - Products) with a diameter of 7
REFITTING mm to the cylinder head.
I - REFITTING PREPARATION OPERATION II - REFITTING OPERATION FOR PART

CONCERNED
(10,02,01,12).
a Refit the camshaft in place by placing the camshaft
a Use an ABRASIVE PAD to clean the bearing faces groove on the timing side vertically and facing
of the camshaft bearings. upwards.
11A-106
K9K
132889 132880
a Refit: a Refit:
- the camshaft bearings, respecting their original po-
- a new rocker cover seal on the rocker cover,
sitions (bearing No. 1 flywheel end).
- the rocker cover,
- camshaft bearing bolts (1) , (3) , (4) and (2) .
a Tighten the camshaft bearing bolts (1) , (3) , (4) and - the rocker cover bolts.
(2) .
a Torque tighten in order the rocker cover bolts (11
a Refit the camshaft bearing bolts in order. N.m).
a Tighten to torque and in order the bolts of the a Connect the oil vapour rebreathing hose on the roc-
camshaft bearings (10 N.m). ker cover.
a Clip the diesel injector fuel return rail on the rocker

III - FINAL OPERATION cover.
a Refit:
- the vacuum pump (see Vacuum pump: Removal

- Refitting) (37A, Mechanical component controls),
- the camshaft seal (see 11A, Top and front of en-

gine, Camshaft seal at timing end: Removal -


19712-1
a Apply four beads (7) of SILICONE ADHESIVE SEA- page 11A-1) ,
LANT (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) with a - the camshaft position sensor (see 13B, Diesel in-
diameter of 2 mm. jection, Camshaft position sensor: Removal -

19D-16) ,
11A-107
K9K
terior protection),
Washing),
- the engine cover.
11A-108
K7J or K7M
a The cylinder head must be removed when removing
and refitting the camshaft (see 11A, Top and front
of engine, Cylinder head: Removal - Refitting,
page 11A-76) .
a For the camshaft removal procedure (see Stripping
the cylinder head) (Technical Note 6010A, 10A,
Engine and peripherals).
a For the camshaft refitting procedure (see Rebuil-
ding the cylinder head) (Technical Note 6010A,
10A, Engine and peripherals).
11A-109
D4F
Essential equipment
indelible pencil Timing belt: Removal - Refitting, page 11A-28) ,
Tightening torquesm
bolts of camshaft bea- 9 N.m - Refitting, page 17A-1) ,
ring cap no.5
- the camshaft seal on the timing end (see 11A, Top
camshaft bearing cap 5 N.m and front of engine, Camshaft seal at timing
bolts (initial torque) end: Removal - Refitting, page 11A-120) ,
camshaft bearing cap 7 N.m + 50˚ ±
bolts 6˚
11A-61) .

IMPORTANT
CONCERNED
REMOVAL

a Remove:
IMPORTANT
tion.
18724
ling circuit: Draining - Refilling, page 19A-7) . a Remove:
a Remove: - the camshaft bolts (1) ,
- the front right-hand wheel (see Wheel: Removal - - the camshafts.

terior protection),
page 11A-1) ,
11A-110
D4F
18724-1 18724-3
a Mark the camshaft caps using a indelible pencil. a Remove the camshaft.
REFITTING

clean the cylinder head joint face on the side of bea-
ring no. 5.
mables - Products) to degrease the cylinder head
joint face on the side of bearing no.5.
WARNING
a risk of leaks.
18724-2
a Remove:
WARNING
- the bolts (2) from camshaft bearing cap no. 5,
- the camshaft bearing caps. grease (avoid finger marks).
11A-111
D4F
19595 18724-2
a Apply a bead of SILICONE ADHESIVE SEALANT a Torque tighten the bolts of camshaft bearing cap
(see Vehicle: Parts and ingredients for the repai- no.5 (9 N.m).
rwork) (04B, Consumables - Products) on the side
of bearing no.5 of the cylinder head.
a Apply a drop of oil to the camshaft bearings.

CONCERNED
a Position the pistons at mid-stroke to prevent any
contact with the valves when tightening the cams-
haft bearings.
a Refit:
- the camshaft,
- the camshaft caps.
11A-112
D4F
18945
a Refit the camshafts, positioning:

- the rails in relation to the tappets,
- the marks on the flywheel end.
11A-113
D4F
terior protection),
- fill the cooling system (see 19A, Cooling, Cooling
ling circuit: Draining - Refilling, page 19A-7) ,
- check the power-assisted steering fluid level in the
power-assisted fluid reservoir,
18724
a Pre-tighten to torque and in order the camshaft
bearing cap bolts (initial torque) (5 N.m).
a Loosen the camshaft bearing cap bolts.
a Torque and angle tighten in order the camshaft
bearing cap bolts (7 N.m + 50˚ ± 6˚).

a Refit:
11A-61) ,
- the camshaft seal on the timing end (see 11A, Top
and front of engine, Camshaft seal at timing
end: Removal - Refitting, page 11A-120) ,
page 11A-1) ,
11A-114
K4J or K4M

bly.
Tightening torquesm
REMOVAL

Refitting) (80A, Battery). 101793
nator: Removal - Refitting, page 12A-12) , a Separate the catalytic converter from the exhaust
manifold.
unit: Removal - Refitting, page 12A-5) , a Remove the exhaust bracket seal.
- the inlet manifold (see 12A, Fuel mixture, Inlet a Remove:
- the coils (see 17A, Ignition, Coils Removal - Re- 19D, Engine mounting, Right-hand suspended
fitting, page 17A-1) , engine mounting: Removal - Refitting, page
19D-16) ,
140) ,
- the engine undertray, - the crankshaft accessories pulley (see 11A, Top
- the right-hand headlight (see Front headlight: Re- - the timing belt (see 11A, Top and front of engine,
moval - Refitting) (80B, Headlights), Timing belt: Removal - Refitting, page 11A-28) ,
- the front right-hand wheel (see Wheel: Removal - - the camshaft pulleys,
- the front right-hand wheel arch liner (see Front - the rocker cover (see 11A, Top and front of engi-
wheel arch liner: Removal - Refitting) (55A, Ex- ne, Rocker cover: Removal - Refitting, page
terior protection), 11A-61) ,
- the lower engine tie-bar (see 19D, Engine moun- - every camshaft seal (see 11A, Top and front of
ting, Lower engine tie-bar: Removal - Refitting, engine, Camshaft seal at timing end: Removal -
page 19D-26) . Refitting, page 11A-120) .
11A-115
K4J or K4M
CONCERNED
14498
a Remove:
- the inlet camshaft (2) ,
- the exhaust camshaft (3) .
11A-116
K4J or K4M
14499
a Remove:
- the valve rockers (4) ,
- the hydraulic tappets (5) .
Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
11A-117
K4J or K4M
REFITTING
Note:
I - REFITTING PREPARATION OPERATION It is essential to reprime the hydraulic tappets as
these may become drained if removed for a long
time.
Camshaft marking

CONCERNED
a Refit:
- the hydraulic thrust bearings,
- the valve rockers,
- the inlet camshaft, by lubricating the inlet camshaft
bearings,
- the exhaust camshaft, by lubricating the exhaust
camshaft bearings.
14518 III - FINAL OPERATION

a Refit:
11A-61) ,
- a new seal on each camshaft (see 11A, Top and
front of engine, Camshaft seal at timing end:
- the camshaft pulleys without tightening them,
1120
a The camshaft can be identified by an etching (6) . engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
a Marks (1) and (2) are for the supplier's use only.
a Mark (3) identifies the camshafts: 19D, Engine mounting, Right-hand suspended
- AM = Inlet 19D-16) ,
- EM = Exhaust
a Always replace:
fold.
- the camshaft studs if the studs have been loosened
at the same time as the nut (see 11A, Top and a Torque tighten the exhaust bracket nuts (21 N.m).
front of engine, Camshaft: Removal - Refitting, a Refit:
page 11A-105) (Technical Note 3887A, 11A, Top
and front of engine), - the lower engine tie-bar (see 19D, Engine moun-
- the exhaust flange seal. page 19D-26) ,
11A-118
K4J or K4M
terior protection),
140) ,
11A-119
Camshaft seal at timing end: Removal - Refitting 11A
K9K
Essential special tooling engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
Mot. 1430 Set of 5 crankshaft and cams-
haft pulley timing pins. - the crankshaft accessories pulley (see 11A, Top
Mot. 1606 High pressure pump-pulley pulley: Removal - Refitting, page 11A-15) ,
retaining tool.
Mot. 1577 Lip seal extractor (shaft dia- Timing belt: Removal - Refitting, page 11A-28) ,
meter 28 mm to 42 mm). - the (Mot. 1430).
Mot. 1632 Tool for fitting PTFE cams-
haft seal II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm
camshaft stud 12 N.m
camshaft pulley nut 30 N.m + 86˚ ±

6˚.
REMOVAL

a Remove:
- the engine cover,

per arm: Removal - Refitting) (85A, Wiping - 118982
Washing), a Increase the hole (1) of the (Mot. 1606) (2) using an
8.5 mm drill bit.


terior protection),

19D-16) ,

11A-120
K9K
118983 123970
a Undo the camshaft pulley hub bolts (3) .
a Fit the (Mot. 1606) on the cylinder head to lock the
camshaft pulley wheel.
a Tighten the camshaft pulley hub bolts (3) .
a Remove:
- the nut (4) from the camshaft pulley,
- the (Mot. 1606),
- the camshaft pulley.
105257
a
Note:
The camshaft seal is removed using the (Mot.
1577).
a Remove the camshaft seal (5) making sure that the

end piece (6) of the tool (Mot. 1577) is always remo-
ved.
a Loosen bolts (7) and (8) fully from the (Mot. 1577).
11A-121
K9K
105270 105272
a Position the claws of the (Mot. 1577) on the cams- a Separate the claws by turning the bolt (10) clockwise
haft. using an open-jawed spanner.
105271 105273
a Push the tool (Mot. 1577) until contact is made a Remove the camshaft seal by turning the bolt (11)
between the ends (9) of the claws and the camshaft clockwise.
seal.
11A-122
K9K
REFITTING

a
WARNING
a risk of leaks.

- the camshaft seal housing in the cylinder head,
- the camshaft seal mating face on the camshaft.
WARNING
a Always replace:
- the camshaft seal,
- the camshaft pulley nut.
11A-123
K9K
CONCERNED
Note:
For camshaft seals delivered fitted to a protective
sleeve:
- do not remove the camshaft seal from its pro-
tective sleeve,
- fit the sleeve fitted with the camshaft seal to the
camshaft,
- push the protective sleeve towards the cylinder
head until the camshaft seal reaches its limit on
the cylinder head,
- fit the seal on the camshaft by following the
recommendations below.
105531
1 - First fitting of the camshaft seal
21687-1
a Screw the stud (12) of the (Mot. 1632) onto the 21687-2
camshaft. a Fit the cover (13) and the collar nut (14) of the (Mot.
a Fit a new camshaft seal on the camshaft. 1632).
11A-124
K9K
21687-3 123075
a Screw on the collar nut until the cover touches the a
cylinder head.
Note:
2 - Second fitting of the camshaft seal The spacer (17) is used to fit the seal (18) and is
used in addition to the tool (Mot. 1632) (19) .
123076
a Depending on the case, the Parts Department deli-
vers seals (15) equipped with a spacer (16) amongst
other things.
11A-125
K9K
3 - Continued for both methods
a Remove:
- the collar nut from the (Mot. 1632),
- the stud of the (Mot. 1632),
- the protective sleeve and the spacer, if fitted then

throw them away.
Note:
Always replace the camshaft stud if it comes
loose when removing the stud from the tool (Mot.
1632) In this case, torque tighten the camshaft
stud (12 N.m).
a Refit:
123073 - the camshaft pulley,
a Position the bell (20) fitted with the spacer on the - a new camshaft pulley nut.
camshaft seal side and then position the collared nut
(21) of the tool (Mot. 1632).
Note:
The spacer fits on the bell of the tool (Mot. 1632)
so that the internal edge of the spacer is on the
side of the camshaft seal.
116756
a Undo the camshaft pulley hub bolts (22) .
a Fit the (Mot. 1606) on the cylinder head to lock the

camshaft pulley wheel.
a Tighten:
- the camshaft pulley hub bolts,
123074 - to torque and angle the camshaft pulley nut (30

N.m + 86˚ ± 6˚.)
a Screw on the collared nut until the spacer fitted on
the bell touches the cylinder head. a Remove the tool (Mot. 1606).
11A-126
K9K
III - FINAL OPERATION - the scuttle panel grille (see Scuttle panel grille:
Washing),
- the engine cover.
107269

1430).
Note:
If the pin (Mot. 1430) does not engage, turn the
camshaft pulley hub using an 18 mm offset
wrench to facilitate the setting of the camshaft
pulley hub.
a Refit:


page 11A-1) ,


19D-16) ,

terior protection),

11A-127
K7J or K7M

ser.
Mot. 1127-01 Camshaft oil seal fitting tool

(timing end) (30 x 42 x 7 seal)
for E engine.
Tightening torquesm
camshaft pulley bolt 45 N.m
WARNING
133714
a Remove:
IMPORTANT - the camshaft pulley bolt (1) using the (Mot. 799-
Wear protective gloves during the operation. 01),

REMOVAL

CONCERNED
a Remove:
(80A, Battery),

terior protection),

19D-26) ,
page 11A-1) , 133712
- the timing belt (see 11A, Top and front of engine, a Remove the camshaft seal on the timing end (2)
Timing belt: Removal - Refitting, page 11A-28) . using a screwdriver.
11A-128
K7J or K7M
REFITTING III - FINAL OPERATION

a
I - REFITTING PREPARATION OPERATION Note:
a parts always to be replaced: Camshaft seal on ti- Oil the threads and under the head of the new
ming end (10,02,02,02). bolt for the camshaft pulley.
a parts always to be replaced: camshaft timing a Refit the camshaft pulley fitted with a new bolt.
sprocket bolt (10,02,02,16).
a Torque tighten the camshaft pulley bolt (45 N.m)
a Use SURFACE CLEANER (see Vehicle: Parts using the tool (Mot. 799-01).
and ingredients for the repairwork) (04B, Consu- a Refit:
- the seal mating face of the camshaft, Timing belt: Removal - Refitting, page 11A-28) ,
- the seal housing in the cylinder head.
page 11A-1) ,
WARNING - the engine tie-bar (see 19D, Engine mounting,
Do not scrape the joint faces of the aluminium, Lower engine tie-bar: Removal - Refitting, page
any damage caused to the joint face will result in 19D-26) ,
a risk of leaks. - the front right-hand wheel arch liner (see Front
terior protection),
WARNING - the front right-hand wheel (see Wheel: Removal -
To ensure proper sealing, the gasket surfaces Refitting) (35A, Wheels and tyres),
ger marks).
(80A, Battery).
CONCERNED
133713
a Fit a new seal using the tool (Mot. 1127-01).
11A-129
D4F

ser.
Mot. 1381 Camshaft oil seal removal

tool, 30 x 42 x 7.

haft seal.
Tightening torquesm
camshaft pulley bolt 30 N.m + 60˚ ±

6˚
IMPORTANT
18722
a Remove:
REMOVAL
- the camshaft pulley bolt (1) using the (Mot. 799-
01),
a Disconnect the battery (see Battery: Removal - Re- CONCERNED
a Remove:


terior protection),

page 11A-1) ,

18722-1
unit: Removal - Refitting, page 12A-5) , a Fit the tool (Mot. 1381) on the camshaft seal at the
timing end.
Timing belt: Removal - Refitting, page 11A-28) . a Screw the nut (2) of the tool (Mot. 1381).
11A-130
D4F
CONCERNED
18722-2
a Remove the camshaft seal at the timing end while ti-
ghtening the bolt (Mot. 1381) of the tool (3) . 19592
a Screw the stud (4) of the tool (Mot. 1587) into the
camshaft.
REFITTING

- the mating face of the camshaft seal at the timing
end on the camshaft,
- the housing of the camshaft seal at the timing end
of the cylinder head.
WARNING
a risk of leaks.
WARNING
The joint faces must be clean, dry and free from 19592-1
grease (avoid finger marks). a Fit the protector with a new timing end camshaft seal
to the camshaft (5) (taking care not to touch the timi-
a parts always to be replaced: Camshaft seal on ting end camshaft seal).
ming end (10,02,02,02).
11A-131
D4F
19592-2 19592-3
a Fit the cover (6) and the collar nut (7) of the (Mot.
1587).
19592-4
a Screw on the collar nut until the cover touches the

cylinder head.
a Remove:
- the camshaft seal protector at the timing end.

a Refit the camshaft pulley.
11A-132
D4F
a Torque and angle tighten the camshaft pulley bolt
(30 N.m + 60˚ ± 6˚) using the tool (Mot. 799-01).
a Refit:
page 11A-1) ,
terior protection),
- check the level of power-assisted steering fluid in
the power-assisted steering fluid reservoir,
11A-133
K4J or K4M
Essential special tooling ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) .
bly.

haft seal
Tightening torquesm
REMOVAL

101793
a Remove:
a Remove the exhaust bracket nuts.
nator: Removal - Refitting, page 12A-12) , a Separate the catalytic converter from the exhaust
manifold.
valve: Removal - Refitting, page 12A-15) , a Position the (Mot. 1390) under the engine.
- the inlet manifold (see 12A, Fuel mixture, Inlet a Remove:

- the oil separator (see 11A, Top and front of engi- 19D-16) ,
140) , - the accessories belt (see 11A, Top and front of
- the front bumper (see Front bumper: Removal - and front of engine, Crankshaft accessories
Refitting) (55A, Exterior protection), pulley: Removal - Refitting, page 11A-15) ,
- the right-hand headlight (see Front headlight: Re- - the timing belt (see 11A, Top and front of engine,
moval - Refitting) (80B, Headlights), Timing belt: Removal - Refitting, page 11A-28) ,
Refitting) (35A, Wheels and tyres), - the camshaft pulleys,
- the front right-hand wheel arch liner (see Front - the rocker cover (see 11A, Top and front of engi-
wheel arch liner: Removal - Refitting) (55A, Ex- ne, Rocker cover: Removal - Refitting, page
terior protection), 11A-61) .
11A-134
K4J or K4M
II - OPERATION FOR REMOVAL OF PART - the exhaust flange seal.
CONCERNED
CONCERNED
132953
a Remove the camshaft seals (2) .
18687
REFITTING a
Note:
Always hold the camshaft seal with the protector
a Refit the rocker cover (see 11A, Top and front of (3) when handling, as this type of camshaft seal
engine, Rocker cover: Removal - Refitting, page is very FRAGILE. Touching the camshaft seal (4)
11A-61) . is strictly forbidden in order to avoid any oil leaks
once the camshaft seal is fitted on the engine.
WARNING
a risk of leaks.
WARNING
ger marks).

- the seal mating face of each camshaft,
- the cylinder head seal housings.
a Always replace:
- every camshaft seal,
11A-135
K4J or K4M
1 - Refitting the exhaust side seal
105531
126220
a Position the protector fitted with a new seal (5) on
the camshaft (taking care not to touch the seal).
126219
a Screw the stud (6) of the (Mot. 1632) onto the cams-
haft.
11A-136
K4J or K4M
2 - Refitting the inlet side seal
126217
a Fit the cover (7) and the collar nut (8) of the (Mot. 126224
1632). a Position the protector fitted with a new seal (9) on
the camshaft (taking care not to touch the seal).
cylinder head.
a Remove
- the camshaft seal protector.
11A-137
K4J or K4M
105531
126222
a Fit the cover (11) and the collar nut (12) of the (Mot.
1632).
cylinder head.
a Remove
- the camshaft seal protector.
126223
a Screw the stud (10) of the (Mot. 1632) onto the a Refit:
camshaft.
- the camshaft pulleys without tightening them,
page 11A-1) ,
19D-16) .
11A-138
K4J or K4M
fold.
a Remove:
page 19D-26) ,
terior protection),
140) ,
11A-139
Oil decanter: Removal - Refitting 11A
K4J or K4M
Tightening torquesm
new oil separator bolts 15 N.m valve: Removal - Refitting, page 12A-15) ,

REMOVAL manifold: Removal - Refitting, page 12A-24) ,

fitting, page 17A-1) .
a Remove:
- the air resonator (see 12A, Fuel mixture, Air reso- II - OPERATION FOR REMOVAL OF PART
nator: Removal - Refitting, page 12A-12) , CONCERNED
14497-4
a Remove:
- the oil decanter bolts,
- the oil separator.
11A-140
K4J or K4M
REFITTING

a Always replace the oil decanter bolts.
WARNING
a risk of leaks.
WARNING
When cleaning parts, it is essential that the parts
14516
do not impact on each other, otherwise their
mating faces may be damaged and therefore a Apply RESIN ADHESIVE (see Vehicle: Parts and
their adjustments may be altered, which could ingredients for the repairwork) (04B, Consuma-
damage the engine. bles - Products) using a stipple roller on the joint
face of the oil separator until the joint face is comple-
a Use SUPER CLEANING AGENT FOR JOINT FA- tely coated.
clean:
CONCERNED
- the oil separator joint face if it is to be re-used,
a Refit the oil separator.
- the rocker cover joint face.
- the oil separator joint face if it is to be re-used,
- the rocker cover joint face.
WARNING
ger marks).
WARNING
11A-141
K4J or K4M
14497-4
a Torque tighten in order the new oil separator bolts
(15 N.m).

a Refit:
11A-142
FUEL MIXTURE
Air filter: Removal - Refitting 12A
K9K
REMOVAL REFITTING
I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATION OPERATION

a Remove the air filter unit (see 12A, Fuel mixture, a Clean the air filter unit.
Air filter unit: Removal - Refitting, page 12A-5) .
WARNING
If the air filter is fitted incorrectly in the air filter
CONCERNED
unit, unfiltered air may enter the engine.

CONCERNED
a Refit the air filter in the air filter unit cover.
a Fit the air filter unit cover.

a Refit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-5) .
132602
a Remove the bolts (1) from the air filter unit.

a Move aside the air filter unit cover (2) .
132605
a Remove the air filter (3) from the air filter unit cover.
12A-1
FUEL MIXTURE
D4F
REMOVAL III - FINAL OPERATION

I - REMOVAL PREPARATION OPERATION ter unit: Removal - Refitting, page 12A-5) .
a Remove the air filter unit (see 12A, Fuel mixture,


CONCERNED
113509
a Remove:
- the bolts (1) from the air filter box cover,
- the air filter box cover,
- the air filter.
REFITTING

a Clean the air filter housing.
WARNING

CONCERNED
a Refit:
- the air filter,
- the air filter unit cover.
12A-2
FUEL MIXTURE
K4J or K4M
REMOVAL

a Remove the air resonator (see 12A, Fuel mixture,
Air resonator: Removal - Refitting, page 12A-12) .

CONCERNED
132683
a Remove the air filter (2) .
REFITTING

a Clean the air filter cover.
132681
a Remove:
CONCERNED
- the bolts (1) from the air filter box cover,
a Refit:
- the air filter,

a Refit the air resonator (see 12A, Fuel mixture, Air
resonator: Removal - Refitting, page 12A-12) .
12A-3
FUEL MIXTURE
K7J or K7M
REMOVAL a Refit the air filter unit cover bolts.
107574
a Remove the bolts from the air filter unit cover.
a Unclip the clips from the air filter unit cover.
a Remove the air filter unit cover.

CONCERNED
a Remove the air filter.
REFITTING

a Clean the air filter housing.
WARNING

CONCERNED
a Refit the air filter in the air filter unit.

a Refit the air filter unit cover.
a Fasten the clips onto the cover of the air filter unit.
12A-4
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
K9K
Tightening torquesm
clip of the air filter unit 5.5 N.m

air outlet pipe
REMOVAL

132606
a Remove the bolt (2) from the turbocharger pressure
sensor.
a Move aside the turbocharger pressure sensor.
K9K, and 740

a Disconnect the air temperature sensor connector (3)
.
20792
a Unclip:
unit by pressing on the pins (1) . - the wiring of the exhaust gas recirculation solenoid
valve at (4) from the air filter unit,
- the wiring at (5) from the air filter unit.
Note:
a Loosen the clip (6) of the air filter unit air outlet pipe
from the air filter unit.
a Disconnect the air filter unit air outlet pipe from the
air filter unit.
12A-5
FUEL MIXTURE
K9K
CONCERNED
132603
a Remove:
132604
- the bolts (7) from the air flowmeter,
a Raise the front section of the air filter unit (A) to re-
move it from its mountings. - the air flowmeter from the air filter unit,
a Slide the air filter unit towards the timing at (B) . - the air flowmeter seal,
a Remove the air filter unit. - the air filter (see 12A, Fuel mixture, Air filter: Re-
REFITTING a Refit:
- the air filter (see 12A, Fuel mixture, Air filter: Re-
I - WHEN REPLACING THE PART CONCERNED moval - Refitting, page 12A-1) in the new air filter
a Always replace the air flowmeter seal. unit,
- a new seal on the air flowmeter,
- the air flowmeter fitted with its seal on the air filter
unit.

CONCERNED
a Slip the air filter unit towards the gearbox while fitting
it in its mounting.
Note:
Check the condition of the air filter unit moun-
tings, replace them if necessary.
a Clip the air filter unit onto its mountings.

a Connect the air filter unit air outlet pipe to the air filter
unit.
12A-6
FUEL MIXTURE
K9K
a Torque tighten the clip of the air filter unit air out-
let pipe (5.5 N.m).
a Clip:
- the wiring on the air filter unit,
- the wiring of the exhaust gas recirculation solenoid
valve on the air filter unit.
K9K, and 740

a Connect the air temperature sensor connector.
a Position the turbocharger pressure sensor on the air

filter unit.
a Clip the air filter unit air inlet pipe onto the air filter
unit.
12A-7
FUEL MIXTURE
K4J or K4M
Tightening torquesm
air filter unit bolts 8 N.m
REMOVAL

132684
a Disconnect the brake servo hose (3) .
14843
a Disconnect:
- the petrol vapour rebreathing solenoid valve con-
nector (1) ,
- the petrol vapour rebreathing pipe (2) .
132685
a Remove the expansion bottle bolts (4) .
a Remove the expansion bottle.
12A-8
FUEL MIXTURE
K4J or K4M
CONCERNED
14843
a Remove:
- the air filter unit bolt (5) ,
- the air filter unit by shifting it towards the right.
REFITTING

CONCERNED
a Refit the air filter unit.
a Torque tighten the air filter unit bolts (8 N.m).
a Refit the expansion bottle.
a Connect:
- the brake servo pipe,
- the petrol vapour rebreathing pipe,
- the petrol vapour rebreathing solenoid valve con-

nector.

12A-9
FUEL MIXTURE
D4F
Tightening torquesm
air filter unit clip on the 5.5 N.m

throttle valve
REMOVAL
132658
a Undo the air filter unit clip (2) on the throttle valve.
a Disconnect the oil vapour rebreathing hose (3) from
the air filter unit.

CONCERNED
a Remove the air filter unit:
- lift out the air filter unit to remove it from the rocker
132655 cover,
a Disconnect the air filter unit air inlet pipe (1) from the - push the air filter unit towards the right to remove it
air filter unit. from the throttle valve.
REFITTING

CONCERNED
a Refitting the air filter unit:
- push the air filter unit towards the left to attach it to
the throttle valve,
- lower the air filter unit to attach it to the rocker co-
ver.
a Torque tighten the air filter unit clip on the throttle
valve (5.5 N.m).
a Connect:
- the oil vapour rebreathing hose to the air filter unit,
- the air filter unit air inlet pipe onto the air filter unit.
12A-10
FUEL MIXTURE
K7J or K7M
REMOVAL REFITTING
OPERATION FOR REMOVAL OF PART OPERATION FOR REFITTING PART CONCERNED

CONCERNED
a Position the air filter unit.
a Connect:
- the air intake sleeve,
- the oil vapour rebreathing pipe .
a Clip the fuel pipe onto the air filter unit.
a Refit the air filter unit.
107574
a Remove the bolts (1) from the air filter unit.
107361
a Move aside the air filter unit slightly.
a Unclip the fuel pipe from the air filter unit.
a Disconnect:
- the oil vapour rebreathing pipe (2) ,
- the air intake sleeve (3) .
a Remove the air filter unit.
12A-11
FUEL MIXTURE
Air resonator: Removal - Refitting 12A
K4J or K4M
REMOVAL

CONCERNED
132682
a Remove the air resonator strap (1) .
a Unclip:
- the cooling hose (2) .
- the air resonator air inlet pipe on the body.
a Remove the air resonator (3) .
REFITTING
REFITTING OPERATION FOR PART CONCERNED

a Refit the air resonator.
a Clip:
- the air resonator air inlet pipe on the body.
- the cooling hose.
a Refit the air resonator strap.
12A-12
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
K9K
Tightening torquesm
clip of the air filter unit 5.5 N.m

air outlet pipe
REMOVAL

114509
a Loosen the clips (3) on the turbocharger air outlet pi-
pe.
a Disconnect the turbocharger air outlet pipe:
- on the turbocharger,
- on the air flowmeter.
a Remove the turbocharger outlet air pipe.
132606
a Unclip the wiring of the exhaust gas recirculation so-
lenoid valve at (1) from the air filter unit.
K9K, and 740

a Disconnect the air temperature sensor connector (2)
.
12A-13
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
K9K
CONCERNED
K9K, and 740
a Connect the air temperature sensor connector.
a Clip the wiring of the exhaust gas recirculation sole-

noid valve onto the air filter unit.
134077
a Remove:
- the flowmeter bolts (4) ,
- the flowmeter.
REFITTING

a Always replace the air flowmeter seal.

CONCERNED
a Refit:
- a new seal on the air flowmeter,
- the air flowmeter fitted with its seal on the air filter
unit.

a Refit the air filter unit air outlet pipe to the air filter
unit.
a Connect the turbocharger air outlet pipe:
- on the turbocharger,
- on the air flowmeter.

a Torque tighten the clip of the air filter unit air out-
let pipe (5.5 N.m).
12A-14
FUEL MIXTURE
Throttle valve: Removal - Refitting 12A
D4F
Tightening torquesm
throttle valve bolts 10 N.m
REMOVAL


CONCERNED
132664
a Remove:
- the throttle valve bolts (2) ,
- the throttle valve.
132665
a Disconnect the connector (1) from the throttle valve.
132663
a Remove the throttle valve seal (3) .
REFITTING
a Always replace the throttle valve seal.
12A-15
FUEL MIXTURE
D4F
a Use SURFACE CLEANER (see Vehicle: Parts a Reinitialise the programming of the stops (see Fault
and ingredients for the repairwork) (04B, Consu- finding - Replacement of components) (17B, Pe-
mables - Products) to clean and degrease: trol injection).
- the throttle valve joint face if it is to be re-used,
- the inlet manifold seal housing.
WARNING
WARNING
a risk of leaks.

CONCERNED
132664
a Refit:
- a new seal on the inlet manifold,

a In order, torque tighten the throttle valve bolts (10

N.m).
a Connect the throttle valve connector.

12A-16
FUEL MIXTURE
K7J
REMOVAL


CONCERNED
107357
a Disconnect:
- the connector (2) from the throttle valve potentio-
meter,
- the stepper motor connector (3) .
a Remove the throttle valve by tilting it.
107356 REFITTING
a Unclip the throttle valve ball joint at (1) .
CONCERNED
a Refit the throttle valve.
a Connect:
- the throttle valve potentiometer connector,
- the stepper motor connector.
a Clip the ball joint onto the throttle valve.
12A-17
FUEL MIXTURE
K4J, and 712 or 713 – K4M, and 734 or 745
Tightening torquesm
REMOVAL

a Remove:

CONCERNED
116635
a Remove:
- the throttle valve,
- the throttle valve seals.
REFITTING
a Always replace the throttle valve seals.

CONCERNED
a Refit the throttle valve, with new gaskets.

116660
a Disconnect: a Torque tighten the throttle valve bolts (14 N.m).
- the throttle valve connector (1) , a Connect:
- the accelerator cable (2) . - the accelerator cable,
- the throttle valve connector.
a Refit:

12A-18
FUEL MIXTURE
K7M, and 734
Tightening torquesm
REMOVAL


CONCERNED
141068
a Remove:
REFITTING
a parts always to be replaced: Throttle valve seal

141067
(11,04,06,25).
a Disconnect the connector (1) from the throttle valve.

CONCERNED
a Refit:
- a new throttle valve seal,
a Torque tighten the throttle valve bolts (9 N.m).
a Connect the throttle valve connector.
12A-19
FUEL MIXTURE
K4M, and 674
Tightening torquesm
throttle valve lower bolts 14 N.m
upper bolt of the throttle 8 N.m

valve
REMOVAL

a Remove:
- the air resonator (see 12A, Fuel mixture, Air reso- 141055
nator: Removal - Refitting, page 12A-12) , a Disconnect the connector (2) from the throttle valve.

CONCERNED
141057
a Remove the upper bolt (3) from the throttle valve.
141056
a Disconnect the fuel pipes (1) from the throttle valve.
12A-20
FUEL MIXTURE
K4M, and 674
a Remove:
116635
a Remove:
- the throttle valve lower bolts (4) ,
REFITTING
a parts always to be replaced: Throttle valve seal

(11,04,06,25).

CONCERNED
a Refit:
- new seals on the throttle valve,
- the throttle valve lower bolts (14 N.m),
- the upper bolt of the throttle valve (8 N.m).
a Connect:
- the throttle valve connector,
- the fuel pipes on the throttle valve.
12A-21
FUEL MIXTURE
Throttle valve: Cleaning 12A
D4F or K4J or K4M or K7J or K7M
Essential equipment
compressed air nozzle
IMPORTANT
tion.
IMPORTANT
Always wear protective gear (gloves, goggles and
breathing masks).
Note:
Be sure to work in a clean environment so as not to
allow any contamination of the throttle valve. 124736
a Hold the throttle valve flap open manually.
CLEANING
Note:
I - CLEANING PREPARATION OPERATION Do not spray any cleaning product onto the out-
side of the cylinder, inside the spring housing or
a Remove the throttle valve (see 12A, Fuel mixture, onto the connector.
Throttle valve: Removal - Refitting, page 12A-15)
. a Spray CARBURETTOR CLEANER (see Vehicle:
Parts and ingredients for the repairwork) (04B,
Consumables - Products) into the air vent until all
II - CLEANING THE PART CONCERNED
traces of clogging have disappeared.
a
Note:
The CARBURETTOR CLEANING product
damages the seals.
a Remove the seal(s) of the throttle valve.
12A-22
FUEL MIXTURE
Throttle valve: Cleaning 12A
124737 124738
a Remove the residues of CARBURETTOR CLEA- a Use a compressed air nozzle to blast the throttle
NER and the residual dirt using a LINT-FREE valve edges and the air vent.
CLOTH (see Vehicle: Parts and ingredients for
parts always to be replaced: Throttle valve seal
the repairwork) (04B, Consumables - Products).
(11,04,06,25)
Note:
If the throttle valve is dropped or receives any
other impact, it will need to be replaced.

a Refit the throttle valve (see 12A, Fuel mixture,
.
12A-23
FUEL MIXTURE
Inlet manifold: Removal - Refitting 12A
D4F
Tightening torquesm
injector rail bolts 7 N.m
inlet manifold nuts on 8 N.m

the rocker cover (initial
torque)
inlet manifold bolts on 3 N.m

the cylinder head (initial
torque)
inlet manifold nuts on 17 N.m

the rocker cover
inlet manifold bolts on 9 N.m

the cylinder head
110421
IMPORTANT a Remove:
- the bolt (1) from the engine oil filler neck,
During this operation, be sure to:
- the engine oil filler neck,
- refrain from smoking or bringing red hot objects
close to the working area, - the dipstick.
- be careful of fuel splashes when disconnecting the
union.
IMPORTANT
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
To prevent impurities from entering the circuit, plugs
must be fitted to the openings of all the fuel circuit
components exposed to the open air.
REMOVAL

12A-24
FUEL MIXTURE
D4F
CONCERNED
121733
a Disconnect:
110421
- the oil vapour rebreathing pipe union from the inlet
manifold (2) ,
- the brake servo pipe union from the inlet manifold

(3) ,
- the petrol vapour rebreathing pipe union from the

inlet manifold (4) ,
- the pressure sensor connector (5) ,
- the temperature sensor connector (6)
- the throttle body connector (7) ,
- all injector connectors (8) .

109729
WARNING a Remove:
To disconnect the spark plug leads, pull on the - the nuts (10) from the inlet manifold on the rocker
extensions and not on the leads. cover,
- the inlet manifold bolts from the cylinder head,
a Disconnect:
- the intake distributor.
- the ignition wiring harnesses from the spark plugs
(9) ,
When replacing the inlet manifold
- the fuel supply pipe union on the injector rail.
a Using the workbench, remove:
- the injector rail bolts,
- the injector rail,

WARNING
To avoid any corrosion or damage, protect the - the throttle valve bolts,
areas on which fuel is likely to run. - the throttle valve,
12A-25
FUEL MIXTURE
D4F
- temperature sensor ,
- the inlet manifold pressure sensor.
REFITTING

- the housing of each inlet manifold seal,

109729
- the seal face of the injector holder shim. a Tighten to torque and in order:
a Always replace the inlet manifold seals. - the inlet manifold nuts on the rocker cover (17
N.m),
a Fit new seals to the inlet manifold. - the inlet manifold bolts on the cylinder head (9
N.m).
When replacing the inlet manifold
a Refit:
- temperature sensor ,
- the inlet manifold pressure sensor,
- the throttle valve with a new seal.
a Torque tighten the throttle valve bolts (10 N.m).
a Refit the injector rail.
a Torque tighten the injector rail bolts (7 N.m).

CONCERNED
a Refit the inlet manifold, with its new seals.
- the intake distributor nuts on the rocker cover,
- the inlet manifold bolts from the cylinder head,
a Pre-tighten to torque:
- the inlet manifold nuts on the rocker cover (ini-

tial torque) (8 N.m),
- the inlet manifold bolts on the cylinder head

(initial torque) (3 N.m).
12A-26
FUEL MIXTURE
D4F
106640
a Apply a bead of FLUORSTAR 2L grease (see Vehi- - the engine oil filler neck,
cle: Parts and ingredients for the repairwork)
(04B, Consumables - Products) 2 mm in diameter
on the internal perimeter of the high-tension caps at
the spark plug end.
a Connect:
- the fuel supply pipe union on the injector rail,
- the ignition wiring harnesses from the spark plugs,
- all injector connectors,
- the throttle body connector ,
- the temperature sensor connector
- the pressure sensor connector,
- the petrol vapour rebreathing pipe union on the in-
let manifold,
- the brake servo pipe union on the inlet manifold,
- the oil vapour rebreathing pipe union to the inlet
manifold.
a Refit:
- the dipstick,
12A-27
FUEL MIXTURE
K7J
Tightening torquesm
inlet manifold mountings 25 N.m
intake distributor strut 21 N.m

mountings
WARNING
REMOVAL

a Remove the air filter unit (see 12A, Fuel mixture, a Disconnect the petrol vapour rebreathing pipe from
Air filter unit: Removal - Refitting, page 12A-5) . the inlet manifold at (2) .
107357
133724
a Disconnect the fuel supply pipe on the injector rail at a Disconnect the injector connectors (3) .
(1) . a Move the injector wiring to one side.
a Insert the blanking plugs. a Remove the throttle valve (see 12A, Fuel mixture,
a Unclip the fuel supply pipe from the inlet manifold. Throttle valve: Removal - Refitting, page 12A-15)
.
12A-28
FUEL MIXTURE
K7J
133144 133161
a Unclip the inlet manifold wiring at (7) .
a Remove:

CONCERNED
133143
a Disconnect:
- the brake servo pipe on the inlet manifold,

133138
- the oil vapour rebreathing pipe on the inlet manifold
at (6) . a Remove:
- the intake distributor strut mountings (8) ,
a Unclip the ball joint from the accelerator cable on the
inlet manifold. - the intake distributor strut.
12A-29
FUEL MIXTURE
K7J
a Remove:
- the inlet manifold,
- the inlet manifold seals.
REFITTING

a parts always to be replaced: intake distributor
seal (10,07,01,07).
WARNING
To prevent the surrounding components from
overheating, do not damage (tear, pierce, bend,
etc.) a heat shield.
Any damaged heat shields must be replaced.
107486
WARNING
a Remove the upper bolts (9) from the inlet manifold.
ger marks).
a Fit the new seals to the inlet manifold.

CONCERNED
a Refit the inlet manifold, starting with the centre lower
nut.
a Torque tighten the inlet manifold mountings (25
N.m).
a Refit the inlet manifold strut.
a Torque tighten the intake distributor strut moun-
tings (21 N.m).
133175 a Refit the engine undertray.

a Remove the inlet manifold lower nuts (10) . a Clip the accelerator cable ball joint onto the inlet ma-
nifold.
Note: a Connect:
To completely remove the centre lower nut: - the oil vapour rebreathing pipe from the intake dis-
tributor,
- remove the nuts at the ends,
- detach the inlet manifold from the cylinder
head. - the air inlet pressure sensor connector,
- the connector of the air inlet temperature sensor.
a Clip the wiring onto the inlet manifold.
12A-30
FUEL MIXTURE
K7J
a Refit the throttle valve (see 12A, Fuel mixture,
.
a Position the injector wiring.
a Connect:
- the injector connectors,
- the petrol vapour rebreathing pipe from the inlet
manifold.
a Connect the fuel supply pipe to the injector rail.
a Clip the fuel supply pipe onto the inlet manifold.
12A-31
FUEL MIXTURE
K4J, and 712 or 713 – K4M, and 734 or 745
Tightening torquesm
intake distributor bolts 9 N.m
REMOVAL

a Remove:
valve: Removal - Refitting, page 12A-15) .
II - OPERATION FOR REMOVAL OF PART 133502

CONCERNED
133503
133501
a Remove:
a Disconnect:
- the inlet manifold bolts (4) ,
- the connector (1) from the air temperature sensor,
- the connectors (2) from the coils,
- the connector (3) of the inlet air pressure sensor.
a When replacing the inlet manifold, remove:
- the air temperature sensor,
- the inlet air pressure sensor.
12A-32
FUEL MIXTURE
K4J, and 712 or 713 – K4M, and 734 or 745
REFITTING

- the housing of each inlet manifold seal,
- the seal face of the injector holder shim.
a Always replace the inlet manifold seals.

CONCERNED
a When replacing the inlet manifold, refit:
a Refit the inlet manifold, fitted with new seals.
133502
133503
a Torque tighten in order the intake distributor bolts
(9 N.m).
a Connect:
- the air inlet pressure sensor connector.
- the windings connectors,
- the air temperature sensor connector,
12A-33
FUEL MIXTURE
K4J, and 712 or 713 – K4M, and 734 or 745
a Refit:
12A-34
FUEL MIXTURE
K7M, and 734
Tightening torquesm
inlet manifold mountings 25 N.m
inlet manifold strut 21 N.m

mounting
inlet manifold spacer 12 N.m

bolts
inlet manifold spacer 14 N.m

nuts
WARNING
141053
REMOVAL
a Disconnect the fuel supply pipe on the injector rail at
(1) .
Towing and lifting) (02A, Lifting equipment). a Unclip the fuel supply pipe from the inlet manifold.
a Remove:
141051
a Disconnect the petrol vapour rebreathing pipe (2)
from the inlet manifold.
12A-35
FUEL MIXTURE
K7M, and 734
141063
a Unclip the throttle valve wiring at (3) .
a Disconnect the connector (4) from the additional fuel

system fuel pipe.
141049
a Unclip the pipe of the additional fuel system at (5) .
a Remove the injector connectors (8) .
141052
a Disconnect:
141064 - the brake servo pipe (11) on the inlet manifold,
a Remove: - the oil vapour rebreathing pipe on the inlet manifold
at (12) .
- the bolts (6) ,
- the nuts (7) of the spacer between the throttle valve

and the inlet manifold,
- the spacer between the throttle valve and the inlet

manifold,
- the inlet manifold cone.
a Remove the inlet manifold seal.
12A-36
FUEL MIXTURE
K7M, and 734
133161 107486
a Remove the upper bolts (15) from the inlet manifold.
a Unclip the inlet manifold wiring at (13) .
a Remove:

CONCERNED
141050
a Remove the inlet manifold strut mountings (14) .
12A-37
FUEL MIXTURE
K7M, and 734
REFITTING

seal (10,07,01,07).
WARNING
WARNING
ger marks).
133175 a Fit new seals to the inlet manifold.

a Remove the inlet manifold lower nuts (16) .
a When replacing the inlet manifold, remove: II - REFITTING OPERATION FOR PART
CONCERNED
- the air inlet pressure sensor.
Note:
a Refit the inlet manifold, starting with the centre lower
To completely remove the centre lower nut:
nut.
- remove the outer nuts,
a Torque tighten the inlet manifold mountings (25
- detach the inlet manifold from the cylinder N.m).
head.
a Refit the intake distributor strut.
a Remove: a Torque tighten the inlet manifold strut mounting
- the inlet manifold, (21 N.m).
a Clip on the inlet manifold wiring.
a Connect:
- the oil vapour rebreathing pipe from the intake dis-
tributor,
- the air inlet temperature sensor connector,
- the connector of the injectors.
a Refit:
- the intake distributor seal,
12A-38
FUEL MIXTURE
K7M, and 734
- the inlet manifold cone,
- the spacer between the throttle valve and the inlet
manifold.
- the inlet manifold spacer bolts (12 N.m),
- the inlet manifold spacer nuts (14 N.m).
a Clip:
- the additional fuel system pipe,
- the throttle valve wiring.
a Connect the petrol vapour rebreathing pipe to the in-
let manifold.
a Clip the fuel supply pipe onto the inlet manifold.
a Connect the fuel supply pipe to the injector rail.
a Refit:
12A-39
FUEL MIXTURE
K4M, and 674
Tightening torquesm
intake distributor bolts 9 N.m
REMOVAL

a Remove:
- the air filter unit (see 12A, Fuel mixture, Air filter 141065

CONCERNED
141054
a Remove:
- the inlet manifold bolts (4) ,
141066 - the inlet manifold seals.

a Disconnect: a When replacing the inlet manifold, remove:
- the connector (1) from the air temperature sensor,
- the coil connectors (2) ,
- the air inlet pressure sensor (3) .
REFITTING

seal (10,07,01,07)
12A-40
FUEL MIXTURE
K4M, and 674
mables - Products) to clean and degrease the hou-
sing of each inlet manifold seal.

CONCERNED
a Refit:
- a new seal on the inlet manifold,
141065
- the inlet manifold fitted with a new seal.
141054
a Torque tighten in order the intake distributor bolts
(9 N.m).
a Connect:
- the windings connectors,
- the air temperature sensor connector.

a Refit:
12A-41
FUEL MIXTURE
Injector holder shim: Removal - Refitting 12A
K4J or K4M

bly.
Tightening torquesm
bolts 1 and 2 on the 30 N.m

injector holder shim
bolts 3, 4, 5, 6, 7, 8, 9 25 N.m
and 10 on the injector
holder shim
upper timing cover bolt 46 N.m
101793
REMOVAL
I - REMOVAL PREPARATION OPERATION a Separate the catalytic converter from the exhaust
manifold.
Towing and lifting) (02A, Lifting equipment). a Remove the exhaust bracket seal.
a Disconnect the battery (see Battery : Removal - a Position the (Mot. 1390) under the engine.
a Remove:
a Remove:
- the engine undertray bolts, 19D, Engine mounting, Right-hand suspended
19D-16) ,
- the right-hand headlight (see Front headlight: Re- page 11A-1) ,
- the front right-hand wheel (see Wheel: Removal - sisted steering pump: Removal - Refitting)
Refitting) (35A, Wheels and tyres), (36B, Power-assisted steering).
terior protection),
page 19D-26) .
12A-42
FUEL MIXTURE
K4J or K4M
133057 132680
a Remove: a
- the bolt (2) of the power-assisted steering pipe clip, WARNING
- the nuts (3) from the injector rail protector, To avoid any corrosion or damage, protect the
a Disconnect:
- the injector connectors (4) ,
- the fuel supply pipe union (5) from the injector rail.
a Remove:
- the intake distributor (see 12A, Fuel mixture, Inlet
manifold: Removal - Refitting, page 12A-24) .
12A-43
FUEL MIXTURE
K4J or K4M
CONCERNED
133267
a Remove:
133264
- the injector holder shim bolts,
a Remove the bolt (6) from the injection wiring chan-
nel. - the injector holder shim,
- the injector holder shim seal.
REFITTING

- the cylinder head joint face,
- the joint face of the injector holder shim, if it is to be
reused.
WARNING
ger marks).
133265
a Remove the bolt (7) from the upper timing cover. WARNING
a risk of leaks.
a Always replace:
- the injector holder shim seal,
12A-44
FUEL MIXTURE
K4J or K4M
II - REFITTING OPERATION FOR PART a Connect:
CONCERNED
- the fuel supply pipe union on the injector rail,
a Refit:
- a new injector holder shim seal, - the injector connectors.
- the injector holder shim. a Refit:
- the injector rail protector,
- the power-assisted steering pipe clip bolt,


page 11A-1) ,

19D-16) .

133267
a Tighten to torque and in order: a Position the catalytic converter on the exhaust mani-
fold.
- bolts 1 and 2 on the injector holder shim (30
N.m), a Torque tighten the exhaust bracket nuts (21 N.m).
- bolts 3, 4, 5, 6, 7, 8, 9 and 10 on the injector hol-
der shim (25 N.m). a Refit:
a Refit the upper timing cover bolt. - the lower engine tie-bar (see 19D, Engine moun-
a Torque tighten the upper timing cover bolt (46 ting, Lower engine tie-bar: Removal - Refitting,
N.m). page 19D-26) ,
a Refit the injection wiring channel bolt. - the front right-hand wheel arch liner (see Front
terior protection),
a Refit: - the front right-hand wheel (see Wheel: Removal -
manifold: Removal - Refitting, page 12A-24) , - the right-hand headlight (see Front headlight: Re-
- the throttle valve (see 12A, Fuel mixture, Throttle moval - Refitting) (80B, Headlights),
- the air filter unit (see 12A, Fuel mixture, Air filter Refitting) (55A, Exterior protection),
a Remove the blanking plugs. ting) (80A, Battery).
12A-45
FUEL MIXTURE
Exhaust manifold: Removal - Refitting 12A
D4F
CONCERNED
Tightening torquesm
exhaust manifold studs 9 N.m
exhaust manifold nuts 25 Nm
IMPORTANT
REMOVAL


a Remove: 120312
a Remove:
- the engine undertray, - the nuts (2) from the exhaust manifold,
- the catalytic converter (see 19B, Exhaust, Cataly- - the exhaust manifold,
- the exhaust manifold gasket.
REFITTING

- the exhaust manifold joint face if it is to be re-used,
a parts always to be replaced: exhaust manifold

seal (10,07,02,07).
Note:
If a stud loosens during removal, coat it with
120301 HIGH RESISTANCE THREADLOCK (see Vehi-
a Remove: (04B, Consumables - Products).
- the bolts (1) from the heat shield,
a Torque tighten the exhaust manifold studs (9
- the heat shield. N.m).
12A-46
FUEL MIXTURE
D4F
CONCERNED
120312
a Refit:
- a new exhaust manifold seal,
- the exhaust manifold.
a Tighten to torque and in order the exhaust manifold
nuts (25 Nm).

a Refit:
- the heat shield on the exhaust manifold,
12A-47
FUEL MIXTURE
K4J or K4M
Tightening torquesm
exhaust manifold nuts 26 N.m
IMPORTANT
REMOVAL

111467
a Remove:
a Remove:
nator: Removal - Refitting, page 12A-12) , - the upstream oxygen sensor (3) (see 17B, Petrol
injection, Oxygen sensors: Removal - Refitting,
- the air filter unit (see 12A, Fuel mixture, Air filter page 17B-12) ,
- the bolts (4) from the upper heat shield,
- the upper heat shield.

CONCERNED
101793
manifold.
a Remove: 101797
- the exhaust bracket gasket, a Remove:
- the bolt (2) from the exhaust manifold stay. - the exhaust manifold bolts,
12A-48
FUEL MIXTURE
K4J or K4M
- the exhaust manifold, When replacing the exhaust manifold
- the exhaust manifold gasket. a Refit the lower heat shield.
When replacing the exhaust manifold II - REFITTING OPERATION FOR PART

CONCERNED
101502
a Remove: 101797
- the lower heat shield bolts (5) , a Refit:
- the lower heat shield. - a new exhaust manifold seal,

REFITTING a Torque tighten in order the exhaust manifold nuts
(26 N.m).
a Use SURFACE CLEANER (see Vehicle: Parts III - FINAL OPERATION
a Refit:
- the upper heat shield,
- the exhaust manifold joint face if it is to be re-used,
- the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
a Always replace: page 17B-12) ,
- the exhaust bracket gasket, - the exhaust manifold strut bolt,
- the exhaust manifold gasket. - a new exhaust bracket seal.

Note:
HIGH RESISTANCE THREADLOCK (see Vehi- a Refit:
cle: Parts and ingredients for the repairwork) - the air filter unit (see 12A, Fuel mixture, Air filter
(04B, Consumables - Products). unit: Removal - Refitting, page 12A-5) ,
a Torque tighten the exhaust manifold studs (9 - the air resonator (see 12A, Fuel mixture, Air reso-
N.m). nator: Removal - Refitting, page 12A-12) .
12A-49
FUEL MIXTURE
K4J or K4M
12A-50
FUEL MIXTURE
K7J or K7M
CONCERNED
Tightening torquesm
REMOVAL

a Remove:
133136
a Remove:
- the nuts (2) from the exhaust flange,
- the nuts (3) from the exhaust manifold,
- the exhaust manifold,
- the exhaust manifold gasket.
REFITTING

a parts always to be replaced: exhaust manifold
seal (10,07,02,07).
a parts always to be replaced: ring between ex-
haust manifold and catalytic converter (10,08,02,
20).
133147
a Remove:
- the nuts (1) from the heat shield,
- the heat shield.
12A-51
FUEL MIXTURE
K7J or K7M
a Use SURFACE CLEANER (see Vehicle: Parts II - OPERATION FOR REFITTING PART
- the exhaust manifold joint face if it is to be reused,
WARNING
ger marks).
Note:
HIGH RESISTANCE THREADLOCK (see Vehi-
WARNING
To prevent the surrounding components from 133136
a Refit the exhaust manifold.
a Screw on the exhaust manifold nuts in order, without
tightening them.
a Torque tighten the exhaust manifold studs (9 N.m) a Tighten to torque and in order the exhaust manifold
if loosened. nuts (25 N.m).
a Fit:
- the new sealing ring between the exhaust manifold III - FINAL OPERATION
and the catalytic converter, a Refit:
- the new gasket on the cylinder head. - the heat shield,
a Check that there are no leaks.
12A-52
FUEL MIXTURE
K9K, and 740
Tightening torquesm
exhaust gas recircula- 25 N.m

tion assembly bolts
bolts for the « timing 12 N.m

end lifting ring - air inlet
metal tube assembly »
coolant circulation cover 12 N.m

bolts
IMPORTANT 114341
Wear protective gloves during the operation. a Fit the tool (Ms. 583) on each of the cooling hoses
(1) of the coolant circulation cover.
a Remove the bolts (2) from the coolant circulation co-
REMOVAL ver.
a Remove the coolant circulation cover.
a Disconnect the battery (see Battery : Removal - WARNING

Refitting) (80A, Battery). Prepare for the flow of fluid, and protect the sur-
a Remove:
a Remove the seals from the coolant circulation cover.
- the engine cover,
- the turbocharger oil supply pipe (see 12B, Turbo-

charging, Turbocharger oil pipe: Removal - Re-
fitting, page 12B-7) ,


tic converter: Removal - Refitting, page 19B-9) , 112329
a Remove:
- the turbocharger oil return pipe (see 12B, Turbo-
charging, Turbocharger oil pipe: Removal - Re- - the bolts (3) of the « timing end lifting eye - air inlet
fitting, page 12B-7) , metal tube » assembly,
- the lifting eye on the timing end,
- the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-1) . - the air inlet metal tube,
12A-53
FUEL MIXTURE
K9K, and 740
- the air inlet metal tube seals, a Use SURFACE CLEANER (see Vehicle: Parts
- the exhaust gas recirculation rigid pipe (see 14A,
Antipollution, Exhaust gas recirculation rigid
pipe: Removal - Refitting, page 14A-19) , - the seal housings of the coolant circulation cover,
- the bolts (4) from the exhaust gas recirculation as- - the joint face of the exhaust gas cooler support on
sembly, the gearbox side,
- the exhaust gas recirculation assembly. - the seal housings of each air inlet metal tube,
- the housing of the air inlet metal tube in the cylinder
head,
CONCERNED
- the housing of the air inlet metal tube in the ex-
haust gas cooler support on the gearbox side,
- the exhaust manifold joint face if it is to be reused.
WARNING
ger marks).

CONCERNED
114532
a Remove:
a Mark the position of the exhaust manifold gasket.
a Remove the exhaust manifold gasket.
REFITTING

a Always replace:
- the air inlet metal tube seals, 114532
- the coolant circulation cover seals, a Refit:
- the exhaust manifold gasket. - a new exhaust manifold seal,
a Use ABRASIVE PADS to clean the joint face: - the exhaust manifold.
- of the cylinder head, a Torque tighten in order the exhaust manifold nuts
(26 N.m).
- of the exhaust manifold, if it is to be reused.

WARNING
Do not scrape the joint faces of the aluminium, a Refit the exhaust gas recirculation assembly.
any damage caused to the joint face will result in a Fit the bolts of the exhaust gas recirculation assem-
a risk of leaks. bly without tightening them.
12A-54
FUEL MIXTURE
K9K, and 740
a Torque tighten the exhaust gas recirculation as-
sembly bolts (25 N.m).
a Refit:

pipe: Removal - Refitting, page 14A-19) ,
- the new seals on the air inlet metal tube,
- the air inlet metal tube,
a Torque tighten the bolts for the « timing end lifting

ring - air inlet metal tube assembly » (12 N.m).
a Refit new coolant circulation cover seals on the coo-

lant circulation cover.
a Fit the coolant circulation cover.
a Torque tighten the coolant circulation cover bolts

(12 N.m).
a Remove the tool (Ms. 583) from each of the cooling

hoses of the coolant circulation cover.
a Refit:

bocharger: Removal - Refitting, page 12B-1) ,




- the engine cover.

12A-55
FUEL MIXTURE
K9K, and 700
CONCERNED
Tightening torquesm
IMPORTANT
REMOVAL

a Remove:
- the engine cover,
- the turbocharger oil supply pipe (see 12B, Turbo- 20848-1
charging, Turbocharger oil pipe: Removal - Re- a Remove:
a Mark the position of the exhaust manifold gasket.
a Remove the exhaust manifold gasket.
tic converter: Removal - Refitting, page 19B-9) , REFITTING
charging, Turbocharger oil pipe: Removal - Re- I - REFITTING PREPARATION OPERATION
fitting, page 12B-7) , a Always replace the exhaust manifold gasket.
- the turbocharger (see 12B, Turbocharging, Tur- a Use ABRASIVE PADS to clean the joint face:
- of the cylinder head,
Antipollution, Exhaust gas recirculation rigid - of the exhaust manifold, if it is to be reused.
pipe: Removal - Refitting, page 14A-19) .
WARNING
a risk of leaks.
12A-56
FUEL MIXTURE
K9K, and 700
a Use SURFACE CLEANER (see Vehicle: Parts - the turbocharger oil return pipe (see 12B, Turbo-
and ingredients for the repairwork) (04B, Consu- charging, Turbocharger oil pipe: Removal - Re-
mables - Products) to clean and degrease the joint fitting, page 12B-7) ,
faces:
- of the cylinder head, tic converter: Removal - Refitting, page 19B-9) ,
- of the exhaust manifold, if it is to be reused. - the engine undertray,

WARNING
To ensure proper sealing, the gasket surfaces charging, Turbocharger oil pipe: Removal - Re-
must be clean, dry and not greasy (avoid any fin- fitting, page 12B-7) ,
ger marks).
II - REFITTING OPERATION FOR PART - the engine cover.
CONCERNED
20848-1
a Refit:
- a new exhaust manifold seal,
a Torque tighten in order the exhaust manifold nuts

(26 N.m).
a Refit:


12A-57
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
K9K, and 740
Tightening torquesm
new turbocharger studs 9 N.m

on the exhaust manifold
new turbocharger stud 9 N.m

on the turbocharger
new upper turbocharger 28 N.m

nuts
turbocharger air outlet 5.5 Nm

pipe clip
turbocharger air outlet 10 N.m

pipe nuts
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera- 134070
tion. a Remove the nuts (1) from the turbocharger air outlet
pipe.
a Undo the turbocharger air outlet pipe clip (2) on the
IMPORTANT turbocharger.
Wear protective gloves during the operation. a Disconnect the turbocharger air outlet pipe from the
turbocharger.
a Move aside the air outlet pipe of the turbocharger.
a Remove the turbocharger air outlet pipe seal.
a Remove:
- the engine cover,




fitting, page 12B-7) .
12B-1
TURBOCHARGING
K9K, and 740
II - OPERATION FOR REMOVAL OF PART a Always replace:
CONCERNED
- the turbocharger seal,
- the turbocharger air outlet pipe seal,
- the turbocharger studs and nuts.
WARNING
a risk of leaks.
a Use ABRASIVE PADS to clean:
- the exhaust manifold joint face,
- the turbocharger gasket face if reused.


113560
- the turbocharger joint face if it is to be reused,
a Remove:
- the turbocharger air outlet pipe seal housing,
- the turbocharger nuts (3) ,
- the joint face of the exhaust gas cooler support on
- the turbocharger, the gearbox side.
- the turbocharger seal.
WARNING
a must be clean, dry and not greasy (avoid any fin-
ger marks).
WARNING
Ensure that no foreign bodies enter the turbine or a Tighten to torque:
compressor during the refitting operation.
- the new turbocharger studs on the exhaust ma-
Check that the turbocharger oil return pipe is not nifold (9 N.m),
partially or completely blocked by scale. Check
that there are no leaks. If there are, replace the - the new turbocharger stud on the turbocharger
part. (9 N.m).

WARNING CONCERNED
Following a turbocharger fault, check that the
intercooler and air circuit assembly are not full of a Refit:
oil. If they are, remove them and clean them with
- a new turbocharger seal on the exhaust manifold,
a cleaning tray or station and dry them with a
compressed air gun. - the turbocharger.
a Use an open wrench to fit the new turbocharger nuts

without tightening them (the turbocharger must be in
contact with the manifold and the wrench should no
longer turn without effort).
a Put a paint mark on the turbocharger coinciding with
a lower nut crest of the turbocharger.
12B-2
TURBOCHARGING
K9K, and 740
a Tighten the turbocharger bottom nut until the top of
the nut is aligned with the paint mark made on the
turbocharger (the final tightening angle is 60˚).
a Torque tighten the new upper turbocharger nuts
(28 N.m).

a Refit a new turbocharger air outlet pipe seal on the
turbocharger air outlet pipe.
a Fit the turbocharger air outlet pipe.
a Connect the turbocharger air outlet pipe to the turbo-
charger.
- the turbocharger air outlet pipe clip (5.5 Nm),
- the turbocharger air outlet pipe nuts (10 N.m).
a Refit:
- the engine cover.
12B-3
TURBOCHARGING
K9K, and 700
Tightening torquesm
new turbocharger studs 9 N.m

on the exhaust manifold
new turbocharger stud 9 N.m

on the turbocharger
new upper turbocharger 28 N.m

nuts
turbocharger air outlet 5.5 N.m

pipe clips
IMPORTANT
tion.
24748
a Unclip the clip (1) from the turbocharger pressure re-
IMPORTANT gulating valve control hose.
Wear protective gloves during the operation. a Disconnect the turbocharging pressure regulating
valve control hose.
a Undo the turbocharger air outlet pipe clips (2) .
a Disconnect:
a Disconnect the battery (see Battery : Removal - - the turbocharger air outlet pipe from the turbochar-
Refitting) (80A, Battery). ger,
- the turbocharger air outlet pipe from the exhaust
a Remove:
gas recirculation solenoid valve support.
- the engine cover, a Move aside the air outlet pipe of the turbocharger.




12B-4
TURBOCHARGING
K9K, and 700
II - OPERATION FOR REMOVAL OF PART a Use ABRASIVE PADS to clean:
CONCERNED
WARNING
ger marks).
- the new turbocharger studs on the exhaust ma-
nifold (9 N.m),
- the new turbocharger stud on the turbocharger
113560
(9 N.m).
a Remove:
- the turbocharger nuts (3) ,
CONCERNED
- the turbocharger, a Refit:
- the turbocharger seal. - a new turbocharger seal on the exhaust manifold,
- the turbocharger.
REFITTING
a Use an open wrench to fit the new turbocharger nuts
without tightening them (the turbocharger must be in
I - REFITTING PREPARATION OPERATION contact with the manifold and the wrench should no
a longer turn without effort).
WARNING a Put a paint mark on the turbocharger coinciding with

a lower nut crest of the turbocharger.
Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation. a Tighten the turbocharger bottom nut until the top of
the nut is aligned with the paint mark made on the
Check that the turbocharger oil return pipe is not
turbocharger (the final tightening angle is 60˚).
partially or completely blocked by scale. Check
that there are no leaks. If there are, replace the a Torque tighten the new upper turbocharger nuts
part. (28 N.m).

WARNING
Following a turbocharger fault, check that the a Fit the turbocharger air outlet pipe.
intercooler and air circuit assembly are not full of a Connect:
oil. If they are, remove them and clean them with
a cleaning tray or station and dry them with a - the turbocharger air outlet pipe to the exhaust gas
compressed air gun. recirculation solenoid valve support,
- the turbocharger air outlet pipe onto the turbochar-
a Always replace:
ger.
- the turbocharger seal on the manifold,
a Torque tighten the turbocharger air outlet pipe
- the turbocharger studs and nuts on the manifold. clips (5.5 N.m).
12B-5
TURBOCHARGING
K9K, and 700
a Connect the turbocharger pressure regulating valve
control hose.
a Clip on the turbocharger pressure regulating valve
control hose clip.
a Refit:
- the engine cover.
12B-6
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting 12B
K9K

Note:
Mot. 1566 Spanner for removing high
pressure pipes. This procedure deals with removing and refitting the
turbocharger oil return pipe and the turbocharger oil
Mot. 1746 Offset spanner for tightening supply pipe.
high pressure pump pipes.
Essential equipment REMOVING THE TURBOCHARGER OIL

SUPPLY PIPE
self-contained starter
diagnostic tool I - REMOVAL PREPARATION OPERATION

Tightening torquesm
a Remove:
new turbocharger oil Torx bolt 18
- the engine cover,
supply pipe hollow bolt N.m or Hexa-
to the turbocharger gonal bolt 14 - the air filter unit (see 12A, Fuel mixture, Air filter
N.m unit: Removal - Refitting, page 12A-5) .
turbocharger oil supply shouldered

pipe nut on the cylinder nut 35 N.m or K9K, and 700
head non-shoulde-
red nut 23 N.m
turbocharger oil return 12 N.m

pipe bolts
IMPORTANT
tion.
IMPORTANT
Wear protective gloves during the operation. 19709
the rocker cover.
WARNING a Loosen the clip (2) for the air filter unit air outlet pipe
Ensure that no foreign bodies enter the turbine or on the turbocharger.
compressor during the refitting operation.
Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Check that
there are no leaks. If there are, replace the part.
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
Failure to observe the following instructions will lead
to the turbocharger breaking again.
12B-7
TURBOCHARGING
K9K
CONCERNED
K9K, and 740
113848
121633
a Loosen the nut (5) for the turbocharger oil supply
a Unclip the oil vapour rebreathing hose diaphragm pipe on the cylinder head, using the tool (Mot.
(3) from the air filter unit air outlet pipe. 1566).
a Loosen the clip (4) for the air filter unit air outlet pipe a Remove:
on the turbocharger.
- the turbocharger oil supply pipe hollow bolt (6) from
the turbocharger,
- the turbocharger oil supply pipe.
a Remove the air outlet pipe from the air filter box.
a Wipe away any oil run-off.
REFITTING THE TURBOCHARGER OIL

SUPPLY PIPE

a Always replace:
- the turbocharger oil supply pipe,
- the turbocharger oil supply pipe hollow bolt.
12B-8
TURBOCHARGING
K9K
- the turbocharger oil supply pipe nut on the cy-
linder head (shouldered nut 35 N.m or non-
shouldered nut 23 N.m) using tool (Mot. 1566) or
tool (Mot. 1746).

a Refit the air outlet pipe onto the air filter unit.
a Tighten the air filter air outlet pipe clip on the turbo-
charger.
K9K, and 740

a Clip the oil vapour rebreathing hose diaphragm onto
the air filter unit air outlet pipe.
K9K, and 700

114285
a Connect the oil vapour rebreathing hose to the roc-
a ker cover.
Note:
These two turbocharger oil supply pipes may be
used on the same engine. The tightening torque a Refit:
of the end pieces (7) on the cylinder head is dif- - the air filter unit (see 12A, Fuel mixture, Air filter
ferent, depending on the following: unit: Removal - Refitting, page 12A-5) ,
- if the end piece is shouldered (8) ; in this - the engine cover.
case, there is no need to apply HIGH RESIS-
TANCE THREADLOCK (see Vehicle: Parts a Connect the battery (see Battery : Removal - Refit-
and ingredients for the repairwork) (04B, ting) (80A, Battery).
Consumables - Products) to the thread of the a Disconnect the high pressure pump flow actuator
end piece, connector and the connector for each diesel fuel in-
- if the end piece is not shouldered (9) ; in this jector in order to prevent the engine from starting.
case, it is essential to apply HIGH RESIS-
a Connect a self-contained starter.
TANCE THREADLOCK (see Vehicle: Parts
and ingredients for the repairwork) (04B, a Run the starter until the oil pressure warning light
Consumables - Products) to the thread of the goes out on the instrument panel (wait for a few se-
end piece. conds).
a Switch off the ignition.
II - REFITTING OPERATION FOR PART a Disconnect the self-contained starter.

CONCERNED a Connect the high pressure pump flow actuator con-
nector and the connector for each diesel fuel injec-
a Refit a new turbocharger oil supply pipe. tor.
a Fit the turbocharger oil supply pipe nut on the cylin- a Start the engine.
der head, without tightening it. a Let the engine idle then depress the accelerator se-
veral times with no load.
a Switch off the ignition.
- a new turbocharger oil supply pipe hollow bolt
a Check:
to the turbocharger (Torx bolt 18 N.m or Hexa-
gonal bolt 14 N.m), - that the turbocharger is operating correctly,
12B-9
TURBOCHARGING
K9K
- that there are no oil leaks from the turbocharger. OPERATION FOR REMOVAL OF PART
CONCERNED
a Use the diagnostic tool to check for an absence of
stored faults; deal with these and clear them as ne-
cessary.
REMOVING THE TURBOCHARGER OIL

RETURN PIPE
a Remove:
- the engine cover,

123810
a Remove the turbocharger oil return pipe bolts (1) .
a Rotate the turbocharger oil return pipe to facilitate its

removal.
a Remove:
- the turbocharger oil return pipe from the cylinder

block,
- the turbocharger oil return pipe gaskets.
12B-10
TURBOCHARGING
K9K
REFITTING THE TURBOCHARGER OIL

RETURN PIPE
a Always replace the turbocharger oil return pipe

seals.
a Use SURFACE CLEANER (see Vehicle: Towing

and lifting) (04B, Consumables - Products) to clean
and degrease:
- the seal housing on the turbocharger oil return pipe

if it is to be reused,
- the turbocharger oil return pipe joint face if it is to
be reused,
- the turbocharger oil return pipe joint face on the tur-

bocharger,
- the turbocharger oil return pipe housing in the cylin-

der block.
WARNING
ger marks).
a Lubricate the turbocharger oil return pipe O-ring with

clean engine oil.

CONCERNED
a Refit the turbocharger oil return pipe in the cylinder

block.
a Torque tighten the turbocharger oil return pipe
bolts (12 N.m).
a Refit:


- the engine cover.

12B-11
TURBOCHARGING
Intercooler: Removal - Refitting 12B
K9K, and 718
REMOVAL

a Remove the front bumper (see Front bumper: Re-
moval - Refitting) (55A, Exterior protection).

CONCERNED
141748
a Loosen the clip (2) on the intercooler air inlet pipe.
a Disconnect the intercooler air inlet pipe.
141746
a Loosen the clip (1) on the intercooler air outlet pipe.
a Disconnect the intercooler air outlet pipe.
12B-12
TURBOCHARGING
K9K, and 718
141750 141747
141751 141749
a Remove the intercooler upper bolts (3) . a Remove the intercooler lower bolts (4) .
REFITTING

CONCERNED
a Refit:
- the intercooler,
- the intercooler bolts.
a Connect the intercooler air inlet and outlet pipes.
12B-13
TURBOCHARGING
K9K, and 718
a Tighten the clips of the intercooler air inlet and outlet
pipes.
a Refit the front bumper (see Front bumper: Remo-
val - Refitting) (55A, Exterior protection).
12B-14
FUEL SUPPLY
Fuel circuit: Operating diagram 13A
K7M, and 734 – K4M, and 674
Operating diagram of the fuel supply circuit
117096
I - MAIN FUEL SUPPLY SYSTEM - an engine fuel supply pipe (12) .

The supply circuit does not have a return.
The supply pressure does not vary with engine load.
The circuit comprises:
- a rail (1) without a return pipe union and without a
supply pressure regulator,
- a single pipe (2) coming from the tank,
- a « pump - sender - fuel filter » supply assembly
equipped with the pressure regulator (3) , the pump
(4) and the fuel filter (5) (all located in the tank),
- a fuel vapour recirculation tank (6) .
II - ADDITIONAL FUEL SUPPLY SYSTEM:

The circuit comprises:
- an additional petrol tank (7) fitted with a fuel pump (8)
,
- a drain pipe (9) for excess petrol (upon filling),
- a petrol vapour recirculation pipe (10) ,
- a fuel filter (11) (integrated into the pipe),
13A-1
FUEL SUPPLY
Fuel filter: Removal - Refitting 13A
D4F
CONCERNED
IMPORTANT

close to the working area,
union.
IMPORTANT
tion.
IMPORTANT
tion.
132674
a Disconnect the fuel filter unions (1) .
WARNING a Insert the blanking plugs.
WARNING
Note:
This method is applicable to the D4F engine.
For K7J, K4J and K4M engines, the fuel filter is built
into the fuel level sensor module (see 19C, Tank,
Fuel level sensor module: Removal - Refitting,
page 19C-13) .
132675
REMOVAL a Unclip the fuel filter at (2) .
a Remove the fuel filter.


13A-2
FUEL SUPPLY
D4F
REFITTING

CONCERNED
a Refit the fuel filter.
a Clip on the fuel filter.
a Connect the fuel filter unions.
13A-3
FUEL SUPPLY
K9K
IMPORTANT
IMPORTANT

union.
134087
IMPORTANT
a Remove:
tion.
- the bolt (1) from the fuel filter strap,
- the fuel filter strap.

IMPORTANT a Refit the fuel filter strap to a new fuel filter.
tion.
CONCERNED
Note:
Be sure to have the new fuel filter to hand before
starting work.
Note:
Periodically bleed the water contained in the diesel
filter via the bleed screw.
REMOVAL

a Unclip the fuel filter from the fuel filter support.
21749
a Disconnect the connector (2) from the water detec-

tion sensor (if fitted).
13A-4
FUEL SUPPLY
K9K
a Clip the fuel filter onto the fuel filter support.
III - BLEEDING
134088
Note:
Mark the position of the fuel pipe unions in rela- 21749
tion to the fuel filter before removing the fuel fil-
ter. a
WARNING
WARNING rounding components.
areas on which fuel is likely to run. a Periodically drain any water contained inside the fuel
filter:
- place a container underneath the fuel filter,
WARNING
- turn the bleed screw (4) a maximum of one turn,
Keep the pipe unions away from contaminated
areas. - allow it to run out until fuel appears,
- close the bleed screw.
a Disconnect the fuel pipe unions (3) from the fuel fil-
ter.
a Remove the fuel filter.
REFITTING

CONCERNED
a Position the fuel filter.

a Connect:
- the fuel pipe unions to the fuel filter, observing the

original position of the fuel pipe unions,
- the water detection sensor connecter (if fitted).
13A-5
FUEL SUPPLY
Fuel pressure: check 13A
K4J or K4M or K7J or K7M
Mot. 1311-08 Union for measuring fuel

pressure.
Mot. 1311-01 Fuel pressure test kit.
CHECKING
a
IMPORTANT

- be careful of fuel splashes when disconnecting
the union.
133025
IMPORTANT
tion.
IMPORTANT
tion.
WARNING
I - PREPARATION OPERATION FOR CHECK

133033
a Remove the bolts (1) from the fuel pipe protector.
a Remove the fuel pipe protector.
13A-6
FUEL SUPPLY
II - TEST OPERATION
a Start the vehicle to run the fuel pump.
a Read the pressure, which should be constant (ap-
proximately 3.5 bar ± 0.2 bar).
Note:
It may take several seconds to obtain a correct
pressure reading.

a Disconnect:
- the fuel supply union from the " « T » " union,
- the pipe fitted with a pressure gauge contained in
the test kit (Mot. 1311-01) onto the " « T » " union,
- the " « T » " union on the fuel supply union.
134309
a Connect the fuel supply union.
a Unclip the fuel supply pipe at (2) .
a Clip on the fuel supply union.
a Disconnect the fuel supply union at (3) . a Fit the fuel pipe protector.
a Refit the fuel pipe protector bolts.
134308
a Connect:
- a " « T » " union (Mot. 1311-08) to the fuel supply

union,
- the pipe fitted with a pressure gauge contained in

the test kit (Mot. 1311-01) onto the " « T » " union,
- the fuel supply union to the " « T » " union.
13A-7
FUEL SUPPLY
D4F

pressure.
CHECKING
a
IMPORTANT

the union.
IMPORTANT
110421
a Remove:
tion.
- the bolt (1) from the engine oil filler neck,
- the engine oil filler neck.
IMPORTANT
tion.
WARNING
116887
a Ensure you have a checking tool (Mot. 1311-01) and
a “T” union (Mot. 1311-08).
13A-8
FUEL SUPPLY
D4F
II - TEST OPERATION
133634
a Disconnect fuel supply pipe union on the injector rail.
a Connect:
- the pipe fitted with a test pressure gauge (Mot.

1311-01) with the "T" union (Mot. 1311-08),
- the "T" union (Mot. 1311-08) on the injector rail,
- the injector rail fuel supply union to the "T" union

(Mot. 1311-08).
a Start the engine.
a Record the pressure; this should be constant at 3.5

bar.
Note:
It may take a few seconds to obtain a correct
injector rail pressure reading.
a Disconnect the "T" union (Mot. 1311-08) from the in-

jector rail.
a Connect the fuel supply pipe union on the injector

rail.
a Refit the engine oil filler neck.
13A-9
FUEL SUPPLY
Fuel flow: check 13A
D4F

pressure.
Essential equipment
graduated measuring cylinder
IMPORTANT

union.
110421
a Remove:
IMPORTANT - the bolt (1) from the engine oil filler neck,
Wear leaktight gloves (Nitrile type) for this opera- - the engine oil filler neck.
tion.
a “T” union (Mot. 1311-08).
a Assemble the long hose of the test tool (Mot. 1311-
IMPORTANT 01) and the "T" union (Mot. 1311-08).
a Disconnect the fuel supply pipe union from the injec-
tion.
tor rail.
WARNING
13A-10
FUEL SUPPLY
D4F
133635 133006
a Connect: a Remove the relay (2) .
- the "T" union (Mot. 1311-08) on the injector rail, a Shunt the relay in order to supply the electric fuel
pump.
- the fuel supply union to the "T" union (Mot. 1311-
08).
Note:
II - FUEL FLOW CHECK The flow reading should be 80 to 120 l/h.
a Immerse the hose in a 2000 ml graduated measu-
ring cylinder.
a Unclip the cover from the engine compartment con-
a Refit:
nection unit.
- the relay,
- the engine compartment connection unit cover.
a Disconnect:
- the fuel supply union on the "T" union (Mot. 1311-
08),
- the "T" union (Mot. 1311-08) from the injector rail.
a Connect the fuel supply union on the injector rail.
a Separate the test tool (Mot. 1311-01) from the "T"
union (Mot. 1311-08).
a Refit the engine oil filler neck.
13A-11
FUEL SUPPLY

pressure.
Essential equipment
graduated measuring cylinder
CHECKING
a
IMPORTANT

133025
the union.
IMPORTANT
tion.
IMPORTANT
tion.
WARNING

a Position the vehicle on a two-post lift (see Vehicle: 133033
Towing and lifting) (02A, Lifting equipment). a Remove the bolts (1) from the fuel pipe protector.
a Remove the fuel pipe protector.
a “T” union (Mot. 1311-08).
a Assemble the long hose of the test tool (Mot. 1311-
01) and the "T" union (Mot. 1311-08).
13A-12
FUEL SUPPLY
a Unclip the cover from the engine compartment con-
nection unit.
134309
a Unclip the fuel supply pipe at (2) .

133711
a Disconnect the fuel supply union at (3) .
a Remove the relay (4) .
a Shunt the relay in order to supply the electric fuel

pump.
Note:
The flow reading should be 80 to 120 l/h.
a Refit:
- the relay,
- the cover to the engine compartment connection

unit.
a Disconnect:
134306
- the fuel supply union from the " « T » " union,
a Connect:
- the " « T » " union (Mot. 1311-08) from the fuel tank
- the" « T » " union (Mot. 1311-08) onto the fuel tank fuel supply union.
fuel supply union,
- the fuel supply union to the " « T » " union.
II - FUEL FLOW CHECK
a Fit the fuel pipe protector.
a Immerse the hose in a 2000 ml graduated measu-
ring cylinder. a Refit the fuel pipe protector bolts.
13A-13
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
K9K
I - RISKS RELATING 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 must not be
used when carrying out work on an injection system.
All After-Sales operations must be performed under
very clean conditions. Having carried out an operation Part number for set of blanking plugs: (see Vehicle:
in good conditions means that no impurities (particles a Parts and ingredients for the repairwork) (04B, Con-
few microns in size) have penetrated the system during sumables - Products).
dismantling.
The cleanliness principle must be applied from the filter Note:

to the injectors.
There is no specific set of blanking plugs for S9U
What are the sources of contamination? and S9W engines. In order to comply with the
cleanliness recommendations, use plugs that are
- metal or plastic swarf,
compatible with the blanking plug sets for F9Q,
- paint, G9U, G9T or ZD3 engines.
- fibres:
3 - Protective bags
• cardboard,
Use hermetically-resealable plastic bags, using adhe-
• brushes, sive tape, for example, to store components which will
be refitted and reused. Stored parts will therefore be
• paper, less subject to the risk of contamination.
• clothing, These are single-use bags: after use they must be dis-
carded.
• cloth,
- foreign bodies such as hair,

4 - Cleaning products
- ambient air,
Two cleaning products can be used:
- etc.
- an injector cleaner (see Vehicle: Parts and ingre-
Products),
WARNING
- an aerosol spray brake cleaner (see Vehicle: Parts
Do not clean the engine with a high pressure clea-
ner to prevent damaging the connections.
mables - Products).
To use the injector cleaner, be sure to have a clean

1 - Cleaning cloths brush in good condition (the brush must not lose any
bristles) as well as a clean container which has no im-
Use lint-free cleaning cloths (see Vehicle: Parts and
purities in it.
ingredients for the repairwork) (04B, Consumables -
Products).
It is prohibited to use cloths or ordinary paper towels: Note:

these produce lint and lose fibres, which then contami- Use a new injector cleaner each time work is car-
nate the fuel circuit. ried out (a used cleaning agent will contain impuri-
Each cloth must only be used once. ties).
13B-1
DIESEL INJECTION
K9K
II - ADVICE TO BE FOLLOWED BEFORE ANY After opening the fuel circuit, the use of brushes, clea-
OPERATION ning agents, air blow guns, rifle-type brushes or stan-
dard cloths is strictly prohibited: these items are likely
1) Carry out the work in a clean working area and take to allow impurities to enter the system.
care to protect removed components from dust using
plastic bags which are hermetically-resealable, for When replacing a component with a new one or when
example. refitting it after storing it in a plastic bag, do not unpack
it until it is time to fit it on the vehicle.
2) Always order the following from the Parts Depart-
ment before carrying out work:
IV - CLEANING
- a new set of blanking plugs, specific to the engine,
There are currently two procedures for cleaning the
- enough lint-free cleaning cloths. fuel circuit before opening it in order to carry out work in
- one of the two cleaning products for fuel pipe the workshop.
unions,
These procedures enable the fuel circuit to be cleaned
- the parts that are always to be replaced after each to prevent contamination from entering: they both have
removal operation, mentioned in the operational pro- the same end result and neither is preferred over the
cedures specific to the vehicle (see related Workshop other.
Repair Manual).
3) Wear safety goggles fitted with side shields to pre- 1 - Cleaning using injector cleaner
vent the cleaning product from splashing the eyes. Clear the access to the unions that need opening, fol-
4) Wear leaktight protective gloves (Nitrile type) to lowing the work procedures specific to the vehicle (see
avoid prolonged contact with the skin. the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Note: Pour the injector cleaning agent into a container which

is free from impurities.
When using leather protective gloves, wear a pair of
leaktight protective gloves (Nitrile type) over the top.
5) Before carrying out work on the injection system, IMPORTANT

use plastic bags or clean rags, for example, to protect: Wear leaktight gloves (Nitrile type) for this opera-
tion.
- the accessories and timing belts,
Dip a clean brush, which is not shedding bristles, into
- the electrical accessories (starter, alternator, power-
the container of injector cleaning agent.
assisted steering pump, sensors and electrical con-
nectors),
- the flywheel face. IMPORTANT

tion.
III - INSTRUCTIONS TO BE FOLLOWED DURING
THE OPERATION
Clean the unions carefully using the brush and the in-
Wash your hands before and while carrying out the jector cleaning agent.
work.
Blast the components that have been cleaned with
Replace leaktight protective gloves (Nitrile type) when compressed air (tools, workbench, and also parts,
they are soiled or damaged. unions and around the injection system). Check that no
bristles from the brush have come away and that the
All components removed from the injection system area is clean.
must be stored in a hermetically sealed plastic bag
once they have been capped. Wipe the sections that were cleaned with fresh clea-
ning cloths.
Reseal the bag hermetically, for example using adhesi-
ve tape, even if the bag must be opened shortly afte- Open the circuit at the unions and immediately fit the
rwards: ambient air can be a source of impurities. relevant blanking plugs.
13B-2
DIESEL INJECTION
K9K
WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with com-
pressed air. Use cleaning cloths only, if necessary.
2 - Using the brake cleaner

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
tion.
IMPORTANT
tion.
Spray the brake cleaner onto the unions to be opened.

Clean the unions carefully using fresh cleaning cloths.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Check that no
bristles from the brush have come away and that the
area is clean.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.
WARNING
pressed air. Use cleaning cloths only, if necessary.
13B-3
DIESEL INJECTION
K9K
Set of plugs for DELPHI injection:
13B-4
DIESEL INJECTION
K9K
20977
13B-5
DIESEL INJECTION
K9K
Set of plugs for SIEMENS injection:
13B-6
DIESEL INJECTION
K9K
113430
13B-7
DIESEL INJECTION
Diesel injection: List and location of components 13B
K9K
135089
(1) Diesel injector

(2) Air temperature sensor
(3) Air filter unit
(4) Diesel injection computer
(5) Engine compartment connec-
tion unit
(6) Camshaft position sensor
(7) High pressure pump
(8) Fuel temperature sensor
(9) Injector rail
(10) Rail pressure sensor
(11) Fuel filter
(12) Manual priming pump
20841
(1) Diesel injection computer
13B-8
DIESEL INJECTION
K9K
19726 21378
(2) Venturi (11) Pre-postheating unit

(3) Heater plugs
(4) High-pressure pump
132606
(12) Turbocharger pressure sensor

102084
(5) Diesel injector

(6) Fuel temperature sensor
(7) Flow actuator
(8) Accelerometer
(9) Rail pressure sensor
(10) Injector rail
13B-9
DIESEL INJECTION
K9K
132914 114508
(13) Camshaft position sensor (15) Exhaust gas recirculation sole-

noid valve
114529
114498
(14) Coolant temperature sensor.
(16) Inertia switch
13B-10
DIESEL INJECTION
K9K
134687
(17) Crankshaft position sensor
13B-11
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K

K9K, and 700
a For diesel injection computer configuration (see
Fault finding - Replacement of components)
(Technical Note 3845A, 13B, Diesel injection).
K9K, and 740

a For diesel injection computer configuration (see
Fault finding - Replacement of components)
(Technical Note 6500A, 13B, Diesel injection).
REMOVAL

134697
Refitting) (80A, Battery). a Disconnect the connector from the brake fluid level
sensor.
a Unclip the power-assisted steering reservoir by:
- pressing on the tab (A) of the power-assisted stee-
ring fluid reservoir,
- and pulling the power-assisted steering fluid reser-
voir towards (B) .
a Move the power-assisted steering reservoir to one
side.
13B-12
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
K9K
CONCERNED
20841
a Disconnect the connectors (1) from the diesel injec-

tion computer.
a Remove:
- the diesel injection computer nuts (3) ,
- the diesel injection computer.
REFITTING

CONCERNED
a Position the diesel injection computer making sure
that the positioning lug is engaged and then fit the
computer onto the studs.
a Connect the diesel injection computer connectors.

a Fit the power-assisted steering reservoir.
a Clip on the power-assisted steering fluid reservoir.

a Connect the brake fluid level sensor connector.

13B-13
DIESEL INJECTION
Camshaft position sensor: Removal - Refitting 13B
K9K
REMOVAL
Mot. 1453 Multiple-adjusting engine

mounting support with retai- I - REMOVAL PREPARATION OPERATION
ning straps.
Mot. 1453-01 Additional winder nut on Towing and lifting) (02A, Lifting equipment).
a Remove:
Essential equipment
- the engine cover,
safety strap(s)
Washing),

Removal - Refitting) (56A, Exterior equipment).
132913
a Fit the (Mot. 1453) equipped with (Mot. 1453-01)

a Remove:
13B-14
DIESEL INJECTION
K9K
132608 132930
a Remove: a Remove the nut (3) from the rubber pad on the right-
hand suspended engine mounting.
a Lift the engine slightly using the tool (Mot. 1453)
equipped with the tool (Mot. 1453-01) until the right-
- the lower engine tie-bar bolt (2) , hand suspended engine mounting rubber pad is de-
tached from the right-hand suspended engine
mounting cover.
a Remove:
- the bolts (4) from the right-hand suspended engine
mounting cover,
- the right-hand suspended engine mounting cover.
13B-15
DIESEL INJECTION
K9K
CONCERNED
a Always replace the camshaft position sensor seal.

CONCERNED
a Refit the camshaft position sensor fitted with a new

seal.
a Connect the camshaft position sensor connector.
a Refit:
132914 - the right-hand suspended engine mounting cover

bolts.
a Disconnect the connector (5) from the camshaft po-
sition sensor.
with the tool (Mot. 1453-01) to bring the right-hand
suspended engine mounting rubber pad into contact
with the right-hand suspended engine mounting co-
ver.
a Refit:
- the nut of the rubber pad on the right-hand suspen-

ded engine mounting,
a Remove:

132915
a Remove: a Refit:
- the bolt (6) from the camshaft position sensor, - the scuttle panel grille (see Scuttle panel grille:
- the camshaft position sensor, Removal - Refitting) (56A, Exterior equipment),
- the camshaft position sensor seal. - the windscreen wiper arms (see Windscreen wi-
Washing),
- the engine cover.
13B-16
DIESEL INJECTION
Crankshaft position sensor: Removal - Refitting 13B
K9K
REMOVAL II - FINAL OPERATION

a Refit:
I - REMOVAL PREPARATION OPERATION - the battery tray (see Battery tray: Removal - Re-
a Remove:
- the engine cover, (80A, Battery).

(80A, Battery),


CONCERNED
134687
a Disconnect the crankshaft position sensor connector

(1) .
a Remove:
- the crankshaft position sensor bolt (2) ,
- the crankshaft position sensor.
REFITTING

CONCERNED
a Refit the crankshaft position sensor.
a Connect the crankshaft position sensor connector.
13B-17
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
K9K
Essential special tooling Removal - Refitting) (56A, Exterior equipment),
Mot. 1430 Set of 5 crankshaft and cams- - the front right-hand wheel (see Wheel: Removal -
haft pulley timing pins. Refitting) (35A, Wheels and tyres),
Mot. 1606 High pressure pump-pulley - the front right-hand wheel arch liner (see Front
retaining tool. wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
Mot. 1525 Extractor for timing gear with - the engine undertray bolts,
tapered hub.
Mot. 1525-02 Adapter sockets for Mot.1525.
Tightening torquesm 19D-16) ,
the high pressure pump 23 N.m - the camshaft position sensor (see 13B, Diesel in-
bolts jection, Camshaft position sensor: Removal -
high pressure pump pul- 70 N.m - the accessories belt (see 11A, Top and front of
ley nut engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
right-hand suspended 25 N.m
engine mounting sup- - the high pressure pipe between the pump and the
port bolts rail (see 13B, Diesel injection, High-pressure
pipe between the rail and injector: Removal -
Refitting, page 13B-35) .
IMPORTANT
tion.
IMPORTANT
REMOVAL


a Remove:
- the engine cover,

Washing),
13B-18
DIESEL INJECTION
K9K
19654 19654-1
134252 134690
a Unclip the upper timing cover at (1) . a Remove the bolt (2) from the lower timing cover.
a Remove the upper timing cover. a Unclip the lower timing cover at (3) .
a Unclip: a Remove the lower timing cover.
- the fuel supply pipe,
- the wiring of the camshaft position sensor.
13B-19
DIESEL INJECTION
K9K
132887 19655
a Remove: a Insert the tool (Mot. 1430) (7) in the hole of the
camshaft pulley hub and the hole of the cylinder
- the right-hand suspended engine mounting support
head.
bolts (4) ,
- the right-hand pendulum suspension support.
107270
a Position the engine at Top Dead Centre. The cams-
haft pulley hole (5) should be opposite the cylinder
head hole (6) .
13B-20
DIESEL INJECTION
K9K
CONCERNED
23169
a
23168
a Fit the (Mot. 1606) (8) on the cylinder head. Note:
If necessary, remove the spacer at the end pus-
hrod of the (Mot. 1525) to improve the positio-
Note:
ning.
If necessary, turn the engine slowly to adjust the
position of the (Mot. 1606) on the high pressure a Fit the tool (Mot. 1525) (10) equipped with the tool
pump pulley teeth. (Mot. 1525-02) onto the high pressure pump pulley.
a Screw the (Mot. 1525) pushrod until it makes con-
a Immobilise the high pressure pump pulley using a 32
tact with the high pressure pump shaft.
mm spanner and then remove the nut (9) of the
high pressure pump pulley.
Note:
Check that the pushrod of the tool (Mot. 1525) is
correctly oriented and is pressing against the
high pressure pump shaft. Adjust the tool (Mot.
1525) if necessary.
13B-21
DIESEL INJECTION
K9K
CONCERNED
a Refit the high pressure pump on the cylinder head
by inserting it into the high pressure pump pulley.
Note:
Check that the high pressure pump shaft is cor-
rectly orientated in relation to the high pressure
pump pulley.
a Refit the engine cover bracket.

a Fit the high pressure pump bolts without tightening
them.
134076
a Remove:
- the high pressure pump bolts (11) ,
- the bracket (12) from the engine cover.
a Gradually screw the pushrod of the (Mot. 1525) until

the high pressure pump becomes detached.
Note:
Guide and support the high pressure pump with
one hand as it is being removed using the (Mot.
134076
1525)
a Torque tighten in order the high pressure pump
bolts (23 N.m).
a Remove the high pressure pump.
a Torque tighten the high pressure pump pulley nut
(70 N.m) while holding the high pressure pump pul-
Note: ley using a 32 mm spanner.
If the high pressure pump is being reused, keep

it in a sealed bag during the removal operation. Note:
Check that the timing belt is correctly positioned
a Remove the tool (Mot. 1525) equipped with the tool and in good condition.
(Mot. 1525-02) from the high pressure pump pulley.
a Remove the (Mot. 1606) from the cylinder head.
REFITTING
a Check for an index pin on the high pressure pump

shaft.
13B-22
DIESEL INJECTION
K9K
19654-1
132887 a Refit the lower timing cover bolt (15) .
a Refit the right-hand suspended mounting support.
a Clip:
a Torque tighten in order the right-hand suspended
engine mounting support bolts (25 N.m). - the wiring of the camshaft position sensor,
a Clip on the upper timing cover.
a Refit:
- the high pressure pipe between the pump and the
rail (see 13B, Diesel injection, High-pressure
pipe between the rail and injector: Removal -
page 11A-1) ,
19659 19D, Engine mounting, Right-hand suspended
a Refit the lower timing cover, by positioning the tab 19D-16) ,
(13) in the opening (14) of the inner timing cover.
a Clip on the lower timing cover.
terior protection),
13B-23
DIESEL INJECTION
K9K
Washing),
- the engine cover.
13B-24
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K

CONCERNED

a Remove:
- the engine cover,
- the high pressure pipe between the injector rail and
the diesel fuel injector of cylinder number 4 (see
13B, Diesel injection, High-pressure pipe
between the rail and injector: Removal - Refit-
ting, page 13B-35) .
133525
a
WARNING
Note:
Take care to ensure that no impurities get into
the high pressure pump once the actuator is
removed.
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Only use cleaning cloths.
a Remove:
- the flow actuator bolts (1) ,
- the high pressure pump flow actuator (by hand with
small tugs and successive turns).
13B-25
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting 13B
K9K
REFITTING

CONCERNED
a
Note:
Do not lubricate the seals with grease or old die-
sel fuel. Use the applicator provided in the kit for
the new part.
a Refit the flow actuator to the high pressure pump.
a Refit:
- the high pressure pipe between the injector rail and
the diesel fuel injector of cylinder number 4 (see
13B, Diesel injection, High-pressure pipe
between the rail and injector: Removal - Refit-
- the engine cover.
13B-26
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K
Tightening torquesm
Venturi bolt 5.5 N.m
IMPORTANT
IMPORTANT
tion.
134692
Note: a Disconnect from the Venturi:
Make sure that you have a new venturi before ope- - the diesel return pipe (1) ,
ning the fuel circuit.
- the diesel injector fuel return rail (2) .
REMOVAL
- the openings of the Venturi,
I - REMOVAL PREPARATION OPERATION - the diesel fuel return pipe opening.
a Remove the engine cover.
WARNING
13B-27
DIESEL INJECTION
Venturi: Removal - Refitting 13B
K9K
CONCERNED CONCERNED
a Refit the venturi to the high pressure pump.
a Torque tighten the Venturi bolt (5.5 N.m).

- the openings of the Venturi,
a Connect:
- the diesel injector fuel return rail to the Venturi,
- the diesel fuel return pipe to the Venturi.
134693
WARNING
a Remove:
- the Venturi bolt (3) ,
- the Venturi (by hand with small tugs and successi-

ve turns).
114535
REFITTING
a Prime the fuel circuit using the manual priming pump
(4) until the disconnected pipes are filled with fuel
I - REFITTING PREPARATION OPERATION (automatic degassing).
a a Check that there are no fuel leaks.

a Start the engine.
WARNING
Do not remove the blanking plugs from each a Check that there are no fuel leaks.
component until the last moment. a Refit the engine cover.
cle.
Note:
the new part.
13B-28
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K
Essential equipment
diagnostic tool
IMPORTANT
Note:
Check that there are no diesel leaks after each ope-
ration.
114535
Note: a Prime the fuel circuit using the manual priming pump
The diagnostic tool can be used to test the high (1) until the disconnected pipes are filled with fuel
pressure circuit with the engine running. This com- (automatic degassing).
mand can be used to run fault finding on a leak due a Check that there are no fuel leaks.
to an incorrectly fitted or tightened union. This com-
mand only works if the engine coolant temperature a Connect the diagnostic tool to the vehicle.
is over 60˚C. The fault finding procedure does not a Deal with present faults,
reveal small leaks caused by insufficient tightening.
Note:
CHECKING Certain faults will prevent this test from being
a Remove the front engine cover. carried out: deal with them first.
Note:
The engine automatically runs a cycle of four
accelerations and decelerations to lower the rail
pressure.
Note:
Do not leave anything on the side of the engine
housing during the test phase (significant vibra-
tion).
13B-29
DIESEL INJECTION
High pressure pipe: Checking 13B
K9K
K9K, and 700

a Run command SC001 High pressure circuit sea-
ling test.
Note:
Command SC001 cannot be run on engines fit-
ted with computers with programme number
00BE and software version 0077. For these
computers, carry out reprogramming which, in
most cases, will enable command SC001 to run
again.
K9K, and 740

a Run command AC626 High pressure circuit sea-
ling test.
a Check that there are no fuel leaks.

a Deal with the causes of any possible leaks.
a Use the diagnostic tool to check for stored faults;
deal with these and clear them as necessary.
a Disconnect the diagnostic tool.
13B-30
DIESEL INJECTION
High-pressure pipe between the pump and rail: Removal - Refitting 13B
K9K

WARNING
pressure pipes.
Tighten to a torque of 38 N.m the « pump-rail » and
Mot. 1746 Offset spanner for tightening « rail-injector » high pressure pipes, part no.:
high pressure pump pipes. - 77 01 207 025
- 77 01 207 026
Tightening torquesm - 77 01 207 027

- 77 01 207 028
nut for the high pressure 24 N.m
pipe between the high - 77 01 207 029
pressure pump and the For high pressure pipes with different part numbers,
yellow coloured injector tighten to a torque of 24 Nm.
rail on the high pres-
sure pump
nut for the high pressure 28 N.m REMOVAL

pipe between the high
pressure pump and the I - REMOVAL PREPARATION OPERATION
silver coloured injector
rail on the high pres- a Disconnect the battery (see Battery : Removal -
sure pump Refitting) (80A, Battery).
nut for the high pressure 24 N.m a Remove:

- the engine cover,
pressure pump and the
yellow coloured injector - the dipstick.
rail on the injector rail

engine wiring channel 21 N.m

nut
dipstick guide nut 21 N.m
IMPORTANT
tion.
IMPORTANT
To avoid all risk of damage to the systems, apply 114527
tion recommendations before carrying out any a Remove:
repair (see 13B, Diesel injection, Diesel injec- - the nut (1) from the dipstick guide,
- the nut (2) from the engine wiring channel,
- the dipstick guide.
13B-31
DIESEL INJECTION
K9K
a Plug the opening of the dipstick guide tube on the
cylinder block.
133519
a Disconnect:
133524
- the connector (4) from each injector.
WARNING

a Fit blanking plugs to:
133519 - the high pressure pump openings,

a Disconnect: - the fuel supply pipe opening,
- the flow actuator connector (5) , - the diesel fuel return pipe opening.
- the fuel temperature sensor connector (6) . a Move aside the engine wiring channel.
13B-32
DIESEL INJECTION
K9K
CONCERNED
20960
a
133515
a Clean the nuts of the high pressure pipe between WARNING

the high pressure pump and the injector rail (see Before fitting a new high pressure pipe, lightly
13B, Diesel injection, Diesel injection: Precau- lubricate the nut threads with the oil from the
tions for repair, page 13B-1) . applicator provided in the new parts kit.
Be careful not to allow oil into the high pressure
WARNING pipe.
Prepare for the flow of fluid, and protect the sur- Do not lubricate high pressure pipes supplied
rounding components. without an applicator, as these high pressure
pipes are self-lubricating.
a Remove:
- the nut (9) of the high pressure pipe between the
WARNING
high pressure pump and the injector rail from the
high pressure pump, Do not remove the blanking plugs from each
- the nut (10) of the high pressure pipe between the
high pressure pump and the injector rail from the Also, do not remove the components from their
injector rail, packaging until they are to be fitted to the vehi-
cle.
- the high pressure pipe between the high pressure
pump and the injector rail.
a Fit blanking plugs to: CONCERNED
- the high pressure pump opening, a Remove the blanking plugs from:
- the injector rail opening. - the injector rail opening,
- the high pressure pump opening.
REFITTING
a Refit a new high pressure pipe between the high
pressure pump and the injector rail.
a Fit without tightening the nuts of the high pressure
a Always replace the high pressure pipe between the pipe between the high pressure pump and the injec-
high pressure pump and the injector rail. tor rail.
13B-33
DIESEL INJECTION
K9K
a Tighten to torque: a Refit the engine cover.
- the nut for the high pressure pipe between the
high pressure pump and the yellow coloured
injector rail on the high pressure pump (24 N.m)
using the tool (Mot. 1566),
high pressure pump and the silver coloured in-
jector rail on the high pressure pump (28 N.m)
injector rail on the injector rail (24 N.m) using
the tool (Mot. 1746),
jector rail on the injector rail (28 N.m) using the
tool (Mot. 1746).

- the diesel fuel return pipe opening,
a Connect:
- the fuel supply pipe union to the high pressure
pump,
- the diesel return pipe union to the high pressure
pump,
a Remove the plug from the dipstick guide opening on
the cylinder block.
- the engine wiring channel nut (21 N.m),
a Refit the dipstick.
a Check the high pressure circuit (see 13B, Diesel in-
jection, High pressure pipe: Checking, page 13B-
29) .
13B-34
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
K9K
The following method describes the removal and refit-
Essential special tooling ting operation for one or more high pressure pipes
between the injector rail and the diesel fuel injector but
Mot. 1746 Offset spanner for tightening
not the removal and refitting operation for all four high
high pressure pump pipes.
pressure pipes between the injector rail and the diesel
fuel injector at the same time.
Tightening torquesm When replacing the four high pressure pipes between
the injector rail and the diesel fuel injector, follow the in-
nuts for the high pres- 24 N.m jector rail procedure (see 13B, Diesel injection, Injec-
sure pipe(s) between tor rail: Removal - Refitting, page 13B-39) .
the injector rail and the
yellow coloured diesel
fuel injector REMOVAL
nuts for the high pres- 28 N.m
sure pipe(s) between I - REMOVAL PREPARATION OPERATION
silver coloured diesel a Disconnect the battery (see Battery : Removal -
fuel injector Refitting) (80A, Battery).
engine wiring channel 21 N.m a Remove:

nut
- the engine cover,
dipstick guide nut 21 N.m
- the dipstick.
IMPORTANT
tion.
IMPORTANT
WARNING
Tighten to a torque of 38 N.m the « pump-rail » and

« rail-injector » high pressure pipes, part no.:
- 77 01 207 025
114527
- 77 01 207 026
a Remove:
- 77 01 207 027
- the nut (1) from the dipstick guide,
- 77 01 207 028
- 77 01 207 029 - the nut (2) from the engine wiring channel,
For high pressure pipes with different part numbers,
- the dipstick tube.
tighten to a torque of 24 N.m.
a Fit a plug to the dipstick guide opening in the cylin-
der block.
13B-35
DIESEL INJECTION
K9K
133519
a Disconnect:
133524
WARNING

133519 a Fit blanking plugs to:
a Disconnect:
- the high pressure pump openings,
- the flow actuator connector (5) ,
- the fuel temperature sensor connector (6) .
13B-36
DIESEL INJECTION
K9K
CONCERNED

a Always replace:
- the high pressure pipe(s) between the injector rail
and the removed diesel fuel injector(s),
- the clip(s) of the high pressure pipes between the
injector rail and the removed diesel fuel injector(s).
133516
a Clean the nuts of the high pressure pipe(s) between
the injector rail and the diesel fuel injector (see 13B,
Diesel injection, Diesel injection: Precautions for
repair, page 13B-1) .
WARNING
Prepare for the flow of fluid, and protect the sur- 20960
rounding components. a
a Remove: WARNING
- the nut (9) for the high pressure pipe(s) between Before fitting a new high pressure pipe, lightly
the injector rail and the diesel fuel injector from the lubricate the nut threads with the oil from the
injector(s), applicator provided in the new parts kit.
- the nut (10) for the high pressure pipe(s) between Be careful not to allow oil into the high pressure
the injector rail and the diesel fuel injector from the pipe.
injector rail,
Do not lubricate high pressure pipes supplied
- the high pressure pipe(s) between the injector rail without an applicator, as these high pressure
and the diesel fuel injector. pipes are self-lubricating.
a Fit blanking plugs to:
- the opening(s) of the diesel fuel injector(s), WARNING
- the opening(s) on the injector rail. To prevent impurities from entering the circuit,
place protective plugs on all fuel circuit compo-
nents exposed to the open air.

CONCERNED
- the opening(s) of the diesel fuel injector(s),
13B-37
DIESEL INJECTION
K9K
- the opening(s) on the injector rail. a Refit the engine cover.
a Refit one or more new high pressure pipes between
the injector rail and the diesel fuel injector.
a Fit without tightening the nuts for the high pressure
pipe(s) between the injector rail and the diesel fuel
injector.
a Refit and then lock the new clip(s) for the high pres-
sure pipes between the injector rail and the diesel
fuel injector.
- the nuts for the high pressure pipe(s) between
the injector rail and the yellow coloured diesel
fuel injector (24 N.m) using tool (Mot. 1746),
- the nuts for the high pressure pipe(s) between
the injector rail and the silver coloured diesel
fuel injector (28 N.m) using tool (Mot. 1746).

- the diesel fuel return pipe opening,
a Connect:
- the fuel supply pipe union to the high pressure
pump,
- the diesel return pipe union to the high pressure
pump,
the cylinder block.
- the engine wiring channel nut (21 N.m),
29) .
13B-38
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
K9K

IMPORTANT
Mot. 1746 Offset spanner for tightening
high pressure pump pipes. Wear leaktight gloves (Nitrile type) for this opera-
tion.
pressure pipes.
IMPORTANT
Tightening torquesm
studs of the injection rail 8 N.m tion recommendations before carrying out any
on the cylinder head repair (see 13B, Diesel injection, Diesel injec-
injector rail nuts 28 N.m
nuts for the high pres- 24 N.m REMOVAL

sure pipe(s) between
yellow coloured diesel I - REMOVAL PREPARATION OPERATION
fuel injector a Disconnect the battery (see Battery : Removal -
nuts for the high pres- 28 N.m
sure pipe(s) between a Remove:
silver coloured diesel - the engine cover,
fuel injector - the dipstick.
yellow coloured injector
sure pump

sure pump

yellow coloured injector

pipe between the high 114527
pressure pump and the a Remove:
rail on the injector rail - the nut (1) from the dipstick guide,
engine wiring channel 21 N.m - the nut (2) from the engine wiring channel,
nut - the dipstick guide.
dipstick guide nut 21 N.m a Fit a plug on the opening of the dipstick guide in the
cylinder block.
13B-39
DIESEL INJECTION
K9K
133519
a Disconnect:
133524
WARNING

133519
a Disconnect:
- the flow actuator connector (5) , a Fit blanking plugs on:
- the fuel temperature sensor connector (6) . - the high pressure pump openings,
a Remove:

pump and the injector rail (see 13B, Diesel injec-
tion, High-pressure pipe between the pump and
rail: Removal - Refitting, page 13B-31) ,
- the high pressure pipes between the injector rail

and the diesel fuel injector (see 13B, Diesel injec-
tion, High-pressure pipe between the rail and
injector: Removal - Refitting, page 13B-35) .
13B-40
DIESEL INJECTION
K9K
CONCERNED
a Always replace:

pump and the injector rail,
- the high pressure pipes between the injector rail

and the diesel fuel injector,
- the clips securing the high pressure pipes between

the injector rail and the diesel fuel injector.
133523
a Disconnect the injector rail pressure sensor connec-
tor (9) .
20960
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
133522
pipes are self-lubricating.
a Remove:
- the nuts (10) from the injector rail,
WARNING
cle.
13B-41
DIESEL INJECTION
K9K
a In the event of replacement, torque tighten the - the nut for the high pressure pipe between the
studs of the injection rail on the cylinder head (8 high pressure pump and the silver coloured in-
N.m). jector rail on the injector rail (28 N.m) using the
tool (Mot. 1746).
CONCERNED III - FINAL OPERATION
a Refit the injector rail. a Fit the engine wiring channel.
a Fit without tightening the injector rail bolts. a Remove the blanking plugs from:
a Remove the blanking plugs from: - the diesel fuel return pipe opening,
- the injector rail opening, - the fuel supply pipe opening,
- the high pressure pump opening. - the high pressure pump openings.
a Refit a new high pressure pipe between the high a Connect:

pressure pump and the injector rail. - the fuel supply pipe union to the high pressure
a Fit without tightening the nuts of the high pressure pump,
pipe between the high pressure pump and the injec- - the diesel return pipe union to the high pressure
tor rail. pump,
a Remove the blanking plugs from: - the fuel temperature sensor connector,
- the openings of each diesel fuel injector, - the fuel flow actuator connector,
- the injector rail openings. - all injector connectors,
a Refit the new high pressure pipes between the injec- - all heater plug connectors.
tor rail and the diesel fuel injector.
a Fit without tightening the nuts for the high pressure the cylinder block.
pipe(s) between the injector rail and the diesel fuel
injector.
a Refit and then lock the new clips for the high pressu-
re pipes between the injector rail and the diesel fuel - the engine wiring channel nut (21 N.m),
injector.
- the injector rail nuts (28 N.m),
- the nuts for the high pressure pipe(s) between ting) (80A, Battery).
the injector rail and the yellow coloured diesel
a Check the high pressure circuit (see High pressure
fuel injector (24 N.m) using the (Mot. 1746),
pipes: Removal - Refitting) .
- the nuts for the high pressure pipe(s) between a Refit the engine cover.
the injector rail and the silver coloured diesel
fuel injector (28 N.m) using the (Mot. 1746).
injector rail on the high pressure pump (24 N.m)
jector rail on the high pressure pump (28 N.m)
injector rail on the injector rail (24 N.m) using
the tool (Mot. 1746),
13B-42
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
K9K
20803
The rail pressure sensor (1) is integral with the injector
rail.
Replace the « injector rail - rail pressure sensor » as-
sembly in the event of a rail pressure sensor fault (see
13B, Diesel injection, Injector rail: Removal - Refit-
ting, page 13B-39) .
13B-43
DIESEL INJECTION
Fuel temperature sensor: Removal - Refitting 13B
K9K
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
fuel temperature sensor 15 N.m

on the high pressure
pump
IMPORTANT
tion recommendations before carrying out any 133519
tion: Precautions for repair, page 13B-1) . a Disconnect the fuel temperature sensor connector
(1) .
Note: WARNING
Ensure you have a new fuel temperature sensor to Prepare for the flow of fluid, and protect the sur-
hand before opening up the fuel circuit. rounding components.
REMOVAL WARNING
pressed air. Use cleaning cloths only, if neces-
a Remove the front engine cover. sar y.
102317
a Remove the fuel temperature sensor (2) from the

high pressure pump.
13B-44
DIESEL INJECTION
Fuel temperature sensor: Removal - Refitting 13B
K9K
REFITTING

a
WARNING
cle.
Note:
the new part.

CONCERNED
a Refit the fuel temperature sensor onto the high pres-
sure pump.
a Torque tighten the fuel temperature sensor on the
high pressure pump (15 N.m).

a Start the engine.
13B-45
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K
CHECKING
Mot. 1711 Kit for measuring injector leak

rate.
Essential equipment
diagnostic tool
PARTS AND CONSUMABLES FOR THE REPAIR

Consumables:
- cleaning cloths (part no. 77 11 211 707).
IMPORTANT
tion.
IMPORTANT
109463
the safety and cleanliness instructions and opera- a Disconnect:
tion recommendations before carrying out any - the diesel injector fuel return rail from the diesel in-
repair (see 13B, Diesel injection, Diesel injec- jectors (1) ,
- the diesel injector fuel return rail from the Venturi
(2) .
WARNING
a Fit a blanking plug on the opening of the Venturi.
Note:
It is essential to fit a blanking plug to the Venturi
to avoid depriming the diesel return circuit.
13B-46
DIESEL INJECTION
Leak flow from injectors: Check 13B
K9K
a Connect:
- the diesel injector fuel return rail to the Venturi,
- the diesel injector fuel return rail to the diesel injec-
tors.
a Replace the faulty injector(s) (see 13B, Diesel in-
jection, Diesel injector: Removal - Refitting, page
13B-48) .
a Disconnect the diagnostic tool.
107637
a Connect four of the transparent pipes (3) of the tool

(Mot. 1711) onto each diesel injector return.
a Insert these pipes in the four graduated measuring

cylinders (4) of the (Mot. 1711).
Note:
If necessary, attach the graduated measuring
cylinder rail of the (Mot. 1711) to the bonnet.
a Connect the diagnostic tool.
K9K, and 700
a Measure the leak flow of the diesel injectors (see

Fault finding - Tests) (Technical Note 3845A, 13B,
Diesel injection).
K9K, and 740
a Measure the leak flow of the diesel injectors (see

Fault finding - Tests) (Technical Note 6500A, 13B,
Diesel injection).
a Disconnect the transparent pipes from the (Mot.

1711).
a Remove the transparent pipes from the graduated

measuring cylinder of the (Mot. 1711).
a Empty the diesel fuel out of the graduated measu-

ring cylinders.
a Remove the blanking plug from the opening of the

Venturi.
13B-47
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B
K9K
a Remove:
Essential equipment - the engine cover,
brush with non abrasive bristles - the high pressure pipe(s) between the injector rail
and the diesel injector (see 13B, Diesel injection,
diagnostic tool High-pressure pipe between the rail and injec-
tor: Removal - Refitting, page 13B-35) .
Tightening torquesm II - OPERATION FOR REMOVAL OF PART

CONCERNED
clamp bolt of the diesel 28 N.m
injector concerned
IMPORTANT
tion.
IMPORTANT
The following procedure deals with removing and refit-

ting one or several diesel injectors but not four at the
same time.
When replacing four diesel injectors: 133520
- follow the removal procedure for the injector rail (see a Disconnect the diesel injector fuel return rail (1) from
13B, Diesel injection, Injector rail: Removal - Re- the diesel injector(s) concerned.
a Fit blanking plugs on the openings of the diesel in-
- apply the following operating procedure for all four injector(s) concerned.
jectors (refer to the removal operation for the part
concerned),
- follow the injector rail refitting procedure (see 13B,
Diesel injection, Injector rail: Removal - Refitting,
page 13B-39) .
Note:
Working on the diesel injectors is not permitted.
REMOVAL

13B-48
DIESEL INJECTION
K9K
a Clean the nozzle of the diesel injector(s):
- either using cleaning cloths (part no. 77 11 211
707) soaked in INJECTOR CLEANING PRODUCT
(see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products),
- Or using brush with non abrasive bristles.
WARNING
It is strictly forbidden to clean the injectors with:

- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
a Wipe using cleaning cloths (part no. 77 11 211 707).
2 - Cleaning the diesel injector well(s) concerned

133521 a To clean the injector well(s) of the diesel injectors
concerned (see Injector well cleaning tool: Use)
a Remove the bolt (2) from the bracket on the diesel
(Technical Note 6040A,13B, Diesel injection).
injector(s) concerned.

Note: CONCERNED
If reusing the diesel injectors, always mark the a

diesel injector in relation to its cylinder before
WARNING
removing it.
If one or more of the diesel injectors is being component until the last moment.
reused, keep the injector(s) in a sealed plastic
bag during the removal operation. Also, do not remove the components from their
a Remove the diesel injector(s) concerned with their cle.
clamp.
a Remove the heat protection washer in the diesel in- Note:

jector well. If reusing a diesel injector, refit the diesel injector
in the cylinder marked beforehand.
REFITTING If replacing one or more diesel injectors, note the
alphanumeric code of the injector and the cylin-
a Always replace the heat protection washer of the der on which it is fitted.
diesel injector concerned.
a Fit new heat protection washers in the diesel injector
well(s) concerned.
a Refit the diesel injector with its clamp.
1 - Cleaning the injector(s) (if they are to be

reused).
a Soak the diesel injector(s) in INJECTOR CLEA-

NING PRODUCT (see Vehicle: Parts and ingre-
Products).
13B-49
DIESEL INJECTION
K9K
K9K, and 740

a If replacing one or more diesel injectors, use the dia-
gnostic tool to program the alphanumeric code no-
ted beforehand (see Fault finding - Replacement
of components) (Technical Note 6500A, 13B, Die-
sel injection).

29) .
19724
a Torque tighten the clamp bolt of the diesel injec-
tor concerned (28 N.m).
a Remove the blanking plug(s) from the diesel injec-
tor(s) concerned.
a Connect the diesel injector fuel return rail to the die-
sel injector(s) concerned.

a Refit the high pressure pipe(s) between the injector
rail and the diesel injector (see 13B, Diesel injec-
tion, High-pressure pipe between the rail and in-
jector: Removal - Refitting, page 13B-35) .
K9K, and 700

a If replacing one or more diesel injectors, use the dia-
gnostic tool to program the alphanumeric code no-
ted beforehand (see Fault finding - Replacement
of components) (Technical Note 3845A, 13B, Die-
sel injection).
13B-50
DIESEL INJECTION
Accelerometer: Removal - Refitting 13B
K9K
Emb. 1797 24 mm socket for removing

and refitting clutch master
cylinder
Essential equipment
diagnostic tool
Tightening torquesm
accelerometer 20 N.m
REMOVAL

134686
a Remove the accelerometer (2) using the (Emb.
1797).
CONCERNED
REFITTING

CONCERNED
a Refit the accelerometer.
a Torque tighten the accelerometer (20 N.m) using

the (Emb. 1797).
a Connect the accelerometer connector.
a Connect the diagnostic tool.
a Clear the engine adaptives using command RZ003

Engine parameter adaptives.
134685 a Start the engine and leave it running for a few minu-
tes whilst depressing the accelerator slightly a few ti-
a
mes.
Note:
Make sure that the metal tabs of the accelerome-
ter connector are unlocked correctly to prevent a Using diagnostic tool, check that there are no sto-
breaking the accelerometer connector. red faults; deal with them if necessary.
a Disconnect the accelerometer connector (1) . a Refit the engine cover.
13B-51
PREHEATING
Pre/postheating unit: Removal - Refitting 13C
K9K
Essential equipment
diagnostic tool
REMOVAL


CONCERNED
134086
a Remove:
- the pre-postheating unit nut (2) ,
- the pre/postheating unit.
REFITTING

CONCERNED
a Refit the pre-postheating unit.
a Connect the pre-postheating unit connector.
114535 II - FINAL OPERATION

a Disconnect the pre-postheating unit connector (1) . a Connect the battery (see Battery : Removal - Refit-
a Use the diagnostic tool to check for an absence of
stored faults; deal with these and clear them as ne-
cessary.
13C-1
PREHEATING
Heater plugs Removal - Refitting 13C
K9K
Essential equipment
hinged wrench for heater plug
Tightening torquesm
heater plugs 15 N.m
REMOVAL
127905
a
CONCERNED
Note:
If the heater plugs jam, use the heater plug
removal tool (see Tool for removing heater
plugs: Use) (Technical Note 5197A, 06A, Tools).
a Unscrew the heater plugs (2) using a 10 mm long ra-

dio socket connected to a universal joint or a hinged
wrench for heater plug.
a Use a hose to unscrew the heater plugs completely.
a Remove the heater plugs.
a Throughout the removal operation, plug the heater

plug wells on the cylinder head using clean cloths.
REFITTING

CONCERNED
127895
a Remove the protection from the heater plug well
a Disconnect the connector (1) from each heater plug. openings on the cylinder head.
a Fit without tightening the heater plugs using a hose.

IMPORTANT a Torque tighten the heater plugs (15 N.m).
tion. a Connect the connector for each heater plug.
a Clean the edges of the heater plugs using a com- II - FINAL OPERATION
pressed air nozzle to avoid any impurities getting
into the cylinders. a Refit the engine cover.
13C-2
ANTIPOLLUTION
Fuel vapour recirculation circuit: Operating diagram 14A
D4F or K4J or K4M or K7J
97393
(1) Inlet manifold

(2) Petrol vapour absorber with
built-in bleed solenoid valve
(3) Fuel tank
(4) Fresh air vent
14A-1
ANTIPOLLUTION
Fuel vapour canister: Removal - Refitting 14A
IMPORTANT terior protection).

- refrain from smoking or bringing red hot objects CONCERNED
union.
IMPORTANT
tion.
IMPORTANT
tion.
WARNING
132517
a Remove the bolts (1) from the fuel vapour absorber.
a Move aside the fuel vapour absorber.
WARNING
areas.
WARNING
REMOVAL
a Position the vehicle on the two-post lift (see Vehicle:


a Remove:

14A-2
ANTIPOLLUTION
Fuel vapour canister: Removal - Refitting 14A
a Refit:
terior protection),
132515
a Disconnect the following from the fuel vapour absor-

ber:
- the union (2) of the fuel tank fuel vapour inlet pipe,
- the union (3) of the fuel vapour circulation pipe lea-

ding to the intake distributor.

a Remove the fuel vapour absorber.
REFITTING

CONCERNED
a Fit the fuel vapour absorber.

solenoid valve.
a Connect the following to the fuel vapour absorber:
- the union of the fuel tank fuel vapour inlet pipe,
- the union of the fuel vapour circulation pipe leading

to the intake distributor.
14A-3
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
K9K, and 718 or 740
Mot. 1729 Pin wrench for removing the

EGR valve.
Tightening torquesm

tion solenoid valve bolts
a Remove:
- the engine cover,

CONCERNED
114508
a Disconnect the connector (1) from the exhaust gas

recirculation solenoid valve.
a Remove:
- the bolts (2) from the exhaust gas recirculation so-

lenoid valve,
- the exhaust gas recirculation solenoid valve, by

tugging it lightly to remove it from the exhaust gas
cooler mounting on the gearbox end,
- the exhaust gas recirculation solenoid valve seal.
14A-4
ANTIPOLLUTION
K9K, and 718 or 740
a
Note:
Use the tool (Mot. 1729) to detach the exhaust
gas recirculation solenoid valves jammed in their
exhaust gas cooler mountings on the gearbox
end.
Remove:
- the bracket bolt (3) from the air filter unit,
- the air filter unit bracket.
Position the lugs (4) of the tool (Mot. 1729) in the
bracket holes of the exhaust gas recirculation
solenoid valve.
Unlock the exhaust gas recirculation solenoid
valve by turning it on its axis using the (Mot.
1729).
Refit:
133820 - the air filter unit bracket,

- the bolt on the air filter unit bracket.
REFITTING
a Always replace the exhaust gas recirculation sole-

noid valve seal with a new one.
a Clean using ABRASIVE PADS :
- the joint face of the exhaust gas recirculation sole-

107634 noid valve if it is being reused,
- the joint face of the exhaust gas cooler mounting

on the gearbox end.


noid valve if it is being reused,

on the gearbox end.
WARNING
ger marks).
14A-5
ANTIPOLLUTION
K9K, and 718 or 740
CONCERNED
a Refit:
- a new exhaust gas recirculation solenoid valve seal
on the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve.
a Torque tighten the exhaust gas recirculation sole-
noid valve bolts (10 N.m).
a Connect the exhaust gas recirculation solenoid val-
ve connector.

a Refit:
- the engine cover.
a If the exhaust gas recirculation solenoid valve is
being replaced, program the exhaust gas recircula-
tion solenoid valve (see Fault finding - Replace-
ment of components) (13B, Diesel injection).
14A-6
ANTIPOLLUTION
K9K, and 700
Tightening torquesm

tion solenoid valve nuts
heat shield bolt of the 10 N.m

exhaust gas recircula-
tion solenoid valve

a Remove:
- the engine cover,

CONCERNED
24745
a Remove:
- the nuts (2) from the exhaust gas recirculation sole-

noid valve,
- the bolt (3) from the heat shield of the exhaust gas
recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve heat

shield,
- the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve seal.
Note:
Clean the exhaust gas recirculation solenoid
valve if it is being reused (see the recommended
procedure in Technical Note 3916A).
24748
a Disconnect the connector (1) from the exhaust gas
recirculation solenoid valve. REFITTING
a Always replace the exhaust gas recirculation sole-

noid valve seal with a new one.
a Clean using ABRASIVE PADS :

- the joint face of the exhaust gas recirculation unit.
14A-7
ANTIPOLLUTION
K9K, and 700
- the joint face of the exhaust gas recirculation unit.
WARNING
ger marks).

CONCERNED
a Refit:
- a new exhaust gas recirculation solenoid valve seal
on the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve,
- exhaust gas recirculation solenoid valve heat
shield.
- the exhaust gas recirculation solenoid valve
nuts (10 N.m),
- the heat shield bolt of the exhaust gas recircu-
lation solenoid valve (10 N.m).
a Connect the exhaust gas recirculation solenoid val-
ve connector.

a Refit:
- the engine cover.
a If the exhaust gas recirculation solenoid valve is
being replaced, program the exhaust gas recircula-
tion solenoid valve (see Fault finding - Replace-
ment of components) (13B, Diesel injection).
14A-8
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 718 or 740
CONCERNED
Tightening torquesm
bolts of the exhaust gas 12 N.m

cooler mounting on the
gearbox end
bolts of the exhaust gas 12 N.m

cooler mounting on the
timing end
IMPORTANT
tion.
REMOVAL

a Disconnect the battery (see Battery : Removal - a Remove the following on the workbench:
Refitting) (80A, Battery). - the bolts (1) from the exhaust gas cooler mounting
a Remove: on the gearbox end,
- the engine cover, - the exhaust gas cooler mounting seal on the gear-
box end,
unit: Removal - Refitting, page 12A-5) , - the bolts (2) from the exhaust gas cooler mounting
on the timing end,
- the exhaust gas cooler mounting seal on the timing
- the engine undertray, end,
- the front right-hand wheel (see Wheel: Removal - - the exhaust gas cooler.
- the catalytic converter (see 19B, Exhaust, Cataly- REFITTING
- the exhaust gas recirculation assembly (see 14A,
Antipollution, Exhaust gas recirculation as-
sembly: Removal - Refitting, page 14A-12) . a
Note:
Take care not to damage the joint faces of the
exhaust gas cooler to prevent any coolant leaks.
14A-9
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A
K9K, and 718 or 740
a Always replace: a Adjust the exhaust gas cooler in relation to the two
exhaust gas cooler mountings.
- the exhaust gas cooler mounting seal on the gear-
box end,
- the exhaust gas cooler mounting seal on the timing WARNING
end. Ensure that the seals between the cooler and its
two supports are correctly positioned to avoid
any coolant leaks.
WARNING
Do not scrape the joint faces of the aluminium, a Tighten:
any damage caused to the joint face will result in - the exhaust gas cooler mounting bolts on the gear-
a risk of leaks. box end,
a Use an ABRASIVE PAD to clean: - the exhaust gas cooler mounting bolts on the timi-
ng end.
- the joint faces of the exhaust gas cooler if it is to be
reused, a Remove:
- the joint face of the exhaust gas cooler mounting - the exhaust gas recirculation assembly bolts,
on the gearbox end,
- the exhaust gas recirculation assembly.
- the joint face of the exhaust gas cooler mounting a On the workbench, torque tighten:
on the timing end.
- the bolts of the exhaust gas cooler mounting on
a Use SURFACE CLEANER (see Vehicle: Parts the gearbox end (12 N.m),
mables - Products) to clean and degrease: - the bolts of the exhaust gas cooler mounting on
the timing end (12 N.m).
- the joint faces of the exhaust gas cooler if it is to be
reused,
on the gearbox end, a Refit:
- the joint face of the exhaust gas cooler mounting - the exhaust gas recirculation assembly (see 14A,
on the timing end. Antipollution, Exhaust gas recirculation as-
sembly: Removal - Refitting, page 14A-12) ,
II - REFITTING OPERATION FOR PART - the catalytic converter (see 19B, Exhaust, Cataly-
CONCERNED tic converter: Removal - Refitting, page 19B-9) ,
a On the workbench, refit: - the front right-hand wheel (see Wheel: Removal -
- new seals on the exhaust gas cooler mountings,
- the exhaust gas cooler.
Note:
- the engine cover.
The exhaust gas cooler must be able to move in
relation to the two exhaust gas cooler mountings
in order to be adjusted correctly.
a On the workbench, fit without tightening:

- the exhaust gas cooler mounting bolts on the gear-
box end,
- the exhaust gas cooler mounting bolts on the timi-
ng end.
a Refit:
- the exhaust gas recirculation assembly,
- the exhaust gas recirculation assembly bolts.
14A-10
ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting 14A
K9K, and 718 or 740
112326
a (1) Exhaust gas cooler mounting on the gearbox
end.
(2) Exhaust gas cooler mounting on the timing end.
a Refer to the exhaust gas cooler operating procedure
(see 14A, Antipollution, Intercooler: Removal -
Refitting, page 14A-9) .
14A-11
ANTIPOLLUTION
Exhaust gas recirculation assembly: Removal - Refitting 14A
K9K, and 718 or 740
Tightening torquesm

tion assembly bolts
bolts on the « timing 12 N.m

end lifting eye - air inlet
metal tube assembly »
coolant circulation cover 12 N.m

132881
bolts
turbocharger air outlet 5.5 N.m the rocker cover.
pipe clip
turbocharger air outlet 10 N.m

pipe nuts
IMPORTANT
IMPORTANT
tion.
REMOVAL

121633
a Unclip the oil vapour rebreathing hose diaphragm
a Disconnect the battery (see Battery : Removal - (2) from the air filter unit air outlet pipe.
a Remove the « oil vapour rebreathing hose
a Remove: diaphragm - oil vapour rebreathing hose » assem-
- the engine cover, bly.
- the air filter unit (see 12A, Fuel mixture, Air filter a Undo the air filter unit air outlet pipe clip (3) from the
unit: Removal - Refitting, page 12A-5) . turbocharger.
a Disconnect the air filter unit air outlet pipe from the
turbocharger.
a Remove the air outlet pipe from the air filter unit.
14A-12
ANTIPOLLUTION
K9K, and 718 or 740
a Move the coolant circulation cover aside.
WARNING
a Remove:
- the coolant circulation cover seals,


134070
a Remove the nuts (4) from the turbocharger air outlet CONCERNED
pipe.
a Undo the turbocharger air outlet pipe clip (5) from
the turbocharger.
a Disconnect the turbocharger air outlet pipe from the
turbocharger.
a Move aside the turbocharger air outlet pipe.
a Remove the turbocharger air outlet pipe seal.
112329
a Remove:
- the bolts (8) of the « timing end lifting eye - air inlet
metal tube » assembly,
- the lifting eye on the timing end,
- the air inlet metal tube seals,

114341
a Fit the tool (Ms. 583) on every cooling hose (6) of the - the bolts (9) from the exhaust gas recirculation as-
coolant circulation cover. sembly,
a Remove the coolant circulation cover bolts (7) . - the exhaust gas recirculation assembly.
14A-13
ANTIPOLLUTION
K9K, and 718 or 740
REFITTING - the air inlet metal tube,

I - REFITTING PREPARATION OPERATION a Torque tighten the bolts on the « timing end lifting
a Always replace: eye - air inlet metal tube assembly » (12 N.m).
- the air inlet metal tube seals,

- the coolant circulation cover seals,
a Refit:
- the turbocharger air outlet pipe seal.
a Use ABRASIVE PADS to clean the joint faces of the tic converter: Removal - Refitting, page 19B-9) ,
exhaust gas cooler mounting on the gearbox end.
WARNING Refitting) (35A, Wheels and tyres),
Do not scrape the aluminium joint faces of the,
any damage caused to the joint face will result in - new coolant circulation cover seals on the coolant
a risk of leaks. circulation cover.
a Fit the coolant circulation cover.
and ingredients for the repairwork) (04B, Consu- a Torque tighten the coolant circulation cover bolts
mables - Products) to clean and degrease: (12 N.m).
- the housing of the coolant circulation cover seals, a Remove the tool (Ms. 583) from each of the cooling
hoses of the coolant circulation cover.
- the exhaust gas cooler mounting joint faces on the
gearbox end, a Refit a new turbocharger air outlet pipe seal on the
turbocharger air outlet pipe.
- the housing of each air inlet metal tube seal,
- the housing of the turbocharger air outlet pipe seal,
a Connect the turbocharger air outlet pipe to the turbo-
- the housing of the air inlet metal tube in the cylinder charger.
head,
- the housing of the air inlet metal tube in the ex-
- the turbocharger air outlet pipe clip (5.5 N.m),
haust gas cooler mounting on the gearbox end.
- the turbocharger air outlet pipe nuts (10 N.m).
WARNING a Refit the air outlet pipe onto the air filter unit.
To ensure proper sealing, the gasket surfaces a Connect the air filter unit air outlet pipe to the turbo-
must be clean, dry and not greasy (avoid any fin- charger.
ger marks).
a Tighten the clip of the air filter unit air outlet pipe on
the turbocharger.
II - REFITTING OPERATION FOR PART a Refit the « oil vapour rebreathing hose diaphragm -
CONCERNED oil vapour rebreathing hose » assembly.
a Refit the exhaust gas recirculation assembly. a Clip the oil vapour rebreathing hose diaphragm onto
the air filter unit air outlet pipe.
a Fit the exhaust gas recirculation assembly bolts wi-
thout tightening them. a Connect the oil vapour rebreathing hose to the roc-
ker cover.
a Torque tighten the exhaust gas recirculation as-
sembly bolts (25 N.m). a Refit:
a Refit: - the air filter unit (see 12A, Fuel mixture, Air filter
Antipollution, Exhaust gas recirculation rigid - the engine cover.
- new seals on the air inlet metal tube, ting) (80A, Battery).
14A-14
ANTIPOLLUTION
K9K, and 718 or 740
14A-15
ANTIPOLLUTION
K9K, and 700
Mot. 1567 Long nose pliers for EGR

duct clips.
Tightening torquesm

tion unit bolts
air inlet metal tube bolt 25 N.m
turbocharger air outlet 5.5 N.m

pipe clips
IMPORTANT
24748
a Disconnect:
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera- - the brake servo pipe union (1) from the vacuum
tion. pump,
- the air temperature sensor connector (2) from the
turbocharger air outlet pipe,
REMOVAL
nector (3) .
14A-16
ANTIPOLLUTION
K9K, and 700
- the turbocharger,
- the exhaust gas recirculation unit.
a Move aside the turbocharger air outlet pipe.

CONCERNED
24748
109946
a Remove:
- the bolts (7) from the lifting eye at the timing end,
- the bolt (8) from the air inlet metal tube,
- the air inlet metal tube seals.
19708
a Loosen the turbocharger air outlet pipe clips (4) .
Note: 102074
When disconnecting the turbocharger air outlet a Remove:
pipe, be careful not to damage:
- the clips (9) from the exhaust gas recirculation rigid
- the control pipe union (5) of the turbocharging
pipe,
pressure regulation valve,
- the turbocharging pressure sensor pipe union - the exhaust gas recirculation rigid pipe,
(6) . - the bolts (10) from the EGR unit,
a Disconnect the turbocharger air outlet pipe from: - the exhaust gas recirculation unit.
14A-17
ANTIPOLLUTION
K9K, and 700
REFITTING a Refit the engine cover.

I - REFITTING PREPARATION OPERATION ting) (80A, Battery).

- the housing of each air inlet metal tube seal,
- the housing of each cylinder head metal tube seal,
- the housing of each metal tube seal in the exhaust
gas recirculation unit.
a Always replace:
- the exhaust gas recirculation rigid pipe,
- the exhaust gas recirculation rigid pipe clips,
- the air inlet metal tube seals.

CONCERNED
a Refit the EGR unit.
a Torque tighten the exhaust gas recirculation unit
bolts (30 N.m).
a Refit:
- the new exhaust gas recirculation rigid pipe,
- the new clips to the exhaust gas recirculation rigid
pipe using the tool (Mot. 1567),
- new seals on the air inlet metal tube,
- the air inlet metal tube.
a Torque tighten the air inlet metal tube bolt (25
N.m).
a Refit the engine lifting eye at the timing end.

a Connect the turbocharger air outlet pipe to:
- the turbocharger,
- the exhaust gas recirculation unit.
a Torque tighten the turbocharger air outlet pipe
clips (5.5 N.m).
a Connect:
- exhaust gas recirculation solenoid valve connector
,
- the connector of the inlet air temperature sensor on
the air pipe at the turbocharger outlet,
- the brake servo pipe union to the vacuum pump.
14A-18
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting 14A
K9K
K9K, and 718 or 740

K9K, and 700
First fitting of the rigid exhaust gas recirculation
pipe
112326
Second fitting of the rigid exhaust gas recirculation

pipe
20802
a (1) Rigid exhaust gas recirculation pipe.
a Refer to the operation procedure concerning the ex-
haust gas recirculation assembly (see 14A, Antipol-
lution, Exhaust gas recirculation assembly:
131602
a (1) Rigid exhaust gas recirculation pipe.
a Refer to the operation procedure concerning the ex-
haust gas recirculation assembly (see 14A, Antipol-
lution, Exhaust gas recirculation assembly:
14A-19
STARTING - CHARGING
Alternator: Removal - Refitting 16A
D4F
Tightening torquesm
alternator mounting 50 N.m

bolts
alternator upper bolt 25 N.m
alternator lower bolt 50 N.m
alternator positive termi- 25 N.m

nal nut
IMPORTANT
REMOVAL
I - REMOVAL PREPARATION OPERATION 132656

a Remove the engine oil dipstick (1) .
Towing and lifting) (02A, Lifting equipment). a Disconnect the pinking sensor connector (2) .
a Remove:
terior protection),
page 11A-1) .
16A-1
STARTING - CHARGING
D4F
II - OPERATION FOR REMOVAL OF PART - the alternator lower nut (7) .
CONCERNED
132707
132678 a Remove the alternator lower bolt (8) .
a Remove the nut (3) on the alternator positive termi-
a Remove the alternator from its mounting.
nal.
a Disconnect:
- the alternator connector (4) ,
- the connector (5) from the pressure sensor of the
power-assisted steering pipe.
a Move aside the alternator wiring.
132709
a Remove:
- the alternator bracket bolts (9) ,
- the alternator bracket.
132706
a Remove:
- the alternator upper bolt (6) ,
16A-2
STARTING - CHARGING
D4F
CONCERNED
a Refit the alternator.
- the alternator upper bolt (25 N.m),
- the alternator lower bolt (50 N.m).
a Position the alternator wiring.
a Refit the alternator positive terminal nut.
a Torque tighten the alternator positive terminal nut
(25 N.m).
a Connect:
- the alternator connector,
- the connector of the power-assisted steering pipe
pressure sensor.

132708
a Refit:
a Remove the alternator.
REFITTING page 11A-1) ,
I - REFITTING PREPARATION OPERATION - the front right-hand wheel arch liner (see Front
a Fit the alternator in the engine compartment. terior protection),
a Refit the alternator mounting. - the front right-hand wheel (see Wheel: Removal -
- the dipstick.
a Connect:
- the pinking sensor connector,
(80A, Battery).
132709
a Torque tighten in order the alternator mounting

bolts (50 N.m).
16A-3
STARTING - CHARGING
K9K
CONCERNED
Tightening torquesm
alternator bolts 25 N.m

nal nut
IMPORTANT
REMOVAL

a Disconnect the battery (see Battery : Removal - 123829
Refitting) (80A, Battery). a Disconnect the alternator excitation connector (1) .

a Remove the nut (2) from the alternator positive ter-
a Remove:
minal.
- the engine cover, a Move aside the alternator wiring.

Washing), a
WARNING
Removal - Refitting) (56A, Exterior equipment), In order to avoid any refrigerant leaks, do not

terior protection),

19D-16) ,

page 11A-1) .
16A-4
STARTING - CHARGING
K9K
CONCERNED
WARNING
123831 a Torque tighten the alternator positive terminal nut

(14 N.m).
a Remove the bolts (3) from the alternator.
a Connect the alternator excitation connector.
a Move the alternator away from the multifunction sup-
port using a screwdriver.
a Remove the alternator (4) .
a Refit:
REFITTING - the accessories belt (see 11A, Top and front of
I - REFITTING PREPARATION OPERATION page 11A-1) ,

19D-16) ,

terior protection),



Washing),
18987
- the engine cover.
a Compress the alternator rings (5) using pliers or a a Connect the battery (see Battery : Removal - Refit-
vice to facilitate fitting the alternator. ting) (80A, Battery).
16A-5
STARTING - CHARGING
K7J or K7M
CONCERNED
Tightening torquesm
positive terminal nut on 24 N.m

the alternator
REMOVAL

a Remove:
(80A, Battery),
- the front right-hand wheel (see Wheel: Removal - 133016
a Unclip the alternator wiring from the multifunction
- the front right-hand wheel arch liner (see Front support at (1) .
terior protection),
19D-26) ,
page 11A-1) .
133166
a Remove the nut (2) on the alternator positive termi-

nal.
a Disconnect:
- the alternator positive terminal,
- the alternator regulator connector (3) .
a Move aside the alternator wiring.
16A-6
STARTING - CHARGING
K7J or K7M
19D-26) ,
terior protection),
(80A, Battery).
a Adjust the headlight beams (see Front headlight:
Adjusting) (80B, Headlights).
133162
a Remove:
- the alternator bolts (4) ,
- the alternator.
REFITTING

CONCERNED
a Connect:
- the alternator positive terminal,
- the alternator regulator connector.
a Refit the positive terminal nut on the alternator.
a Torque tighten the positive terminal nut on the al-
ternator (24 N.m).
a Clip the alternator wiring onto the multifunction sup-
port.
a Refit:
page 11A-1) ,
16A-7
STARTING - CHARGING
K4J or K4M

bly.
Tightening torquesm

nal nut
REMOVAL
101793
manifold.
a Remove:
a Remove:
- the front bumper (see Front bumper: Removal - engine mounting: Removal - Refitting, page
Refitting) (55A, Exterior protection), 19D-16) ,
- the right-hand headlight (see Front headlight: Re- - the accessories belt (see 11A, Top and front of
moval - Refitting) (80B, Headlights), engine, Accessories belt: Removal - Refitting,
page 11A-1) ,
Refitting) (35A, Wheels and tyres), - the front end panel (see Front: Removal - Refit-
ting) (42A, Upper front structure).
terior protection),
page 19D-26) .
16A-8
STARTING - CHARGING
K4J or K4M
133057 132817
a Remove: a Remove:
- the power-assisted steering pipe clip bolt (2) , - the bolt (5) from the power-assisted steering high
pressure pipe,
- the bolts (3) from the injector rail protector,
- the power-assisted steering high pressure pipe
union (6) .
sure pipe.
132816
a Fit the tool (Ms. 583) (4) on the power-assisted
16A-9
STARTING - CHARGING
K4J or K4M
CONCERNED

a Always replace the exhaust bracket seal.

CONCERNED
a Torque tighten the alternator positive terminal nut
(24 N.m).
a Connect the alternator regulator connector.
WARNING
132814 Also, do not remove the components from their

a Disconnect the connector (7) from the alternator re- cle.
gulator.
a Remove the nut (8) from the alternator positive ter-
minal. a Fit the power-assisted steering high pressure pipe.
a Move aside the alternator wiring. a Refit:

- the power-assisted steering high pressure pipe
union,
- the bolt on the power-assisted steering high pres-
sure pipe.
a Refit:
- the power-assisted steering pipe clip bolt.
a Refit:
- the front end panel (see Front: Removal - Refit-
ting) (42A, Upper front structure),
page 11A-1) ,
132815 19D, Engine mounting, Right-hand suspended
a Remove: 19D-16) .
- the alternator bolts (9) , a Remove the tool (Mot. 1390).
- the alternator. a Refit a new exhaust bracket seal.
16A-10
STARTING - CHARGING
K4J or K4M
a Refit:
page 19D-26) ,
terior protection),
16A-11
STARTING - CHARGING
Starter: Removal - Refitting 16A
K7J or K7M
CONCERNED
Tightening torquesm
starter bolts 45 N.m
starter supply wiring nut 8 N.m
starter excitation wiring 5 N.m

nut
REMOVAL


a Remove: 133139
- the engine undertray bolts, a Remove:
- the engine undertray. - the starter feed wiring nut (3) ,
- the starter excitation wiring nut (4) .
a Move the starter wiring aside.
133138
a Remove:
133159
- the strut nut (1) on the intake distributor,
a Remove:
- the strut bolt (2) on the cylinder block, - the starter bolts (5) ,
- the intake distributor strut. - the starter.
16A-12
STARTING - CHARGING
K7J or K7M
REFITTING

a Check that the centring dowel is in place.

CONCERNED
a Refit the starter.
a Torque tighten the starter bolts (45 N.m).
a Fit the starter wiring.
a Refit:
- the starter supply wiring nut,
- the starter excitation wiring nut.
- the starter supply wiring nut (8 N.m),
- the starter excitation wiring nut (5 N.m).
FINAL OPERATION
a Refit:
- the intake distributor strut,
16A-13
STARTING - CHARGING
D4F
CONCERNED
Tightening torquesm
starter bolts 44 Nm
starter supply cable nut 8 N.m
starter excitation cable 5 N.m

nut
REMOVAL

a Remove the engine oil dipstick.
120512
a Remove:
- the starter supply cable nut (2) ,
- the starter excitation cable nut (3) .
120512
a Disconnect the pinking sensor connector (1) .
16A-14
STARTING - CHARGING
D4F
CONCERNED
a Torque tighten the starter bolts (44 Nm).
- the starter supply cable nut (8 N.m),
- the starter excitation cable nut (5 N.m).

a Connect the pinking sensor connector.
a Refit the engine oil dipstick.
120411
120413
a Remove:
- the starter bolts (4) ,
- the starter.
REFITTING
a Check that the starter centring dowel is in place.
16A-15
STARTING - CHARGING
K9K, and 718 or 740
Tightening torquesm
starter supply terminal 8 N.m

nut
nut on the starter sole- 5 N.m

noid
REMOVAL

134255
a Unclip the engine wiring at (2) .
a Remove:
- the bolt (3) from the engine wiring retaining brac-

ket,
- the engine wiring retaining bracket.

CONCERNED
20792
unit by pressing on the pins (1) .
Note:
134254
a Remove:
- the nut (4) on the starter solenoid,
16A-16
STARTING - CHARGING
K9K, and 718 or 740
- the starter supply terminal nut (5) . a Refit the engine cover.
134253
a Remove:
- the starter.
REMOVAL


CONCERNED
- the starter supply terminal nut (8 N.m),
- the nut on the starter solenoid (5 N.m).

a Refit the engine wiring retaining bracket.
a Clip:
- the air filter unit air inlet pipe onto the air filter unit.
16A-17
STARTING - CHARGING
K4J or K4M
Tightening torquesm
starter bolts 44 N.m

nut
REMOVAL

a Remove:
(80A, Battery),
132767
a Unclip:
- the power-assisted steering pipe (1) ,
matic transmission computer: Removal - Refit- - the expansion bottle hose (2) .
132766
a Remove the bolts (3) from the engine wiring channel
and from the automatic gearbox.
16A-18
STARTING - CHARGING
K4J or K4M
133273 132890
a Disconnect the tachometer connector (4) . a Disconnect the connector (6) from the oil level sen-
sor.

CONCERNED
133272
a Disconnect the upstream oxygen sensor connector
(5) .
132691
a Remove:
16A-19
STARTING - CHARGING
K4J or K4M
- the tachometer connector.
a Refit the bolts on the engine wiring channel and on
the automatic transmission.
a Clip:
a Refit:
133271
a Remove: - the battery (see Battery : Removal - Refitting)
(80A, Battery),
- the starter.
REFITTING

a Check that the centring dowel is in place.

CONCERNED
a Torque tighten the starter bolts (44 N.m).
a Refit:
- the starter excitation cable nut,
- the starter supply cable nut.
- the starter excitation cable nut (5 N.m),
- the starter supply cable nut (8 N.m).

a Connect:
- the oil level sensor connector,
- the upstream oxygen sensor connector,
16A-20
STARTING - CHARGING
K9K, and 700
Tightening torquesm
starter supply terminal 8 N.m

nut
nut on the starter sole- 5 N.m

noid
REMOVAL

a Remove:
- the engine undertray bolts, 134257
- the engine undertray, a Unclip the cooling hose (2) between the heater ma-
trix and the coolant pump inlet pipe.
20797
a Remove the bolt (3) from the thermoplunger unit
134258
support.
a Disconnect the brake servo vacuum pipe union (1)
from the vacuum pump. a Move aside the thermoplunger unit support.
16A-21
STARTING - CHARGING
K9K, and 700
CONCERNED


CONCERNED
- the starter supply terminal nut (8 N.m),
- the nut on the starter solenoid (5 N.m).

a Fit the thermoplunger unit support.
a Clip the cooling hose between the heater matrix and
the coolant pump inlet pipe.
134259 a Connect the brake servo vacuum pipe union to the
vacuum pump.
a Remove:
a Refit:
- the starter supply terminal nut (4) ,
- the nut (5) on the starter solenoid. tic converter: Removal - Refitting, page 19B-9) ,
a Move the starter wiring aside. - the engine undertray.

20797
a Remove:
- the starter.
16A-22
STARTING - CHARGING
Alternator pulley: Removal - Refitting 16A
K4J or K4M
a To remove and refit the alternator pulley (see 16A,
Starting - Charging, Alternator pulley: Removal -
Refitting, page 16A-23) (Technical Note 5008A,
16A, Starting - Charging).
16A-23
IGNITION
Coils Removal - Refitting 17A
K7J or K7M
Tightening torquesm
ignition coil unit bolts 9 N.m
REMOVAL

CONCERNED
132847
a
WARNING
To disconnect the spark plug leads, pull on the
extensions and not on the leads.
a Disconnect:
- the spark plug leads (1) on the spark plugs,
- the spark plug leads on the ignition coil unit,
- the ignition coil unit connector.
a Remove:
- the ignition coil unit bolts,
- the ignition coil unit.
17A-1
IGNITION
K7J or K7M
REFITTING
106640
a When refitting the ignition wiring harness, it is essen-

tial to apply a bead of FLUORSTAR 2L 2 mm in dia-
meter on the internal perimeter of the high-tension
caps at the spark plug end and at the coil end (see
rwork) (04B, Consumables-Products).

CONCERNED
a Refit the ignition coil unit.
a Torque tighten the ignition coil unit bolts (9 N.m).
a Connect:
- the ignition coil unit connector,
- the spark plug leads on the ignition coil unit,
- the spark plug leads to the spark plugs.
17A-2
IGNITION
D4F
Tightening torquesm
coil bolts 8 N.m
REMOVAL


CONCERNED
113044
a Remove:
- the coil bolts (3) ,
- the coil.
REFITTING

CONCERNED
a Refit the coil.
a Torque tighten the coil bolts (8 N.m).
113044
a Disconnect:
- the high voltage wiring (1) from the coil,
- the coil connector (2) .
17A-3
IGNITION
D4F
106640
a Apply a bead of FLUORSTAR 2L grease (see Vehi-
the coil end.
a Connect:
- the coil connector,
- the high voltage wiring of the coil.
17A-4
IGNITION
K4J or K4M
REMOVAL

CONCERNED
14843
a Disconnect the coil connectors (1) .
a Remove:
- the coil bolts (2) ,
- the coils.
17A-5
IGNITION
K4J or K4M
REFITTING
106443
a Apply a bead of FLUOSTAR 2L grease (see Vehi-
cle: Parts and consumables for repair) (04B,
Consumables - Products) 2 mm in diameter on the
internal perimeter of the high tension caps on the
four coils.
a Always replace the coil bolts.

CONCERNED
a Refit the coils.
a Connect the coil connectors.
17A-6
IGNITION
Spark plugs: Removal - Refitting 17A
K7J or K7M
REMOVAL
Ele. 1382 Set of plug wrenches 16 & 21 I - OPERATION FOR REMOVAL OF PART
mm torque 17.5 & 28 N.m + CONCERNED
square adapter 9-9.52 for
wrench Ele. 1086
Tightening torquesm
spark plugs 28 N.m
Spark plug electrode gap
Type of spark plug Gap (mm)
CHAMPION 0.95 ± 0.05
EYQUEM 0.90 ± 0.10
NGK 0.90 ± 0.10
SAGEM 0.90 ± 0.10
132847
a
WARNING
To disconnect the spark plug leads, pull on the
a Disconnect the spark plug leads (1) on the spark

plugs.
a Remove the spark plugs using (Ele. 1382).
II - REFITTING PREPARATION OPERATION

a Check and, if necessary, correct the electrode gap
for each spark plug.
17A-7
IGNITION
K7J or K7M
106640
a When refitting the ignition wiring harness, it is essen-
tial to apply a bead of FLUOSTAR 2L (2 mm in dia-
meter) to the internal edge of the high-tension caps
on the spark plug and coil sides (see Vehicle: Parts
mables - Products).
III - REFITTING OPERATION FOR PART

CONCERNED
a Refit the spark plugs.
a Torque tighten the spark plugs (28 N.m) using (Ele.
1382) fitted with the grey sleeve.
IV - FINAL OPERATION
a Connect the spark plug leads to the spark plugs.
17A-8
IGNITION
K4J or K4M
REFITTING
Ele. 1382 Set of plug wrenches 16 & 21 I - REFITTING PREPARATION OPERATION

mm torque 17.5 & 28 N.m +
square adapter 9-9.52 for a Check and, if necessary, correct the electrode gap
wrench Ele. 1086 for each spark plug.

Tightening torquesm CONCERNED
spark plugs 28 N.m
a Torque tighten the spark plugs (28 N.m) using (Ele.
1382) fitted with the grey sleeve.
a Refit the ignition coils (see 17A, Ignition, Coils Re-
CHAMPION 0.95 ± 0.05 moval - Refitting, page 17A-1) .
EYQUEM 0.95 ± 0.05
NGK 0.95 ± 0.05
REMOVAL
a Remove the ignition coils (see 17A, Ignition, Coils


CONCERNED
132449
a Remove the spark plugs using (Ele. 1382) (1) .
17A-9
IGNITION
D4F
Ele. 1933 23 N.m tightening wrench for

spark plugs
Ele. 1382-01 14 mm Plug spanner.
Essential equipment
set of feeler gauges
Tightening torquesm
spark plugs 23 N.m
CHAMPION 0.90 ± 0.05 132677
NGK 0.85 ± 0.05 a
WARNING
REMOVAL To disconnect the spark plug leads, pull on the
I - REMOVAL PREPARATION OPERATION Disconnect the spark plug wiring.

CONCERNED
132700
a Remove the spark plugs using the (Ele. 1933) (1)

equipped with the (Ele. 1382-01) (2) .
17A-10
IGNITION
D4F
REFITTING

a Check and, if necessary, correct the spark plug elec-
trode gaps using a set of feeler gauges.

CONCERNED
132700
a Torque tighten the spark plugs (23 N.m) using the
(Ele. 1933) fitted with the (Ele. 1382-01).
17A-11
IGNITION
D4F
106640
a Apply a bead of FLUORSTAR 2L grease (see Vehi-
the spark plug end.
a Connect the spark plug wiring.
17A-12
PETROL INJECTION
Fuel injection: List and location of components 17B
D4F
132654
(1) Air pressure sensor

(2) Throttle valve
(3) Petrol injection computer
tion unit
132664
(2) Throttle valve
17B-1
PETROL INJECTION
D4F
121739

(6) Pinking sensor
113044
(9) Ignition coil
109725
(7) Crankshaft position sensor

(8) Coolant temperature sensor
121732
(10) Oxygen sensor
17B-2
PETROL INJECTION
D4F
132671 132519
(11) Oil pressure sensor (14) Fuel vapour absorber
132677 132674
(12) Spark plugs (15) Fuel filter

(13) Injector rail
17B-3
PETROL INJECTION
K7J or K7M
132478
(1) Ignition coil

(2) Air filter
(3) Throttle valve
(6) Injection computer
(7) Oil pressure sensor
(8) Upstream oxygen sensor
(10) TDC sensor
132847
(1) Ignition coil
17B-4
PETROL INJECTION
K7J or K7M
107356 132841
(3) Throttle valve (7) Oil pressure sensor

133173
(8) Upstream oxygen sensor

132694
(6) Injection computer
17B-5
PETROL INJECTION
K7J or K7M
133172 107357
(11) Downstream oxygen sensor (11) Injectors

(12) Idle speed regulator
(13) Throttle position potentiometer
109219
(14) Pinking sensor

133171

(10) TDC sensor
17B-6
PETROL INJECTION
K7J or K7M
141060
(17) Additional fuel system tank
133722

tion unit
FLEXFUEL VEHICLE
141062
(16) Fuel supply solenoid valve
17B-7
PETROL INJECTION
K4J or K4M
133514

(2) Throttle valve potentiometer
(3) Petrol injection computer
tion unit
(5) Automatic transmission compu-
ter (if fitted)
(7) Ignition coil
132808
(2) Throttle valve potentiometer
17B-8
PETROL INJECTION
K4J or K4M
132809 111465
(8) Pinking sensor (10) Upstream oxygen sensor
133270 132689
(9) Crankshaft position sensor (11) Downstream oxygen sensor
17B-9
PETROL INJECTION
K4J or K4M
132519 132812
(12) Fuel vapour absorber (14) Oil pressure sensor
FLEXFUEL VEHICLE
132764
141062
(15) Fuel supply solenoid valve
17B-10
PETROL INJECTION
K4J or K4M
141060
(16) Additional fuel system tank
17B-11
PETROL INJECTION
Oxygen sensors: Removal - Refitting 17B
K7J or K7M
1 - Upstream oxygen sensor
Tightening torquesm
upstream oxygen sen- 44 N.m

sor
dow n s t r e a m oxygen 44 Nm
sensor
WARNING
To prevent the surrounding components from ove-
rheating, do not damage (tear, pierce, bend, etc.) a
heat shield.
WARNING
Do not use any product designed to improve the
133018
electrical contact in the injection computer and oxy-
gen sensor connectors or on the bodies of the oxy-
gen sensors.
Failure to respect this advice causes the oxygen
sensor to malfunction and results in failure to com-
ply with the emission control standard.
WARNING
If the connections are corroded, repair the wiring
(see Wiring: Precautions for repair)(Technical
Note 6015A, 88A, Wiring).
REMOVAL

a Remove: 133173
- the engine undertray bolts, a Unclip the oxygen sensor connector from its moun-
ting.
(1) .
a Remove the oxygen sensor (2) using the (Mot.

1495-01).
17B-12
PETROL INJECTION
K7J or K7M
2 - Downstream oxygen sensor a Clip the downstream oxygen sensor connector on its
mounting.
2 - Downstream oxygen sensor

a Refit the downstream oxygen sensor.
a Torque tighten the downstream oxygen sensor
(44 Nm) using the (Mot. 1495-01).
a Clip the downstream oxygen sensor connector on its
mounting.

133172

from its mounting.
tor (3) .
a Remove the downstream oxygen sensor (4) using
the (Mot. 1495-01).
REFITTING

a Clean the threading of the oxygen sensors using a
WIRE BRUSH.
- the oxygen sensor thread holes,
- the threading of the oxygen sensors if they are to
be reused.

CONCERNED
1 - Upstream oxygen sensor

a Refit the upstream oxygen sensor.
a Torque tighten the upstream oxygen sensor (44
N.m) using the tool (Mot. 1495-01).
a Connect the upstream oxygen sensor connector.
17B-13
PETROL INJECTION
D4F

Tightening torquesm
oxygen sensor 44 N.m
WARNING
gen sensors.
Failure to respect this advice prevents the oxygen
sensor from operating correctly and results in
failure to comply with the emission control standard.
132658
a Disconnect the brake servo pipe (1) from the intake
distributor.
WARNING
(see Wiring: Precautions for repair) (Technical
REMOVAL

17B-14
PETROL INJECTION
D4F
CONCERNED
132696
a Remove the oxygen sensor (3) using the (Mot.

121732
1495-01).
REFITTING

a Clean the threading of the oxygen sensor using a
WIRE BRUSH.
- the oxygen sensor thread hole,

- the threading of the oxygen sensor if it is to be
reused.

CONCERNED
132697 a Refit the oxygen sensor.

a Unclip the oxygen sensor connector. a Torque tighten the oxygen sensor (44 N.m).
a Disconnect the oxygen sensor connector (2) . a Connect the oxygen sensor connector.
a Clip the oxygen sensor connector.

a Connect the brake servo pipe to the intake distribu-
tor.
17B-15
PETROL INJECTION
K4J or K4M
Tightening torquesm
upstream oxygen sen- 44 N.m

sor
dow n s t r e a m oxygen 44 N.m

sensor
WARNING
gen sensors.
ply with the emission control standard. 111465
a Unclip the upstream oxygen sensor connector (1) .
a Disconnect the upstream oxygen sensor connector.

WARNING
If the connections are corroded, repair the wiring a Remove the upstream oxygen sensor (2) using the
(see Wiring: Precautions for repair) (Technical (Mot. 1495-01).
REFITTING THE UPSTREAM OXYGEN

SENSOR
Note:
This procedure is for removal - refitting of the ups-
tream oxygen sensor and the downstream oxygen I - REFITTING OPERATION FOR PART
sensor. CONCERNED
a Refit the upstream oxygen sensor.

REMOVAL OF THE UPSTREAM OXYGEN
a Torque tighten the upstream oxygen sensor (44
SENSOR N.m) using the tool (Mot. 1495-01).
I - REMOVAL PREPARATION OPERATION a Connect the upstream oxygen sensor connector.
a Remove: a Clip on the upstream oxygen sensor connector.

unit: Removal - Refitting, page 12A-5) . a Refit:

17B-16
PETROL INJECTION
K4J or K4M
REMOVING THE DOWNSTREAM OXYGEN

SENSOR


CONCERNED
132687
a Unclip the downstream oxygen sensor wiring (2) .
132686
a Unclip the downstream oxygen sensor connector (1)
.
tor.
132689
a Remove the downstream oxygen sensor (3) using
the (Mot. 1495-01).
REFITTING THE DOWNSTREAM OXYGEN

SENSOR

a Refit the downstream oxygen sensor.
a Torque tighten the downstream oxygen sensor
(44 N.m) using the (Mot. 1495-01).
17B-17
PETROL INJECTION
K4J or K4M
a Clip on the downstream oxygen sensor wiring.
17B-18
PETROL INJECTION
Throttle body potentiometer: Removal - Refitting 17B
K7J or K7M

CONCERNED

107357
a Disconnect:
- the connector from the throttle valve potentiometer
107356 (2) ,
a Unclip the ball joint (1) from the throttle valve. - the idling stepper motor connector (3) .
a Remove:
- the throttle valve by tilting it,
- the throttle valve potentiometer bolts,
- the throttle valve potentiometer.
REFITTING

CONCERNED
a Refit:
- the throttle valve potentiometer,
- the throttle valve by tilting it.
a Connect:
- the idling stepper motor connector,
- the throttle valve potentiometer connector.
a Clip the ball joint onto the throttle valve.
17B-19
PETROL INJECTION
Throttle body potentiometer: Removal - Refitting 17B
K4J or K4M
REMOVAL

a Remove:

CONCERNED
132808
a Remove:
- the bolts (2) from the throttle valve potentiometer,
- the throttle valve potentiometer.
REFITTING
I - OPERATION FOR REFITTING PART

CONCERNED
a Refit the throttle valve potentiometer.
132807 a Connect the throttle valve potentiometer connector

a Disconnect the connector (1) from the throttle valve
potentiometer. II - FINAL OPERATION
a Refit:
17B-20
PETROL INJECTION
Petrol injection computer: Removal - Refitting 17B
K7J or K7M
REFITTING
Essential equipment
diagnostic tool CONCERNED
a a Refit the petrol injection computer.
WARNING a Connect the petrol injection computer connectors.

electrical contact in the injection computer and II - FINAL OPERATION
oxygen sensor connectors or on the bodies of a Connect the battery (see Battery: Removal - Refit-
the oxygen sensors. ting) (80A, Battery).
Failure to respect this advice prevents the oxy- a Carry out the necessary configurations and/or pro-
gen sensor from operating correctly and results gramming, using the diagnostic tool (see Fault fin-
in failure to comply with the emission control ding - Replacement of components) (17B, Petrol
standard. injection).
REMOVAL


CONCERNED
132660
a Disconnect the connector (1) from the petrol injec-

tion computer.
a Remove:
- the nuts (2) from the petrol injection computer,
- the petrol injection computer.
17B-21
PETROL INJECTION
D4F
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
petrol injection compu- 8 N.m

ter nuts
WARNING
gen sensors.
Failure to respect this advice prevents the oxygen
sensor from operating correctly and results in
failure to comply with the emission control standard.
132660
WARNING
a Disconnect the connector (1) from the petrol injec-
If the connections are corroded, repair the wiring tion computer.
Note 6015A, 88A, Wiring). a Remove:
- the nuts (2) from the petrol injection computer,

REMOVAL - the petrol injection computer.

REFITTING
CONCERNED
a Refit:
- the petrol injection computer,
- the petrol injection computer nuts.
a Torque tighten the petrol injection computer nuts

(8 N.m).
a Connect the petrol injection computer connectors.

a Carry out the necessary configurations and/or pro-

gramming, using the diagnostic tool (see Fault fin-
ding - Replacement of components) (17B, Petrol
injection).
17B-22
PETROL INJECTION
K4J or K4M
CONCERNED
Essential equipment
diagnostic tool
WARNING
gen sensors.
WARNING
132694
REMOVAL a Disconnect the connector (1) from the petrol injec-

tion computer.
I - REMOVAL PREPARATION OPERATION a Remove:
a Disconnect the battery (see Battery : Removal - - the nuts (2) from the petrol injection computer,
Refitting) (80A, Battery). - the fuel injection computer.
REFITTING

CONCERNED
a Refit the petrol injection computer.
a Connect the petrol injection computer connector.
a Carry out the necessary configurations and/or pro-
gramming, using the diagnostic tool (see Fault fin-
ding - Replacement of components) (17B, Petrol
injection).
17B-23
PETROL INJECTION
Pinking sensor: Removal - Refitting 17B
D4F

cylinder
Tightening torquesm
pinking sensor 23 N.m
REMOVAL
a Remove the engine oil dipstick.

CONCERNED
121739
a Remove the pinking sensor using the tool (Emb.

1797).
REFITTING

CONCERNED
a Refit the pinking sensor using the tool (Emb. 1797).
a Torque tighten the pinking sensor (23 N.m).
a Refit the engine oil dipstick.
17B-24
PETROL INJECTION
K4J or K4M
cylinder
Tightening torquesm
REMOVAL
132809
1797).
REFITTING

CONCERNED
a Refit the pinking sensor.
a Torque tighten the pinking sensor (20 N.m) using
133057
the tool (Emb. 1797).
a Remove: a Connect the pinking sensor connector.
- the bolt (1) from the power-assisted steering pipe

clip, II - FINAL OPERATION
- the bolts (2) from the injector rail protector, a Refit:
- the injector rail protector. - the injector rail protector,

- the bolt of the power-assisted steering pipe clip.
17B-25
PETROL INJECTION
K7J or K7M
cylinder
Tightening torquesm
intake distributor strut 21 N.m

mountings
REMOVAL

a Remove:
133132
1797).
REFITTING

CONCERNED
a Refit the pinking sensor using the tool (Emb. 1797).
a Torque tighten the pinking sensor (20 N.m) using
the tool (Emb. 1797).
a Refit the intake distributor strut.
a Torque tighten the intake distributor strut moun-
tings (21 N.m).
133138
a Remove:
- the intake distributor strut mountings (2) ,
- the intake distributor strut.
17B-26
PETROL INJECTION
K7J or K7M
REMOVAL

CONCERNED
133171
(1) .
a Remove:
- the crankshaft position sensor bolts (2) ,
REFITTING

a In the event of replacement, program the crankshaft
position sensor (see Fault finding - Replacement
of components) (17B, Petrol injection).
17B-27
PETROL INJECTION
D4F
Tightening torquesm a Refit the air filter unit (see 12A, Fuel mixture, Air fil-
crankshaft position sen- 8 N.m
sor bolts
REMOVAL


CONCERNED
121409
(1) .
a Remove:
REFITTING

CONCERNED
a Torque tighten the crankshaft position sensor
bolts (8 N.m).
17B-28
PETROL INJECTION
K4J or K4M
Tightening torquesm

nut
REMOVAL

a Remove:
(80A, Battery),
nator: Removal - Refitting, page 12A-12) , 132767
- the automatic transmission computer (see Auto- a Unclip:

matic transmission computer: Removal - Refit- - the power-assisted steering pipe (1) ,
- the expansion bottle hose (2) .
132766
a Remove the bolts (3) from the engine wiring channel
and from the automatic gearbox.
17B-29
PETROL INJECTION
K4J or K4M
133273 132691
a Disconnect the tachometer connector (4) . a Remove:
a Move aside the wiring assembly.
133272
(5) .
17B-30
PETROL INJECTION
K4J or K4M
II - OPERATION FOR REMOVAL OF PART a Clip:
CONCERNED
a Refit:
(80A, Battery).
133270

(8) .
a Remove:
REFITTING

CONCERNED
a Fit the wiring assembly.
- the starter excitation cable nut (5 N.m),
- the starter supply cable nut (8 N.m).

a Connect:
- the tachometer connector.

a Refit the bolts of the engine wiring channel and of
the automatic gearbox.
17B-31
PETROL INJECTION
Injector rail - Injectors: Removal - Refitting 17B
K7J or K7M
Tightening torquesm WARNING

injector rail bolts 10 N.m To prevent impurities from entering the circuit, place
IMPORTANT
REMOVAL
- refrain from smoking or bringing red hot objects I - REMOVAL PREPARATION OPERATION
union.
IMPORTANT
Use the diagnostic tool before any operation is car- CONCERNED
ried out on the injection circuit to check:
- that the rail is not under pressure,
- that the fuel temperature is not too high.
Working on the circuit with the engine running is
strictly forbidden.
IMPORTANT
Be careful when removing the injectors or the injec-
tion rail as there will be a quantity of fuel in the rail
and the union.
IMPORTANT
tion.
133177
WARNING a Disconnect:
To avoid any corrosion or damage, protect the - the injector connectors (1) ,
- the fuel supply pipe (2) from the injector rail.
WARNING a Remove:
Do not blast with compressed air once the fuel cir- - the injector rail bolts (3) ,
cuit is open, otherwise impurities may enter the sys-
tem. Only use cleaning cloths. - the injector rail.
a Remove:
- the clip from each injector,
- the injectors from the injector rail.
17B-32
PETROL INJECTION
K7J or K7M
REFITTING

a parts always to be replaced: injector clip on in-
jector rail (11,04,04,10).
a Always replace the O-rings at the base of the injec-
tors (if the injector was removed, also replace the
seal at the injector head).
a Check that the fuel unions « click » into place when
connecting.

CONCERNED
a Refit:
- the new seals to the injectors,
- the injectors on the injector rail,
- the clip on each injector,
a Connect:
- the fuel supply pipe on the injector rail,
- the injector connectors.

17B-33
PETROL INJECTION
D4F
CONCERNED
Tightening torquesm
IMPORTANT
tion.
IMPORTANT

union.
107885
IMPORTANT a Remove:
tion. - the injector rail bolts (1) ,
- the « injector rail - injector » assembly.
REMOVAL a Disconnect the connector from each injector.

a Unclip the wiring on the injector rail.
a Disconnect the battery (see Battery: Removal - Re- IMPORTANT
fitting) (80A, Battery). Be careful when removing the injectors or the
a Remove: injection rail as there will be a quantity of fuel in
the rail and the union.
- the intake distributor (see 12A, Fuel mixture, Inlet
manifold: Removal - Refitting, page 12A-24) .
17B-34
PETROL INJECTION
D4F
a Refit:
101492
a Remove:
- the clip (2) from each injector,
- the injectors (3) from the injector rail.
REFITTING
a parts always to be replaced: injector clip on in-

jector rail (11,04,04,10).
a Always replace the injector seals.

CONCERNED
a Refit:
- new seals on the injectors,
- new clips on each injector.
a Connect the connector on each injector.
a Clip the wiring on the injector rail.
a Refit the « injector rail - injector » assembly.
a Torque tighten in order the injector rail bolts (6

N.m).
17B-35
PETROL INJECTION
K4J or K4M
CONCERNED
Tightening torquesm
REMOVAL

132680
a
WARNING
IMPORTANT
Be careful when removing the injectors or the
133057 injection rail as there will be a quantity of fuel in
a Remove: the rail and the union.
- the bolt (1) from the power-assisted steering pipe a Disconnect:

clip,
- the injector connectors (3) ,
- the fuel supply pipe union (4) from the injector rail.
a Remove:
- the injector rail bolts (5) .
17B-36
PETROL INJECTION
K4J or K4M
a Refit:
128397
a Remove:
- the clip (6) from each injector,

- the injectors (7) from the injector rail,
- the seals of each injector.
REFITTING

a Always replace:
- the seals of each injector,
- the clip of each injector.
a Refit:
- new seals on each injector,
- a new clip on each injector.

CONCERNED
a Refit the « injector rail - injector » assembly.

a Connect:
- the union of the injector rail supply pipe,
- the injector connectors.
17B-37
COOLING
Engine cooling circuit: Specifications 19A
Vehicles in the current range have cooling systems - circuit using a “D” type coolant,
with the following basic specifications:
- passenger compartment heating systems equipped
- hermetically-sealed pressurised circuit (expansion with a "heater matrix" type radiator located under the
chamber valve), dashboard which helps to cool the engine.
Volume of coolant
Engine Quantity Grade

(litres)
D4F 728 5
K4J/K4M 5.7
K9K 706 ?
GLACEROL RX
K7J/K7M 5.7 (type D)
Only use coolant
K9K 700 ?
K9K 718 ?
K9K 740 ?
Special notes: - protection down to - -40˚C ± 2 “extreme cold” coun-

tries.
- protection down to -25˚C ± 2 for cold and temperate
countries,
Thermostat opening temperatures
Engine Start of ope- End of opening

ning (˚C) (˚C)
D4F 728 89 101
K4J/K4M 89 101
K9K 706 83 95
K7J/K7M 89 101
K9K 700 83 95
K9K 718 83 95
K9K 740 83 95
19A-1
COOLING
Engine cooling circuit: check 19A
1 - Checking the expansion bottle cap valve
Mot. 1700 Fault finding and filling-blee-

ding cooling system.
Ms. 554-07 Cooling system tester kit

(complete). Contains plugs
554-01, 554-04, 554-06
IMPORTANT
When working in the engine compartment, take
care as the radiator fan(s) may start up unexpecte-
dly (risk of being cut).
To avoid any risk of serious burns when the engine
is hot:
- do not open the expansion bottle cap,
- do not drain the cooling system,
- do not open the bleed screw(s).
107138
a Use the cooling system filling and diagnostic tool

(Mot. 1700). Consult the user's manual for this tool
Note: (see Cooling system filling and diagnostic tool:
There are two procedures for checking the cooling Use) (Technical Note 3857A, 19A, Cooling).
system:
- the procedure using the (Mot. 1700) 2 - Checking the sealing of the cooling circuit
- the procedure using the (Ms. 554-07) a Use the cooling system filling and diagnostic tool
(Mot. 1700). Consult the user's manual for this tool
(see Cooling system filling and diagnostic tool:
Expansion bottle cap valve rating: Use) (Technical Note 3857A, 19A, Cooling).
Expansion bottle cap with Valve rating II - CHECKING THE COOLING SYSTEM USING THE
... TOOL (MS. 554-07)
... a brown circle 1.2 bar a
... a yellow marking 1.4 bar WARNING

If the coolant is leaking from the expansion bottle
... a white marking 1.6 bar cap, replace the valve.
... a grey marking 1.8 bar
I - CHECKING THE COOLING SYSTEM USING THE

TOOL (MOT. 1700)
a
WARNING
cap, replace the valve.
19A-2
COOLING
Engine cooling circuit: check 19A
1 - Checking the expansion bottle cap valve a Gradually unscrew the union of the (Ms. 554-07) to
decompress the cooling system then remove the
adapter (Ms. 554-01) and refit the expansion bottle
cap.
97871
a Fit onto the tester (Ms. 554-07), the adapter (Ms.

554-06).
a Fit the expansion bottle cap to the adapter (Ms. 554-

06).
Note:
The pressure should not drop; if it does, look for
the leak.
a Pump with the (Ms. 554-07), the pressure should

stabilise at the expansion bottle cap valve rating with
a test tolerance of ± 0.1 bar.
2 - Checking the sealing of the cooling circuit
a Replace the expansion bottle cap with the adapter

(Ms. 554-01).
a Connect on the adapter (Ms. 554-01) the tool (Ms.

554-07).
a Pump with the (Ms. 554-07) to put the cooling circuit

under pressure.
a Stop pumping at 0.1 bar below the valve rating for

the expansion bottle cap valve with.
Note:
The pressure should not drop; if it does, look for
the leak.
19A-3
COOLING
Engine cooling circuit: List and location of components 19A
K4J or K4M
100052
(1) Engine
(2) Cooling radiator
(3) Expansion bottle
(4) Heater matrix
(5) Thermostat
(6) Bleed screw
(7) Automatic gearbox oil cooler (if
fitted)
(8) Water pump
19A-4
COOLING
D4F
133627
(1) Engine
(3) Heater matrix
(5) Water pump
(6) Thermostat
(7) Bleed screw
19A-5
COOLING
K7J or K7M
134069
(1) Engine
(3) Heater matrix
(5) Water pump
(6) Thermostat
(7) Bleed screw
19A-6
COOLING
Cooling circuit: Draining - Refilling 19A
a Separate the clip on the cooling radiator bottom
Essential special tooling hose using the tool (Mot. 1202-01) or (Mot. 1202-
02) or (Mot. 1448).
Mot. 1202-01 Pliers for large hose clips.
a Disconnect the bottom hose from the cooling radia-
Mot. 1202-02 Pliers for small hose clips. tor.
Mot. 1448 Long nose pliers for hose a Use a compressed air nozzle to blow air into the
clips. system through the expansion bottle opening to re-
move as much coolant as possible.
Mot. 1700 Fault finding and filling-blee-
ding cooling system.
II - CLEANING
Ms. 554-07 Cooling system tester kit a Fill the cooling system with water through the expan-
(complete). Contains plugs sion bottle.
554-01, 554-04, 554-06
a Let the water run until the water collected by the coo-
ling radiator bottom hose becomes clear.
Essential equipment
a Use a compressed air nozzle to blow air into the
coolant draining tray circuit through the expansion bottle opening to re-
move as much water as possible.
a Connect the cooling radiator bottom hose.
pedal press a Fit the clip on the cooling radiator bottom hose using
the tool (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
IMPORTANT
III - FILLING
dly (risk of being cut). a
To avoid any risk of serious burns when the engine Note:
is hot:
There are two procedures for filling the cooling
- do not open the expansion bottle cap, system:
- do not drain the cooling system, - the procedure using the tool (Mot. 1700)
- do not open the bleed screw(s). recommended by Renault. It saves a considera-
ble amount of time because it does not require
the cooling system bleed screws to be opened,
- the procedure without a special tool.
WARNING
Before the operation, protect the electrical accesso-
ries to prevent any risk of shor t circuiting and pro- 1 - Filling procedure with the tool (Mot. 1700)
tect the belts to avoid damaging them. a Fill the cooling system with engine coolant recom-
mended by the manufacturer (see Vehicle: Parts
I - DRAINING mables - Products) using the tool (Mot. 1700) (see
Cooling circuit Filling) (Technical Note 3857A,
19A, Cooling).
a Remove:
- the expansion bottle cap,
a Position the coolant draining tray under the vehi-

cle.
19A-7
COOLING
2 - Filling method without special tools Location of the bleed screws
a
K9K
WARNING
It is essential to open all of the bleed screws to
remove as much as air as possible in the cooling
system. Failure to perform this procedure may
prevent the cooling system from filling properly
and may damage the engine.
133915
133916
a Open the bleed screws (1) .
19A-8
COOLING
K7J or K7M D4F
133911 132679
a Open the bleed screw (1) .
133912
a Open the bleed screws (1) .
19A-9
COOLING
K4J or K4M D4F
a Maintain the engine speed at 2500 rpm using the

pedal press for 5 minutes.
a Stabilise the engine speed at 2000 rpm until the fan

assembly has been activated twice.
K7J or K7M
a Maintain the engine speed at 2500 rpm using a pe-

dal press, until the fan assembly has been activated
for a third time.
133914
K4J or K4M
a Open the bleed screw (1) . a Maintain the engine speed at 3000 rpm using a pe-
dal press, until the fan assembly has been activated
for a third time.
a Fill the cooling system with engine coolant recom-

mended by the manufacturer (see Vehicle: Parts
mables - Products) (see 19A, Cooling, Engine coo-
K9K
ling circuit: Specifications, page 19A-1) via the
expansion bottle until it overflows. a Maintain the engine speed at 1500 rpm, sharply va-
rying the engine speed (up to the maximum) 2 to 3
a Close all the bleed screws as soon as the coolant
times approximately every 2 minutes until the fan
starts to flow in a continuous stream.
assembly starts for the second time.
a Pressurise the system using the (Ms. 554-07) to
check that there are no leaks (see 19A, Cooling,
Engine cooling circuit: check, page 19A-2) .
a Clean any surfaces soiled by the coolant. a Check that the heating is operating correctly.
a Allow the engine to cool until the coolant temperatu-

IV - BLEEDING re is less than 50˚C.
a a Make sure the coolant fluid level is at the
« Maximum » mark.
WARNING
Do not open the bleed screw whilst the engine is a Refit the expansion bottle cap.
running; this would damage the engine.
a Deactivate the air conditioning system so that the V - FINAL OPERATION

engine cooling fan is not operating from the start of
the operation. a Remove the coolant draining tray.
a Start the engine. a Refit the engine undertray.
19A-10
COOLING
Cooling radiator: Removal - Refitting 19A
D4F
Essential equipment
WARNING
refrigerant charging station When carrying out a repair that requires a complete
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
Tightening torquesm drive out the water, fill and bleed the circuit and
then measure the effective protection.
bolt securing the bracket 8 N.m
The criteria to be met are:
of the connecting pipe
betwe e n the - protection down to -25˚C ± 2 for cold and tempe-
« condenser - dehydra- rate countries,
tor reservoir » on the
- protection down to -40˚C ± 2 for "extreme cold"
dehydrator reservoir
countries.
betwe e n the
WARNING
« compressor -
condenser » on the con- To prevent moisture from entering the system,
denser place plugs on the cold loop components which are
open to the air.
betwe e n the REMOVAL
« expansion valve -
dehydrator reservoir »
on the dehydrator reser-
voir a Position the vehicle on a two-post lift (see Vehicle:
a Remove:
IMPORTANT
When working in the engine compartment, take - the engine undertray bolts,
care as the radiator fan(s) may start up unexpecte- - the engine undertray.
a Drain:
is hot: - the cooling system (see 19A, Cooling, Cooling
- do not open the bleed screw(s). (62A, Air conditioning).
WARNING
a Remove:
rounding components. - the front bumper (see Front bumper: Removal -
- the audible warning (see Horn: Removal - Refit-
ting) (82B, Horn),
- the bonnet catch (see Bonnet latch: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
19A-11
COOLING
D4F
- the engine cooling fan assembly (see 19A, Coo-
ling, Engine cooling fan assembly: Removal -
133630
a Remove the bolt (3) securing the bracket of the con-
necting pipe between the « expansion valve - dehy-
133629 drator reservoir » on the dehydrator reservoir.
a Remove:
a Uncouple the « expansion valve - dehydrator
- the bolt (1) from the bracket of the « expansion val- reservoir » connecting pipe from the dehydrator re-
ve - condenser » connecting pipe, servoir.
- the bolt (2) from the « compressor - condenser » a Insert the blanking plugs.
connecting pipe bracket on the condenser.
a Uncouple the « compressor - condenser » connec-
ting pipe from the condenser.
133005
a Disconnect the connector (4) from the air conditio-
ning circuit pressure sensor.
19A-12
COOLING
D4F
II - OPERATION FOR REMOVAL OF PART a Always replace the clip of the cooling radiator top
CONCERNED cooling hose.
WARNING
cle.
WARNING
WARNING
To avoid any leaks, check that the pipe surface is
face must be clean and scratch free.
132989
a Remove the clip (5) from the top cooling hose of the When replacing the « cooling radiator -
cooling radiator. condenser » assembly:
a Disconnect the top cooling hose from the cooling ra- a Refit the dehydrator reservoir on the « cooling radia-
diator. tor - condenser » assembly.

a Remove the « cooling radiator - condenser » as-
sembly. a Lubricate the new seal with air conditioning oil (see
Air conditioning: Parts and consumables for the
repair work) (62A, Air conditioning) to facilitate fit-
When replacing the « cooling radiator -
ting.
condenser » assembly:
a Fit the new seal on the « condenser - dehydrator
a Remove the bolt securing the bracket of the connec- reservoir » connecting pipe.
ting pipe between the « condenser - dehydrator
reservoir » on the dehydrator reservoir. a Connect the « condenser - dehydrator reservoir »
connecting pipe to the dehydrator reservoir.
a Uncouple the « condenser - dehydrator reservoir »
connecting pipe from the dehydrator reservoir. a Torque tighten the bolt securing the bracket of the
connecting pipe between the « condenser - de-
a Insert the blanking plugs. hydrator reservoir » on the dehydrator reservoir
(8 N.m).
a Remove the dehydrator reservoir from the « cooling
radiator - condenser » assembly.
CONCERNED
REFITTING a Refit the « cooling radiator - condenser » assembly.
a Connect the top cooling hose on the cooling radia-

I - REFITTING PREPARATION OPERATION tor.
a parts always to be replaced: refrigerant pipe seal a Refit a new clip on the cooling radiator top cooling
(30,02,02,52). hose.
19A-13
COOLING
D4F
III - FINAL OPERATION - fill the refrigerant circuit (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).
a Connect the connector of the air conditioning circuit
pressure sensor.
a Lubricate the new seals using air conditioning oil
(see Air conditioning: Parts and consumables
for the repair work) (62A, Air conditioning) to make
fitting easier.
a Fit new seals on:
- the « compressor - condenser » connecting pipe
on the condenser,
- the « expansion valve - dehydrator reservoir » con-
necting pipe on the dehydrator reservoir.
a Connect:
on the condenser,
- the bolt securing the bracket of the connecting
pipe between the « compressor - condenser »
on the condenser (8 N.m),
pipe between the « expansion valve - dehydra-
tor reservoir » on the dehydrator reservoir (8
N.m).
a Refit:
nisms),
ting) (82B, Horn),
,
19A-14
COOLING
K4J or K4M
IMPORTANT
When working in the engine compartment, take ling, Engine cooling fan assembly: Removal -
care as the radiator fan(s) may start up unexpecte- Refitting, page 19A-61) .
To avoid any risk of serious burns when the engine ling circuit: Draining - Refilling, page 19A-7) .
is hot:
WARNING
WARNING
When carrying out a repair that requires a complete
drive out the water, fill and bleed the circuit and
The criteria to be met are: 133509
- protection down to -25˚C ± 2 for cold and tempe-

rate countries,
countries.
REMOVAL

Parts and ingredients for the repairwork) (02A,
Lifting equipment).

a Remove:

Refitting) (55A, Exterior protection), 133510
a Remove the bolts (1) from the condenser on the
ting) (82B, Horn), cooling radiator.

nisms),
19A-15
COOLING
K4J or K4M
II - OPERATION FOR REMOVAL OF PART - the bonnet catch (see Bonnet latch: Removal -
CONCERNED Refitting) (52A, Non-side opening element mecha-
nisms),
ting) (82B, Horn),
19A-7) .
133495
a Remove the clip (2) from the cooling radiator top

cooling hose.
a Disconnect the top cooling hose from the cooling ra-

diator.
a Remove the cooling radiator.
REFITTING

a Always replace the top cooling hose clip.

CONCERNED
a Refit the cooling radiator.
a Connect the top cooling hose to the cooling radiator.
a Refit a new clip on the top cooling hose.
a Refit:
- the condenser bolts on the cooling radiator.
19A-16
COOLING
K7J or K7M
Essential equipment
WARNING
refrigerant charging station When carrying out a repair that requires a complete
Tightening torquesm drive out the water, fill and bleed the circuit and
betwe e n the - protection down to -25˚C ± 2 for cold and tempe-
« condenser - dehydra- rate countries,
tor reservoir » on the
dehydrator reservoir
countries.
betwe e n the
WARNING
« compressor -
condenser » on the con- To prevent moisture from entering the system,
denser place plugs on the cold loop components which are
open to the air.
betwe e n the REMOVAL
« expansion valve -
dehydrator reservoir »
on the dehydrator reser-
voir a Position the vehicle on a two-post lift (see Vehicle:
a Remove:
IMPORTANT
When working in the engine compartment, take - the engine undertray bolts,
care as the radiator fan(s) may start up unexpecte- - the engine undertray.
a Drain:
is hot: - the cooling system (see 19A, Cooling, Cooling
- do not open the bleed screw(s). (62A, Air conditioning).
WARNING
a Remove:
rounding components. - the front bumper (see Front bumper: Removal -
ting) (82B, Horn),
nisms),
19A-17
COOLING
K7J or K7M
133630
a Remove the bolt (3) from the « expansion valve - de-
hydrator reservoir » connecting pipe bracket on the
133538 dehydrator reservoir.
a Remove:
a Disconnect the « expansion valve - dehydrator
- the bolt (1 ) from the « expansion valve - reservoir » connecting pipe from the dehydrator re-
condenser » connecting pipe bracket, servoir.
- the bolt (2) from the « compressor - condenser » a Insert the blanking plugs.
connecting pipe bracket on the condenser.
a Disconnect the « compressor - condenser » connec-
ting pipe from the condenser.
132835
a Disconnect the connector (4) from the air conditio-
ning circuit pressure sensor.
19A-18
COOLING
K7J or K7M
II - OPERATION FOR REMOVAL OF PART a Always replace the clip of the cooling radiator top
CONCERNED hose.
WARNING
cle.
WARNING
WARNING
To avoid any leaks, check that the pipe surface is
face must be clean and scratch free.
132838
When replacing the « cooling radiator -
a Remove the clip (5) from the cooling radiator top condenser » assembly:
cooling hose. a Refit the dehydrator reservoir on the « cooling radia-
tor - condenser » assembly.
a Disconnect the top cooling hose from the cooling ra-
diator. a Remove the blanking plugs.
a Lubricate the new seal with air conditioning oil (see
a Remove the « cooling radiator - condenser » as- Air conditioning: Parts and consumables for the
sembly. repair work) (62A, Air conditioning) to facilitate fit-
ting.
When replacing the « cooling radiator - a Fit the new seal on the « condenser - dehydrator
condenser » assembly: reservoir » connecting pipe.
a Connect the « condenser - dehydrator reservoir »
a Remove the bolt securing the « condenser - dehy-
connecting pipe on the dehydrator reservoir.
drator reservoir » connecting pipe bracket on the de-
hydrator reservoir. a Torque tighten the bolt securing the bracket of the
connecting pipe between the « condenser - de-
a Disconnect the « condenser - dehydrator reservoir » hydrator reservoir » on the dehydrator reservoir
connecting pipe from the dehydrator reservoir. (8 N.m).

CONCERNED
a Remove the dehydrator reservoir from the « cooling
radiator - condenser » assembly. a Refit the « cooling radiator - condenser » assembly.
a Connect the top cooling hose to the cooling radiator.
REFITTING a Refit a new clip on the top cooling hose of the coo-
ling radiator.
I - REFITTING PREPARATION OPERATION III - FINAL OPERATION

a parts always to be replaced: refrigerant pipe seal a Connect the connector of the air conditioning circuit
(30,02,02,52). pressure sensor.
19A-19
COOLING
K7J or K7M
a Lubricate the new seals using air conditioning oil
(see Air conditioning: Parts and consumables
for the repair work) (62A, Air conditioning) to make
fitting easier.
a Fit new seals on:
on the condenser,
a Connect:
on the condenser,
pipe between the « compressor - condenser »
on the condenser (8 N.m),
pipe between the « expansion valve - dehydra-
tor reservoir » on the dehydrator reservoir (8
N.m).
a Refit:
- the bolt on the « expansion valve - condenser »
connecting pipe bracket,
nisms),
ting) (82B, Horn),
,
- fill the refrigerant circuit (see Coolant circuit Drai-
ning - Refilling) (62A, Air conditioning).
19A-20
COOLING
K9K, and BASIC HEATING
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera- - the audible warning (see Horn: Removal - Refit-
tion. ting) (82B, Horn),

IMPORTANT nisms),
care as the radiator fan(s) may start up unexpecte- - the front end panel (see Front: Removal - Refit-
dly (risk of being cut). ting) (42A, Upper front structure),
is hot: - the engine cooling fan assembly (see 19A, Coo-

WARNING ling circuit: Draining - Refilling, page 19A-7) .
CONCERNED
WARNING
rate countries,
countries.
REMOVAL

a Disconnect the battery (see Battery : Removal - a Remove the cooling radiator top cooling hose clip (1)
Refitting) (80A, Battery). from the cooling radiator.
a Remove: a Disconnect the cooling radiator top cooling hose

- the engine undertray bolts, from the cooling radiator.
- the engine undertray, a Remove the cooling radiator.
19A-21
COOLING
K9K, and BASIC HEATING
REFITTING

a Always replace the cooling radiator top cooling hose
clip.

CONCERNED
a Connect the cooling radiator top hose to the cooling
radiator.
a Refit a new cooling radiator top hose clip on the coo-
ling radiator.

a Refit:
nisms),
ting) (82B, Horn),
- bleed the cooling system (see 19A, Cooling, Coo-
19A-22
COOLING
K9K, and AIR CONDITIONING
a Remove:
Essential equipment - the engine undertray bolts,
safety strap(s) - the engine undertray,

IMPORTANT - the audible warning (see Horn: Removal - Refit-
Wear leaktight gloves (Nitrile type) for this operating) (82B, Horn),
tion. - the bonnet catch (see Bonnet latch: Removal -
nisms),
IMPORTANT - the front end panel (see Front: Removal - Refit-

care as the radiator fan(s) may start up unexpecte- - the engine cooling fan assembly (see 19A, Coo-
dly (risk of being cut). ling, Engine cooling fan assembly: Removal -
is hot: a Drain the cooling system (see 19A, Cooling, Coo-
a Attach the condenser to the front impact cross mem-
ber using the safety strap(s).
WARNING
WARNING
rate countries,
countries.
REMOVAL


19A-23
COOLING
CONCERNED
133509
133495
a Remove the cooling radiator top hose clip (2) from

the cooling radiator.
a Disconnect the cooling radiator top hose from the

cooling radiator.
a Remove the cooling radiator.
REFITTING
a Always replace the cooling radiator top hose clip.

CONCERNED
133510
a Remove the condenser bolts (1) from the cooling ra- a Connect the cooling radiator top hose to the cooling
diator. radiator.
a Refit a new cooling radiator top hose clip on the coo-

ling radiator.
a Remove the safety strap(s) from the condenser.
a Refit:
19A-24
COOLING
nisms),
ting) (82B, Horn),
19A-25
COOLING
Water pump: Removal - Refitting 19A
K9K
Tightening torquesm page 11A-1) ,
coolant pump bolts 10 N.m - the crankshaft accessories pulley (see 11A, Top
alternator bolts 25 N.m pulley: Removal - Refitting, page 11A-15) ,
IMPORTANT
tion.
REMOVAL

a Remove:
- the engine cover,
Washing), 102267
Removal - Refitting) (56A, Exterior equipment), a Remove the alternator upper bolt (2) .
- the front right-hand wheel (see Wheel: Removal - a Tilt the alternator forward.
terior protection),
a Remove:
19D-16) ,
19A-26
COOLING
K9K
REFITTING

a
IMPORTANT
tion.
WARNING
a risk of leaks.

- the coolant pump sealing face if it is to be reused,
102266 - the cylinder block sealing face.
a Remove:
a The coolant pump seal must always be replaced.
- the inner timing cover bolts (3) ,
- the inner timing cover.

CONCERNED
102262
a Remove:
- the coolant pump bolts (4) ,
- the coolant pump,
- the coolant pump seal.
19A-27
COOLING
K9K
II - OPERATION FOR REFITTING PART - the right-hand suspended engine mounting (see
CONCERNED 19D, Engine mounting, Right-hand suspended
19D-16) ,
terior protection),
Washing),
- the engine cover.
102262
a Refit: circuit: Draining - Refilling, page 19A-7) ,
- a new coolant pump seal, - bleed the cooling system (see 19A, Cooling, Coo-
- the coolant pump,
- bolts (4) and (5) of the coolant pump.

a Apply one or two drops of FRENETANCHE (see
rwork) (04B, Consumables - Products) to the coo-
lant pump bolt (3) .
a Refit the bolts (3) , (1) and (2) of the coolant pump.
a Tighten to torque and in order the coolant pump

bolts (10 N.m).

a Refit the inner timing cover.
a Fit the alternator in place.

a Refit:

page 11A-1) ,
19A-28
COOLING
K7J or K7M
CONCERNED
Tightening torquesm
bolts 1 to 7 of the coo- 10 N.m

lant pump
bolt 8 of the coolant 25 N.m

pump
WARNING
IMPORTANT
REMOVAL 109240
a Remove:
- the coolant pump bolts,
Towing and lifting) (02A, Lifting equipment). - the coolant pump,
a Drain the cooling system (see 19A, Cooling, Coo- - the coolant pump seal.
a Remove: REFITTING
(80A, Battery), I - REFITTING PREPARATION OPERATION
- the engine undertray bolts, a parts always to be replaced: coolant pump seal
(10,06,01,21).
- the front right-hand wheel (see Wheel: Removal - WARNING

- the front right-hand wheel arch liner (see Front any damage caused to the joint face will result in
wheel arch liner: Removal - Refitting) (55A, Ex- a risk of leaks.
terior protection),
- the engine tie-bar (see 19D, Engine mounting, IMPORTANT

19D-26) , Wear leaktight gloves (Nitrile type) for this opera-
tion.
page 11A-1) , IMPORTANT
- the timing belt (see 11A, Top and front of engine, Wear goggles with side protectors for this opera-
Timing belt: Removal - Refitting, page 11A-28) . tion.
19A-29
COOLING
K7J or K7M
WARNING
ger marks).

CONCERNED
a
WARNING
To check the sealing of the parts supplied with a
seal, fit the seal without sealing resin.
103288
a
a Fit the new coolant pump seal.
WARNING
damage the coolant pump.
Note:
To secure the coolant pump, do not push on the
pinion, use the bolts instead.
Note:
Apply one or two drops of FRENETANCHE (see
rwork) (04B, Consumables - Products) to coo-
lant pump bolts 1 and 8.
a Refit the coolant pump.
a Fit the coolant pump bolts without tightening them.
- bolts 1 to 7 of the coolant pump (10 N.m),
- bolt 8 of the coolant pump (25 N.m).
a Refit:

19A-30
COOLING
K7J or K7M
page 11A-1) ,
19D-26) ,
terior protection),
(80A, Battery).
19A-7) .
19A-31
COOLING
D4F
CONCERNED
Tightening torquesm
coolant pump bolts 10 Nm
IMPORTANT
tion.
REMOVAL


a Remove: 120516
a Remove the water pump bolts.


terior protection),

page 11A-1) ,

- the timing belt (see 11A, Top and front of engine, 120515
a Move the water pump 5 mm away from its bearing
a Drain the cooling system (see 19A, Cooling, Coo- face.
a Pivot the water pump casing in the direction of the
a Clean the cooling system (see 19A, Cooling, Coo- arrows, (1) and then (2) .
a Remove:
a Remove the coolant pump inlet pipe (see 19A, Coo- - the coolant pump,
ling, Water pump inlet pipe: Removal - Refitting,
page 19A-55) . - the coolant pump seal.
19A-32
COOLING
D4F
If replacing the coolant pump: REFITTING

a
IMPORTANT
tion.
WARNING
a risk of leaks.

- the cylinder block sealing face.
132831
a parts always to be replaced: coolant pump seal
a Remove:
(10,06,01,21)
- the coolant pump pipe bolts (3) ,
- the coolant pump pipe. If replacing the coolant pump:
mables - Products) to clean and degrease the coo-
lant pump pipe sealing face.
a Always replace the seal of the coolant pump pipe.
a Refit:
- a new seal on the coolant pump pipe,
- the coolant pump pipe on the coolant pump.
132822
a Remove the seal (4) from the coolant pump pipe.
19A-33
COOLING
D4F
II - OPERATION FOR REFITTING PART III - FINAL OPERATION
CONCERNED
a Refit the coolant pump inlet pipe (see 19A, Cooling,
Water pump inlet pipe: Removal - Refitting, page
19A-55) .
a Fill the cooling system (see 19A, Cooling, Cooling
a Refit:
page 11A-1) ,
120516 terior protection),
a - the front right-hand wheel (see Wheel: Removal -
WARNING
To ensure proper sealing, the gasket surfaces a Connect the battery (see Battery: Removal - Refit-
must be clean, dry and not greasy (avoid any fin- ting) (80A, Battery).
ger marks). a Perform the following operations:
- top up the level in the power-assisted steering fluid
reservoir,
WARNING
To check the sealing of the parts supplied with a - drain the power-assisted steering circuit (see
seal, fit the seal without sealing resin. Power-assisted steering circuit: Bleeding)
a Refit a new coolant pump seal.
a Check that there are no power-assisted steering
fluid leaks.
WARNING a Refit the engine undertray.
damage the coolant pump.
Note:
To secure the coolant pump, do not push on the
pinion, use the bolts instead.
a Refit the coolant pump.

a Tighten to torque and in order the coolant pump
bolts (10 Nm).
19A-34
COOLING
K4J or K4M
REMOVAL
Mot. 1390 Support for removing/refitting I - REMOVAL PREPARATION OPERATION

bly. a Position the vehicle on a two-post lift (see Vehicle:
Tightening torquesm Refitting) (80A, Battery).
a Remove:
bolt 1 of the coolant 27 N.m
pump - the engine undertray bolts,
bolts 2 to 8 of the coo- 10 N.m
lant pump a Drain the cooling system (see 19A, Cooling, Coo-
ling circuit: Draining - Refilling, page 19A-7)
a Remove:
IMPORTANT Refitting) (55A, Exterior protection),
When working in the engine compartment, take - the right-hand headlight (see Front headlight: Re-
care as the radiator fan(s) may start up unexpecte- moval - Refitting) (80B, Headlights),
To avoid any risk of serious burns when the engine Refitting) (35A, Wheels and tyres),
is hot:
- do not open the expansion bottle cap, wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
page 19D-26) .
WARNING
WARNING
rate countries,
countries.
19A-35
COOLING
K4J or K4M
CONCERNED
101793
14505
manifold. a Remove:
a Position the (Mot. 1390) under the engine. - the coolant pump bolts,
a Remove: - the coolant pump.

19D, Engine mounting, Right-hand suspended REFITTING
19D-16) ,
engine, Accessories belt: Removal - Refitting, a
page 11A-1) ,
IMPORTANT
- the crankshaft accessories pulley (see 11A, Top Wear goggles with side protectors for this opera-
and front of engine, Crankshaft accessories tion.
Timing belt: Removal - Refitting, page 11A-28) . IMPORTANT
tion.
WARNING
a risk of leaks.
WARNING
ger marks).
19A-36
COOLING
K4J or K4M
a Use SUPER CLEANING AGENT FOR JOINT FA- II - REFITTING OPERATION FOR PART
CES (see Vehicle: Parts and ingredients for the CONCERNED
clean:
14505
Note:
To fit the coolant pump on the two pins of the
cylinder block, never use the coolant pump pinion
for support. Instead, use the coolant pump bolts
by pretightening them.
10063 Note:
a Apply one to two drops of FRENETANCHE (see
WARNING rwork) (04B, Consumables - Products) to the
Applying excess sealant could cause it to be coolant pump bolts (1) and (4) .
ture of sealant and fluid could damage certain a Refit the coolant pump.
a Apply a bead (2) of RESIN ADHESIVE (see Vehi-
cle: Parts and ingredients for the repairwork) - bolt 1 of the coolant pump (27 N.m),
(04B, Consumables - Products) with a width of 0.6 to
- bolts 2 to 8 of the coolant pump (10 N.m).
1 mm.
a Refit:


19A-37
COOLING
K4J or K4M
page 11A-1) ,
19D-16) .
a Position the catalyst converter on the exhaust mani-
fold.
a Refit:
page 19D-26) ,
terior protection),
19A-7) .
19A-38
COOLING
Thermostat: Removal - Refitting 19A
D4F
The thermostat is integrated with the water chamber.
For removal of the thermostat (see 19A, Cooling, Ple-
num chamber: Removal - Refitting, page 19A-45) .
19A-39
COOLING
K4J or K4M
clips.
Mot. 1202-02 Pliers for small hose clips.
IMPORTANT
is hot:
132769
REMOVAL a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) remove:
I - REMOVAL PREPARATION OPERATION - the cooling radiator top hose clip (1) ,
a Position the vehicle on a two-post lift (see Vehicle: - the clip (2) from the expansion bottle hose.
a Disconnect from the thermostat cover:
a Remove:
- the cooling radiator top hose,
nator: Removal - Refitting, page 12A-12) , - the expansion bottle hose.

19A-40
COOLING
K4J or K4M
REFITTING

mables - Products) to clean and degrease the ther-
mostat housing.
a The thermostat seal must be replaced.

CONCERNED
a Refit:
- a new seal on the thermostat,
- the thermostat,
- the thermostat cover.
a Connect the following to the thermostat cover:
132768 - the expansion bottle hose,
a Remove:
- the thermostat cover bolts (3) , a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
- the thermostat cover. 1202-02) fit:
- the expansion bottle hose clip,
- the cooling radiator top hose clip.

19A-7) .
a Refit:
123733
a Remove:
- the thermostat (4) ,
- the thermostat seal (5) .
19A-41
COOLING
K7J or K7M

clips.
Tightening torquesm
water chamber bolts 10 N.m
IMPORTANT
is hot:
- do not drain the cooling system, 133720
- do not open the bleed screw(s). a Unclip the water chamber cooling hose from the
power-assisted steering pump hose at (1) .
WARNING - the expansion bottle top hose clip (2) on the water
Prepare for the flow of fluid, and protect the sur- chamber,
rounding components. - the cooling radiator hose clip (3) on the water
chamber.
WARNING - the expansion bottle top hose,
change, it is essential to flush the circuit with clean - the cooling radiator hose.
rate countries,
countries.
REMOVAL

a Disconnect the air inlet sleeve from the side mem-
ber.
19A-42
COOLING
K7J or K7M
CONCERNED CONCERNED
a Refit:
- the thermostat,
- the water chamber with a new seal.
a Torque tighten the water chamber bolts (10 N.m).

a Connect to the water chamber:
- the expansion bottle top hose,
- the cooling radiator hose.
- the expansion bottle top hose clip on the water
chamber,
- the cooling radiator hose clip on the water cham-
ber.
a Clip the water chamber cooling hose to the power-
assisted steering pump hose.
133170
a Connect the air inlet sleeve to the side member.
a Remove:
- the water chamber bolts (4) , ling, Cooling circuit: Draining - Refilling, page
19A-7) .
- the water chamber,
- the thermostat.
REFITTING
a parts always to be replaced: Cylinder head coo-

lant outlet unit seal (10,06,01,19).

mables - Products) to clean and degrease.
WARNING
a risk of leaks.
WARNING
ger marks).
19A-43
COOLING
K9K
The thermostat is integrated with the water chamber.
For removal of the thermostat (see 19A, Cooling, Ple-
num chamber: Removal - Refitting, page 19A-45) .
19A-44
COOLING
Plenum chamber: Removal - Refitting 19A
D4F
Essential special tooling ling circuit: Draining - Refilling, page 19A-7) .
Mot. 1448 Long nose pliers for hose a Remove the air filter unit (see 12A, Fuel mixture,
clips. Air filter unit: Removal - Refitting, page 12A-5) .
Tightening torquesm
IMPORTANT
is hot:
132679
1202-02) remove:
- the cooling radiator top hose clip (1) from the water
WARNING chamber,
- the heater matrix hose clip (2) from the water
chamber.
drive out the water, fill and bleed the circuit and a Disconnect from the water chamber:
rate countries,
countries.
WARNING
ries to prevent any risk of shor t circuiting and pro-
tect the belts to avoid damaging them.
REMOVAL

19A-45
COOLING
D4F
CONCERNED
113372
a Torque tighten in order the water chamber bolts
113372 (10 N.m).
a Remove:
- the water chamber bolts,
- the water chamber, - the heater matrix hose,
- the water chamber seal. - the cooling radiator top hose.

1202-02) fit:
REFITTING
- the heater matrix hose clip on the water chamber,
- the cooling radiator top hose clip on the water
chamber.
a Always replace the water chamber seal. a Refit the air filter unit (see 12A, Fuel mixture, Air fil-
and ingredients for the repairwork) (04B, Consu- a Perform the following operations:
mables - Products) to clean and degrease: - fill the cooling system (see 19A, Cooling, Cooling
- the water chamber seal housing if it is to be reused. ling circuit: Draining - Refilling, page 19A-7) .
WARNING

CONCERNED
a Refit the water chamber with a new seal.
19A-46
COOLING
K4J or K4M
a Drain the coolant circuit (see 19A, Cooling, Coo-
Essential special tooling ling circuit: Draining - Refilling, page 19A-7) .
Mot. 1448 Long nose pliers for hose a Remove the air resonator (see 12A, Fuel mixture,
clips. Air resonator: Removal - Refitting, page 12A-12) .
Tightening torquesm
IMPORTANT
is hot:
132767
a Unclip:
- the power-assisted steering pipe (1) ,
WARNING - the coolant hose (2) .

rate countries,
countries.
WARNING
REMOVAL

19A-47
COOLING
K4J or K4M
CONCERNED
132769
132764 1202-02) remove:
- the expansion bottle hose clip (5) ,
tor (3) .
132770
a Using the tool (Mot. 1448) or (Mot. 1202-01) or
(Mot. 1202-02), separate the clip (4) from the heater
matrix hose.
a Disconnect the heater matrix hose from the water
chamber. 132771
a Remove:
- the water chamber bolts,
19A-48
COOLING
K4J or K4M
- the water chamber seal. a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) fit:
REFITTING - the expansion bottle hose clip,

- the cooling radiator top hose clip,
I - REFITTING PREPARATION OPERATION - the heater matrix hose clip.
a Use SURFACE CLEANER (see Vehicle: Parts a Connect the coolant temperature sensor connector.
mables - Products) to clean and degrease: III - FINAL OPERATION
- the cylinder head joint face, a Clip:
- the water chamber housing if it is being reused. - the coolant hose,
WARNING a Refit the air resonator (see 12A, Fuel mixture, Air
To ensure proper sealing, the gasket surfaces resonator: Removal - Refitting, page 12A-12) .
must be clean, dry and not greasy (avoid any fin- a Fill and bleed the cooling system (see 19A, Coo-
ger marks). ling, Cooling circuit: Draining - Refilling, page
19A-7) .
a Always replace the water chamber seal.

CONCERNED
a Refit the water chamber with a new seal.
132771

(12 N.m).

19A-49
COOLING
K7J or K7M

clips.
IMPORTANT
is hot:
WARNING 133720
When carrying out a repair that requires a complete a Unclip the water chamber cooling hose from the
change, it is essential to flush the circuit with clean power-assisted steering pump hose at (1) .
water, blast compressed air through the circuit to a Remove using the (Mot. 1448) :
then measure the effective protection. - the heater matrix hose clip (2) on the water cham-
ber,
- the expansion bottle top hose clip (3) on the water
- protection down to -25˚C ± 2 for cold and tempe- chamber,
rate countries,
- the cooling radiator hose clip (4) on the water
- protection down to -40˚C ± 2 for "extreme cold" chamber.
countries.
- the heater matrix hose,
WARNING - the expansion bottle top hose,
Before the operation, protect the electrical accesso- - the cooling radiator hose.
REMOVAL

a Disconnect the air inlet sleeve from the side mem-
ber.
19A-50
COOLING
K7J or K7M
II - OPERATION FOR REMOVAL OF PART a Use SURFACE CLEANER (see Vehicle: Parts
CONCERNED and ingredients for the repairwork) (04B, Consu-
- the water chamber seal surface.
WARNING
ger marks).
a Apply RESIN ADHESIVE (see Vehicle: Parts and

ingredients for the repairwork) (04B, Consuma-
bles - Products) using a stipple roller on the joint
face of the water chamber until the joint face is com-
pletely coated.
WARNING
133707 ture of sealant and fluid could damage certain
a Remove: components (engine, radiator, etc.).
- the water chamber bolts (5) , a Using a cloth, remove the RESIN ADHESIVE found
- the water chamber. on the water chamber and on the cylinder head.
REFITTING II - REFITTING OPERATION FOR PART

CONCERNED
I - REFITTING PREPARATION OPERATION a Refit the water chamber.

CES (see Vehicle: Parts and ingredients for the III - FINAL OPERATION
clean:
- the water chamber seal surface.
- the cooling radiator hose.
WARNING a Using the (Mot. 1448), fit:
Do not scrape the joint faces of the aluminium, - the heater matrix hose clip on the water chamber,
a risk of leaks. - the expansion bottle top hose clip on the water
chamber,
- the cooling radiator hose clip on the water cham-
ber.
a Clip the water chamber cooling hose to the power-
assisted steering pump hose.
a Connect the air inlet sleeve to the side member.
19A-7) .
19A-51
COOLING
K9K
a Remove:
clips. - the engine undertray.
Mot. 1202-01 Pliers for large hose clips. a Drain the cooling system (see 19A, Cooling, Coo-
Tightening torquesm
water chamber bolts 11 N.m K9K, and 740
a Remove:
IMPORTANT
When working in the engine compartment, take (80A, Battery),
dly (risk of being cut). - the battery tray (see Battery tray: Removal - Re-
is hot:
a Remove the coolant temperature sensor (see 19A,
- do not open the bleed screw(s). Cooling, Coolant temperature sensor: Removal -
WARNING K9K, and 700

rate countries,
countries.
WARNING
REMOVAL
20792
I - REMOVAL PREPARATION OPERATION a Unclip the air filter unit air inlet pipe from the air filter
unit by pressing on the pins (1) .
Towing and lifting) (02A, Lifting equipment). a Move aside the air inlet pipe from the air filter unit.
19A-52
COOLING
K9K
- the clip (7) from the expansion bottle hose.

- the thermoplonger unit hose,
- the expansion bottle top hose.

CONCERNED
20796
a Separate the following from the water chamber

using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) :
- the cooling radiator top hose clip (2) ,
- the thermoplunger unit hose clip (3) ,
- the clip (4) from the expansion bottle hose.
K9K, and 740
121872
a Remove:
- the water chamber bolts (8) ,
- the water chamber seal from the water chamber.
REFITTING

a Always replace the water chamber seal.
135077
a Separate the following from the water chamber
using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) :
- the cooling radiator top hose clip (5) ,
- the thermoplunger unit hose clip (6) ,
19A-53
COOLING
K9K
a Use SURFACE CLEANER (see Vehicle: Parts - the cooling radiator top hose.
1202-02) fit:
- the cylinder head joint face, - the expansion bottle hose clip on the water cham-
- the coolant outlet unit gasket housing if needed to ber,
be reused. - the thermoplunger unit hose clip on the water
chamber,
WARNING - the cooling radiator top hose clip on the water
To ensure proper sealing, the gasket surfaces chamber.
must be clean, dry and not greasy (avoid any fin- a Fit the air filter unit air inlet pipe.
ger marks).
a Clip the air filter unit air inlet pipe onto the air filter
unit.
WARNING a Refit the coolant temperature sensor (see 19A,
Do not scrape the joint faces of the aluminium, Cooling, Coolant temperature sensor: Removal -
any damage caused to the joint face will result in Refitting, page 19A-74) .
a risk of leaks.
K9K, and 740
II - REFITTING OPERATION FOR PART a Refit:
CONCERNED
a Refit the water chamber fitted with a new water fitting) (80A, Battery),
chamber seal. - the battery (see Battery : Removal - Refitting)
(80A, Battery).

121872

(11 N.m).

- the thermoplonger unit hose,
19A-54
COOLING
Water pump inlet pipe: Removal - Refitting 19A
D4F
clips.
Tightening torquesm
coolant pump inlet pipe 12 N.m

bolt on the air conditio-
ning compressor moun-
ting
REMOVAL
I - OPERATION FOR REMOVAL OF PART

CONCERNED
fitting) (80A, Battery). 132818
a Remove: a Separate the clip (1) on the cooling hose of the coo-
lant pump inlet pipe using the tool (Mot. 1448).
- the engine undertray, a Disconnect the cooling hose (2) from the coolant
pump inlet pipe.
- the dipstick.
132826
a Remove:
- the bolt (3) from the coolant pump inlet pipe on the
air conditioning compressor mounting,
- the coolant pump inlet pipe.
19A-55
COOLING
D4F
REFITTING

a Always replace the coolant pump inlet pipe seal.
- the housing of the seal in the coolant pump inlet pi-
pe,
- the coolant pump inlet pipe seal housing if it is
being reused.

CONCERNED
a Refit the coolant pump inlet pipe fitted with a new
seal.
a Torque tighten the coolant pump inlet pipe bolt on
the air conditioning compressor mounting (12
N.m).
a Connect the cooling hose to the coolant pump inlet
pipe.
a Fit the cooling hose clip to the coolant pump inlet
pipe using the tool (Mot. 1448).

19A-7) .
a Refit:
- the dipstick,
19A-56
COOLING
K7J or K7M
clips.
REMOVAL

a Remove:
a Remove:
133150
- the heat shield nuts,
- the heat shield.
- the heater matrix hose clip (1) ,
- the cooling radiator outlet hose clip (2) .
a Disconnect:
- the cooling radiator outlet hose.
a Remove:
- the coolant pump inlet pipe bolt,
- the coolant pump inlet pipe.
REFITTING
a parts always to be replaced: seal between coo-

lant pump inlet pipe and coolant pump inlet
union (10,06,01,23).

- the seal housing in the cylinder block,
- the housing of the seal on the coolant pump inlet

pipe if it is to be reused.
19A-57
COOLING
K7J or K7M
CONCERNED
seal.
a Connect:
- the cooling radiator outlet hose.
- the heater matrix hose clip,
- the cooling radiator outlet hose clip.

a Refit the heat shield.
19A-7) .
19A-58
COOLING
K4J or K4M
clips.
Tightening torquesm
coolant pump inlet pipe 22 N.m

bolt
REMOVAL

Refitting) (80A, Battery). a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
a Remove: 1202-02) remove:
- the cooling radiator bottom hose clip (3) ,
- the heater matrix hose clip (4) .
a Disconnect the following from the coolant pump inlet
a Drain the cooling system (see 19A, Cooling, Coo- pipe:
- the cooling radiator bottom hose,
133057
a Remove:
- the bolt (1) of the power-assisted steering pipe clip,
19A-59
COOLING
K4J or K4M
II - OPERATION FOR REMOVAL OF PART a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot.
CONCERNED 1202-02) fit:
- the heater matrix hose clip,
- the cooling radiator bottom hose clip.
a Refit:
19A-7) .
14492
a Remove:
- the bolt (5) from the coolant pump inlet pipe,
- the water pump inlet pipe.
REFITTING

- the seal housing in the cylinder block,
- the housing of the seal on the coolant pump inlet
pipe if it is to be reused.
a Always replace the coolant pump inlet pipe seal.

CONCERNED
seal.
a Torque tighten the coolant pump inlet pipe bolt
(22 N.m).

a Connect the following to the coolant pump inlet pipe:
- the cooling radiator bottom hose.
19A-60
COOLING
Engine cooling fan assembly: Removal - Refitting 19A
D4F

CONCERNED

a Remove:
ting) (82B, Horn),
nisms),
ting) (42A, Upper front structure). 132996
133005
a Disconnect:
- the engine cooling fan assembly connector (1) ,
(2) .
a Move aside the engine cooling fan assembly wiring.
19A-61
COOLING
D4F
133530
a Unclip the engine cooling fan assembly at (3) .
a Remove the engine cooling fan assembly.
REFITTING

CONCERNED
a Refit the engine cooling fan assembly.
a Clip the engine cooling fan assembly in place.
a Fit the engine cooling fan assembly wiring.
a Connect:

tor,
- the engine cooling fan assembly connector.
a Refit:


nisms),

ting) (82B, Horn),


19A-62
COOLING
K4J or K4M

CONCERNED

a Remove:
ting) (82B, Horn),
nisms),
133497
133057
a Remove:
- the power-assisted steering pipe bolt (1) , 133496
- the bolts (2) from the injector rail protector, a Disconnect:
- the injector rail protector. - the engine cooling fan assembly connector (1) ,
(2) .
19A-63
COOLING
K4J or K4M
132773
a Unclip the engine cooling fan assembly at (3) .

REFITTING

CONCERNED

a Connect:
tor,
a Refit:
- the power-assisted steering pipe bolt,
nisms),
ting) (82B, Horn),
19A-64
COOLING
K7J or K7M
REMOVAL


a Remove:
- the front bumper (see Front bumper: Removal - a Unclip the engine cooling fan assembly at (3) .
Refitting) (55A, Exterior protection), a Remove the engine cooling fan assembly.

ting) (82B, Horn), REFITTING
Refitting) (52A, Non-side opening element mecha- I - REFITTING OPERATION FOR PART
nisms), CONCERNED
- the front end panel (see Front: Removal - Refit- a Refit the engine cooling fan assembly.

CONCERNED a Connect:

tor,
a Refit:


nisms),
133529
a Disconnect: ting) (82B, Horn),

- the engine cooling fan assembly connector (1) ,
- the engine cooling fan assembly resistor connector - the engine undertray.
(2) .
a Move aside the engine cooling fan assembly wiring. ting) (80A, Battery).
19A-65
COOLING
K9K
REMOVAL


a Remove:


ting) (82B, Horn),
- the bonnet catch (see Bonnet latch: Removal - 133496

Refitting) (52A, Non-side opening element mecha- a Disconnect the engine cooling fan assembly resistor
nisms), connector (2) .
- the front end panel (see Front: Removal - Refit- a Unclip the engine cooling fan assembly wiring from
ting) (42A, Upper front structure). the engine cooling fan assembly.

CONCERNED
K9K, and 700
133497

nector (1) .
19A-66
COOLING
K9K
K9K, and 740
134653
a Unclip the engine cooling fan assembly by:

134565
- pulling on the tabs (A) of the engine cooling fan as-
sembly,
nector (3) .
a Unclip the engine cooling fan assembly wiring from - pulling the engine cooling fan assembly towards
the engine cooling fan assembly. (B) .

REFITTING

CONCERNED
a Clip the engine cooling fan assembly to the cooling

radiator.
K9K, and 700
a Connect the engine cooling fan assembly resistor

connector.
a Connect the engine cooling fan assembly connector.
a Clip the engine cooling fan assembly wiring onto the

engine cooling fan assembly.
19A-67
COOLING
K9K
a Refit:
nisms),
ting) (82B, Horn),
19A-68
COOLING
Thermoplunger unit: Removal - Refitting 19A
K9K
IMPORTANT
tion.
REMOVAL

a Remove:
134825
- the engine cover,
a Disconnect:
- the battery (see Battery : Removal - Refitting) - the connector (2) from every thermoplunger,
(80A, Battery),
- the tachometer connector (3) .

Refitting, page 13B-17) .
134827
a Unclip the thermoplunger wiring at (4) .
a Move the thermoplunger wiring to one side.
a Remove:
134826 - the thermoplunger unit support bolt (5) ,
a Unclip the cooling hose from the heater matrix at (1) - the air filter unit (see 12A, Fuel mixture, Air filter
. unit: Removal - Refitting, page 12A-5) ,
19A-69
COOLING
K9K

CONCERNED
134824
a Fit the tool (Ms. 583) to every thermoplunger unit

cooling hose at (7) .
a Separate every thermoplunger unit cooling hose clip
(8) from the thermoplunger unit.
a Disconnect the thermoplunger unit cooling hoses
from the thermoplunger unit.
a Remove the thermoplunger unit.
134823
a Remove
REFITTING
- the thermoplunger unit bolts (6) ,
- the thermoplunger unit mounting. CONCERNED
a Refit the thermoplunger unit.
a Connect the thermoplunger unit cooling hoses to the
thermoplunger unit.
a Fit the clip to every thermoplunger unit cooling hose
on the thermoplunger unit.
a Remove the tool (Ms. 583) from every thermoplun-
ger unit cooling hose.
a Refit:
- the thermoplunger unit mounting,
- the thermoplunger unit bolts.
a Refit:
19A-70
COOLING
K9K
- the thermoplunger unit support bolt.
a Position the thermoplunger wiring.
a Clip on the thermoplunger wiring.
a Connect:
- the tachometer connector,
- the connector of each thermoplunger.
a Clip on the heater matrix cooling hose.
a Refit:
(80A, Battery).
- top up of the coolant level,
a Refit:
- the engine cover.
19A-71
COOLING
Expansion bottle: Removal - Refitting 19A
REMOVAL
Ms. 583 Hose clamp pliers. I - REMOVAL PREPARATION OPERATION

clips.
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.
Take care when carrying out a repair under the bon-
net, as the radiator fan(s) may start to operate
without warning.
Do not open the bleed screw(s) with the engine run-
ning.
132479
a Fit the tool (Ms. 583) on:
WARNING - the expansion bottle top hose (1) ,
The coolant helps to keep the engine running pro- - the expansion bottle bottom hose (2) .
perly (heat exchange).
The system does not operate using pure water.
WARNING
cap, replace the valve.
WARNING
19A-72
COOLING
Expansion bottle: Removal - Refitting 19A
II - OPERATION FOR REMOVAL OF PART - the expansion bottle.
CONCERNED
REFITTING

CONCERNED
a Refit the expansion bottle.
a Connect:
- the expansion bottle bottom hose,
- the expansion bottle top hose.
1202-02) fit:
- the expansion bottle bottom hose clip,
- the expansion bottle top hose clip.
a Remove the tool (Ms. 583) from:
132479 - the expansion bottle top hose,
a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot. - the expansion bottle bottom hose.
1202-02) remove:
a Top up the coolant level in the expansion bottle.
- the clip (3) from the expansion bottle top hose,
- the clip (4) from the expansion bottle bottom hose.
a Disconnect:
- the expansion bottle bottom hose.
132479
a Remove:
- the expansion bottle bolts (5) ,
19A-73
COOLING
Coolant temperature sensor: Removal - Refitting 19A
D4F
CONCERNED
Tightening torquesm
coolant temperature 23 Nm
sensor
IMPORTANT
without warning.
ning.
WARNING 133628
tor (1) .
a Remove:
- the coolant temperature sensor (2) ,
WARNING - the coolant temperature sensor seal.
The coolant helps to keep the engine running pro-
REFITTING

REMOVAL a Always replace the coolant temperature sensor seal.
I - REMOVAL PREPARATION OPERATION II - REFITTING OPERATION FOR PART

a Remove the air filter unit (see 12A, Fuel mixture, CONCERNED
Air filter unit: Removal - Refitting, page 12A-5) . a Refit the coolant temperature sensor fitted with a
new seal.
a Torque tighten the coolant temperature sensor
(23 Nm).
a Connect the coolant temperature sensor connector.

19A-74
COOLING
D4F
19A-75
COOLING
K4J or K4M
Tightening torquesm
coolant temperature 30 N.m

sensor
IMPORTANT
without warning.
ning.
132767
WARNING a Unclip:
Before the operation, protect the electrical accesso- - the power-assisted steering pipe (1) ,
- the cooling hose (2) .
a Remove:
- the power-assisted steering pipe,
WARNING - the cooling hose.
REMOVAL

19A-76
COOLING
K4J or K4M
II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION
CONCERNED
a Clip:
- the cooling hose,
132764

tor (3) .
a Remove the coolant temperature sensor.
REFITTING
Note:
Apply 1 to 2 drops of FRENETANCHE (see
rwork) (04B, Consumables - Products) to the
coolant temperature sensor thread (only if the
sensor is to be reused).

mables - Products) to clean and degrease the ma-
ting face of the coolant temperature sensor on the
water chamber.

CONCERNED
a Refit the coolant temperature sensor.

(30 N.m).
19A-77
COOLING
K7J or K7M
REMOVAL
Tightening torquesm
coolant temperature 22 N.m
CONCERNED
sensor
IMPORTANT
is hot:
WARNING
133169
a Remove:
WARNING
The coolant helps to keep the engine running pro- - the coolant temperature sensor connector (1) ,
- the coolant temperature sensor.
REFITTING
a Degrease the cylinder head joint face using SURFA-

CE CLEANER (see Vehicle: Parts and ingre-
Products).
WARNING
a risk of leaks.
WARNING
ger marks).
19A-78
COOLING
K7J or K7M
CONCERNED
a Refit:
- the coolant temperature sensor,
- the coolant temperature sensor connector.
(22 N.m).

- top up the cooling system,
19A-79
COOLING
K9K
IMPORTANT
without warning.
ning.
WARNING
135078
a Unclip the cooling hoses from the heater matrix at

WARNING (1) .
K9K, and 700

REMOVAL

a Remove:
K9K, and 740

a Remove:
(80A, Battery),
134258
a Disconnect the brake servo vacuum pipe union (2)

from the vacuum pump.
19A-80
COOLING
K9K
a Move the brake servo vacuum pipe away from the REFITTING
vacuum pump.

CONCERNED a Always replace the coolant temperature sensor seal.
- the mating face of the coolant temperature sensor
if it is to be reused,
- the water chamber housing.

CONCERNED
a Refit:
- a new coolant temperature sensor seal on the coo-
lant temperature sensor,
- the coolant temperature sensor,
- the coolant temperature sensor clip.
121867 III - FINAL OPERATION

tor (3) .
K9K, and 700
a Fit the brake servo vacuum pipe.
a Connect the brake servo vacuum pipe union to the
vacuum pump.
K9K, and 740

a Clip on the heater matrix cooling hoses.
a Refit:
(80A, Battery).
135076
a Remove:
- the clip (4) from the coolant temperature sensor,
- the coolant temperature sensor, ling circuit: Draining - Refilling, page 19A-7) .
- the coolant temperature sensor seal. a Refit the engine undertray.
19A-81
EXHAUST
Exhaust: Parts and consumables for the repair work 19B
D4F
(1) Silencer
(ZC) Area to be cut
133917
19B-1
EXHAUST
K4J K4M
(1) Silencer
(2) Expansion chamber
(ZC) Area to be cut
133918
19B-2
EXHAUST
K7J
(1) Silencer
(2) Expansion chamber
(ZC) Area to be cut
133919
19B-3
EXHAUST
K9K
(1) Silencer
(ZC) Area to be cut
133920
19B-4
EXHAUST
Exhaust: Precautions for repair 19B
I - PARTS AND CONSUMABLES FOR THE REPAIR III - SPECIAL NOTES ON THE SINGLE UNIT
EXHAUST PIPE
1 - Parts always to be replaced:

1 - Cutting the single unit exhaust pipe
- the exhaust trunking (if fitted)
The exhaust pipe is a « single unit type » .
- the seal or sealing ring on the connection between the To replace different parts of the exhaust system it must
catalytic converter or catalytic pre-converter and the be cut.
rest of the exhaust system
To do this be sure to carry out these precautions in the
- the exhaust clip(s) (if fitted) following order:
- correctly identify the area to be cut, as explained be-
2 - Consumables (see Part number in Technical low,
Note 5068, 04B, Consumables - Products): - use the cutting tool correctly,
- exhaust mastic - position the exhaust trunking correctly.
- surface cleaner
2 - Identifying the area of the exhaust system to be
- abrasive pads cut
Two marks made on the exhaust system define the
II - ADVICE TO OBSERVE area to be cut (see 19B, Exhaust, Exhaust: Parts and
consumables for the repair work, page 19B-1) (see
MR for vehicle concerned, 19B, Exhaust).
IMPORTANT
Do not park and run the engine in a place where Example of cutting area
combustible substances and materials such as
grass or leaves can come into contact with the hot
exhaust system.
IMPORTANT
Catalytic converters contain ceramic fibres; these
are contained within a closed unit, and cannot dis-
perse. Cutting or drilling catalytic converters is pro-
hibited.
1 - During removal and refitting, the catalytic converter

or catalytic pre-converter must not receive any knocks
or impacts as this could damage it. 99226
2 - The whole exhaust pipe is made of stainless steel.
3 - After working on the bracket between the catalytic

converter or catalytic pre-converter and the rest of the
exhaust system, ensure that the connection is perfectly
sealed.
To do this:
- clean the pressure faces of the connection using the

ABRASIVE PADS,
- degrease the pressure faces of the connection using

SURFACE CLEANER and clean cloths,
- always replace the seal or sealing ring on the connec-

tion.
19B-5
EXHAUST
102118
Fit the (1) on the exhaust pipe.
Tighten the two bolts on the tool until they touch the
pipe in order to clamp the tool onto the pipe.
Turn the cutting tool using the handle and pressing it
100649 against the pipe (as indicated in the diagram above).
Before cutting the exhaust system, draw a line (D)
Tighten the two bolts on the tool whilst cutting, until the
between the two marks (P1) and (P2) .
pipe is completely cut.
The distance between the two marks on the exhaust
pipe is (X1) : 90 mm.
Note:
3 - Operate tool Mot. 1199-01 Do not over-tighten the tool onto the pipe to avoid
deforming it.
Once the pipe is cut, file and deburr the end of the pipe
to be used on the vehicle again.
4 - Positioning the exhaust trunking
Note:
Do not reuse an old exhaust trunking.
14747
19B-6
EXHAUST
Exhaust trunking with 1 bolt
Note:
If necessary, use a workshop jack to lift and hold
the heavy and bulky components of the exhaust
system.
Position the second exhaust pipe onto the lugs inside

the exhaust trunking.
95478
Exhaust trunking with 2 bolts
99227
Check that the two cut marks (3) are aligned (if applica-
ble).
Position the trunking so that there is no risk of contact

between its bolt or bolts and the heat shields.
Tighten to torque:
- the exhaust trunking nut with 1 bolt (25 Nm) (if fit-
ted),
- the exhaust trunking nuts with 2 bolts (21 Nm) (if

fitted).
119681
Check the following and deal with if necessary:
Fit the exhaust trunking onto the part of the exhaust
system fitted to the vehicle. - no underbody contact between the exhaust system
and the heat shields,
Position the pipe onto the lugs (2) inside the exhaust
trunking. - all of the heat shields are present and secure.
Tighten the exhaust trunking bolt(s) slightly (depending
on the version).
Note:
Position the second part of the exhaust system under
the vehicle, fitting it in the exhaust trunking. All damaged heat shields must be replaced.
Start the engine.
Check that there are no leaks: deal with any leaks.
19B-7
EXHAUST
Note:
If there is a leak from THE EXHAUST TRUNKING
WITH 1 BOLT, apply EXHAUST MASTIC to the tru-
nking (see Products recommended for repair)
(Technical Note 5068, 04B, Consumables - Pro-
ducts).
If the application of exhaust mastic does not fix the
leak:
- remove and replace the used exhaust trunking,
- check the condition of the exhaust pipes (condition
of the pipe surface, deburring of the area cut,
damage to the pipes).
- fit the new trunking in accordance with the instruc-
tions given before.
19B-8
EXHAUST
Catalytic converter: Removal - Refitting 19B
D4F
IMPORTANT
repair (see 19B, Exhaust, Exhaust: Precautions
for repair, page 19B-5) .
IMPORTANT
Wear heat protective gloves during the operation.
IMPORTANT
Catalytic converters contain ceramic fibres, these
are contained within a closed unit, and cannot dis-
perse. Drilling or cutting catalytic converters is pro-
hibited.
132697
a Disconnect the oxygen sensor connector (1) .
WARNING
To prevent the surrounding components from ove- CONCERNED
heat shield.
REMOVAL

a Remove:
132673
a Remove the catalytic converter clip (2) .
19B-9
EXHAUST
D4F
REFITTING
a When replacing the catalytic converter, refit the oxy-

gen sensor (see 17B, Petrol injection, Oxygen
sensors: Removal - Refitting, page 17B-12) .
a Use ABRASIVE PADS to clean the catalytic conver-

ter bearing faces on the exhaust manifold (see Vehi-
a Next, degrease these bearing faces using SURFA-

CE CLEANER and clean cloths (see Vehicle: Parts
mables - Products).
132695
a Remove the bolts (3) from the catalytic converter

heat shield.
109399

20).
parts always to be replaced: Catalytic converter

clip (10,08,02,17).

CONCERNED
a Refit:
132669 - the exhaust bracket sealing ring,
a Remove:
- the catalytic converter.
- the catalytic converter heat shield (4) ,
a Tighten the exhaust bracket nuts.
- the nuts (5) from the exhaust flange,
a Refit:
- the catalytic converter,
- the catalytic converter heat shield,
- the exhaust flange sealing ring.
- the catalytic converter clip.
a When replacing the catalytic converter, remove the
oxygen sensor (see 17B, Petrol injection, Oxygen a Tighten the clip bolt while guiding the exhaust pipe
sensors: Removal - Refitting, page 17B-12) . to ensure correct alignment.
19B-10
EXHAUST
D4F
a Check:
- that all the exhaust pipe heat shields are in place
and properly attached.
- that there is no contact with the underbody,
- that there are no leaks.

a Connect the oxygen sensor connector.
19B-11
EXHAUST
K4J or K4M
Tightening torquesm
IMPORTANT
IMPORTANT
132686
a Unclip the downstream oxygen sensor connector (1)
IMPORTANT
.
are contained within a closed unit, and cannot dis- a Disconnect the downstream oxygen sensor connec-
perse. Drilling or cutting catalytic converters is pro- tor.
hibited.
WARNING
heat shield.
REMOVAL


Refitting) (80A, Battery). a Unclip the downstream oxygen sensor wiring (2) .
a Remove:

19B-12
EXHAUST
K4J or K4M
CONCERNED
132897
101793
132896
a Remove:
- the catalytic converter heat shield clips (3) ,
132690
- the catalytic converter heat shield bolts (4) ,
a Remove:
- the catalytic converter heat shield.
- the clip (6) between the expansion chamber and
the catalytic converter,
19B-13
EXHAUST
K4J or K4M
If replacing the catalytic converter a Make sure that there is no contact with the underbo-
dy.
a Remove the downstream oxygen sensor (see 17B,
Petrol injection, Oxygen sensors: Removal - Re-
REFITTING

a Use ABRASIVE PADS to clean the bearing faces of
the catalytic converter.
mables - Products) to degrease the bearing faces of
the catalytic converter.
a Always replace:
- the clip between the expansion chamber and the
catalytic converter.
If replacing the catalytic converter

a Remove the downstream oxygen sensor (see 17B,
Petrol injection, Oxygen sensors: Removal - Re-

CONCERNED
a Refit:
- a new exhaust flange seal,
- the catalytic converter.
a Refit a new clip between the expansion chamber
and the catalytic converter.

a Refit the catalytic converter heat shield.
a Clip on the downstream oxygen sensor wiring.
a Refit:
19B-14
EXHAUST
K9K
Tightening torquesm
turbocharger studs 9 N.m Refitting) (35A, Wheels and tyres),
catalytic converter nuts 28 N.m
on the turbocharger - the engine undertray.

tream strut bolt on the
cylinder block
catalytic c o nverter 21 N.m

downstream strut bolts
on the gearbox

downstream strut nut on
the gearbox

tream strut bolts on the
catalytic converter

downstream strut bolt
on the catalytic conver-
ter
132608
IMPORTANT a Remove:
Wear protective gloves during the operation. - the lower engine tie-bar tie rod bolts (1) ,
- the lower engine tie-bar bolt (2) ,
IMPORTANT
IMPORTANT
To avoid any risk of damaging the systems, apply
tion recommendations before carrying out the
repair (see Exhaust: Precautions for repair)(19B,
Exhaust).
REMOVAL
a Remove:
- the engine cover,
19B-15
EXHAUST
K9K
CONCERNED
114992
a Remove the bolts from the exhaust flange (3) fitted
with their springs. 123816
a Remove the catalytic converter downstream strut
bolt (4) from the catalytic converter.
a Undo the following on the gearbox:
- the bolt (5) of the catalytic converter downstream
strut,
- the catalytic converter downstream strut nut (6) .
a Remove the catalytic converter downstream strut by
sliding it upwards.
19B-16
EXHAUST
K9K
REFITTING
109399
a Always replace:
112328
a Undo the catalytic converter upstream strut bolt (7) . - the exhaust flange ring,
a Remove: - the catalytic converter seal.
- the catalytic converter upstream strut bolts (8) , a Use SURFACE CLEANER (see Vehicle: Parts
- the catalytic converter upstream strut, mables - Products) to clean and degrease:
- the catalytic converter nuts (9) .
- the turbocharger joint face,
- the turbocharger joint face if it is to be reused.
Note:
When removing the catalytic converter, take care
not to damage the oil return pipe of the turbo- WARNING
charger and the power-assisted steering pipes To ensure proper sealing, the joint faces must be
on the steering box. clean, dry and not greasy (avoid any finger
marks).
a Remove:
a Refit:
- the catalytic converter seal. - a new catalytic converter seal on the turbocharger,
- a new exhaust flange ring on the catalytic conver-

ter.
a If replacing the turbocharger studs, torque tighten
the turbocharger studs (9 N.m).

CONCERNED
Note:
When refitting the catalytic converter, take care
not to damage the oil return pipe of the turbo-
charger and the power-assisted steering pipes
on the steering box.
19B-17
EXHAUST
K9K
a Refit the catalytic converter. - the engine undertray,
Note: Refitting) (35A, Wheels and tyres),
Check that there is no contact between the cata- - the air filter unit (see 12A, Fuel mixture, Air filter
lytic conver ter and the turbocharger oil return unit: Removal - Refitting, page 12A-5) ,
pipe during the entire catalytic converter tighte- - the engine cover.
ning operation.
a Refit the catalytic converter upstream strut. ting) (80A, Battery).
- the catalytic converter upstream strut bolt on the
cylinder block,
- the upstream strut bolt on the sump.
a Refit the catalytic converter downstream strut.
- the catalytic converter downstream strut bolt on the
gearbox,
- the catalytic converter downstream strut nut on the
gearbox,
- the catalytic converter upstream strut bolts on the
catalytic converter,
- the catalytic converter downstream strut bolt on the
catalytic converter,
- the catalytic converter nuts on the turbocharger.
- the catalytic converter nuts on the turbocharger
(28 N.m),
- the catalytic converter upstream strut bolt on
the cylinder block (50 N.m),
- the catalytic converter downstream strut bolts
on the gearbox (21 N.m),
- the catalytic converter downstream strut nut on
the gearbox (21 N.m),
- the catalytic converter upstream strut bolts on
the catalytic converter (26 N.m),
- the catalytic converter downstream strut bolt
on the catalytic converter (21 N.m).
a Tighten the catalytic converter upstream strut bolt on
the sump.

a Refit:
- the exhaust bracket bolts fitted with their springs,
19B-18
EXHAUST
K7J

IMPORTANT
IMPORTANT
132842
IMPORTANT
a Remove:
are contained within a closed unit, and cannot dis- - the nuts (1) from the exhaust manifold heat shield,
perse. Drilling or cutting catalytic converters is pro-
- the exhaust manifold heat shield,
hibited.
WARNING
heat shield.
WARNING
gen sensors.
REMOVAL

19B-19
EXHAUST
K7J
CONCERNED
133018
a Unclip the upstream oxygen sensor connector from

its mounting. 133031
a Disconnect the upstream oxygen sensor connector a Remove:

(2) .
- the mountings (4) of the catalytic converter exhaust
a Remove upstream oxygen sensor using the (Mot. flange on the expansion chamber,
1495-01).
- the seal between the catalytic converter and the
expansion chamber.
133027

from its mounting. 133136
a Disconnect the downstream oxygen sensor connec- a Remove the nuts (5) from the catalytic converter ex-
tor (3) . haust flange on the exhaust manifold.
19B-20
EXHAUST
K7J
133020 133164
a Remove:
- the catalytic converter heat shield bolts (6) ,
- the seal between the catalytic converter and the

exhaust manifold.
a When replacing the catalytic converter, remove the

downstream oxygen sensor (see 17B, Petrol injec-
tion, Oxygen sensors: Removal - Refitting, page
17B-12) .
REFITTING

133035
a When replacing the catalytic converter, refit the
downstream oxygen sensor (see 17B, Petrol injec-
tion, Oxygen sensors: Removal - Refitting, page
17B-12) .
a Use ABRASIVE PADS to clean the bearing faces of

the catalytic converter on the exhaust manifold and
on the expansion chamber (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products).
a Next, degrease these bearing faces using SURFA-

CE CLEANER and clean cloths (see Vehicle: Parts
mables - Products).
19B-21
EXHAUST
K7J
a Refit:
- the exhaust manifold heat shield.
a Check:
109399
20).
a Always replace the seal between the catalytic con-
verter and the expansion chamber.

CONCERNED
a Refit:
- a new seal between the catalytic converter and the
exhaust manifold,
- a new seal between the catalytic converter and the
expansion chamber,
- the catalytic converter heat shield bolts,
- the nuts of the exhaust flange of the catalytic con-
verter on the exhaust manifold,
- the catalytic converter exhaust flange mountings
on the expansion chamber.

a Refit the upstream oxygen sensor using the (Mot.
1495-01).
a Connect:
- the downstream oxygen sensor connector.
a Clip:
- the upstream oxygen sensor connector on its
mounting,
- the downstream oxygen sensor connector on its
mounting.
19B-22
EXHAUST
Expansion chamber: Removal - Refitting 19B
K4J or K4M
IMPORTANT
IMPORTANT
WARNING
heat shield.
Any damaged heat shields must be replaced. 132690
a Remove the clip (1) between the expansion cham-
ber and the catalytic converter.
REMOVAL


CONCERNED
a Cut the exhaust pipe (see 19B, Exhaust, Exhaust:
Precautions for repair, page 19B-5) in the desi-
gnated area to be cut (see 19B, Exhaust, Exhaust:
Parts and consumables for the repair work, page
19B-1) .
132895
a Remove:
- the expansion chamber bolt (2) ,
- the expansion chamber.
19B-23
EXHAUST
K4J or K4M
REFITTING

a Always replace the clip between the expansion
chamber and the catalytic converter.

CONCERNED
a Refit:
- the expansion chamber,
- a new clip between the expansion chamber and the
catalytic converter.
a Fit a new sleeve between the expansion chamber
and the silencer (see 19B, Exhaust, Exhaust: Pre-
cautions for repair, page 19B-5) .
IMPORTANT
Position the « nut and bolt securing the sleeve »
assembly so that the assembly cannot come into
contact with the underbody.
a Tighten the sleeve while supporting the exhaust pipe

to ensure they are aligned.

a Check:
19B-24
EXHAUST
K7J
Essential equipment
component jack
IMPORTANT
IMPORTANT
IMPORTANT 133031
Wear heat protective gloves during the operation. a Remove the nuts (1) from the exhaust flange.
a Remove the exhaust flange.
REMOVAL

a Remove:

CONCERNED
Precautions for repair, page 19B-5) at the desi-
gnated area to be cut (see Vehicle: Parts and in-
gredients for the repairwork) (04B, Consumables
- Products).
133032
Note:
a Remove:
Place a component jack under the expansion
chamber. - the exhaust flange seal on the catalytic converter,
- the bolt (2) from the expansion chamber on the ex-
haust rubber mounting bush,
- the expansion chamber.
19B-25
EXHAUST
K7J
REFITTING

a Always replace the seal between the catalytic con-
verter and the expansion chamber.
WARNING

mables - Products) to clean the bearing faces of the
catalytic converter and the expansion chamber.

CONCERNED
a Refit:
- a new exhaust flange seal on the catalytic conver-
ter,
- the expansion chamber,
- the expansion chamber bolt on the exhaust rubber
mounting bush.
a Position the exhaust flange.
a Refit the exhaust flange nuts.
a Fit a new sleeve between the expansion chamber
IMPORTANT


a Check:
19B-26
EXHAUST
Connector pipe: Removal - Refitting 19B
IMPORTANT
IMPORTANT
WARNING
heat shield.
a Remove the clip (1) from the catalytic converter.

REMOVAL


CONCERNED
Precautions for repair, page 19B-5) in the desi-
19B-1) .
132510
a Remove:
- the mounting bolt (2) from the connector pipe rub-

ber mounting bush,
- the connector pipe.
REFITTING
a Always replace the catalytic converter clip.
19B-27
EXHAUST
Connector pipe: Removal - Refitting 19B
CONCERNED
a Refit:
- the connector pipe,
- a new catalytic converter clip.
a Fit a new sleeve between the catalytic converter clip
IMPORTANT


a Check:
19B-28
EXHAUST
Silencer: Removal - Refitting 19B
IMPORTANT
IMPORTANT
WARNING
heat shield.
a Remove:
REMOVAL - the mounting bolts (1) from the rubber mounting
bush of the silencer,
I - REMOVAL PREPARATION OPERATION - the silencer.
REFITTING
CONCERNED I - REFITTING OPERATION FOR PART
CONCERNED
Precautions for repair, page 19B-5) in the desi- a Refit the silencer.
a Fit a new sleeve between the catalytic converter clip
19B-1) .
IMPORTANT

a Check:

19B-29
TANK
Fuel tank: Draining 19C

D4F
pressure.
Essential equipment
pneumatic transfer pump for fuels
IMPORTANT

union.
IMPORTANT
tion. 133635
a Disconnect the fuel supply union (1) from the injector
rail.
IMPORTANT a Fit a « T » union (Mot. 1311-08).

tion.
WARNING
WARNING
I - DRAINING PREPARATION OPERATION

19C-1
TANK
K4J or K4M or K7J
134309
a Unclip the fuel supply union at (3) .

133025
a Disconnect the fuel supply union at (4) .
133033
134306
a Remove the bolts (2) from the fuel pipe protector.
a Fit a « T » union (Mot. 1311-08).
a Move aside the fuel pipe protector.
II - TANK DRAINING PROCEDURE

a Connect a pneumatic transfer pump for fuels to
the « T » union output (Mot. 1311-08).
a Drain the fuel tank.
19C-2
TANK
a Disconnect the pneumatic transfer pump for
fuels.
a Remove the « T » union (Mot. 1311-08).
K4J or K4M or K7J

a Position the fuel pipe protector.
a Refit the fuel pipe protector bolts.

19C-3
TANK
K9K
I - OIL SERVICE
IMPORTANT
IMPORTANT

union.
IMPORTANT 134088
Wear leaktight gloves (Nitrile type) for this opera- a Disconnect the fuel supply pipe union (1) from the
tion. fuel filter.
WARNING
IMPORTANT
Wear goggles with side protectors for this opera- rounding components.
tion.
a Fit a plug on the opening of the fuel filter.
99641
a Connect the rubber pneumatic pump vacuum pipe

(2) onto the fuel supply pipe.
a Activate the pneumatic pump.
a Let the fuel flow out until it the flow is intermittent.
II - REFITTING
a Remove the plug from the opening of the fuel filter.
19C-4
TANK
K9K
a Connect the fuel filter fuel supply pipe union to the
fuel filter.
19C-5
TANK
Fuel tank: Removal - Refitting 19C
D4F or K4J or K7J or K9K
REMOVAL
Essential equipment
component jack
Tightening torquesm a Disconnect the battery (see Battery : Removal -
fuel tank bolts 21 N.m
a Drain the fuel tank (see 19C, Tank, Fuel tank: Drai-
silencer rubber moun- 21 N.m ning, page 19C-1) .
ting bush bolts on the
a Raise the rear bench seat.
body
a Open the inspection flap.
expansion chamber rub- 21 N.m
ber mounting bush bolt
on the body D4F or K4J or K7J
IMPORTANT

union.
IMPORTANT
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera- 132513
tion.
a Disconnect:
- the fuel level sensor module connector (1) ,
WARNING - the fuel outlet pipe union (2) from the fuel level sen-
sor module.
must be fitted to the openings of all the fuel circuit a Insert the blanking plugs.
WARNING
19C-6
TANK
K9K
132510
a Remove the rubber mounting bush bolt (6) from the
132514
expansion chamber on the body.
a Disconnect:
- the fuel outlet pipe union (3) from the fuel level sen-
sor module,
- the fuel return pipe union (4) from the fuel level
sensor module,
- the fuel level sensor module connector (5) .
a Remove:
- the rear right-hand wheels (see Wheel: Removal -
- the fuel tank filler neck (see 19C, Tank, Filler
neck: Removal - Refitting, page 19C-11) .
132509
a Remove the rubber mounting bush bolts (7) from the
silencer on the body.
a Position the exhaust pipe resting on the rear axle.
a Remove the heat shield under the fuel tank.
19C-7
TANK
a Remove the parking brake cables at the drum bra-
kes or at the rear disc brake callipers (see Parking
ANTI-LOCK BRAKES brake cables: Removal - Refitting) (37A, Mechani-
cal component controls).

CONCERNED
D4F or K4J or K7J
132501
a Unclip the wheel sensor wiring connectors (8) from

the fuel tank.
132503
a Disconnect the fuel return pipe union (10) .
a Fit a component jack under the fuel tank.
132502
a Remove the brake pipe strut bolts (9) on the rear

axle.
a Remove the brake pipe strut on the rear axle.
19C-8
TANK
a Refit:
- the parking brake cables (see Parking brake ca-
bles: Removal - Refitting) (37A, Mechanical com-
ponent controls),
- the brake pipe strut on the rear axle,
- the heat shield under the fuel tank.
- the silencer rubber mounting bush bolts on the
body (21 N.m),
- the expansion chamber rubber mounting bush
132499 bolt on the body (21 N.m).
ANTI-LOCK BRAKES
a Clip the wheel sensor wiring connectors onto the
fuel tank.
a Refit:
- the fuel tank filler neck (see 19C, Tank, Filler
neck: Removal - Refitting, page 19C-11) ,
- the rear right-hand wheels (see Wheel: Removal -
132500
D4F or K4J or K7J
a Remove:
- the fuel tank bolts (11) ,
a Connect:
- the fuel tank (this operation requires two people).
- the fuel level sensor module connector,
REFITTING - the fuel outlet pipe union of the fuel level sensor
module.

CONCERNED
a Refit the fuel tank (this operation requires two peo-
ple). K9K
a Torque tighten the fuel tank bolts (21 N.m). a Remove the blanking plugs.
a Connect:
a Remove the component jack.
- the fuel outlet pipe union of the fuel level sensor
module,
D4F or K4J or K7J
- the fuel return pipe union of the fuel level sensor
a Remove the blanking plugs. module,
a Connect the fuel return pipe union. - the fuel level sensor module connector.
19C-9
TANK
a Close the inspection flap.
a Refit the rear bench seat.
19C-10
TANK
Filler neck: Removal - Refitting 19C
a Drain the tank (see 19C, Tank, Fuel tank: Draining,
page 19C-1) .
Tightening torquesm
a Remove the rear right-hand wheel (see Wheel: Re-
filler neck earth nut 21 N.m moval - Refitting) (35A, Wheels and tyres).

IMPORTANT CONCERNED

union.
IMPORTANT
tion.
IMPORTANT
tion.
132505
WARNING a Remove:
To avoid any corrosion or damage, protect the - the filler neck plug,
- the filler neck bolts (1) .
WARNING
areas.
WARNING
REMOVAL

a Position the vehicle on the two-post lift (see Vehicle:
Towing and lifting) (02, Lifting equipment).
Refitting) (80A, Battery). a Remove the filler neck earth nut (2) .
19C-11
TANK
Filler neck: Removal - Refitting 19C
REFITTING

a Always replace the clip on the « filler neck - fuel
tank » connecting hose.

CONCERNED
a Fit the filler neck.
a Connect:
- the filler neck hose of the fuel tank,
- the anti-splashback pipe union of the fuel tank filler
neck.
a Refit the new clip on the « filler neck - fuel tank »
connecting hose.
a Clip the filler neck onto the body.
132504 a Tighten the filler neck earth nut (21 N.m).
a Unclip the filler neck from the body at (3) . a Refit the filler neck plug.

a Refit the rear right-hand wheel (see Wheel: Remo-
val - Refitting) (35A, Wheels and tyres).
132507
a Remove the clip (4) from the « filler neck - fuel tank »
connecting hose on the fuel tank side.
a Disconnect:
- the union (5) of the anti-splashback pipe from the

fuel tank filler neck,
- the fuel tank filler neck hose.
a Remove the filler neck.
19C-12
TANK
Fuel level sensor module: Removal - Refitting 19C
D4F or K4J or K4M or K7J or K9K
REMOVAL
Mot. 1397 Universal petrol tank gauge I - REMOVAL PREPARATION OPERATION

nut wrench.
a Drain the fuel tank (see 19C, Tank, Fuel tank: Drai-
IMPORTANT
ning, page 19C-1) .
During this operation, be sure to: a Raise the rear bench seat.
- refrain from smoking or bringing red hot objects a Open the inspection flap.
- be careful of fuel splashes when disconnecting the II - OPERATION FOR REMOVAL OF PART
union. CONCERNED
D4F or K4J or K7J

IMPORTANT
tion.
IMPORTANT
tion.
WARNING
WARNING
Keep the pipe unions away from contaminated 132513
areas.
a Disconnect:
- the fuel level sensor module connector (1) ,
WARNING - the fuel outlet pipe union (2) from the fuel level sen-
sor module.
WARNING
To prevent the tank from deforming, refit the fuel
sender unit nut to the tank well immediately.
19C-13
TANK
K9K
12156
132514
a Disconnect:
- the fuel outlet pipe union (3) from the fuel level sen-
sor module,
- the fuel return pipe union (4) from the fuel level
sensor module,
- the fuel level sensor module connector (5) .

132520
a Remove:
- the nut from the fuel level sensor module using the
tool (Mot. 1397) (6) ,
- the fuel level sensor module, taking care not to da-
mage the float,
- the fuel level sensor module seal.
a Let the fuel drain from the fuel level sensor module.
WARNING
To prevent the tank from deforming, refit the fuel
level sensor module nut to the tank well immedia-
tely.
19C-14
TANK
REFITTING

a Always replace:
- the nut of the fuel level sensor module,
- the fuel level sensor module seal.

CONCERNED
100658
a Tighten the fuel level sensor module nut using the

tool (Mot. 1397) until the nut mark (9) corresponds
with the fuel tank mark (10) .
D4F or K4J or K7J
a Connect:
- the fuel level sensor module connector,
118996
- the fuel outlet pipe union of the fuel level sensor
a Position:
module.
- the new seal (7) in the neck correctly,
- the fuel level sensor module (8) on the fuel tank.
Note:
K9K
A lug on the fuel level sensor module and a
a Connect:
recess in the fuel tank allow a unique positioning
in the fuel tank. - the fuel outlet pipe union of the fuel level sensor
module,
a Use a hand to press the fuel level sensor module to
grip the seal. - the fuel return pipe union of the fuel level sensor
module,
a Refit a new nut on the fuel tank.
- the fuel level sensor module connector.

a Close the inspection flap.
a Refit the rear bench seat.
19C-15
TANK
19C-16
TANK
Additional fuel circuit petrol pump: Removal - Refitting 19C
K4M or K7M, and 674 or 734
CONCERNED
IMPORTANT

union.
IMPORTANT
tion.
IMPORTANT
tion.
141058
a Remove the clip (1) from the fuel pump of the addi-
WARNING tional fuel system.
a Disconnect the additional fuel system pipe from the
additional fuel system fuel pump.
WARNING
Note:
The additional fuel system tank has a capacity of
0.9 litres.
REMOVAL

a Remove the additional fuel system tank (see 19C,
Tank, Additional fuel circuit reservoir: Removal -
Refitting, page 19C-19) . 139109
a Remove the additional fuel system fuel pump fol-
lowing the direction of the arrow (2) .
19C-17
TANK
Additional fuel circuit petrol pump: Removal - Refitting 19C
K4M or K7M, and 674 or 734
REFITTING

a Always replace the additional fuel system pipe clip.

CONCERNED
a Refit the additional fuel system pump.
a Connect the additional fuel system pipe to the addi-
tional fuel system fuel pump.
a Refit the clip on the additional fuel system fuel pump.

a Refit the additional fuel system tank (see 19C, Tank,
Additional fuel circuit reservoir: Removal - Refit-
ting, page 19C-19) .
19C-18
TANK
Additional fuel circuit reservoir: Removal - Refitting 19C
K7M, and 734 – K4M, and 674
Essential equipment
pneumatic transfer pump for fuels
IMPORTANT

union.
IMPORTANT
tion.
139096
a Remove the cap (1) for the additional fuel system
tank.
IMPORTANT
tion.
WARNING
WARNING
99641
a Drain the fuel by siphoning it through the filler neck
of the additional fuel system using the pneumatic
transfer pump for fuels.
Note:
The additional fuel system tank has a capacity of
0.9 litres.
REMOVAL

19C-19
TANK
K7M, and 734 – K4M, and 674
CONCERNED
139090
a Cut the clip (5) .
139095
a Remove the filler neck.
a Remove the bolt (2) .
a Disconnect the pipe connector (3) .
141062
a Remove:
139097 - the clip (6) of the fuel supply solenoid valve,
a Remove: - the pipe of the fuel supply solenoid valve.
- the runoff pipe clip (4) ,
- the runoff pipe,
- the windscreen wiper mechanism (see Winds-

creen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing).
19C-20
TANK
K7M, and 734 – K4M, and 674
REFITTING

a Always replace the clips on the pipes of the additio-
nal fuel system.

CONCERNED
a Refit:
- the additional fuel system tank,
- the additional fuel system tank bolt (8) .
a Connect the connector (7) of the additional fuel sys-
tem fuel pump.
a Refit:
- the pipe of the fuel supply solenoid valve,
- a new clip (6) on the pipe of the fuel supply sole-
139092 noid valve,
a Disconnect the connector (7) from the additional fuel
- the filler neck,
system fuel pump.
- a new clip (5) on the filler neck,
- the windscreen wiper mechanism (see Winds-
creen wiper mechanism: Removal - Refitting)
(85A, Wiping - Washing),
- the runoff pipe,
- a new clip (4) on the runoff pipe.
a Connect the pipe connector (3) .
a Refit the bolt (2) of the filler neck.
a Fill the additional fuel system tank.
a Refit the cap of the additional fuel system tank (1)
139093
a Remove:
- the additional fuel system tank bolt (8) ,
- the additional fuel system tank.
19C-21
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
D4F
a Remove:
Mot. 1453 Multiple-adjusting engine (80A, Battery),
ning straps.
Essential equipment - the windscreen wiper arms (see Windscreen wi-

safety strap(s) Washing),
REMOVAL
a Position the vehicle on a two-post lift (see Vehicle: ting, Lower engine tie-bar: Removal - Refitting,
Towing and lifting) (02A, Lifting equipment). page 19D-26) .
132704
a Fit:
- the (Mot. 1453) (1) ,
- a safety strap(s) (2) on the tool (Mot. 1453).
a Mark the position of the suspended mounting on the

body.
19D-1
ENGINE MOUNTING
D4F
CONCERNED
132984
132983
a Remove the nut (3) from the suspended engine
mounting rubber pad shaft on the gearbox.
a Slightly lower the gearbox.
a Remove:
the gearbox.
132985
a Remove:
- the rubber pad mounting bolts (5) from the suspen-
ded engine mounting on the gearbox,
- the rubber pad mounting from the suspended engi-
ne mounting on the gearbox.
19D-2
ENGINE MOUNTING
D4F
- the (Mot. 1453).
a Refit:
page 19D-26) ,
Washing),
(80A, Battery).
132986
a Remove the engine wiring bracket bolt (6) of the
suspended engine mounting rubber pad shaft on the
gearbox.
a Move aside the engine wiring of the suspended en-
gine mounting rubber pad shaft on the gearbox.
a Remove:
rubber pad shaft on the gearbox,
- the suspended engine mounting rubber pad shaft
from the gearbox.
REFITTING

CONCERNED
a Refit the suspended engine mounting rubber pad
shaft on the gearbox.
a Position the engine wiring on the suspended engine
a Refit:
ne mounting on the gearbox,
the gearbox.
a Remove:
19D-3
ENGINE MOUNTING
Essential special tooling matic transmission computer: Removal - Refit-
mounting support with retai- - the petrol injection computer (see 17B, Petrol in-
ning straps. jection, Petrol injection computer: Removal -
Essential equipment
safety strap(s) fitting) (80A, Battery),

REMOVAL per arm: Removal - Refitting) (85A, Wiping -
Washing),
I - REMOVAL PREPARATION OPERATION - the scuttle panel grille (see Scuttle panel grille:
a Position the vehicle on a two-post lift (see Vehicle: Removal - Refitting) (56A, Exterior equipment),
a Remove:
- the air resonator (see 12A, Fuel mixture, Air reso- - the engine undertray,
- the battery (see Battery : Removal - Refitting) ting, Lower engine tie-bar: Removal - Refitting,
(80A, Battery), page 19D-26) .
132704
a Fit: - a safety strap(s) (2) on the tool (Mot. 1453).
- the (Mot. 1453) (1) , a Mark the position of the suspended mounting on the
body.
19D-4
ENGINE MOUNTING
II - OPERATION FOR REMOVAL OF PART - the rubber pad mounting from the suspended engi-
CONCERNED ne mounting on the gearbox,
- the rubber pad nuts of the gearbox suspended en-
gine mounting on the gearbox suspended engine
mounting support,
- the rubber pad of the suspended engine mounting
on the gearbox from the suspended engine moun-
ting rubber pad support on the gearbox.
from the gearbox.
REFITTING

CONCERNED
a Refit:
133505
on the gearbox,
a Unclip the engine wiring (3) from the suspended en-
- the rubber pad of the suspended engine mounting
gine mounting.
on the gearbox onto the suspended engine moun-
ting rubber pad support on the gearbox,
- the suspended engine mounting support on the
gearbox.
a Raise the gearbox slightly.
a Refit the nut of the suspended engine mounting rub-
ber pad shaft on the gearbox.
a Clip the engine wiring to the suspended engine
mounting.
a Remove:
- the (Mot. 1453).
a Refit:
133484 ting, Lower engine tie-bar: Removal - Refitting,
page 19D-26) ,
mounting rubber pad shaft on the gearbox. - the engine undertray,
a Slightly lower the gearbox. - the scuttle panel grille (see Scuttle panel grille:
a Remove:
- the rubber pad mounting bolts (5) from the suspen- per arm: Removal - Refitting) (85A, Wiping -
ded engine mounting on the gearbox, Washing),
19D-5
ENGINE MOUNTING
(80A, Battery),
19D-6
ENGINE MOUNTING
K7J or K7M
ning straps.
Essential equipment - the windscreen wiper arms (see Windscreen wi-

safety strap(s) per arm: Removal - Refitting) (85A, Wiping -
Washing),
REMOVAL - the scuttle panel grille (see Scuttle panel grille:

I - REMOVAL PREPARATION OPERATION - the engine undertray bolts,

Towing and lifting) (02A, Lifting equipment). - the engine undertray,
a Remove:
- the battery (see Battery : Removal - Refitting) ting, Lower engine tie-bar: Removal - Refitting,
(80A, Battery), page 19D-26) .
132704
a Fit: mounting on the body.

- the (Mot. 1453),
- a safety strap(s) on the tool (Mot. 1453).
a Mark the position of the left-hand suspended engine
19D-7
ENGINE MOUNTING
K7J or K7M
CONCERNED
133534
133710
a Unclip the engine wiring (1) from the left-hand sus-
pended engine mounting.
132985

a Remove:


the gearbox,
- the rubber pad mounting bolts (4) from the suspen-

ded engine mounting on the gearbox,
19D-8
ENGINE MOUNTING
K7J or K7M
- the rubber pad mounting from the suspended engi- a Clip the engine wiring on the left-hand suspended
ne mounting on the gearbox. engine mounting.
a Remove:
- the (Mot. 1453).
a Refit:
page 19D-26) ,
Washing),
132986 fitting) (80A, Battery),
a Remove the engine wiring bracket bolt (5) of the - the petrol injection computer (see 17B, Petrol in-
suspended engine mounting rubber pad shaft on the jection, Petrol injection computer: Removal -
gearbox. Refitting, page 17B-21) ,
a Remove the engine wiring from the suspended engi- - the battery (see Battery : Removal - Refitting)
ne mounting rubber pad shaft on the gearbox. (80A, Battery).
a Remove:

from the gearbox.
REFITTING

CONCERNED
a Refit the suspended engine mounting rubber pad
shaft on the gearbox.
a Fit the engine wiring to the suspended engine moun-

ting rubber pad shaft on the gearbox.
a Refit:
- the engine wiring bracket bolt of the suspended en-

gine mounting rubber pad shaft on the gearbox,
ne mounting on the gearbox,
the gearbox.
19D-9
ENGINE MOUNTING
K9K
Essential special tooling fitting) (80A, Battery),
Mot. 1453 Multiple-adjusting engine - the windscreen wiper arms (see Windscreen wi-
mounting support with retai- per arm: Removal - Refitting) (85A, Wiping -
ning straps. Washing),
Mot. 1453-01 Additional winder nut on - the scuttle panel grille (see Scuttle panel grille:
engine lift support Mot. 1453. Removal - Refitting) (56A, Exterior equipment).
Essential equipment
safety strap(s)
REMOVAL

a Remove:
- the engine cover,
134833
a Remove the power-assisted steering low pressure

pipe bracket bolt (3) from the left-hand suspended
engine mounting support on the body.
a Move aside the power-assisted steering low pressu-

re pipe.

suspended engine mounting support on the body.
132608
a Remove:
- the lower engine tie-bar stud (2) ,
- the lower engine tie-bar, 133127
- the battery (see Battery : Removal - Refitting) a Fit the (Mot. 1453) equipped with (Mot. 1453-01)
(80A, Battery), and a safety strap(s).
19D-10
ENGINE MOUNTING
K9K
CONCERNED
134836
a Unclip the clutch control pipe from the left-hand sus-

134834 pended engine mounting support on the gearbox at
(7) .
a Remove the left-hand suspended engine mounting
shaft nut (5) .
pipe bolt (8) from the left-hand suspended engine
mounting support on the gearbox.
134835
134837
a Remove:
a Remove:
- the bolts (6) from the left-hand suspended engine
- the left-hand suspended engine mounting support
mounting support on the body, bolts (9) on the gearbox,
- the left-hand suspended engine mounting support - the left-hand suspended engine mounting support
on the body. on the gearbox.
19D-11
ENGINE MOUNTING
K9K
REFITTING - the engine undertray,

- the engine cover.
CONCERNED
a Refit:
on the gearbox,
bolts on the gearbox,
on the left-hand suspended engine mounting sup-
port on the gearbox.
a Clip the clutch control pipe onto the left-hand sus-
pended engine mounting support on the gearbox.
a Refit:
on the body,
bolts,
- the left-hand suspended engine mounting shaft
nut.
a Remove:
a Clip the engine wiring onto the left-hand suspended
engine mounting support on the body.
a Position the power-assisted steering low pressure
pipe.
a Refit the power-assisted steering low pressure pipe
bracket bolt onto the left-hand suspended engine
mounting support on the body.
a Refit:
Washing),
(80A, Battery),
19D-12
ENGINE MOUNTING
ning straps.
REMOVAL - the windscreen wiper arms (see Windscreen wi-

Washing),
a Remove: - the engine undertray bolts,
- the battery (see Battery : Removal - Refitting) - the lower engine tie-bar (see 19D, Engine moun-
(see Battery : Removal - Refitting) (80A, Batte- ting, Lower engine tie-bar: Removal - Refitting,
ry), page 19D-26) .
132704
a Fit:
- the (Mot. 1453) (1) ,
- a strap on the tool (Mot. 1453) (2) .
body.
19D-13
ENGINE MOUNTING
CONCERNED
132984
133505
a Unclip the engine wiring (3) from the suspended en-

gine mounting.
132985
a Remove the following from the gearbox:
support on the body,
132983
- the suspended engine mounting support on the bo-
a Remove the nut (4) from the suspended engine dy.
mounting shaft on the gearbox.
a Remove the following from the gearbox:
rubber pad,
- the rubber pad of the suspended engine mounting.
19D-14
ENGINE MOUNTING
REFITTING

CONCERNED
a Refit:
- the suspended engine mounting support on the

gearbox,
- the engine wiring channel of the suspended engine

mounting,
- the suspended engine mounting support on the bo-

dy,
- the rubber pad of the suspended engine mounting.
a Raise the gearbox slightly.
a Refit the nut of the suspended engine mounting rub-

138919
ber pad shaft on the gearbox.
a Remove the bolts (7) of the engine wiring channel on
the suspended engine mounting support of the gear-
box. II - FINAL OPERATION
a Move aside the engine wiring of the suspended en-
a Remove:
gine mounting support on the gearbox.
- the safety strap(s) of the tool (Mot. 1453),
- the (Mot. 1453).
a Refit:

page 19D-26) ,

138916
a Remove the following from the gearbox: Washing),
- the gearbox support bolts (8) ,
- the gearbox support. fitting) (80A, Battery),


(80A, Battery),

19D-15
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
D4F
REMOVAL

ning straps. a Remove:
Essential equipment per arm: Removal - Refitting) (85A, Wiping -
Washing),
safety strap(s)
132701
a Fit:
- the (Mot. 1453) (1) ,
body.
19D-16
ENGINE MOUNTING
D4F
CONCERNED
132659
a Remove:

rubber pad,

cover,
- the suspended engine mounting.
REFITTING

CONCERNED

the position marked during removal.
a Remove:
- the (Mot. 1453).
a Refit:


Washing).
19D-17
ENGINE MOUNTING
K9K
REMOVAL

mounting support with retai- I - REMOVAL PREPARATION OPERATION
ning straps.
Mot. 1453-01 Additional winder nut on Towing and lifting) (02A, Lifting equipment).
a Remove:
Essential equipment
- the engine cover,
safety strap(s)
indelible pencil per arm: Removal - Refitting) (85A, Wiping -
Washing),

132913
a Fit the (Mot. 1453) equipped with (Mot. 1453-01)

a Remove:
19D-18
ENGINE MOUNTING
K9K
CONCERNED
132608
a Remove:
19731
a Mark the position of the right-hand suspended engi-
- the lower engine tie-bar tie rod, ne mounting rubber pad on the body using a indeli-
ble pencil.
a Remove the bolts (3) from the right-hand suspended
engine mounting rubber pad.
a Raise the engine slightly using the tool (Mot. 1453)
fitted with the tool (Mot. 1453-01) until the right-hand
suspended engine mounting rubber pad detaches
from the body.
a Remove:
mounting cover,
- the right-hand suspended engine mounting « cover
- rubber pad » assembly.
REFITTING

CONCERNED
a Refit:
- the right-hand suspended engine mounting « cover
- rubber pad » assembly,
- the bolts of the right-hand suspended engine
mounting cover.
with the tool (Mot. 1453-01) until the right-hand sus-
pended engine mounting rubber pad touches the bo-
dy.
19D-19
ENGINE MOUNTING
K9K
a Position the right-hand suspended engine mounting
rubber pad according to the marks made during re-
moval.
a Refit the bolts of the right-hand suspended engine
mounting rubber pad.
a Refit:
a Remove:
a Refit:
Washing),
- the engine cover.
19D-20
ENGINE MOUNTING
K4J or K4M
REMOVAL

ning straps. a Remove
Essential equipment per arm: Removal - Refitting) (85A, Wiping -
Washing),
safety strap(s)
132701
a Fit:
- the (Mot. 1453),
ne mounting on the body.
19D-21
ENGINE MOUNTING
K4J or K4M
CONCERNED
133058
a Remove:
- the bolt (1) from the rubber pad on the right-hand

suspended engine mounting,

mounting cover,
REFITTING

CONCERNED

the position marked during removal.
a Remove:
- the safety strap(s) from the tool (Mot. 1453).
- the (Mot. 1453),
a Refit:


Washing).
19D-22
ENGINE MOUNTING
K7J or K7M

ning straps.
Essential equipment
safety strap(s)
REMOVAL
133715
a Unclip the wiring from the body at (2) .
a Move aside the wiring.
a Remove:
Washing),
133726
19D-23
ENGINE MOUNTING
K7J or K7M
133727
a Fit:
- the (Mot. 1453),
ne mounting on the body.
19D-24
ENGINE MOUNTING
K7J or K7M
II - OPERATION FOR REMOVAL OF PART II - FINAL OPERATION
CONCERNED
a Remove:
- the (Mot. 1453).
a Refit:
Washing).
a Fit the wiring.
a Clip the wiring onto the body.
solenoid valve.
133528
a Remove the bolts (3) from the suspended engine

mounting rubber pad.
a Slightly raise the engine until the suspended engine

mounting rubber pad detaches from the body using
a Remove:

cover,
REFITTING

CONCERNED
a Fit the right-hand suspended engine mounting.
a Refit the bolts of the suspended engine mounting

cover.
a Lower the engine until the suspended engine moun-

ting rubber pad touches the body.
a Position the suspended engine mounting rubber pad

in the position marked during removal.
a Refit the bolts of the suspended engine mounting ru-

bber pad.
19D-25
ENGINE MOUNTING
Lower engine tie-bar: Removal - Refitting 19D
D4F
REMOVAL II - FINAL OPERATION

a Remove:

CONCERNED
132667
a Remove:
- the bolt (1) of the rear suspended engine mounting
tie rod,
- the rear suspended engine mounting bolt (2) ,
- the rear suspended engine mounting tie rod,
- the stud (3) of the rear suspended engine mounting
on the subframe,
- the rear suspended engine mounting.
REFITTING

CONCERNED
a Refit:
- the rear suspended engine mounting,
- the rear suspended engine mounting tie rod.
19D-26
ENGINE MOUNTING
K9K, and 718 or 740
REMOVAL

a Remove:

CONCERNED
132609
a Remove:
- the bolts (3) from the lower engine tie-bar support,
- the lower engine tie-bar support.
REFITTING

CONCERNED
a Refit:
- the lower engine tie-bar support,
132608
a Remove:
- the lower engine tie-bar tie rod.
- the bolts (1) of the lower engine tie-bar tie rod,
19D-27
ENGINE MOUNTING
K4J or K4M
REMOVAL

a Remove:

CONCERNED
132810
a Remove:
- the lower engine tie-bar bolts (1) ,
REFITTING
I - OPERATION FOR REFITTING PART

CONCERNED
a Refit the lower engine tie-bar.
19D-28
ENGINE MOUNTING
K7J or K7M
REMOVAL

a Remove:

CONCERNED
133022
a Remove:
- the studs (1) from the lower engine tie-bar,
REFITTING

CONCERNED
a Refit the lower engine tie-bar.
19D-29

MR423THALIA1

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1 Engine and peripherals

10A ENGINE AND CYLINDER BLOCK ASSEMBLY

11A TOP AND FRONT OF ENGINE

12A FUEL MIXTURE

13A FUEL SUPPLY

13B DIESEL INJECTION

16A STARTING - CHARGING

17B PETROL INJECTION

JANUARY 2009 Edition Anglaise

© Renault s.a.s 2008

19D ENGINE MOUNTING

JANUARY 2009 Edition Anglaise

© Renault s.a.s 2008

SYMBOL - THALIA - Section 1

ENGINE AND CYLINDER BLOCK

Engine oil: Draining - Crankshaft accessories

Oil filter: Removal - Refitting 10A-57 Timing belt: Removal -

Oil pressure sensor:

Drive plate: Removal - Throttle valve: Removal -

12A FUEL MIXTURE 13B DIESEL INJECTION

Throttle valve: Cleaning 12A-22 High pressure pump:

Exhaust manifold: Removal - High pressure pipe:

High-pressure pipe between

Turbocharger oil pipe: Injector rail: Removal -

Intercooler: Removal - Rail pressure sensor:

Fuel temperature sensor:

13A FUEL SUPPLY Leak flow from injectors:

Fuel flow: check 13A-10

Diesel injection: Precautions Heater plugs Removal -

Diesel injection: List and

Diesel injection computer: 14A ANTIPOLLUTION

14A ANTIPOLLUTION 17B PETROL INJECTION

Exhaust gas recirculation Pinking sensor: Removal -

Exhaust gas recirculation

Engine cooling circuit: List

16A STARTING - CHARGING Cooling circuit: Draining -

Plenum chamber: Removal -

Water pump inlet pipe:

Throttle body potentiometer:

Petrol injection computer:

Exhaust: Parts and

Exhaust: Precautions for

Catalytic converter: Removal

Connector pipe: Removal -

Silencer: Removal - Refitting 19B-29

Fuel tank: Draining 19C-1

Fuel tank: Removal -

Filler neck: Removal -

Fuel level sensor module:

Additional fuel circuit petrol

Additional fuel circuit

19D ENGINE MOUNTING

Left-hand suspended engine

Lower engine tie-bar:

a Fit blanking plugs.

a Fit blanking plugs on:

a Disconnect the connector (19) from the accelerator

a Unclip the potentiometer connector (20) from the

a Move the potentiometer wiring away from the sup-

a Disconnect the connector (21) from the fan of the

II - OPERATION FOR REMOVAL OF PART

I - REFITTING PREPARATION OPERATION

III - FINAL OPERATION - the power-assisted steering pump reservoir,

Ms. 583 Hose clamp pliers.