Renault Laguna III Manual
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Renault Laguna III Manual

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Table of Contents

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General vehicle information
0
01A
01C
01D
02A
03B
04B
"The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer in
the production of the various component units and accessories from which the vehicles are
constructed".
X91
AUGUST 2009
All rights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part reference
numbering system is forbidden without the prior written authority of Renault.
© Renault s.a.s 2007
EDITION ANGLAISE

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Summary of Contents for Renault Laguna III

  • Page 1 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".

  • Page 2: Laguna Iii - Section

    LAGUNA III - Section 0 LAGUNA III - Section 0 ContentsPages Contents Pages VEHICLE MECHANICAL SPECIFICATIONS COLLISION Vehicle: Specifications 01A-1 Vehicle involved in a side impact: Description 03B-7 Vehicle involved in a rear impact: Description 03B-13 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification...

  • Page 3: Table Of Contents

    VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 123275 Dimensions in metres: 1.014 2.756 0.925 4.695 1.557 (F) (unladen) 1.445 1.512 1.811 01A-1...

  • Page 4: Table Of Contents

    VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications Engine Gearbox Emissions Engine type Engine suf- Cubic Gearbox Gearbox standard fix capacity(cc) type suffix Euro 4 Euro 5 1998 Euro 4 007, 018 Euro 3, 4 and 5 1598 016, 019 Euro 3 and 4 Euro 1, 3 and 4 1461 013, 022...
  • Page 5 VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 123276 Dimensions in metres: 1.014 2.758 1.031 4.776 1.557 (F) (unladen) 1.455 1.512 1.811 01A-3...

  • Page 6: Table Of Contents

    VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications Engine Gearbox Emissions Engine type Engine suf- Cubic Gearbox Gearbox standard fix capacity(cc) type suffix Euro 4 Euro 5 1998 Euro 4 007, 018 Euro 3 and 4 1598 016, 019 Euro 3 and 4 Euro 4 1461 013, 022...

  • Page 7: Table Of Contents

    VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications 141547 Dimensions in metres: 1.019 2.693 0.931 4.643 1.547 (F) (unladen) 1.401 1.542 2.082 01A-5...

  • Page 8: Table Of Contents

    VEHICLE MECHANICAL SPECIFICATIONS Vehicle: Specifications Engine Gearbox Emissions Engine type Engine suf- Cubic Gearbox Gearbox standard fix capacity(cc) type suffix Euro 4 Euro 5 1998 Euro 4 007, 018 Euro 3 and 4 Euro 4 007, 009 Euro 3 and 4 Euro 4 007, 009 Euro 4 and 5...
  • Page 9 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification I - LOCATION OF VEHICLE IDENTIFICATION III - DETAILED VIEW OF THE VEHICLE PLATE (A) IDENTIFICATION PLATE Plate (A) 123654 19031 II - LOCATION OF THE VEHICLE IDENTIFICATION NUMBER (B) Vehicle type mine and type num- ber;...
  • Page 10 VEHICLE BODYWORK SPECIFICATIONS Vehicle: Identification IV - COLD-MARKING OF THE BODY Marking (C) 123656 Note: If the complete body is being replaced, it must be marked in compliance with the current regulations. 01C-2...
  • Page 11 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value B91 or K91 124288 Section 1 WARNING The clearance values are given for information pur- poses. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/...
  • Page 12 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 2 Section 4 124254 124257 (X2) = 5 mm ± ± ± ± 2 (X4) = ± ± ± ± 1 mm Section 3 Section 5 124256 124253 (X3) = 4 mm ± ± ± ± 1.5 (X5) = 0.4 mm ±...
  • Page 13 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 6 Section 8 124258 124287 (X6) = 3.5 mm ± ± ± ± 1.2 (X8) = Plating Section 7 Section 9 124285 124279 (X7) = 4.5 mm ± ± ± ± 1.2 (X9) = 4 mm ±...
  • Page 14 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 10 Section 12 124286 124282 (X10) = 4.5 mm ± ± ± ± 1.2 (X12) = 4.7 mm ± ± ± ± 1.2 Section 11 124280 (X11) = 4.2 mm ± ± ± ± 1.2 01C-6...
  • Page 15 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value 124289 Section 13 WARNING The clearance values are given for information pur- poses. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/ air-tightness.
  • Page 16 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 14 Section 16 124277 124278 (X14) = 4 mm ± ± ± ± 1.9 (X16) = 3.7 mm ± ± ± ± 1.25 Section 15 Section 17 124273 124275 (X15) = 4 mm ± ± ± ± 1.7 (X17) = 1 mm ±...
  • Page 17 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 18 Section 20 124276 124281 (X18) = ± ± ± ± 1 mm (X20) = 4 mm ± ± ± ± 0.8 Section 19 Section 21 124252 124271 (X19) = 2 mm ± ± ± ± 1 (X21) = 4.5 mm ±...
  • Page 18 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 22 Section 24 124270 124283 (X22) = 4 mm ± ± ± ± 2 (X24) = 2 mm ± ± ± ± 0.6 Section 23 124274 (X23) = 4 mm ± ± ± ± 1.6 01C-10...
  • Page 19 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value 124290 Section 25 WARNING The clearance values are given for information pur- poses. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/ air-tightness.
  • Page 20 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 26 Section 28 124260 124267 (X26) = 2 mm ± ± ± ± 1 (X28) = ± ± ± ± 2.2 mm Section 27 Section 29 124259 124265 (X27) = 4.2 mm ± ± ± ± 1.75 (X29) = 4 mm ±...
  • Page 21 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 30 Section 32 124261 124263 (X30) = 1 mm ± ± ± ± 1.2 (X32) = 1 mm ± ± ± ± 1.7 Section 31 Section 33 124264 124262 (X31) = 0.4 mm ± ± ± ± 0.4 (X33) = 1 mm ±...
  • Page 22 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 34 (X34) = 6.5 mm ± ± ± ± 2.4 124268 134840 01C-14...
  • Page 23 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 36 WARNING The clearance values are given for information pur- poses. When adjusting clearances, certain rules have to be followed: - maintain symmetry with respect to the opposite side, - ensure the flush fitting is correct, - check correct operation of the opening, and water/ air-tightness.
  • Page 24 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 38 Section 40 133295 133300 (X38) = 0.4 mm ± ± ± ± 0.4 (X40) = 1 mm ± ± ± ± 0.9 Section 39 Section 41 133293 133299 (X39) = 3.5 mm ± ± ± ± 1.2 (X41) = 4.5 mm ±...
  • Page 25 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 42 Section 44 133301 133297 (X42) = 4 mm ± ± ± ± 1 (X44) = 4.5 mm ± ± ± ± 1.5 Section 43 Section 45 133292 133308 (X43) = 1.5 mm ± ± ± ± 0.9 (X45) = 1.3 mm ±...
  • Page 26 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 47 (X47) = 4 mm ± ± ± ± 2 133307 134839 01C-18...
  • Page 27 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 48 Section 50 133313 133315 (X48) = 5.4 mm ± ± ± ± 1.5 (X50) = 4 mm ± ± ± ± 1.5 Section 49 Section 51 133316 133314 (X49 (a)) = 1 mm ± ± ± ± 0.8 (X51) = 0.4 mm ±...
  • Page 28 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 52 Section 54 133312 133311 (X52) = 4 mm ± ± ± ± 1.2 (X54) = 4 mm ± ± ± ± 1.5 Section 53 Section 55 133310 133302 (X53) = 2 mm ± ± ± ± 0.7 (X55) = 4 mm ±...
  • Page 29 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 56 Section 58 133309 133304 (X56) = 4 mm ± ± ± ± 2 (X58) = 0 mm Section 57 Section 59 133303 133305 (X57) = 4 mm ± ± ± ± 1 (X59) = 4 mm ±...
  • Page 30 VEHICLE BODYWORK SPECIFICATIONS Vehicle panel gaps: Adjustment value Section 60 133306 (X60) = 5 mm ± ± ± ± 0.5 01C-22...
  • Page 31 The documentation is intended to cover all vehicles in The design quality of our vehicles demands that noth- the RENAULT range throughout the world, but may not ing is left to chance in making a good repair, and it is cover equipment designed for use in specific countries.
  • Page 32 MECHANICAL INTRODUCTION Vehicle: Precautions for the repair 4 - Safety 5 - Conclusion The procedures contained in this document merit your Operations on certain equipment and certain parts (for attention. Please read them carefully in order to reduce instance: spring-shock absorber assembly, automatic the risk of injury, and avoid using incorrect procedures transmission, brake system, ABS, airbag, common rail that could damage the vehicle or make it dangerous in...
  • Page 33 MECHANICAL INTRODUCTION Tightening torques: General information I - TABLE OF STANDARD TORQUES The property class is indicated on the bolt (1) or (2) . II - FUNCTION OF A BOLTED ASSEMBLY Fastenings Standard The bolting system connects parts of an assembly to tightening prevent their separation or sliding when submitted to Diameter...
  • Page 34 MECHANICAL INTRODUCTION Tightening torques: General information Creating tension (or preload) F0 Customer complaints resulting from incorrect tighten- ing may be, following assembly, a safety issue (fire, loss of control of the vehicle etc.), an immobilising fault or a noise. III - TIGHTENING PROCEDURES The two controlled tightening procedures adapted to automotive repairs because of their low cost and sim- ple operation are torque tightening and angle tighten-...
  • Page 35 MECHANICAL INTRODUCTION Tightening torques: General information For example: - 1 torque wrench 4 - 40 N.m, - 1 torque wrench 20 - 100 N.m, - 1 torque wrench 80 - 400 N.m, - 1 angle measurement disc. The torque wrenches used must comply with the ISO 6789 standard.
  • Page 36 MECHANICAL INTRODUCTION Tightening torques: General information It is advisable to handle the wrench with care and to stop tightening when the required value is displayed on the wrench. 120743 If the length of the wrench is modified (extending the handle, adapting an end piece) it is essential to recali- brate the wrench to its new configuration.
  • Page 37 (20km/h) and over a maximum distance of 18 miles (30 km) (with the gear lever in neutral). Vehicles fitted with Renault Card: - If the vehicle battery is flat, the steering column remains locked. In this case, fit a new battery or...
  • Page 38 LIFTING EQUIPMENT Vehicle: Towing and lifting B91 or D91 or K91 2 - Position of rear attachment point 128237 122657 Fully screw in the towing ring supplied in the onboard vehicle tool kit located in the luggage compartment in- side the emergency spare wheel. II - LIFTING POINT USING A TROLLEY JACK IMPORTANT To prevent any accidents, the trolley jack must only...
  • Page 39 LIFTING EQUIPMENT Vehicle: Towing and lifting B91 or D91 or K91 III - LIFTING POINT USING A VEHICLE LIFT 2 - Fitting the straps 1 - Safety advice reminder 4-WHEEL STEERING If a four-wheel drive vehicle is locked in a rear wheel lock position, attempting to raise the vehicle on a four- post lift may cause it to fall.
  • Page 40 LIFTING EQUIPMENT Vehicle: Towing and lifting B91 or D91 or K91 3 - Permitted lifting points Rear lifting points IMPORTANT Only the jacking points described in this section allow the vehicle to be raised in complete safety. Do not raise the vehicle using points other than those described in this section.
  • Page 41 COLLISION Vehicle involved in an impact: Impact fault finding I - CHECKING THE SUBFRAME 124328 a Chronological order of checks: - Front impact: • (Gd) - (Ng) = (Gg) - (Nd) • (Nd) - (Hg) = (Ng) - (Hd) - Rear impact: •...
  • Page 42 COLLISION Vehicle involved in an impact: Impact fault finding II - DETAILED VIEW OF INSPECTION POINTS Points Gd, Gg Front side member rear guide Points Ad, Ag 124331 Points Hg, Hd Radiator cross member mounting on 124329 front side member Points Bd, Bg Rear axle guide 124332 124330...
  • Page 43 COLLISION Vehicle involved in an impact: Impact fault finding Points Jd, Jg Rear side member rear leader pin 124333 03B-3...
  • Page 44 COLLISION Vehicle involved in a frontal impact: Description COMBINATIONS FOR REPLACING WELDED STRUCTURAL PARTS IN ACCORDANCE WITH IMPACT SUSTAINED 125025 1st Degree - (2) front panel mounting bracket, - (3) front side end cross member. 125026 - (1) front end cross member mounting stiffener, 03B-4...
  • Page 45 COLLISION Vehicle involved in a frontal impact: Description 2nd Degree 125027 - (4) front section of front right-hand side member, - (5) scuttle side panel, - (6) battery tray bracket, - (7) front section of front left-hand side member, - (8) front side member closure panel, front section, - (9) scuttle side panel upper stiffener.
  • Page 46 COLLISION Vehicle involved in a frontal impact: Description 3rd Degree 125028 - (10) front right-hand half unit, - (11) upper linkage mounting, - (12) front left-hand half unit. 03B-6...
  • Page 47 COLLISION Vehicle involved in a side impact: Description B91 or K91 125037 B91 or K91 1st Degree 125038 03B-7...
  • Page 48 COLLISION Vehicle involved in a side impact: Description - (1) upper body, - (4) body side, front section. - (2) sill panel, - (3) body side closure panel, B91 or K91 2nd Degree 125039 - (5) scuttle side panel, - (6) A-pillar reinforcement, - (7) B-pillar reinforcement, - (8) sill panel closure panel, - (9) sill panel reinforcement,...
  • Page 49 COLLISION Vehicle involved in a side impact: Description B91 or K91 3rd Degree 125040 - (11) roof, - (27) front subframe rear mounting unit, - (12) windscreen pillar lining, - (28) front side member, centre section. - (13) roof rear cross member, - (14) roof panel arch, - (15) roof middle cross member, - (16) roof front cross member,...
  • Page 50 COLLISION Vehicle involved in a side impact: Description 134770 1st Degree 134771 03B-10...
  • Page 51 COLLISION Vehicle involved in a side impact: Description - (31) sill panel. - (29) body side front section, - (30) body side closure panel, front section, 2nd Degree 134772 - (32) scuttle side panel reinforcement, - (33) A-pillar reinforcement, - (34) windscreen pillar reinforcement, - (35) B-pillar reinforcement, - (36) sill panel reinforcement.
  • Page 52 COLLISION Vehicle involved in a side impact: Description 3rd Degree 134773 - (37) roof, - (38) roof rear cross member, - (39) roof middle cross member, - (40) roof front cross member, - (41) A-pillar lining, - (42) side floor, - (43) A-pillar lining, - (44) sill panel lining.
  • Page 53 COLLISION Vehicle involved in a rear impact: Description 125034 03B-13...
  • Page 54 COLLISION Vehicle involved in a rear impact: Description 125033 1st Degree 128233 03B-14...
  • Page 55 COLLISION Vehicle involved in a rear impact: Description - (1) rear end panel, - (2) rear wing panel. 1st Degree 125031 - (3) rear wing panel, - (4) cross member closure panel component, - (5) absorber mounting cross member. 03B-15...
  • Page 56 COLLISION Vehicle involved in a rear impact: Description 2nd Degree 125029 - (6) rear wheel arch, - (7) rear wing panel rain channel, - (8) rear side member, - (9) light mounting lining, - (10) rear floor, rear section. 03B-16...
  • Page 57 COLLISION Vehicle involved in a rear impact: Description 2nd Degree 125030 - (11) rear wheel arch, - (12) rear end pillar closure panel, - (13) rear side member, - (14) rear end panel, - (15) rear cross member, rear section, - (16) rear floor, rear section, - (17) rear wing panel rain channel.
  • Page 58 COLLISION Vehicle involved in a rear impact: Description 3rd Degree 125035 - (18) quarter panel reinforcement, - (19) shoulder harness reinforcement, - (20) rear wheel arch, - (21) side roof rail lining, - (22) grab handle fixed bridge piece, - (23) rear subframe assembly, - (24) rear side member assembly.
  • Page 59 COLLISION Vehicle involved in a rear impact: Description 3rd Degree 125036 - (25) rear wheel arch, - (26) rear side member assembly, - (27) side roof rail lining, rear section, - (28) rear subframe assembly, - (29) side roof rail lining, front section, - (30) roof bar mounting reinforcement, - (31) quarter panel reinforcement.
  • Page 60 COLLISION Vehicle involved in a rear impact: Description 134769 1st Degree 134774 03B-20...
  • Page 61 COLLISION Vehicle involved in a rear impact: Description - (33) rear end panel. - (32) body side rear section, 2nd Degree 134768 - (34) quarter panel lining, - (35) rear light mounting element, upper section. 03B-21...
  • Page 62 COLLISION Vehicle involved in a rear impact: Description 3rd Degree 134775 - (36) rear side parcel shelf, - (37) rear inner wheel arch, - (38) rear side rain channel, - (39) rear parcel shelf, - (40) body side extension. 03B-22...
  • Page 63 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair Consumables for mechanical repair: DEFINITION PACKAGING PART NUMBER MECHANICAL SEALANTS SILICOR 85 g tube 77 11 236 470 sealing paste MASTIXO 100 g tube 77 11 236 172 Joint face seal BEARING SEALING KIT 77 11 237 896 For crankshaft bearing cap side...
  • Page 64 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539 CLOTH FOR INJECTION SYSTEM 77 11 211 707 SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166 SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439...
  • Page 65 77 11 230 111 Varnish for repairing heated rear screens BRAKE 0.5 L container 77 11 218 589 DOT 4, ISO CLASS 6, RENAULT STANDARD: 03-50-006, 5 L container 77 11 238 318 For vehicles with and without elec- tronic stability program (ESP)
  • Page 66 P O W E R - A S S I S T E D 1 L container STEERING FLUID Oil for power-assisted steering: Pump assembly (Laguna III) PLANETELF PAG 488 77 11 172 668 250 ml container SANDEN SP 10...
  • Page 67 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair SPR CC SPRAY 500 ml aerosol 77 11 211 654 STRUCTURAL ADHESIVE STRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885 HIGH PERFORMANCE STRUC- 1 195 ml cartridge 77 11 419 113 TURAL ADHESIVE GLAZING PRODUCTS AND ADHESIVES...
  • Page 68 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair GREASE CLEAN GREASE 300 ml aerosol 77 11 236 174 OPENING ELEMENT MECHA- 20 g sachets 77 11 419 865 NISM GREASE SOUNDPROOFING SPR GREY EVOLUTION 1 l cartridge 77 11 419 114 SPR GREY EVOLUTION SPRAY 400 ml aerosol 77 11 419 116...
  • Page 69 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair SURFACE CLEANER HEPTANE 500 ml container 77 11 170 064 SOLVENT SURF ACE CLEANER 5 L container 77 01 404 178 WATER-BA S E D S U R FACE 5 L container 77 11 421 337 CLEANER ANTISTATIC THINNER (for plastic...
  • Page 70 CONSUMABLES - PRODUCTS Vehicle: Parts and consumables for the repair I-PREMIA REACTIVE PRIMER (do 400 ml aerosol 77 11 419 416 not use on aluminium) ADHÉRA SPRAY (adhesion pro- 400 ml aerosol 77 11 423 734 moter for thermoplastics) 77 11 423 735 PRIMARA BLACK (adhesion pro- 1 L container moter/primer for thermoplastics)
  • Page 71 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 72 The procedures may be modified as a result of changes introduced by the manufacturer in numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which the vehicles are constructed".
  • Page 73 LAGUNA III - Section 1 LAGUNA III - Section 1 ContentsPages Contents Pages ENGINE AND CYLINDER BLOCK ENGINE AND CYLINDER BLOCK ASSEMBLY ASSEMBLY Engine - gearbox assembly: Flywheel: Removal - Refitting 10A-277 Removal - Refitting 10A-1 Drive plate: Removal - Engine oil: Draining - Refitting...
  • Page 74 Contents TOP AND FRONT OF ENGINE TURBOCHARGING Camshaft seal, timing end: Turbocharging: Precautions Removal - Refitting 11A-287 for the repair 12B-1 Valves: Adjustment 11A-304 Turbocharger: Removal - Refitting 12B-4 Oil decanter: Removal - Refitting 11A-307 Turbocharger oil pipe: Removal - Refitting 12B-35 Lifting eyes: Removal - Refitting...
  • Page 75 Contents DIESEL INJECTION ANTIPOLLUTION Diesel return pipe: Removal - Exhaust gas recirculation: Refitting 13B-98 Operating diagram 14A-6 Diesel injector fuel return rail: Fuel vapour recirculation Removal - Refitting 13B-108 circuit: Operating diagram 14A-7 Injector rail protector: Fuel vapour recirculation Removal - Refitting 13B-126 circuit: Check 14A-8...
  • Page 76 Contents PETROL INJECTION COOLING Petrol injection: List and Coolant pump inlet pipe: location of components 17B-1 Removal - Refitting 19A-139 Oxygen sensors: Removal - Expansion bottle: Removal - Refitting 17B-17 Refitting 19A-152 Accelerator pedal Electric coolant pump: potentiometer: Removal - Removal - Refitting 19A-159 Refitting...
  • Page 77 Contents EXHAUST Exhaust fuel injector: Removal - Refitting 19B-121 Exhaust fuel injector cooler: Removal - Refitting 19B-125 Particle filter: Cleaning 19B-129 Connecting hose: Removal - Refitting 19B-135 TANK Sender: Removal - Refitting 19C-1 Pump - sender - filter: Removal - Refitting 19C-4 Fuel tank: Draining 19C-7...
  • Page 78 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting Special tooling required IMPORTANT Mot. 1448 Remote operation pliers for Wear protective gloves during the operation. hose clips. Mot. 1390 Support for removal - refitting of engine - gearbox assembly IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- Equipment required...
  • Page 79 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123344 124751 a Unclip: a Undo the clip (5) for the air pipe at the outlet of the air filter box on the turbocharger side. - the clip (1) on each of the turbocharging pressure a Disconnect the air filter unit air outlet pipe on the tur- regulation pipes, bocharger side.
  • Page 80 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). 124125 a Remove: - the nuts (8) from the exhaust flange,...
  • Page 81 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124138 123036 a Disconnect the connectors (10) from the Protection a Remove the bolt (13) from the max fuse box. a Move the max fuse box to one side. and Switching Unit.
  • Page 82 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123714 142916 a Use a flat-blade screwdriver (17) to unclip the pow- er-assisted steering fluid reservoir. a Move the power steering reservoir to one side. 123712 a Remove: 142912 - the fuses (15) from the max fuse box, a Separate the clip (18) of the expansion bottle cooling...
  • Page 83 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123730 123467 a Disconnect: a Separate the clip (19) of the expansion bottle cooling pipe on the cooling radiator side using the tool (Mot. - the engine cooling fan assembly connector (21) , 1448).
  • Page 84 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123738 123728 a Pull the clip (23) on the intercooler air inlet pipe. a Disconnect the intercooler air inlet pipe. 123730 a Remove: 123739 a Pull the clip (24) on the intercooler air outlet pipe. - the «...
  • Page 85 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Disconnect: - the « condenser - expansion valve » connecting pipe, - the « compressor - condenser » connecting pipe. a Insert the blanking plugs. 142917 a Remove the bolt (28) of the air conditioning pipe on the compressor.
  • Page 86 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front upper structure). 123884 123959 a Remove the earth wiring nuts (30) from the front left- hand side member.
  • Page 87 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 142913 123154 a Disconnect the supply connectors (33) from the bat- tery disconnection unit. 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, place protective plugs on all fuel circuit compo-...
  • Page 88 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 142914 122865 a Separate the clip (39) on the pipe of the power-as- sisted steering pump using the tool (Mot. 1448). a Disconnect the pipe from the power-assisted steer- ing pump.
  • Page 89 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 120202 122725 Note: a Remove the gearbox control cable: Be prepared for fluid to drain from the power- - by unclipping it at (42) using an open-jawed span- assisted steering.
  • Page 90 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the gearbox control cables from their supports (46) II - OPERATION FOR REMOVAL OF PART CONCERNED 113919 17765 a Position the (Mot. 1390) under the engine. 134244 a Disconnect the rigid clutch pipe from the clutch thrust bearing by lifting the retaining clip (44) .
  • Page 91 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a For standard replacements (see Engine: Standard replacement) (Technical Note 6027A, 10A, Engine and cylinder block assembly). a parts always to be replaced: seal between cata- lytic converter and exhaust downpipe hose (10, 08,02,21), parts always to be replaced: exhaust downpipe...
  • Page 92 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Clip: III - FINAL OPERATION - the petrol injection computer wiring, - the feed wiring on the battery disconnection unit. a Clip: - the gearbox control cables onto their supports, a Refit the earth cable on the gearbox.
  • Page 93 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Connect: a Refit: - the intercooler air outlet pipe, - a new exhaust flange seal, - the intercooler air inlet pipe. - the exhaust flange nuts. a Fit the following components onto the cooling radia- tor: a Refit new differential output seals (see Differential - the expansion bottle cooling pipe,...
  • Page 94 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the turbocharging pressure regulation pipes. a Clip on: - the clip on the anti-pumping valve pipe, - the clip on each of the turbocharging pressure reg- ulation pipes. a Refit: - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery),...
  • Page 95 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting Special tooling required IMPORTANT Mot. 1448 Remote operation pliers for Wear protective gloves during the operation. hose clips. Mot. 1390 Support for removal - refitting REMOVAL of engine - gearbox assembly Equipment required I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 96 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Attach the "radiator - condenser - fan unit" assembly to the radiator upper cross member. a Remove the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure).
  • Page 97 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123402 124084 a Remove the bolt (5) from the expansion bottle. a Remove the bolts (6) from the "expansion valve - compressor" and "condenser - compressor" con- necting pipe unions on the compressor. a Disconnect the unions (7) from the "expansion valve - compressor"...
  • Page 98 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124087 123376 a Disconnect the following from the inlet distributor: a Unclip the clutch control pipe from the left-hand sus- pended engine mounting at (8) . - the brake servo pipe union (12) , a Disconnect the clutch control pipe (9) by pressing on - the fuel return pipe union (13) .
  • Page 99 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124088 124085 a Disconnect the petrol vapour rebreathing solenoid a Disconnect the connector from: valve connector (15) . - the coil wiring (17) , - the injector wiring (18) , - the camshaft sensor (19) , - the coolant temperature sensor (20) , - the gearbox sensor (21) ,...
  • Page 100 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 115097 123452 a Remove the bolt (29) from the wiring bracket on the a Remove the earth wiring nut (23) . gearbox. a Disconnect the connector from: a Move aside the wiring bracket on the gearbox. a Remove: - the pinking sensor (24) , - the oil pressure sensor (25) ,...
  • Page 101 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the heat shield behind the right-hand side under- body protector. 124081 a Remove the earth strap bolt (33) . 123355 a Unpick the wiring (34) on the gearbox bracket. a Unclip the downstream oxygen sensor connector (37) .
  • Page 102 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123546 124077 a Disconnect the crankshaft position sensor connector a Separate the clip (42) on the coolant pipe between (40) . the water chamber and the cooling radiator using the tool (Mot.
  • Page 103 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124078 123358 a Remove using the (Mot. 1448) : a Remove: - the clip (44) from the coolant pipe between the - the bolts (46) from the exhaust flange, thermostat unit and the thermostat unit cooling ra- - the exhaust flange springs, diator,...
  • Page 104 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 123457 a Remove: 123347 - the central nut (49) from the left-hand suspended a Remove: engine mounting rubber pad, - the lower linkage bolts (47) , - the nuts (50) from the left-hand suspended engine mounting rubber pad, - the lower linkage (48) .
  • Page 105 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Torque tighten: - the left-hand suspended engine mounting rub- ber pad central nut (62 N.m), - the left-hand suspended engine mounting rub- ber pad nuts (105 N.m). a Remove the tool (Mot.
  • Page 106 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Refit: - the bolt on the underbody protector on the right- hand side, - the nut on the underbody protector on the right- hand side. a Clip the wiring onto the gearbox bracket. a Refit the earth strap bolt.
  • Page 107 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Fit the starter wiring. clip. a Torque tighten: a Clip the clutch control pipe onto the left-hand sus- pended engine mounting. - the starter excitation connector nut (5 N.m), a Fit the "expansion valve - compressor"...
  • Page 108 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front left-hand driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Drive- shafts), - the front right-hand driveshaft (see Front right- hand driveshaft: Removal - Refitting) (29A,...
  • Page 109 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the diesel injection computer (see 13B, Diesel in- Special tooling required jection, Diesel injection computer: Removal - Refitting, page 13B-36) , Mot. 1448 Remote operation pliers for hose clips.
  • Page 110 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the front end panel (see Front end panel: Remov- al - Refitting) (42A, Upper front structure). a Disconnect: - the pressostat connector, - the engine cooling fan resistor connector, - the engine cooling fan connector.
  • Page 111 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 123698 a Rotate the clip (4) of the intercooler air inlet pipe at the intercooler end.
  • Page 112 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting on the condenser. a Disconnect the air conditioning hoses on the con- denser. a Insert the blanking plugs. 122867 122876 a Remove the nut (9) from the air conditioning hose on the compressor.
  • Page 113 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123716 123714 a Remove the main supply fuses (14) . a Remove: - the fuse holder cover (10) , - the strut nuts (11) , - the strut from the left-hand suspended engine mounting.
  • Page 114 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 123712 a Separate the fuse holder (16) from the fuse holder plate.
  • Page 115 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting M9R, and 805 or 809 or 845 or 849 123711 a Unclip: - the computer wiring (24) from the engine wiring 101027 mounting, - the supply unit wiring (25) from the engine wiring mounting.
  • Page 116 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123884 123709 a Attach the engine wiring mounting (27) onto the en- gine. a Disconnect: - the fuel heater connector, - the windscreen washer pump connector. 123883 a Remove the nuts (26) from the earth wires on the side members.
  • Page 117 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123708 123570 a Remove: - the connecting hose nuts (29) , - the connecting hose seal. 123706 a Disconnect: - the cooling hoses (28) from the heater matrix by pressing each side of the quick-release union, - the fuel return pipe quick-release union from the tank return pipe,...
  • Page 118 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 116152 123703 Note: Prepare for the flow of power-assisted steering fluid. Fit a oil recovery tray. a Remove the bolt (30) from the power-assisted steer- ing pipes on the power-assisted steering box. a Remove the lower power-assisted steering pipe.
  • Page 119 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED a Remove: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the left-hand suspended engine mounting (see 19D, Engine mounting, Left-hand suspended...
  • Page 120 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the blanking plugs from the power-assisted steer- ing pipes and from the power-assisted steering M9R, and 742 or 744 or 746 or 748 or 754 or 800 box.
  • Page 121 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove the blanking plugs from the air conditioning a Fit the intercooler air inlet pipe on the intercooler. hoses. Note: WARNING Check that the intercooler air inlet pipe is cor- rectly clipped onto the intercooler by checking T o avoid any leaks, check that the pipe surface is that a click can be heard.
  • Page 122 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Refit: M9R, and 800 or 802 or 805 or 806 or 808 or 809 - the front right-hand wheel driveshaft (see Front or 816 or 845 or 849 right-hand driveshaft: Removal - Refitting) a Fill the power-assisted steering fluid reservoir with (29A, Driveshafts),...
  • Page 123 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Drain: Special tooling required - the gearbox (see Manual gearbox oils: Draining - Ms. 583 Pipe clamps. Filling) (21A, Manual gearbox), - the engine, if necessary (see 10A, Engine and Mot.
  • Page 124 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124562 124542 a Remove the bolt (2) from the max fuse box. a Remove the fuses (5) from the max fuse box. a Remove the max fuse box (3) from its housing. 124541 a Unclip the max fuse box fuse mountings (6) .
  • Page 125 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124545 124548 a Remove the feed wiring from the engine wiring a Remove the nut (9) from the left-hand side member channel by pressing on the clip (7) . earth.
  • Page 126 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123523 123529 a Fit the (Ms. 583) on the clutch pipe hose on the brake fluid reservoir outlet. a Disconnect the clutch control pipe (11) . a Insert the blanking plugs. 101743 a Unclip the control cables from the manual gearbox: - from the anchoring ball joints at (12) ,...
  • Page 127 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 780 122876 a Remove the bolts (14) from the compressor con- necting pipes. 124555 a Uncouple the connecting pipes from the compres- sor. WARNING To avoid any corrosion or damage, protect the WARNING areas on which fuel is likely to run.
  • Page 128 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 782 123972 139055 WARNING T o avoid any corrosion or damage, protect the areas on which fuel is likely to run. a Disconnect: - (39) the high pressure pump supply pipes, - (40) the pipes from the diesel injector fuel return rail.
  • Page 129 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 112621 123520 a Disconnect the brake servo pipe from the vacuum a Unclip the fuel pipes at (20) . pump (18) . 123402 a Remove the bolt (21) from the expansion bottle. 124551 a Move the cooling radiator top hose clip (19) to one side using the (Mot.
  • Page 130 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the fan assembly, - the fan assembly resistor, - the diesel heater, - on the diesel filter mounting. a Move aside the fan assembly wiring. a Remove: - the front left-hand wheel driveshaft (see Front left- hand driveshaft: Removal - Refitting) (29A, Driveshafts),...
  • Page 131 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 780 123526 a Rotate the clip (26) on the intercooler air inlet pipe. a Disconnect the intercooler air inlet pipe from the in- 123779 a Remove the bolts (28) from the exhaust bracket. tercooler.
  • Page 132 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the particle filter pressure sensor connector (38) . K9K, and 782 139188 122859 a Disconnect the power-assisted steering pump as- sembly connectors (29) . a Unpick the power-assisted steering pump assembly connector wiring.
  • Page 133 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 112813 123788 a Remove the left-hand suspended engine mounting shaft nut (34) . a Remove the left-hand suspended engine mounting shaft rubber pad with a copper hammer.
  • Page 134 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Fit: - the “engine - gearbox” assembly in the engine K9K, and 782 compartment using the (Mot. 1390), a Connect: - the rubber pad from the left-hand suspended en- - the particle filter pressure sensor connector, gine mounting a Position the left-hand suspended engine mounting...
  • Page 135 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Clip the fuse holders onto the max fuse box. - the fan assembly, a Refit the max fuse box fuses. - the air conditioning pressostat. a Position the expansion bottle. a Clip on the max fuse box cover.
  • Page 136 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting Special tooling required Tightening torquesm Ms. 583 Pipe clamps. "expansion valve - com- 8 N.m pressor" connecting Mot. 1448 Remote operation pliers for pipe union bolt on the hose clips.
  • Page 137 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove: - the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-13) , - the air outlet pipe to the air filter box, - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the front wheels (see Wheel: Removal - Refitting)
  • Page 138 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 128379 128380 a Remove from the compressor: a Fit the (Ms. 583) (4) on the low pressure pipe of the power-assisted steering pump. - the expansion valve - compressor connecting pipe a Separate the low pressure pipe clip (5) using the tool union bolt (2) , (Mot.
  • Page 139 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the union (9) from the power-assisted steering pump high pressure pipe. 130531 a Disconnect: 131083 - the pipe: a Remove the bolt (10) from each bracket of the pow- •...
  • Page 140 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 130532 128263 a Unclip the manual gearbox control cables: a Disconnect: - from the anchoring ball joints at (14) , - the fuel rebreathing pipe union (18) , - from the cable sleeve stops at (15) .
  • Page 141 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 128632 128370 a Disconnect the upstream oxygen sensor connector a Disconnect the connector (22) from the camshaft (27) . position sensor. 128373 a Disconnect the crankshaft position sensor connector 128276 a Disconnect: (28) .
  • Page 142 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 128282 128385 a Disconnect: a Disconnect the alternator connector (32) . - the connector (29) from the oil pressure sensor, a Remove the nut (33) from the alternator positive ter- - the pinking sensor connector (30) .
  • Page 143 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 122879 130501 a Disconnect the connectors (36) of the air condition- a Remove the gearbox earth cable bolt (37) . ing compressor. a Unclip the wiring on the multifunction support. Note: Before removing the earth terminal, mark its position using an indelible marker by drawing a...
  • Page 144 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123355 128454 a Unclip the downstream oxygen sensor connector a Remove the clip (42) from the cooling hose between (40) . the coolant outlet unit and the cooling radiator using a Disconnect the downstream oxygen sensor connec- the (Mot.
  • Page 145 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 128374 a Remove: 128259 a Remove: - the nuts (44) from the exhaust flange, - the exhaust bracket ring. - the rear suspended engine mounting bolts (45) , - the rear suspended engine mounting (46) .
  • Page 146 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 123457 123542 a Remove: a Lift the vehicle to remove the "engine-gearbox" as- sembly. - the left-hand suspended engine mounting shaft nut (47) from the gearbox, Note: - the nuts (48) from the left-hand suspended engine mounting rubber pad on the gearbox, Check to ensure that there are no components obstructing the movement of the body around the...
  • Page 147 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the nuts on the left-hand suspended engine mounting rubber pad shaft on the gearbox (105 N.m). a Remove the (Mot. 1390). a Refit the engine tie-bar. a Torque tighten the engine tie-bar bolts (190 N.m). III - FINAL OPERATION.
  • Page 148 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Fit the starter wiring harness. - the power-assisted steering high pressure pipe a Tighten to torque: union (21 N.m), - the power-assisted steering high pressure pipe - the nut on the starter excitation connector (5 bracket nut (8 N.m), N.m), - the power-assisted steering high pressure pipe...
  • Page 149 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - differential output seals (see Differential output seal: Removal - Refitting) , - the front left-hand driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Drive- shafts), - the front right-hand driveshaft (see Front right-...
  • Page 150 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Mot.
  • Page 151 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the engine undertray, - the headlights (see Headlight: Removal - Refit- ting) (80B, Headlights), - the bonnet catch (see Bonnet lock: Removal - Refitting) (52A, Non-side opening element mecha- nisms), - the audible warning (see Audible warning: Re- moval - Refitting) (82B, Horn),...
  • Page 152 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the protection and switching unit (see Protection - the bolt (8) from the max fuse box, and Switching Unit: Removal - Refitting) (87G, - the max fuse box. Engine compartment connection unit).
  • Page 153 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 134195 134514 a Disconnect the connector of the automatic transmis- a Move aside the clip of the power-assisted steering sion computer wiring (11) . lower hose using the (Mot. 1448). a Remove the bolt (12) from the power-assisted steer- a Drain the power-assisted steering circuit by discon- ing pipe support.
  • Page 154 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 134194 134192 a Move aside the clips (1 4) of the power-assisted steering fluid reservoir hoses using the (Mot. 1448). a Disconnect the hoses from the power-assisted steering fluid reservoir. 134193 a Remove: - the power-assisted steering pipe bolts (15) ,...
  • Page 155 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove: - the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) (41A, Front lower structure), - the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the front row upstream oxygen sensor (see 17B, Petrol injection, Oxygen sensors: Removal -...
  • Page 156 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 134184 134188 a Unclip the gearbox control (19) . a Remove: a Disconnect the gearbox control (20) . - the bolts (22) from the lower engine tie-bar, - the lower engine tie-bar II - OPERATION FOR REMOVAL OF PART CONCERNED 22860...
  • Page 157 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Position the « engine - gearbox » assembly in the vehicle. a Refit: - the central nut of the left-hand suspended engine mounting rubber pad, - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended...
  • Page 158 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - the radiator mounting cross member (see Radiator - the front right-hand driveshaft (see Front right- mounting cross member: Removal - Refitting) hand driveshaft: Removal - Refitting) , (41A, Front lower structure).
  • Page 159 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Perform the following operations: - fill and bleed the cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A- 16) , - fill the refrigerant circuit using a refrigerant charg- ing station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning).
  • Page 160 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Mot.
  • Page 161 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Drain: - the refrigerant circuit using a refrigerant charging station (62A, Air conditioning), - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-16) . WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.
  • Page 162 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 133887 116152 a Loosen the clip (3) of the air outlet pipe on the air fil- a Remove the bolt (6) of the power-assisted steering ter unit. bracket. a Unclip the vacuum pipes (4) of the turbocharger con- trol solenoid valve.
  • Page 163 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove: - the power assisted steering fluid reservoir, - the battery disconnection unit (see Battery dis- connection unit: Removal - Refitting) (80A, Bat- tery), - the protection and switching unit (see Protection and Switching Unit: Removal - Refitting) (87G, Engine compartment connection unit).
  • Page 164 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 137882 138346 a Remove the max fuse box clip (12) . a Unclip the fuse holder assembly (14) . a Move the max fuse box to one side. a Move the max fuse box to one side.
  • Page 165 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 138114 138344 a Remove the earth nuts (17) from the front left-hand a Unclip the engine wiring connector (19) from the side member. front left-hand wing panel. a Move the earth wiring away from the front left-hand a Disconnect the engine wiring connector.
  • Page 166 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 138342 137873 a Unclip the wiring (23) from the protective sheath of a Disconnect the connector (25) from the electric die- the gearbox wiring. sel heater. a Unclip the wiring of the electric diesel heater. a Move aside the wiring of the electric diesel heater.
  • Page 167 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 138115 138341 a Remove: a Disconnect: - the bolt (26) of the protective sheath of the gearbox - the turbocharger control solenoid valve connector wiring, (29) . - the nut (27) of the protective sheath of the gearbox - the connector (30) from the exhaust gas tempera- wiring.
  • Page 168 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 134093 137874 a Remove: a Disconnect the fuel temperature sensor connector (37) . - the nut (34) of the rigid cooling pipes, a Unclip (38) the fuel return pipes from their supports. - the bolt (35) of the rigid cooling pipes.
  • Page 169 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 138347 134226 a Remove: a Disconnect the inlet cooling hose (42) of the exhaust cooler. - the air conditioning pipe nut (41) , a Move aside the inlet cooling hose of the exhaust - the air conditioning pipe, cooler.
  • Page 170 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 133904 124147 a Remove the nuts (44) from the connecting hose on a Remove the particle filter bolt (45) on the rubber the catalytic pre-converter. mounting bush. a Move aside the « connecting hose - particle filter » Note: assembly.
  • Page 171 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 124144 137921 a Remove the exhaust heat shield clip (47) . a Unclip the gearbox control from its support by push- a Move aside the exhaust heat shield. ing on the union (49) .
  • Page 172 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Remove: - the left-hand suspended engine mounting (see 19D, Engine mounting, Left-hand suspended engine mounting: Removal - Refitting, page 19D-1) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) .
  • Page 173 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Position the « engine - gearbox » assembly in the vehicle. a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) ,...
  • Page 174 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Connect the union of the brake servo vacuum pipe. - the bolt of the protective sheath of the gearbox wir- a Fit the inlet cooling hose of the exhaust cooler. ing.
  • Page 175 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting a Clip the max fuse box on its support. a Clip on the vacuum pipes of the turbocharger control a Fit the max fuse box. solenoid valve. a Torque tighten the clip of the air filter unit air out- a Refit: let pipe (6 N.m).
  • Page 176 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting - a leak test (see Refrigerant circuit: Check) (62A, Air conditioning). a Check that the air conditioning system is working correctly (see Air conditioning: Check) (62A, Air conditioning). a Fill and bleed the power-assisted steering circuit (see Power-assisted steering circuit: Bleeding) (36B, Power-assisted steering).
  • Page 177 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- oil recovery tray tion. oil change wrench oil change end piece with an 8 mm square drive I - PARTS AND CONSUMABLES FOR THE REPAIR WORK a parts always to be replaced: Drain plug seal on Tightening torquesm...
  • Page 178 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Copper seal 122486 113764 a Place the oil recovery tray under the engine oil drain plug (2) . Note: a Remove the drain plug (2) from the engine oil sump There are two types of drain seals for this using the oil change wrench.
  • Page 179 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling III - FILLING WARNING Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine). Correct the engine oil level if necessary before delivering the vehicle to the customer.
  • Page 180 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling I - OIL SERVICE a Position the vehicle on a two-post lift (see Vehicle: Equipment required Towing and lifting) (MR 415, 02A, Lifting equip- oil recovery tray ment). Tightening torquesm drain plug 34 Nm Average oil capacity...
  • Page 181 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling II - FILLING a Consumable : - Engine oil (see Engine oil: Specifications) (Tech- nical Note 6013A, 04A, Lubricants). a Fill the engine with oil, observing the recommended amount. a Wait at least 10 minutes. a Check the oil level using the dipstick.
  • Page 182 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required oil recovery tray oil change wrench oil change end piece with an 8 mm square drive Tightening torquesm drain plug 20 N.m Average oil capacity (adjusting using dipstick) (l) Engine Oil change with- Oil change with...
  • Page 183 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling II - FILLING WARNING Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine). Correct the engine oil level if necessary before delivering the vehicle to the customer.
  • Page 184 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required oil recovery tray oil change wrench oil change end piece with an 8 mm square drive Tightening torquesm drain plug 20 N.m Average oil capacity (adjusting using dipstick) (l) Engine Oil change with- Oil change with...
  • Page 185 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling a Use a funnel to fill the engine with oil recommended by the manufacturer (see Engine oil: Specifica- tions) (Technical Note 6013A, 04, Lubricants). Note: When filling up the engine oil, always leave at least 10 minutes for the oil to drain down before checking the level on the dipstick a Check the engine oil level if necessary.
  • Page 186 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required oil recovery tray oil change wrench oil change end piece with an 8 mm square drive Tightening torquesm drain plug 20 N.m Average oil capacity (adjusting using dipstick) (l) Engine Oil change with- Oil change with...
  • Page 187 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling 128256 113765 a Place the oil recovery tray 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 a - the drain plug on the sump.
  • Page 188 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling a Use a funnel to fill the engine with engine oil recom- mended by the manufacturer (see Engine oil: Specifications) (Technical Note 6013, 04A, Lubri- cants). Note: When filling up the engine oil, always leave at least 10 minutes for the oil to drain down before checking the level on the dipstick a Check the engine oil level if necessary.
  • Page 189 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required Tightening torquesm oil recovery tray drain plug 35 N.m Average oil capacity (adjust with dipstick) (l) O i l c h a n ge O i l change Engine without oil fil- plus oil filter...
  • Page 190 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling 22307 116952 a Fit a oil recovery tray under the engine oil drain a Refit: plug. - a new seal on the drain plug, a Remove the drain plug (2) . - the drain plug.
  • Page 191 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling - the engine cover. 10A-114...
  • Page 192 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Equipment required oil recovery tray oil change wrench torque wrench oil change end piece with an 8 mm square drive Tightening torquesm engine oil sump drain 44 N.m plug Average oil capacity (adjust with dipstick) (l) Engine Draining...
  • Page 193 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling III - DRAINING a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). 133896 a Remove the drain plug (3) from the engine oil sump using the oil change wrench.
  • Page 194 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - REMOVAL OPERATION Equipment required oil recovery tray Tightening torquesm oil filter unit cover 25 Nm WARNING Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine).
  • Page 195 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a parts always to be replaced: Oil filter cartridge (10,05,05,04). parts always to be replaced: Oil filter cover seal (10,05,05,10). a Clean the oil filter unit cover. 113869 a Fit: - a new cover seal (5) ,...
  • Page 196 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting REFITTING Special tooling required Mot. 1654 Oil filter removing tool (64 I - REFITTING PREPARATIONS OPERATION mm diameter). a parts always to be replaced: Oil filter (10,05,05, 03). Equipment required a Lubricate the oil filter seal with new engine oil.
  • Page 197 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter) Equipment required oil recovery tray IMPORTANT Wear latex gloves during the operation. WARNING Always check the oil level using the dipstick.
  • Page 198 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Top up the engine oil level with oil recommended by the manufacturer (see Vehicle: Parts and consum- ables for the repair) (MR 415, 04B, Consumables - Products). a Start the engine and wait until the oil pressure warn- ing light goes out on the instrument panel.
  • Page 199 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter) Equipment required oil recovery tray IMPORTANT Wear latex gloves during the operation. WARNING Always check the oil level using the dipstick.
  • Page 200 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Tighten the new oil filter 3/4 of a turn by hand or us- ing the (Mot. 1329). III - FINAL OPERATION. a Wipe any oil run-off with a cloth. a Top up the engine oil in accordance with the quantity recommended by the manufacturer (see Engine oil: Specifications) (MR 415, 04A, Lubricants).
  • Page 201 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter) Equipment required oil recovery tray IMPORTANT Wear leaktight gloves (nitrile type) for this opera- tion.
  • Page 202 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting 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 until the oil pressure warning light goes out on the instrument panel.
  • Page 203 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Place an oil recovery container under the oil filter. WARNING II - OPERATION FOR REMOVAL OF PART CONCERNED Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine).
  • Page 204 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Top up the oil with oil recommended by the manu- facturer (see Engine oil: Specifications) (Techni- cal Note 6013A, 04A, Lubricants). Note: When topping up the engine oil, always allow 10 minutes for the oil to settle before checking the oil level with the dipstick.
  • Page 205 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1280-01 Oil filter removing tool (86 mm diameter). Equipment required oil recovery tray IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 206 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Wipe any oil run-off with a cloth. WARNING Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine). Correct the engine oil level if necessary before delivering the vehicle to the customer.
  • Page 207 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter unit: Removal - Refitting Special tooling required M9R, and 742 or 744 or 746 or 748 or 754 Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm oil filter unit bolts (initial 5 N.m torque) oil filter unit bolts...
  • Page 208 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter unit: Removal - Refitting 113296 116380 a Remove the alternator positive terminal nut. a Remove the oil filter unit coolant outlet union bolts a Disconnect: (6) . a Remove the clip (7) from the oil filter unit coolant in- - the alternator connector (4) , let union hose using the tool (Mot.
  • Page 209 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter unit: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the oil filter unit coolant outlet union gasket face. CONCERNED 1 - If reusing the oil filter unit a parts always to be replaced: Oil filter cartridge (10,05,05,04) 2 - If replacing the oil filter unit a Remove the oil pressure sensor from the old oil filter...
  • Page 210 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter unit: Removal - Refitting a Fit a new seal on the oil filter unit coolant outlet union. a Refit the oil filter unit coolant outlet union bolts on the oil filter. a Fit the clip for the oil filter unit coolant inlet union hose using the tool (Mot.
  • Page 211 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting Special tooling required Mot. 990-03 Tool for fitting crankshaft seals (timing end). Tightening torquesm engine tie-bar bolt on 115 Nm the subframe engine tie-bar bolt on 190 Nm the sump REMOVAL I - REMOVAL PREPARATION OPERATION...
  • Page 212 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting - the right-hand suspended engine mounting (see II - REFITTING OPERATION FOR PART 19D, Engine mounting, Right-hand suspended CONCERNED engine mounting: Removal - Refitting, page 19D-51) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-50) .
  • Page 213 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 416, 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal -...
  • Page 214 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1790 Crankshaft seal fitting tool (timing end) REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 215 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 118584 a Fit the new crankshaft seal on the timing end (2) on the (Mot. 1790) (3) . 118585 a Position the (Mot. 1790) (3) fitted with a crankshaft seal on the timing end.
  • Page 216 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting - the front right-hand wheel (see Wheel: Removal - Refitting) (MR 415, 35A, Wheels and tyres). 10A-139...
  • Page 217 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATIONS OPERATION a Always replace the crankshaft seal on the timing crankshaft seal 47 Nm end. REMOVAL II - REFITTING OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION a Use surface cleaner (see Vehicle: Parts and con-...
  • Page 218 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 113656 113662 a Engage the new crankshaft seal lugs in the timing cover notches. a Manually tighten the crankshaft seal using the tool supplied in the spare parts kit for the new crankshaft seal.
  • Page 219 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting III - FINAL OPERATION. a Refit: - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) ,...
  • Page 220 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1385 Tool for fitting the crankshaft seal, timing end (35 x 47 x 7). REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 221 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 14523 a Refit a new crankshaft seal using the (Mot. 1385) (2) III - FINAL OPERATION. a Refit: - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-50) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended...
  • Page 222 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting a Clean and degrease the crankshaft mating face with Special tooling required SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Mot. 1706 Tool for fitting crankshaft seal Products).
  • Page 223 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 120120 a Position the (Mot. 1706) with the seal. a Tighten the (Mot. 1706) using the crankshaft acces- sories pulley bolt (3) . a Bring the (Mot. 1706) into contact with the engine. a Remove: - the crankshaft accessories pulley bolt, - the (Mot.
  • Page 224 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting Special tooling required Mot. 1577 Lip seal extractor (shaft diam- eter 28 mm to 42 mm). Mot. 1912 Adapter for seal extractor Mot.1577 (shaft diameter 36 mm to 60 mm) Mot.
  • Page 225 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 137933 a Remove the shaft (6) from the tool (Mot. 1577). 137931 a Remove the end piece (4) of the tool (Mot. 1577) from the extractor.
  • Page 226 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 137935 137937 a Fit the cup (8) of the tool (Mot. 1912) on the tool a Fit the circlips (10) on the tool (Mot. 1577) using cir- (Mot.
  • Page 227 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 137939 137939 a Extract the crankshaft seal by screwing the threaded a Position the claws of the tool (Mot. 1577) on the in- rod (14) of the tool. ner face of the seal.
  • Page 228 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 137928 137930 a Position the crankshaft pulley bolt (18) . a Fit the protector (15) equipped with the seal (16) on the timing sprocket. a Tighten the crankshaft pulley bolt until the bell hous- ing of the tool (Mot.
  • Page 229 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 133896 a Torque tighten: - the right-hand engine tie-bar bolts (180 N.m) (1) - the left-hand engine tie-bar bolts (105 N.m) (2) . a Refit: - the engine undertray, - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection),...
  • Page 230 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the manual gearbox (see Manual gearbox: Re- Special tooling required moval - Refitting) (MR 415, 21A, Manual gear- box), Mot. 1791 Crankshaft seal fitting tool (flywheel end) - the clutch (see Pressure plate - Disc: Removal - Refitting) (MR 415, 20A, Clutch), REMOVAL...
  • Page 231 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 118580 a Fit the tappet (5) of the (Mot. 1791). 118578 a Fit the centring device (2) of the (Mot. 1791). a Tighten the bolt (6) on the tappet of the (Mot.
  • Page 232 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the differential output seals (see Differential out- put seal: Removal - Refitting) (MR 415, 21A, Manual gearbox), - the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 415, 29A, Driveshafts), - the front left-hand wheel driveshaft (see Front left- hand driveshaft: Removal - Refitting) (MR 415,...
  • Page 233 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 - the gearbox (see Manual gearbox: Removal - Re- fitting) (21A, Manual gearbox), Tightening torquesm - the clutch pressure plate (see Pressure plate -...
  • Page 234 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the joint face of the crankshaft cover on the cylinder...
  • Page 235 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 III - FINAL OPERATION a Refit: - the flywheel (see 10A, Engine and cylinder block assembly, Flywheel: Removal - Refitting, page 10A-277) , - the clutch pressure plate (see Pressure plate -...
  • Page 236 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the battery tray (see Battery tray: Removal - Re- Special tooling required fitting) (MR 415, 80A, Battery), Mot. 991-01 Crankshaft seal fitting tool - the air filter box (see 12A, Fuel mixture, Air filter (flywheel end) (85 x 105 x 8 unit: Removal - Refitting, page 12A-13) , seal).
  • Page 237 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 120206 a Disconnect the upstream oxygen sensor connector (1) . a Remove: - the lifting bracket bolt on the timing end, 21926 a Remove: - the lifting bracket on the timing end, - the heat shield clips on the bulkhead, - the bolt (3) from the catalytic converter bracket on the catalytic converter,...
  • Page 238 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 120228 21921 a Remove: a Remove: - the nuts (7) from the starter heat shield, - the nut (9) from the starter excitation terminal, - the starter heat shield. - the nut (10) from the starter supply terminal.
  • Page 239 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 21935 a Check that the starter centring dowel (12) is in place. 124127 a Remove the crankshaft seal on the gearbox side us- II - REFITTING OPERATION FOR PART ing a screwdriver and a wooden block to avoid dam- CONCERNED...
  • Page 240 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting a Torque tighten: III - FINAL OPERATION. a Refit: - the catalytic converter upstream strut bolt on the catalytic converter (11 Nm), - the drive plate (see 10A, Engine and cylinder block assembly, Drive plate: Removal - Refit- - the catalytic converter bracket bolt on the cata- ting, page 10A-287) (MR 415, 23A, Automatic...
  • Page 241 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the front wheels (see Wheel: Removal - Refitting) (MR 415, 35A, Wheels and tyres), - the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-13) , - the battery tray (see Battery tray: Removal - Re- fitting) (MR 415, 80A, Battery), - the battery (see Battery: Removal - Refitting)
  • Page 242 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 805 or 809 or 845 or 849 - the automatic transmission (see Automatic gear- box oil: Draining - Filling) (23A, Automatic trans- Tightening torquesm mission), - the refrigerant circuit (see Refrigerant circuit: crankshaft cover bolts 5 N.m Draining - Filling) (62A, Air conditioning).
  • Page 243 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 805 or 809 or 845 or 849 II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 114414 114068 Note: Note: Touching the lip of the seal is strictly forbidden.
  • Page 244 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 805 or 809 or 845 or 849 III - FINAL OPERATION a Refit: - the drive plate (see 10A, Engine and cylinder block assembly, Drive plate: Removal - Refit- ting, page 10A-287) , - the automatic transmission (see Automatic gear- box: Removal - Refitting) (23A, Automatic trans-...
  • Page 245 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting M9R, and 805 or 809 or 845 or 849 - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the battery (see Battery: Removal - Refitting) (80A, Battery).
  • Page 246 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the manual gearbox (see Manual gearbox: Re- Special tooling required moval - Refitting) (21A, Manual gearbox), Mot. 1129-01 Tool for fitting the crankshaft - the « pressure plate - disc » assembly (see Pres- seal, flywheel end (80 x 100 x sure plate - Disc: Removal - Refitting) (20A, 8 seal).
  • Page 247 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts - the radiator mounting cross member (see Radiator and consumables for the repair) (04B, Consuma- mounting cross member: Removal - Refitting) bles - Products) to clean and degrease: (41A, Front lower structure), - the differential output seals (see Differential out-...
  • Page 248 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting a Remove: Special tooling required - the front wheels (see Wheel: Removal - Refitting) Mot. 1390 Support for removal - refitting (35A, Wheels and tyres), of engine - gearbox assembly - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- Equipment required...
  • Page 249 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the radiator cross member mounting (see Radiator cross member mounting: Removal - Refitting) (41A, Front lower structure), - the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the front row upstream oxygen sensor (see 17B, Petrol injection, Oxygen sensors: Removal - Refitting, page 17B-17) ,...
  • Page 250 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the sump (see 10A, Engine and cylinder block REFITTING assembly, Lower cover: Removal - Refitting, page 10A-180) , I - REFITTING PREPARATION OPERATION - the oil level sensor (see 10A, Engine and cylinder a Always replace the "crankshaft seal support on the block assembly, Oil level sensor: Removal - Re- gearbox side - crankshaft seal on the gearbox side"...
  • Page 251 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting a Torque tighten the bolts of the "crankshaft seal support on the gearbox side - crankshaft seal on the gearbox side" assembly (9 N.m). III - FINAL OPERATION a Refit: - the cylinder block base plate (see Cylinder block base plate: Removal - Refitting) ,...
  • Page 252 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the front row upstream oxygen sensor (see 17B, - the front bumper (see Front bumper: Removal - Petrol injection, Oxygen sensors: Removal - Refitting) (55A, Exterior protection), Refitting, page 17B-17) , - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec-...
  • Page 253 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). Equipment required a Drain: refrigerant charging station - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-16) , component support - the air conditioning circuit using a refrigerant...
  • Page 254 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting - the « intermediate pipe - compressor » connecting II - OPERATION FOR REMOVAL OF PART pipe (see Compressor - intermediate pipe con- CONCERNED necting pipe: Removal - Refitting) , - the lower engine tie-bars (see 1 9 D, Engine mounting, Lower engine tie-bar: Removal - Re- fitting, page 19D-85) ,...
  • Page 255 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 135728 a Remove: 135729 - the seal protector (5) , - the guide bolts . Note: T ouching the lip of the seal is strictly forbidden. Any contact with it will result in the lip being per- manently damaged, which will cause an oil leak.
  • Page 256 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting III - FINAL OPERATION - the electric coolant pump of the exhaust cooler a Refit the drive plate (see 10A, Engine and cylinder (see 19A, Cooling, Electric coolant pump: Re- moval - Refitting, page 19A-159) , block assembly, Drive plate: Removal - Refitting, page 10A-287) .
  • Page 257 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting REFITTING Special tooling required Mot. 1716 Removes housing with sili- I - REFITTING PREPARATION OPERATION cone seals. a Degrease and clean the joint faces using SURFACE CLEANER (see Vehicle: Parts and consumables Tightening torquesm for the repair) (04B, Consumables - Products).
  • Page 258 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 22307 a Refit the sump. a Torque tighten in order the sump bolts (9 N.m). III - FINAL OPERATION a Fill up the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-100) .
  • Page 259 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting Special tooling required Mot. 1716 Removes housing with sili- cone seals. Tightening torquesm sump bolts 10 Nm REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 260 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Check that the sump is not: - scratched, - deformed. If this is the case, replace the sump. a Check that the base plate is not scratched. 115241 a Manually tighten the sump bolts until they make con- tact.
  • Page 261 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting - the lower cover, - the sump seal. Tightening torquesm sump bolts on the gear- 44 Nm REFITTING I - REFITTING PREPARATIONS OPERATION a Use SURFACE CLEANER (see Vehicle: Parts REMOVAL and consumables for the repair) (MR 415, 04B, Consumables - Products) to clean and degrease:...
  • Page 262 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 15159 15195 a Apply a bead of MASTIXO (see Vehicle: Parts and a Torque tighten and in order: consumables for the repair) (MR 415, 04B, Con- - sump bolts (8), (15), (4), (19), (11) and (12) (18 sumables - Products): Nm), - at (A) each side of bearing no.1,...
  • Page 263 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REMOVAL OPERATION FOR PART Special tooling required CONCERNED Mot. 1716 Removes housing with sili- cone seals. Tightening torquesm sump bolts (initial 5 Nm torque) sump bolts 16 Nm IMPORTANT Wear goggles with side protectors for this opera- tion.
  • Page 264 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Use SUPER CLEANING AGENT FOR JOINT FA- CES (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products) and a wooden spatula to clean the joint faces: - of the sump, - of the cylinder block.
  • Page 265 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 123704 a Refit the lower cover. a Pre-tighten in order and to torque the sump bolts (initial torque) (5 Nm). a Torque tighten in order the sump bolts (16 Nm). III - FINAL OPERATION.
  • Page 266 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting Tightening torquesm sump bolts on the gear- 44 N.m sump bolts on the cylin- 14 N.m der block lower engine tie-bar 180 N.m bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 267 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Unclip the rail protector drain pipe from: - the lower engine tie-bar. - the gearbox, 2 - If replacing the sump - the sump. a Remove: a Move the rail protector drain pipe away from the sump.
  • Page 268 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Note: If the sump cannot be extracted because it is in contact with the oil pump strainer, do not force the removal of the sump as this may damage the oil splash plate.
  • Page 269 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Degrease the joint face using SURFACE CLEANER - four drops (9) of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the re- (see Vehicle: Parts and consumables for the re- pair) (04B, Consumables - Products) and CLEAN pair) (04B, Consumables - Products) with a diame- CLOTHS.
  • Page 270 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Refit: - the engine undertray, - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres). 20171 a Torque tighten in order the sump bolts on the cyl- inder block (14 N.m).
  • Page 271 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting Tightening torquesm sump bolts 14 N.m sump bolts on the gear- 44 N.m sump bolt on the multi- 21 N.m function support relay bearing bolts on 44 N.m the sump right-hand transmission 21 N.m bracket bolt on the relay...
  • Page 272 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the sump joint face if it is to be re-used, - the cylinder block gasket face.
  • Page 273 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 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.). II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the new seal on the sump,...
  • Page 274 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Refit: - the rear suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Re- moval - Refitting, page 19D-85) , - the oil level sensor (see 10A, Engine and cylinder block assembly, Oil level sensor: Removal - Re- fitting, page 10A-237) .
  • Page 275 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Drain the engine oil (see 10A, Engine and cylinder Special tooling required block assembly, Engine oil: Draining - Refilling, page 10A-100) . Mot. 1431 Flywheel locking tool. a Remove: Equipment required - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),...
  • Page 276 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting - the protection and switching unit (see Protection and Switching Unit: Removal - Refitting) (87G, Engine compartment connection unit), - the air resonator (see 12A, Fuel mixture, Air res- onator: Removal - Refitting, page 12A-28) , - the electric coolant pump of the turbocharger (see 19A, Cooling, Electric coolant pump: Removal - Refitting, page 19A-159) ,...
  • Page 277 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting - the crankshaft seal on the gearbox side (see 10A, II - OPERATION FOR REMOVAL OF PART Engine and cylinder block assembly, Crank- CONCERNED shaft seal, gearbox end: Removal - Refitting, page 10A-153) .
  • Page 278 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Finish cleaning the joint faces using a GREY ABRA- SIVE PAD part number 77 01 405 943. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).
  • Page 279 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 138669 a Refit: - new sump seals. - the sump. a Torque tighten in order the sump bolts (32 N.m). a Refit: - the oil pump pinion on the oil pump chain, - the «...
  • Page 280 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting III - FINAL OPERATION a Refit: - a new seal of the coolant - oil heat exchanger sup- port, - the coolant - oil heat exchanger support. 138126 a Apply drops of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the re- pair) (04B, Consumables - Products) at (7) on the new the lower timing cover seal.
  • Page 281 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Fit the flywheel locking tool (Mot. 1431) on the drive - the battery disconnection unit (see Battery dis- plate. connection unit: Removal - Refitting) (80A, Bat- a Refit the crankshaft accessories pulley (see 11A, tery), Top and front of engine, Crankshaft accessories - the pipe between the reservoir and the steering box...
  • Page 282 ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres),...
  • Page 283 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting REMOVAL Special tooling required Mot. 1914 Tool for fitting G9 con rod I - REMOVAL PREPARATION OPERATION bearing shells a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 284 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 140940 WARNING Failure to observe the following procedure may damage the oil pump strainer. 123834 a Disconnect the oil level sensor connector (if Undo the bolts of the engine oil sump. a Fit a component jack to support the engine oil equipped) (2) .
  • Page 285 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting II - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2 140917 a Tilt the engine oil sump forwards in order to access 139306 the oil pump bolts. a Use SURFACE CLEANER (see Vehicle: Parts a Partially loosen the oil pump bolts 3 mm to 5 mm.
  • Page 286 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 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.
  • Page 287 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 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.
  • Page 288 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 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.
  • Page 289 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 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.
  • Page 290 ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 140918 123824 a Disconnect the crankshaft position sensor (4) to pre- a Tilt the engine oil sump forwards in order to access vent the engine from starting. the oil pump bolts. a Refit the oil filter (see 10A, Engine and cylinder a Torque tighten the oil pump bolts (25 N.m) using block assembly, Oil filter: Removal - Refitting,...
  • Page 291 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting a The oil-water heat exchanger is not sold separately in the Parts Department; to replace it, it is necessary to replace the oil filter unit (see 10A, Engine and cylinder block assembly, Oil filter unit: Removal - Refitting, page 10A-130) (MR 415, 10A, Engine and peripherals).
  • Page 292 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm oil-wa t e r h e a t 49 Nm exchanger nipple...
  • Page 293 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Clean and degrease the oil-water heat exchanger joint faces with SURFACE CLEANER (see Vehi- cle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products).
  • Page 294 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting Special tooling required Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm oil cooler nipple 60 Nm IMPORTANT Wear latex gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION 116811...
  • Page 295 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Refit: - the new oil-water heat exchanger seal, - the oil cooler, - the oil-coolant heat exchanger fitting. a Torque tighten the oil cooler nipple (60 Nm).
  • Page 296 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 780 Tightening torquesm oil-wa t e r h e a t 39 N.m exchanger bolt oil filter holder bolt 28 N.m IMPORTANT Wear latex gloves during the operation. IMPORTANT Wear heat protective gloves during the operation.
  • Page 297 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting a Move aside the intercooler air inlet pipe. K9K, and 782 II - OPERATION FOR REMOVAL OF PART CONCERNED 138389 123835 a Disconnect the oil pressure sensor connector (7) . 138390 a Remove: - the nut (4) on the intercooler air inlet pipe,...
  • Page 298 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting 123966 107306 a Remove: a Refit new seals (10) and (11) on the oil-water heat exchanger. - the bolt (9) from the oil-coolant heat exchanger, a Apply soapy water to the two seals (10) in contact - the oil-water heat exchanger.
  • Page 299 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting a Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-16) . a Refit: - the engine undertray, - the engine cover. 10A-222...
  • Page 300 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting Special tooling required Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm oil filter nipple 49 N.m REMOVAL 119615 a Fit hose clamps (Ms. 583) (1) on the cooling hoses. I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: a Separate the clips (2) on the cooling hoses using the...
  • Page 301 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting a Bleed the cooling system (see Cooling system: REFITTING Bleed) . I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant-engine oil heat exchanger seal on the cylinder block (10,05, 05,12).
  • Page 302 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting Special tooling required Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm oil-wa t e r h e a t 32 N.m exchanger bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 303 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Refit: - a new seal to the oil-water heat exchanger, - the oil-water heat exchanger. a Torque tighten the oil-water heat exchanger bolts (32 N.m).
  • Page 304 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the oil pressure sensor. Tightening torquesm a Tighten to torque the oil pressure sensor (15 Nm). oil pressure sensor 15 Nm a Connect the oil pressure sensor connector.
  • Page 305 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting a Disconnect the battery (see Battery: Removal - Re- fitting) (MR 415, 80A, Battery). Equipment required refrigerant charging station Tightening torquesm oil pressure sensor 40 Nm bracket bolt for the 8 Nm "intermediate pipe-com- pressor"...
  • Page 306 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION. CONCERNED WARNING Do not remove the blanking plugs from each component until the last moment. Also, do not remove the components from their packaging until they are to be fitted to the vehi- cle.
  • Page 307 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1495-01 22 mm socket for removal - refitting of oxygen sensors. Tightening torquesm oil pressure sensor 35 Nm REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 308 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Coat the threading of the oil pressure sensor with SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products).
  • Page 309 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - REFITTING OPERATION FOR PART Special tooling required CONCERNED a Refit the new oil pressure sensor. Mot. 1495 22 mm socket for removal - a Tighten the new oil pressure sensor using the (Mot. refitting of oxygen sensors - 1/2"...
  • Page 310 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION a Coat the threading of the oil pressure sensor with oil pressure sensor 32 N.m SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the repair) (04B, Con- REMOVAL sumables - Products).
  • Page 311 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pressure sensor 15 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 312 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting a Refit a new plastic clip to the oil pressure sensor connector. Note: Ensure that the wiring of the oil pressure sensor connector passes underneath the connector and does not come into contact with the driveshaft. II - FINAL OPERATION a Refit: - the lower engine tie-bar (see 19D, Engine mount-...
  • Page 313 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting REFITTING Special tooling required Mot. 1495-01 22 mm socket for removal - I - REFITTING PREPARATION OPERATION refitting of oxygen sensors. a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consum- ables - Products) to clean and degrease the joint Tightening torquesm face of the engine oil pressure sensor.
  • Page 314 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting Tightening torquesm oil level sensor 20 Nm REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. II - REMOVAL OPERATION FOR PART CONCERNED 115097 a Disconnect the connector (1) from the oil level sen- sor.
  • Page 315 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting REMOVAL II - FINAL OPERATION. a Refit: I - REMOVAL PREPARATION OPERATION - the front right-hand wheel (see Wheel: Removal - a Position the vehicle on a two-post lift (see Vehicle: Refitting) (MR 415, 35A, Wheels and tyres), Towing and lifting) (MR 415, 02A, Lifting equip- - the engine undertray,...
  • Page 316 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment). a Remove: - the engine undertray bolts, - the engine undertray.
  • Page 317 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting REMOVAL III - FINAL OPERATION. a Refit: I - REMOVAL PREPARATION OPERATION - the engine undertray, a Position the vehicle on a two-post lift (see Vehicle: - the engine undertray bolts. Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 318 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting Tightening torquesm oil level sensor 25 N.m REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 123464 128366 a Disconnect the connector (1) from the oil level sen- sor. 128368 a Remove the oil level sensor using a "Crowfoot" type end piece (2) .
  • Page 319 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil level sensor bolts 8 Nm REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 320 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting a Check the engine oil level. a Adjust the engine oil level if necessary. 10A-243...
  • Page 321 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting REMOVAL II - FINAL OPERATION a Refit: I - REMOVAL PREPARATION OPERATION - the oil pressure sensor (see 10A, Engine and cyl- a Position the vehicle on a two-post lift (see Vehicle: inder block assembly, Oil pressure sensor: Re- moval - Refitting, page 10A-227) , Towing and lifting) (02A, Lifting equipment).
  • Page 322 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting a The engine and gearbox assembly must be re- moved to remove/refit the oil pump (see 10A, En- gine and cylinder block assembly, Engine - gearbox assembly: Removal - Refitting, page 10A-1) .
  • Page 323 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the anti-emulsion plate. Tightening torquesm oil pump bolts 25 Nm oil splash plate bolt 25 Nm IMPORTANT Wear latex gloves during the operation. REMOVAL I - OPERATION FOR REMOVAL OF PART CONCERNED a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip-...
  • Page 324 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - FINAL OPERATION. a Refit: - the lower cover (see 10A, Engine and cylinder block assembly, Lower cover: Removal - Refit- ting, page 10A-180) , - the engine undertray, - the engine undertray bolts.
  • Page 325 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pump bolts on the 25 N.m cylinder block REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 326 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the oil pump. Note: If necessary, use a locally produced hook to fit the oil pump chain to the oil pump pinion. a Refit: - the oil pump bolts on the cylinder block, - the bolt for the oil splash plate on the oil pump.
  • Page 327 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting REMOVAL REFITTING I - REMOVAL PREPARATION OPERATION I - REFITTING PREPARATIONS OPERATION a Position the vehicle on a two-post lift (see Vehicle: a Always replace the right-hand differential output Towing and lifting) (MR 415, 02A, Lifting equip- seal.
  • Page 328 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pump bolts 25 N.m IMPORTANT Wear leaktight gloves (nitrile type) for this opera- tion. REMOVAL I - OPERATION FOR REMOVAL OF PART CONCERNED a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 329 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting a Refit the engine undertray. 10A-252...
  • Page 330 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the headlights (see Headlight: Removal - Refit- Special tooling required ting) (80B, Headlights), Mot. 1390 Support for removal - refitting - the bonnet catch (see Bonnet lock: Removal - of engine - gearbox assembly Refitting) (52A, Non-side opening element mecha- nisms),...
  • Page 331 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the front and rear catalytic pre-converters (see Front catalytic pre-converter: Removal - Refit- ting) and (see Rear catalytic pre-converter: Re- moval - Refitting) . 22860 a Position the pads of the (Mot. 1390) under areas (A) 134185 a Remove the central nut (1) from the rubber pad on a Remove the right-hand suspended engine mounting...
  • Page 332 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the inlet manifold (see 12A, Fuel mixture, Inlet - the cylinder block base plate (see Cylinder block distributor: Removal - Refitting, page 12A-75) , base plate: Removal - Refitting) . - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) , II - REMOVAL OPERATION FOR THE OIL PUMP...
  • Page 333 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting a Couple the gearbox to the engine (see Automatic - the oil level sensor (see 10A, Engine and cylinder block assembly, Oil level sensor: Removal - Re- gearbox: Removal - Refitting) (23A, Automatic fitting, page 10A-237) , transmission).
  • Page 334 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting a Refill: - the engine oil (see 1 0 A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-100) , - the cooling circuit (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-16) , - the refrigerant circuit using a refrigerant charging station (see Refrigerant circuit: Draining - Fill-...
  • Page 335 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the alternator (see 16A, Starting - Charging, Al- ternator: Removal - Refitting, page 16A-1) , Tightening torquesm - the power-assisted steering pump (see Power-as- sisted steering pump: Removal - Refitting) oil pump bolts 25 N.m (36B, Power-assisted steering).
  • Page 336 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 136291 a Remove: 136258 - the oil pump cover bolts (4) , a Remove: - the oil pump cover. - the oil pump pinion bolts (2) , - the oil pump pinion.
  • Page 337 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - OPERATION FOR REBUILDING THE OIL PUMP a Refit: - the "valve - spring - valve centring device" assem- bly, - the locking pin of the oil pump discharge valve, - the oil pump driven gear, - the oil pump cover.
  • Page 338 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the lower engine tie-bars (see 1 9 D, Engine...
  • Page 339 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check F4R or K4M or K9K or M4R or M9R or V4Y or V9X Special tooling required Mot. 836-05 Oil pressure gauge kit. Mot. 1495-01 22 mm socket for removal - refitting of oxygen sensors. Mot.
  • Page 340 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check F4R or K4M or K9K or M4R or M9R or V4Y or V9X 122879 132033 a Disconnect the air conditioning compressor connec- a In place of the oil pressure sensor, fit the tool (Mot. tors (1) .
  • Page 341 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check F4R or K4M or K9K or M4R or M9R or V4Y or V9X - 6000 rpm: 5.65 bar. a Oil pressure values: a Switch off the engine. - idle speed: 0.4 bar, - 4000 rpm: 2 to 4 bar.
  • Page 342 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting Special tooling required Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm multifunction support 50 Nm bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 343 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION. CONCERNED a Connect the cooling hoses to the multifunction sup- port. a Fit: - the cooling hose clips using tool (Mot. 1448), - the air conditioning compressor connector support.
  • Page 344 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting Tightening torquesm multifunction support 44 N.m bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 345 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - FINAL OPERATION a Refit: - the air conditioning compressor (see Compressor: Removal - Refitting) (62A, Air conditioning), - the alternator (see 16A, Starting - Charging, Al- ternator: Removal - Refitting, page 16A-1) . M9R, and 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Refit the power-assisted steering pump (see Power-...
  • Page 346 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED Equipment required refrigerant charging station Tightening torquesm multifunction support 44 Nm bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 347 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the air conditioning compressor (see Compressor: Removal - Refitting) (MR 415, 62A, Air condition- ing), - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 416,...
  • Page 348 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting REMOVAL II - REMOVAL OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 349 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting a Connect the battery (see Battery: Removal - Refit- ting) (MR 415, 80A, Battery). a Adjust the headlights (see Headlight: Adjustment) (MR 415, 80B, Headlights). 123832 a Tighten the multifunction support bolts in order. II - FINAL OPERATION.
  • Page 350 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required refrigerant charging station Tightening torquesm multifunction support 44 Nm bolts multifunction support 25 N.m bolt on the cylinder block REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 351 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting a Fill the refrigerant circuit using a refrigerant charg- REFITTING ing station (see Refrigerant circuit: Draining - Filling) (62A, Air conditioning). I - REFITTING OPERATION FOR PART a Refit: CONCERNED - the engine undertray, - the engine cover.
  • Page 352 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm multifunction support 25 N.m bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 353 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray.
  • Page 354 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting K9K, and TL4 - the radiator mounting cross member (see Radiator Special tooling required mounting cross member: Removal - Refitting) (41A, Front lower structure), Mot. 582 Flywheel locking tool. - the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle compo- nents), Tightening torquesm...
  • Page 355 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting K9K, and TL4 a Fill up the manual gearbox (see Manual gearbox II - REFITTING OPERATION FOR PART CONCERNED oils: Draining - Filling) (21A, Manual gearbox). a Fit the flywheel. a Refit: a Fit the new flywheel bolts without tightening them.
  • Page 356 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot.
  • Page 357 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 or 800 or 802 or 806 or 808 or 816 II - REFITTING OPERATION FOR PART - the front wheels (see Wheel: Removal - Refitting) CONCERNED (35A, Wheels and tyres), - the air filter unit (see 12A, Fuel mixture, Air filter...
  • Page 358 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting F4R, and PK4 - the gearbox (see Manual gearbox: Removal - Re- Special tooling required fitting) (21A, Manual gearbox), Mot. 1677 Flywheel locking tool. - the « pressure plate - disc » assembly (see Pres- sure plate - Disc: Removal - Refitting) (21A, Manual gearbox).
  • Page 359 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting F4R, and PK4 II - REFITTING OPERATION FOR PART - the front wheel arch liners (see Front wheel arch CONCERNED liner: Removal - Refitting) (55A, Exterior protec- tion), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
  • Page 360 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting - the front axle subframe (see Front axle subframe: Special tooling required Removal - Refitting) (31A, Front axle compo- nents), Mot. 1677 Flywheel locking tool. - the manual gearbox (see Manual gearbox: Re- moval - Refitting) (21A, Manual gearbox).
  • Page 361 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting II - REFITTING OPERATION FOR PART - the front left-hand wheel driveshaft (see Front left- CONCERNED hand driveshaft: Removal - Refitting) (29A, Driveshafts). a Fit the flywheel. a Fill the manual gearbox (see Manual gearbox oils: a Fit the new flywheel bolts without tightening them.
  • Page 362 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting M4R, and TL4 - the radiator mounting cross member (see Radiator Special tooling required mounting cross member: Removal - Refitting) (41A, Front lower structure), Mot. 1677 Flywheel locking tool. - the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle compo- nents), Tightening torquesm...
  • Page 363 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting M4R, and TL4 - the flywheel bolt threading on the crankshaft. - the front left-hand wheel driveshaft (see Front left- hand driveshaft: Removal - Refitting) (29A, Driveshafts). II - REFITTING OPERATION FOR PART a Fill up the manual gearbox (see Manual gearbox CONCERNED oils: Draining - Filling) (21A, Manual gearbox).
  • Page 364 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting M9R, and 805 or 809 or 845 or 849 - the front bumper (see Front bumper: Removal - Special tooling required Refitting) (55A, Exterior protection), Mot. 1316 Engine flywheel immobiliser - the headlights (see Headlight: Removal - Refit- tool.
  • Page 365 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting M9R, and 805 or 809 or 845 or 849 II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a Visually inspect the condition of the crown wheel and the drive plate.
  • Page 366 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting M9R, and 805 or 809 or 845 or 849 III - FINAL OPERATION - the battery tray (see Battery tray: Removal - Re- a Refit: fitting) (80A, Battery), - the battery (see Battery: Removal - Refitting) - the automatic transmission (see Automatic gear- (80A, Battery).
  • Page 367 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting F4R, and AJ0 a Drain: Special tooling required - the engine, if necessary (see 10A, Engine and Mot. 582-01 Flywheel locking tool. cylinder block assembly, Engine oil: Draining - Refilling, page 10A-100) , Equipment required - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-16) ,...
  • Page 368 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting F4R, and AJ0 - the left-hand suspended engine mounting (see 19D, Engine mounting, Left-hand suspended engine mounting: Removal - Refitting, page 19D-1) , - the « engine-gearbox » assembly (see 10A, En- gine and cylinder block assembly, Engine - gearbox assembly: Removal - Refitting, page 10A-1) ,...
  • Page 369 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting F4R, and AJ0 - the front left-hand driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A, Drive- shafts), - the front right-hand driveshaft (see Front right- hand driveshaft: Removal - Refitting) (29A, Driveshafts), - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec-...
  • Page 370 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting - the headlights (see Headlight: Removal - Refit- Special tooling required ting) (80B, Headlights), Mot. 1390 Support for removal - refitting - the bonnet catch (see Bonnet lock: Removal - of engine - gearbox assembly Refitting) (52A, Non-side opening element mecha- nisms),...
  • Page 371 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting 22860 a Position the pads of the (Mot. 1390) under areas (A) a Remove the right-hand suspended engine mounting (see 1 9 D , Engine mounting, Right-hand sus- pended engine mounting: Removal - Refitting, 134185 a Remove the central nut (1) from the rubber pad on page 19D-51) .
  • Page 372 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 102813 133842 a Position the (Mot. 919-02) (2) . a Remove: - the drive plate bolts (3) , - the washer, - the drive plate.
  • Page 373 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting a Refit: - the front and rear catalytic pre-converters (see Front catalytic pre-converter: Removal - Refit- ting) and (see Rear catalytic pre-converter: Re- moval - Refitting) , - the front row upstream oxygen sensor (see 17B, Petrol injection, Oxygen sensors: Removal - Refitting, page 17B-17) , - the inlet manifold (see 12A, Fuel mixture, Inlet...
  • Page 374 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting - the headlights (see Headlight: Removal - Refit- ting) (80B, Headlights), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), - the front wheels (see Wheel: Removal - Refitting)
  • Page 375 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting - the front bumper (see Front bumper: Removal - Special tooling required Refitting) (55A, Exterior protection). a Drain: Mot. 1431 Flywheel locking tool. - the cooling system (see 19A, Cooling, Cooling Equipment required system: Draining - Refilling, page 19A-16) , - the air conditioning circuit using a refrigerant...
  • Page 376 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting - the « intermediate pipe - compressor » connecting II - OPERATION FOR REMOVAL OF PART pipe (see Compressor - intermediate pipe con- CONCERNED necting pipe: Removal - Refitting) (62A, Air con- ditioning), - the lower engine tie-bars (see 1 9 D, Engine mounting, Lower engine tie-bar: Removal - Re-...
  • Page 377 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting II - REFITTING OPERATION FOR PART III - FINAL OPERATION a Remove the engine from component support (see CONCERNED Engine support equipment: Use) . a Couple the gearbox to the engine (see Automatic gearbox: Removal - Refitting) (23A, Automatic transmission).
  • Page 378 ENGINE AND CYLINDER BLOCK ASSEMBLY Drive plate: Removal - Refitting - the « cooling radiator - condenser - intercooler » (see 19A, Cooling, Cooling radiator: Removal - Refitting, page 19A-28) assembly, - the engine cooling fan assembly (see 19A, Cool- ing, Engine cooling fan assembly: Removal - Refitting, page 19A-121) , - the air filter unit (see 12A, Fuel mixture, Air filter...
  • Page 379 TOP AND FRONT OF ENGINE Pressure at end of compression: Check II - TEST OPERATION a Press the vehicle start button to trigger the engine Equipment required starting phase. petrol compression gauge Diagnostic tool Note: The engine will be driven by the starter for 20 seconds, without being started.
  • Page 380 TOP AND FRONT OF ENGINE Pressure at end of compression: Check Special tooling required Mot. 1772 Flexible end piece for taking end of compression pressure measurements. Equipment required diesel compression gauge Diagnostic tool I - PREPARATION OPERATION FOR CHECK a Remove: - the engine cover, - heater plugs (see 13C, Preheating, Heater plugs: Removal - Refitting, page 13C-3) .
  • Page 381 TOP AND FRONT OF ENGINE Pressure at end of compression: Check a Open the discharge valve to release all of the pres- sure in the diesel compression gauge. a Make progress with the diagram sheet. a Take the same measurement for the other cylinders. a Compare the results obtained.
  • Page 382 TOP AND FRONT OF ENGINE Pressure at end of compression: Check II - TEST OPERATION a Press the vehicle start button to trigger the engine Equipment required starting phase. petrol compression gauge Diagnostic tool Note: The engine will be driven by the starter for 20 seconds, without being started.
  • Page 383 TOP AND FRONT OF ENGINE Pressure at end of compression: Check II - TEST OPERATION Special tooling required Mot. 1592 Flexible end piece for taking end of compression pressure measurements. Equipment required diesel compression gauge self-contained starter Diagnostic tool CHECK I - PREPARATION OPERATION FOR CHECK a Remove the heater plugs (see 13C, Preheating, Heater plugs: Removal - Refitting, page 13C-3) .
  • Page 384 TOP AND FRONT OF ENGINE Pressure at end of compression: Check a Run the following commands: - RZ009 "Vehicle functions programming", - VP036 "Inhibit fuel supply". a Operate the starter for 15 seconds until the needle of the diesel compression gauge stabilises to ob- tain the maximum value.
  • Page 385 TOP AND FRONT OF ENGINE Pressure at end of compression: Check II - TEST OPERATION a Press the vehicle start button to carry out an engine Equipment required starting phase. petrol compression gauge Diagnostic tool Note: The engine will be under the action of the starter motor for 20 s, without starting.
  • Page 386 TOP AND FRONT OF ENGINE Pressure at end of compression: Check Equipment required petrol compression gauge self-contained starter Diagnostic tool CHECK I - PREPARATION OPERATION FOR CHECK a Remove: - the engine cover, - the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) ,...
  • Page 387 TOP AND FRONT OF ENGINE Pressure at end of compression: Check a Follow the start-up cycle until the compression III - FINAL OPERATION a Remove the petrol compression gauge. gauge needle stabilises to obtain the maximum val- a Refit: - the spark plugs (see 17A, Ignition, Plugs: Re- Note: moval - Refitting, page 17A-10) , The engine is operated by the starter for 20 sec-...
  • Page 388 TOP AND FRONT OF ENGINE Pressure at end of compression: Check Equipment required diesel compression gauge self-contained starter Diagnostic tool CHECK I - PREPARATION OPERATION FOR CHECK a Remove: 138337 - the engine cover, a Screw the conversion hose end piece (2) of the die- - the lifting eye on the timing end (see 11A, Top and sel compression gauge onto the hose.
  • Page 389 TOP AND FRONT OF ENGINE Pressure at end of compression: Check II - TEST OPERATION 1 - Automatic mode a Connect the Diagnostic tool. a In the Diagnostic tool : - select the repair mode, - select the programming mode, - Run command SC031: OPERATIONAL FAULT FINDING OF THE CYLINDERS.
  • Page 390 TOP AND FRONT OF ENGINE Pressure at end of compression: Check - the lifting eye on the timing end (see 11A, Top and front of engine, Lifting eyes: Removal - Refit- ting, page 11A-318) , - the engine cover. a In the Diagnostic tool : - select the repair mode, - select other configurations mode, - Run command VP037: STOP FUEL SUPPLY IN-...
  • Page 391 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting Equipment required brush with non abrasive bristles Tightening torquesm fixed roller bolt 44 N.m tensioning roller bolt 25 N.m right-hand side member 44 N.m tie-rod bolts REMOVAL IMPORTANT Wear protective gloves during the operation. 122377 a Remove the right-hand side member tie-rod bolts (1) WARNING...
  • Page 392 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 114021 a Remove: 114854 a Place a 3 mm Allen key in the tensioning roller hole - the tensioning roller bolts (3) , (2) .
  • Page 393 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING II - REFITTING OPERATION FOR PART CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: Accessories belt M9R, and 746 or 809 or 849 (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),...
  • Page 394 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting - the right-hand side member tie-rod bolts. a Torque tighten the right-hand side member tie-rod bolts (44 N.m). a Refit: - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres),...
  • Page 395 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED Tightening torquesm fixed roller bolt 25 Nm tensioning roller bolt 50 Nm IMPORTANT Wear protective gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 396 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a parts always to be replaced: Accessories belt (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), - parts always to be replaced: Accessories ten- sioning roller bolt (10,10,01,09).
  • Page 397 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - REMOVAL OPERATION FOR PART Special tooling required CONCERNED Mot. 1368 Tool for tightening eccentric tensioning roller bolt. 8 mm Torx wrench and 12.7 mm square. Tightening torquesm tensioning roller bolt 40 Nm WARNING The tensioning roller must be replaced when the...
  • Page 398 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Use a brush to remove any deposits from the crank- shaft pulley v-grooves. a parts always to be replaced: Accessories belt (10,10,01,03), parts always to be replaced: Accessories belt tensioning roller (10,10,01,04), parts always to be replaced: Accessories ten- sioning roller bolt (10,10,01,09).
  • Page 399 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting - a 125 mm (7) extension piece, - a junior (8) torque wrench. II - REFITTING OPERATION FOR PART CONCERNED a Turn the accessories belt tensioning roller clockwise using a 14 mm spanner. a Lock the tensioning roller using a 6 mm Allen key.
  • Page 400 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 401 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting a Turn the crankshaft twice. III - FINAL OPERATION. a Refit: - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 416, 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (MR 415, 35A, Wheels and tyres).
  • Page 402 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm tensioning roller bolts 25 N.m fixed roller bolt 25 N.m WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 403 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new tension wheel, - a new fixed roller. a Tighten to torque: - the tensioning roller bolts (25 N.m), - the fixed roller bolt (25 N.m).
  • Page 404 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting - the front right-hand wheel (see Wheel: Removal - Special tooling required Refitting) (35A, Wheels and tyres), Mot. 1715 Belt tension checking tool - the front right-hand wheel arch liner (see Front (frequency indicator).
  • Page 405 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART 2 - Alternator and air conditioning compressor CONCERNED accessories belt 1 - Power-assisted steering accessories belt 133862 a Turn the accessories belt automatic tensioner anti- clockwise using a 14 mm offset wrench.
  • Page 406 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a In case of reuse, clean the crankshaft accessories V-pulley using a brush to get rid of any deposit. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles.
  • Page 407 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 1 - Power-assisted steering belt a Refit: - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray.
  • Page 408 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting Equipment required brush with non abrasive bristles Tightening torquesm fixed roller bolts 50 Nm tensioning roller bolt 62 N.m WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 409 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 133907 a Remove: 133909 a Fit a 4 mm Allen key in the tensioning roller hole (4) . - the guards (6) from the fixed rollers, a Turn the tensioning roller clockwise and push on the - the fixed roller bolts, key at the same time until the tensioning roller locks.
  • Page 410 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit new fixed rollers. a Torque tighten the fixed roller bolts (50 Nm). a Refit: - the guards for the fixed rollers, - a new tensioning roller.
  • Page 411 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm crankshaft accessories 40 Nm + 110˚ ± ± ± ± pulley bolt 10˚ IMPORTANT Wear protective gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul-...
  • Page 412 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Parts always to be replaced: - the crankshaft accessories pulley bolt, - the crankshaft accessories pulley. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the new crankshaft accessories pulley,...
  • Page 413 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - REMOVAL OPERATION FOR PART Special tooling required CONCERNED Mot. 1789 Tool for immobilising the crankshaft pulley, timing end Equipment required two-claw extractor for exterior socket Tightening torquesm crankshaft accessories 68 Nm pulley bolt (initial torque)
  • Page 414 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting - the crankshaft accessories pulley bolt, - the (Mot. 1789). a Tighten: - the bolt of the (Mot. 1789) on the cylinder block, - to torque the crankshaft accessories pulley bolt (initial torque) (68 Nm).
  • Page 415 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1770 Crankshaft pulley locking tool. Tightening torquesm crankshaft accessories 50 Nm + 85˚ ± ± ± ± pulley bolt 6˚...
  • Page 416 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Always replace the crankshaft accessories pulley bolt. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accesso- ries pulley.
  • Page 417 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting - the engine undertray bolts, Special tooling required - the engine undertray. Mot. 1489 TDC locating pin. - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, Mot.
  • Page 418 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 103271 14491-1 a Position the camshaft grooves (6) almost horizontal- a Remove the lifting eye bolts (2) . ly and offset towards the bottom turning the crank- shaft in the operating direction (clockwise at timing end).
  • Page 419 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft acces- sories pulley bolts (10,03,03,10) parts always to be replaced: Crankshaft acces- sories pulley (10,03,03,07) 14490 a The camshaft grooves (8) must be horizontal and offset downwards.
  • Page 420 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the new crankshaft accessories pulley. a Torque tighten the new bolt on the crankshaft ac- cessories pulley (40 N.m + 115˚ ± ± ± ± 10˚). III - FINAL OPERATION.
  • Page 421 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm crankshaft accessories 44 N.m + 90˚ pulley bolt WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 422 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting III - FINAL OPERATION a Remove the screwdriver from the starter hole. a Refit: - the accessories belts (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex-...
  • Page 423 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm crankshaft accessories 50 Nm + 85˚ ± ± ± ± pulley bolt 6˚ WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 424 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft acces- sories pulley bolts (10,03,03,10). a In case of reuse, clean the crankshaft accessories V-pulley using a brush to get rid of any deposit. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles.
  • Page 425 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1489 TDC locating pin. Tightening torquesm the crankshaft accesso- 120 N.m + 95˚ ries pulley bolt ± ± ± ± 15˚ TDC setting pin plug 25 N.m WARNING...
  • Page 426 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft acces- sories pulley bolts (10,03,03,10). WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a If reusing the crankshaft accessories pulley, clean the crankshaft accessories pulley V-grooves with a brush to eliminate any deposits.
  • Page 427 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 14489 a Turn the crankshaft clockwise (timing end) smoothly using the bolt of the crankshaft accessories pulley, until the crankshaft presses against the tool (Mot. 1489) (8) . a Torque tighten the crankshaft accessories pulley bolt (120 N.m + 95˚...
  • Page 428 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Disconnect the battery (see Battery: Removal - Re- Special tooling required fitting) (MR 415, 80A, Battery). a Remove: Mot. 1054 TDC setting pin. - the engine cover, Mot. 1496 Camshaft timing tool.
  • Page 429 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 124125 120211 a Remove: a Remove the TDC pin plug (4) . - the nuts (3) from the exhaust flange, - the exhaust harness seal, a Remove: - the accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Remov- al - Refitting, page 11A-33) , - the right-hand suspended engine mounting (see...
  • Page 430 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 21878 15106 a Remove: a Rotate the engine clockwise (timing end) so that the camshaft grooves are offset below the centre line - the upper timing cover bolts (6) , and almost horizontal.
  • Page 431 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Position of the TDC pin before the setting point 15163-2 15106-1 a At the setting point the camshaft grooves must be Position of the TDC pin at the setting point horizontal and offset below the centre line.
  • Page 432 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 2 - Removing the timing belt 3 - Unlocking camshaft pulleys 21877-1 123141 a Slacken the timing belt by undoing the tensioning a Fit the tool (Mot. 1801) fitted with (Mot. 1509-01) roller nut (11) .
  • Page 433 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - parts always to be replaced: Timing fixed roller Position of the TDC pin at the setting point (10,02,04,05), - the exhaust harness seal, II - REFITTING OPERATION FOR PART CONCERNED 1 - Adjusting the timing 15163-1...
  • Page 434 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 15201 a Refit: - the new tensioning roller, ensuring that the lug (16) is positioned in the groove (17) , - the tensioning roller nut. 104703 Note: WARNING Ensure that the tool (Mot. 1496) is correctly fitted and that the inlet camshaft pulley and the Always degrease: exhaust camshaft pulley can rotate freely so that...
  • Page 435 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 3 - Timing belt tension 123141 a Fit the tool (Mot. 1801) fitted with (Mot. 1509-01). 15256 a Bring the toothed sprockets of the tool (Mot. 1801) into contact with the camshaft pulleys. Note: a Tighten to torque: When tightening the tensioning roller, use a 6...
  • Page 436 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Position of the TDC pin before the setting point 15163-2 15106-1 a Fit the camshaft setting tool (Mot. 1496) (without Position of the TDC pin at the setting point forcing it). b - Checking the tension 15163-1 a Rotate the crankshaft clockwise by two turns (timing...
  • Page 437 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 123141 123147 a Fit the tool (Mot. 1801) fitted with (Mot. 1509-01). a Remove: a Bring the toothed sprockets of the tool (Mot. 1801) - the bolt (20) on the tool (Mot. 1496), into contact with the camshaft pulleys.
  • Page 438 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the upper timing cover nuts, - the upper timing cover. a Tighten: - the upper timing cover nuts, - the upper timing cover. a Refit the breather pipe clip on the gearbox. a Clip the breather pipe to the gearbox.
  • Page 439 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 1 - First timing cover assembly type Special tooling required Mot. 1489 TDC locating pin. Mot. 1430 Set of 5 crankshaft and cam- shaft pulley timing pins. Tightening torquesm crankshaft accessories 120 N.m + 95˚...
  • Page 440 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 2 - Second timing cover assembly type 135493 135495 135492 135494 11A-62...
  • Page 441 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 3 - Both continued in the same way for removal 135475 123845 a Remove the bolts (11) from the right-hand suspend- ed engine mounting support. a Turn the timing belt slightly to remove the right-hand suspended engine mounting support.
  • Page 442 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 14489-1 a Turn the crankshaft clockwise (timing end) smoothly 107270 until the crankshaft comes in to contact with the tool a Turn the crankshaft to position the hole in the cam- (Mot.
  • Page 443 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109046 a Undo the timing belt tensioning roller bolt (17) . a Remove: - the timing belt, - the timing belt tensioning roller bolt, - the timing belt tensioning roller. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Timing belt (10,02,...
  • Page 444 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - REFITTING OPERATION FOR PART by one tooth to the right of the vertical axis (22) , CONCERNED - the crankshaft is properly resting against the TDC setting pin (with the crankshaft timing sprocket col- let (23) at the top).
  • Page 445 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109044 a Fit a new timing belt starting with the crankshaft sprocket. a Align the timing belt marks with the marks: - of the crankshaft timing sprocket, - of the camshaft pulley, - of the high pressure pump pulley.
  • Page 446 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109047 a Check that the camshaft pulley hub bolts are not ful- ly up against the camshaft pulley wheel. 109045 a Tighten the camshaft pulley hub bolts. a Remove: - the (Mot. 1489), 11A-68...
  • Page 447 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the (Mot. 1430). 109049 a Set the camshaft pulley using the (Mot. 1430). 107272 a Refit the old crankshaft accessories pulley bolt with a spacer (28) (which does not cover the crankshaft timing sprocket mark) on the crankshaft.
  • Page 448 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109045 a Check that the crankshaft timing sprocket collet (29) is positioned vertically at the top. Note: After the two turns, the adjustable index of the tensioning roller may be in two different positions. The rotation of the tension wheel eccentric depends on the position.
  • Page 449 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting First position of the timing tension wheel Second position of the timing tensioning roller adjustable index adjustable index 111083 111082 111081 111081 a Undo the timing tension wheel bolt by up to one turn, a Undo the timing tension wheel bolt by up to one turn, holding the adjustable index with a 6 mm Allen key.
  • Page 450 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the (Mot. 1430). a Rotate the crankshaft twice in a clockwise direction (timing end) before the camshaft pulley hub hole is opposite the cylinder head hole. a Screw tool (Mot. 1489) into the cylinder block. a Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes in to contact with the tool (Mot.
  • Page 451 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the engine undertray, - the engine undertray bolts, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal -...
  • Page 452 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting REMOVAL Special tooling required Mot. 799-01 Timing gear wheel immobil- I - REMOVAL PREPARATION OPERATION iser. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Mot.
  • Page 453 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the rear suspended engine mounting. II - OPERATION FOR REMOVAL OF PART CONCERNED 14487 a Remove: 103268 a Loosen the nut (5) of the timing tensioning roller. - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , Note:...
  • Page 454 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting REFITTING - PROCEDURE 1 I - REFITTING PREPARATION OPERATION a parts always to be replaced: Timing belt (10,02, 04,02), parts always to be replaced: Timing belt tension- ing roller (10,02,04,04), parts always to be replaced: Timing fixed roller (10,02,04,05), parts always to be replaced: Crankshaft acces-...
  • Page 455 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 103268 103268 a Refit: a Check that the mark (9) on the camshaft dephaser is vertical and pointing upwards. - the crankshaft timing sprocket (12) , a Make a mark (10) with a pencil between the cam- - a new timing belt, shaft dephaser gear and the rocker cover.
  • Page 456 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 3 - Timing belt tension 130493 103263 a Position the adjustable index (15) opposite the mark (16) , by turning the eccentric (17) clockwise using a 6 mm Allen key. a Torque tighten the timing tensioning roller nut (7 N.m).
  • Page 457 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109052 109051 a Remove: - the timing flap from the lower timing cover, - the lifting eye bolt from the (Mot. 1496), - the timing tool (Mot. 1496) fitted with the (Mot. 1750), - the (Mot.
  • Page 458 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 5 - Checking the timing a Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing. a Screw tool (Mot. 1489) into the cylinder block. a Move the crankshaft slowly and smoothly until it comes into contact with the tool (Mot.
  • Page 459 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Remove the camshaft dephaser (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refitting, page 11A-275) . 1 - Adjusting the timing Note: If the stud loosens with the nut (see 11A, Top and front of engine, Camshaft: Removal - Refitting, page 11A-245) (Technical Note 3887A,11A, Top and front of engine).
  • Page 460 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 111337 130493 a Fit the (Mot. 1496) with the (Mot. 1750) (25) . 14489 a Refit the tool (Mot. 1489) on the cylinder block. 111336 a Fit: a Use a screwdriver (28) to check that the flywheel does not turn (clockwise at the timing end), other- - the (Mot.
  • Page 461 Position: 108879 a Refit a new timing tensioning roller by positioning the - the RENAULT badge (30) etched on the stem of lug of the timing tensioning roller in the groove (33) . the exhaust camshaft sprocket vertically and point-...
  • Page 462 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 130495 130497 a Refit a new timing belt starting with the sprocket of a Refit a new timing fixed roller (35) . each camshaft (without moving the sprocket of each a Torque tighten the timing fixed roller bolt (50 camshaft).
  • Page 463 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 130497 109052 a Refit the lower timing cover (39) . a Remove: a Tighten to torque the lower timing cover bolts (12 - the timing flap from the lower timing cover, N.m).
  • Page 464 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 5 - Checking the timing a Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing. a Screw tool (Mot. 1489) into the cylinder block. a Move the crankshaft slowly and smoothly until it comes into contact with the tool (Mot.
  • Page 465 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the rear suspended engine mounting. a Torque tighten: - the rear suspended engine mounting bolt on the rear suspended engine mounting support (180 N.m),...
  • Page 466 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting REMOVAL Special tooling required Mot. 1431 Flywheel locking tool. I - REMOVAL PREPARATION OPERATION Mot. 1716 Removes housing with sili- cone seals. WARNING Mot. 1766 Top dead centre locating pin. Applying pressure to the engine oil sump is strictly forbidden.
  • Page 467 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115738 114026 a Remove: a Fit the flywheel locking tool (Mot. 1431) onto the cyl- inder block. - the engine mounting bolts (2) and (3) , a Remove: - the engine mounting. - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) ,...
  • Page 468 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting II - REMOVING THE TIMING BELT 115515 a Remove the tool (Mot. 1431). a Align the groove (5) on the crankshaft with the hole (6) on the cylinder block (pistons at mid-stroke). 114031 a Remove the bolts from the timing cover, around the rim and in the hole (4) .
  • Page 469 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 114030 114032 a Loosen the bolts (8) of the timing sprocket (exhaust a Remove: side). - the bolts (8) from the timing sprocket, a Compress the hydraulic tensioner piston (9) with the - the timing sprocket washer (14) , timing chain tensioner guide (10) .
  • Page 470 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting REFITTING II - REFITTING THE TIMING CHAIN a Set the engine at top dead centre. a Fit the top dead centre setting pin (Mot. 1766). I - REFITTING PREPARATION a Clean the joint faces of the timing cover using SU- PER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) .
  • Page 471 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 114430 a Place the new washer (26) of the timing sprocket (25) . a Finger tighten the new bolts (27) of the sprocket. Note: Allow the timing sprocket (25) to rotate freely . 114429 a Fit the new timing chain guide (21) .
  • Page 472 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 114431 a Fit the new timing chain tensioner guide (28) . a Torque tighten the bolt of the timing chain ten- sioner guide (25 N.m) (29) . a Fit the new timing hydraulic tensioner (30) with its locking pin (32) .
  • Page 473 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Fit the pins (37) of the tool into the wear compensa- tion pinion holes. Note: Do not fit the collet (34) of the tool into the groove on the exhaust side of the camshaft. a Turn the tool to align the shafts on the spacer (35) and the hole (36) .
  • Page 474 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 114905 114031 a Apply a bead of SILICONE ADHESIVE SEALANT a Refit the timing cover. a Finger tighten the timing cover bolts in order from (1) (see Vehicle: Parts and consumables for the re- pair) to the timing face: to (23) until they make contact.
  • Page 475 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 114026 114025 a Refit the engine mounting. a Refit the engine mounting reinforcement (39) . a Finger tighten the engine mounting bolts in order (1) a Finger tighten the reinforcement bolts in order (1) to to (6) until they make contact.
  • Page 476 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Refit: - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) , - the new accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refit- ting, page 11A-13) .
  • Page 477 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 Special tooling required Tightening torquesm Mot. 919-02 Flywheel locking tool. M10 bolts of the sus- 65 N.m pended engine mount- Mot. 1716 Removes housing with sili- ing support cone seals.
  • Page 478 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 - the power-assisted steering pump (see Power-as- sisted steering pump: Removal - Refitting) (36B, Power-assisted steering). 133842 a Fit the flywheel locking tool (Mot. 919-02). a Remove: 133868 a Remove: - the crankshaft accessories pulley (see 11A, Top...
  • Page 479 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 II - REMOVING THE TIMING CHAIN 133827 a Remove: - the camshaft dephaser cover bolts (2) , - the camshaft dephaser covers. 101403 134075 a Remove: - the timing cover bolts (3) , - the timing cover.
  • Page 480 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 22937 a Loosen the hydraulic tensioner of the primary chain: - lower the lever to unlock the piston, - lock the lever by inserting a 4 mm Allen key or an iron wire in the housing.
  • Page 481 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 - the upper guide bolts (5) , - the upper guide, - the tensioner guide bolt (6) , - the tensioner guide, - the bolts (7) of the primary chain shoe, - the primary chain shoe, - the primary chain, - the crankshaft sprocket.
  • Page 482 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 133850 127847 133851 127848 a Remove: a Remove: - the bolts (10) of the caps of camshaft bearing no.1, - the "camshaft sprocket - secondary chain" assem- blies, taking care not to remove the iron wires of the - the caps of camshaft bearing no.1, tensioners,...
  • Page 483 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 a Parts always to be replaced: REFITTING - primary timing chain, I - REFITTING PREPARATION OPERATION a Use SUPER CLEANING AGENT FOR JOINT FA- - secondary timing chains, CES (see Vehicle: Parts and consumables for - primary chain hydraulic tensioner, the repair) (04B, Consumables - Products) to clean...
  • Page 484 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 23020 a Check that the spigots of the inlet camshaft (14) and exhaust camshaft (15) are facing upwards and di- rectly in line with the cylinders (16) . a Refit the new hydraulic tensioners of the secondary chains equipped with new bolts.
  • Page 485 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 Fitting the secondary chain for the front row 101401 a Fit: - the line (17) of the inlet dephaser sprocket opposite the painted link (18) of the chain, - the two lines (19) of the exhaust sprocket opposite the two painted (20) links of the chain.
  • Page 486 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 Fitting the secondary chain of the back row 101402 a Fit: - the point (21) of the sprocket of the inlet dephaser opposite the painted link (22) of the chain, - the two points (23) of the exhaust sprocket oppo- site the two painted links (24) of the chain.
  • Page 487 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 a Unlock the tensioners for the secondary timing chains. a Refit: - the primary chain shoe, - a new primary chain tensioner guide equipped with new bolts, - a new primary chain upper guide equipped with new bolts, - a new primary chain hydraulic tensioner equipped...
  • Page 488 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 101399 a Apply beads of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the re- pair) (04B, Consumables - Products) with a width of 2 to 3 mm to camshaft bearing no.1. 133850 133851 a Refit the no.
  • Page 489 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 101398 134074 a Apply beads of SILICONE ADHESIVE SEALANT a Refit: (see Vehicle: Parts and consumables for the re- - the new dephaser cover seals, pair) (04B, Consumables - Products) with a width of 2.6 to 3.6 mm to the timing cover.
  • Page 490 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting V4Y, and 713 III - FINAL OPERATION a Refit: - the crankshaft seal on the timing side (see 10A, Engine and cylinder block assembly, Crank- shaft seal on timing end: Removal - Refitting, page 10A-134) , - the oil level sensor (see 10A, Engine and cylinder block assembly, Oil level sensor: Removal - Re-...
  • Page 491 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting - the coolant pump (see 19A, Cooling, Coolant Special tooling required pump: Removal - Refitting, page 19A-66) , Mot. 1874 TDC locating pin - the power-assisted steering pump (see Power-as- sisted steering pump: Removal - Refitting) Mot.
  • Page 492 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 137034 134885 a Remove the bolts (6) from the coolant pipe at the a At (2) , unclip the fuel pipes from the engine wiring outlet of the exhaust gas recirculation solenoid support.
  • Page 493 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 134887 138354 a Remove: a Loosen the clip (10) for the intercooler air outlet pipe on the front row upper timing cover. - the bolts (8) from the back row upper timing cover, a Disconnect the intercooler air outlet pipe from the - the back row upper timing cover, front row upper timing cover.
  • Page 494 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting II - TIMING CHAIN REMOVAL OPERATION 134891 a Remove the Top Dead Centre (TDC) pin plug (16) . 134889 a Draw a line (13) level with the crankshaft mark (14) using a indelible pencil.
  • Page 495 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 1 - Removal of the back row timing chain 134896 a Lock the back row timing chain hydraulic tensioner 134894 a Loosen the bolts (18) of the back row timing sprock- using a 3 mm Allen key (20) .
  • Page 496 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting - the bolts (23) from the back row timing chain side 2 - Removal of the oil pump chain guide, - the side guide for the back row timing chain. 134899 a Turn the oil pump chain tensioner in the direction of 134898...
  • Page 497 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 3 - Removal of the front row timing chain 134903 a Lock the front row timing chain hydraulic tensioner 134901 a Remove: using a 3 mm Allen key (34) . a Remove: - the vacuum pump drive stud mounting bolts (31) , - the bolts (35) from the front row timing chain hy-...
  • Page 498 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting - the bolts (37) from the front row timing chain side guide, - the side guide for the front row timing chain. 134906 a Remove: - the timing sprocket on the crankshaft (40) , 135593 a Remove: - the TDC setting pin (Mot.
  • Page 499 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Parts always to be replaced: - the groove (43) , fitted horizontally (big offset (44) upwards). - timing chain hydraulic tensioners, - timing sprocket on the crankshaft, - timing chain sprockets, - timing chain sprocket bolts, - timing chain side guides, - timing chain side guide bolts,...
  • Page 500 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Fit the pins (52) of the tool (Mot. 1880) into the free play take up pinion holes. a Turn the tool (Mot. 1880) to align the shaft of the spacer (50) with the hole (51) on the rocker cover.
  • Page 501 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 3 - Refitting the back row timing chain 135596 a Check that the new oil pump tensioner spring is in 137995 a Check that: the correct position. - the mark (55) on the free play take up pinion is aligned with the centring pin (56) on the upper tim- ing cover of the back row, - the groove (57) , fitted horizontally (big offset (58)
  • Page 502 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting - the mark (61) on the crankshaft sprocket opposite III - FINAL OPERATION the copper link (62) of the timing chain. a Refit the washer for the back row timing chain sprocket.
  • Page 503 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Fit the upper timing cover for the back row. a Fit the back row upper timing cover bolts without tightening them. a Tighten the back row upper timing cover bolts in se- quence.
  • Page 504 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) .
  • Page 505 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting Special tooling required M4R, and 704 Mot. 919-02 Flywheel locking tool. a Disconnect the manual gearbox from the engine (see Manual gearbox: Removal - Refitting) (21A, Mot. 1716 Removes housing with sili- Manual gearbox).
  • Page 506 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Remove: - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , - the crankshaft seal on the timing side (see 10A, Engine and cylinder block assembly, Crank- shaft seal on timing end: Removal - Refitting, page 10A-134) .
  • Page 507 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115880 a Remove the timing cover using the (Mot. 1716) (5) . a Remove the timing cover (6) . a Tighten the crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing sprocket mark) onto the crankshaft.
  • Page 508 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115877 a Engage the timing chain tensioner. a Put a metal rod (10) into the tensioner to keep the chain loose. 115873 a Remove: - the bolt (13) of the timing chain tensioner pad, - the timing chain tensioner pad (14) .
  • Page 509 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115874 115875 a Remove: a Remove the timing chain (17) . - the timing chain guide bolts (15) , REFITTING - the timing chain guide (16) . I - REFITTING PREPARATION OPERATION WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in...
  • Page 510 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Finish cleaning the joint faces using a GREY ABRA- II - OPERATION FOR REFITTING THE TIMING SIVE PAD, part number 77 01 405 943. CHAIN WARNING T o ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks).
  • Page 511 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115875 116041 a Fit the new timing chain (20) so that the marks on the timing chain (21) are aligned with the marks on each of the sprockets. 11A-133...
  • Page 512 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115874 115873 a Refit: a Refit: - the new timing chain guide (22) , - the new timing chain tensioner pad (24) , - the timing chain guide bolts (23) . - the bolts (25) of the timing chain tensioner pad.
  • Page 513 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115878 115877 a Refit: a Remove the metal rod (28) in order to release the timing chain tensioner. - the new timing chain tensioner (26) , a Tighten the old crankshaft accessories pulley bolt fit- - the timing chain tensioner bolts (27) .
  • Page 514 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 116044 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.). 116040 a Apply a bead of SILICONE ADHESIVE SEALANT a Check that:...
  • Page 515 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting 115881 a Refit: - the camshaft dephaser solenoid valve (32) , - the bolt (33) of the camshaft dephaser solenoid valve. a Torque tighten the camshaft dephaser solenoid valve bolt (10 N.m). 115879 a Refit: - the timing cover,...
  • Page 516 TOP AND FRONT OF ENGINE Timing chain: Removal - Refitting a Remove the engine from the component support (see Engine support equipment: Use) . M4R, and 704 a Connect the manual gearbox to the engine (see Manual gearbox: Removal - Refitting) (21A, Man- ual gearbox).
  • Page 517 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the engine undertray, Special tooling required - the crankshaft accessories pulley (see 11A, Top Mot. 1716 Removes housing with sili- and front of engine, Crankshaft accessories cone seals. pulley: Removal - Refitting, page 11A-33) . - the right-hand suspended engine mounting (see Equipment required 19D, Engine mounting, Right-hand suspended...
  • Page 518 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED 120210 a Remove the rocker cover bolts. 123145 a Unclip: Note: The rocker cover bolts are not the same length; - the injector wiring on the gearbox side lifting eye, mark their positions.
  • Page 519 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Use SUPER CLEANING AGENT FOR JOINT FAC- ES (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products) to clean and degrease the joint faces: - on the rocker cover if it is being reused, - on the cylinder head.
  • Page 520 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 120210 a Torque tighten: - the rocker cover bolts (22), (23), (20), (13) (8 Nm), - the rocker cover bolts (1) to (12), (14) to (19), 14517 (21), (24) (12 Nm), a Use a stipple roller to apply RESIN ADHESIVE (see - the rocker cover bolts (22), (23), (20), (13) (12 Vehicle: Parts and consumables for the repair)
  • Page 521 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) . a Refit: - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , - the accessories belt (see 11A, Top and front of...
  • Page 522 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting Tightening torquesm rocker cover bolts (ini- 2 Nm tial torque) rocker cover bolts 8 Nm oil vapour rebreathing 2.5 Nm valve REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the intake distributor (see 12A, Fuel mixture, Inlet 123370 a Remove:...
  • Page 523 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Always replace: - the rocker cover seal, - the oil vapour rebreathing valve seal. WARNING The joint faces must be clean, dry and free from grease (avoid finger marks).
  • Page 524 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 780 REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 123533 a Disconnect: - the damper valve connector (2) , - the connector (3) from the camshaft position sen- 123532 sor.
  • Page 525 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 780 123299 123296 a Remove the clip (6) from the intercooler inlet air a Unclip (8) the cover from the injector rail protector. a Remove: pipe. a Disconnect the intercooler air inlet pipe from the tur- - the injector rail protector cover bolt (9) , bocharger.
  • Page 526 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 780 - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Re- moval - Refitting, page 13B-108) .
  • Page 527 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 780 II - OPERATION FOR REMOVAL OF PART CONCERNED 19712-1 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.).
  • Page 528 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 780 a Tighten: - the injector rail protector cover nut, - the injector rail protector cover bolt. a Clip on the injector rail protector cover. a Fit: - the intercooler air inlet pipe, - the clips to the intercooler inlet air pipe in their orig- inal position.
  • Page 529 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the engine undertray bolts, Tightening torquesm - the engine undertray, rocker cover bolts 1 to 12 N.m - the accessories belt (see 11A, Top and front of 13, 16 to 20, 23 to 24 engine, Accessories belt: Removal - Refitting, page 11A-13) , rocker cover bolts 14,...
  • Page 530 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 128634 a Disconnect the camshaft dephaser solenoid valve 128636 connector (3) . a Remove the rocker cover bolts. a Remove: - the camshaft dephaser solenoid valve sensor bolt Note: (4) , The rocker cover bolts do not have the same...
  • Page 531 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to degrease: - the rocker cover joint face if it is to be re-used, - the cylinder head joint face.
  • Page 532 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 14497 a Refit the rocker cover. a Refit: a Tighten to torque and in order: - every camshaft seal (see 11A, Top and front of engine, Camshaft seal, timing end: Removal - - rocker cover bolts 1 to 13, 16 to 20, 23 to 24 (12 Refitting, page 11A-287) ,...
  • Page 533 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the oil separator (see 11A, Top and front of en- gine, Oil decanter: Removal - Refitting, page 11A-307) , - the coils (see 17A, Ignition, Coils: Removal - Re- fitting, page 17A-1) ,...
  • Page 534 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting Special tooling required Mot. 1431 Flywheel locking tool. Mot. 1766 Top dead centre locating pin. Equipment required component support REMOVAL I - REMOVAL PREPARATION OPERATION WARNING It is strictly forbidden to apply any pressure to the engine oil sump.
  • Page 535 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the oil decanter (see 11A, Top and front of en- II - REMOVAL OF THE ROCKER COVER gine, Oil decanter: Removal - Refitting, page 11A-307) , - the diesel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refit- ting, page 13B-108) , - the high pressure pipes between the rail and the in-...
  • Page 536 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting REFITTING II - REFITTING THE ROCKER COVER I - REFITTING PREPARATION OPERATION a Use SUPER CLEANING AGENT FOR JOINT FA- CES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean: - the joint face on the rocker cover, - the joint face on the cylinder head.
  • Page 537 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 114904 a Tighten in order and successively, the rocker cover - the high pressure pipes between the rail and the in- bolts (12), (15),(18) and (21) to gradually fit the rock- jectors (see 13B, Diesel injection, High pressure er cover on the cylinder head.
  • Page 538 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting M9R, and 800 or 802 or 803 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Refit the exhaust gas pressure sensor (see 19B, Ex- haust, Exhaust gas pressure sensor: Removal - Refitting, page 19B-93) .
  • Page 539 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the fuel supply union (4) , - the camshaft position sensor connector. Tightening torquesm rocker cover bolts (ini- 2 N.m tial torque) rocker cover bolts (tight- 8 N.m ening torque) IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 540 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the rocker covers on the front and rear rows. II - REFITTING OPERATION FOR PART CONCERNED REFITTING I - REMOVAL PREPARATION OPERATION Note: The rocker cover is sealed by a composite seal that can withstand being removed and refitted a number of times.
  • Page 541 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the engine cover. 11A-163...
  • Page 542 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the crankshaft accessories pulley (see 11A, Top Special tooling required and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , Mot. 1448 Remote operation pliers for hose clips.
  • Page 543 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the high pressure pipe between the rails (see 13B, Diesel injection, High pressure pipe between rails: Removal - Refitting, page 13B-184) , - the diesel injectors (see 13B, Diesel injection, Diesel injector: Removal - Refitting, page 13B- 229) , - the damper valve (see 12A, Fuel mixture, Damp-...
  • Page 544 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 137884 138625 a Remove: a Remove the nut (4) for the engine wiring. a Move aside the engine wiring. - the lifting eye at the flywheel end (see 11A, Top and front of engine, Lifting eyes: Removal - Re- a Remove: fitting, page 11A-318)
  • Page 545 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 2 - Back row 3 - Front and back row 138624 137041 a Disconnect the hose at the inlet of the heater matrix (8) on the cylinder head outlet intermediate coolant duct.
  • Page 546 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting Back row Front row 136285 136287 136286 136288 a Very carefully detach the rocker cover concerned: - using a screwdriver in the notches, - using the tool (Mot. 1716). 11A-168...
  • Page 547 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Use SUPER CLEANING AGENT FOR JOINT FA- CES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean the gasket faces: - of the rocker covers, - on the cylinder head.
  • Page 548 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING THE ROCKER COVER 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.).
  • Page 549 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting a Fit the engine wiring onto the engine wiring support - the high pressure pipe between the pump and the at the flywheel end. rail (see 13B, Diesel injection, High pressure a Refit the nut for the engine wiring onto the engine pipe between pump and rail: Removal - Refit- ting, page 13B-140) ,...
  • Page 550 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , a Remove the engine from the component support (see Engine support equipment: Use) .
  • Page 551 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 Special tooling required Mot. 1720 Engine stand. Mot. 1672 Lower engine support. Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Mot. 1453-01 Additional handle nut for engine lifting support tool Mot.
  • Page 552 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 138399 138550 a Disconnect the turbocharger pressure sensor con- a Unclip the injector rail protector cover at (8) . a Remove: nector (4) . a Unclip the wiring (5) of the turbocharging pressure - the bolts (9) from the injector rail protector cover, sensor.
  • Page 553 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 138540 135494 a Unclip the diesel injector wiring (23) . a Disconnect the diesel injector connectors (24) . a Move aside the diesel injector wiring. a Remove: - the damper valve (see 12A, Fuel mixture, Damp- er valve: Removal - Refitting, page 12A-39) , - the right-hand suspended engine mounting (see...
  • Page 554 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 128247 128246 a Remove the tie rod rear bolts (12) . a Fit the (Mot. 1720) (14) fitted with the (Mot. 1672) (15) . a Remove the (Mot. 1453) fitted with the (Mot. 1453- 01).
  • Page 555 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 138427 139198 a Unclip the connector (17) of the exhaust gas temper- a Remove: ature sensor on the air inlet metal tube. - the bolts (19) from the lifting eye at the timing end, - the lifting eye on the timing end, - the air inlet metal tube, - the air inlet metal tube seals.
  • Page 556 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 a Use SURFACE CLEANER (see Vehicle: Parts II - OPERATION FOR REMOVAL OF PART CONCERNED and consumables for the repair) (04B, Consuma- bles - Products) and CLEAN CLOTHS to degrease: - the cylinder head joint face, - the housing of the rocker cover seal, if reusing, - the housing of each air inlet metal tube seal,...
  • Page 557 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 19712-1 WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mix- 115069 ture of sealant and fluid could damage certain components (engine, radiator, etc.).
  • Page 558 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 782 - the damper valve (see 12A, Fuel mixture, Damp- er valve: Removal - Refitting, page 12A-39) . a Connect the diesel injector connectors. a Clip on the diesel injector wiring. a Connect the camshaft position sensor connector.
  • Page 559 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the accessories belt (see 11A, Top and front of Special tooling required engine, Accessories belt: Removal - Refitting, page 11A-13) , Mot. 1448 Remote operation pliers for hose clips. - the engine undertray bolts, - the engine undertray, Mot.
  • Page 560 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 14499 124751 a Remove: - the valve rockers (1) , - the hydraulic tappets (2) . Note: T o prevent any risk of unpriming the hydraulic tappets make sure that they are vertical. 123165 a Undo the air filter unit air outlet pipe clips (3) .
  • Page 561 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 123344 123343 a Unclip: a Disconnect the coolant temperature sensor connec- tor (8) . - the clip (4) of each turbocharging pressure regula- a Move aside the clip (9) of each water chamber cool- tion hose, ing hose using tool (Mot.
  • Page 562 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Disconnect: - the oil vapour rebreather solenoid valve connector (11) , - the injector connectors (12) , - the throttle valve connector (13) , - the brake servo vacuum pipe union (14) on the in- take distributor, - the petrol vapour rebreather pipe union (15) on the intake distributor.
  • Page 563 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the cylinder head gasket. REFITTING I - REFITTING PREPARATION OPERATION a Always replace the cylinder head bolts. 1 - CLEANING THE CYLINDER HEAD a Clean the cylinder head. IMPORTANT Wear goggles with side protectors for this opera- tion.
  • Page 564 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting Consumables - Products) to dissolve the part of the seal that is still attached to the cylinder head and the cylinder block. a Apply the product to the part to be cleaned, wait ap- proximately ten minutes then remove the residue with a wooden spatula.
  • Page 565 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Connect: II - REFITTING OPERATION FOR PART CONCERNED - the petrol vapour rebreather pipe union on the in- take distributor, - the brake servo vacuum pipe union on the intake distributor, - the throttle valve connector, - the injector connectors,...
  • Page 566 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the front right-hand driveshaft (see Front right- hand driveshaft: Removal - Refitting) (MR 415, 29A, Driveshafts), - the suspended engine mounting (see 19D, Engine mounting, Lower engine tie-bar: Removal - Re- fitting, page 19D-85) , - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories...
  • Page 567 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 a Remove: Special tooling required - the engine cover, Mot. 1448 Remote operation pliers for - the front right-hand wheel (see Wheel: Removal - hose clips. Refitting) (35A, Wheels and tyres), - the front right-hand wheel arch liner (see Front Equipment required wheel arch liner: Removal - Refitting) (55A, Ex-...
  • Page 568 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 111748 a Remove: - the dipstick, - the dipstick well bolts (3) , - the dipstick well. 123532 a Undo the clip (1) from the intercooler outlet pipe. a Disconnect the intercooler air outlet pipe from the damper valve.
  • Page 569 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 121514 a Undo the air filter box air outlet pipe clip (5) on the turbocharger. a Disconnect the air filter box air outlet pipe from the turbocharger. a Remove the breather pipe on the cylinder head.
  • Page 570 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION IMPORTANT Wear goggles with side protectors for this opera- tion. IMPORTANT Wear latex gloves during the operation. WARNING 19712 Do not scrape the joint faces of the aluminium,...
  • Page 571 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 a Using SURFACE CLEANER (see Vehicle: Parts a Fit: and consumables for the repair) (04B, Consum- - the new cylinder head gasket, centred by two dow- ables - Products) and CLEAN CLOTHS degrease els, the cylinder head and cylinder block gasket faces.
  • Page 572 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 780 a Refit: - the pipes from the diesel injector fuel return rail. a Connect the intercooler cooling system cover hoses. - the rocker cover (see 11A, Top and front of en- a Refit the intercooler cooling system cover hose clips gine, Rocker cover: Removal - Refitting, page 11A-139) ,...
  • Page 573 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the throttle valve (see 12A, Fuel mixture, Throttle Special tooling required valve: Removal - Refitting, page 12A-49) , Mot. 1448 Remote operation pliers for - the coils (see 17A, Ignition, Coils: Removal - Re- hose clips.
  • Page 574 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 128376 128618 a Remove: a Remove: - the nut (4) from the exhaust manifold stay, - the dipstick (1) , - the bolt (5) from the exhaust manifold stay, - the bolts (2) from the dipstick guide tube, - the exhaust manifold stay.
  • Page 575 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 128616 a Using the (Mot. 1448) or (Mot. 1202-01) or (Mot. 103259 1202-02) remove: a Remove: - the cooling radiator top hose clip (7) on the water chamber, - the cylinder head bolts, - the heater matrix inlet hose clip (8) on the water...
  • Page 576 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Always replace: - the cylinder head bolts, - the ring between the exhaust manifold and the cat- alytic converter, - the cylinder head gasket. 11A-198...
  • Page 577 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Strip the cylinder head (see Cylinder head: Strip- CLEANING THE CYLINDER HEAD ping) (Technical Note 6023A, 10A, Engine and pe- ripherals). a Test the cylinder head for any cracks with the cylin- IMPORTANT Wear goggles with side protectors for this opera- der head testing kit (see Garage Equipment cata-...
  • Page 578 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting II - REFITTING OPERATION FOR PART III - FINAL OPERATION. a Connect: CONCERNED - the cooling radiator top hose to the water chamber, - the heater matrix inlet hose to the water chamber, - the coolant temperature sensor connector, a Using the (Mot.
  • Page 579 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the oil separator (see 11A, Top and front of en- gine, Oil decanter: Removal - Refitting, page 11A-307) ,...
  • Page 580 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Remove: Special tooling required - the accessories belt (see 11A, Top and front of Mot. 1431 Flywheel locking tool. engine, Accessories belt: Removal - Refitting, page 11A-13) , Equipment required - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) .
  • Page 581 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Remove: - the damper valve (see 12A, Fuel mixture, Damp- er valve: Removal - Refitting, page 12A-39) , - Depending on the version, the catalytic pre-con- verter or the catalytic converter at the turbocharger outlet (see 19B, Exhaust, Catalytic pre-convert- er: Removal - Refitting, page 19B-22) or (see 19B, Exhaust, Catalytic converter: Removal -...
  • Page 582 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the dipstick guide. M9R, and 742 or 744 or 746 or 748 M9R, and 754 or 800 or 802 or 803 or 805 or 806 or 808 or 809 or 816 or 845 or 849 114037 a Remove: - the bolts (8) of the EGR pipe at the EGR cooler out-...
  • Page 583 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting M9R, and 754 or 800 or 802 or 803 or 805 or 806 or 808 or 809 or 816 or 845 or 849 114038 a Remove the air pipe (10) between the EGR cooler control solenoid valve and the EGR cooler.
  • Page 584 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 114253 a Remove the hydraulic tappet - valve rocker assem- blies. Note: Mark each hydraulic tappet - valve rocker assem- bly in relation to the cylinder head. Immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.
  • Page 585 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting REFITTING parts always to be replaced: exhaust gas recir- culation pipe bolt (11,07,01,18) I - REFITTING PREPARATION OPERATION M9R, and 742 or 744 or 746 or 748 a parts always to be replaced: Exhaust gas recir- WARNING culation pipe seal (11,07,01,15) Protect the oilway so that foreign bodies do not...
  • Page 586 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 114054 a Refit the cylinder head. a Tighten to torque and in order: - the cylinder head bolts (initial torque) (5 N.m), - the cylinder head bolts (final torque) (30 N.m + 114874 a Fit the new cylinder head gasket (13) on the cylinder 300˚...
  • Page 587 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the bolts of the EGR pipe on the EGR cooler end. M9R, and 754 or 800 or 802 or 803 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Refit: - the new EGR pipe at the EGR cooler outlet (check for the seal on the EGR solenoid valve end),...
  • Page 588 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the high pressure pipe between the pump and the rail (see 13B, Diesel injection, High pressure M9R, and 742 or 744 or 746 or 748 pipe between pump and rail: Removal - Refit- a Fit a new seal on the dipstick guide tube.
  • Page 589 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Refit: - the EGR pipe at the EGR cooler inlet (see 14A, An- tipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, page 14A-62) , - the engine - gearbox assembly (see 10A, Engine and cylinder block assembly, Engine - gearbox assembly: Removal - Refitting, page 10A-1) , a Top up the engine oil (see 10A, Engine and cylin-...
  • Page 590 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Fit the lifting eye on the timing end (see 11A, Top Special tooling required and front of engine, Lifting eyes: Removal - Re- fitting, page 11A-318) . Mot.
  • Page 591 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Remove: - the rocker covers (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page - the engine wiring, 11A-139) . - the alternator (see 16A, Starting - Charging, Al- ternator: Removal - Refitting, page 16A-1) .
  • Page 592 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 II - OPERATION FOR REMOVAL OF PART CONCERNED 127894 a Mark the position of the camshaft tappets using a in- 127892 delible pencil. a Remove: a Remove: - the bolts (8) of the inner cover on the cylinder - the camshaft tappets using a magnet, heads,...
  • Page 593 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Use SUPER CLEANING AGENT FOR JOINT FA- Back row cylinder head CES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean: - the cylinder block gasket face, - the cylinder head gasket faces on the cylinder block.
  • Page 594 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Clean the gasket faces of the inner timing cover and cylinder heads on the inner timing cover using SU- PER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products).
  • Page 595 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Perform in order and to angle: Front row cylinder head - a first tightening of the cylinder head bolts (93˚ ± ± ± ± 3˚), - a second tightening of the cylinder head bolts (93˚...
  • Page 596 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Refit: III - FINAL OPERATION - the camshafts (see 11A, Top and front of engine, Camshaft: Removal - Refitting, page 11A-245) , - the injector holder shim (see 12A, Fuel mixture, Injector holder shim: Removal - Refitting, page 12A-93) , - the injector rail - injectors (see 17B, Petrol injec-...
  • Page 597 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Refit: - the rocker covers (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) . - the camshaft position sensors (see Camshaft po- sition sensor: Removal - Refitting) , - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) ,...
  • Page 598 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting V4Y, and 713 a Remove the engine lifting eye at the timing end (see 11A, Top and front of engine, Lifting eyes: Re- moval - Refitting, page 11A-318) . a Refit the engine - gearbox assembly (see 10A, En- gine and cylinder block assembly, Engine - gear- box assembly: Removal - Refitting, page 10A-1) .
  • Page 599 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the power-assisted steering pump (see Power-as- Special tooling required sisted steering pump: Removal - Refitting) (36A, Power-assisted steering), Mot. 1431 Flywheel locking tool. - the vacuum pump (see Vacuum pump: Removal - Refitting) (37A, Mechanical component controls), Tightening torquesm - the crankshaft accessories pulley (see 11A, Top...
  • Page 600 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the high pressure pipes between the rail and the in- - the high pressure pump (see 13B, Diesel injec- jector (see 13B, Diesel injection, High pressure tion, High pressure pump: Removal - Refitting, pipe between rail and injector: Removal - Refit- page 13B-62) .
  • Page 601 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the O-ring for the coolant pump outlet pipe on the cylinder head outlet intermediate coolant duct side. 135579 a Remove: 135580 a Remove: - the bolts (4) from the inter-intake distributors pipe on the timing side, - the bolts (3) from the inter-intake distributors pipe - the inter-intake distributors pipe on the timing side,...
  • Page 602 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 1 - Front row 134910 a Remove the nuts (8) from the front row exhaust 137887 a Remove the engine wiring nut (5) from the fuel dis- manifold heat shield. a Disconnect the diesel fuel discharge hose from the charge pipe support.
  • Page 603 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 2 - Back row 135577 134912 a Remove: - the bolts (10) from the exhaust manifold heat shield on the back row, - the exhaust manifold heat shield on the back row. II - OPERATION FOR REMOVAL OF PART CONCERNED 135578...
  • Page 604 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 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 deteri- oration of the camshaft.
  • Page 605 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting Front row 138139 135104 a Refit new cylinder head gaskets. Back row 138137 a At (1 4) , apply beads of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) with a width of 5 mm to the joint faces of the cylinder block.
  • Page 606 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting Front row II - REFITTING OPERATION FOR PART CONCERNED 138140 135578 Back row 138138 a At (1 5) , apply beads of SILICONE ADHESIVE 135577 SEALANT (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) with WARNING a width of 5 mm to the joint faces of the cylinder...
  • Page 607 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Torque tighten and angle tighten the cylinder head - a new O-ring to the inter-intake distributors pipe on bolts (30 N.m + 300˚ ± ± ± ± 6˚) in order. the timing side, - the inter-intake distributors pipe on the timing side, Note:...
  • Page 608 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the high pressure pipes between the rail and the in- jector (see 13B, Diesel injection, High pressure pipe between rail and injector: Removal - Refit- ting, page 13B-161) , - the high pressure pipe between the pump and the rail (see 13B, Diesel injection, High pressure pipe between pump and rail: Removal - Refit-...
  • Page 609 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the vacuum pump (see Vacuum pump: Removal - Refitting) (37A, Mechanical component controls), - the power-assisted steering pump (see Power-as- sisted steering pump: Removal - Refitting) (36A, Power-assisted steering), - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) , - the accessories belt (see 11A, Top and front of...
  • Page 610 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Place the engine on the component support (see Special tooling required Engine support equipment: Use) . a Drain the engine (see 10A, Engine and cylinder Mot. 919-02 Flywheel locking tool. block assembly, Engine oil: Draining - Refilling, page 10A-100) .
  • Page 611 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) , - the rocker cover (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) , - the timing sprockets (see Timing sprocket: Re- moval - Refitting) ,...
  • Page 612 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Refit: REFITTING - the new cylinder head gasket on the cylinder block, I - REFITTING PREPARATION OPERATION - the cylinder head, - the new cylinder head bolts. WARNING Protect the oilway so that foreign bodies do not enter the oil pipes in the cylinder head.
  • Page 613 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the rocker cover (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) , - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) , - the inlet distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the throttle valve (see 12A, Fuel mixture, Throttle...
  • Page 614 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 615 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 - the dipstick. 138817 138538 a Disconnect: a Remove the dipstick guide bolts (1) . a Move aside the dipstick guide. - the exhaust gas recirculation solenoid valve con- nector (3) , - the vacuum pipe (4) of the exhaust gas recircula- tion valve solenoid valve,...
  • Page 616 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 139158 139156 a Unclip the heater matrix cooling pipe at (7) . a Use the tool (Mot. 1448) to separate the clips (9) on the water chamber cooling pipes. a Disconnect the water chamber cooling pipes.
  • Page 617 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 138813 139192 a Unclip the alternator wiring (10) on the rail protector. a Remove: a Disconnect: - the alternator protector bolt (15) , - all heater plug connectors, - the alternator protector.
  • Page 618 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 138812 139190 a Disconnect: a Disconnect the fuel drain pipe (19) on the injector rail protector. - the fuel supply pipe union (17) from the exhaust fuel injector solenoid valve, - the fuel supply pipe union (18) from the exhaust fuel injector.
  • Page 619 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION Note: The operation to remove the cylinder head IMPORTANT requires two people. Wear goggles with side protectors for this opera- a Remove the tool (Mot.
  • Page 620 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 a Use a SURFACE CLEANER (see Vehicle: Parts a Fit: and consumables for the repair) (04B, Consuma- - the new cylinder head gasket on the cylinder block, bles - Products) and CLEAN CLOTHS to degrease - the cylinder head on the cylinder block.
  • Page 621 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 a Refit: - the fuel supply pipe opening of the exhaust fuel in- jector solenoid valve, - the dipstick guide, - the fuel supply pipe opening of the exhaust fuel in- - the dipstick, jector.
  • Page 622 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 782 11A-244...
  • Page 623 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting Tightening torquesm engine tie-bar bolt on 190 Nm engine tie-bar mounting engine tie-bar bolt on 115 Nm the subframe REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 624 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED 123155 a Remove the camshafts (3) . 14499 a Remove: - the valve rockers (4) , - the hydraulic tappets (5) . Note: T o prevent any risk of unpriming the hydraulic tappets make sure that they are vertical.
  • Page 625 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REFITTING Note: I - REFITTING PREPARATIONS OPERATION It is essential to reprime the hydraulic tappets as these may become drained if removed for a long time. Camshaft marking a To check if re-priming is necessary, press the top of the tappet with your thumb.
  • Page 626 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the engine undertray, - the engine undertray bolts, a Tighten the engine undertray bolts. a Refit: - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 416,...
  • Page 627 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the rocker cover (see 11A, Top and front of en- Special tooling required gine, Rocker cover: Removal - Refitting, page 11A-139) , Mot. 1606 High pressure pump pulley support tool. - the vacuum pump (see Vacuum pump: Removal - Refitting) (37A, Mechanical component controls).
  • Page 628 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 113563 118983 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.
  • Page 629 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING T o ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks). WARNING Applying excess sealant could cause it to be 113563 squeezed out when parts are tightened.
  • Page 630 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-33) , - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-13) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended...
  • Page 631 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the engine cover, - the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-13) ,...
  • Page 632 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REFITTING II - REFITTING OPERATION FOR PART CONCERNED a Refit: I - REFITTING PREPARATION OPERATION - the hydraulic tappets, - the valve rockers, Camshaft markings - the inlet camshaft, by lubricating the inlet camshaft bearings, - the exhaust camshaft, by lubricating the exhaust camshaft bearings.
  • Page 633 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the engine cover. 11A-255...
  • Page 634 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Remove: Special tooling required - the accessories belt (see 11A, Top and front of Mot. 1431 Flywheel locking tool. engine, Accessories belt: Removal - Refitting, page 11A-13) , Mot. 1573 Cylinder head support - the coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-66) .
  • Page 635 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Remove: II - CAMSHAFT REMOVAL OPERATION - the vacuum pump (see Vacuum pump: Removal - Refitting) , - the high pressure pipe between the pump and the rail (see 13B, Diesel injection, High pressure pipe between pump and rail: Removal - Refit- ting, page 13B-140) , - the oil decanter (see 11A, Top and front of en-...
  • Page 636 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting Refitting the high pressure pump pinion a Carry out this operation only when replacing the ex- haust side camshaft or the high pressure pump drive pinion. a Immobilise the high pressure pump drive pinion in a vice with jaws.
  • Page 637 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Remove the rocker cover from the (Mot. 1573). II - CAMSHAFT REFITTING OPERATION 127872 a Position: - the groove (12) on the exhaust side camshaft hori- zontally (large segment (13) facing upwards), 114274 a Fit the rocker cover on the (Mot.
  • Page 638 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting M9R, and 800 or 802 or 803 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Refit the exhaust gas pressure sensor (see 19B, Ex- haust, Exhaust gas pressure sensor: Removal - Refitting, page 19B-93) .
  • Page 639 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 a Fit the engine on the component support (see En- Special tooling required gine support equipment: Use) . a Drain the engine oil (see 10A, Engine and cylinder Mot.
  • Page 640 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 - the alternator (see 16A, Starting - Charging, Al- ternator: Removal - Refitting, page 16A-1) . 133843 133842 a Fit the flywheel locking tool (Mot. 919-02) (5) . a Remove: - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories...
  • Page 641 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 II - CAMSHAFT REMOVAL OPERATION 133831 a Remove: - the bolts (5) of the camshaft sensor mountings, - the camshaft mountings. 127893 a Mark the position of the camshaft bearing caps us- a Remove the camshafts.
  • Page 642 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 127893 23001 a Refit the camshaft bearing caps (9) . 23020 a Fit the camshafts: 22934 a Tighten to torque and in order: - by positioning them correctly (see Camshaft: Check) , - the bolts of the camshaft bearing caps (initial - by positioning the camshaft lugs (7) in the cylinder...
  • Page 643 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 133831 a Refit the camshaft position sensor mountings. III - FINAL OPERATION a Refit: 133843 - the timing chain (see 11A, Top and front of en- gine, Timing chain: Removal - Refitting, page 11A-88) , - the crankshaft seal on the timing side (see 10A, Engine and cylinder block assembly, Crank-...
  • Page 644 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting V4Y, and 713 a Refit: - the rocker covers (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) , - the camshaft position sensors (see Camshaft po- sition sensor: Removal - Refitting) .
  • Page 645 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the crankshaft seal on the timing side (see 10A, Special tooling required Engine and cylinder block assembly, Crank- shaft seal on timing end: Removal - Refitting, Mot. 1573 Cylinder head support page 10A-134) , - the alternator (see 16A, Starting - Charging, Al- Equipment required...
  • Page 646 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the diesel injectors (see 13B, Diesel injection, Rocker cover back row Diesel injector: Removal - Refitting, page 13B- 229) , - the damper valve (see 12A, Fuel mixture, Damp- er valve: Removal - Refitting, page 12A-39) , - the injector rails (see 13B, Diesel injection, Injec- tor rail: Removal - Refitting, page 13B-189) , - the rocker covers (see 11A, Top and front of en-...
  • Page 647 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Immobilise the high pressure pump drive pinion in a Removal of the high pressure pump drive pinion a Carry out this operation only when replacing the vice with jaws. a Fit a new high pressure pump drive pinion bolt with- camshaft on the exhaust side of the front row or the high pressure pump drive pinion.
  • Page 648 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the high pressure pipe between the pump and the - the coolant pump (see 19A, Cooling, Coolant rail (see 13B, Diesel injection, High pressure pump: Removal - Refitting, page 19A-66) , pipe between pump and rail: Removal - Refit- - the accessories belt (see 11A, Top and front of ting, page 13B-140) ,...
  • Page 649 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Place the engine on the component support (see Special tooling required Engine support equipment: Use) . a Drain the engine (see 10A, Engine and cylinder Mot. 919-02 Flywheel locking tool. block assembly, Engine oil: Draining - Refilling, Mot.
  • Page 650 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the ignition coils (see 17A, Ignition, Coils: Re- moval - Refitting, page 17A-1) , - the rocker cover (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) , - the timing sprockets (see Timing sprocket: Re- moval - Refitting) ,...
  • Page 651 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting II - CAMSHAFT REFITTING OPERATION 116043 115775 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.).
  • Page 652 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting III - FINAL OPERATION a Refit: - the injector rail (see 13B, Diesel injection, Injec- tor rail: Removal - Refitting, page 13B-189) , - the timing sprockets (see Timing sprocket: Re- moval - Refitting) , - the rocker cover (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page...
  • Page 653 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting a The engine and gearbox assembly must be re- moved to remove/refit the camshaft dephaser (see 10A, Engine and cylinder block assembly, En- gine - gearbox assembly: Removal - Refitting, page 10A-1) .
  • Page 654 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1490-01 For locking and adjusting the camshaft pulleys. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 655 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Always replace: - the exhaust camshaft pulley nut, - the inlet camshaft pulley dephaser bolt. WARNING Failure to adhere to the following procedure may cause the timing belt to be incorrectly timed.
  • Page 656 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-49) , - the air filter box (see 12A, Fuel mixture, Air filter...
  • Page 657 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting a Removal - refitting of the camshaft dephaser is in- cluded in the removal - refitting of the timing chain (see 11A, Top and front of engine, Timing chain: Removal - Refitting, page 11A-88) . 11A-279...
  • Page 658 TOP AND FRONT OF ENGINE Camshaft dephaser: Function I - SPECIAL NOTES II - OPERATION AND PROGRAMMING The camshaft dephaser modifies the valve timing. 115496 The oil is supplied to the dephaser by a solenoid valve (2) located on the timing cover. Supply by a variable opening cyclic ratio signal enables oil to be distributed to the mechanism and the dephaser angle to be adjusted.
  • Page 659 TOP AND FRONT OF ENGINE Camshaft dephaser: Function - after the engine has started, - outside idling speed and no load, - threshold of mapping reached according to load and engine speed reached, - threshold of mapping reached according to the cool- ant temperature.
  • Page 660 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm camshaft dephaser 10 N.m solenoid valve bolt engine tie-bar bolts 190 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 661 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting III - FINAL OPERATION. a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the engine cover, - the engine tie-bar, - the engine tie-bar bolts.
  • Page 662 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting Tightening torquesm camshaft dephaser 10 N.m solenoid valve bolt REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. II - OPERATION FOR REMOVAL OF PART CONCERNED 128447 a Remove:...
  • Page 663 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting Tightening torquesm camshaft dephaser 9 N.m solenoid valve bolt anti-roll bar linkage 44 N.m upper nut REMOVAL I - REMOVAL PREPARATION OPERATION 1 - Front row camshaft dephaser solenoid valve a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 664 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting a Connect the camshaft dephaser solenoid valve con- - the camshaft dephaser solenoid valve, nector. - the camshaft dephaser solenoid valve seal. 2 - Back row camshaft dephaser solenoid valve 2 - Back row camshaft dephaser solenoid valve a Refit: a Disconnect the camshaft dephaser solenoid valve...
  • Page 665 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting - the timing belt (see 11A, Top and front of engine, Special tooling required Timing belt: Removal - Refitting, page 11A-50) . Mot. 1801 Camshaft sprocket locking tool F4 engines. II - OPERATION FOR REMOVAL OF PART CONCERNED Mot.
  • Page 666 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Prod- ucts), clean and degrease the joint faces of the fol- lowing: - of the cylinder head,...
  • Page 667 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-13) , - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (MR 416, 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal -...
  • Page 668 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1606 High pressure pump pulley support tool. Mot. 1577 Lip seal extractor (shaft diam- eter 28 mm to 42 mm). Mot.
  • Page 669 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting - the camshaft pulley. 105270 a Position the claws of the (Mot. 1577) on the cam- 123970 shaft. 105257 105271 a Push the tool (Mot. 1577) until contact is made be- tween the ends (9) of the claws and the camshaft Note: seal.
  • Page 670 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. a Degrease the camshaft seal bearing face on the tim- ing end using SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Con-...
  • Page 671 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting a Fit a new camshaft seal on the camshaft at the tim- II - REFITTING OPERATION FOR PART CONCERNED ing end. Note: For camshaft seals delivered fitted to a protective sleeve: - do not remove the camshaft seal from its pro- tective sleeve,...
  • Page 672 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 2 - Second fitting of the camshaft seal 21687-3 a Screw on the collar nut until the cover touches the 123076 a Depending on the case, the Parts Department deliv- cylinder head.
  • Page 673 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 3 - Continued for both methods a Fit the camshaft pulley. a Refit a new camshaft pulley nut. a Undo the camshaft pulley hub bolts. a Fit the (Mot. 1606) on the cylinder head to lock the camshaft pulley wheel.
  • Page 674 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Special tooling required CONCERNED Mot. 1577 Lip seal extractor (shaft diam- eter 28 mm to 42 mm). REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 675 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 1 - Removing the exhaust side seal 130550 a Separate the claws by turning the nut (3) clockwise 130548 a Position the claws of the (Mot. 1577) on the cam- using an open-jawed spanner.
  • Page 676 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 2 - Removing the inlet side seal 130553 a Separate the claws by turning the nut (5) clockwise 130552 a Position the claws of the (Mot. 1577) on the cam- using an open-jawed spanner.
  • Page 677 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting REFITTING 1 - Refitting the exhaust side seal I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the seal mating face of each camshaft, - the cylinder head seal housings.
  • Page 678 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 105531 130557 a Fit the cover (11) and the collar nut (12) of the. 130556 a Screw the stud (10) of theonto the camshaft. 130558 a Screw on the collar nut until the cover touches the cylinder head.
  • Page 679 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 2 - Refitting the inlet side seal 105531 130559 a Position the protector fitted with a new seal (13) on the camshaft (taking care not to touch the seal). a Remove the camshaft seal protector.
  • Page 680 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting III - FINAL OPERATION. a Refit: - the exhaust camshaft pulley. - the camshaft dephaser (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refit- ting, page 11A-275) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-50) , - the right-hand suspended engine mounting (see...
  • Page 681 TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A-303...
  • Page 682 TOP AND FRONT OF ENGINE Valves: Adjustment II - ADJUSTMENT OPERATION Special tooling required Mot. 856-02 Dial gauge support. Mot. 252-01 Pressure plate for measuring piston liner protrusion. Equipment required indelible pencil Dial gauge magnetic holder ADJUSTMENT 86911 a Set the cylinder valves (1) in the end of exhaust, be- ginning of inlet position.
  • Page 683 TOP AND FRONT OF ENGINE Valves: Adjustment 14274 14678-1 a Lift the rod (7) of the Dial gauge (without changing the position of the « dial gauge - holder » assembly). a Mount the valve tappet (8) to be measured on the plate of the (Mot.
  • Page 684 TOP AND FRONT OF ENGINE Valves: Adjustment III - FINAL OPERATION. a Refit: - the rocker cover (see 11A, Top and front of en- gine, Rocker cover: Removal - Refitting, page 11A-139) , - the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Re- moval - Refitting, page 13B-108) , - the right-hand suspended engine mounting (see...
  • Page 685 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting Tightening torquesm oil separator bolts 10 Nm turbocharger bracket 11 Nm bolt IMPORTANT Wear latex gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 123171 120169 a Undo the intercooler air inlet pipe clip (1) .
  • Page 686 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Always replace the oil decanter bolts. a Use SUPER CLEANING AGENT FOR JOINT FAC- ES (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products) to clean and degrease the joint faces: - of the oil decanter in case of reuse, - of the rocker cover.
  • Page 687 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 120209 a Refit: - the oil decanter, - the new oil decanter bolts. a Tighten to torque and in order the oil separator bolts (10 Nm).
  • Page 688 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting a The oil decanter is integrated into the rocker cover. To remove the oil decanter (see 11A, Top and front of engine, Rocker cover: Removal - Refitting, page 11A-139) . 11A-310...
  • Page 689 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting Equipment required tweezers REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove the front engine cover. 113282 a Rotate the clip (3) on the intercooler air inlet pipe. a Disconnect the intercooler air inlet pipe.
  • Page 690 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting 123798 115068 a Remove the intercooler air inlet pipe seal on the tur- a Disconnect: bocharger side using a tweezers. - the oil vapour rebreathing pipe to the oil separator, - the injector connector for cylinder 1, timing end.
  • Page 691 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting a Refit the nut of the cooling radiator top hose on the - the oil separator bolts. intercooler air inlet pipe. a Tighten the nut of the cooling radiator top hose on the intercooler air inlet pipe.
  • Page 692 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION a Always replace the oil separator filter. new oil separator bolts 15 N.m REMOVAL WARNING Do not scrape the joint faces of the aluminium, I - REMOVAL PREPARATION OPERATION any damage caused to the joint face will result in a Remove:...
  • Page 693 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-49) , - the three coils on the flywheel end (see 17A, Igni- tion, Coils: Removal - Refitting, page 17A-1) , - the engine cover.
  • Page 694 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting - the water pump inlet pipe (see 19A, Cooling, Coolant pump inlet pipe: Removal - Refitting, Tightening torquesm page 19A-139) . oil separator bolts 10 N.m II - OPERATION FOR REMOVAL OF PART CONCERNED REMOVAL I - REMOVAL PREPARATION OPERATION...
  • Page 695 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting II - REFITTING OPERATION FOR PART - the damper valve (see 12A, Fuel mixture, Damp- CONCERNED er valve: Removal - Refitting, page 12A-39) , a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - a new oil separator seal, - the front wheel arch liners (see Front wheel arch...
  • Page 696 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting II - REMOVAL OPERATION FOR THE TIMING END Special tooling required LIFTING EYE Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm lifting eye bolts 55 N.m lifting eye bolt 8 N.m lifting eye bolts 28 N.m...
  • Page 697 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting a Torque tighten the lifting eye bolt (8 N.m). FITTING THE TIMING END LIFTING EYE ONTO THE TIMING COVER II - FINAL OPERATION a Refit: FITTING OPERATION FOR THE LIFTING EYE - the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Ex- terior protection),...
  • Page 698 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 133471 a Undo: 134934 a Remove: - the clip (4) for the throttle valve air inlet pipe, - the clip for the air filter unit air outlet pipe. - the lifting eye bolts (6) , a Remove the clip from the oil vapour rebreathing pipe - the lifting eye.
  • Page 699 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting - the vacuum pipe from the brake servo. a Fit the clip onto the oil vapour rebreathing pipe using the (Mot. 1448). a Fill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-16) .
  • Page 700 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting REMOVING THE TIMING END LIFTING II - REMOVAL OPERATION FOR THE LIFTING EYE I - REMOVAL PREPARATION OPERATION FOR THE LIFTING EYE 133890 a Remove: - the bolts (2) from the lifting eye at the timing end, 133890 a Remove: - the lifting eye on the timing end.
  • Page 701 TOP AND FRONT OF ENGINE Lifting eyes: Removal - Refitting II - REMOVAL OPERATION FOR THE LIFTING EYE 137942 a Unclip the engine wiring (3) from the lifting eye. 137944 a Remove: a Separate the engine wiring from the lifting eye. - the gearbox side lifting eye bolts (6) , - the gearbox side lifting eye.
  • Page 702 FUEL MIXTURE Air inlet: Description Air inlet circuit 123973 Air resonator air inlet pipe Air resonator Air filter box air inlet pipe Air filter unit Air flowmeter Air filter box outlet air pipe Air resonator Throttle valve Inlet manifold (10) Air resonator on inlet manifold 12A-1...
  • Page 703 FUEL MIXTURE Air inlet: Description K9K, and 780 Diagram of the air inlet circuit 123800 Air resonator Air filter unit Air flowmeter Air filter box outlet air pipe Turbocharger Intercooler air inlet pipe Air-to-air intercooler Intercooler air outlet pipe Air inlet valve (10) Metal air inlet tube 12A-2...
  • Page 704 FUEL MIXTURE Air inlet: Description AIR INLET CIRCUIT DIAGRAM 125427 Air inlet Air resonator Air filter box air inlet pipe Air filter box Air filter box air outlet pipe Turbocharger Intercooler air inlet pipe Air-to-air intercooler Intercooler air outlet pipe (10) Throttle valve (11)
  • Page 705 FUEL MIXTURE Air inlet: Description Air inlet circuit 128001 Air resonator air inlet pipe Air resonator Air inlet pipe of the air filter box Air filter unit Air filter unit air outlet pipe Air resonator Throttle valve Inlet manifold 12A-4...
  • Page 706 FUEL MIXTURE Air inlet: Description Diagram of the air inlet circuit 136255 Air resonator Air filter unit Air flowmeter Air filter unit air outlet pipe Turbocharger Turbocharger air outlet pipe Intercooler Intercooler air outlet pipe Damper valve air inlet pipe (10) Damper valve (11)
  • Page 707 FUEL MIXTURE Air inlet: Description K9K, and 782 Diagram of the air inlet circuit 144358 Air resonator Air filter unit Air flowmeter Air filter outlet air pipe Turbocharger air inlet pipe Turbocharger Intercooler air inlet pipe Intercooler Intercooler air outlet pipe (10) Damper valve (11)
  • Page 708 FUEL MIXTURE Air filter: Removal - Refitting K4M or M4R REMOVAL I - REMOVAL PREPARATION OPERATION 128272 a Unclip the air filter unit cover at (1) . 123390 a Unclip the air filter unit cover at (1) . 12A-7...
  • Page 709 FUEL MIXTURE Air filter: Removal - Refitting K4M or M4R II - OPERATION FOR REMOVAL OF PART CONCERNED 128271 a Raise the air filter unit cover. a Remove the air filter from the air filter unit. 123389 a Raise the air filter unit cover. a Remove the air filter from the air filter unit.
  • Page 710 FUEL MIXTURE Air filter: Removal - Refitting K9K or M9R REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 122994 a Move aside the air filter cover. 122424 a Move the turbocharger control solenoid valve (1) a Remove the filter element.
  • Page 711 FUEL MIXTURE Air filter: Removal - Refitting REMOVAL REFITTING I - REFITTING PREPARATION OPERATION I - REMOVAL PREPARATION OPERATION a Clean the air filter housing. WARNING If the air filter is fitted incorrectly in the air filter box, unfiltered air may enter the engine. II - REFITTING OPERATION FOR PART CONCERNED a Refit the air filter.
  • Page 712 FUEL MIXTURE Air filter: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 133470 a Loosen the air filter unit cover bolts (2) . 133465 a Remove: a Move aside the air filter cover. a Remove the air filter.
  • Page 713 FUEL MIXTURE Air filter: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 134096 a Loosen the air filter unit cover bolts (3) . a Move aside the air filter cover. 134095 a Remove the injection computer protector (1) by a Remove the air filter.
  • Page 714 FUEL MIXTURE Air filter unit: Removal - Refitting K9K or M9R Tightening torquesm air filter box air outlet 5.5 Nm pipe clip on the air flow- meter side REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (MR 415, 80A, Battery).
  • Page 715 FUEL MIXTURE Air filter unit: Removal - Refitting K9K or M9R 123288 122990 a Remove the cover (3) from the Protection and a Disconnect the connectors (5) from the Protection Switching Unit. and Switching Unit. a Move aside the Protection and Switching Unit. 122989 a Unclip the protection and switching unit (4) from its 122991...
  • Page 716 FUEL MIXTURE Air filter unit: Removal - Refitting K9K or M9R II - REMOVAL OPERATION FOR PART CONCERNED Note: When fitting the Protection and Switching Unit wiring, ensure that the sealing grommets are cor- rectly positioned. a Position and clip the Protection and Switching Unit into its mounting.
  • Page 717 FUEL MIXTURE Air filter unit: Removal - Refitting Tightening torquesm air flowmeter bolts on 4 Nm the air filter box air filter box air outlet 5.5 Nm pipe clip on the air flow- meter REMOVAL I - REMOVAL PREPARATION OPERATION 123391 a Disconnect the air filter box air outlet pipe (3) from the air flowmeter.
  • Page 718 FUEL MIXTURE Air filter unit: Removal - Refitting 123393 123396 123394 123398 a Remove: a Remove the Protection and Switching Unit housing bolt (6) . - the battery tray upper cover (4) , a Remove the Protection and Switching Unit housing. - the battery tray right-hand side section (5) .
  • Page 719 FUEL MIXTURE Air filter unit: Removal - Refitting II - REMOVAL OPERATION FOR PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Refit the air filter box. a Unclip the air filter box. a Connect the air filter box air inlet pipe. a Clip on the air filter box.
  • Page 720 FUEL MIXTURE Air filter unit: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION 123395 a Remove the battery tray side cover. a Disconnect the air filter box inlet air pipe (3) . 123165 a Undo the air filter box air outlet pipe clip (1) .
  • Page 721 FUEL MIXTURE Air filter unit: Removal - Refitting Tightening torquesm clip of the air filter unit 5.5 N.m air outlet pipe on the throttle valve clip of the air filter unit 5.5 N.m air outlet pipe on the air filter unit REMOVAL I - REMOVAL PREPARATION OPERATION 128264...
  • Page 722 FUEL MIXTURE Air filter unit: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED a Unclip the air filter unit. Note: Be careful not to break the air filter unit mount- ings when removing. a Remove the air filter unit. REFITTING I - REFITTING OPERATION FOR PART CONCERNED...
  • Page 723 FUEL MIXTURE Air filter unit: Removal - Refitting a Connect the air filter unit air outlet pipe onto: - the air filter unit, - the throttle valve. a Tighten to torque: - the clip of the air filter unit air outlet pipe on the throttle valve (5.5 N.m), - the clip of the air filter unit air outlet pipe on the air filter unit (5.5 N.m).
  • Page 724 FUEL MIXTURE Air filter unit: Removal - Refitting Tightening torquesm clip of the air filter unit 5.5 N.m air outlet pipe REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). 134198 a Remove the Protection and Switching Unit nut (3) .
  • Page 725 FUEL MIXTURE Air filter unit: Removal - Refitting a Remove: - the battery disconnection unit protector. a Connect the battery (see Battery: Removal - Refit- - the air filter unit, ting) (80A, Battery). - the air filter unit air inlet pipe. If replacing the air filter unit a Remove the air flowmeter (see 12A, Fuel mixture, Air flowmeter: Removal - Refitting, page 12A-33)
  • Page 726 FUEL MIXTURE Air filter unit: Removal - Refitting Tightening torquesm clip of the air filter unit 6 N.m air outlet pipe REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). 124323 a Unlock the push-button (2) by pulling it upwards.
  • Page 727 FUEL MIXTURE Air filter unit: Removal - Refitting 136271 136272 a Remove the Protection and Switching Unit nut (4) . a Unclip: a Unclip: - the turbocharger vacuum control valve wiring, - the wiring of the Protection and Switching Unit from - the turbocharger vacuum control valve (6) from the the upper mounting of the battery disconnection air filter unit.
  • Page 728 FUEL MIXTURE Air filter unit: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION If replacing the air filter unit a Remove the air flowmeter (see Air flowmeter: Re- moval - Refitting) . a Refit the air flowmeter on the new air filter unit (see 12A, Fuel mixture, Air flowmeter: Removal - Re- fitting, page 12A-33) .
  • Page 729 FUEL MIXTURE Air resonator: Removal - Refitting F4R or K4M or K9K or M4R or M9R REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), - the front bumper (see Front bumper: Removal -...
  • Page 730 FUEL MIXTURE Air resonator: Removal - Refitting F4R or K4M or K9K or M4R or M9R II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING OPERATION FOR PART CONCERNED a Refit the air resonator. a Clip the air resonator air inlet pipe on the body. II - FINAL OPERATION.
  • Page 731 FUEL MIXTURE Air resonator: Removal - Refitting F4R or K4M or K9K or M4R or M9R 127391 a Ensure that the battery cover is properly fitted into the battery tray at (7) . a Clip on the back of the battery cover. a Lock the battery cover clips by a quarter of a turn.
  • Page 732 FUEL MIXTURE Air resonator: Removal - Refitting REMOVAL II - FINAL OPERATION a Refit: I - REMOVAL PREPARATION OPERATION - the front bumper (see Front bumper: Removal - a Position the vehicle on a two-post lift (see Vehicle: Refitting) (55A, Exterior protection), Towing and lifting) (02A, Lifting equipment).
  • Page 733 FUEL MIXTURE Air resonator: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 734 FUEL MIXTURE Air flowmeter: Removal - Refitting Tightening torquesm air flowmeter bolts 4 Nm air filter box air outlet 5.5 Nm pipe clip on the air flow- meter REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 123390 a Unclip the air filter box cover at (3) .
  • Page 735 FUEL MIXTURE Air flowmeter: Removal - Refitting 123401 a Remove the air flowmeter seal (5) . REFITTING I - REFITTING PREPARATIONS OPERATION a Always replace the air flowmeter seal. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the air flowmeter on the air filter box cover, - the air flowmeter bolts.
  • Page 736 FUEL MIXTURE Air flowmeter: Removal - Refitting K9K or M9R REMOVAL II - REMOVAL OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION 123691 a Remove: 123690 a Disconnect the air flowmeter connector (1) . a Loosen the air outlet pipe clip (2) on the air filter box. - the bolts (3) from the air flowmeter, a Move aside the air filter box air outlet pipe.
  • Page 737 FUEL MIXTURE Air flowmeter: Removal - Refitting Equipment required Diagnostic tool Tightening torquesm air flowmeter bolts 4 Nm clip of the air filter unit 6 N.m air outlet pipe REMOVAL I - REMOVAL PREPARATION OPERATION 133468 a Remove the injection computer bolts (1) . a Move the injection computer aside.
  • Page 738 FUEL MIXTURE Air flowmeter: Removal - Refitting a Align the mark of the air filter unit air outlet pipe with that of the air flowmeter. Note: If the marks are not aligned, the air filter unit air outlet pipe risks getting damaged when in con- tact with other parts (coolant outlet unit).
  • Page 739 FUEL MIXTURE Air flowmeter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm air flowmeter bolts 4 Nm clip of the air filter unit 6 N.m air outlet pipe REMOVAL I - REMOVAL PREPARATION OPERATION 136273 a Disconnect the air flowmeter connector (2) .
  • Page 740 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 Equipment required Diagnostic tool Tightening torquesm intercooler outlet air 5.5 N.m pipe clip REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 741 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - OPERATION FOR REMOVAL OF PART CONCERNED 123694 a Remove: 123693 a Disconnect the turbocharger pressure sensor con- - the air inlet spacer (7) , nector (5) .
  • Page 742 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Refit the damper valve strut. a Connect the turbocharger pressure sensor connec- tor. III - FINAL OPERATION a Connect the damper valve connector.
  • Page 743 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the engine undertray bolts, Equipment required - the engine undertray. Diagnostic tool Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve side REMOVAL I - REMOVAL PREPARATION OPERATION...
  • Page 744 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 122374 a Undo the intercooler outlet air pipe clip (4) on the damper valve side. a Disconnect the intercooler outlet air pipe from the damper valve.
  • Page 745 FUEL MIXTURE Damper valve: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the damper valve strut bolts on the intake distribu- tor. a Tighten: - the damper valve strut bolts on the damper valve, - the damper valve strut bolts on the intake distribu- tor.
  • Page 746 FUEL MIXTURE Damper valve: Removal - Refitting REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 113853 a Remove: - the bolts (2) from the damper valve strut, 123532 a Undo the clip (1) from the intercooler outlet pipe.
  • Page 747 FUEL MIXTURE Damper valve: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products) to clean and degrease the pressure faces: - of the exhaust gas recirculation mounting on the gearbox side, - the air inlet valve, II - REFITTING OPERATION FOR PART...
  • Page 748 FUEL MIXTURE Damper valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required Diagnostic tool REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 134035 a Disconnect the connector (2) from the damper valve. a Remove: - the damper valve bolts (3) , - the damper valve,...
  • Page 749 FUEL MIXTURE Damper valve: Removal - Refitting - go to repair mode, - display the « before/after repair procedure » for the computer selected, - select « Damper valve » in the « List of compo- nents stored by the computer » section, - carry out the operations described in the «...
  • Page 750 FUEL MIXTURE Throttle valve: Removal - Refitting Special tooling required Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm throttle valve bolts 10 Nm air filter box air outlet 5.5 Nm pipe clip on the throttle valve IMPORTANT Wear latex gloves during the operation.
  • Page 751 FUEL MIXTURE Throttle valve: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED 123383 123381 a Disconnect the connector (4) from the throttle valve. WARNING Prepare for the flow of fluid, and protect the sur- rounding components. Fit the (5) (Ms. 583) to the throttle valve coolant hoses.
  • Page 752 FUEL MIXTURE Throttle valve: Removal - Refitting a Connect: - the oil vapour rebreathing hose on the rocker cov- - the air filter box air outlet pipe on the throttle valve. a Tighten the air filter box air outlet pipe clip on the throttle valve (5.5 Nm).
  • Page 753 FUEL MIXTURE Throttle valve: Removal - Refitting a Move the intercooler outlet air pipe to one side. Tightening torquesm II - OPERATION FOR REMOVAL OF PART throttle valve bolts 12 N.m CONCERNED REMOVAL I - REMOVAL PREPARATION OPERATION 123725 a Disconnect the connector (2) from the throttle valve. a Remove: - the throttle valve bolts (3) , 123724...
  • Page 754 FUEL MIXTURE Throttle valve: Removal - Refitting III - FINAL OPERATION a Fit the intercooler outlet air pipe. a Refit the intercooler air outlet pipe bolts. a Tighten the intercooler outlet air pipe bolts. a Refit the bolt of the air pipe retaining bracket on the inlet distributor.
  • Page 755 FUEL MIXTURE Throttle valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm throttle valve bolts 10 N.m clip of the air filter unit 5.5 N.m air outlet pipe on the throttle valve clip of the air filter unit 5.5 N.m air outlet pipe on the air filter unit...
  • Page 756 FUEL MIXTURE Throttle valve: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the throttle valve joint face if it is to be re-used, - the inlet manifold seal housing.
  • Page 757 FUEL MIXTURE Throttle valve: Removal - Refitting a Fit the air filter unit air outlet pipe. a Connect the air filter unit air outlet pipe onto: - the air filter unit, - the throttle valve. a Torque tighten: - the clip of the air filter unit air outlet pipe on the throttle valve (5.5 N.m), - the clip of the air filter unit air outlet pipe on the air filter unit (5.5 N.m).
  • Page 758 FUEL MIXTURE Throttle valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required Diagnostic tool Tightening torquesm throttle valve bolts 8 N.m air pipe clip on the throt- 6 N.m tle valve REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 759 FUEL MIXTURE Throttle valve: Removal - Refitting 133472 a In order, torque tighten the throttle valve bolts (8 N.m). a Connect the throttle valve connector. III - FINAL OPERATION a Fit the air filter unit air outlet pipe on the throttle valve.
  • Page 760 FUEL MIXTURE Throttle valve: Cleaning F4R or K4M or M4R or V4Y Equipment required compressed air nozzle IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. IMPORTANT Always wear protective gear (gloves, goggles and breathing masks). Note: Be sure to work in a clean environment so as not to 124736 allow any contamination of the throttle valve.
  • Page 761 FUEL MIXTURE Throttle valve: Cleaning F4R or K4M or M4R or V4Y 124737 124738 a Remove the residues of CARBURETTOR CLEAN- a Use a compressed air nozzle to blast the throttle ER and the residual dirt using a LINT-FREE CLOTH valve edges and the air vent.
  • Page 762 FUEL MIXTURE Front inlet distributor: Removal - Refitting - the turbocharger (see 12B, Turbocharging, Tur- Special tooling required bocharger: Removal - Refitting, page 12B-4) . Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm intake distributor bolts 32 N.m on the front row oil vapour rebreathing 10 N.m...
  • Page 763 FUEL MIXTURE Front inlet distributor: Removal - Refitting 136264 136259 a Remove the cooling hose clip (3) from the exhaust a Remove: fuel injector cooler using the (Mot. 1448). - the rigid cooling pipe bolt (5) at the inter-cylinder a Disconnect the cooling hose from the exhaust fuel head cooling pipe outlet, injector cooler.
  • Page 764 FUEL MIXTURE Front inlet distributor: Removal - Refitting 136260 136265 a Disconnect the coolant temperature sensor connec- a Remove: tor (7) . - the inter-cylinder head intake distributor bolts (10) a Remove: on the gearbox side, - the bolts (8) from the rigid inter-cylinder head cool- - the inter-cylinder head intake distributor on the ing pipe, gearbox side,...
  • Page 765 FUEL MIXTURE Front inlet distributor: Removal - Refitting 138335 134033 a Unclip: a Remove the support bolts (13) from the exhaust gas intercooler control solenoid valve. - the diesel return pipe (11) , a Move aside the support from the exhaust gas inter- - the wiring from the heater plugs (12) on the back cooler control solenoid valve.
  • Page 766 FUEL MIXTURE Front inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 137919 a Remove: - the intake distributor bolts (17) on the front row, 136266 a Remove the high-pressure pipe bolt (15) between - the intake distributor on the front row, the rails.
  • Page 767 FUEL MIXTURE Front inlet distributor: Removal - Refitting - the inter-cylinder head intake distributor, on the gearbox side. a Refit the cooling pipe support at the expansion bottle outlet. a Refit: - the cooling pipe support at the expansion bottle outlet, - new inter-cylinder head cooling pipe seals, - the inter-cylinder head cooling pipe.
  • Page 768 FUEL MIXTURE Front inlet distributor: Removal - Refitting - the exhaust gas recirculation rigid pipe (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, page 14A-62) , - the damper valve (see 12A, Fuel mixture, Damp- er valve: Removal - Refitting, page 12A-39) . a Fill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-16) .
  • Page 769 FUEL MIXTURE Rear inlet distributor: Removal - Refitting - the turbocharger (see 12B, Turbocharging, Tur- Special tooling required bocharger: Removal - Refitting, page 12B-4) . Mot. 1448 Remote operation pliers for hose clips. Tightening torquesm intake distributor bolts 32 N.m on the back row oil vapour rebreathing 10 N.m...
  • Page 770 FUEL MIXTURE Rear inlet distributor: Removal - Refitting 136264 136259 a Remove the cooling hose clip (3) from the exhaust a Remove: fuel injector cooler using the (Mot. 1448). - the rigid cooling pipe bolt (5) at the inter-cylinder a Disconnect the cooling hose from the exhaust fuel head cooling pipe outlet, injector cooler.
  • Page 771 FUEL MIXTURE Rear inlet distributor: Removal - Refitting 136260 136265 a Disconnect the coolant temperature sensor connec- a Remove: tor (7) . - the inter-cylinder head intake distributor bolts (11) a Remove: on the gearbox side, - the bolts (8) from the inter-cylinder head cooling - the inter-cylinder head intake distributor on the pipe, gearbox side,...
  • Page 772 FUEL MIXTURE Rear inlet distributor: Removal - Refitting 138335 134033 a Unclip: a Remove the support bolts (14) from the exhaust gas intercooler control solenoid valve. - the diesel return pipe (12) , a Move aside the support from the exhaust gas inter- - the wiring from the heater plugs (13) on the back cooler control solenoid valve.
  • Page 773 FUEL MIXTURE Rear inlet distributor: Removal - Refitting 136266 134028 a Remove the high-pressure pipe bolt (16) between a Remove the bolts (18) from the oil vapour rebreath- the rails. ing diaphragm. a Separate the oil vapour rebreathing hose clip from the oil vapour rebreathing diaphragm.
  • Page 774 FUEL MIXTURE Rear inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Refit: - a new intake distributor seal on the back row, - the intake distributor on the back row. 137918 a Remove: - the intake distributor bolts (19) on the back row,...
  • Page 775 FUEL MIXTURE Rear inlet distributor: Removal - Refitting a Refit the support on the exhaust gas cooler control - the turbocharger oil pipes (see 12B, Turbocharg- solenoid valve. ing, Turbocharger oil pipe: Removal - Refitting, a Fit: page 12B-35) , - the lower engine tie-bars (see 1 9 D, Engine - the wiring from the pre-heater plugs on the back mounting, Lower engine tie-bar: Removal - Re-...
  • Page 776 FUEL MIXTURE Inlet distributor: Removal - Refitting Tightening torquesm intake distributor lower 27 Nm bolts intake distributor upper 20 Nm bolts throttle valve bolts 10 Nm air filter box air outlet 5.5 Nm pipe clip on the throttle valve IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area,...
  • Page 777 FUEL MIXTURE Inlet distributor: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED 123381 a Remove the bolts (3) from the throttle valve. a Move the throttle valve to one side. 123378 a Remove the upper bolt (4) from the intake distribu- a Remove the throttle valve seal.
  • Page 778 FUEL MIXTURE Inlet distributor: Removal - Refitting 123379 123379 a Remove: a Tighten to torque and in order the intake distributor lower bolts (27 Nm). - in order the inlet manifold bolts, a Torque tighten the intake distributor upper bolts - the intake distributor, (20 Nm).
  • Page 779 FUEL MIXTURE Inlet distributor: Removal - Refitting a Refit the engine cover. 12A-78...
  • Page 780 FUEL MIXTURE Inlet distributor: Removal - Refitting Tightening torquesm injector rail bolts 10 Nm intake distributor bolts 25 Nm right-hand suspended 62 Nm engine mounting on the intake distributor IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union.
  • Page 781 FUEL MIXTURE Inlet distributor: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED 120218 Note: 123154 The intake distributor bolts are not the same a Disconnect: length, mark their position. a Remove: - the fuel injector connectors (6) , - the cylinder head support bolt (8) on the intake dis- - the upstream oxygen sensor connector.
  • Page 782 FUEL MIXTURE Inlet distributor: Removal - Refitting - the air inlet pressure sensor clip, - the inlet air pressure sensor, - the injector rail bolts, - the injector rail, - the injector seals. a Always replace: - the injector seals, - the oil vapour heater seals.
  • Page 783 FUEL MIXTURE Inlet distributor: Removal - Refitting - the oil vapour rebreathing pipe union on the oil va- pour heater. a Refit the engine cover. 12A-82...
  • Page 784 FUEL MIXTURE Inlet distributor: Removal - Refitting - the EGR solenoid valve (see 14A, Antipollution, Exhaust gas recirculation solenoid valve: Re- Equipment required moval - Refitting, page 14A-11) , refrigerant charging station - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), roller-type stud removal tool - the front right-hand wheel arch liner (see Front...
  • Page 785 FUEL MIXTURE Inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED M9R, and 742 or 744 or 746 or 748 or 754 123609 a Remove: 123009 a Remove: - the inlet distributor bolts (4) , - the turbocharging pressure sensor support bolts - the inlet distributor nuts (5) , (2) , - the inlet distributor,...
  • Page 786 FUEL MIXTURE Inlet distributor: Removal - Refitting a Tighten the new studs using a roller-type stud re- moval tool. M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - REFITTING OPERATION FOR PART a Refit the power-assisted steering pump (see Power- CONCERNED assisted steering pump: Removal - Refitting)
  • Page 787 FUEL MIXTURE Inlet distributor: Removal - Refitting Tightening torquesm bolts 1 to 5 of the inlet 9 N.m manifold bolts 6 to 8 of the inlet 12 N.m manifold IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union.
  • Page 788 FUEL MIXTURE Inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 128405 a Disconnect the following from the inlet manifold: 128408 a Remove: - the intake distributor pressure sensor connector (4) - the intake distributor bolts (8) , - the brake servo pipe union (5) , - the intake distributor, - the oil vapour rebreathing hose.
  • Page 789 FUEL MIXTURE Inlet distributor: Removal - Refitting 128408 a Tighten to torque and in order: - bolts 1 to 5 of the inlet manifold (9 N.m), - bolts 6 to 8 of the inlet manifold (12 N.m). III - FINAL OPERATION. a Connect the following to the inlet manifold: - the brake servo pipe union, - the oil vapour rebreathing hose,...
  • Page 790 FUEL MIXTURE Inlet distributor: Removal - Refitting Special tooling required Mot. 1448 Remote operation pliers for hose clips. Ms. 583 Pipe clamps. Tightening torquesm inlet manifold mount- 7 N.m ings(initial torque) inlet manifold mount- 13 N.m ings(torque) support bolt of the igni- 25 N.m tion coil connector on the inlet manifold...
  • Page 791 FUEL MIXTURE Inlet distributor: Removal - Refitting 133474 134539 a Disconnect the connector (6) from the fuel vapour a Separate the clips (10) on the cooling hoses using recirculation solenoid valve. the tool (Mot. 1448). a Remove the bolts (7) from the fuel vapour recircula- a Disconnect the cooling hoses.
  • Page 792 FUEL MIXTURE Inlet distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 133475 a Pretighten to torque and in order the inlet manifold 133475 mountings(initial torque) (7 N.m). a Remove: a Tighten to torque and in order the inlet manifold - the inlet manifold bolts (12) , mountings(torque) (13 N.m).
  • Page 793 FUEL MIXTURE Inlet distributor: Removal - Refitting a Refit: - the damper valve control solenoid valve, - the vacuum canister. a Connect: - the air pipe to the control diaphragm. - the air pipe to the inlet manifold, - the damper valve control solenoid valve connector. a Refit the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-49) a Fill the cooling system (see Cooling system: Fill-...
  • Page 794 FUEL MIXTURE Injector holder shim: Removal - Refitting - the multifunction support (see 10A, Engine and cylinder block assembly, Multifunction sup- Equipment required port: Removal - Refitting, page 10A-265) , refrigerant charging station - the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the «...
  • Page 795 FUEL MIXTURE Injector holder shim: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts II - OPERATION FOR REMOVAL OF PART CONCERNED and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the cylinder head gasket face, - the gasket face of the injector holder shim, in case of reuse.
  • Page 796 FUEL MIXTURE Injector holder shim: Removal - Refitting - the right-hand pendulum suspension bolt (62 Nm). III - FINAL OPERATION. a Refit: - the dipstick well, - the dipstick, - the « injector rail - injector » assembly (see 17B, Petrol injection, Injector rail - Injectors: Remov- al - Refitting, page 17B-39) , - the intake distributor (see 12A, Fuel mixture, Inlet...
  • Page 797 FUEL MIXTURE Injector holder shim: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm nuts and bolts of the 8 N.m injector holder shim (ini- tial torque) nuts and bolts of the 25 N.m injector holder shim (torque) IMPORTANT During this operation, be sure to:...
  • Page 798 FUEL MIXTURE Injector holder shim: Removal - Refitting 116548 a Pretighten in order and to torque the nuts and bolts of the injector holder shim (initial torque) (8 N.m). a Tighten in order and to torque the nuts and bolts of the injector holder shim (torque) (25 N.m).
  • Page 799 FUEL MIXTURE Exhaust manifold: Removal - Refitting Tightening torquesm exhaust manifold studs 8 Nm exhaust manifold nuts 33 Nm exhaust manifold stay 43 Nm bolts exhaust clamp bolts 21 Nm IMPORTANT Wear protective gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION 124799 a Remove the bolts (2) from the exhaust clamp.
  • Page 800 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 109399 a Always replace: - the ring (4) between the exhaust manifold and the catalytic converter, - the exhaust manifold gasket. 115094 Note: a Remove: If a stud loosens during the operation, coat it with frein de vis haute resistance (see Vehicle: - the exhaust manifold nuts in order,...
  • Page 801 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - REFITTING PART CONCERNED 115094 a Screw on the exhaust manifold nuts without tighten- ing them. a Tighten to torque and in order the exhaust manifold nuts (33 Nm). III - FINAL OPERATION. a Refit: - the exhaust manifold heat shield, - the exhaust manifold heat shield bolts.
  • Page 802 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - REMOVAL OPERATION FOR PART CONCERNED Tightening torquesm exhaust manifold nuts 25 Nm IMPORTANT Wear heat protective gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 803 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - REFITTING OPERATION FOR PART - the engine undertray, CONCERNED - the engine undertray bolts. a Refit: a Tighten the engine undertray bolts. a Connect the battery (see Battery: Removal - Refit- - the new exhaust manifold gasket, - the exhaust manifold, ting) (MR 415, 80A, Battery).
  • Page 804 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the turbocharger oil pipes (see 12B, Turbocharg- ing, Turbocharger oil pipe: Removal - Refitting, Equipment required page 12B-35) , roller-type stud removal tool - the turbocharger (see 12B, Turbocharging, Tur- bocharger: Removal - Refitting, page 12B-4) .
  • Page 805 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the rigid EGR pipe bolts (2) on the exhaust mani- fold by applying a maximum loosening torque of 40 N.m to avoid breaking the bolts, - the bolt (3) securing the exhaust gas recirculation rigid pipe on the cylinder head, - the rigid EGR pipe bolts (4) on the intercooler by...
  • Page 806 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the exhaust manifold nuts, - the exhaust manifold gasket, - the exhaust gas recirculation rigid pipe seals, - the EGR rigid pipe bolts. a Refit the exhaust manifold studs using a roller-type stud removal tool.
  • Page 807 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 a Refit the rigid EGR pipe heat shield bolts. a Tighten the rigid EGR pipe heat shield bolts. a Refit: - the turbocharger (see 12B, Turbocharging, Tur- bocharger: Removal - Refitting, page 12B-4) , - the turbocharger oil pipe (see 12B, Turbocharg- ing, Turbocharger oil pipe: Removal - Refitting,...
  • Page 808 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Remove: - the engine tie-bar (see 19D, Engine mounting, Tightening torquesm Lower engine tie-bar: Removal - Refitting, page 19D-85) , exhaust manifold nuts 18 N.m...
  • Page 809 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - OPERATION FOR REMOVAL OF PART CONCERNED 123929 123889 Note: If the bolts do not loosen: - apply SUPER RELEASING AGENT (see Vehi- cle: Parts and consumables for the repair) (04B, Consumables - Products),...
  • Page 810 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - REFITTING OPERATION FOR PART CONCERNED 113279 a Remove: 113279 - the exhaust manifold nuts, a Refit: - the exhaust manifold studs, - a new seal for the exhaust gas recirculation rigid...
  • Page 811 FUEL MIXTURE Exhaust manifold: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 M9R, and 800 or 802 or 806 or 808 or 816 a Refit: - the right-hand differential output seal (see Differ- ential output seal: Removal - Refitting) (21A, Manual gearbox), - the front right-hand driveshaft (see Front right-...
  • Page 812 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 780 Tightening torquesm exhaust manifold nuts 26 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 813 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 780 - the catalytic converter (see 19B, Exhaust, Cata- lytic converter: Removal - Refitting, page 19B- 32) , - the turbocharger oil return pipe (see 12B, Turbo- charging, Turbocharger oil pipe: Removal - Re- fitting, page 12B-35) , - the turbocharger (see 12B, Turbocharging, Tur- bocharger: Removal - Refitting, page 12B-4) .
  • Page 814 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 780 II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 113561 114532 a Remove: a Refit: - the nuts (9) from the exhaust manifold, - a new exhaust manifold gasket in the position - the exhaust manifold.
  • Page 815 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 780 - the exhaust gas recirculation solenoid valve (see 14A, Antipollution, Exhaust gas recirculation solenoid valve: Removal - Refitting, page 14A- 11) . a Connect the damper valve connector. a Refit the damper valve strut. a Connect the intercooler air outlet pipe on the damper valve.
  • Page 816 FUEL MIXTURE Exhaust manifold: Removal - Refitting Special tooling required Mot. 1495-01 22 mm socket for removal - refitting of oxygen sensors. Tightening torquesm exhaust manifold studs 9 Nm upstream oxygen sen- 44 Nm bolts of the lower heat shield12 N exhaust manifold nuts 26 Nm exhaust manifold stay...
  • Page 817 FUEL MIXTURE Exhaust manifold: Removal - Refitting 126381 126380 a Disconnect the upstream oxygen sensor connector a Remove: (4) . - the bolts (6) from the upper heat shield, - the upper heat shield. II - OPERATION FOR REMOVAL OF PART CONCERNED 128455 a Unclip the heater matrix hoses from the heater ma-...
  • Page 818 FUEL MIXTURE Exhaust manifold: Removal - Refitting When replacing the exhaust manifold 109399 a Always replace: - the ring (8) between the exhaust manifold and the catalytic converter, - the exhaust manifold gasket. 126617 a Remove: Note: - the lower heat shield bolts (7) , If a stud comes loose during removal, smear it - the lower heat shield, with HIGH RESISTANCE THREADLOCK (see...
  • Page 819 FUEL MIXTURE Exhaust manifold: Removal - Refitting When replacing the exhaust manifold II - REFITTING OPERATION FOR PART CONCERNED 126617 a Refit the upstream oxygen sensor using the (Mot. 1495-01). 126382 a Refit: a Torque tighten the upstream oxygen sensor (44 Nm).
  • Page 820 FUEL MIXTURE Exhaust manifold: Removal - Refitting a Refit: - the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the engine undertray. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery). 12A-119...
  • Page 821 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 782 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm exhaust manifold nuts 26 N.m IMPORTANT Wear protective gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: 139182 Towing and lifting) (02A, Lifting equipment).
  • Page 822 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 782 139182 a Torque tighten in order the exhaust manifold nuts (26 N.m). III - FINAL OPERATION a Refit: - the turbocharger (see 12B, Turbocharging, Tur- bocharger: Removal - Refitting, page 12B-4) , - the turbocharger oil pipes (see 12B, Turbocharg- ing, Turbocharger oil pipe: Removal - Refitting, page 12B-35) ,...
  • Page 823 FUEL MIXTURE Front exhaust manifold: Removal - Refitting Equipment required refrigerant charging station Tightening torquesm exhaust manifold studs 15 Nm exhaust manifold nuts 31 N.m IMPORTANT Wear protective gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: 134206 a Disconnect the front row upstream oxygen sensor Towing and lifting) (02A, Lifting equipment).
  • Page 824 FUEL MIXTURE Front exhaust manifold: Removal - Refitting REFITTING - the engine cover. a Fill the refrigerant circuit using a refrigerant charg- ing station (see Refrigerant circuit: Draining - I - REFITTING PREPARATION OPERATION a parts always to be replaced: exhaust manifold Filling) (62A, Air conditioning).
  • Page 825 FUEL MIXTURE Front exhaust manifold: Removal - Refitting - the oil pressure sensor (see 10A, Engine and cyl- inder block assembly, Oil pressure sensor: Re- Tightening torquesm moval - Refitting, page 10A-227) , - the starter (see 16A, Starting - Charging, Starter: front exhaust manifold 18 N.m Removal - Refitting, page 16A-31) ,...
  • Page 826 FUEL MIXTURE Front exhaust manifold: Removal - Refitting a Drain the cooling system (see 19A, Cooling, Cool- ing system: Draining - Refilling, page 19A-16) . a Remove the coolant outlet unit (see 19A, Cooling, Water chamber: Removal - Refitting, page 19A- 100) .
  • Page 827 FUEL MIXTURE Front exhaust manifold: Removal - Refitting - the front exhaust manifold heat shield. II - OPERATION FOR REMOVAL OF PART CONCERNED 137946 Note: Apply SUPER RELEASING AGENT (see Vehi- 134114 a Remove the clip (7) between the front exhaust man- cle: Parts and consumables for the repair) (04B, Consumables - Products) before loosen- ifold and the turbocharger.
  • Page 828 FUEL MIXTURE Front exhaust manifold: Removal - Refitting - the heat shield studs of the front exhaust manifold, if they have become loose. a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products) to clean and degrease: - the cylinder head surface, - the exhaust manifold joint faces if they are being reused,...
  • Page 829 FUEL MIXTURE Front exhaust manifold: Removal - Refitting - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-51) , - the lower engine tie-bars (see 1 9 D, Engine mounting, Lower engine tie-bar: Removal - Re- fitting, page 19D-85) , - the starter (see 16A, Starting - Charging, Starter: Removal - Refitting, page 16A-31) ,...
  • Page 830 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting Equipment required refrigerant charging station Tightening torquesm exhaust manifold studs 15 N.m rear exhaust manifold 31 N.m bolts IMPORTANT Wear protective gloves during the operation. REMOVAL 133477 a Disconnect the rear row upstream oxygen sensor I - REMOVAL PREPARATION OPERATION connector (1) .
  • Page 831 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting REFITTING - the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-75) , - the front right-hand driveshaft (see Front right- I - REFITTING PREPARATION OPERATION hand driveshaft: Removal - Refitting) (29A, a parts always to be replaced: exhaust manifold Driveshafts), seal (10,07,02,07).
  • Page 832 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting REMOVAL Special tooling required Mot. 1448 Remote operation pliers for I - REMOVAL PREPARATION OPERATION hose clips. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- Tightening torquesm fitting) (80A, Battery).
  • Page 833 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting 134225 138351 a Remove the clip (1) from the turbocharger cooling a Unclip the wiring (5) from the crankshaft position hose using the (Mot. 1448). sensor of the catalytic pre-converter strut. a Disconnect the turbocharger cooling hose. a Remove the nuts (6) from the catalytic pre-converter a Remove: lower stay.
  • Page 834 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting 138360 138353 a Loosen the nut (9) on the catalytic pre-converter up- per stay. a Remove the catalytic pre-converter upper stay. 134229 a Remove: - the catalytic pre-converter lower stay studs (7) , 137925 - the catalytic pre-converter lower stay nuts (8) , a Remove the nut (10) on the rigid cooling pipes of the...
  • Page 835 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting a Remove the turbocharger heat shield. WARNING T o prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. 134226 a Unclip the cooling hose at the inlet of the exhaust gas cooler from the back row rail protector.
  • Page 836 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting 134107 137953 a Remove the clip (19) on the cooler hose at the ex- a Move aside the clip (15) of the cooling hose at the haust fuel injector cooler inlet using the (Mot. 1448). exhaust gas recirculation solenoid valve outlet using a Disconnect the cooler hose at the exhaust fuel injec- the (Mot.
  • Page 837 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 137948 Note: Apply SUPER RELEASING AGENT (see Vehi- cle: Parts and consumables for the repair) (04B, Consumables - Products) before loosen- ing the nuts of the exhaust manifold. 137947 a Remove: a Remove:...
  • Page 838 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting - the nuts between the turbocharger and the catalytic pre-converter, - the catalytic pre-converter stay studs, - the clip between the turbocharger and the rear ex- haust manifold, - the nuts on the turbocharger exhaust gas cooler, - the studs on the turbocharger exhaust gas cooler, if they were loosened during the removal operation, - the turbocharger heat shield nuts,...
  • Page 839 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting a Tighten the following in order: a Without tightening, fit the nut of the catalytic pre-con- verter upper stay. - the bolts on the exhaust gas recirculation solenoid a Refit the catalytic pre-converter lower stay. valve, a Without tightening, fit the nuts of the lower stay onto - the nuts on the turbocharger exhaust gas cooler,...
  • Page 840 FUEL MIXTURE Rear exhaust manifold: Removal - Refitting a Fill and bleed the cooling system (see 19A, Cool- ing, Cooling system: Draining - Refilling, page 19A-16) . a Refit the engine cover. 12A-139...
  • Page 841 TURBOCHARGING Turbocharging: Precautions for the repair F4R or K9K or M9R or V9X III - APPLICATION CONDITIONS OF INSTRUCTIONS Equipment required The instructions below must be followed when repla- parts washer cing a turbocharger due to mechanical damage: - damage to the bearing system, I - TURBOCHARGER: GENERAL INSTRUCTIONS - broken shaft or turbine wheel, For the turbocharging pressure regulator check (see...
  • Page 842 TURBOCHARGING Turbocharging: Precautions for the repair F4R or K9K or M9R or V9X • Clean the turbocharger air pipes. Check that there are no metal objects inside the air flowmeter (2) . Remove: Note: - the air pipe(between the air filter unit and the turbo- When carrying out an operation on the air or lubri- charger) (A) , cation circuit, it is necessary to plug the open holes...
  • Page 843 TURBOCHARGING Turbocharging: Precautions for the repair F4R or K9K or M9R or V9X One by one, clean the pipes removed with the parts V - LUBRICATION CIRCUIT**: INSTRUCTIONS washer : FOLLOWING MECHANICAL DAMAGE TO THE TURBOCHARGER - brush as much of the inside of the pipe as possible (only use brushes with plastic bristles), - wash plenty of cleaning product from the cleaning sta- Note:...
  • Page 844 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 Equipment required roller-type stud removal tool tweezers Tightening torquesm turbocharger studs 15 N.m exhaust manifold stud 9 N.m turbocharger strut bolt 25 N.m on the flywheel end turbocharger lower nuts 12 N.m (initial torque)
  • Page 845 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 a Remove: - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front right-hand driveshaft (see Front right- hand driveshaft: Removal - Refitting) (29A, Driveshafts), - the right-hand differential output seal (see Differ-...
  • Page 846 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 II - OPERATION FOR REMOVAL OF PART CONCERNED 114471 a Remove: 113277 - the bolts (11) from the strut, - the strut, Note: - the exhaust manifold stud using a roller-type stud Apply SUPER RELEASING AGENT (see Vehi- removal tool, cle: Parts and consumables for the repair)
  • Page 847 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 - the turbocharger studs. a Refit the new turbocharger studs using a roller-type stud removal tool. a Torque tighten the turbocharger studs (15 N.m) using a roller-type stud removal tool or using the stud recesses.
  • Page 848 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 II - REFITTING OPERATION FOR PART CONCERNED 115739 a In order, fit (without tightening): 114471 - the transversal bolt (14) , a Refit: - the nuts (15) , - the new turbocharger strut, - the nut (16) .
  • Page 849 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 742 or 744 or 746 or 748 or 754 a Connect the battery (see Battery: Removal - Refit- - the engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, page ting) (80A, Battery).
  • Page 850 TURBOCHARGING Turbocharger: Removal - Refitting a Disconnect the battery (see Battery: Removal - Re- fitting) (MR 415, 80A, Battery). a Remove the front engine cover. Tightening torquesm turbocharger studs 5 Nm turbocharger oil return 12 Nm pipe bolts oil return pipe retaining 12 Nm bolt on the turbocharger turbocharger upper nut...
  • Page 851 TURBOCHARGING Turbocharger: Removal - Refitting 124751 123344 a Undo the air filter unit air outlet pipe clip (4) on the a Undo the air filter box air outlet pipe clip (5) at the air turbocharger side. filter box end. a Disconnect: - the oil vapour rebreathing pipe union on the air filter box air outlet pipe.
  • Page 852 TURBOCHARGING Turbocharger: Removal - Refitting a Unclip the wiring for the turbocharging pressure reg- ulation valve control solenoid valve and the braking assistance double non-return valve from the air filter box air outlet pipe a Remove: - the air filter box air outlet pipe, - the engine undertray bolts, - the engine undertray, - the front right-hand wheel (see Wheel: Removal -...
  • Page 853 TURBOCHARGING Turbocharger: Removal - Refitting a Always replace: If replacing the turbocharger - the seal between the turbocharger and the exhaust manifold, - the turbocharger oil return pipe seal, - the turbocharger nuts. Note: If a stud comes loose during removal, smear it with HIGH RESISTANCE THREADLOCK (see Vehicle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products).
  • Page 854 TURBOCHARGING Turbocharger: Removal - Refitting a Refit: - the engine undertray bolts. a Tighten the engine undertray bolts. - the new turbocharger oil return pipe seal to the tur- bocharger oil return pipe, a Refit the air filter box air outlet pipe. - the turbocharger oil return pipe to the new turbo- a Clip: charger.
  • Page 855 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Disconnect the battery (see Battery: Removal - Re- Special tooling required fitting) (80A, Battery). Ms. 583 Pipe clamps.
  • Page 856 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 M9R, and 800 or 802 or 806 or 808 or 816 a Drain the gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox).
  • Page 857 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - OPERATION FOR REMOVAL OF PART CONCERNED 123926 a Clamp the turbocharger cooling pipe hoses (6) using 113277 the tool (Ms.
  • Page 858 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 If replacing the turbocharger: 114471 a Remove: 116297 a Remove: - the bolts (12) from the turbocharger strut, - the turbocharger rigid cooling pipe bolts (14) , - the turbocharger strut.
  • Page 859 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 - parts always to be replaced: Turbocharger oil return pipe (10,09,03,02), - parts always to be replaced: seal between ex- haust manifold and turbocharger (10,09,01,07), - parts always to be replaced: turbocharger rigid cooling pipe seal (10,09,01,09),...
  • Page 860 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 II - REFITTING OPERATION FOR PART CONCERNED 115739 a Fit without tightening and in order the transversal bolt (17) , nuts (18) and (19) on the turbocharger.
  • Page 861 TURBOCHARGING Turbocharger: Removal - Refitting M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Connect the turbocharger cooling hoses. a Connect: a Refit the turbocharger cooling hose clips using the - the air flowmeter connector, tool (Mot.
  • Page 862 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 780 Equipment required Diagnostic tool Tightening torquesm new studs of the turbo- 9 N.m charger on the mani- fold, manifold side new stud of the turbo- 9 N.m charger on the mani- fold, turbocharger side nuts of the turbocharger 28 N.m IMPORTANT...
  • Page 863 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 780 123823 123823 a Remove: a Remove: - the turbocharger upper nuts (4) , - the turbocharger lower nut (5) , - the engine undertray bolts, - the turbocharger, - the engine undertray, - the turbocharger seal on the exhaust manifold.
  • Page 864 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 780 - the exhaust manifold on the turbocharger. - the exhaust gas recirculation solenoid valve (see a Next, degrease these bearing faces using SUR- 14A, Antipollution, Exhaust gas recirculation solenoid valve: Removal - Refitting, page 14A- FACE CLEANER and CLEAN CLOTHS (see Vehi- 11) .
  • Page 865 TURBOCHARGING Turbocharger: Removal - Refitting a Drain the cooling system (see 19A, Cooling, Cool- Special tooling required ing system: Draining - Refilling, page 19A-16) . Mot. 1448 Remote operation pliers for hose clips. Equipment required tweezers Tightening torquesm turbocharger studs 10 N.m new turbocharger nuts 62 N.m...
  • Page 866 TURBOCHARGING Turbocharger: Removal - Refitting 134228 134107 a Rotate the intercooler air inlet pipe clip (4) on the tur- a Remove: bocharger. - the exhaust gas recirculation rigid pipe (see 14A, a Disconnect the intercooler air inlet pipe on the turbo- Antipollution, Exhaust gas recirculation rigid charger.
  • Page 867 TURBOCHARGING Turbocharger: Removal - Refitting 137922 134093 a Remove the bolts (7) of the gearbox control support. a Remove: a Move aside the gearbox control support. - the nut (10) of the rigid cooling pipes, - the bolt (11) of the rigid cooling pipes. a Move aside the rigid cooling pipes.
  • Page 868 TURBOCHARGING Turbocharger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 134113 134101 Note: Apply SUPER RELEASING AGENT (see Vehi- cle: Parts and consumables for the repair) (04B, Consumables - Products) to the turbo- charger studs to prevent the studs from breaking when the nuts are undone.
  • Page 869 TURBOCHARGING Turbocharger: Removal - Refitting If replacing the turbocharger 134115 a Disconnect: 134090 a Remove: - the exhaust gas pressure sensor connector, - the turbocharger coolant pipe (18) (see Turbo- - the exhaust gas temperature sensor connector . charger coolant pipe: Removal - Refitting) , - the connector support bolts (19) , Note: - the exhaust gas temperature sensor (20) (see...
  • Page 870 TURBOCHARGING Turbocharger: Removal - Refitting - the turbocharger washers, - the turbocharger air outlet pipe seal, - the exhaust gas cooler studs on the turbocharger, if they were loosened during the removal operation, - the exhaust gas cooler nuts on the turbocharger. a Using SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma- bles - Products), clean and degrease the bearing fa-...
  • Page 871 TURBOCHARGING Turbocharger: Removal - Refitting - new clips between the turbocharger and the ex- haust manifolds, - the turbocharger, - the turbocharger strut. - new turbocharger washers. a Tighten to torque: - the new turbocharger nuts (62 N.m), - the turbocharger strut bolts (25 N.m), - the new turbocharger strut nuts (25 N.m).
  • Page 872 TURBOCHARGING Turbocharger: Removal - Refitting a Fit the clip of the intercooler air inlet pipe on the tur- bocharger a Torque tighten the nut of the intercooler air inlet pipe (21 N.m). a Refit the air filter unit outlet pipe. a Torque tighten the clip on the turbocharger air in- let pipe (6 N.m).
  • Page 873 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 782 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm new turbocharger studs 9 N.m on the turbocharger new turbocharger stud 9 N.m on the exhaust manifold turbocharger nuts 28 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 874 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 782 REFITTING III - FINAL OPERATION a Refit: I - REFITTING PREPARATION OPERATION - the turbocharger oil pipes (see 12B, Turbocharg- ing, Turbocharger oil pipe: Removal - Refitting, page 12B-35) , - the exhaust gas recirculation assembly (see 14A, WARNING Antipollution, Exhaust gas recirculation as- Ensure that no foreign bodies enter the turbine or...
  • Page 875 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting Special tooling required Note: Ms. 583 Pipe clamps. This procedure deals with removing and refitting the Mot. 1448 Remote operation pliers for turbocharger oil supply pipe and the turbocharger hose clips. oil return pipe. Mot.
  • Page 876 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting 124133 124132 a Remove: a Remove the bolt (1) from the turbocharger cooling pipe heat shield. - the nuts (3) from the starter heat shield, a Position the (Ms. 583) on the turbocharger cooling - the starter heat shield.
  • Page 877 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Refit the turbocharger oil supply pipe. a Fit without tightening: - the turbocharger oil supply pipe union on the turbo- charger, - the turbocharger oil supply pipe hollow bolt onto the cylinder block,...
  • Page 878 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting - the front right-hand wheel arch liner (see Front II - OPERATION FOR REMOVAL OF PART wheel arch liner: Removal - Refitting) (MR 416, CONCERNED 55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (MR 415, 35A, Wheels and tyres).
  • Page 879 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Fit the turbocharger oil return pipe, first positioning it in the cylinder block. a Refit the turbocharger oil return pipe bolts on the tur- bocharger. a Torque tighten the turbocharger oil return pipe bolts on the turbocharger (8 N.m).
  • Page 880 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm turbocharger oil pipe 10 N.m bolts turbocharger oil supply 16 N.m pipe hollow bolt on the cylinder block REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 881 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - REFITTING OPERATION FOR PART III - FINAL OPERATION CONCERNED M9R, and 742 or 744 or 746 or 748 or 754 a Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, page 19B-32) .
  • Page 882 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 780 Special tooling required Note: Mot. 1566 Tool for removing high pres- sure pipes. This procedure deals with removing and refitting the oil return pipe and oil supply pipe. Mot. 1746 Offset wrench for tightening High Pressure pump pipes.
  • Page 883 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 780 122425 123812 a Unclip the electric wiring (3) from the air filter unit air outlet pipe. a Undo the clips (4) for the air filter unit air outlet pipe. a Remove the air outlet pipe from the air filter box. 122424 a Disconnect: - the air flow sensor connector (1) ,...
  • Page 884 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 780 a Torque tighten: II - OPERATION FOR REMOVAL OF PART CONCERNED - the turbocharger oil supply pipe nut on the cyl- inder head (35 N.m) using the tool (Mot. 1566) or the tool (Mot.
  • Page 885 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 780 REMOVING THE TURBOCHARGER OIL II - OPERATION FOR REMOVAL OF PART CONCERNED RETURN PIPE I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 886 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 780 REFITTING THE TURBOCHARGER OIL RETURN PIPE I - REFITTING PREPARATION OPERATION a Always replace: - the turbocharger oil return pipe flat seal, - the turbocharger oil return pipe O-ring. a Lubricate the turbocharger oil return pipe O-ring with engine oil.
  • Page 887 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting Special tooling required Tightening torquesm Mot. 1448 Remote operation pliers for turbocharger heat shield 8 N.m hose clips. nuts upper oil return pipe 10 N.m Equipment required bolts tweezers IMPORTANT Tightening torquesm Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 888 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Remove: a Remove the lower engine tie-bars (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refit- - the engine cover, ting, page 19D-85) . - the engine undertray bolts, - the engine undertray, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front wheel arch liners (see Front wheel arch...
  • Page 889 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting 138360 138353 a Loosen the nut (9) of the catalytic pre-converter up- per stay. a Remove the catalytic pre-converter upper stay. 134229 a Remove: - the catalytic pre-converter lower stay studs (7) , 137925 - the catalytic pre-converter lower stay nuts (8) , a Remove the nut (10) of the rigid cooling pipes of the...
  • Page 890 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Remove the turbocharger heat shield. WARNING T o prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield. Any damaged heat shields must be replaced. 138352 a Remove the catalytic pre-converter nuts (12) from the turbocharger.
  • Page 891 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the turbocharger oil supply pipe, CONCERNED - the turbocharger oil supply pipe seals. 1 - Removing the turbocharger oil supply pipe 2 - Removing the lower oil return pipe 134112 134110 a Remove:...
  • Page 892 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting - the catalytic pre-converter stay nuts if they were loosened during the removal operation, - the catalytic pre-converter studs if they were loos- ened during the removal operation. a Use engine oil to lubricate the new O-ring of the tur- bocharger oil return pipe on the cylinder block side.
  • Page 893 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Torque tighten the lower oil return pipe bolts (10 - the lower stay nuts on the catalytic pre-converter. a Tighten to torque: N.m). - the catalytic pre-converter upper stay nut (21 III - FINAL OPERATION N.m), a Clip on the turbocharger control solenoid valve.
  • Page 894 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Disconnect the battery (see Battery: Removal - Re- II - OPERATION FOR REMOVAL OF PART fitting) (80A, Battery). CONCERNED a Remove: - the engine cover, - the engine undertray bolts, - the engine undertray, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front wheel arch liners (see Front wheel arch...
  • Page 895 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting - the exhaust gas recirculation rigid pipe (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, page 14A-62) , - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-13) , - the oil supply pipe and the lower oil return pipe of the turbocharger (see 12B, Turbocharging, Tur- bocharger oil pipe: Removal - Refitting, page...
  • Page 896 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 782 - the exhaust gas recirculation assembly (see 14A, Special tooling required Antipollution, Exhaust gas recirculation as- sembly: Removal - Refitting, page 14A-52) . Mot. 1566 Tool for removing high pres- sure pipes.
  • Page 897 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 782 a Torque tighten: II - OPERATION FOR REMOVAL OF PART CONCERNED - the nut of the turbocharger oil supply pipe (35 N.m) using the tool (Mot. 1566) or the tool (Mot. 1746), - the turbocharger oil supply pipe hollow bolt (14 N.m).
  • Page 898 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 782 REFITTING THE TURBOCHARGER OIL RETURN PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil pipe seal (10,09,03,05). II - REFITTING OPERATION FOR PART CONCERNED a Refit the new seals onto the turbocharger oil return pipe.
  • Page 899 TURBOCHARGING Intercooler: Removal - Refitting - the radiator mounting cross member (see Radiator mounting cross member: Removal - Refitting) Equipment required (MR 416, 41A, Front lower structure). safety strap(s) II - OPERATION FOR REMOVAL OF PART CONCERNED REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 900 TURBOCHARGING Intercooler: Removal - Refitting - the intercooler air outlet pipe seal. II - REFITTING OPERATION FOR PART CONCERNED a Refit the intercooler by: - fitting it into the notch for the « engine cooling fan - condenser - cooling radiator » assembly mount- ings, - clipping it into the «...
  • Page 901 TURBOCHARGING Intercooler: Removal - Refitting Equipment required tweezers REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment). a Remove: - the engine undertray bolts, - the engine undertray, - the front wheels (see Wheel: Removal - Refitting) (MR 415, 35A, Wheels and tyres),...
  • Page 902 TURBOCHARGING Intercooler: Removal - Refitting 123699 122999 a Press on the intercooler pads (3) . a Rotate the intercooler (4) . a Separate the intercooler from the cooling radiator. REFITTING I - REFITTING PREPARATION OPERATION Note: Check that the intercooler is not full of oil. If it is, clean it using SURFACE CLEANER (see Vehi- cle: Parts and consumables for the repair) (MR 415, 04B, Consumables - Products) and...
  • Page 903 TURBOCHARGING Intercooler: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 115068 a Remove the following using a tweezers : 122999 a Clip: - the intercooler air inlet pipe seal, - the intercooler at (5) , - the intercooler air outlet pipe seal. - the intercooler at (6) , - the engine cooling radiator deflectors onto the in- tercooler.
  • Page 904 TURBOCHARGING Intercooler: Removal - Refitting III - FINAL OPERATION. 123701 a Rotate the intercooler air inlet pipe clip into the Locked position. a Connect the pipe to the intercooler until you hear a CLICK from the clip. Note: Check that the clip is correctly fitted inside the neck of the intercooler.
  • Page 905 TURBOCHARGING Intercooler: Removal - Refitting a Disconnect the turbocharger air outlet pipe on the in- tercooler. Equipment required cleaning trough parts washer compressed air nozzle REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 906 TURBOCHARGING Intercooler: Removal - Refitting - separate the intercooler from the engine cooling assembly at (4) . REFITTING I - REFITTING PREPARATION OPERATION Note: Following a turbocharger fault, check that the intercooler and the air circuit assembly are not full of oil. If this is the case, remove and clean them with a cleaning trough or a parts washer.
  • Page 907 TURBOCHARGING Intercooler: Removal - Refitting Equipment required tweezers REMOVAL I - REMOVAL PREPARATION OPERATION 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, - the front wheels (see Wheel: Removal - Refitting) 137899 a Remove the right-hand air scoop (2) from the radia-...
  • Page 908 TURBOCHARGING Intercooler: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 138349 138350 a Loosen the clip (4) on the intercooler outlet air pipe. a Disconnect the intercooler air outlet pipe. a Move the intercooler outlet air pipe to one side. 123701 a Rotate the clip (5) on the intercooler air inlet pipe.
  • Page 909 TURBOCHARGING Intercooler: Removal - Refitting When replacing the intercooler 137890 137890 a Remove: - the bolt (7) of the air conditioning pipe support, - the air conditioning pipe support, - the cooling hose support from the intercooler. a Refit on the new intercooler: - the cooling hose support on the intercooler, - the air conditioning pipe support, - the bolts of the air conditioning pipe support.
  • Page 910 TURBOCHARGING Intercooler: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Fit the intercooler on the radiator. a Clip the intercooler onto the radiator. 115068 a Use a tweezers to remove the seal from the inter- cooler air inlet pipe. 123701 a Rotate the intercooler air inlet pipe clip into its «...
  • Page 911 TURBOCHARGING Intercooler: Removal - Refitting - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray. 12B-71...
  • Page 912 FUEL SUPPLY Manual priming pump: Removal - Refitting 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 1 3 B , Diesel injection, Diesel injection: Precautions for the repair, page 13B-1) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction).
  • Page 913 FUEL SUPPLY Manual priming pump: Removal - Refitting a Lower the intermediate pipe and place it on the front and rear axles. M9R, and 742 or 744 or 746 or 748 or 754 M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 a Remove the particle filter (see 19B, Exhaust, Parti- cle filter: Removal - Refitting, page 19B-71) .
  • Page 914 FUEL SUPPLY Manual priming pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 123637 a Remove the bulkhead heat shield clips (7) . a Separate the heat shield from the bulkhead without 123782 a Unclip the fuel pipe filler neck (8) from the body. damaging it.
  • Page 915 FUEL SUPPLY Manual priming pump: Removal - Refitting III - FINAL OPERATION a Fit the bulkhead heat shield. a Refit: - the bulkhead heat shield clips, - the intermediate pipe heat shield, - the intermediate pipe heat shield clips. M9R, and 742 or 744 or 746 or 748 or 754 a Fit the intermediate pipe.
  • Page 916 FUEL SUPPLY Manual priming pump: Removal - Refitting 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 1 3 B , Diesel injection, Diesel injection: Precautions for the repair, page 13B-1) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction).
  • Page 917 FUEL SUPPLY Manual priming pump: Removal - Refitting K9K, and 780 K9K, and 782 a Remove the particle filter (see 19B, Exhaust, Parti- cle filter: Removal - Refitting, page 19B-71) . 123417 123781 a Remove: - the clips (4) of the exhaust pipe heat shield, - the exhaust pipe heat shield.
  • Page 918 FUEL SUPPLY Manual priming pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 123637 a Remove the bulkhead heat shield clips (5) . a Separate the heat shield from the bulkhead without 123782 a Unclip the fuel pipe filler neck (6) from the body. damaging it.
  • Page 919 FUEL SUPPLY Manual priming pump: Removal - Refitting K9K, and 780 K9K, and 782 123571 122996 a Disconnect the manual priming pump union (8) from a Disconnect the manual priming pump union (10) the fuel heater. from the fuel filter. a Insert the blanking plugs.
  • Page 920 FUEL SUPPLY Manual priming pump: Removal - Refitting K9K, and 780 K9K, and 782 a Refit: a Connect: - the particle filter (see 19B, Exhaust, Particle fil- - the manual priming pump union to the fuel heater, ter: Removal - Refitting, page 19B-71) , - the manual priming pump union to the fuel supply - the front right-hand wheel arch liner (see Front pipe.
  • Page 921 FUEL SUPPLY Manual priming pump: Removal - Refitting - the engine undertray bolts, - the engine undertray, IMPORTANT - the expansion bottle (see 19A, Cooling, Expan- To avoid all risk of damage to the systems, apply sion bottle: Removal - Refitting, page 19A-152) . the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 922 FUEL SUPPLY Manual priming pump: Removal - Refitting a Connect the fuel inlet union to the electric diesel fuel heater. III - FINAL OPERATION a Refit: - the expansion bottle (see 19A, Cooling, Expan- sion bottle: Removal - Refitting, page 19A-152) , - the engine undertray.
  • Page 923 FUEL SUPPLY Fuel filter: Removal - Refitting K9K or M9R 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 1 3 B , Diesel injection, Diesel injection: Precautions for the repair, page 13B-1) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction).
  • Page 924 FUEL SUPPLY Fuel filter: Removal - Refitting K9K or M9R a Remove the fuel filter. Note: If the fuel filter is to be re-used, fit blanking plugs. III - OPERATION FOR REMOVAL OF PART CONCERNED (2 FITTING) a Clean the fuel pipe unions before disconnecting the pipes (see 13B, Diesel injection, Diesel injection: Precautions for the repair, page 13B-1) .
  • Page 925 FUEL SUPPLY Fuel filter: Removal - Refitting K9K or M9R a Remove the fuel filter. II - REFITTING OPERATION FOR PART CONCERNED (2 FITTING) a Refit the electric diesel fuel heater (see 13A, Fuel Note: supply, Electric diesel fuel heater: Removal - Re- If the fuel filter is to be re-used, fit blanking plugs.
  • Page 926 FUEL SUPPLY Fuel filter: Removal - Refitting F4R or K4M or M4R a The fuel filter is located in the tank and built into the “pump - sender - filter” assembly. To remove the fil- ter, remove the “pump - sender - filter” assembly (see 19C, Tank, Pump - sender - filter: Removal - Refitting, page 19C-4) .
  • Page 927 FUEL SUPPLY Fuel filter: Removal - Refitting a The fuel filter is located in the tank and integrated into the « pump - sender - filter » assembly. To re- move the filter, remove the « pump - sender - filter » assembly (see 19C, Tank, Pump - sender - filter: Removal - Refitting, page 19C-4) .
  • Page 928 FUEL SUPPLY Electric diesel fuel heater: Removal - Refitting K9K or M9R or V9X II - OPERATION FOR REMOVAL OF PART CONCERNED 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 1 3 B , Diesel injection, Diesel injection:...
  • Page 929 FUEL SUPPLY Electric diesel fuel heater: Removal - Refitting K9K or M9R or V9X II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION CONCERNED a Refit the expansion bottle (see 19A, Cooling, Ex- pansion bottle: Removal - Refitting, page 19A- 152) .
  • Page 930 FUEL SUPPLY Fuel pressure: Check F4R or K4M or M4R I - PREPARATION OPERATION FOR CHECK Special tooling required Mot. 1311-01 Pressure gauges and petrol pressure measuring unions. Mot. 1311-08 Union for taking fuel pres- sure measurements. CHECK IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting...
  • Page 931 FUEL SUPPLY Fuel pressure: Check F4R or K4M or M4R II - TEST OPERATION 124575 a Disconnect fuel supply pipe union on the injector rail. 124361 a Disconnect fuel supply pipe union on the injector rail. a Connect: a Connect: - the pipe (1) fitted with a test pressure gauge (Mot.
  • Page 932 FUEL SUPPLY Fuel pressure: Check F4R or K4M or M4R a Clip the fuel pipe on the right-hand suspended en- gine mounting. a Refit the engine cover. 128621 a Disconnect fuel supply pipe union on the injector rail. a Unclip the fuel pipe from the right-hand suspended engine mounting.
  • Page 933 FUEL SUPPLY Fuel pressure: Check CHECK Special tooling required Mot. 1311-01 Pressure gauges and petrol I - PREPARATION OPERATION FOR CHECK pressure measuring unions. Mot. 1311-08 Union for taking fuel pres- sure measurements. IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - beware of fuel splashes when disconnecting the...
  • Page 934 FUEL SUPPLY Fuel pressure: Check a Connect the quick-release union of the fuel supply II - TEST OPERATION pipe to the injector rail. a Refit the engine cover. 134869 a Disconnect the quick-release union (1) from the fuel supply pipe. a Connect: - the pipe (2) fitted with the test pressure gauge (Mot.
  • Page 935 FUEL SUPPLY Fuel flow: Check F4R or K4M or M4R Special tooling required Mot. 1311-01 Pressure gauges and petrol pressure measuring unions. Mot. 1311-08 Union for taking fuel pres- sure measurements. Equipment required graduated measuring cylinder IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the...
  • Page 936 FUEL SUPPLY Fuel flow: Check F4R or K4M or M4R 124362 128622 a Connect: a Unclip the fuel pipe from the right-hand suspended engine mounting. - the "T" union (Mot. 1311-08) (1) to the injector rail, a Connect: - the fuel supply union to the "T" union (Mot. 1311- 08).
  • Page 937 FUEL SUPPLY Fuel flow: Check F4R or K4M or M4R a Disconnect: - the fuel supply union on the "T" union (Mot. 1311- 08), - the "T" union (Mot. 1311-08) on the injector rail. a Connect the fuel supply pipe union on the injector rail.
  • Page 938 FUEL SUPPLY Fuel flow: Check a Assemble the long hose of the test tool (Mot. 1311- Special tooling required 01) and the T quick-release union (Mot. 1311-08). Mot. 1311-01 Pressure gauges and petrol pressure measuring unions. Mot. 1311-08 Union for taking fuel pres- sure measurements.
  • Page 939 FUEL SUPPLY Fuel flow: Check - the Protection and Switching Unit cover. a Disconnect: - the fuel supply pipe quick-release union from the T union (Mot. 1311-08), - the quick-release T union (Mot. 1311-08) from the fuel pipe on the injector rail side. a Connect the fuel supply pipe quick-release union to the pipe on the injector rail side.
  • Page 940 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 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.
  • Page 941 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X II - ADVICE TO BE FOLLOWED BEFORE ANY After opening the fuel circuit, the use of brushes, clean- OPERATION ing 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.
  • Page 942 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 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...
  • Page 943 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 13B-4...
  • Page 944 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X Set of plugs for DELPHI injection: 13B-5...
  • Page 945 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 20977 13B-6...
  • Page 946 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X Set of plugs for SIEMENS injection: 13B-7...
  • Page 947 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 113430 13B-8...
  • Page 948 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 13B-9...
  • Page 949 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X Set of plugs: 13B-10...
  • Page 950 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 113737 13B-11...
  • Page 951 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 13B-12...
  • Page 952 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X Set of plugs: 13B-13...
  • Page 953 DIESEL INJECTION Diesel injection: Precautions for the repair K9K or M9R or V9X 138585 13B-14...
  • Page 954 DIESEL INJECTION Diesel injection: List and location of components M9R, and 742 or 744 or 746 or 748 or 754 122423 Manual priming pump Fuel pressure regulator on the injector rail Diesel injectors Rail pressure sensor Fuel temperature sensor High pressure pump Air flowmeter Diesel injection computer Turbocharger control solenoid...
  • Page 955 DIESEL INJECTION Diesel injection: List and location of components M9R, and 742 or 744 or 746 or 748 or 754 M9R, and 744 or 748 or 754 122432 Fuel temperature sensor 124534 High pressure pump M9R, and 742 or 746 113291 High pressure pump 122425...
  • Page 956 DIESEL INJECTION Diesel injection: List and location of components M9R, and 742 or 744 or 746 or 748 or 754 122399 122431 Diesel injection computer (10) Camshaft position sensor 122424 122427 Turbocharger control solenoid (11) EGR solenoid valve valve 13B-17...
  • Page 957 DIESEL INJECTION Diesel injection: List and location of components M9R, and 742 or 744 or 746 or 748 or 754 122426 (12) Damper valve (13) Turbocharger pressure sensor 122429 (16) Preheating unit 13B-18...
  • Page 958 DIESEL INJECTION Diesel injection: List and location of components 123286 Manual priming pump High-pressure pump Exhaust gas recirculation sole- noid valve Diesel injectors Camshaft position sensor Turbocharging air pressure sen- Air flowmeter Protection and Switching Unit Diesel injection computer (10) Coolant temperature sensor (11) Rail pressure sensor...
  • Page 959 DIESEL INJECTION Diesel injection: List and location of components 111748 High-pressure pump 121888 Camshaft position sensor 111746 Diesel injectors 122399 Diesel injection computer 13B-20...
  • Page 960 DIESEL INJECTION Diesel injection: List and location of components 123827 111747 (10) Coolant temperature sensor (12) Fuel temperature sensor 114076 (11) Rail pressure sensor 123846 (13) Flow regulation solenoid valve (14) Pressure regulation solenoid valve 13B-21...
  • Page 961 DIESEL INJECTION Diesel injection: List and location of components 123824 (15) Crankshaft position sensor 122429 (16) Pre-postheating unit 13B-22...
  • Page 962 DIESEL INJECTION Diesel injection: List and location of components M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 124141 Manual priming pump Injection rail pressure regulator Injectors Rail pressure sensor Diesel temperature sensor High pressure pump Air flowmeter...
  • Page 963 DIESEL INJECTION Diesel injection: List and location of components M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 122432 122425 Diesel temperature sensor Air flowmeter 124534 122399 High pressure pump Diesel injection computer 13B-24...
  • Page 964 DIESEL INJECTION Diesel injection: List and location of components M9R, and 800 or 802 or 805 or 806 or 808 or 809 or 816 or 845 or 849 122424 123692 Turbocharger control solenoid (12) EGR solenoid valve valve (13) Turbocharger pressure sensor (14) Damper valve 122431...
  • Page 965 DIESEL INJECTION Diesel injection: List and location of components 133906 Manual priming pump Injectors Fuel temperature sensor High pressure pump Air flowmeter Injection computer Turbocharger control solenoid valve Exhaust gas cooler control sole- noid valve Camshaft position sensor (10) Exhaust gas recirculation sole- noid valve (11) Air inlet valve...
  • Page 966 DIESEL INJECTION Diesel injection: List and location of components 137913 137873 (15) Exhaust gas temperature sensor (17) Electrical diesel fuel reheater 137863 137954 (16) Rail pressure sensor (18) Crankshaft position sensor 13B-27...
  • Page 967 DIESEL INJECTION Diesel injection: List and location of components 137917 133903 (19) Exhaust fuel injector (21) Particle filter pressure sensor 133892 133905 (20) Fuel pressure regulator (22) Particle filter temperature sensor 13B-28...
  • Page 968 DIESEL INJECTION Diesel injection: List and location of components 136260 (23) Coolant temperature sensor 137878 (24) Pre-postheating unit 13B-29...
  • Page 969 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 123520 138817 Manual priming pump Exhaust gas recirculation sole- noid valve 138545 Diesel injectors 138816 High pressure pump 13B-30...
  • Page 970 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 138549 143758 Camshaft position sensor Air flowmeter 138399 122399 Turbocharging pressure sensor Diesel injection computer 13B-31...
  • Page 971 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 114213 138897 Coolant temperature sensor (11) Fuel temperature sensor 138544 (10) Rail pressure sensor 138394 (12) Damper valve 13B-32...
  • Page 972 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 139195 144362 (13) Exhaust fuel injector solenoid (15) Electric diesel fuel heater valve 138541 (16) Flow regulation solenoid valve (17) Pressure regulation solenoid valve 144222 (14) Thermoplunger unit 13B-33...
  • Page 973 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 123824 139171 (18) Crankshaft position sensor (20) Exhaust gas temperature sensor 122429 139201 (19) Pre-postheating unit (21) Exhaust gas pressure sensor 13B-34...
  • Page 974 DIESEL INJECTION Diesel injection: List and location of components K9K, and 782 139172 (22) Exhaust fuel injector 13B-35...
  • Page 975 DIESEL INJECTION Diesel injection computer: Removal - Refitting Equipment required Diagnostic tool REMOVAL I - REFITTING PREPARATIONS OPERATION a Apply the procedure before repair using the Dia- gnostic tool : - connect the Diagnostic tool, - select the « diesel injection computer » , - go to repair mode, - display the «...
  • Page 976 DIESEL INJECTION Diesel injection computer: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the diesel injection computer on its mounting. a Tighten the diesel injection computer mounting nuts. a Fit the diesel injection computer and its mounting into the engine compartment.
  • Page 977 DIESEL INJECTION Diesel injection computer: Removal - Refitting Equipment required Diagnostic tool REMOVAL I - REFITTING PREPARATIONS OPERATION a Apply the procedure before repair using the Dia- gnostic tool : - connect the Diagnostic tool, - select the « diesel injection computer » , - go to repair mode, - display the «...
  • Page 978 DIESEL INJECTION Diesel injection computer: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the diesel injection computer on its mounting. a Tighten the diesel injection computer mounting nuts. a Fit the diesel injection computer and its mounting into the engine compartment.
  • Page 979 DIESEL INJECTION Diesel injection computer: Removal - Refitting Equipment required Diagnostic tool WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxy- gen sensor connectors or on the bodies of the oxy- gen sensors.
  • Page 980 DIESEL INJECTION Diesel injection computer: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the diesel injection computer. II - FINAL OPERATION a Refit the protector cover of the diesel injection com- puter. a Connect the diesel injection computer connectors. a Connect the battery (see Battery: Removal - Refit- ting) (80A, Battery).
  • Page 981 DIESEL INJECTION Camshaft position sensor: Removal - Refitting a Remove: Equipment required - the cooling radiator top hose, tweezers - the intercooler inlet air pipe. REMOVAL II - REMOVAL OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 122431 a Disconnect the connector (4) from the camshaft po- 122430...
  • Page 982 DIESEL INJECTION Camshaft position sensor: Removal - Refitting REFITTING I - REFITTING PREPARATIONS OPERATION a Always replace: - the camshaft sensor seal. 115069 Note: Check that the intercooler air inlet pipe seal is fit- ted in the right direction on the turbocharger side. a Fit a new seal to the intercooler air inlet pipe on the 115068 a Remove the intercooler air inlet pipe seal on the tur-...
  • Page 983 DIESEL INJECTION Camshaft position sensor: Removal - Refitting a Refit: - the intercooler air inlet pipe bolts on the intake dis- tributor, - the cooling radiator top hose nut on the intercooler air inlet pipe. a Tighten: - the intercooler air inlet pipe bolts on the intake dis- tributor, - the cooling radiator top hose nut on the intercooler air inlet pipe.
  • Page 984 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 780 REMOVAL II - REMOVAL OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 121889 a Disconnect the connector (2) from the camshaft po- sition sensor.
  • Page 985 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 780 REFITTING I - REFITTING PREPARATIONS OPERATION a Always replace the camshaft position sensor seal. a Lubricate the camshaft position sensor seal. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the new camshaft position sensor seal, - the camshaft position sensor, - the camshaft position sensor bolt.
  • Page 986 DIESEL INJECTION Camshaft position sensor: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit: Tightening torquesm camshaft position sen- 10 Nm - a new camshaft position sensor seal, sor bolt - the camshaft position sensor. a Tighten to torque the camshaft position sensor REMOVAL bolt (10 Nm).
  • Page 987 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 782 - the clip (3) from the intercooler air inlet pipe. a Disconnect the intercooler air inlet pipe. Equipment required a Move aside the intercooler air inlet pipe. tweezers REMOVAL I - REMOVAL PREPARATION OPERATION 138399 a Disconnect the turbocharger pressure sensor con-...
  • Page 988 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 782 II - OPERATION FOR REMOVAL OF PART CONCERNED 138550 a Unclip the injector rail protector cover at (8) . a Remove: 138549 a Disconnect the connector (10) from the camshaft - the bolts (9) of the injector rail protector cover, position sensor.
  • Page 989 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 782 - a new intercooler air inlet pipe seal. II - REFITTING OPERATION FOR PART CONCERNED a Refit a new camshaft position sensor seal. a Lubricate the camshaft position sensor seal with new engine oil.
  • Page 990 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting Tightening torquesm crankshaft position sen- 10 Nm sor bolt REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 991 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting III - FINAL OPERATION. a Refit: - the engine undertray, - the engine undertray bolts. 13B-52...
  • Page 992 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting REMOVAL II - FINAL OPERATION. a Refit: I - REMOVAL PREPARATION OPERATION - the engine undertray, a Position the vehicle on a two-post lift (see Vehicle: - the engine undertray bolts. Towing and lifting) (MR 415, 02A, Lifting equip- ment).
  • Page 993 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting a Torque tighten the crankshaft position sensor bolt (10 N.m). a Connect the crankshaft position sensor connector. Tightening torquesm crankshaft position sen- 10 N.m sor bolt II - FINAL OPERATION a Refit the engine undertray. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 994 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 780 Special tooling required Mot. 1771 Kit for measuring SIEMENS injector leakage flow rate. Equipment required graduated measuring cylinder Diagnostic tool CHECK I - PREPARATION OPERATION FOR CHECK a Remove the front engine cover. 123533 a Disconnect: - the damper valve connector (2) ,...
  • Page 995 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 780 - the dipstick. a Remove the dipstick well bolts. a Move the dipstick well to one side. 123299 a Remove the clip (7) from the intercooler inlet air pipe. a Disconnect the intercooler air inlet pipe from the tur- 124555 a Detach the fuel return pipe (11) .
  • Page 996 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 780 a Disconnect the 8 mm diameter angled union fitted - the dipstick. a Fit: with its hose contained in the (Mot. 1771) from the high pressure pump union. a Remove the blanking plug from the diesel injector - the intercooler air inlet pipe, - the intercooler inlet air pipe clip in its original posi- fuel return rail opening.
  • Page 997 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 782 CHECK Special tooling required Mot. 1771 Kit for measuring SIEMENS I - PREPARATION OPERATION FOR CHECK injector leakage flow rate. Equipment required graduated measuring cylinder self-contained starter Diagnostic tool tweezers IMPORTANT To avoid all risk of damage to the systems, apply...
  • Page 998 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 782 138399 138550 a Disconnect the turbocharger pressure sensor con- a Unclip the injector rail protector cover at (8) . a Remove: nector (4) . a Unclip the wiring (5) of the turbocharging pressure - the bolts (9) from the injector rail protector cover, sensor.
  • Page 999 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 782 a Insert this pipe in the 500 ml graduated measuring cylinder. a Fit the clip for the intercooler air outlet pipe. a Clip the intercooler air outlet pipe on the damper valve.
  • Page 1000 DIESEL INJECTION High pressure pump leak flow: Check K9K, and 782 - a new intercooler air inlet pipe seal. a Disconnect the 8 mm angled union fitted with its pipe contained in the tool (Mot. 1771) from the high pressure pump union. a Remove the blanking plug from the diesel injector fuel return rail opening.

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