Renault F4R Manual
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Renault F4R Manual

Renault F4R Manual

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Table of Contents

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Engine and peripherals
1
ENGINE AND CYLINDER BLOCK ASSEMBLY
10A
TOP AND FRONT OF ENGINE
11A
FUEL MIXTURE
12A
12B
13A
13B
13C
14A
16A
17A
17B
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
X95, and F4R or F9Q or K4M or K9K
JUNE 2008
© Renault s.a.s 2008
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
Edition Anglaise

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Summary of Contents for Renault F4R

  • Page 1 ANTIPOLLUTION STARTING - CHARGING IGNITION PETROL INJECTION X95, and F4R or F9Q or K4M or K9K JUNE 2008 Edition Anglaise "The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
  • Page 2 COOLING EXHAUST TANK ENGINE MOUNTING X95, and F4R or F9Q or K4M or K9K JUNE 2008 Edition Anglaise "The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault. specifications current when it was prepared.
  • Page 3 MEGANE III - Section 1 MEGANE III - Section 1ContentsPage Contents Page ENGINE AND CYLINDER BLOCK TOP AND FRONT OF ENGINE ASSEMBLY Crankshaft seal at timing end Timing belt: Removal - Removal - Refitting 10A-1 Refitting 11A-29 Crankshaft seal at gearbox Rocker cover: Removal - end : Removal - Refitting 10A-12...

  • Page 4: Table Of Contents

    Contents FUEL MIXTURE DIESEL INJECTION Inlet manifold: Removal - Diesel injection: Precautions Refitting 12A-23 for repair 13B-1 Injector holder shim: Diesel injection: List and Removal - Refitting 12A-31 location of components 13B-12 Exhaust manifold - Intake Diesel injection computer: distributor: Removal - Removal - Refitting 13B-17 Refitting...
  • Page 5 Contents DIESEL INJECTION IGNITION Diesel injector: Removal - Coils Removal - Refitting 17A-1 Refitting 13B-136 Spark plugs: Removal - Accelerometer: Removal - Refitting 17A-5 Refitting 13B-150 PETROL INJECTION PREHEATING Oxygen sensors: Removal - Pre/postheating unit: Refitting 17B-1 Removal - Refitting 13C-1 Petrol injection computer: Heater plugs Removal -...

  • Page 6: Right-Hand Suspended

    Contents COOLING TANK Water pump inlet pipe: Fuel tank: Draining 19C-1 Removal - Refitting 19A-83 Fuel tank: Removal - Expansion bottle: Removal - Refitting 19C-4 Refitting 19A-96 Filler neck: Removal - Electric water pump: Refitting 19C-14 Removal - Refitting 19A-99 Fuel level sensor module: Coolant temperature sensor: Removal - Refitting...
  • Page 7 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1385 Crankshaft oil seal fitting tool (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 8 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - REFITTING OPERATION FOR PART - the scoop under the scuttle panel grille (see Scoop CONCERNED under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi-...
  • Page 9 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting - the scoop under the scuttle panel grille (see Scoop Essential special tooling under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), Mot. 1577 Lip seal extractor (shaft dia- meter 28 mm to 42 mm).
  • Page 10 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 105261 a Push on the tool (Mot. 1577) until contact is made 105257 between the ends (5) of the jaws and the crankshaft a Fit the end piece (2) onto the tool (Mot.
  • Page 11 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 105263 a Screw down the threaded rod (7) of the (Mot. 1577). a Remove the crankshaft seal using the tool (Mot. 20772 1577).
  • Page 12 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting 20770 20768 a Fit the protector equipped with the crankshaft seal onto the spacer, taking care not to touch the cranks- haft seal. 20767 a Screw on the nut until the cover touches the spacer. 20769 a Fit the cover (10) and the nut (11) (positioning the thread (12) of the nut towards the outside of the en-...
  • Page 13 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), K9K, and 830 a Refit the lower engine tie-bar (see 19D, Engine...
  • Page 14 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting - the right-hand suspended engine mounting (see Essential special tooling 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page Mot. 990-03 Crankshaft oil seal fitting tool 19D-18) , (timing end).
  • Page 15 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts - the lower engine tie-bar (see 19D, Engine moun- and ingredients for the repairwork) (04B, Consu- ting, Lower engine tie-bar: Removal - Refitting, mables - Products) to clean and degrease: page 19D-33) , - the crankshaft accessories pulley (see 11A, Top...
  • Page 16 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 990-03 Crankshaft oil seal fitting tool (timing end). REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 17 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at timing end Removal - Refitting II - REFITTING OPERATION FOR PART - the accessories belt (see 11A, Top and front of CONCERNED engine, Accessories belt: Removal - Refitting, page 11A-7) , - 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 18 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the front bumper (see Front bumper: Removal - Essential special tooling Refitting) (55A, Exterior protection). Mot. 1129-01 Crankshaft oil seal fitting tool a Drain the manual gearbox (see Manual gearbox (flywheel end) (80 x 100 x 8 oil: Draining - Refilling) (21A, Manual gearbox).
  • Page 19 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 134550 134544 a Remove the crankshaft seal (1) using a screwdriver. a Refit the crankshaft seal using the (Mot.
  • Page 20 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the front right-hand wheel driveshaft (see Front ri- - bleed the clutch control circuit (see Clutch circuit: ght-hand wheel driveshaft: Removal - Refitting) Bleeding) (37A, Mechanical component controls). (29A, Driveshafts), a Refit the engine cover.
  • Page 21 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting Essential special tooling Mot. 1579 Lip seal extractor (shaft dia- a Remove the lower engine tie-bar (see 19D, Engine meter 80 mm to 98 mm). mounting, Lower engine tie-bar: Removal - Refit- ting, page 19D-33) .
  • Page 22 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 105266 a Push the tool (Mot. 1579) until contact is made 105259 between the ends (5) of the jaws and the crankshaft a Fit the end piece (1) of the (Mot.
  • Page 23 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any fin- ger marks). a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease:...
  • Page 24 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the front axle subframe (see Front axle sub-fra- - the battery (see Battery : Removal - Refitting) me: Removal - Refitting) (31A, Front axle compo- (80A, Battery), nents), - the engine cover.
  • Page 25 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the front left-hand wheel driveshaft (see Front left- Essential special tooling hand wheel driveshaft: Removal - Refitting) (29A, Driveshaft), Mot. 991-01 Crankshaft oil seal fitting tool (fly w h e e l e n d ) ( s e a l...
  • Page 26 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting REFITTING - the « clutch pressure plate - disc » assembly (see Mechanism / Disk: Removal - Refitting) (21A, Manual gearbox), I - REFITTING PREPARATION OPERATION - the manual gearbox (see Manual gearbox: Remo- val - Refitting) (21A, Manual gearbox), - the left-hand suspended engine mounting (see...
  • Page 27 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-4) (12A, Fuel mixture), - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery),...
  • Page 28 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the front left-hand wheel driveshaft (see Front left- Essential special tooling hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), Mot. 991-01 Crankshaft oil seal fitting tool (fly w h e e l e n d ) ( s e a l...
  • Page 29 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 124128 124127 a Refit a new crankshaft seal at the gearbox end, a Remove the crankshaft seal on the gearbox side using the tool (Mot.
  • Page 30 ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal at gearbox end : Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the new differential output seals (see Differential output seal: Removal - Refitting) (21A, Manual gearbox), - the front left-hand wheel driveshaft (see Front left-...
  • Page 31 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting K4M, and 848 Tightening torquesm sump bolts on the cylin- 14 N.m der block sump bolts on the gear- 44 N.m bolt mounting the multi- 25 N.m function support on the sump bolts 2 and 3 of the 44 N.m...
  • Page 32 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 134682 136574 a Remove: a Remove: - the bolt (3) from the relay bearing flange, - the dipstick guide bolts (2) from the injector holder - the bolts (4) from the relay bearing, shim, - the relay bearing,...
  • Page 33 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Engine oil sump seal (10,03,01,09). a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease: - the sump joint face if it is to be reused, - the cylinder block gasket face.
  • Page 34 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: 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 20167 20171...
  • Page 35 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting 135708 a Fit the relay bearing bolt (1) without tightening it. a Tighten to torque: - the bolts 2 and 3 of the relay bearing (44 N.m), - the bolt 1 of the relay bearing (44 N.m), - the bolt 4 of the relay bearing flange (21 N.m).
  • Page 36 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting - the sump bolts on the cylinder block, - the sump, Tightening torquesm - the sump seal. sump bolts (A) to (F) 18 N.m sump bolts (1) to (18) 15 N.m REFITTING I - REFITTING PREPARATION OPERATION REMOVAL...
  • Page 37 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting 15159 15195 a Tighten to torque and in order: - the sump bolts (A) to (F) (18 N.m), Note: - the sump bolts (1) to (18) (15 N.m). Do not cut the two tabs on the crankshaft closure panel seal, which sit higher than the cylinder a Connect the oil vapour rebreathing pipe to the sump.
  • Page 38 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm sump bolts 15 N.m sump bolts on the 44 N.m manual gearbox lower engine tie-bar 62 N.m support bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: 135762 Towing and lifting) (02A, Lifting equipment).
  • Page 39 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting WARNING Prepare for the flow of fluid, and protect the sur- rounding components. a Remove: - the sump bolts on the cylinder block, - the sump, - the sump seal. REFITTING 135760 I - REFITTING PREPARATION OPERATION a parts always to be replaced: Engine oil sump...
  • Page 40 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting 15159 15195 a Apply a bead of MASTIXO (see Vehicle: Parts and a Tighten to torque and in order: ingredients for the repairwork) (04B, Consuma- - the sump bolts (15 N.m), bles - Products): - the sump bolts on the manual gearbox (44 N.m).
  • Page 41 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting Tightening torquesm sump bolts 14 N.m sump bolts on the gear- 44 N.m catalytic converter ups- 50 N.m tream strut bolt on the cylinder block catalytic converter ups- 26 N.m tream strut bolts on the catalytic converter multifunction support 25 N.m...
  • Page 42 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting 135486 123834 a Undo the bolt (3) of the catalytic converter upstream a Disconnect the connector (6) from the oil level sen- strut from the sump. sor. a Remove: - the bolt (4) of the catalytic converter upstream strut from the cylinder block, - the bolt (5) of the catalytic converter upstream strut from the catalytic converter,...
  • Page 43 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a Wipe the oil pump strainer with a CLEAN CLOTH. IMPORTANT Wear goggles with side protectors for this opera- tion.
  • Page 44 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting a Refit the oil level sensor to the new sump. II - REFITTING OPERATION FOR PART CONCERNED a Fit: - a new sump seal to the sump, - the sump fitted with a new seal. 20166 20171 a Refit:...
  • Page 45 ENGINE AND CYLINDER BLOCK ASSEMBLY Sump: Removal - Refitting - the catalytic converter upstream strut bolts on the catalytic converter (26 N.m). a Tighten the catalytic converter upstream strut bolt on the sump. a Torque tighten the multifunction support lower bolt (25 N.m).
  • Page 46 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Essential special tooling IMPORTANT Mot. 1018 Sump plug tool. Wear leaktight gloves (Nitrile type) for this opera- tion. Essential equipment oil recovery container WARNING Always check the oil level using the dipstick. oil draining wrench Do not exceed the maximum level on the dipstick torque wrench...
  • Page 47 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling a Refit a new seal on the drain plug. a Screw the drain plug onto the engine oil sump. a Torque tighten the drain plug (20 N.m) using a tor- que wrench and a 8 mm square drain plug soc- ket.
  • Page 48 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Essential special tooling Tightening torquesm Mot. 1018 Sump plug tool. drain plug 20 N.m Essential equipment oil recovery container Average oil capacity (adjust using dipstick) (litres) Engine Draining Oil change with oil filter replace- ment 5.25 I - RECOMMENDATIONS FOR REPAIR...
  • Page 49 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling a Clean the traces of oil around the drain plug so that any possible leaks can be detected. a Remove the oil recovery container. IV - FILLING a Position the vehicle back on the ground. a Fill the engine with oil, observing the recommended amount.
  • Page 50 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling Essential special tooling Tightening torquesm Mot. 1018 Sump plug tool. drain plug 20 N.m Essential equipment oil recovery container Average oil capacity (adjust using dipstick) (litres) Engine Draining Oil change plus oil filter replace- ment I - RECOMMENDATIONS FOR REPAIR WARNING...
  • Page 51 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling 136474 113765 a Remove: a Refit: - the engine undertray bolts, - a new seal on the sump drain plug, - the engine undertray. a Place the oil recovery container under the engine. - the drain plug on the sump.
  • Page 52 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling II - OIL SERVICE Essential special tooling a Position the vehicle on a two-post lift (see Vehicle: Mot. 1018 Sump plug tool. Towing and lifting) (02A, Lifting equipment). Essential equipment oil recovery container Tightening torquesm drain plug...
  • Page 53 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling a Clean the traces of oil around the drain plug so that any possible leaks can be detected. a Remove the oil recovery container. III - FILLING a Fill the engine with oil, observing the recommended amount.
  • Page 54 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter). Essential equipment oil recovery container IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 55 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Check the oil level using the dipstick. a Adjust the engine oil level if necessary. Note: The engine oil level must be between the “mini- mum” and “maximum” marks on the dipstick. 10A-49...
  • Page 56 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter). Essential equipment oil recovery container IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 57 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Check for leaks from the oil filter. a Refit the engine undertray. a Wait at least 10 minutes. a Check the oil level using the dipstick. a Adjust the engine oil level if necessary. 10A-51...
  • Page 58 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1329 Oil filter removing tool (76 mm diameter). Essential equipment oil recovery container IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 59 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting a Top up the engine oil with oil recommended by the manufacturer (see Vehicle: Parts and ingredients for the repairwork) (04B Consumables - Products). a Start the engine and wait until the oil pressure war- ning light goes out on the instrument panel.
  • Page 60 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting REFITTING Essential special tooling Mot. 1280-01 Oil filter removing tool, 86 mm I - REFITTING PREPARATION OPERATION diameter. a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- Essential equipment mables - Products) to clean and degrease the cylin- der block joint face.
  • Page 61 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting REMOVAL Essential equipment I - REMOVAL PREPARATION OPERATION refrigerant charging station a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Tightening torquesm a Remove: oil-water heat exchan- 39 N.m - the engine cover,...
  • Page 62 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting a Remove the "intermediate pipe - compressor" con- necting pipe seal. a Fit a suitable blanking plug to: - the opening of the "intermediate pipe - compres- sor" connecting pipe, - the compressor opening. a Separate the "intermediate pipe - compressor"...
  • Page 63 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: refrigerant pipe seal (30,02,02,52). a parts always to be replaced: coolant-engine oil heat exchanger seal on the cylinder block (10,05, 05,12).
  • Page 64 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting a Clip the "intermediate pipe - compressor" connec- ting pipe fitted with a new seal onto the air conditio- ning compressor. a Refit: - the bolt for the "intermediate pipe - compressor" connecting pipe onto the air conditioning compres- sor, - the front bumper (see Front bumper: Removal -...
  • Page 65 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting Essential special tooling Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. Tightening torquesm oil-water heat exchan- 60 N.m ger nipple IMPORTANT Wear latex gloves during the operation. REMOVAL 116811 I - REMOVAL PREPARATION OPERATION...
  • Page 66 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting a parts always to be replaced: coolant-engine oil II - OPERATION FOR REMOVAL OF PART CONCERNED heat exchanger seal on the cylinder block (10,05, 05,12). II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new seal to the oil-water heat exchanger,...
  • Page 67 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting Essential special tooling Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. Tightening torquesm oil-water heat exchan- 44 N.m ger nipple REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 68 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 136201 a Fit the tools (3) (Ms. 583) onto the intercooler ho- ses. 135646 a Remove the front end panel bolts (2) . a Tilt the front panel.
  • Page 69 ENGINE AND CYLINDER BLOCK ASSEMBLY Exchanger: Removal - Refitting a Connect the oil-water heat exchanger hoses. a Fit the hose clips on the oil-water heat exchanger using the tool (Mot. 1448). a Remove the tools (Ms. 583) from the oil-water heat exchanger hoses.

  • Page 70: Refitting

    ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - REFITTING OPERATION FOR PART Essential special tooling CONCERNED a Refit the oil pressure sensor using the (Mot. 1495). Mot. 1495 22 mm oxygen sensor remo- val/refitting socket - 1/2" a Connect the oil pressure sensor connector.
  • Page 71 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pressure sensor 33 N.m K4M, and 848 alternator strut bolt on 25 N.m the alternator alternator strut bolt on 25 Nm the cylinder block REMOVAL...
  • Page 72 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting K4M, and 858 or 866 K4M, and 858 or 866 a Connect the pinking sensor connector. III - FINAL OPERATION K4M, and 858 or 866 a Refit: - the alternator strut, - the bolt for the alternator strut onto the cylinder block, - the bolt for the alternator strut onto the alternator.
  • Page 73 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting Essential special tooling Mot. 1495-01 22 mm socket for removing/ refitting oxygen sensors. Tightening torquesm oil pressure sensor 39 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 74 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting Tightening torquesm oil pressure sensor 35 Nm REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine undertray bolts, - the engine undertray. II - OPERATION FOR REMOVAL OF PART CONCERNED 135654 a Remove the oil pressure sensor (2) .
  • Page 75 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) (02A, Lifting equipment). a Remove: - the engine undertray bolts, - the engine undertray.
  • Page 76 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting K4M, and 858 or 866 Tightening torquesm oil level sensor 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). a Remove: - the engine undertray bolts, - the engine undertray.
  • Page 77 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting III - FINAL OPERATION a Refit the engine undertray. 10A-71...
  • Page 78 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting Tightening torquesm oil level sensor 25 Nm 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.
  • Page 79 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting Tightening torquesm oil level sensor 25 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 Remove: - the engine cover, - the engine undertray bolts,...
  • Page 80 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 136204 a Disconnect the connector (3) from the oil level sen- sor. 135646 a Remove the front end panel bolts (2) . a Tilt the front end panel.
  • Page 81 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil level sensor: Removal - Refitting a Tighten to torque the oil level sensor (25 N.m). II - FINAL OPERATION a Refit: - a new intercooler air outlet pipe (see 12B, Turbo- charging, Intercooler air outlet pipe: Removal - Refitting, page 12B-56) , - the front panel, - the bonnet catch (see Bonnet latch: Removal -...
  • Page 82 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 - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 83 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION oil pump bolts 25 N.m a Check for centring rings on the cylinder block. oil splash plate bolt 25 N.m II - REFITTING OPERATION FOR PART CONCERNED REMOVAL a Position the oil pump pinion on the chain.
  • Page 84 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 - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 85 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting a Refit: - the engine undertray, - the dipstick, - the engine cover. 10A-79...
  • Page 86 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm oil pump bolts 25 N.m oil splash plate bolt 25 Nm IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 87 ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Position the oil pump pinion on the chain. a Refit the oil pump. a Torque tighten the oil pump bolts (25 N.m). a Refit the oil splash plate.

  • Page 88: Oil Pressure: Check 10A

    10 minutes before checking the level with a a Engine + End pieces: dipstick. - F4R: (G) + (C) + (F) , I - PARTS AND CONSUMABLES FOR THE REPAIR - K9K: (G) + (C) + (F) , WORK...
  • Page 89 F9Q engine: - idle speed: 1 bar, - 3000 rpm : 4.5 to 5.9 bar. F4R engine: - idle speed: 0.5 bar, - 4000 rpm : 2.2 to 4 bar. K9K engine: - idle speed: 0.8 bar, - 4000 rpm : 3.4 to 5.2 bar.
  • Page 90 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- Essential equipment fitting) (55A, Exterior protection). refrigerant charging station a Remove: Tightening torquesm - the engine undertray bolts, bolts 2 and 3 of the mul-...
  • Page 91 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K4M, and 848 K4M, and 858 or 866 136483 135930 a Disconnect the connector (1) from the air temperatu- a Unclip the hoses (2) from the cooling fan assembly. re sensor on the intake manifold. a Remove the oil filter (see 10A, Engine and cylinder block assembly, Oil filter: Removal - Refitting, page 10A-48) .
  • Page 92 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135713 a Remove the lower bolts (5) from the front end panel. 135258 a Move the front end panel aside. a Remove: - the multifunction support bolts (6) , - the multifunction support.
  • Page 93 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting a Pretighten to torque the bolts 2 and 3 of the multi- - the front bumper (see Front bumper: Removal - function support (5 N.m). Refitting) (55A, Exterior protection), a Loosen bolts 2 and 3 by one half-turn. a Pretighten to torque and in order the multifunction support bolts (initial torque) (5 N.m).
  • Page 94 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting a Refit the engine cover. 10A-88...
  • Page 95 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the audible warning (see Horn: Removal - Refit- ting) (82B, Horn), Essential equipment - the frontal impact cross member (see Front im- refrigerant charging station pact cross member: Removal - Refitting) (41A, Front lower structure), - the bonnet catch (see Bonnet latch: Removal - Tightening torquesm...
  • Page 96 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135719 a Remove: 123832 - the front end panel clips (3) , a Remove: - the front end panel upper bolts (4) . - the multifunction support bolts (6) , - the multifunction support.
  • Page 97 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the audible warning (see Horn: Removal - Refit- ting) (82B, Horn), - the cooling radiator side air deflectors, - the upper air deflector of the cooling radiator, - the front bumper supports (see Front bumper...
  • Page 98 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- Essential equipment nisms). refrigerant charging station 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).
  • Page 99 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135296 a Remove the lower bolts (5) from the front end panel. 135698 a Slightly tilt the front end panel towards the front of the vehicle.
  • Page 100 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting a Check that the air conditioning is working correctly - the intercooler air inlet pipe (see 12B, Turbochar- ging, Intercooler air inlet pipe: Removal - Refit- (see Air conditioning: Check) (62A, Air conditio- ting, page 12B-41) , ning).
  • Page 101 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting Essential equipment refrigerant charging station 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 - 135647 Refitting) (80A, Battery).
  • Page 102 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 137193 a Remove: - the multifunction support bolts (3) , - the multifunction support. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the multifunction support.
  • Page 103 ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting - the bolts for the engine wiring harness channel, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-7) , - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the front impact cross member (see Front impact...
  • Page 104 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting Essential special tooling IMPORTANT Ms. 583 Hose clamp pliers. Wear protective gloves during the operation. Mot. 1448 Long nose pliers for hose clips. REMOVAL Mot. 1390 Support for removing/refitting the engine - gearbox assem- I - REMOVAL PREPARATION OPERATION bly.
  • Page 105 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 136460 136450 a Disconnect the fuel vapour rebreathing pipe (1) from a Disconnect the fuel supply pipe (3) from the injector the throttle valve. rail. a Unclip the fuel vapour rebreathing pipe from the throttle valve.
  • Page 106 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K4M, and 848 K4M, and 858 or 866 134553 134484 109149 101743 a Unclip: a Unclip from the manual gearbox controls: - the gear control cables from the manual gearbox - the anchoring ball joints at (4) , by pressing at (A) , - the sleeve stops at (5) .
  • Page 107 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Disconnect the reverse gear switch connector. 136542 a Place the tool (Ms. 583) between the brake fluid re- servoir and the clutch master cylinder. a Remove the hydraulic clutch pipe (see Clutch cir- cuit: Removal - Refitting) (37A, Mechanical com- ponent controls).
  • Page 108 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (31A, Front axle components), - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha-...
  • Page 109 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135482 135954 a Disconnect from the cooling fan assembly: - the connector (10) , - the resistor connector (11) , - the relay unit (12) of the front end panel. a Unclip the cooling fan assembly wiring.
  • Page 110 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the bottom cooling hose (15) from the cooling ra- diator. 10A-104...
  • Page 111 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the seal of the « condenser - expansion valve » connecting pipe, - the seal of the « compressor - condenser » con- necting pipe. a Insert the blanking plugs. a Disconnect the pressostat connector from the con- denser.
  • Page 112 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting HEADLIGHT WASHERS WITH BLADE 135508 a Disconnect the connectors (22) from the offset posi- tive terminal. 136535 a Unclip the offset positive terminal wiring from the off- a Remove the bolt (1 9) between the windscreen set positive terminal.
  • Page 113 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135722 a Remove the connectors (26) from the Protection and Switching Unit. a Remove: - the Protection and Switching Unit, 135506 a Unclip the battery wiring channel (24) from the left- - the engine wiring.
  • Page 114 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135724 135709 a Remove the bolt (28) from the « compressor - ex- a Remove: pansion valve » connecting pipe bracket. - the earth nut on the body, a Disconnect the « compressor - expansion valve » - the earth terminal on the body (30) .
  • Page 115 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the expansion bottle outlet hose. II - OPERATION FOR REMOVAL OF PART CONCERNED 135720 136472 a Mark the positions of the suspended engine moun- tings on the body. a Support the « engine - gearbox » assembly on the engine marks (36) with the (Mot.
  • Page 116 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Remove the (Mot. 1390) from the « engine - gearbox » assembly. III - FINAL OPERATION a Connect: - the hose between the heater matrix and the coolant pump inlet pipe, - the hose between the heater matrix and the coolant outlet unit, - the expansion bottle outlet hose.
  • Page 117 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Fit a new seal on the « compressor - expansion valve » connecting pipe. HEADLIGHT WASHERS WITH BLADE a Couple the « compressor - expansion valve » con- a Refit the bolt between the windscreen washer reser- necting pipe on the compressor.
  • Page 118 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Connect: - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the cooling fan assembly connector, - the breather pipe on the gearbox. - the cooling fan assembly resistor connector, a Refit the hydraulic clutch pipe (see Clutch circuit: - the relay unit on the front end panel.
  • Page 119 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 Essential special tooling Tightening torquesm Mot. 1448 Long nose pliers for hose connecting pipe bolts on 8 N.m clips. the condenser Mot. 1202-02 Pliers for small hose clips. air filter unit air outlet 5.5 N.m pipe clip on the turbo-...
  • Page 120 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 - the front left-hand wheel driveshaft (see Front left- hand wheel driveshaft: Removal - Refitting) WARNING (29A, Driveshafts), In order to avoid any refrigerant leaks, do not - the differential output seals (see Differential out- damage (deform, twist, etc.) the pipe.
  • Page 121 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 136392 136639 a Remove the bolts (2) from the exhaust bracket. a Undo the air filter unit air outlet pipe clip (3) from the turbocharger. a Move the exhaust bracket away from the catalytic a Disconnect the air filter unit air outlet pipe from the converter.
  • Page 122 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 135512 135951 a Disconnect the connector (4) from the refrigerant cir- a Separate the cooling radiator bottom cooling hose cuit pressure sensor. clip (10) on the cooling radiator using the tool (Mot. 1448).
  • Page 123 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 a Disconnect from the cooling radiator: - the expansion bottle top cooling hose, - the cooling radiator top cooling hose. a Remove the bonnet catch (see Bonnet latch: Re- moval - Refitting) (52A, Non-side opening element mechanisms).
  • Page 124 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 135482 135510 a Disconnect: a Tilt the front end panel towards the vehicle front (1) . - the fan assembly connector (18) , a Remove the front end panel by pulling it upwards (2) - the fan assembly resistor connector (21) .
  • Page 125 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 K9K, and 830 135507 a Remove the power cable nuts (24) from the battery disconnection unit. 136669 a Move aside the power cables. a Remove the air resonator support nuts (26) . a Move aside the air resonator support.
  • Page 126 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 135721 a Remove the Protection and Switching Unit cover (29) . 135504 a Remove: - the bolt (31) from the engine fuse box, - the nuts (32) from the engine fuse box. a Move aside the engine fuse box.
  • Page 127 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 - the diesel heater wiring from the radiator mounting cross member. K9K, and 832 a Move aside the diesel heater wiring. 134484 134490 a Disconnect the brake servo pipe union (36) from the vacuum pump.
  • Page 128 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 K9K, and 830 134486 135416 a Fit the tool (Ms. 583) (40) onto the clutch master cy- linder supply pipe. a Disconnect the clutch pipe from the clutch master cylinder by pulling on the clip (41) .
  • Page 129 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 135509 135501 a Remove the bolt (42) of the "dehydrator reservoir - a Separate the expansion bottle bottom cooling hose compressor" connecting pipe from the compressor. clip (43) on the expansion bottle.
  • Page 130 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 K9K, and 832 135499 a Separate the clip (44) of each heater matrix cooling hose on the heater matrix (45) . 134494 a Disconnect the heater matrix cooling hoses (45) a Unclip the fuel supply pipe from the "rubber pad - co- from the heater matrix.
  • Page 131 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 a Disconnect the fuel supply pipe (50) from the high pressure pump. K9K, and 830 a Fit suitable blanking plugs on: - on the fuel supply pipe union, - on the high pressure pump opening.
  • Page 132 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 K9K, and 832 K9K, and 830 135411 134221 a Remove the bolts (52) of the "rubber pad - cover" as- sembly of the right-hand suspended engine moun- ting from the body.
  • Page 133 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 K9K, and 832 K9K, and 830 134485 135849 a Remove the bolt (54) from the left-hand suspended a Remove the bolt (55) from the left-hand suspended engine mounting support on the gearbox.
  • Page 134 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 a Lower the engine using the (Mot. 1453) fitted with the (Mot. 1453-01) until the "rubber pad - cover" as- K9K, and 830 sembly of the right-hand suspended engine moun- a Remove the blanking plug ting touches the body.
  • Page 135 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 a Fit the earth cable on the vehicle body. - from the opening of the "dehydrator reservoir - compressor" connecting pipe. a Torque tighten the earth cable nut on the body (8 a Refit a new seal on the "dehydrator reservoir - com- N.m).
  • Page 136 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 a Refit the bonnet catch (see Bonnet latch: Removal a Connect the connector of the refrigerant circuit pres- - Refitting) (52A, Non-side opening element mecha- sure sensor.
  • Page 137 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting K9K, and 830 or 832 - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), K9K, and 832 - the battery (see Battery : Removal - Refitting) a Refit the lower engine tie-bar.
  • Page 138 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting Essential special tooling WARNING Mot. 1448 Long nose pliers for hose To avoid any corrosion or damage, protect the clips. areas on which fuel is likely to run. Mot. 1390 Support for removing/refitting the engine - gearbox assem- bly.
  • Page 139 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection).
  • Page 140 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135512 135739 a Remove the bolt (8) from the intercooler air outlet pi- a Disconnect the connector (2) from the refrigerant cir- cuit pressure sensor. a Unclip: - the refrigerant circuit pressure sensor wiring (3) from the "condenser - evaporator"...
  • Page 141 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135794 135997 a Pull the clip (11) from the intercooler inlet air pipe. a Disconnect the intercooler air inlet pipe. a Move the intercooler air outlet pipe to one side. 135998 a Separate the radiator hose clips (12) using the tool (Mot.
  • Page 142 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135511 135645 a Unclip the engine wiring (13) from the front end pa- nel. 135646 a Remove the front end panel bolts (15) . 135647 a Remove the bolts (14) from the engine wiring chan- nel.
  • Page 143 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135482 135508 a Disconnect: a Disconnect the connectors (20) from the battery dis- connection unit. - the fan assembly connector (16) , - the fan assembly resistor connector (17) . a Unclip: - the fan assembly wiring (18) , - the relay unit (19) .
  • Page 144 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135721 a Remove the cover (25) from the Protection and Swit- ching Unit. 135506 a Unclip the power wiring channel (22) from the left- hand suspended engine mounting. a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-1) .
  • Page 145 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135504 135565 a Remove: a Disconnect the vacuum pipe union (30) from the va- cuum pump. - the bolt (27) from the engine fuse box, - the nuts (28) from the engine fuse box. a Move aside the engine fuse box.
  • Page 146 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 136172 136178 a Remove the retaining bolt (33) from the "intermedia- te pipe - compressor" connecting pipe. 136179 a Separate the clips (35) on the expansion bottle ho- ses using the tool (Mot. 1448). a Disconnect the hoses from the expansion bottle.
  • Page 147 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 136171 135548 a Separate the clip (36) of the exhaust cooler hose using the tool (Mot. 1448). a Disconnect the hose from the exhaust cooler. 135569 a Disconnect: - the fuel supply pipe union (38) , 135550 - the diesel return pipe union (39) .
  • Page 148 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 134619 a Remove the central bolt (41) of the rubber pad sup- 136177 port of the left-hand suspended engine mounting. a Support the "engine - gearbox" assembly on the a Raise the vehicle, moving the engine towards the marks (40) using the tool (Mot.
  • Page 149 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Remove the tool (Mot. 1390) from the "engine - a Refit: gearbox" assembly. - the Protection and Switching Unit cover, - the earth cable nut on the body. III - FINAL OPERATION a Torque tighten the earth cable nut on the body (8 a Remove the blanking plugs.
  • Page 150 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Fit the new seals on: - the front left-hand driveshaft (see Front left-hand wheel driveshaft: Removal - Refitting) (29A, Dri- - the "condenser - expansion valve" connecting pipe veshafts), on the condenser side, - the front right-hand driveshaft (see Front right- - the "compressor - condenser"...
  • Page 151 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting Essential special tooling IMPORTANT Mot. 1448 Long nose pliers for hose Wear protective gloves during the operation. clips. Mot. 1390 Support for removing/refitting REMOVAL the engine - gearbox assem- bly. I - REMOVAL PREPARATION OPERATION Essential equipment a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 152 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the front left-hand wheel driveshaft (see Front left- hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), - the differential output seals (see Differential out- put seal: Removal - Refitting) (21A, Manual gear- box), - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting,...
  • Page 153 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135739 135794 a Remove the bolt (7) on the intercooler air outlet pipe. a Unclip the intercooler air inlet pipe at (9) . a Disconnect the intercooler air inlet pipe. a Move the intercooler air outlet pipe to one side.
  • Page 154 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the expansion bottle top cooling hose. 135954 a Separate the following on the radiator: 135736 a Remove the bolts (14) from the fan assembly wiring - the expansion bottle top cooling hose clip (Mot. channel.
  • Page 155 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Remove the front end panel. 135296 a Remove the lower bolts (17) from the front end pa- 135508 a Disconnect the connectors (22) from the battery dis- nel. connection unit. a Unclip the wiring of the offset positive terminal.
  • Page 156 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135721 a Remove the cover (26) from the Protection and Swit- ching Unit. 135506 a Unclip the power wiring channel (24) from the left- hand suspended engine mounting. a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-1) .
  • Page 157 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the manual gearbox control cables from their sup- port (31) . 135504 a Remove: 137122 - the bolts (28) from the engine fuse box, a Unclip the vacuum pipe (32) from the brake servo. - the nuts (29) from the engine fuse box.
  • Page 158 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting 135779 135501 a Separate the clip (Mot. 1448) of the expansion bottle bottom cooling hose using the tool (34) . a Disconnect the bottom cooling hose from the expan- sion bottle. 134645 a Disconnect the petrol vapour rebreathing pipe (36) .
  • Page 159 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Detach the left-hand suspended engine mounting II - OPERATION FOR REMOVAL OF PART CONCERNED support on the gearbox from the left-hand suspen- ded engine mounting rubber pad. a Mark the position of the left-hand suspended engine mounting support on the body using a indelible pencil.
  • Page 160 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Connect the Protection and Switching Unit connec- - the petrol vapour rebreathing pipe, tors. - the cooling hoses to the heater matrix, a Fit the protection and switching unit. - the expansion bottle bottom cooling hose.
  • Page 161 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting a Fit the clip: a Refit: - of the radiator bottom cooling hose using the tool - the bonnet catch (see Bonnet latch: Removal - (Mot. 1448), Refitting) (52A, Non-side opening element mecha- nisms), - of the expansion bottle top cooling hose using the tool (Mot.
  • Page 162 ENGINE AND CYLINDER BLOCK ASSEMBLY Engine/gearbox assembly: Removal - Refitting - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray, - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-4) , - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the battery (see Battery : Removal - Refitting)
  • Page 163 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting - the front bumper (see Front bumper: Removal - Essential special tooling Refitting) (55A, Exterior protection). a Drain the manual gearbox (see Manual gearbox Mot. 1677 Flywheel locking tool. oil: Draining - Refilling) (21A, Manual gearbox). a Remove: Tightening torquesm - the starter (see 16A, Starting - Charging, Starter:...
  • Page 164 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 134546 134545 a Lock the flywheel using tool (Mot. 1677) (1) . a Position the flywheel equipped with new bolts. a Remove: a Fit the new bolts on the flywheel without tightening - the flywheel bolts,...
  • Page 165 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting a Perform the following operations: - the new differential output seals (see Differential output seal: Removal - Refitting) (21A, Manual - fill the manual gearbox with oil (see Manual gear- gearbox), box oil: Draining - Refilling) (21A, Manual gear- box), - the front right-hand wheel driveshaft (see Front ri-...
  • Page 166 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting a Remove: Essential special tooling - the front left-hand wheel driveshaft (see Front left- Mot. 582 Flywheel locking tool. hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), - the front right-hand wheel driveshaft (see Front ri- Tightening torquesm ght-hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts),...
  • Page 167 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135857 a Lock the flywheel using tool (Mot. 582) (1) . 134218 a Lock the flywheel using tool (Mot. 582) (1) . a Remove: a Remove: - the flywheel bolts (2) , - the flywheel bolts (2) ,...
  • Page 168 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED K9K, and JR5 a Refit: - the flywheel, - new flywheel bolts. - the (Mot. 582). K9K, and TL4 135857 a Tighten to torque and in order the flywheel bolts (50 N.m).
  • Page 169 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting - the front axle subframe (see Front axle sub-fra- - the battery (see Battery : Removal - Refitting) me: Removal - Refitting) (31A, Front axle compo- (80A, Battery), nents), - the engine cover. - the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (31A, Front axle components),...
  • Page 170 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting a Remove: Essential special tooling - the front left-hand wheel driveshaft (see Front left- Mot. 1677 Flywheel locking tool. hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), - the front right-hand wheel driveshaft (see Front ri- Tightening torquesm ght-hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts),...
  • Page 171 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting REFITTING - the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protec- tion), I - REFITTING PREPARATION OPERATION - the front wheels (see Wheel: Removal - Refitting) a Use SURFACE CLEANER (see Vehicle: Parts (35A, Wheels and tyres), and ingredients for the repairwork) (04B, Consu-...
  • Page 172 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting - the front left-hand wheel driveshaft (see Front left- Essential special tooling hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), Mot. 1431 Flywheel locking tool. - the differential output seals (see Differential out- put seal: Removal - Refitting) (21A, Manual gear- box), Tightening torquesm...
  • Page 173 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 134249 a Position the (Mot. 1431). 134249 a Torque tighten in order the flywheel bolts (30 N.m a Lock the flywheel using tool (Mot. 1431) (1) . + 56˚...
  • Page 174 ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting - the front axle subframe (see Front axle sub-fra- me: Removal - Refitting) (31A, Front axle compo- nents), - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the front left-hand wheel driveshaft (see Front left- hand wheel driveshaft: Removal - Refitting)
  • Page 175 TOP AND FRONT OF ENGINE Final compression pressure: Check II - TEST OPERATION a Press the vehicle start button to trigger the engine Essential equipment starting phase. petrol compression gauge diagnostic tool Note: The engine will be driven by the starter for 20 seconds, without being started.
  • Page 176 TOP AND FRONT OF ENGINE Final compression pressure: Check Essential special tooling K9K, and 830 Mot. 1592 Compression pressure test end piece-hose. Essential equipment diesel compression gauge self-contained starter diagnostic tool CHECKING I - PREPARATION OPERATION FOR CHECK a Remove the preheater plugs (see 13C, Preheating, Heater plugs Removal - Refitting, page 13C-3) .
  • Page 177 TOP AND FRONT OF ENGINE Final compression pressure: Check a Undo: - the adapter of the diesel compression gauge on the (Mot. 1592). - the diesel compression gauge on the hose end piece (Mot. 1592), - the flexible end piece (Mot. 1592) using an open- jawed spanner.
  • Page 178 TOP AND FRONT OF ENGINE Final compression pressure: Check II - TEST OPERATION a Press the vehicle start button to trigger the engine Essential equipment starting phase. petrol compression gauge diagnostic tool Note: the engine will be driven by the starter for 20 CHECKING seconds, without being started.
  • Page 179 TOP AND FRONT OF ENGINE Final compression pressure: Check a Force the vehicle's + after ignition feed. Essential special tooling a Connect the diagnostic tool. Mot. 1592 Compression pressure test a Run commands: end piece-hose. - RZ009: "VEHICLE FUNCTION PROGRAM- Essential equipment MING", diesel compression gauge...
  • Page 180 TOP AND FRONT OF ENGINE Final compression pressure: Check a Remove the card from the reader to interrupt the + after ignition feed and wait for the loss of communi- cation message to appear on the diagnostic tool. Note: If the message does not appear, wait 9 minutes. a When the loss of communication message appears or after waiting 9 minutes, force the vehicle's + after ignition feed.
  • Page 181 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm tensioning roller bolt 40 N.m 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 182 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting a Tighten to torque the tensioning roller bolt (40 N.m). a Turn the accessories belt tensioning roller clockwise using a 16 mm spanner. a Lock the tensioning roller using a 6 mm Allen key. a Refit a new accessories belt.
  • Page 183 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment offset spanner Tightening torquesm new accessories belt 40 N.m tensioning roller bolt 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 184 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a Use a brush to remove any deposits from the crankshaft accessories pulley V grooves. a parts always to be replaced: Accessories belt (10,10,01,03).
  • Page 185 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm accessories belt tensio- 50 N.m ning roller bolt WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 186 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Accessories belt (10,10,01,03). a parts always to be replaced: Accessories belt tensioning roller (10,10,01,04). WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles.
  • Page 187 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm accessories belt tensio- 50 N.m ning roller bolt WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pul- ley.
  • Page 188 TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a Clean the V-grooves of the crankshaft accessories pulley. 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).
  • Page 189 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1489 TDC locating pin. K9K, and 832 Tightening torquesm crankshaft accessories 120 N.m + 95˚ ± ± ± ± 15˚ pulley bolt TDC pin plug 23 N.m...
  • Page 190 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting REFITTING K9K, and 830 or 834 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.
  • Page 191 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 135472 14489 a Remove the TDC setting pin plug (7) . 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) .
  • Page 192 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm crankshaft accessories 40 N.m + 110˚ ± ± ± ± 10 pulley bolt 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 193 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 parts always to be replaced: Crankshaft acces- sories pulley (10,03,03,07). II - REFITTING OPERATION FOR PART CONCERNED a Refit:...
  • Page 194 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting - the front right-hand wheel (see Wheel: Removal - Essential special tooling Refitting) (35A, Wheels and tyres), Mot. 1489 TDC locating pin. - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- Mot.
  • Page 195 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting K4M, and 848 135260 a Remove: 136454 - the lifting eye bolts (5) , a Remove: - the lifting eye. - the nut (2) securing the engine wiring on the lifting eye, - the dipstick guide bolt (3) from the lifting eye.
  • Page 196 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 14491-1 135905 a Position the camshaft grooves (8) almost horizontal- a The camshaft grooves (10) must be horizontal and ly and offset towards the bottom turning the cranks- offset downwards. haft in the operating direction (clockwise at timing a Remove the TDC setting pin (Mot.
  • Page 197 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 135907 136543 a Remove: a Position an 8mm male offset Allen key or a ratchet - the crankshaft accessories pulley bolt (11) , extension piece in the crankshaft position sensor ho- - the crankshaft accessories pulley.
  • Page 198 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting K4M, and 848 135240 a Fit: 135257 - the timing tool (Mot. 1496) (12) fitted with the (Mot. a If the crankshaft is not pressing against the TDC set- 1750) (13) , ting pin, bring the crankshaft back by turning the flywheel using a screwdriver (15) .
  • Page 199 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting a Torque tighten the lifting eye bolts (10 N.m). a Fit the engine wiring on the lifting eye. K4M, and 858 or 866 K4M, and 848 a Clip the engine wiring connector on the lifting eye. a Refit: - the engine wiring retaining bolt on the lifting eye, - the dipstick guide on the lifting eye.
  • Page 200 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting - the engine cover. 11A-26...
  • Page 201 TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting Essential equipment brush with non abrasive bristles Tightening torquesm crankshaft accessories 40 N.m + 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- ley.
  • Page 202 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 Clean the crankshaft accessories pulley V grooves using a brush with non abrasive bristles if it is to be reused.
  • Page 203 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Essential special tooling K9K, and 830 or 834 Mot. 1489 TDC locating pin. a Remove the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refit- Mot. 1430 Set of 5 crankshaft and cams- ting, page 19D-33) .
  • Page 204 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 830 a Remove the camshaft position sensor (see 13B, Diesel injection, Camshaft position sensor: Re- moval - Refitting, page 13B-19) . 11A-30...
  • Page 205 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 832 135493 135495 135492 135494 11A-31...
  • Page 206 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 135475 135476 a Remove: - the upper timing cover (1) by pressing on the clips (2) , - the bolt (3) from the intermediate timing cover (4) , - the intermediate timing cover (4) by pressing on the clips (5) , - the lower timing cover (6) by pressing on the clips (7) .
  • Page 207 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 830 or 834 136660 136654 136662 a Unclip the upper timing cover at (8) . a Remove: 136656 - the bolt (9) from the upper timing cover, - the upper timing cover, - the lower timing cover by pressing the clips (10) .
  • Page 208 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 832 K9K, and 830 or 834 135496 136658 a Remove the bolts (11) from the right-hand suspen- a Remove the bolts (12) from the right-hand suspen- ded engine mounting support on the cylinder head. ded engine mounting support on the cylinder head.
  • Page 209 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 contact with the (Mot. a Turn the crankshaft clockwise (timing end) using the 1489).
  • Page 210 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED K9K, and 832 109046 a Undo the timing belt tensioning roller bolt (18) . a Loosen the timing belt tensioning roller by turning the eccentric cam using a 6 mm Allen key.
  • Page 211 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the crankshaft is resting on the tool (Mot. 1489) (the cotter (24) of the crankshaft timing sprocket K9K, and 830 or 834 must be vertical and upwards). 136389 109043 a Refit the new timing belt tensioning roller.
  • Page 212 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the crankshaft is resting on the tool (Mot. 1489) (the cotter (30) of the crankshaft timing sprocket upwards). 14489 a Check that the crankshaft is resting on the tool (Mot. 1489) while turning the crankshaft clockwise using the old crankshaft accessories pulley bolt and its spacer.
  • Page 213 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109044 a Fit the 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 214 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109047 Note: Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel. 11A-40...
  • Page 215 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 109045 a Refit the camshaft pulley hub lower bolt (34) . a Tighten the camshaft pulley hub bolts. a Remove: - the (Mot. 1489), - the (Mot. 1430). 11A-41...
  • Page 216 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 107270 109048 a Turn the crankshaft two turns clockwise (timing end) using the old crankshaft accessories pulley bolt and Note: its spacer until the hole (35) of the camshaft pulley If the tool (Mot.
  • Page 217 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting First position of the index of the timing belt Second position of the adjustable index of the tensioning roller timing belt tensioning roller 111083 111082 111081 111081 a Loosen the timing belt tensioning roller bolt by up to a Loosen the timing belt tensioning roller bolt by up to one turn while holding the adjustable index with a 6 one turn while holding the adjustable index with a 6...
  • Page 218 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Remove: - the (Mot. 1489), - the (Mot. 1430). a Turn the crankshaft two turns clockwise (timing end) using the old crankshaft accessories pulley bolt and its spacer until the hole of the camshaft pulley hub is opposite the hole in the cylinder head.
  • Page 219 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 830 a Refit the camshaft position sensor (see 13B, Diesel injection, Camshaft position sensor: Removal - Refitting, page 13B-19) . a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) ,...
  • Page 220 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Essential special tooling Mot. 1054 TDC setting pin. Tightening torquesm timing tensioning roller 10 N.m bolts timing tensioning roller 25 N.m TDC pin plug 25 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: 137204 Towing and lifting) (02A, Lifting equipment).
  • Page 221 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 104329 a Rotate the crankshaft in a clockwise direction at the 137203 timing end. a Remove: a Bring the camshaft pulley mark to half a tooth before - the bolts (3) of the high pressure pump support the mark on the inner timing cover.
  • Page 222 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 137200 137202 a Remove: a Using a Torx wrench, bring the adjustable index (6) opposite the mark (7) by turning the eccentric (8) - the bolts (5) of the timing tensioning roller, anti-clockwise.
  • Page 223 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Check III - FINAL OPERATION a Apply a drop of SILICONE ADHESIVE SEALANT (see Vehicle: Parts and ingredients for the repai- rwork) (04B, Consumables - Products) to the TDC setting pin plug. a Refit the TDC pin plug.
  • Page 224 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Essential special tooling Tightening torquesm Mot. 1453 Multiple-adjusting engine camshaft dephaser 25 N.m mounting support with retai- blanking cover ning straps. the clip of the turbochar- 6 N.m Mot. 1453-01 Additional winder nut on ger air outlet pipe engine lift support Mot.
  • Page 225 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 135754 136595 a Remove the clips (1) from the electric coolant pump (2) . a Move aside the electric coolant pump. 137150 a Remove: - the nuts (3) from the exhaust connecting hose, - the rubber mounting bush retaining bolt (4) from the exhaust hose, - the connecting hose seal.
  • Page 226 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment).
  • Page 227 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 135746 134647 a Remove: - the bolt (8) from the air pipe on the intake distribu- tor, - the retaining bracket bolts (9) on the turbocharger air outlet pipe. a Loosen the clip (10) on the intercooler outlet air pipe. a Disconnect the turbocharger air outlet pipe.
  • Page 228 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 134650 138084 a Unclip the turbocharger vacuum pipe clip (14) . a Disconnect the vacuum pipe from the turbocharger. 15105 a Remove the nut (12) from the engine wiring on the gearbox side lifting eye.
  • Page 229 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 136953 a Fit the tool (Mot. 1453) equipped with the tool (Mot. 1453-01) with a safety strap(s) (16) a Remove the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspen- ded engine mounting: Removal - Refitting, page 19D-18) .
  • Page 230 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 136467 a Remove the bolts (17) from the bulkhead heat shield. WARNING 136598 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.
  • Page 231 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Position of TDC pin before setting point CONCERNED Adjusting the timing a Refit: - the crankshaft accessories pulley, - the crankshaft accessories pulley bolt. 15163-2 Position of TDC pin setting point 15106...
  • Page 232 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 15106-1 136603 a At the setting point the camshaft grooves must be a Slacken the timing belt by undoing the tensioning horizontal and offset below the centre line. roller nut (23) . a Remove: - the tensioning roller nut, - the tensioning roller,...
  • Page 233 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 135741 135741 a Remove: - the exhaust camshaft pulley nut (27) , - the inlet camshaft dephaser bolt (28) . a Remove the (Mot. 1801). a Remove: - the exhaust camshaft pulley. - the camshaft dephaser (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refit- ting, page 11A-177) .
  • Page 234 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a parts always to be replaced: seal between cata- Position of pin setting point lytic converter and exhaust downpipe hose (10, 08,02,21). II - REFITTING OPERATION FOR PART CONCERNED 1 - 1 - Adjusting the timing Note: If the exhaust camshaft stud is loosened (see 1 1 A , Top and front of engine, Camshaft:...
  • Page 235 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 15201 a Refit: - the inlet camshaft dephaser, - the inlet camshaft dephaser bolt, - the exhaust camshaft pulley. 104703 - the exhaust camshaft pulley nut, - a new tensioning roller, ensuring that the lug (29) is WARNING positioned in the groove (30) , Always degrease:...
  • Page 236 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 3 - Timing belt tension 135741 a Position the (Mot. 1801). 15256 a Bring the toothed sprockets of the (Mot. 1801) into contact with the camshaft pulleys. Note: a Tighten to torque: When tightening the tensioning roller, use a 6 mm Allen key to stop the roller moving during the - the toothed sprocket nuts (80 N.m),...
  • Page 237 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting Position of TDC pin before setting point 15163-2 15106-1 a Fit the tool (Mot. 1496) (without forcing it). Position of TDC pin setting point b - Checking the tension 15163-1 a Rotate the crankshaft clockwise by two turns (timing end) and before the end of the two turns insert the 15256...
  • Page 238 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 21880 a Remove: - the bolt (33) from the (Mot. 1496), - the camshaft setting tool (Mot. 1496). a Angle tighten the exhaust camshaft pulley nut (86˚ 135741 ± ± ± ± 6˚). a Position the (Mot.
  • Page 239 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Refit the gearbox side lifting eye. - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, a Fit the engine wiring. page 11A-7) , a Refit the engine wiring nut on the gearbox side lifting - the radiator mounting cross member (see Radiator eye.
  • Page 240 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting REMOVAL Essential special tooling Mot. 1489 TDC locating pin. I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Mot. 799-01 Timing gear wheel immobili- Towing and lifting) (02A, Lifting equipment).
  • Page 241 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Move aside the engine wiring. - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-15) . a Check the crankshaft timing with the tool (Mot. 1489) by turning the crankshaft using the accesso- ries pulley bolt and a spacer.
  • Page 242 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a parts always to be replaced: Crankshaft acces- II - OPERATION FOR REMOVAL OF PART CONCERNED sories pulley bolts (10,03,03,10). II - REFITTING OPERATION FOR PART CONCERNED a The first procedure applies to the replacement of any component inside the timing cover that does not require one or both camshaft pulleys to be loosened.
  • Page 243 Fit: - the (Mot. 1496) (8) fitted with the (Mot. 1750) on 135899 a Check that the camshaft pulley mark (10) (Renault the end of the camshaft, sign) is vertical and pointing upwards. - a lifting eye bolt (9) to secure the tool (Mot. 1496).
  • Page 244 136522 a Check that the exhaust camshaft pulley mark (11) ning roller lug in the groove (12) . (Renault sign) and the camshaft dephaser line are a Screw on the tensioning roller nut without tightening vertical and pointing upwards. a Use a pencil to make marks between the exhaust camshaft pulley, the camshaft dephaser and the roc- ker cover.
  • Page 245 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Refit the crankshaft accessories pulley. K4M, and 848 135899 a Torque tighten the fixed roller bolt (50 N.m) (15) . 3 - Timing belt tension 135257 103263 14489 a Position the adjustable index (16) opposite the mark (17) , by turning the eccentric (18) clockwise using a a Use a screwdriver (19) to check that the flywheel 6 mm Allen key.
  • Page 246 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Torque and angle tighten the new crankshaft ac- cessories pulley bolt (40 N.m + 145˚ ± ± ± ± 15˚) K4M, and 858 or 866 (crankshaft in contact with the TDC setting pin). 136543 135901 a Remove:...
  • Page 247 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Move the crankshaft slowly and smoothly and rest it a Torque tighten the timing tensioning roller nut (27 on the TDC setting pin. N.m). a Remove the TDC setting rod (Mot. 1489). 5 - Checking the timing a Ensure that the index and the notch on the timing tensioning roller are in the correct position before...
  • Page 248 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 1 - Adjusting the timing Note: If the stud loosens with the nut (see 11A, Top and front of engine, Camshaft: Removal - Refitting, page 11A-114) (Technical Note 3887A,11A, Top and front of engine). WARNING Always degrease: - the end of the crankshaft (timing end),...
  • Page 249 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 135905 111337 a Fit the (Mot. 1496) with the (Mot. 1750) (28) . 103261 a Position the camshaft grooves horizontally and be- 135240 low the centre line, by turning the camshafts with the a Fit: (Mot.
  • Page 250 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 K4M, and 858 or 866 135257 136543 14489 a Use a screwdriver (31) to check that the flywheel 14489 does not turn (clockwise at the timing end), otherwi- a Use a ratchet extension piece (33) to check that the se bring the crankshaft back into contact with the flywheel does not turn (clockwise at the timing end),...
  • Page 251 K4M, and 858 or 866 135895 136534 a Position: a Position: - the RENAULT badge (35) etched on the exhaust - the RENAULT badge (38) etched on the exhaust camshaft pulley stem vertically and pointing camshaft pulley stem vertically and pointing upwards,...
  • Page 252 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 108879 a Fit a new tensioning roller by positioning the tensio- ning roller lug in the groove (40) . 135896 a Screw on the tensioning roller nut without tightening a Refit a new timing belt on the pulley of each cams- haft (without moving each of the camshaft pulleys).
  • Page 253 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 858 or 866 135898 a Fit a new fixed roller (43) . a Torque tighten the fixed roller bolt (50 N.m). 136526 a Refit a new timing belt on the pulley of each cams- haft (without moving each of the camshaft pulleys).
  • Page 254 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 Note: Check that the exhaust camshaft pulley nut and the inlet camshaft pulley nut do not come into contact with their respective pulleys. Also, from time to time, secure the pulley of each camshaft against its respective camshaft.
  • Page 255 135899 136522 a Check that: a Check that: - the RENAULT badge (50) etched on the exhaust - the RENAULT badge (52) etched on the exhaust camshaft pulley stem is positioned vertically and camshaft pulley stem is positioned vertically and...
  • Page 256 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 K4M, and 858 or 866 135898 136524 a Fit the camshaft pulley locking tool (Mot. 1490-01) a Fit the camshaft pulley locking tool (Mot. 1490-01) (54) (use the bolt and nut of the upper timing cover (55) (use the bolt and nut of the upper timing cover to fit the (Mot.
  • Page 257 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 K4M, and 858 or 866 135257 136543 14489 a Use a screwdriver (56) to check that the flywheel 14489 does not turn (clockwise at the timing end), otherwi- a Use a ratchet extension piece (58) to check that the se bring the crankshaft back into contact with the flywheel does not turn (clockwise at the timing end),...
  • Page 258 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M, and 848 135892 a Refit the lower timing cover (60) . a Tighten to torque the lower timing cover bolts (12 135235 a Tighten to torque the inlet camshaft pulley nut (30 N.m).
  • Page 259 3 - Checking the tension a Rotate the crankshaft twice clockwise at the timing end and before aligning the RENAULT marks on the camshaft pulleys, made previously by the operator, screw the TDC setting pin (Mot. 1489) into the cylin- der block.
  • Page 260 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 4 - Checking the timing a Check that the tensioning roller pointers are correct- ly positioned before checking the timing adjustment. a Screw the TDC setting pin (Mot. 1489) into the cylin- der block.
  • Page 261 TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting a Tighten to torque: - the upper timing cover bolts (46 N.m), - the upper timing cover nuts (46 N.m). a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) , - the accessories belt (see 11A, Top and front of...
  • Page 262 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 832 Tightening torquesm rocker cover bolts 11 N.m lower engine tie-bar bolt 180 N.m on the subframe lower engine tie-bar bolt 180 N.m on the lower engine tie- bar support IMPORTANT Wear leaktight gloves (Nitrile type) for this opera-...
  • Page 263 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 830 K9K, and 832 a the damper valve (see 12A, Fuel mixture, Air inlet flap: Removal - Refitting, page 12A-11) . 136654 136656 a Remove: - the bolt (3) from the upper timing cover, - the upper timing cover by pressing the clips (4) .
  • Page 264 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 830 135845 135880 112325 a Disconnect the oil vapour rebreathing pipe from the air filter unit air outlet pipe at (5) . 135879 a Separate the clip (6) of the oil vapour rebreathing pipe on the oil vapour rebreathing valve.
  • Page 265 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting bracket, - the oil vapour rebreathing valve bracket. K9K, and 830 a Disconnect the brake servo pipe from the vacuum pump. a Remove: - the nuts (9) of the oil vapour rebreathing valve, - the oil vapour rebreathing valve, - the oil vapour rebreathing valve seal from the oil vapour rebreathing valve.
  • Page 266 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 832 134702 a Remove: - the injector rail protector cover mounting bolts (15) 134700 a Unclip the fuel return rail from the rocker cover at (17) . - the injector rail protector cover mounting. K9K, and 832 134701 a Unclip the diesel injector wiring from the rocker co-...
  • Page 267 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 830 K9K, and 832 135489 a Remove: - the rocker cover bolts (19) , 135860 a Unclip the fuel return rail from the rocker cover at - the rocker cover, (18) .
  • Page 268 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the rocker cover, - the rocker cover seal. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Rocker cover gas- ket (10,02,01,12). WARNING 19712-1 Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
  • Page 269 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED K9K, and 830 a Refit the oil vapour rebreathing valve. a Connect the brake servo pipe onto the vacuum pump. a Refit the oil vapour rebreathing valve bracket. a Fit the gearbox breather pipe mounting.
  • Page 270 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K, and 830 a Refit the camshaft position sensor (see 13B, Diesel injection, Camshaft position sensor: Removal - Refitting, page 13B-19) . a Tighten to torque: - the lower engine tie-bar bolt on the subframe (180 N.m), - the lower engine tie-bar bolt on the lower engi- ne tie-bar support (180 N.m).
  • Page 271 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- Essential special tooling ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , Mot. 1490-01 Locking and adjusting cams- haft pulleys. - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-7) ,...
  • Page 272 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K4M, and 848 K4M, and 858 or 866 135235 136530 a Undo: a Remove the camshaft dephaser blanking cover (4) . a Undo: - the exhaust camshaft sprocket nut (1) , - the inlet camshaft sprocket nut (2) .
  • Page 273 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 a parts always to be replaced: Camshaft dephaser sprocket bolt (10,02,02,06). WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
  • Page 274 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the camshafts while positioning them correctly (see Upper engine: Specifications) (Technical Note 6023A, 10A, Engine and peripherals). 14517 136589 a Refit the rocker cover. a Tighten the rocker cover bolts in order as illustrated above.
  • Page 275 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the ignition coils (see 17A, Ignition, Coils Remo- val - Refitting, page 17A-1) , K4M, and 858 or 866 - the inlet manifold (see 12A, Fuel mixture, Inlet a Refit: manifold: Removal - Refitting, page 12A-23) , - the camshaft dephaser, - the timing belt (see 11A, Top and front of engine,...
  • Page 276 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the windscreen wiper arms (see Scuttle panel Essential special tooling grille: Removal - Refitting) (85A, Wiping - Washing), Mot. 1453 Multiple-adjusting engine mounting support with retai- - the scuttle panel grille (see Scuttle panel grille: ning straps.
  • Page 277 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 134647 138091 a Loosen the clip (2) on the intercooler air inlet pipe. a Remove: a Disconnect the intercooler air inlet pipe. - the gearbox side lifting eye bolts (4) , a Remove the intercooler inlet air pipe.
  • Page 278 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 134642 134643 a Unclip the oil vapour rebreathing pipe at (6) . a Remove the oil vapour rebreathing pipe. 134642 a Disconnect: - the upstream oxygen sensor connector (8) , - the camshaft position sensor connector (9) , - the oil vapour recirculation solenoid valve connec- tor (10) ,...
  • Page 279 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 135744 134636 a Disconnect the oil vapour rebreathing pipe at (15) . a Disconnect the petrol vapour rebreathing pipe at (17) . a Remove the oil vapour rebreathing pipe. a Remove the petrol vapour rebreathing pipe. 134645 a Disconnect the petrol vapour rebreathing pipe at 134637...
  • Page 280 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (31A, Front axle components), a Drain the manual gearbox (see Manual gearbox oil: Draining - Refilling) (21A, Manual gearbox).
  • Page 281 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 136467 a Remove: - the bolts (25) from the upper heat shield, - the upper heat shield, - the catalytic converter (see 19B, Exhaust, Cataly- 135754 tic converter: Removal - Refitting, page 19B-17) a Remove the clips (2 2) from the electric coolant pump.
  • Page 282 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 136953 a Fit the (Mot. 1453) equipped with (Mot. 1453-01) and a safety strap(s). a Remove: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-29) .
  • Page 283 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the oil separator (see 11A, Top and front of engi- ne, Oil decanter: Removal - Refitting, page 11A- 205) . II - OPERATION FOR REMOVAL OF PART CONCERNED 134641 a Detach the rocker cover using a hammer as a lever 134640 and detach it using the tool (Mot.
  • Page 284 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 120210 a Tighten to torque and in order: - the rocker cover bolts (22), (23), (20), (13) (8 N.m), - the rocker cover bolts (1) to (12), (14) to (19), 14517 (21), (24) (12 N.m), - the rocker cover bolts (22), (23), (20), (13) (12...
  • Page 285 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting - the catalytic converter (see 19B, Exhaust, Cataly- - the air pressure sensor connector on the intercoo- tic converter: Removal - Refitting, page 19B-17) ler air outlet pipe, - the air temperature sensor connector on the inter- - the upper heat shield, cooler air outlet pipe, - the connecting hose (see 19B, Exhaust, Connec-...
  • Page 286 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting Tightening torquesm rocker cover bolts (ini- 2.5 N.m tial torque) rocker cover bolts 13 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, 16186 - the injector rail protector (see 13B, Diesel injec- a Remove: tion, Injector rail protector: Removal - Refitting, page 13B-70) .
  • Page 287 TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 16186 a Pretighten to torque and in order the rocker cover bolts (initial torque) (2.5 N.m). a Torque tighten in order the rocker cover bolts (13 N.m). a Connect the injector connectors. III - FINAL OPERATION a Refit: - the injector rail protector (see 13B, Diesel injec-...
  • Page 288 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REMOVAL - the oil separator (see 11A, Top and front of engi- ne, Oil decanter: Removal - Refitting, page 11A- 205) , I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: K4M, and 848 Towing and lifting) (02A, Lifting equipment).
  • Page 289 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a Refit the camshafts while positioning them correctly (see Upper engine: Specifications) (Technical Note 6023A, 10A, Engine and peripherals). a Always replace the studs of the inlet and exhaust camshafts if the stud loosens along with the nut of the inlet or exhaust camshaft (see 11A, Top and...
  • Page 290 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the camshaft position sensor (see 17B, Petrol in- - the windscreen wiper arms (see Windscreen wi- jection, Camshaft position sensor: Removal - per arm: Removal - Refitting) (85A, Wiping - Refitting, page 17B-13) , Washing), - the camshaft dephaser solenoid valve (see 11A,...
  • Page 291 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the right-hand suspended engine mounting (see Essential special tooling 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page Mot. 1606 High pressure pump-pulley 19D-18) . retaining tool. K9K, and 830 a Remove the camshaft position sensor (see 13B, Tightening torquesm Diesel injection, Camshaft position sensor: Re-...
  • Page 292 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting K9K, and 830 135845 135880 112325 a Disconnect the oil vapour rebreathing pipe from the air filter unit air outlet pipe at (1) . 135879 a Separate the clip (2) of the oil vapour rebreathing pipe on the oil vapour rebreathing valve.
  • Page 293 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting bracket, - the oil vapour rebreathing valve bracket. K9K, and 830 a Disconnect the brake servo pipe from the vacuum pump. a Remove: - the nuts (5) of the oil vapour rebreathing valve, - the oil vapour rebreathing valve, - the oil vapour rebreathing valve seal from the oil vapour rebreathing valve.
  • Page 294 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting K9K, and 832 134702 a Remove: - the injector rail protector cover mounting bolts (11) 134700 a Unclip the fuel return rail from the rocker cover at (13) . - the injector rail protector cover mounting. K9K, and 832 134701 a Unclip the diesel injector wiring from the rocker co-...
  • Page 295 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting K9K, and 830 K9K, and 832 135489 a Remove: - the rocker cover bolts (15) , - the rocker cover, 135860 - the rocker cover seal. a Unclip the fuel return rail from the rocker cover at (14) .
  • Page 296 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the rocker cover seal. a Remove the vacuum pump (see Vacuum pump: Removal - Refitting) (37A, Mechanical component controls). 118983 a Undo the camshaft pulley hub bolts (19) . a Fit the (Mot. 1606) on the cylinder head to lock the camshaft pulley wheel.
  • Page 297 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts II - OPERATION FOR REMOVAL OF PART CONCERNED and ingredients for the repairwork) to clean and degrease: - the bearing faces of the camshaft bearings on the cylinder head, - the bearing faces of the camshaft bearings on the camshaft bearings,...
  • Page 298 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting a Refit the camshaft bearings. 113563 a Refit the camshaft bearing bolts (1) , (3) , (4) and (2) in order. a Tighten the camshaft bearing bolts (1) , (3) , (4) and (2) in order.
  • Page 299 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting K9K, and 830 a Refit the oil vapour rebreathing valve. a Connect the brake servo pipe to the vacuum pump. a Refit the oil vapour rebreathing valve bracket. a Fit the gearbox breather pipe mounting. a Refit the nut of the gearbox breather pipe mounting.
  • Page 300 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-15) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting,...
  • Page 301 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REMOVAL - the camshaft seals on the timing end (see 11A, Top and front of engine, Camshaft seal at timi- ng end: Removal - Refitting, page 11A-186) , I - REMOVAL PREPARATION OPERATION - the oil separator, a Position the vehicle on a two-post lift (see Vehicle: - the rocker cover (see 11A, Top and front of engi-...
  • Page 302 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 14499 a Remove: - the valve rockers (2) , - the hydraulic tappets (3) . Note: T o prevent any risk of unpriming the hydraulic tappets make sure that they are vertical. 11A-128...
  • Page 303 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting REFITTING Note: I - REFITTING PREPARATION OPERATION If the exhaust camshaft stud is loosened (see 11A, Top and front of engine, Camshaft: Removal - Refitting, page 11A-114) (see Tech- Camshaft marking nical Note 3884A, Replacing F4 camshaft pulley studs).
  • Page 304 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting,...
  • Page 305 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the scoop under the scuttle panel grille (see Scoop Essential special tooling under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), Mot. 799-01 Timing gear wheel immobili- ser. - the camshaft position sensor (see 13B, Diesel in- jection, Camshaft position sensor: Removal - Refitting, page 13B-19) , Tightening torquesm...
  • Page 306 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the camshaft bearing cap cover, 136226 a Remove: 136229 a Remove: - the inner timing cover bolts (3) , - the camshaft (4) , - the inner timing cover, - the camshaft seal on the timing end. - the rocker cover (see 11A, Top and front of engi- ne, Rocker cover: Removal - Refitting, page 11A-88) .
  • Page 307 TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting - the cylinder head joint face. III - FINAL OPERATION a Refit: a parts always to be replaced: Camshaft seal on ti- ming end (10,02,02,02). - the rocker cover (see 11A, Top and front of engi- ne, Rocker cover: Removal - Refitting, page parts always to be replaced: Camshaft timing 11A-88) ,...
  • Page 308 TOP AND FRONT OF ENGINE Camshaft: 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, - the vacuum pump (see Vacuum pump: Removal - Refitting) (37A, Mechanical component controls),...
  • Page 309 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting Essential special tooling IMPORTANT Mot. 1448 Long nose pliers for hose clips. Use the diagnostic tool before any operation is car- ried out on the injection circuit to check: Mot. 1390 Support for removing/refitting the engine - gearbox assem- - that the rail is not under pressure,...
  • Page 310 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),...
  • Page 311 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 830 135845 135880 112325 a Disconnect the oil vapour rebreathing pipe union from the air filter unit air outlet pipe at (1) . 135879 a Separate the oil vapour rebreathing pipe clip (2) from the oil vapour rebreathing valve.
  • Page 312 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting valve, - the bracket of the oil vapour rebreathing valve. K9K, and 830 a Disconnect the brake servo pipe union from the va- cuum pump. a Remove: - the nuts (5) of the oil vapour rebreathing valve, - the oil vapour rebreathing valve, - the seal of the oil vapour rebreathing valve.
  • Page 313 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 134702 a Remove: - the bolts (11) of the injector rail protector cover 134700 a Unclip the diesel injector fuel return rail from the roc- support, ker cover at (13) . - the injector rail protector cover support.
  • Page 314 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 135489 a Remove: - the rocker cover bolts (14) , 134703 - the rocker cover. a Remove: - the dipstick, - the dipstick guide bolts (16) . K9K, and 830 a Move aside the dipstick guide.
  • Page 315 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 K9K, and 830 135487 135875 a Disconnect the hose (18) of the turbocharging pres- a Disconnect the hose (19) of the turbocharging pres- sure regulator solenoid valve from the turbocharger. sure regulator solenoid valve from the turbocharger.
  • Page 316 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 K9K, and 830 135410 136639 a Undo the air filter unit air outlet pipe clip (21) from a Undo the air filter unit air outlet pipe clip (22) from the turbocharger.
  • Page 317 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 135484 135485 a Unclip the heater matrix cooling hose from the water a Separate the heater matrix cooling hose clip (28) chamber (23) . from the water chamber cooling hose using the tool (Mot.
  • Page 318 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the fuel temperature sensor connector (33) , K9K, and 832 - the connector (34) from the fuel pressure regula- tion solenoid valve, - the connector (35) from the fuel flow regulation so- lenoid valve, - all heater plug connectors, - the connector for each diesel injector.
  • Page 319 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 134707 a Disconnect the fuel supply pipe union (41) from the high pressure pump. 11A-145...
  • Page 320 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 830 a Fit a suitable blanking plug on: - the fuel supply pipe union opening, - the high pressure pump opening. K9K, and 832 135873 135468 a Disconnect the fuel drain pipe from the injector rail protector (45) .
  • Page 321 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K9K, and 832 K9K, and 830 123969 136665 a Remove the alternator upper bolt (46) . a Remove the alternator upper bolt (49) . a Loosen the alternator lower bolt (47) . a Loosen the alternator lower bolt (50) .
  • Page 322 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting REFITTING K9K, and 832 I - REFITTING PREPARATION OPERATION Note: T ur n the camshaft slightly to facilitate the removal IMPORTANT of the cylinder head bolt on the camshaft position Wear goggles with side protectors for this opera- sensor target.
  • Page 323 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 1 - Cleaning the cylinder head joint face 3 - Cleaning the joint face of the rocker cover WARNING WARNING Do not scrape the joint faces of the aluminium, Protect the oilway so that foreign bodies do not any damage caused to the joint face will result in enter the oil pipes in the cylinder head.
  • Page 324 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Fit: - the alternator upper bolt (25 N.m). - a new cylinder head gasket, centred by two dowels, K9K, and 832 a Connect the fuel drain pipe on the injector rail pro- - the cylinder head on the cylinder block.
  • Page 325 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - all heater plug connectors, - the fuel flow regulation solenoid valve connector, - the fuel temperature sensor connector, - the injector rail pressure sensor connector. a Connect: - the coolant temperature sensor connector, - the heater matrix cooling hose to the water cham- ber cooling hose.
  • Page 326 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Refit: K9K, and 830 - the support of the injector rail protector cover, a Refit the camshaft position sensor (see 13B, Diesel - the injector rail protector cover. injection, Camshaft position sensor: Removal - a Clip on the injector rail protector cover.
  • Page 327 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Drain the cooling system (see 19A, Cooling, Coo- Essential special tooling ling circuit: Draining - Refilling, page 19A-17) . Mot. 1448 Long nose pliers for hose clips. Tightening torquesm cylinder head bolts 30 N.m 180˚...
  • Page 328 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 120242 134642 a Disconnect the coolant temperature sensor connec- a Disconnect the injector connectors (6) . tor (3) from the water chamber. 135777 a Disconnect: 135793 a Disconnect: - the oil vapour rebreathing solenoid valve connector - the air temperature sensor connector (4) on the in- (7) , tercooler air outlet pipe,...
  • Page 329 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 135779 a Remove: - the oil vapour rebreathing pipe (9) , - the petrol vapour rebreathing pipe (10) . a Disconnect the vacuum pipe connector (11) from the brake servo. a Move the brake servo vacuum pipe to one side.
  • Page 330 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting Top and front of engine, Camshaft dephaser solenoid valve: Removal - Refitting, page 11A- 184) , - the ignition coils (see 17A, Ignition, Coils Remo- val - Refitting, page 17A-1) , - the spark plugs (see 17A, Ignition, Spark plugs: Removal - Refitting, page 17A-5) .
  • Page 331 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Remove: - the hydraulic tappets (18) . - the front right-hand wheel driveshaft (see Front ri- ght-hand wheel driveshaft: Removal - Refitting) II - OPERATION FOR REMOVAL OF PART (29A, Driveshafts), CONCERNED - the right-hand differential output seal (see Front ri-...
  • Page 332 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts 1 - Cleaning the cylinder head joint face and ingredients for the repairwork) (04B, Consu- mables - Products) to degrease: - the cylinder head gasket face if being reused, IMPORTANT Wear goggles with side protectors for this opera- - the cylinder block gasket face.
  • Page 333 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Fit: III - FINAL OPERATION - a new cylinder head gasket, - the cylinder head equipped with new bolts on the cylinder block. a Check that the centring devices are present and in good condition on the cylinder block.
  • Page 334 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the turbocharger (see 12B, Turbocharging, Tur- - the bolt of the intercooler air outlet pipe on the inlet bocharger: Removal - Refitting, page 12B-8) , manifold, - the catalytic converter (see 19B, Exhaust, Cataly- - the dipstick guide.
  • Page 335 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray, - the battery tray (see Battery : Removal - Refit- ting) (80A, Battery), - the battery (see Battery : Removal - Refitting) (80A, Battery), - the engine cover,...
  • Page 336 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the intercooler air inlet pipe (see 12B, Turbochar- Essential special tooling ging, Intercooler air inlet pipe: Removal - Refit- ting, page 12B-41) , Mot. 1448 Long nose pliers for hose clips.
  • Page 337 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 135568 135563 a Disconnect: a Disconnect the connector (4) from the EGR bypass control solenoid valve. - the damper valve connector (1) , - the inlet pressure sensor connector (2) . a Separate the injection wiring.
  • Page 338 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting 135990 135987 a Disconnect the connector (6) from the camshaft po- a Disconnect the coolant temperature sensor connec- sition sensor. tor (8) . 135530 135550 a Disconnect the heater plug connectors (7) . a Separate the clips (9) from the water chamber hoses using the tool (Mot.
  • Page 339 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Position the (Mot. 1390) under the engine. a Remove the tool (Mot. 1453). II - OPERATION FOR REMOVAL OF PART CONCERNED 135565 a Disconnect the vacuum pipe (10) from the vacuum pump.
  • Page 340 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts REFITTING and ingredients for the repairwork) (04B, Consu- mables - Products) to degrease: I - REFITTING PREPARATION OPERATION - the cylinder head gasket face if being reused, a parts always to be replaced: Cylinder head bolts - the cylinder block gasket face.
  • Page 341 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Fit the injection wiring. a Connect: - the heater plug connectors, - the camshaft position sensor connector, - the turbocharger control solenoid valve connector, - the EGR bypass control solenoid valve connector, - the injector connectors, - the inlet pressure sensor connector, - the connector to the damper flap.
  • Page 342 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the turbocharger outlet exhaust gas duct (see 12B, Turbocharging, Turbocharger outlet exhaust gas duct: Removal - Refitting, page 12B-49) , - the intercooler air inlet pipe (see 12B, Turbochar- ging, Intercooler air inlet pipe: Removal - Refit- ting, page 12B-41) , - the battery tray (see Battery tray: Removal - Re-...
  • Page 343 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the front section of the front wheel arch liners (see Essential special tooling Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), Mot. 1448 Long nose pliers for hose clips.
  • Page 344 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting K4M, and 848 136470 a Remove: - the exhaust manifold strut nut (2) from the exhaust 135260 manifold, a Unclip the wiring from the lifting eye. - the exhaust manifold strut bolt (3) from the cylinder a Remove: block, - the engine wiring retaining nut,...
  • Page 345 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the camshaft dephaser (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refit- ting, page 11A-177) . a Remove: - the oil separator (see 11A, Top and front of engi- ne, Oil decanter: Removal - Refitting, page 11A- 205) , - the rocker cover (see 11A, Top and front of engi-...
  • Page 346 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 134573 134578 a Remove: - the cylinder head bolts, - the cylinder head. a Mount the cylinder head on the cylinder head sup- port (Mot.
  • Page 347 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts 1 - Cleaning the cylinder head joint face and ingredients for the repairwork) (04B, Consu- mables - Products) to degrease: - the cylinder head gasket face if being reused, IMPORTANT Wear goggles with side protectors for this opera- - the cylinder block gasket face.
  • Page 348 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting a Fit: III - FINAL OPERATION - a new cylinder head gasket, - the cylinder head equipped with new bolts on the cylinder block. WARNING In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder head mounting holes.
  • Page 349 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the coolant temperature sensor connector, K4M, and 848 - the hose to the heater matrix, a Refit the dipstick guide. - the top hose to the water chamber. a Torque tighten the dipstick guide tube bolt (10 a Using the (Mot.
  • Page 350 TOP AND FRONT OF ENGINE Cylinder head: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) ,...
  • Page 351 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting K4M, and 858 or 866 - the right-hand suspended engine mounting (see Essential special tooling 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page Mot. 1490-01 Locking and adjusting cams- 19D-18) , haft pulleys.
  • Page 352 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting K4M, and 858 or 866 103264 111339 a Undo: a Place the camshaft dephaser in a vice fitted with jaws. - the camshaft dephaser bolt (3) , - the exhaust camshaft sprocket nut (4) . a Remove the tool (Mot.
  • Page 353 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting K4M, and 858 or 866 a Degrease the end of the camshaft (timing end) and - the scoop under the scuttle panel grille (see Scoop clean the bores and bearing faces of the camshaft under scuttle panel grille: Removal - Refitting) dephaser.
  • Page 354 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Essential special tooling Removal - Refitting) (56A, Exterior equipment), Mot. 1801 Camshaft sprocket locking - the scoop under the scuttle panel grille (see Scoop tool - F4 engine.
  • Page 355 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting WARNING Always degrease: - the end of the crankshaft (timing end), - the timing sprocket bore and bearing faces, - the crankshaft accessories pulley bearing faces, - the camshaft ends (timing end), - the camshaft sprocket bores and bearing faces.
  • Page 356 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting a Position the (Mot. 1801). a Torque tighten the camshaft dephaser bolt (100 N.m). a Fit a new blanking cover on the camshaft dephaser. a Torque tighten the new blanking cover on the camshaft dephaser (15 N.m).
  • Page 357 TOP AND FRONT OF ENGINE Camshaft dephaser: Removal - Refitting - the battery (see Battery: Removal - Refitting) (80A, Battery), - the engine cover. 11A-183...
  • Page 358 TOP AND FRONT OF ENGINE Camshaft dephaser solenoid valve: Removal - Refitting K4M, and 858 or 866 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 136578 a Remove:...
  • Page 359 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 135749 a Remove the bolt (2) of the camshaft dephaser sole-...
  • Page 360 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- Essential special tooling ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , Mot. 1490-01 Locking and adjusting cams- haft pulleys.
  • Page 361 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the exhaust camshaft sprocket, - the inlet camshaft sprocket nut, - the inlet camshaft sprocket. K4M, and 858 or 866 105257 Note: The camshaft seal is removed from the timing end using the (Mot.
  • Page 362 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting 135237 135232 a Push the tool (Mot. 1577) until contact is made a Remove the camshaft seal by turning the bolt (9) between the ends of the claws and the camshaft clockwise.
  • Page 363 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting a Degrease the bearing surfaces of the timing end camshaft seals using SURFACE CLEANER (see Vehicle: Parts and ingredients for the repai- rwork) (04B, Consumables - Products): - the seal mating face of each camshaft, - the camshaft seal housings.
  • Page 364 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting K4M, and 848 a Refit: - the inlet camshaft sprocket, - a new nut on the inlet camshaft sprocket, - the exhaust camshaft sprocket, - a new nut on the exhaust camshaft sprocket, K4M, and 858 or 866 a Refit: - the camshaft dephaser,...
  • Page 365 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the crankshaft accessories pulley (see 11A, Top and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-15) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) ,...
  • Page 366 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: Essential special tooling Removal - Refitting) (56A, Exterior equipment), Mot. 1606 High pressure pump-pulley - the scoop under the scuttle panel grille (see Scoop retaining tool.
  • Page 367 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 118983 a Undo the camshaft pulley hub bolts (3) . 123970 a Fit the (Mot. 1606) on the cylinder head to lock the camshaft pulley wheel.
  • Page 368 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting 105270 105272 a Position the claws of the (Mot. 1577) on the cams- a Separate the claws by turning the bolt (9) clockwise haft. using an open-jawed spanner. 105271 105273 a Push the tool (Mot.
  • Page 369 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting a parts always to be replaced: Camshaft timing II - REFITTING OPERATION FOR PART sprocket nut (10,02,02,18). CONCERNED WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
  • Page 370 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting 1 - First fitting of the camshaft seal 21687-1 a Fit a new camshaft seal on the camshaft. 21687-2 a Fit the cover (12) and the collar nut (13) of the (Mot. 1632).
  • Page 371 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting 2 - Second fitting of the camshaft seal 21687-2 123076 a Fit the cover (19) equipped with the spacer on the a Depending on the case, the Parts Department deli- camshaft seal end and the collar nut (20) of the tool vers seals (14) equipped with a spacer (15) amongst (Mot.
  • Page 372 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting a Remove: III - FINAL OPERATION - the collar nut from the (Mot. 1632), - the cover from the (Mot. 1632), - the stud of the (Mot. 1632), - the protection sleeve.
  • Page 373 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine cover.
  • Page 374 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- Essential special tooling ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , Mot. 1801 Camshaft sprocket locking tool - F4 engine.
  • Page 375 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED a Remove the camshaft seals using a screwdriver. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Camshaft seal on ti- ming end (10,02,02,02).
  • Page 376 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the exhaust camshaft pulley. - a new nut on the exhaust camshaft pulley. a Tighten to torque: - the toothed sprocket nuts (80 N.m), - the exhaust camshaft pulley nut (30 N.m ± ± ± ± 86˚). a Remove the tool (Mot.
  • Page 377 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting - the camshaft position sensor (see 13B, Diesel in- Essential special tooling jection, Camshaft position sensor: Removal - Refitting, page 13B-19) , Mot. 799-01 Timing gear wheel immobili- ser.
  • Page 378 TOP AND FRONT OF ENGINE Camshaft seal at timing end: Removal - Refitting REFITTING - the high pressure pipe between the pump and the rail (see 13B, Diesel injection, High-pressure pipe between the pump and rail: Removal - Re- I - REFITTING PREPARATION OPERATION fitting, page 13B-71) , a Use SURFACE CLEANER (see Vehicle: Parts - the timing belt (see 11A, Top and front of engine,...
  • Page 379 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting - the oil separator. Tightening torquesm oil separator bolts 15 N.m K4M, and 858 or 866 REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) , - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping -...
  • Page 380 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting a Use SUPER CLEANING AGENT FOR JOINT FA- II - REFITTING OPERATION FOR PART CES (see Vehicle: Parts and ingredients for the CONCERNED repairwork) (04B, Consumables - Products) to clean: K4M, and 848 - the joint face on the oil separator if it is to be re- used,...
  • Page 381 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting - new bolts on the oil separator. a Torque tighten in order the oil separator bolts (15 N.m). III - FINAL OPERATION a Refit: - the inlet manifold (see 12A, Fuel mixture, Inlet manifold: Removal - Refitting, page 12A-23) , - the three ignition coils on the flywheel end (see 17A, Ignition, Coils Removal - Refitting, page...
  • Page 382 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting Essential special tooling Mot. 1448 Long nose pliers for hose clips. Tightening torquesm oil separator bolts 30 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 383 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the oil separator. a Fit the oil separator clip on the cylinder block using the tool (Mot. 1448). a Refit the oil separator bolts. a Torque tighten the oil separator bolts (30 N.m).
  • Page 384 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting Tightening torquesm oil separator bolts 12 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 385 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting a Remove: - the front right-hand wheel driveshaft (see Front ri- ght-hand wheel driveshaft: Removal - Refitting) (29A, Driveshafts), - the right-hand differential output seal (see Diffe- rential output seal: Removal - Refitting) (21A, Manual gearbox), - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting,...
  • Page 386 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting REFITTING II - REFITTING OPERATION FOR PART CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: oil separator bolt (11,04,06,23). WARNING When cleaning parts, it is essential that the parts do not impact on each other, otherwise their mating faces may be damaged and therefore their adjustments may be altered, which could...
  • Page 387 TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting a Refit: - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the upstream oxygen sensor (see 17B, Petrol in- jection, Oxygen sensors: Removal - Refitting,...
  • Page 388 FUEL MIXTURE Air resonator: Removal - Refitting REMOVAL REFITTING I - REFITTING OPERATION FOR PART I - REMOVAL PREPARATION OPERATION CONCERNED a Position the vehicle on a two-post lift (see Vehicle: a Refit the air resonator. Towing and lifting) (02A, Lifting equipment). II - FINAL OPERATION a Remove: a Refit:...
  • Page 389 FUEL MIXTURE Air filter: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the battery cover. 134239 a Pull the air filter unit slide valve upwards at (3) . 138705 a Move aside the wiring (1) . II - OPERATION FOR REMOVAL OF PART CONCERNED 134237 a Remove the air filter (4) .
  • Page 390 FUEL MIXTURE Air filter: Removal - Refitting II - REFITTING OPERATION WARNING If the air filter is fitted incorrectly in the air filter unit, unfiltered air may enter the engine. a Refit: - the air filter, - the air filter unit slide valve, - the air filter unit slide valve bolts.
  • Page 391 FUEL MIXTURE Air filter unit: Removal - Refitting Tightening torquesm air filter unit bolts 8 N.m air filter unit air outlet 6 N.m pipe clip REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the battery (see Battery : Removal - Refit- ting) (80A, Battery).
  • Page 392 Air filter unit: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED F9Q or K9K F4R or K4M 135707 a Loosen the clip (4) of the air outlet pipe on the air fil- ter unit. a Move the air outlet pipe of the air filter unit to one si-...
  • Page 393 FUEL MIXTURE Air filter unit: Removal - Refitting - the « air filter unit - air filter - air sleeve » assembly (6) , - the air sleeve of the « air filter unit - air filter - air sleeve » assembly. F9Q or K9K If replacing the air filter unit a Remove the air flowmeter (see 12A, Fuel mixture,...
  • Page 394 FUEL MIXTURE Air flowmeter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool Tightening torquesm air filter box air outlet 5.5 N.m pipe clip on the air flow- meter REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 395 FUEL MIXTURE Air flowmeter: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Air flowmeter seal (11,04,06,26). II - REFITTING OPERATION FOR PART CONCERNED a Refit the air flowmeter, fitted with a new seal. a Connect the air flowmeter connector.
  • Page 396 FUEL MIXTURE Air flowmeter: Removal - Refitting Essential equipment diagnostic tool Tightening torquesm air flowmeter 4 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), 114993 - the scuttle panel grille (see Scuttle panel grille:...
  • Page 397 FUEL MIXTURE Air flowmeter: Removal - Refitting - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the engine cover. a Apply the after repair procedure using the diagnos- tic tool : - connect the diagnostic tool, - select «...
  • Page 398 FUEL MIXTURE Air inlet flap: Removal - Refitting K9K, and 832 or 834 Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 121889 a Disconnect: - the damper valve connector (4) , - the connector (5) from the camshaft position sen- sor.
  • Page 399 FUEL MIXTURE Air inlet flap: Removal - Refitting K9K, and 832 or 834 134490 135464 a Disconnect the brake servo pipe union (7) from the a Remove: vacuum pump. - the damper valve bolts (9) , II - OPERATION FOR REMOVAL OF PART - the damper valve, CONCERNED - the damper valve seal.
  • Page 400 FUEL MIXTURE Air inlet flap: Removal - Refitting K9K, and 832 or 834 III - FINAL OPERATION a Connect the brake servo pipe union to the vacuum pump. a Fit the manual gearbox breather to its support. a Refit the gearbox breather mounting nut. a Clip the damper valve wiring onto the injector rail protector cover.
  • Page 401 FUEL MIXTURE Air inlet flap: Removal - Refitting Essential equipment diagnostic tool Tightening torquesm damper valve bolts 10 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 Remove: - the engine cover, - the engine undertray bolts,...
  • Page 402 FUEL MIXTURE Air inlet flap: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 136193 a Disconnect the connector (3) from the damper valve. 135646 a Remove the front end panel bolts (2) . a Tilt the front end panel. 136195 a Remove intercooler air outlet pipe (see 12B, Turbo- a Remove:...
  • Page 403 FUEL MIXTURE Air inlet flap: Removal - Refitting REFITTING - the engine undertray, - the engine cover. I - REFITTING PREPARATION OPERATION a Apply the after repair procedure using the diagnos- a Use SURFACE CLEANER (see Vehicle: Parts tic tool : and ingredients for the repairwork) (04B, Consu- - connect the diagnostic tool, mables - Products) to clean and degrease:...
  • Page 404 FUEL MIXTURE Throttle valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm throttle valve bolts 10 N.m air pipe clip on the 6 N.m throttle valve air pipe clip on the air fil- 6 N.m ter unit REMOVAL I - REMOVAL PREPARATION OPERATION...
  • Page 405 FUEL MIXTURE Throttle valve: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 135923 a Remove: 135923 - the throttle valve bolts (6) , a Refit: - the throttle valve. - a new seal on the inlet manifold, a Remove the throttle valve seal. - the throttle valve.
  • Page 406 FUEL MIXTURE Throttle valve: Removal - Refitting OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm throttle valve bolts 10 N.m REMOVAL a Remove the front engine cover. 135782 a Disconnect the connector (2) from the throttle valve. 135796 a Remove the bolts (1) on the intercooler outlet air pi- a Move the intercooler outlet air pipe to one side.
  • Page 407 FUEL MIXTURE Throttle valve: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Throttle valve seal (11,04,06,25). II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new seal on the throttle valve, - the throttle valve, - the throttle valve bolts.
  • Page 408 FUEL MIXTURE Throttle valve: Cleaning F4R or K4M Essential equipment compressed air nozzle IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. IMPORTANT Wear goggles with side protectors for this opera- tion. Note: Be sure to work in a clean environment so as not to 124736 allow any contamination of the throttle valve.
  • Page 409 FUEL MIXTURE Throttle valve: Cleaning F4R or K4M III - FINAL OPERATION a Refit the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) 124737 a Remove the cleaning product and the dirt residue using lint-free CLEANING CLOTHS.
  • Page 410 FUEL MIXTURE Inlet manifold: Removal - Refitting - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) . 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...
  • Page 411 FUEL MIXTURE Inlet manifold: Removal - Refitting K4M, and 858 or 866 136460 a Disconnect the brake servo pipe union (5) from the inlet manifold. 136579 a Disconnect the connector (7) from the camshaft de- phaser solenoid valve. a Unclip the camshaft dephaser solenoid valve wiring from the inlet manifold.
  • Page 412 FUEL MIXTURE Inlet manifold: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 136482 136482 a Remove: a Refit the inlet manifold. - the inlet manifold bolts (8) , a Tighten to torque and in order: - the inlet manifold, - bolts 1 to 5 of the inlet manifold (9 N.m), - the inlet manifold seals.
  • Page 413 FUEL MIXTURE Inlet manifold: Removal - Refitting a Connect: - the connector of each coil, - the air temperature sensor connector. a Refit: - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) , - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille:...
  • Page 414 FUEL MIXTURE Inlet manifold: Removal - Refitting Tightening torquesm injector rail bolts 10 N.m throttle valve bolts 10 N.m inlet manifold bolts 25 N.m cylinder head mounting 62 N.m bolt on the inlet manifold IMPORTANT 134642 During this operation, be sure to: a Remove: - refrain from smoking or bringing red hot objects - the oil vapour rebreathing pipe (1) ,...
  • Page 415 FUEL MIXTURE Inlet manifold: Removal - Refitting 134642 134638 a Disconnect: - the oil vapour rebreathing pipe (7) , - the brake servo vacuum pipe (8) . 134636 a Disconnect: - the injector connectors (4) , - the injector rail fuel supply pipe (5) , - the petrol vapour rebreathing pipe (6) .
  • Page 416 FUEL MIXTURE Inlet manifold: Removal - Refitting 135782 135700 a Disconnect the connector (13) from the throttle val- a Remove the bolt (15) from the « compressor - ex- pansion valve » connecting pipe on the inlet mani- fold. II - OPERATION FOR REMOVAL OF PART CONCERNED Note: The inlet manifold bolts are not the same length;...
  • Page 417 FUEL MIXTURE Inlet manifold: Removal - Refitting a Torque tighten the throttle valve bolts (10 N.m). REFITTING II - OPERATION FOR REFITTING PART I - REFITTING PREPARATION OPERATION CONCERNED a parts always to be replaced: Intake distributor a Refit: seal (10,07,01,07) a Use SURFACE CLEANER (see Vehicle: Parts - a new seal on the inlet manifold, and ingredients for the repairwork) (04B, Consu-...
  • Page 418 FUEL MIXTURE Injector holder shim: Removal - Refitting K4M, and 858 or 866 Tightening torquesm bolts 1 and 2 on the 30 N.m injector holder shim bolts 3, 4, 5, 6, 7, 8, 9 25 N.m and 10 on the injector holder shim upper timing cover bolt 46 N.m...
  • Page 419 FUEL MIXTURE Injector holder shim: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts II - OPERATION FOR REMOVAL OF PART CONCERNED and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease: - the cylinder head joint face, - the gasket face of the injector holder shim, in case of reuse.
  • Page 420 FUEL MIXTURE Injector holder shim: Removal - Refitting III - FINAL OPERATION a Refit: - the « injector rail - injector » assembly (see 17B, Petrol injection, Injector rail - Injectors: Remo- val - Refitting, page 17B-19) , - the inlet manifold (see 12A, Fuel mixture, Inlet manifold: Removal - Refitting, page 12A-23) , - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) .
  • Page 421 FUEL MIXTURE Exhaust manifold - Intake distributor: Removal - Refitting Tightening torquesm exhaust manifold - inlet 33 N.m manifold nuts bolts on the right-hand 25 N.m lifting eye inlet manifold air inlet 25 N.m pipe bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 422 FUEL MIXTURE Exhaust manifold - Intake distributor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 137477 a Remove: 137481 - the bolts (4) from the lifting eye on the right-hand si- - the lifting eye on the right-hand side. 137480 a Remove: - the "exhaust manifold - inlet manifold"...
  • Page 423 FUEL MIXTURE Exhaust manifold - Intake distributor: Removal - Refitting REFITTING - the intercooler air inlet pipe (see 12B, Turbochar- ging, Intercooler air inlet pipe: Removal - Refit- ting, page 12B-41) , I - REFITTING PREPARATION OPERATION - the scoop under the scuttle panel grille (see Scoop a parts always to be replaced: exhaust gas recir- under scuttle panel grille: Removal - Refitting) culation pipe bolt (11,07,01,18),...
  • Page 424 FUEL MIXTURE Exhaust manifold: Removal - Refitting Essential special tooling Mot. 1495-01 22 mm socket for removing/ a Remove: refitting oxygen sensors. - the centre section of the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), Tightening torquesm - the centre section of the scoop under the scuttle exhaust manifold studs...
  • Page 425 FUEL MIXTURE Exhaust manifold: Removal - Refitting - the ring between the exhaust manifold and the ca- talytic converter. 135927 a Unclip the heater matrix hoses from the retaining 136514 bracket (5) . a Remove: a Remove: - the nut (2) from the exhaust manifold stay, - the bolt (3) from the exhaust manifold stay, - the heater matrix hose retaining bracket bolt, - the exhaust manifold strut.
  • Page 426 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the upstream oxygen sensor using the (Mot. 1495- CONCERNED 01). REFITTING I - REFITTING PREPARATION OPERATION 109399 135711 a parts always to be replaced: Exhaust manifold a Remove: seal (10,07,02,07).
  • Page 427 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 135911 a Refit the upstream oxygen sensor using the tool 135711 (Mot. 1495-01). a Refit: a Refit the lower heat shield. - a new exhaust manifold seal, a Screw on the bolts (4) and (5) without tightening.
  • Page 428 FUEL MIXTURE Exhaust manifold: Removal - Refitting B95 or D95 a Refit the coils (see 17A, Ignition, Coils Removal - Refitting, page 17A-1) . a Refit the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) B95 or D95 a Refit: - the scoop under the scuttle panel grille (see Scoop...
  • Page 429 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 830 or 832 - the turbocharger oil supply pipe (see 12B, Turbo- charging, Turbocharger oil pipe: Removal - Re- Tightening torquesm fitting, page 12B-22) , - the turbocharger oil return pipe (see 12B, Turbo- exhaust manifold nuts 26 N.m charging, Turbocharger oil pipe: Removal - Re-...
  • Page 430 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 830 or 832 II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 113561 114532 a Remove: a Refit: - the nuts (2) from the exhaust manifold, - a new exhaust manifold gasket in the position mar- - the exhaust manifold.
  • Page 431 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 830 or 832 K9K, and 830 a Refit the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refit- ting, page 19D-33) . a Refit: - the engine undertray, - the engine cover.
  • Page 432 FUEL MIXTURE Exhaust manifold: Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, Tightening torquesm page 19D-33) , - the connecting hose (see 19B, Exhaust, Connec- exhaust manifold nuts 25 N.m ting hose: Removal - Refitting, page 19B-60) , - the catalytic converter (see 19B, Exhaust, Cataly- tic converter: Removal - Refitting, page 19B-17)
  • Page 433 FUEL MIXTURE Exhaust manifold: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 21936 21936 a Refit: a Remove: - a new exhaust manifold gasket, - the exhaust manifold. - the nuts (2) from the exhaust manifold, a Screw on the exhaust manifold nuts without tighte- - the exhaust manifold, ning them.
  • Page 434 FUEL MIXTURE Exhaust manifold: Removal - Refitting a Refit: - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting)
  • Page 435 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 836 II - OPERATION FOR REMOVAL OF PART CONCERNED 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).
  • Page 436 FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K, and 836 II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the scoop under the centre section of the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) , - the scuttle panel grille centre section (see Scuttle panel grille: Removal - Refitting) .

  • Page 437: Turbocharging: Precautions For Repair

    TURBOCHARGING Turbocharging: Precautions for repair F4R or F9Q or K9K I - TURBOCHARGER: GENERAL INSTRUCTIONS III - APPLICATION CONDITIONS OF INSTRUCTIONS To test the turbocharger pressure regulator see Tech- nical Note 3419A, Turbocharger fault finding, 12B, The instructions below must be followed when repla- Turbocharger, Fault finding - tests.
  • Page 438 TURBOCHARGING Turbocharging: Precautions for repair F4R or F9Q or K9K • Clean the turbocharger air pipes. Check that there are no metal objects inside the flow- meter (2) . Remove: Note: - the air pipe (A) (between the air filter box and the tur-...
  • Page 439 TURBOCHARGING Turbocharging: Precautions for repair F4R or F9Q or K9K Clean the removed pipes one by one using the clea- V - LUBRICATION CIRCUIT**: INSTRUCTIONS ning station: FOLLOWING MECHANICAL DAMAGE TO THE TURBOCHARGER - brush as much of the inside of the pipe as possible...
  • Page 440 TURBOCHARGING Turbocharging: Precautions for repair Exhaust manifold Essential equipment Turbine wheel Bearing system (bearing parts washer wheel shaft) Air filter unit air outlet pipe I - TURBOCHARGER: GENERAL INSTRUCTIONS Turbocharger air outlet pipe For the turbocharging pressure regulator check (see Intercooler air outlet pipe Fault Finding - Tests) (Technical Note 3419A, 12B, Turbocharging).
  • Page 441 TURBOCHARGING Turbocharging: Precautions for repair 3 - List of instructions - Drain the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-40) . - Replace the oil filter (see 10A, Engine and cylinder block assembly, Oil filter: Removal - Refitting, page 10A-48) .
  • Page 442 TURBOCHARGING Turbocharging: Precautions for repair For air pipes made up of several components: - mark (10) the fitting position of each component, - separate all the components. 112771 Dry the pipes one by one using a compressed air gun. For pipes comprising several components: 112770 - assemble the components, taking note of their correct One by one, clean the pipes removed with the parts...
  • Page 443 TURBOCHARGING Turbocharging: Precautions for repair VI - GENERAL INSTRUCTIONS TO BE FOLLOWED WHEN REMOVING A TURBOCHARGER Always replace: - the oil supply pipe: • if the pipe is blocked, even partially (due to scale, carbonised oil etc.), • if the pipe is fitted with self-retaining seals. - the oil return pipe: •...
  • Page 444 TURBOCHARGING Turbocharger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm turbocharger nuts 25 Nm turbocharger bracket 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 445 TURBOCHARGING Turbocharger: Removal - Refitting III - FINAL OPERATION a Refit: - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the turbocharger oil pipe (see 12B, Turbochar- ging, Turbocharger oil pipe: Removal - Refit- ting, page 12B-22) , - the exhaust gases duct at the turbocharger outlet (see 12B, Turbocharging, Turbocharger outlet...
  • Page 446 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 830 or 832 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm a Disconnect the turbocharging pressure regulation valve control hose from the turbocharger. turbocharger studs on 9 Nm the exhaust manifold K9K, and 832 turbocharger stud on 9 Nm...
  • Page 447 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 830 or 832 a parts always to be replaced: seal between ex- haust manifold and turbocharger (10,09,01,07). K9K, and 830 a Use ABRASIVE PADS to clean the joint faces: - the exhaust manifold, - of the turbocharger if reused.
  • Page 448 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 830 or 832 K9K, and 830 a Refit the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refit- ting, page 19D-33) . a Refit: - the engine undertray, - the engine cover. a Connect the battery (see Battery : Removal - Refit- ting) (80A, Battery).
  • Page 449 TURBOCHARGING Turbocharger: Removal - Refitting Essential special tooling WARNING Ms. 583 Hose clamp pliers. Metal objects may enter the oil and air circuits as a result of a broken turbocharger. Failure to observe the following instructions will lead Tightening torquesm to the turbocharger breaking again.
  • Page 450 TURBOCHARGING Turbocharger: Removal - Refitting - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection). a Drain the manual gearbox (see Manual gearbox oil: Draining - Refilling) (21A, Manual gearbox). a Remove: - the front right-hand wheel driveshaft (see Front ri- ght-hand wheel driveshaft: Removal - Refitting)
  • Page 451 TURBOCHARGING Turbocharger: Removal - Refitting 136467 a Remove: - the bolts (6) from the bulkhead upper heat shield, - the bulkhead upper heat shield, - the connecting hose (see 19B, Exhaust, Connec- 135708 ting hose: Removal - Refitting, page 19B-60) , a Remove: - the catalytic converter (see 19B, Exhaust, Cataly- - the bolts (4) from the relay bearing support,...
  • Page 452 TURBOCHARGING Turbocharger: Removal - Refitting 134635 138084 a Remove the bolt (7) from the turbocharger retaining a Remove the intercooler air inlet pipe retaining bolts bracket. (9) . a Move the intercooler air outlet pipe to one side. 135707 a Loosen the air filter unit air outlet pipe clip (10) on the air filter unit end.
  • Page 453 TURBOCHARGING Turbocharger: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 124751 a Undo the clip (11) for the air pipe at the outlet of the 21933 air filter box on the turbocharger side. a Remove the turbocharger lower nuts (14) . 136954 a Disconnect the connector (12) from the turbochar- 124130...
  • Page 454 TURBOCHARGING Turbocharger: Removal - Refitting REFITTING - a new turbocharger oil return pipe to the turbochar- ger, - the oil return pipe retaining bolts to the turbochar- I - REFITTING PREPARATION OPERATION ger, a parts always to be replaced: seal between ex- - the turbocharger cooling duct, haust manifold and turbocharger (10,09,01,07).
  • Page 455 TURBOCHARGING Turbocharger: Removal - Refitting a Remove the tools (Ms. 583) from the turbocharger a Refit: cooling hoses. - the scoop under the scuttle panel grille (see Scoop a Refit: under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the turbocharger oil pipes (see 12B, Turbochar- - the scuttle panel grille (see Scuttle panel grille: ging, Turbocharger oil pipe: Removal - Refit-...
  • Page 456 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 836 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm turbocharger studs on 9 N.m the exhaust manifold turbocharger stud on 9 N.m the turbocharger 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 457 TURBOCHARGING Turbocharger: Removal - Refitting K9K, and 836 a Use ABRASIVE PADS to clean the joint faces: - the exhaust manifold, - of the turbocharger if reused. a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) and CLEAN CLOTHS to clean and degrease the joint faces: - the exhaust manifold,...
  • Page 458 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 Essential special tooling WARNING Mot. 1566 Spanner for removing high Ensure that no foreign bodies enter the turbine or pressure pipes. compressor during the refitting operation. Mot. 1746 Offset spanner for tightening Check that the turbocharger oil return pipe is not high pressure pump pipes.
  • Page 459 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 a Disconnect the air filter unit air outlet pipe from the air filter unit. K9K, and 830 136639 a Undo the air filter unit air outlet pipe clip (4) from the 135880 a Disconnect the oil vapour rebreathing pipe from the turbocharger.
  • Page 460 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 830 K9K, and 832 136643 a Remove the turbocharger oil supply pipe hollow bolt 135487 (5) . a Remove the turbocharger oil supply pipe hollow bolt a Loosen the nut (6) for the turbocharger oil supply (5) .
  • Page 461 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 a Refit a new hollow bolt for the turbocharger oil sup- a Start the engine. ply pipe bolt on the turbocharger. a Let the engine idle then depress the accelerator se- a Tighten to torque: veral times with no load.
  • Page 462 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 830 K9K, and 832 135844 135843 136641 135488 a Remove the turbocharger oil return pipe bolts (1) . a Remove the turbocharger oil return pipe bolts (1) .
  • Page 463 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K, and 830 or 832 REFITTING THE TURBOCHARGER OIL RETURN PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil pipe seal (10,09,03,05). a Lubricate the new turbocharger oil return pipe O-ring with clean engine oil.
  • Page 464 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm turbocharger oil supply 44 N.m pipe hollow bolt on the cylinder block turbocharger oil supply 12 N.m pipe hollow bolt on the turbocharger turbocharger oil return 11 N.m pipe bolts on the turbo-...
  • Page 465 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Remove: REFITTING THE TURBOCHARGER OIL SUPPLY PIPE - the engine undertray bolts, - the engine undertray. I - REFITTING OPERATION FOR PART CONCERNED a Refit the turbocharger oil supply pipe. a Fit without tightening: - the turbocharger oil supply pipe hollow bolt onto the cylinder block, - the turbocharger oil supply pipe hollow bolt to the...
  • Page 466 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING THE TURBOCHARGER OIL CONCERNED RETURN PIPE I - REFITTING PREPARATION OPERATION a Always replace: - the turbocharger oil return pipe seal on the cylinder block, - the turbocharger oil return pipe seal on the turbo- charger.
  • Page 467 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting Essential special tooling Note: Ms. 583 Hose clamp pliers. This procedure deals with removing and refitting the Mot. 1448 Long nose pliers for hose turbocharger oil supply pipe and the turbocharger clips. oil return pipe. REMOVING THE TURBOCHARGER OIL Tightening torquesm SUPPLY PIPE...
  • Page 468 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting - the exhaust connecting hose (see 19B, Exhaust, Connecting hose: Removal - Refitting, page 19B-60) , - the catalytic converter (see 19B, Exhaust, Cataly- tic converter: Removal - Refitting, page 19B-17) 121264 a Remove: - the hollow bolts (2) from the cooling pipe on the tur- bocharger, - the turbocharger cooling pipe.
  • Page 469 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING THE TURBOCHARGER OIL CONCERNED SUPPLY PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil pipe seal (10,09,03,05). a parts always to be replaced: turbocharger rigid cooling pipe seal (10,09,01,09).
  • Page 470 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting a Tighten to torque: a Connect the battery (see Battery : Removal - Refit- ting) (80A, Battery). - the hollow bolts of the turbocharger cooling a Top up the coolant and carry out the bleed operation pipe on the turbocharger (27 N.m), (see 19A, Cooling, Cooling circuit: Draining - Re- - the bolt for the turbocharger oil pipe heat shield...
  • Page 471 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting - the catalytic converter (see 19B, Exhaust, Cataly- II - OPERATION FOR REMOVAL OF PART tic converter: Removal - Refitting, page 19B-17) CONCERNED 120230 120228 a Remove: a Remove: - the turbocharger oil return pipe bolts (8) on the tur- - the nuts (7) from the starter heat shield, bocharger, - the starter heat shield.
  • Page 472 TURBOCHARGING Turbocharger oil pipe: Removal - Refitting II - REFITTING OPERATION FOR PART - the engine undertray, CONCERNED - the engine cover. a Fit the turbocharger oil return pipe, first positioning it a Connect the battery (see Battery : Removal - Refit- in the cylinder block.
  • Page 473 TURBOCHARGING Intercooler: Removal - Refitting F4R or F9Q or K9K 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 front wheels (see Wheel: Removal - Refitting)
  • Page 474 TURBOCHARGING Intercooler: Removal - Refitting F4R or F9Q or K9K 135794 135797 a Remove: a Remove: - the clip (3) on the intercooler air outlet pipe, - the clip (5) on the intercooler air outlet pipe, - the air pipe at the intercooler outlet.
  • Page 475 TURBOCHARGING Intercooler: Removal - Refitting F4R or F9Q or K9K a Remove: II - REFITTING OPERATION FOR PART CONCERNED - the intercooler air inlet pipe seal, a Refit: - the intercooler air outlet pipe seal. - the intercooler, - a new seal to the intercooler air outlet pipe, - a new seal to the intercooler air inlet pipe.
  • Page 476 TURBOCHARGING Intercooler: Removal - Refitting F4R or F9Q or K9K - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the engine undertray, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
  • Page 477 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting K9K, and 830 Note: This procedure describes removing and refitting the turbocharger air outlet pipe and the intercooler air inlet pipe. REMOVING THE TURBOCHARGER AIR OUTLET PIPE I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 478 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting REMOVING THE INTERCOOLER AIR INLET PIPE I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the turbocharger air outlet pipe, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting)
  • Page 479 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting III - FINAL OPERATION a Refit: - the front right-hand bumper support (see Front bumper support: Removal - Refitting) (42A, Front upper structure), - the right-hand headlight (see Front headlight: Re- moval - Refitting) (80B, Headlights), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the engine undertray,...
  • Page 480 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting Tightening torquesm turbocharger air inlet 8 N.m pipe bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). 135636 a Remove: a Undo the clips (2) for the air filter unit air outlet pipe.
  • Page 481 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting - the turbocharger air inlet pipe. II - OPERATION FOR REMOVAL OF PART CONCERNED 135639 a Loosen the bolt (4) of the intermediate air pipe between the air filter unit and the turbocharger on the turbocharger air inlet pipe.
  • Page 482 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting III - FINAL OPERATION a Fit: - the turbocharger air inlet pipe equipped with a new seal, - the intermediate air pipe between the air filter unit and the turbocharger. a Lubricate the seal between the turbocharger air inlet pipe and the intermediate air pipe between the air fil- ter unit with engine oil.
  • Page 483 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting Tightening torquesm intercooler air inlet pipe 6 N.m clip 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 cover, - the battery cover, - the petrol injection computer cover,...
  • Page 484 TURBOCHARGING Intercooler air inlet pipe: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger air cooler air inlet pipe seal (10,09,04,04). II - REFITTING OPERATION FOR PART CONCERNED a Fit the intercooler air inlet pipe equipped with a new seal.
  • Page 485 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting Tightening torquesm clip of the turbocharger 5 N.m outlet exhaust gas duct (initial torque) bolts on the bracket of 44 N.m the turbocharger outlet exhaust gas duct clip of the turbocharger 20 N.m outlet exhaust gas duct REMOVAL...
  • Page 486 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting - the bracket from the turbocharger outlet exhaust gas duct. 135632 a Remove: 137465 - the nuts (4) from the exhaust flange, a Remove: - the exhaust flange seal. - the clip (6) from the turbocharger outlet exhaust a Move the exhaust pipe to one side.
  • Page 487 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting a Torque tighten the clip of the turbocharger outlet exhaust gas duct (initial torque) (5 N.m). Note: The clip sold as a spare part is different from the original clip. Only the clip sold as a spare part enables torque tightening under the conditions of tightening in After-Sales.
  • Page 488 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting K9K, and 836 Tightening torquesm turbocharger outlet XX N.m exhaust gas duct bolts exhaust bracket bolts XX Nm exhaust fuel injector XX N.m cooler bolts turbocharger outlet XX N.m exhaust gas duct stay bolts IMPORTANT Wear protective gloves during the operation.
  • Page 489 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting K9K, and 836 100000-1 100000-1 a Remove the turbocharger air inlet pipe bolt from the a Remove: exhaust gas recirculation assembly (4) . - the turbocharger air inlet pipe bolts (6) from the tur- bocharger, - the turbocharger air inlet pipe.
  • Page 490 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting K9K, and 836 100000-1 100000-1 a Disconnect: a Remove the bolts (11) from the exhaust bracket. a Move the exhaust pipe to one side. - the exhaust fuel injector connector (8) , - the exhaust fuel injector fuel supply pipe union from the exhaust fuel injector (9) .
  • Page 491 TURBOCHARGING Turbocharger outlet exhaust gas duct: Removal - Refitting K9K, and 836 REFITTING - the exhaust fuel injector cooler. a Torque tighten the exhaust fuel injector cooler bolts (XX N.m). I - REFITTING PREPARATION OPERATION a Remove the blanking plug: a parts always to be replaced: Turbocharger heat shield (10,09,01,02).
  • Page 492 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the engine undertray bolts, - the engine undertray. II - OPERATION FOR REMOVAL OF PART CONCERNED 135406...
  • Page 493 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 115068 a Remove the intercooler air outlet pipe seal at the in- tercooler end using tweezers. 115069 REFITTING Note: Check that the intercooler air outlet pipe seal at I - REFITTING PREPARATION OPERATION the intercooler end is fitted the correct way a parts always to be replaced: turbocharger air...
  • Page 494 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting III - FINAL OPERATION a Refit: - the engine undertray, - the engine cover. 12B-58...
  • Page 495 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting Tightening torquesm intercooler air outlet 6 Nm pipe clip REMOVAL I - REMOVAL PREPARATION OPERATION 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 section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting)
  • Page 496 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 135648 a Undo the clip (3) of the intercooler air outlet pipe on the damper valve. a Disconnect the intercooler air outlet pipe from the damper valve.
  • Page 497 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting a Remove the intercooler air outlet pipe. - the engine undertray, - the engine cover. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Intercooler air out- let pipe (10,09,04,03). II - REFITTING OPERATION FOR PART CONCERNED a Fit an air pipe to the outlet of the new intercooler.
  • Page 498 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting 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 cover, - the petrol injection computer cover, - the engine undertray bolts, - the engine undertray, - the front wheels (see Wheel: Removal - Refitting)
  • Page 499 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting 135296 135796 a Remove the lower bolts (4) from the front end panel. a Remove the intercooler outlet pipe bolts (8) from the throttle unit. a Slightly tilt the front panel towards the front of the ve- hicle.
  • Page 500 TURBOCHARGING Intercooler air outlet pipe: Removal - Refitting - the engine wiring channel bolts, - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- nisms), - the frontal impact cross member (see Front im- pact cross member: Removal - Refitting) (41A, Front lower structure), - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper...
  • Page 501 FUEL SUPPLY Manual priming pump: Removal - Refitting F9Q or K9K REMOVAL IMPORTANT OPERATION FOR REMOVAL OF PART To avoid all risk of damage to the systems, apply CONCERNED the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 502 FUEL SUPPLY Manual priming pump: Removal - Refitting F9Q or K9K 136605 a Unclip the manual priming pump from the expansion bottle at (3) . a Remove the manual priming pump. REFITTING REFITTING OPERATION FOR PART CONCERNED a Fit the manual priming pump. a Clip the manual priming pump onto the expansion bottle.
  • Page 503 FUEL SUPPLY Fuel filter: Removal - Refitting F9Q or K9K II - REMOVAL OF PART CONCERNED IMPORTANT Consult the safety and cleanliness advice and ope- ration recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) . WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run.
  • Page 504 FUEL SUPPLY Fuel filter: Removal - Refitting F9Q or K9K Bleeding the circuit a Fit a pipe to the injector rail fuel supply union. a Push the pipe onto the injector rail fuel supply union. a Prime the fuel supply circuit using the manual primi- ng pump until fuel runs into the container.
  • Page 505 FUEL SUPPLY Fuel filter: Removal - Refitting F4R or K4M a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects II - OPERATION FOR REMOVAL OF PART...
  • Page 506 FUEL SUPPLY Fuel filter: Removal - Refitting F4R or K4M 132676 a Unclip (2) the fuel filter at (3) . a Remove the fuel filter from the fuel tank. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the fuel filter.

  • Page 507: Fuel Pressure: Check

    FUEL SUPPLY Fuel pressure: check F4R or K4M CHECKING Essential special tooling Mot. 1311-01 Fuel pressure test kit. I - PREPARATION OPERATION FOR CHECK Mot. 1311-08 Union for measuring fuel pressure. IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects...
  • Page 508 FUEL SUPPLY Fuel pressure: check F4R or K4M II - TEST OPERATION 137774 137773 a Disconnect fuel supply pipe union on the injector rail. a Disconnect fuel supply pipe union on the injector rail. a Unclip the fuel pipe from the right-hand suspended a Connect: engine mounting.
  • Page 509 FUEL SUPPLY Fuel pressure: check F4R or K4M III - FINAL OPERATION a Disconnect the « T » union (Mot. 1311-08) from the injector rail. a Separate the test tool (Mot. 1311-01) from the « T » union. a Connect the fuel supply pipe union on the injector rail.
  • Page 510 FUEL SUPPLY Fuel flow: check F4R or K4M Essential special tooling Mot. 1311-01 Fuel pressure test kit. Mot. 1311-08 Union for measuring fuel pressure. Essential equipment graduated measuring cylinder IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects...
  • Page 511 FUEL SUPPLY Fuel flow: check F4R or K4M 137771 138709 a Unclip the fuel pipe from the right-hand suspended a Unclip the fuel pipe from the right-hand suspended engine mounting. engine mounting. a Connect: a Disconnect the fuel supply union on the injector rail.
  • Page 512 FUEL SUPPLY Fuel flow: check F4R or K4M a Separate the checking tool (Mot. 1311-01) from the « T » union (Mot. 1311-08). K4M or M4R a Clip the fuel pipe on the right-hand suspended engi- ne mounting. a Refit the engine cover.

  • Page 513: Diesel Injection: Precautions For Repair

    DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K I - RISKS RELATING TO CONTAMINATION A set of blanking plugs should be used once only and used plugs must be discarded: once used, the plugs The high-pressure direct injection system is highly sen- are soiled and cleaning them is not sufficient to make sitive to contamination.
  • Page 514 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K II - ADVICE TO BE FOLLOWED BEFORE ANY After opening the fuel circuit, the use of brushes, clea- OPERATION ning agents, air blow guns, rifle-type brushes or stan- dard cloths is strictly prohibited: These items are likely 1) Carry out the work in a clean working area and take to allow impurities to enter the system.
  • Page 515 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K WARNING To prevent impurities from entering, once the fuel circuit is opened, it must not be blasted with com- pressed air. Use cleaning cloths only, if necessary. 2 - Using the brake cleaner Clear the access to the unions that need opening, fol- lowing the work procedures specific to the vehicle (see the relevant Workshop Repair Manual).
  • Page 516 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K 13B-4...
  • Page 517 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K Set of plugs: 13B-5...
  • Page 518 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K 16148 13B-6...
  • Page 519 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K 13B-7...
  • Page 520 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K Set of plugs for DELPHI injection: 13B-8...
  • Page 521 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K 20977 13B-9...
  • Page 522 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K Set of plugs for SIEMENS injection: 13B-10...
  • Page 523 DIESEL INJECTION Diesel injection: Precautions for repair F9Q or K9K 113430 13B-11...

  • Page 524: Diesel Injection: List And Location Of Components

    DIESEL INJECTION Diesel injection: List and location of components K9K, and 832 134042 134494 134707 Manual priming pump High pressure pump 13B-12...
  • Page 525 DIESEL INJECTION Diesel injection: List and location of components K9K, and 832 134705 121888 Exhaust gas recirculation sole- Camshaft position sensor noid valve 134215 135008 Turbocharging air pressure sen- Diesel injectors 13B-13...
  • Page 526 DIESEL INJECTION Diesel injection: List and location of components K9K, and 832 134041 134212 Air flowmeter Injection computer 135721 Protection and switching unit 114213 (10) Coolant temperature sensor 13B-14...
  • Page 527 DIESEL INJECTION Diesel injection: List and location of components K9K, and 832 135007 134043 (11) Rail pressure sensor (13) Air inlet valve 134706 133985 (12) Fuel temperature sensor (14) Fuel filter 13B-15...
  • Page 528 DIESEL INJECTION Diesel injection: List and location of components K9K, and 832 134706 135505 (15) Flow regulation solenoid valve (18) Pre-postheating unit (16) Pressure regulation solenoid valve 123824 (17) Crankshaft position sensor 13B-16...
  • Page 529 DIESEL INJECTION Diesel injection computer: Removal - Refitting F9Q or K9K II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery). 134212 a Disconnect the connectors (2) from the diesel injec- tion computer.
  • Page 530 DIESEL INJECTION Diesel injection computer: Removal - Refitting F9Q or K9K - go to repair mode, - display the « After repair procedure » for the selec- ted computer, - carry out the operations described in the « After re- pair procedure »...
  • Page 531 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 832 or 834 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 532 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 832 or 834 REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: camshaft sensor seal (11,11,04,02). a Lubricate the camshaft position sensor seal with new engine oil. II - REFITTING OPERATION FOR PART CONCERNED a Refit:...
  • Page 533 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 830 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 engine undertray bolts,...
  • Page 534 DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K, and 830 III - FINAL OPERATION a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) , - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille:...
  • Page 535 DIESEL INJECTION Camshaft position sensor: Removal - Refitting Tightening torquesm bypass control 10 N.m solenoid valve bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. 135989 a Remove the bolts (4) from the EGR bypass control solenoid valve.
  • Page 536 DIESEL INJECTION Camshaft position sensor: Removal - Refitting 135991 a Remove: - the bolt (6) from the camshaft position sensor, - the camshaft position sensor. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the camshaft position sensor. a Connect the camshaft position sensor connector. II - FINAL OPERATION a Refit the EGR bypass control solenoid valve.
  • Page 537 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting REMOVAL II - FINAL OPERATION a Refit the engine undertray. 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.
  • Page 538 DIESEL INJECTION Crankshaft position sensor: Removal - Refitting REMOVAL II - FINAL OPERATION a Refit the engine undertray. a Connect the battery (see Battery : Removal - Refit- I - REMOVAL PREPARATION OPERATION ting) (80A, Battery). a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 539 DIESEL INJECTION Leak flow from high-pressure pump: Check K9K, and 832 a Disconnect the intercooler air outlet pipe from the Essential special tooling damper valve. a Separate the intercooler air outlet pipe slightly from Mot. 1771 Kit for measuring SIEMENS injector leak rate.
  • Page 540 DIESEL INJECTION Leak flow from high-pressure pump: Check K9K, and 832 a Connect the 8 mm diameter offset union fitted with its hose contained in the tool (Mot. 1771) to the high pressure pump union. a Immerse this hose in the 500 ml graduated measu- ring cylinder.
  • Page 541 DIESEL INJECTION Leak flow from high-pressure pump: Check K9K, and 832 a Connect the diesel injector fuel return rail to the high pressure pump. a Refit: - the injector rail protector cover, - the injector rail protector cover nut, - the injector rail protector cover bolt. a Clip on the injector rail protector cover.
  • Page 542 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 832 - the engine undertray, Essential special tooling - the accessories belt (see 11A, Top and front of Mot. 1768 Injection pump-pulley extrac- engine, Accessories belt: Removal - Refitting, tor claws. page 11A-7) , - the crankshaft accessories pulley (see 11A, Top Mot.
  • Page 543 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 832 - the turbocharger air outlet pipe (see 12B, Turbo- charging, Intercooler air inlet pipe: Removal - Refitting, page 12B-41) , - the high pressure pipe between the high pressure pump and the injector rail (see 13B, Diesel injec- tion, High-pressure pipe between the pump and rail: Removal - Refitting, page 13B-71) .
  • Page 544 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 832 a Fit a suitable blanking plug on the opening of: REFITTING - the diesel injector fuel return rail union, I - REFITTING PREPARATION OPERATION - the high pressure pump. If replacing the high pressure pump II - OPERATION FOR REMOVAL OF PART CONCERNED...
  • Page 545 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 832 II - REFITTING OPERATION FOR PART CONCERNED a Refit the high pressure pump. a Torque tighten the high pressure pump bolts (23 N.m). III - FINAL OPERATION a Remove the blanking plugs from the opening of: - the high pressure pump, - the diesel injector fuel return rail union.
  • Page 546 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 832 - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the engine undertray, - the accessories belt (see 11A, Top and front of...
  • Page 547 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 - the front right-hand wheel (see Wheel: Removal - Essential special tooling Refitting) (35A, Wheels and tyres), Mot. 1430 Set of 5 crankshaft and cams- - the front section of the front right-hand wheel arch haft pulley timing pins.
  • Page 548 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 136654 136658 a Remove: - the right-hand suspended engine mounting support bolts (3) , - the right-hand pendulum suspension support. 136656 a Unclip the upper timing cover at (1) . a Remove: - the bolt (2) from the upper timing cover, - the upper timing cover.
  • Page 549 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 WARNING T o avoid any corrosion or damage, protect the areas on which fuel is likely to run. 135872 a Disconnect the diesel injector fuel return rail from the high pressure pump (6) .
  • Page 550 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 II - OPERATION FOR REMOVAL OF PART CONCERNED 19655 a Insert the tool (Mot. 1430) (9) in the hole of the 23168 camshaft pulley hub and the hole of the cylinder a Fit the (Mot.
  • Page 551 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 23169 136623 a Remove the high pressure pump bolts (13) . a Gradually screw the pushrod of the (Mot. 1525) until Note: the high pressure pump becomes detached. If necessary, remove the spacer at the end pus- hrod of the (Mot.
  • Page 552 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 II - REFITTING OPERATION FOR PART III - FINAL OPERATION CONCERNED a Refit the high pressure pump on the cylinder head by inserting it into the high pressure pump pulley. Note: Check that the high pressure pump shaft is cor- rectly orientated in relation to the high pressure...
  • Page 553 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 830 - the camshaft position sensor (see 13B, Diesel in- jection, Camshaft position sensor: Removal - Refitting, page 13B-19) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) , - the scoop under the scuttle panel grille (see Scoop...
  • Page 554 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 a Remove: Essential special tooling - the engine cover, Mot. 1525 Extractor for timing gear with - the front right-hand wheel (see Wheel: Removal - tapered hub. Refitting) (35A, Wheels and tyres), Mot.
  • Page 555 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 134496 136746 a Remove: a Pull the clip (1) on the intermediate air pipe between the turbocharger and the intercooler. - the alternator protector bolt (3) . a Remove: - the alternator protector.
  • Page 556 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 136618 136742 a Disconnect the fuel supply pipe union (4) from the a Remove the alternator upper bolt (7) . high pressure pump. a Loosen the alternator lower bolt (8) . a Fit a suitable blanking plug on: a Tilt the alternator forward.
  • Page 557 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 136616 136615 a Remove: a Disconnect the injector rail pressure sensor connec- tor (11) . - the dipstick, a Unclip the diesel drain pipe (12) from the injector rail - the dipstick guide bolts (10) .
  • Page 558 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 136613 136740 a Disconnect the diesel injector fuel return rail from the a Remove: Venturi at (15) . - the nuts (18) from the injector rail protector, a Place a suitable blanking plug on the Venturi ope- - the injector rail protector.
  • Page 559 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 - the fuel supply pipe union protection bracket, - the high pressure pump REFITTING I - REFITTING PREPARATION OPERATION a Always replace the seal on the intermediate air pipe between the turbocharger and the intercooler.
  • Page 560 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 a Remove the blanking plugs from: II - REFITTING OPERATION FOR PART CONCERNED - the opening of the fuel supply solenoid valve of the exhaust fuel injector, - the opening of the high pressure pump, - the pipe openings of the exhaust fuel injector fuel supply solenoid valve.
  • Page 561 DIESEL INJECTION High pressure pump: Removal - Refitting K9K, and 834 a Refit: - display the "After repair procedure" for the selected computer, - a new seal on the intermediate air pipe between the turbocharger and the intercooler, - select "High pressure pump" in the "List of compo- nents stored by this computer"...
  • Page 562 DIESEL INJECTION High pressure pump: Removal - Refitting - the crankshaft accessories pulley (see 11A, Top Essential special tooling and front of engine, Crankshaft accessories pulley: Removal - Refitting, page 11A-15) , Mot. 1668 Locking high pressure pump sprocket. - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Mot.
  • Page 563 DIESEL INJECTION High pressure pump: Removal - Refitting 135548 136231 a Remove the bolts (3) from the high pressure pump rear support. WARNING T o prevent impurities from entering the circuit, place protective plugs on all fuel circuit compo- nents exposed to the open air. a Disconnect the supply pipe union (1) from the high pressure pump.
  • Page 564 DIESEL INJECTION High pressure pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the tool (Mot. 1525) equipped with the tool (Mot. CONCERNED 1525-03), a Fit the "high pressure pump support - high pressure - the (Mot. 1668). pump"...
  • Page 565 DIESEL INJECTION High pressure pump: Removal - Refitting a Connect the connector to the regulator on the high pressure pump. a Remove the blanking plugs. a Connect the supply pipe union on the high pressure pump. a Refit: - the high pressure pipe between the pump and the rail (see 13B, Diesel injection, High-pressure pipe between the pump and rail: Removal - Re- fitting, page 13B-71) ,...
  • Page 566 DIESEL INJECTION Fuel flow actuator: Removal - Refitting K9K, and 830 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 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 567 DIESEL INJECTION Fuel flow actuator: Removal - Refitting K9K, and 830 a Make sure that no impurities enter the high pressure pump when the fuel flow actuator is removed. WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system.
  • Page 568 DIESEL INJECTION Fuel flow actuator: Removal - Refitting K9K, and 834 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 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 569 DIESEL INJECTION Fuel flow actuator: Removal - Refitting K9K, and 834 137860 a Remove: - the flow actuator bolts (3) , - the flow actuator from the high pressure pump (by hand with small tugs and successive turns). REFITTING I - REFITTING PREPARATION OPERATION Note: Do not lubricate the seals with grease or old die- sel fuel.
  • Page 570 DIESEL INJECTION Venturi: Removal - Refitting K9K, and 830 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm Venturi bolt 5.5 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 571 DIESEL INJECTION Venturi: Removal - Refitting K9K, and 830 a Remove the blanking plugs from: - the opening of the diesel fuel return pipe union, - the Venturi opening. a Connect the diesel return pipe to the Venturi. II - FINAL OPERATION a Refit the turbocharger air outlet pipe (see 12B, Tur- bocharging, Intercooler air inlet pipe: Removal - Refitting, page 12B-41) .
  • Page 572 DIESEL INJECTION Venturi: Removal - Refitting K9K, and 834 Tightening torquesm Venturi bolt 5.5 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 573 DIESEL INJECTION Venturi: Removal - Refitting K9K, and 834 II - OPERATION FOR REMOVAL OF PART - the diesel fuel return pipe union to the Venturi. CONCERNED a Refit the engine cover. 137856 a Remove: - the Venturi bolt (3) , - the Venturi from the high pressure pump (with small tugs and successive turns).
  • Page 574 DIESEL INJECTION Diesel return pipe: Removal - Refitting a The diesel return pipe is not sold separately by the Parts Department; to replace it, it is necessary to re- place the fuel temperature sensor (see 13B, Diesel injection, Fuel temperature sensor: Removal - Refitting, page 13B-118) .
  • Page 575 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting 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 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 576 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting III - FINAL OPERATION a Refit: - the injector rail protector (see 13B, Diesel injec- tion, Injector rail protector: Removal - Refitting, page 13B-70) , - the engine cover. a Connect the battery (see Battery : Removal - Refit- ting) (80A, Battery).
  • Page 577 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting K9K, and 832 Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 578 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting K9K, and 832 a Unclip the diesel fuel injector wiring from the rocker cover. 121889 a Disconnect: - the damper valve connector (4) , - the connector (5) from the camshaft position sen- sor.
  • Page 579 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting K9K, and 832 a Fit a suitable blanking plug to: II - OPERATION FOR REMOVAL OF PART CONCERNED - the opening of the diesel injector fuel return rail, - the high pressure pump opening. First step for removing the fuel return rail unions from the diesel injectors 111749...
  • Page 580 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting K9K, and 832 Second step for removing the fuel return rail unions from the diesel injectors 120940 Note: With sufficient force applied to the clip while 134700 pressing continuously with the screwdriver, the a Unclip the diesel injector fuel return rail from the roc- diesel fuel injector fuel return rail unions will ker cover at (16) .
  • Page 581 DIESEL INJECTION Diesel injector fuel return rail: Removal - Refitting K9K, and 832 a Lubricate the unions of the diesel injector fuel return a Clip the wiring for the damper valve onto the injector rail using SILICONE-FREE LUBRICANT (see Ve- rail protector cover plate.
  • Page 582 DIESEL INJECTION Injector rail protector: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery). a Remove the front engine cover. II - OPERATION FOR REMOVAL OF PART CONCERNED 133986 a Remove: - the bolts (5) from the injector rail protector,...
  • Page 583 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting Essential special tooling Mot. 1566 Spanner for removing high pressure pipes. Tightening torquesm nut on the high pressure 27 N.m pipe between the pump and the rail at the high pressure pump end nut on the high pressure 37 N.m...
  • Page 584 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: High-pressure pipe between the pump and rail (11,05,03,02). 135529 a Clean the high pressure pipe nuts between the pump and the rail (see 13B, Diesel injection, Die- sel injection: Precautions for repair, page 13B-1) 20960...
  • Page 585 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting a Refit the high pressure pipe between the pump and the injector rail. a Tighten to torque: - the nut on the high pressure pipe between the pump and the rail at the high pressure pump end (27 N.m) using the tool (Mot.
  • Page 586 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 830 Essential special tooling Mot. 1746 Offset spanner for tightening high pressure pump pipes. Tightening torquesm nuts for the high pres- 28 N.m sure pipe between the high pressure pump and the injector rail injector rail nuts...
  • Page 587 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 830 135874 136625 a Disconnect: a Remove: - the connector (4) from the injector rail pressure - the nuts (9) from the injector rail protector, sensor, - the injector rail protector.
  • Page 588 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 830 REFITTING I - REFITTING PREPARATION OPERATION 135871 WARNING 20960 Always hold the intermediate injector union in place with a wrench when loosening the high pressure pipes. WARNING Do not damage the injector return nozzle.
  • Page 589 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 830 a Fit the new high pressure pipe between the injector rail and the high pressure pump. a Screw on the nuts for the high pressure pipe between the high pressure pump and the injector rail by hand without tightening, starting at the injector rail end.
  • Page 590 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 832 Essential special tooling Mot. 1566 Spanner for removing high pressure pipes. Mot. 1746 Offset spanner for tightening high pressure pump pipes. Tightening torquesm nuts for the high pres- 28 N.m sure pipe between the high pressure pump and...
  • Page 591 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 832 121889 134703 a Remove: a Disconnect: - the dipstick, - the damper valve connector (4) , - the dipstick guide bolts (20) . - the connector (5) from the camshaft position sen- a Move aside the dipstick guide.
  • Page 592 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 832 134999 134706 a Unclip the diesel injector wiring from the rocker co- a Unclip: ver. - the alternator wiring (21) from the injector rail pro- a Disconnect: tector, - all heater plug connectors,...
  • Page 593 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 832 - the injector rail protector bolt (18) , REFITTING - the injector rail protector. I - REFITTING PREPARATION OPERATION II - OPERATION FOR REMOVAL OF PART CONCERNED a Clean the unions of the high pressure pipe between the high pressure pump and the injector rail (see...
  • Page 594 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 832 a Screw on by hand, without tightening, until contact is a Connect the turbocharger pressure sensor connec- made with the nuts of the high pressure pipe tor.
  • Page 595 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 834 Essential special tooling Mot. 1566 Spanner for removing high pressure pipes. Tightening torquesm nut for the high pressure 28 N.m pipe between the high pressure pump and the injector rail on the high pressure pump nut for the high pressure...
  • Page 596 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 834 137184 137185 a Disconnect the turbocharger pressure sensor con- a Unclip the wiring for the damper valve from the injec- nector (5) . tor rail protector at (8) . a Unclip the cable for the turbocharging pressure sen- a Unclip the injector rail protector cover at (9) .
  • Page 597 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 834 REFITTING I - REFITTING PREPARATION OPERATION 137181 a Remove: - the nut (11) of the high pressure pipe between the high pressure pump and the injector rail from the high pressure pump, - the nut (12) of the high pressure pipe between the high pressure pump and the injector rail from the...
  • Page 598 DIESEL INJECTION High-pressure pipe between the pump and rail: Removal - Refitting K9K, and 834 a Clip the intermediate air pipe between the turbochar- II - REFITTING OPERATION FOR PART CONCERNED ger and the intercooler onto the turbocharger air out- let pipe.
  • Page 599 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1566 Spanner for removing high pressure pipes. Tightening torquesm nuts for the high pres- 27 N.m sure pipe(s) between the injector rail and the diesel injector on the...
  • Page 600 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: High-pressure pipe between the rail and injector (11,05,03,01). 111838 a Clean the nuts of the high pressure pipe(s) between the injector rail and the diesel fuel injector (see 13B, Diesel injection, Diesel injection: Precautions for repair, page 13B-1) .
  • Page 601 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting a Refit one or more new high pressure pipes between the injector rail and the diesel fuel injector. a Using the (Mot. 1566), tighten to torque: - the nuts for the high pressure pipe(s) between the injector rail and the diesel injector on the in- jector side (27 N.m), - the nuts for the high pressure pipe(s) between...
  • Page 602 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 Essential special tooling Mot. 1566 Spanner for removing high pressure pipes. Mot. 1746 Offset spanner for tightening high pressure pump pipes. Tightening torquesm nuts for the high pres- 28 N.m sure pipe(s) between the injector rail and the...
  • Page 603 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 - the dipstick, - the dipstick guide tube bolts. a Move aside the dipstick guide. a Clean the high pressure pipe unions between the rail and the injectors (see 13B, Diesel injection, Diesel injection: Precautions for repair, page 13B-1) .
  • Page 604 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 a Unclip: - the nut(s) for the high pressure pipe(s) between the injector rail and the diesel fuel injector(s) on the in- - the alternator wiring from the injector rail protector, jector side, - the coolant hose from the injection pump protector - the high pressure pipe(s) between the injector rail...
  • Page 605 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 135006 1327 a Loosen the injector rail nuts (19) . WARNING Always hold the intermediate injector union in place with a wrench when loosening the high pressure pipes.
  • Page 606 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 REFITTING II - REFITTING OPERATION FOR PART CONCERNED I - REFITTING PREPARATION OPERATION 1 - Refitting one, two or three high pressure pipes a Remove the blanking plug - the injector rail opening(s), - the opening of the diesel injector(s).
  • Page 607 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 832 - the connector for the fuel flow regulation solenoid valve, - the connector for the fuel pressure regulation sole- noid valve, - the connector for each diesel injector, - all heater plug connectors.
  • Page 608 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 830 Essential special tooling Mot. 1566 Spanner for removing high pressure pipes. Mot. 1746 Offset spanner for tightening high pressure pump pipes. Tightening torquesm nuts for the high pres- 28 N.m sure pipe(s) between the injector rail and the...
  • Page 609 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 830 a Clean the high pressure pipe unions between the rail - the high pressure pipes between the injector rail and the diesel fuel injectors (see 13B, Diesel injec- and the diesel injectors concerned.
  • Page 610 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 830 136625 1327 a Remove: - the nuts (9) from the injector rail protector, WARNING - the injector rail protector. Always hold the intermediate injector union in place with a wrench when loosening the high pressure pipes.
  • Page 611 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 830 REFITTING II - REFITTING OPERATION FOR PART CONCERNED I - REFITTING PREPARATION OPERATION 1 - Refitting one, two or three high pressure pipes a Remove the blanking plugs from: - the injector rail opening(s), - the opening of the diesel injector(s).
  • Page 612 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 830 III - FINAL OPERATION a Refit: - the injector rail protector cover, - the injection rail protector cover bolt. a Clip on the injector rail protector cover plate. a Fit the dipstick guide tube.
  • Page 613 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 REMOVAL Essential special tooling Mot. 1746 Offset spanner for tightening I - REMOVAL PREPARATION OPERATION high pressure pump pipes. a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery).
  • Page 614 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 137184 137185 a Disconnect the turbocharger pressure sensor con- a Unclip the wiring for the damper valve from the injec- nector (5) . tor rail at (8) . a Unclip the cable for the turbocharging pressure sen- a Unclip the injector rail protector cover at (9) .
  • Page 615 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - Removing one, two or three high pressure pipes between the injector rail and the diesel injector 137182 a Clean the nuts (13) of the high pressure pipe(s) between the injector rail and the diesel fuel injec-...
  • Page 616 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 137188 137189 a Remove: a Disconnect the injector rail pressure sensor connec- tor (16) . - the dipstick, a Unclip the diesel drain pipe from the injector rail pro- - the dipstick guide bolts (15) .
  • Page 617 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 137190 137182 a Undo the nuts (25) for the high pressure pipes a Disconnect: between the injector rail and the diesel fuel injectors. a Remove the high pressure pipes between the injec- - the connector (20) for each diesel injector, tor rail and the diesel fuel injectors.
  • Page 618 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 REFITTING II - REFITTING OPERATION FOR PART CONCERNED I - REFITTING PREPARATION OPERATION 1 - Refitting the four high pressure pipes between the injector rail and the diesel fuel injector a Refit the high pressure pipes between the injector rail and the new diesel fuel injectors.
  • Page 619 DIESEL INJECTION High-pressure pipe between the rail and injector: Removal - Refitting K9K, and 834 a Refit the dipstick. - the nut for the intermediate air pipe between the turbocharger and the intercooler, a Clip the expansion bottle lower cooling hose onto the alternator protector.
  • Page 620 DIESEL INJECTION Injector rail: Removal - Refitting - the high pressure pipes between the rail and the in- Essential special tooling jector (see 13B, Diesel injection, High-pressure pipe between the rail and injector: Removal - Mot. 1566 Spanner for removing high Refitting, page 13B-87) , pressure pipes.
  • Page 621 DIESEL INJECTION Injector rail: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: High-pressure pipe between the pump and rail (11,05,03,02). parts always to be replaced: High-pressure pipe between the rail and injector (11,05,03,01). 135575 a Remove the bolts (2) from the diesel fuel temperatu- re sensor support.
  • Page 622 DIESEL INJECTION Injector rail: Removal - Refitting a Connect the battery (see Battery : Removal - Refit- II - REFITTING OPERATION FOR PART CONCERNED ting) (80A, Battery). a Refit: - a new injector rail seal, - the injector rail lower protector, - the injector rail.
  • Page 623 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 832 II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 624 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 832 - the high pressure pipe between the high pressure pump and the injector rail (see 13B, Diesel injec- tion, High-pressure pipe between the pump and rail: Removal - Refitting, page 13B-71) , - the turbocharger air outlet pipe (see 12B, Turbo- charging, Intercooler air inlet pipe: Removal - Refitting, page 12B-41) ,...
  • Page 625 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 830 II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 626 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 830 - the high pressure pipe between the high pressure pump and the injector rail (see 13B, Diesel injec- tion, High-pressure pipe between the pump and rail: Removal - Refitting, page 13B-71) , - the turbocharger air outlet pipe (see 12B, Turbo- charging, Intercooler air inlet pipe: Removal - Refitting, page 12B-41) ,...
  • Page 627 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 834 II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 628 DIESEL INJECTION Injector rail: Removal - Refitting K9K, and 834 - display the "After repair procedure" for the selected computer, - select "Injector rail pressure sensor" in the section "List of components controlled by this computer", - carry out the operations described in the "After re- pair procedure"...
  • Page 629 DIESEL INJECTION Rail pressure sensor: Removal - Refitting 114076 a The injector rail pressure sensor (1) cannot be sepa- rated from the injector rail. a In the event of a fault on the injector rail pressure sensor, replace the « injector rail - injector rail pres- sure sensor »...
  • Page 630 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K, and 832 111747 a The fuel temperature sensor (1) cannot be sapara- ted from the diesel injector fuel return rail. a In the event of a fuel temperature sensor fault, repla- ce the «...
  • Page 631 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery). a Remove the front engine cover. 13B-119...
  • Page 632 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the union (4) of the fuel temperature sensor on the CONCERNED high pressure pump. WARNING To prevent impurities from entering the circuit, place protective plugs on all fuel circuit compo- nents exposed to the open air.
  • Page 633 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting - the diesel return pipe union, - the union of the diesel injector fuel return rail, - the fuel temperature sensor connector. III - FINAL OPERATION a Refit the engine cover. a Connect the battery (see Battery : Removal - Refit- ting) (80A, Battery).
  • Page 634 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K, and 834 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm fuel temperature sensor 15 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 635 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K, and 834 137859 a Remove the fuel temperature sensor (2) from the high pressure pump. REFITTING I - REFITTING PREPARATION OPERATION Note: Do not lubricate the seals with grease or old die- sel fuel.
  • Page 636 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K, and 830 Tightening torquesm fuel temperature sensor 15 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 637 DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K, and 830 a Make sure that no impurities enter the high pressure pump when the fuel temperature sensor is removed. WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system.
  • Page 638 DIESEL INJECTION Leak flow from injectors: Check K9K, and 832 Essential special tooling Mot. 1771 Kit for measuring SIEMENS injector leak rate. Mot. 1711 Kit for measuring injector leak rate. Essential equipment self-contained starter diagnostic tool Tightening torquesm intercooler air outlet 5.5 N.m pipe clip on the damper valve...
  • Page 639 DIESEL INJECTION Leak flow from injectors: Check K9K, and 832 111749 WARNING Ensure that the clip is not completely removed from its housing, otherwise it may be damaged 121889 when the diesel return union is removed. a Disconnect: In the case where a clip has been completely removed from its housing, remove the injector - the connector (4) from the camshaft position sen- concerned and replace the clip with a new clip...
  • Page 640 DIESEL INJECTION Leak flow from injectors: Check K9K, and 832 120940 107637 a Connect the four transparent hoses of the tool (Mot. 1771) on the diesel injectors in place of each union Note: of the diesel injector fuel return rail. With sufficient force applied to the clip while a Insert these hoses in the four graduated measuring pressing continuously with the screwdriver, the...
  • Page 641 DIESEL INJECTION Leak flow from injectors: Check K9K, and 832 a Disconnect: - the injector rail protector cover bolt. a Clip on the injector rail protector cover. - the diagnostic tool, a Fit the damper valve wiring. - the self-contained starter. a Clip the damper valve wiring onto the injector rail III - FINAL OPERATION protector cover.
  • Page 642 DIESEL INJECTION Leak flow from injectors: Check K9K, and 830 Essential special tooling Mot. 1771 Kit for measuring SIEMENS injector leak rate. Mot. 1711 Kit for measuring injector leak rate. Essential equipment self-contained starter diagnostic tool IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 643 DIESEL INJECTION Leak flow from injectors: Check K9K, and 830 a Disconnect the four transparent pipes of the tool (Mot. 1771) from the diesel injectors. a Connect the diesel injector fuel return rail unions to the diesel injectors. Note: Check that the unions of the fuel return rail are correctly connected.
  • Page 644 DIESEL INJECTION Leak flow from injectors: Check K9K, and 834 Essential special tooling Mot. 1771 Kit for measuring SIEMENS injector leak rate. Mot. 1711 Kit for measuring injector leak rate. Essential equipment self-contained starter diagnostic tool IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 645 DIESEL INJECTION Leak flow from injectors: Check K9K, and 834 137184 137185 a Disconnect the turbocharger pressure sensor con- a Unclip the damper valve wiring from the injector rail nector (5) . protector at (8) . a Unclip the turbocharger pressure sensor cable (6) a Unclip the injector rail protector cover at (9) .
  • Page 646 DIESEL INJECTION Leak flow from injectors: Check K9K, and 834 - the self-contained starter. III - FINAL OPERATION a Remove the clip from the turbocharger air outlet pi- a Move the intermediate air pipe between the turbo- charger and the intercooler away from the turbo- charger air outlet pipe.
  • Page 647 DIESEL INJECTION Leak flow from injectors: Check K9K, and 834 a Refit: - the retaining bracket of the intermediate air pipe between the turbocharger and the intercooler, - the bolt of the retaining bracket of the intermediate air pipe between the turbocharger and the intercoo- ler, - the clip of the turbocharger air outlet pipe.
  • Page 648 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 832 II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment compressed air nozzle Tightening torquesm bolt of the diesel injec- 30 N.m tor(s) IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 649 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 832 Cleaning the injector well and the injector WARNING It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner. IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion.
  • Page 650 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 832 114994 114926 a Fit a 11mm by 1/4" socket (2) (socket outer Ø = a Insert a large diameter Phillips screwdriver (Ø > 8 washer Ø) on an extension piece (3) . mm) into the well to block the opening to the com- bustion chamber.
  • Page 651 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 832 III - FINAL OPERATION a Refit: - the high pressure pipe(s) between the injector rail and the diesel injector(s) (see 13B, Diesel injec- tion, High-pressure pipe between the rail and injector: Removal - Refitting, page 13B-87) , - the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Remo-...
  • Page 652 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 830 Essential equipment open-ended spanner compressed air nozzle diagnostic tool Tightening torquesm bolts of the diesel injec- 28 N.m tor bracket IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec-...
  • Page 653 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 830 II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION 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 654 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 830 a Wipe using CLEANING RAGS (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products). IMPORTANT Wear leaktight gloves (Nitrile type) for this opera- tion. 114926 a Insert a large diameter Phillips screwdriver (Ø > 8 mm) into the well to block the opening to the com- bustion chamber.
  • Page 655 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 830 - display the "Before/after repair procedure" for the computer selected, - select "Injector" in the "List of components stored by this computer" section, - carry out the operations described in the "After re- pair procedure"...
  • Page 656 DIESEL INJECTION Diesel injector: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED a If one or more injectors are re-used, always mark a Mot. 1817 Injector well cleaning kit removed injector in relation to its cylinder. Essential equipment Note: diagnostic tool...
  • Page 657 DIESEL INJECTION Diesel injector: Removal - Refitting a Always clean the well of the removed injector (see Injector well cleaning tool: Use) (Technical Note 6040, 13B, Diesel injection). WARNING It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner.
  • Page 658 DIESEL INJECTION Diesel injector: Removal - Refitting - the diesel injector fuel return rail (see 13B, Diesel injection, Diesel injector fuel return rail: Remo- val - Refitting, page 13B-63) , - the injector rail protector (see 13B, Diesel injec- tion, Injector rail protector: Removal - Refitting, page 13B-70) , - the engine cover.
  • Page 659 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 834 Essential equipment compressed air nozzle diagnostic tool Tightening torquesm bolt of the diesel injector 27 N.m bracket IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera- tion recommendations before carrying out any repair (see 13B, Diesel injection, Diesel injec- tion: Precautions for repair, page 13B-1) .
  • Page 660 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 834 - the diesel injector bracket. Cleaning the diesel injector well(s) and the diesel injector(s) WARNING It is strictly forbidden to clean the injectors with: - a wire brush, - an emery cloth, - an ultrasonic cleaner.
  • Page 661 DIESEL INJECTION Diesel injector: Removal - Refitting K9K, and 834 a Insert the wipe-covered extension piece and end III - FINAL OPERATION piece down into the bottom of the well. a Connect the diesel injector fuel return rail to the die- a Clean the injector well (pay particular attention to the sel injector(s).
  • Page 662 DIESEL INJECTION Accelerometer: Removal - Refitting K9K, and 830 or 834 a Remove the accelerometer using (Emb. 1797). Essential special tooling Emb. 1797 24 mm socket for removing REFITTING and refitting clutch master cylinder I - REFITTING OPERATION FOR PART CONCERNED Essential equipment a Refit the accelerometer.
  • Page 663 PREHEATING Pre/postheating unit: Removal - Refitting F9Q or K9K REMOVAL II - OPERATION FOR REMOVAL OF PART CONCERNED I - OPERATION FOR REMOVAL OF PART CONCERNED a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery).
  • Page 664 PREHEATING Pre/postheating unit: Removal - Refitting F9Q or K9K - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
  • Page 665 PREHEATING Heater plugs Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment tool for removing heater plugs hinged wrench for heater plug Tightening torquesm heater plugs 15 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery).
  • Page 666 PREHEATING Heater plugs Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the heater plugs a Tighten to torque the heater plugs (15 N.m) using a 10 mm long socket. a Connect the heater plug connectors. III - FINAL OPERATION a Refit: - the injector rail protector (see 13B, Diesel injec- tion, Injector rail protector: Removal - Refitting,...
  • Page 667 PREHEATING Heater plugs Removal - Refitting K9K, and 832 Essential equipment compressed air nozzle tool for removing heater plugs hinged wrench for heater plug Tightening torquesm heater plugs 15 N.m intercooler air outlet 5.5 N.m pipe clip on the damper valve REMOVAL 121889...
  • Page 668 PREHEATING Heater plugs Removal - Refitting K9K, and 832 II - OPERATION FOR REMOVAL OF PART CONCERNED 134707 134706 a Disconnect the connector (8) from each heater plug. Note: If the heater plugs are seized, use the tool for removing heater plugs (see Heater plug remo- IMPORTANT val tool: Use) (Technical Note 5197A, 06A, Too- Wear goggles with side protectors for this opera-...
  • Page 669 PREHEATING Heater plugs Removal - Refitting K9K, and 832 - the wiring of the camshaft position sensor and damper valve onto the injector rail protector cover. a Connect: - the damper valve connector, - the camshaft position sensor connector. a Fit the intercooler air outlet pipe. a Connect the intercooler air outlet pipe on the damper valve.
  • Page 670 PREHEATING Heater plugs Removal - Refitting K9K, and 830 II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment compressed air nozzle tool for removing heater plugs hinged wrench for heater plug Tightening torquesm heater plugs 15 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, 135861...
  • Page 671 PREHEATING Heater plugs Removal - Refitting K9K, and 830 a Refit: - the turbocharger air outlet pipe (see 12B, Turbo- charging, Intercooler air inlet pipe: Removal - Refitting, page 12B-41) , - the engine cover. 135860 Note: If the heater plugs are seized, use the tool for removing heater plugs (see Heater plug remo- val tool: Use) (Technical Note 5197A, 06A, T oo- ling).
  • Page 672 ANTIPOLLUTION Fuel vapour canister: Removal - Refitting F4R or K4M II - OPERATION FOR REMOVAL OF PART CONCERNED 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 673 ANTIPOLLUTION Fuel vapour canister: Removal - Refitting F4R or K4M REFITTING I - REFITTING PREPARATION OPERATION a Remove the blanking plugs. II - REFITTING OPERATION FOR PART CONCERNED a Connect the fuel vapour absorber pipes. a Refit the fuel vapour absorber on the tank.
  • Page 674 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool Tightening torquesm exhaust gas recircula- 10 N.m tion solenoid valve bolts IMPORTANT Wear protective gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover.
  • Page 675 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: exhaust gas recir- culation solenoid valve seal (11,07,01,13). a Use a SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease the sea- ling surfaces: - of the exhaust gas recirculation solenoid valve if it...
  • Page 676 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm exhaust gas recircula- 10 N.m tion solenoid valve bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 677 ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting III - FINAL OPERATION a Refit: - the exhaust gas recirculation assembly (see 14A, Antipollution, Exhaust gas recirculation as- sembly: Removal - Refitting, page 14A-18) , - the exhaust gas recirculation rigid pipes (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, page 14A-30) , - the intercooler air inlet pipe (see 12B, Turbochar-...
  • Page 678 ANTIPOLLUTION Intercooler: Removal - Refitting Essential special tooling Mot. 1448 Long nose pliers for hose a Remove: clips. - the windscreen wiper arms (see Windscreen wi- Ms. 583 Hose clamp pliers. per arm: Removal - Refitting) , - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) , Tightening torquesm - the brake fluid reservoir from the scoop under the...
  • Page 679 ANTIPOLLUTION Intercooler: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 830 K9K, and 832 135841 135459 a Remove the following on the workbench: - the bolts (1) from the exhaust gas cooler, - the exhaust gas cooler, - the exhaust gas cooler seal.
  • Page 680 ANTIPOLLUTION Intercooler: Removal - Refitting a Use SURFACE CLEANER (see Vehicle: Parts - the exhaust gas cooler, and ingredients for the repairwork) (04B, Consu- - the exhaust gas cooler seal. mables - Products) and CLEAN CLOTHS to de- grease the joint faces: - of the exhaust gas cooler if it is being reused, - of the exhaust gas recirculation mounting on the REFITTING...
  • Page 681 ANTIPOLLUTION Intercooler: Removal - Refitting II - REFITTING OPERATION FOR PART - the bolts of the exhaust gas recirculation rigid CONCERNED pipe on the exhaust gas recirculation assembly (12 N.m). K9K, and 832 a On the workbench, refit: - the exhaust gas cooler with a new seal on the ex- K9K, and 830 haust gas recirculation mounting on the gearbox si- a On the workbench, refit:...
  • Page 682 ANTIPOLLUTION Intercooler: Removal - Refitting - the bolts of the exhaust gas recirculation as- sembly mounting (12 N.m). K9K, and 832 a Refit the exhaust gas recirculation assembly equip- ped with the exhaust gas recirculation rigid pipe on the cylinder head. III - FINAL OPERATION a Fit without tightening: K9K, and 830...
  • Page 683 ANTIPOLLUTION Intercooler: Removal - Refitting K9K, and 830 a Refit: a Refit the rigid exhaust gas recirculation pipe (see 14A, Antipollution, Exhaust gas recirculation ri- - the scoop under the scuttle panel grille (see Scoop gid pipe: Removal - Refitting, page 14A-30) . under scuttle panel grille: Removal - Refitting) .
  • Page 684 ANTIPOLLUTION Intercooler: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm exhaust gas cooler bolts 10 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 Remove: - the engine cover, - the engine undertray bolts,...
  • Page 685 ANTIPOLLUTION Intercooler: Removal - Refitting III - FINAL OPERATION a Refit: - the exhaust gas recirculation assembly (see 14A, Antipollution, Exhaust gas recirculation as- sembly: Removal - Refitting, page 14A-18) , - the exhaust gas recirculation rigid pipes (see 14A, Antipollution, Exhaust gas recirculation rigid pipe: Removal - Refitting, page 14A-30) , - the intercooler air inlet pipe (see 12B, Turbochar-...
  • Page 686 ANTIPOLLUTION Intercooler: Removal - Refitting K9K, and 836 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm exhaust gas cooler bolts 12 N.m on the exhaust gas recirculation mounting bolts of the exhaust gas 12 N.m recirculation assembly mounting REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 687 ANTIPOLLUTION Intercooler: Removal - Refitting K9K, and 836 REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: exhaust gas cooler seal (11,07,01,17) a Use ABRASIVE PADS to clean the joint faces: - of the exhaust gas cooler if it is being reused, - of the exhaust gas recirculation mounting on the gearbox side.
  • Page 688 ANTIPOLLUTION Intercooler: Removal - Refitting K9K, and 836 a Fit without tightening the bolts of the timing end ex- - the engine undertray, haust gas recirculation assembly support on the ex- - the engine cover. haust gas recirculation assembly. a Connect the battery (see Battery: Removal - Refit- a Connect the coolant hose to the exhaust gas cooler.
  • Page 689 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting a Remove: Essential special tooling - the engine cover, Ms. 583 Hose clamp pliers. - the engine undertray bolts, Mot. 1448 Long nose pliers for hose - the engine undertray, clips. - the catalytic converter (see 19B, Exhaust, Cataly- tic converter: Removal - Refitting, page 19B-17) Tightening torquesm bolts of the exhaust gas...
  • Page 690 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 830 135880 a Disconnect the oil vapour rebreathing pipe union from the air filter unit air outlet pipe (1) . a Separate the clip (2) of the oil vapour rebreathing pipe away on the oil vapour rebreathing valve.
  • Page 691 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 830 112325 a Remove the nut (3) from the breather mounting on the gearbox. 135879 a Move the breather mounting away from the gearbox. a Remove: - the bolts (4) of the oil vapour rebreathing valve bracket, - the oil vapour rebreathing valve bracket.
  • Page 692 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting - the injector rail protector cover. K9K, and 832 134699 a Unclip the injector rail protector cover at (6) . a Remove: - the injector rail protector cover bolt (7) , - the injector rail protector cover nut (8) , - the injector rail protector cover.
  • Page 693 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting 135463 134038 a Remove: a Unclip the air flowmeter wiring from the air filter unit air outlet pipe at (15) . - the bolts (13) from the lifting eye at the timing end, a Loosen the clip (16) of the air filter unit air outlet pipe - the lifting eye on the timing end, from the air filter unit.
  • Page 694 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 832 K9K, and 830 135410 136639 a Undo the air filter unit air outlet pipe clip (17) from a Undo the air filter unit air outlet pipe clip (18) from the turbocharger.
  • Page 695 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 832 135842 a Fit the tool (Ms. 583) on each cooling hose (19) of the exhaust gas cooler cover. a Separate the clip (20) of each cooling hose of the ex- haust gas cooler cover (19) on the exhaust gas coo- 135460 ler cover using the tool (Mot.
  • Page 696 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting - the bolts (23) from the exhaust gas recirculation as- II - REFITTING OPERATION FOR PART sembly, CONCERNED - the exhaust gas recirculation assembly. K9K, and 832 a Fit the new exhaust gas recirculation rigid pipe with a new seal on the exhaust gas recirculation assem- bly.
  • Page 697 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting a Remove the tool (Ms. 583) on each cooling hose of the exhaust gas cooler cover. K9K, and 830 a Clip the hose of the turbocharging pressure regula- a Refit the oil vapour rebreathing valve. tion solenoid valve onto the exhaust gas cooler co- a Connect the brake servo pipe union to the vacuum ver.
  • Page 698 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. Tightening torquesm exhaust gas recircula- 25 N.m tion assembly bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 699 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting 137462 135542 135572 a Remove: - the bolts (5) from the exhaust gas recirculation as- sembly, - the exhaust gas recirculation assembly. 135573 a Fit the tools (Ms. 583) on the exhaust gas cooler ho- ses (3) .
  • Page 700 ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting a Remove the tools (Ms. 583) from the exhaust gas cooler hoses. a Connect: - the air pipe of the exhaust gas recirculation bypass control solenoid valve, - the exhaust gas recirculation solenoid valve con- nector.
  • Page 701 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting - the engine undertray bolts, - the engine undertray, Tightening torquesm - the catalytic converter (see 19B, Exhaust, Cataly- bolts of the exhaust gas 25 N.m tic converter: Removal - Refitting, page 19B-17) recirculation rigid pipe bracket on the cylinder head...
  • Page 702 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 830 K9K, and 832 135462 a Remove: - the bolts (2) of the exhaust gas recirculation rigid pipe bracket from the cylinder head, 136647 a Loosen the clip (5) of the exhaust gas recirculation - the bolts (3) of the exhaust gas recirculation rigid...
  • Page 703 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting a Use ABRASIVE PADS to clean the joint face of the II - REFITTING OPERATION FOR PART exhaust manifold. CONCERNED K9K, and 832 WARNING a Fit the new exhaust gas recirculation rigid pipe with Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a new seal.
  • Page 704 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting - the engine cover. a Refit: - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) . - the brake fluid reservoir of the scoop under the scu- ttle panel grille - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) ,...
  • Page 705 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting - the clip of the exhaust gas recirculation upper rigid Essential special tooling pipe. Mot. 1567 Long nose pliers for EGR duct clips. REFITTING THE EXHAUST GAS RECIRCULATION UPPER RIGID PIPE Tightening torquesm I - REFITTING PREPARATION OPERATION a parts always to be replaced: Exhaust gas recir-...
  • Page 706 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting - the scuttle panel grille (see Scuttle panel grille: REFITTING THE EXHAUST GAS Removal - Refitting) (56A, Exterior equipment), RECIRCULATION LOWER RIGID PIPE - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) I - REFITTING PREPARATION OPERATION (56A, Exterior equipment),...
  • Page 707 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting - the engine cover. 14A-36...
  • Page 708 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 836 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 cover, - the engine undertray bolts, - the engine undertray.
  • Page 709 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 836 100000-1 137183 a Disconnect the oil vapour rebreathing pipe from the a Remove: rocker cover (5) . - the bolt (7) of the intermediate air pipe between the turbocharger and the intercooler, - the nut (8) for the intermediate air pipe between the turbocharger and the intercooler,...
  • Page 710 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 836 a Using SURFACE CLEANER (see Vehicle: Parts - the turbocharger air outlet pipe. and ingredients for the repairwork) (04B, Consu- a Remove the turbocharger outlet exhaust gas duct mables - Products) and CLEAN CLOTHS, degrease (see 12B, Turbocharging, Turbocharger outlet the bearing face of:...
  • Page 711 ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 836 a Tighten the clip of the air filter unit air outlet pipe on: - the turbocharger air inlet pipe, - the air filter unit. a Refit: - the engine undertray, - the engine cover.
  • Page 712 STARTING - CHARGING Alternator: Removal - Refitting - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- Tightening torquesm fitting) (55A, Exterior protection). alternator bolts 25 N.m alternator strut bolt on 25 N.m a Remove: the alternator...
  • Page 713 STARTING - CHARGING Alternator: Removal - Refitting K4M, and 858 or 866 a Remove: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the air deflectors, - the headlights (see Front headlight: Removal - Refitting) (80B, Headlights), - the front bumper mountings (see Front bumper support: Removal - Refitting) (42A, Front upper structure),...
  • Page 714 STARTING - CHARGING Alternator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 135920 136573 a Remove the nut (5) on the alternator positive termi- a Remove: nal. - the alternator strut bolt (9) from the cylinder block, a Disconnect the alternator connector (6) .
  • Page 715 STARTING - CHARGING Alternator: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 135892 a Remove the alternator bolt (11) . a Loosen but do not remove the alternator bolt (12) . a Move the alternator away from the multifunction sup- 18987 port using a screwdriver.
  • Page 716 STARTING - CHARGING Alternator: Removal - Refitting - the air deflectors, K4M, and 858 or 866 - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). a Refit: - the alternator strut bolt on the cylinder block, - the alternator strut bolt on the alternator.
  • Page 717 STARTING - CHARGING Alternator: Removal - Refitting - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front Tightening torquesm lower structure), alternator bolts 25 N.m - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- alternator positive termi- 8 N.m...
  • Page 718 STARTING - CHARGING Alternator: Removal - Refitting 135719 135884 a Remove: a Unclip the expansion bottle bottom cooling hose (6) from the high pressure pump protector. - the front end panel clips (3) , a Unclip the alternator wiring from the injector rail pro- - the front end panel upper bolts (4) .
  • Page 719 STARTING - CHARGING Alternator: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 123831 a Undo the alternator bolts (9) . a Remove the alternator bolts (9) as far as possible. 18987 a Move the alternator away from the multifunction sup- a Compress the alternator rings (11) using pliers and a port using a screwdriver.
  • Page 720 STARTING - CHARGING Alternator: Removal - Refitting - the bolts of the engine cooling fan assembly wiring channel on the front end panel. a Clip the expansion bottle top hose onto the front end panel. a Refit: - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- nisms), - the front impact cross member (see Front impact...
  • Page 721 STARTING - CHARGING Alternator: Removal - Refitting Tightening torquesm alternator bolts 25 N.m alternator positive termi- 24 N.m nal nut 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 - Refitting) (80A, Battery).
  • Page 722 STARTING - CHARGING Alternator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 135650 a Disconnect the connector (3) from the alternator re- gulator. a Remove the nut (4) from the alternator positive ter- minal. a Move aside the alternator wiring. 135646 a Remove the front end panel bolts (2) .
  • Page 723 STARTING - CHARGING Alternator: Removal - Refitting REFITTING - the front bumper mountings (see Front bumper support: Removal - Refitting) (42A, Front upper structure), I - REFITTING PREPARATION OPERATION - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front lower structure), - the headlights (see Front headlight: Removal - Refitting) (80B, Headlights),...
  • Page 724 STARTING - CHARGING Alternator: Removal - Refitting - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- Tightening torquesm nisms). alternator bolts 25 N.m a Unclip the cooling system degassing hose. alternator positive termi- 8 N.m nal nut IMPORTANT Wear protective gloves during the operation.
  • Page 725 STARTING - CHARGING Alternator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135296 a Remove the lower bolts (5) from the front end panel. 135699 a Tilt the front end panel slightly towards the front of a Disconnect the alternator connector (6) . the vehicle.
  • Page 726 STARTING - CHARGING Alternator: Removal - Refitting REFITTING - the bonnet catch (see Front bumper support: Re- moval - Refitting) (52A, Non-side opening ele- ment mechanisms), I - REFITTING PREPARATION OPERATION - the audible warning (see Horn: Removal - Refit- ting) (82B, Horn), - the front impact cross member (see Front impact cross member: Removal - Refitting) (41A, Front...
  • Page 727 STARTING - CHARGING Starter: Removal - Refitting K4M, and 848 - the gearbox lifting eye (1) , - the engine undertray bolts, Tightening torquesm - the engine undertray, starter supply wiring nut 8 N.m starter excitation wiring 5 N.m exhaust manifold stay 44 N.m nut on the exhaust manifold...
  • Page 728 STARTING - CHARGING Starter: Removal - Refitting K4M, and 848 - the exhaust manifold strut. - the starter. REFITTING I - REFITTING PREPARATION OPERATION a Check that the centring dowel is in place. II - REFITTING OPERATION FOR PART CONCERNED a Refit the starter.
  • Page 729 STARTING - CHARGING Starter: Removal - Refitting Tightening torquesm starter bolts 44 N.m starter supply terminal 8 N.m nut on the starter sole- 5 N.m noid REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 730 STARTING - CHARGING Starter: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a When replacing the starter, remove the starter pro- tective shield. a Refit the starter protective shield on a new starter. a Check that the starter centring dowel is in place. II - REFITTING OPERATION FOR PART CONCERNED a Refit the starter.
  • Page 731 STARTING - CHARGING Starter: Removal - Refitting K4M, and 858 or 866 OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm starter bolts 44 N.m starter supply cable nut 8 N.m starter excitation cable 5 N.m REMOVAL a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery).
  • Page 732 STARTING - CHARGING Starter: Removal - Refitting K4M, and 858 or 866 REFITTING I - REFITTING PREPARATION OPERATION a Check that the centring dowel is in place. II - REFITTING OPERATION FOR PART CONCERNED a Refit the starter. a Torque tighten the starter bolts (44 N.m). a Fit the starter wiring.
  • Page 733 STARTING - CHARGING Starter: Removal - Refitting Tightening torquesm starter excitation cable 5 N.m starter supply cable nut 8 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 Remove: - the engine cover, - the engine undertray bolts,...
  • Page 734 STARTING - CHARGING Starter: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit the starter. a Fit the starter wiring. a Tighten to torque: - the starter excitation cable nut (5 N.m), - the starter supply cable nut (8 N.m). III - FINAL OPERATION a Refit: - the turbocharger outlet exhaust gas duct (see 12B,...
  • Page 735 STARTING - CHARGING Starter: Removal - Refitting Tightening torquesm nut on the positive ter- 8 N.m minal of the starter nut on the starter excita- 7 N.m tion terminal REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 736 STARTING - CHARGING Starter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION 21921 a Remove: 21935 - the nut on the starter excitation terminal (2) , a Check that the centring dowel (5) is in place. - the nut on the positive terminal of the starter (3) .
  • Page 737 STARTING - CHARGING Starter: Removal - Refitting - the front section of the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection), - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the lifting eye on the timing end, - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting)
  • Page 738 IGNITION Coils Removal - Refitting Tightening torquesm coil bolts 12 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. II - OPERATION FOR REMOVAL OF PART CONCERNED 135750 a Disconnect the connector (2) from the camshaft de- phaser solenoid valve.
  • Page 739 IGNITION Coils Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 106443 a Apply a bead of FLUOSTAR 2L grease (see Vehi- cle: Parts and ingredients for the repairwork) (04B, Consumables - Products) 2 mm in diameter at (4) on the internal perimeter of the high tension caps on the four coils.
  • Page 740 IGNITION Coils Removal - Refitting Tightening torquesm coil bolts 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. II - OPERATION FOR REMOVAL OF PART CONCERNED 136482 a Disconnect the coil connectors (1) . a Remove: - the coil bolts (2) , - the coils.
  • Page 741 IGNITION Coils Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION 106443 a Apply a bead of FLUOSTAR 2L grease (3) (see Ve- hicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) 2 mm in diameter on the internal perimeter of the high tension caps on the four coils.
  • Page 742 IGNITION Spark plugs: Removal - Refitting a Torque tighten the spark plugs (25 N.m) using the Essential special tooling tool (Ele. 1382). Ele. 1382 Spark plug spanner toolkit 16 & 21 mm torque 1.75 & 28 Note: Nm + square adapter 9-9.52 Use the limited torque wrench of (Ele.
  • Page 743 IGNITION Spark plugs: Removal - Refitting Essential special tooling Ele. 1382 Spark plug spanner toolkit 16 & 21 mm torque 1.75 & 28 Nm + square adapter 9-9.52 for spanner Ele. 1086 Tightening torquesm spark plugs 28 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the coils (see 17A, Ignition, Coils Removal - Re-...
  • Page 744 IGNITION Spark plugs: Removal - Refitting a Torque tighten the plugs (25 N.m) using the tool Essential special tooling (Ele. 1382). Ele. 1382 Spark plug spanner toolkit 16 & 21 mm torque 1.75 & 28 Note: Nm + square adapter 9-9.52 Use the limited torque wrench of (Ele.
  • Page 745 PETROL INJECTION Oxygen sensors: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1495-01 22 mm socket for removing/ refitting oxygen sensors. 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 746 PETROL INJECTION Oxygen sensors: Removal - Refitting REFITTING THE UPSTREAM OXYGEN II - OPERATION FOR REMOVAL OF PART CONCERNED SENSOR I - REFITTING OPERATION FOR PART CONCERNED a Refit the upstream oxygen sensor using the (Mot. 1495-01). a Connect the upstream oxygen sensor connector. a Clip on the upstream oxygen sensor connector.
  • Page 747 PETROL INJECTION Oxygen sensors: Removal - Refitting REFITTING THE DOWNSTREAM OXYGEN SENSOR REFITTING OPERATION FOR PART CONCERNED a Refit the downstream oxygen sensor using the (Mot. 1495-01). a Connect the downstream oxygen sensor connector. a Clip: - the downstream oxygen sensor wiring, - the downstream oxygen sensor connector.
  • Page 748 PETROL INJECTION Oxygen sensors: Removal - Refitting REMOVAL OF THE UPSTREAM OXYGEN Essential special tooling SENSOR Mot. 1495-01 22 mm socket for removing/ refitting oxygen sensors. I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. Tightening torquesm upstream oxygen sen- 34 N.m dow n s t r e a m oxygen...
  • Page 749 PETROL INJECTION Oxygen sensors: Removal - Refitting - the battery (see Battery : Removal - Refitting) (80A, Battery), - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-4) .
  • Page 750 PETROL INJECTION Oxygen sensors: Removal - Refitting - the catalytic converter strut (8) . - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the battery (see Battery : Removal - Refitting) II - OPERATION FOR REMOVAL OF PART (80A, Battery), CONCERNED - the engine cover.
  • Page 751 PETROL INJECTION Petrol injection computer: Removal - Refitting F4R or K4M Essential equipment 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 752 PETROL INJECTION Petrol injection computer: Removal - Refitting F4R or K4M REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the petrol injection computer on the support. a Connect the petrol injection computer connectors. a Fit the « Petrol injection computer - computer support »...
  • Page 753 PETROL INJECTION Pinking sensor: Removal - Refitting Essential special tooling K4M, and 858 or 866 Emb. 1797 24 mm socket for removing and refitting clutch master cylinder Tightening torquesm pinking sensor 20 N.m alternator strut bolt on 25 N.m the alternator alternator strut nut on 25 N.m the cylinder block...
  • Page 754 PETROL INJECTION Pinking sensor: Removal - Refitting - the alternator strut. II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 848 K4M, and 858 or 866 135246 a Disconnect the pinking sensor connector. 136573 a Remove the pinking sensor (6) using the tool (Emb. a Remove: 1797).
  • Page 755 PETROL INJECTION Pinking sensor: Removal - Refitting K4M, and 858 or 866 K4M, and 848 a Refit: - the alternator strut, - the alternator strut nut on the cylinder block, - the alternator strut bolt on the alternator. a Tighten to torque: - the alternator strut bolt on the alternator (25 N.m), - the alternator strut nut on the cylinder block (25...
  • Page 756 PETROL INJECTION Pinking sensor: Removal - Refitting a Connect the pinking sensor connector. Tightening torquesm II - FINAL OPERATION pinking sensor nut 18 N.m a Refit the engine undertray. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 757 PETROL INJECTION Camshaft position sensor: Removal - Refitting K4M, and 858 or 866 Tightening torquesm camshaft position sen- 8 Nm sor bolt REMOVAL I - REMOVAL PREPARATION OPERATION a Remove: - the engine cover, - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the scuttle panel grille (see Scuttle panel grille:...
  • Page 758 PETROL INJECTION Camshaft position sensor: Removal - Refitting REMOVAL - the camshaft position sensor. REFITTING I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. I - REFITTING OPERATION FOR PART CONCERNED II - OPERATION FOR REMOVAL OF PART a Refit the camshaft position sensor.
  • Page 759 PETROL INJECTION Crankshaft position sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment diagnostic tool Tightening torquesm crankshaft position sen- 8 N.m sor bolts REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. a Remove: 135919 a Disconnect the crankshaft position sensor connector...
  • Page 760 PETROL INJECTION Crankshaft position sensor: Removal - Refitting - the crankshaft position sensor. 136549 a Disconnect the crankshaft position sensor connector (2) . 136549 a Remove: - the crankshaft position sensor bolt (4) , - the crankshaft position sensor. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the crankshaft position sensor.
  • Page 761 PETROL INJECTION Crankshaft position sensor: Removal - Refitting II - FINAL OPERATION a Refit the engine undertray. a Refit the engine cover. a Apply the after repair procedure using the diagnos- tic tool : - Connect the diagnostic tool, - select « injection computer » , - go to repair mode, - display the «...
  • Page 762 PETROL INJECTION Crankshaft position sensor: Removal - Refitting 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. II - OPERATION FOR REMOVAL OF PART CONCERNED 102485...
  • Page 763 PETROL INJECTION Injector rail - Injectors: Removal - Refitting - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) , Essential equipment - the intake distributor (see 12A, Fuel mixture, Inlet diagnostic tool manifold: Removal - Refitting, page 12A-23) . II - OPERATION FOR REMOVAL OF PART Tightening torquesm CONCERNED...
  • Page 764 PETROL INJECTION Injector rail - Injectors: Removal - Refitting a Refit the « injector rail - injector » assembly. a Torque tighten the bolts of the « injector rail - injector » assembly (10 N.m). III - FINAL OPERATION a Refit: - the inlet manifold (see 12A, Fuel mixture, Inlet manifold: Removal - Refitting, page 12A-23) , - the throttle valve (see 12A, Fuel mixture, Throttle...
  • Page 765 PETROL INJECTION Injector rail - Injectors: Removal - Refitting Tightening torquesm injector rail bolts 10 N.m 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 766 PETROL INJECTION Injector rail - Injectors: Removal - Refitting - the injector rail - injector assembly. 135779 a Disconnect: - the fuel supply pipe (3) on the injector rail, - the petrol vapour rebreathing pipe (4) . a Remove the petrol vapour rebreathing pipe. 135781 a Remove: II - OPERATION FOR REMOVAL OF PART...
  • Page 767 PETROL INJECTION Injector rail - Injectors: Removal - Refitting a Connect the battery. 17B-23...
  • Page 768 Engine Quantity Grade (litres) K4M 848 5.3 l K4M 858 5.3 l K4M 866 5.3 l GLACEROL F4R 870 6.5 l (type D) K9K 830 6.5 l Only use coolant K9K832 6.5 l K9K 834 6.5 l F9Q 870 6.3 l F9Q 872 6.3 l...

  • Page 769: Engine Cooling Circuit: Check

    COOLING Engine cooling circuit: check 1 - Checking the expansion bottle cap valve Essential special tooling Mot. 1700 Fault finding and filling-blee- ding cooling system. Ms. 554-07 Cooling system tester kit (complete). Contains plugs 554-01, 554-04, 554-06 Ms. 554-06 Spare cap for testing expan- sion bottle valves (2nd fitting).
  • Page 770 COOLING Engine cooling circuit: check a Gradually undo the union of the (Ms. 554-07) to de- 1 - Checking the expansion bottle cap valve compress the cooling system and then remove the adapter (Ms. 554-01) and refit the expansion bottle cap.

  • Page 771: Engine Cooling Circuit: List And Location Of Components

    COOLING Engine cooling circuit: List and location of components K9K, and 830 or 832 135555 19A-4...
  • Page 772 COOLING Engine cooling circuit: List and location of components 135558 19A-5...
  • Page 773 COOLING Engine cooling circuit: List and location of components 135560 Cooling radiator Expansion bottle Water-oil heat exchanger Water pump Engine Thermostat Coolant outlet unit Drain plug Bleed screws 19A-6...
  • Page 774 COOLING Engine cooling circuit: List and location of components K9K, and 834 135561 19A-7...
  • Page 775 COOLING Engine cooling circuit: List and location of components 135564 19A-8...
  • Page 776 COOLING Engine cooling circuit: List and location of components 135566 Cooling radiator Expansion bottle Water-oil heat exchanger Water pump Engine Thermostat Coolant outlet unit Drain plug Bleed screws (10) Thermoplunger unit 19A-9...
  • Page 777 COOLING Engine cooling circuit: List and location of components 135517 Engine Cooling radiator Heater matrix Expansion bottle Water pump Thermostat Coolant outlet unit Coolant pump inlet pipe 19A-10...
  • Page 778 COOLING Engine cooling circuit: List and location of components 135518 Bleed screw (10) Drain plug 19A-11...
  • Page 779 COOLING Engine cooling circuit: List and location of components 135611 Turbocharger Electric coolant pump Coolant outlet unit 19A-12...
  • Page 780 COOLING Engine cooling circuit: List and location of components 135612 Expansion bottle Water pump Radiator Thermostat 19A-13...
  • Page 781 COOLING Engine cooling circuit: List and location of components 135613 Bleed screw Drain plug 19A-14...
  • Page 782 COOLING Engine cooling circuit: List and location of components 135424 Engine Radiator Expansion bottle Water pump Coolant outlet unit Thermoplunger unit (F9Q 870) Water-oil heat exchanger Bleed screws 19A-15...
  • Page 783 COOLING Engine cooling circuit: List and location of components 135423 Intercooler (10) Exhaust fuel injector cooler (F9Q 870) (11) Heater matrix 19A-16...
  • Page 784 COOLING Cooling circuit: Draining - Refilling - the front bumper (see Front bumper: Removal - Essential special tooling Refitting) (55A, Exterior protection), a Position the coolant draining tray under the vehi- Mot. 1700 Fault finding and filling-blee- ding cooling system. cle.
  • Page 785 2 - Filling procedure without a special tool system: - the procedure using the tool (Mot. 1700) recommended by Renault. It saves a considera- WARNING ble amount of time because it does not require It is essential to open all of the bleed screws to...
  • Page 786 COOLING Cooling circuit: Draining - Refilling 1) and (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) via the expansion bottle until it overflows. a Close all the bleed screws as soon as the coolant starts to flow in a continuous stream. a Pressurise the system using the (Ms.
  • Page 787 COOLING Cooling circuit: Draining - Refilling a Position the coolant draining tray under the vehi- Essential special tooling cle. Mot. 1700 Fault finding and filling-blee- ding cooling system. Ms. 554-07 Cooling system tester kit (complete). Contains plugs 554-01, 554-04, 554-06 Essential equipment coolant draining tray compressed air nozzle...
  • Page 788 2 - Filling procedure without a special tool - the procedure using the tool (Mot. 1700) recommended by Renault. It saves a considera- ble amount of time because it does not require WARNING the cooling system bleed screws to be opened, It is essential to open all of the bleed screws to - the procedure without a special tool.
  • Page 789 COOLING Cooling circuit: Draining - Refilling K9K, and 834 135566 a Remove: BLEEDING - the bleed screw (4) of the coolant outlet unit, - the bleed screw (5) of the heater matrix hose. WARNING Do not open the bleed screw whilst the engine is running;...
  • Page 790 COOLING Cooling circuit: Draining - Refilling FINAL OPERATION a Remove the coolant draining tray. a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting)
  • Page 791 COOLING Cooling circuit: Draining - Refilling - the front bumper (see Front bumper: Removal - Essential special tooling Refitting) (55A, Exterior protection). a Position the coolant draining tray under the vehi- Mot. 1700 Fault finding and filling-blee- ding cooling system. cle.
  • Page 792 2 - Filling procedure without a special tool system: - the procedure using the tool (Mot. 1700) recommended by Renault. It saves a considera- WARNING ble amount of time because it does not require It is essential to open all of the bleed screws to...
  • Page 793 COOLING Cooling circuit: Draining - Refilling 1) and (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) via the expansion bottle until it overflows. a Close all the bleed screws as soon as the coolant starts to flow in a continuous stream. a Pressurise the system using the (Ms.
  • Page 794 COOLING Cooling circuit: Draining - Refilling - the front bumper (see Front bumper: Removal - Essential special tooling Refitting) (55A, Exterior protection), a Position the coolant draining tray under the vehi- Mot. 1700 Fault finding and filling-blee- ding cooling system. cle.
  • Page 795 2 - Filling procedure without a special tool system: - the procedure using the tool (Mot. 1700) recommended by Renault. It saves a considera- WARNING ble amount of time because it does not require It is essential to open all of the bleed screws to...
  • Page 796 COOLING Cooling circuit: Draining - Refilling - the bleed screw (3) of the heater matrix hose, - the bleed screw (4) of the cooling radiator bottom F9Q, and 870 hose, - the bleed screw (5) of the cooling radiator. WARNING a Fill the cooling system with engine coolant recom- Before bleeding the cooling system, it is essential mended by the manufacturer (see 19A, Cooling,...
  • Page 797 COOLING Cooling circuit: Draining - Refilling a Refit: - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front sections of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the engine undertray,...
  • Page 798 COOLING Cooling radiator: Removal - Refitting a Remove: Essential special tooling - the engine cover, Mot. 1448 Long nose pliers for hose - the front wheels (see Wheel: Removal - Refitting) clips. (35A, Wheels and tyres), - the front section of the front wheel arch liners (see Essential equipment Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),...
  • Page 799 COOLING Cooling radiator: Removal - Refitting 135961 135963 a Unclip the condenser from each side at (3) . a Attach the condenser to the front impact cross mem- ber using a safety strap(s). 136540 a Unclip the air deflectors at (1) and (2) . a Remove: - the air deflectors, - the headlights (see Front headlight: Removal -...
  • Page 800 COOLING Cooling radiator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART - the expansion bottle degassing hose (5) from the CONCERNED cooling radiator, - the bottom cooling hose (6) from the cooling radia- tor. 135954 135956 135951 a Remove using the (Mot. 1448) : 135957 - the clip for the cooling radiator top cooling hose, a Remove:...
  • Page 801 COOLING Cooling radiator: Removal - Refitting a Remove the cooling radiator from the front end pa- a Fill and bleed the cooling system (see 19A, Coo- nel. ling, Cooling circuit: Draining - Refilling, page 19A-17) . a Refit the engine undertray. REFITTING I - REFITTING OPERATION FOR PART CONCERNED...
  • Page 802 COOLING Cooling radiator: Removal - Refitting - the side air deflectors of the cooling radiator, Essential special tooling - the headlights (see Front headlight: Removal - Mot. 1448 Long nose pliers for hose Refitting) (80B, Headlights), clips. - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper Mot.
  • Page 803 COOLING Cooling radiator: Removal - Refitting 135835 135837 a Use the tool (Mot. 1202-02) to separate the expan- a Using a safety strap(s) (2) , attach the air conditio- sion bottle top cooling hose clip (4) from the cooling ning condenser to the front impact cross member. radiator.
  • Page 804 COOLING Cooling radiator: Removal - Refitting 135838 135479 a Remove the cooling radiator from the front end pa- nel by: - slightly pulling the cooling radiator towards the front of the vehicle (7) , - pulling the cooling radiator upwards (8) . REFITTING I - REFITTING OPERATION FOR PART CONCERNED...
  • Page 805 COOLING Cooling radiator: Removal - Refitting a Fit the air conditioning condenser. a Clip the air conditioning condenser onto the cooling radiator. a Refit: - the audible warning (see Horn: Removal - Refit- ting) (82B, Horn), - the intercooler (see 12B, Turbocharging, Inter- cooler: Removal - Refitting, page 12B-37) , - the intercooler air outlet pipe (see 12B, Turbo- charging, Intercooler air outlet pipe: Removal -...
  • Page 806 COOLING Cooling radiator: Removal - Refitting a Remove: Essential special tooling - the engine cover, Mot. 1448 Long nose pliers for hose clips. - the engine undertray bolts, - the engine undertray, Essential equipment - the front wheels (see Wheel: Removal - Refitting) safety strap(s) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see...
  • Page 807 COOLING Cooling radiator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135996 a Attach the condenser to the front impact cross mem- 135997 ber using a safety strap(s). 135998 a Remove the clips (2) from the cooling radiator hoses using the tool (Mot.
  • Page 808 COOLING Cooling radiator: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the cooling radiator. a Connect the cooling radiator hoses. a Fit the cooling radiator hose clips using the tool (Mot. 1448). II - FINAL OPERATION a Detach the condenser from the front impact cross member.
  • Page 809 COOLING Cooling radiator: Removal - Refitting a Remove: Essential special tooling - the engine cover, Mot. 1448 Long nose pliers for hose - the engine undertray bolts, clips. - the engine undertray, Essential equipment - the front wheels (see Wheel: Removal - Refitting) safety strap(s) (35A, Wheels and tyres), - the front section of the front wheel arch liners (see...
  • Page 810 COOLING Cooling radiator: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135785 a Attach the condenser to the front impact cross mem- 135787 ber using a safety strap(s). 135791 a Remove the clips (1) from the cooling radiator hoses using the tool (Mot.
  • Page 811 COOLING Cooling radiator: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the cooling radiator, - the retaining brackets on the cooling radiator. a Connect the cooling radiator hoses. a Fit the cooling radiator hose clips using the tool (Mot.
  • Page 812 COOLING Water pump: Removal - Refitting - the engine undertray, - the front wheels (see Wheel: Removal - Refitting) Tightening torquesm (35A, Wheels and tyres), coolant pump bolts 12 N.m - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), IMPORTANT...
  • Page 813 COOLING Water pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: Coolant pump seal (10,06,01,21). IMPORTANT Wear goggles with side protectors for this opera- tion. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in...
  • Page 814 COOLING Water pump: Removal - Refitting - the radiator mounting cross member (see Radiator support cross member: Removal - Refitting) (31A, Front axle components), - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection), - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting)
  • Page 815 COOLING Water pump: Removal - Refitting a Remove: Tightening torquesm - the engine cover, bolts 2 to 8 of the coo- 10 N.m - the throttle valve (see 12A, Fuel mixture, Throttle lant pump valve: Removal - Refitting, page 12A-17) , bolt 1 of the coolant 27 N.m - the front wheels (see Wheel: Removal - Refitting)
  • Page 816 COOLING Water pump: Removal - Refitting a Use SUPER CLEANING AGENT FOR JOINT FA- II - OPERATION FOR REMOVAL OF PART CONCERNED CES (see Vehicle: Parts and ingredients for the repairwork) (04B, Consumables - Products) to clean: - the coolant pump sealing face if it is to be reused, - the cylinder block gasket face.
  • Page 817 COOLING Water pump: Removal - Refitting II - REFITTING OPERATION FOR PART - the lower engine tie-bar (see 19D, Engine moun- CONCERNED ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille:...
  • Page 818 COOLING Water pump: Removal - Refitting - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended Tightening torquesm engine mounting: Removal - Refitting, page 19D-18) , coolant pump bolts 10 N.m - the timing belt (see 11A, Top and front of engine, alternator lower bolt 25 N.m Timing belt: Removal - Refitting, page 11A-29) .
  • Page 819 COOLING Water pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 123968 123968 a Refit: a Remove: - a new coolant pump seal, - the coolant pump bolts (4) , - the coolant pump, - the coolant pump, - the bolts (2) and (5) of the coolant pump.
  • Page 820 COOLING Water pump: Removal - Refitting - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-18) , - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment),...
  • Page 821 COOLING Water pump: Removal - Refitting a Remove: - the engine cover, Tightening torquesm - the scuttle panel grille (see Scuttle panel grille: coolant pump bolts 12 N.m Removal - Refitting) (56A, Exterior equipment), - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) IMPORTANT (56A, Exterior equipment),...
  • Page 822 COOLING Water pump: Removal - Refitting II - OPERATION FOR REMOVAL OF PART II - REFITTING OPERATION FOR PART CONCERNED CONCERNED 102422 102422 a Remove: - the coolant pump bolts (1) , Note: - the coolant pump, Apply one to two drops of FRENETANCHE (see Vehicle: Parts and ingredients for the repai- - the coolant pump seal.
  • Page 823 COOLING Water pump: Removal - Refitting - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-7) , - 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 824 COOLING Thermostat: Removal - Refitting F9Q or K4M or K9K a The thermostat cannot be separated from the water chamber. Replace the « water chamber - thermostat » assem- bly if the thermostat is faulty (see 19A, Cooling, Ple- num chamber: Removal - Refitting, page 19A-61) 19A-57...
  • Page 825 COOLING Thermostat: Removal - Refitting - the front section of the front wheel arch liners (see Essential special tooling Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), Mot. 1448 Long nose pliers for hose clips. - the engine undertray bolts, - the engine undertray, - the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection).
  • Page 826 COOLING Thermostat: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 123733 a Remove: 135697 a Using the tool (Mot. 1448), separate the top hose - the thermostat (4) , clip (2) on the coolant outlet unit. - the thermostat seal. a Disconnect the top hose from the coolant outlet unit.
  • Page 827 COOLING Thermostat: Removal - Refitting a Fit the top hose clip on the coolant outlet unit using the tool (Mot. 1448). III - FINAL OPERATION a Refit the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-17) a Fit the intercooler air outlet pipe.
  • Page 828 COOLING Plenum chamber: Removal - Refitting REMOVAL Essential special tooling Mot. 1448 Long nose pliers for hose I - REMOVAL PREPARATION OPERATION clips. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: Tightening torquesm - the engine cover, coolant outlet unit bolts...
  • Page 829 COOLING Plenum chamber: Removal - Refitting K4M, and 848 135927 a Unclip the heater matrix hoses from the retaining bracket (4) . 135922 a Disconnect the TDC sensor connector. a Remove: a Remove: - the heater matrix hose retaining bracket bolt, - the bolts (3) of the engine wiring channel, - the heater matrix hose retaining bracket.
  • Page 830 COOLING Plenum chamber: Removal - Refitting a Tighten to torque and in order: - the coolant outlet unit, - the coolant outlet unit seal. - the coolant outlet unit bolts (initial torque) (4 N.m), - the coolant outlet unit bolts (12 N.m). REFITTING a Refit the heater matrix hose bracket on the retaining bracket.
  • Page 831 COOLING Plenum chamber: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1448 Long nose pliers for hose clips. Car. 1363 Set of trim removal levers. Tightening torquesm coolant outlet unit bolts 11 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 832 COOLING Plenum chamber: Removal - Refitting 135485 135474 a Separate the clip (2) of the cooling radiator top coo- a Remove: ling hose (3) from the coolant outlet unit using the - the coolant outlet unit bolts (5) , tool (Mot. 1448). a Disconnect the cooling radiator top cooling hose (3) - the coolant outlet unit, from the coolant outlet unit using the tool (Car.
  • Page 833 COOLING Plenum chamber: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new coolant outlet unit seal in the coolant outlet unit housing, - the coolant outlet unit. a Torque tighten the coolant outlet unit bolts (11 N.m).
  • Page 834 COOLING Plenum chamber: Removal - Refitting II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1448 Long nose pliers for hose clips. Tightening torquesm coolant outlet unit bolts 10 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 835 COOLING Plenum chamber: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new coolant outlet unit seal, - the coolant outlet unit. a Torque tighten the coolant outlet unit bolts (10 N.m). a Connect the coolant outlet unit hoses. a Position the hose clips on the coolant outlet unit using the tool (Mot.
  • Page 836 COOLING Plenum chamber: Removal - Refitting - the front wheels (see Wheel: Removal - Refitting) Essential special tooling (35A, Wheels and tyres), Mot. 1448 Long nose pliers for hose - the front section of the front wheel arch liners (see clips.
  • Page 837 COOLING Plenum chamber: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135697 136517 a Remove: - the bolts for the engine wiring harness channel, - the coolant outlet unit bolts, - the coolant outlet unit seal. Note: The coolant outlet unit bolts are not the same length.
  • Page 838 COOLING Plenum chamber: Removal - Refitting - the thermostat unit bolts. WARNING II - REFITTING OPERATION FOR PART T o ensure proper sealing, the gasket surfaces CONCERNED must be clean, dry and not greasy (avoid any fin- a Refit: ger marks). - a new seal on the coolant outlet unit, If replacing the coolant outlet unit - the coolant outlet unit.
  • Page 839 COOLING Plenum chamber: Removal - Refitting - the engine undertray, - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection), - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the battery tray (see Battery : Removal - Refit- ting) (80A, Battery),...
  • Page 840 COOLING Engine cooling fan assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED IMPORTANT When working in the engine compartment, take care as the radiator fan(s) may start up unexpecte- dly (risk of being cut). To avoid any risk of serious burns when the engine is hot: - do not open the expansion bottle cap, - do not drain the cooling system,...
  • Page 841 COOLING Engine cooling fan assembly: Removal - Refitting 135482 135950 a Unclip the engine cooling fan assembly at (5) . a Disconnect: a Remove the engine cooling fan assembly from un- - the engine cooling fan assembly connector (2) , derneath the vehicle.
  • Page 842 COOLING Engine cooling fan assembly: Removal - Refitting - the front bumper supports (see Front bumper support: Removal - Refitting) (42A, Front upper IMPORTANT structure), When working in the engine compartment, take - the top air deflector of the cooling radiator, care as the radiator fan(s) may start up unexpecte- - the side air deflectors of the cooling radiator, dly (risk of being cut).
  • Page 843 COOLING Engine cooling fan assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135719 a Remove from the front end panel: 135482 - the clips (3) , a Disconnect: - the upper bolts (4) . - the fan assembly connector (6) , - the fan assembly resistor connector (7) .
  • Page 844 COOLING Engine cooling fan assembly: Removal - Refitting a Connect the battery (see Battery : Removal - Refit- REFITTING ting) (80A, Battery). I - REFITTING OPERATION FOR PART CONCERNED a Refit the fan assembly on the front end panel. a Clip the fan assembly wiring onto the fan assembly. a Connect the following connectors: - the fan assembly, - the fan assembly resistor.
  • Page 845 COOLING Engine cooling fan assembly: Removal - Refitting REMOVAL - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- nisms). I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 846 COOLING Engine cooling fan assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING OPERATION FOR PART CONCERNED a Refit the fan assembly. a Connect: - the fan assembly resistor connector, - the motor-driven fan assembly connector. II - FINAL OPERATION a Refit: - a new intercooler air outlet pipe (see 12B, Turbo-...
  • Page 847 COOLING Engine cooling fan assembly: Removal - Refitting - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- IMPORTANT nisms). When working in the engine compartment, take care as the radiator fan(s) may start up unexpec- tedly (risk of being cut).
  • Page 848 COOLING Engine cooling fan assembly: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 135296 a Remove the lower bolts (4) from the front end panel. 135482 a Tilt the front end panel slightly towards the front of a Disconnect: the vehicle.
  • Page 849 COOLING Engine cooling fan assembly: Removal - Refitting REFITTING - the engine undertray, - the engine cover. I - REFITTING OPERATION FOR THE PART a Connect the battery (see Battery : Removal - Refit- a Refit the fan assembly. ting) (80A, Battery). a Adjust the headlights (see Front headlight: Adjus- a Clip the fan assembly wiring onto the fan assembly.
  • Page 850 COOLING Water pump inlet pipe: Removal - Refitting Essential special tooling K4M, and 848 Mot. 1202-02 Pliers for small hose clips. Mot. 1202-01 Pliers for large hose clips. Mot. 1448 Long nose pliers for hose clips. Tightening torquesm coolant pump inlet pipe 22 N.m bolt coolant pump inlet pipe...
  • Page 851 COOLING Water pump inlet pipe: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 K4M, and 848 136574 a Remove: 135254 - the dipstick, a Unclip the alternator wiring (5) . - the dipstick guide bolts (4) from the injector holder a Using the (Mot.
  • Page 852 COOLING Water pump inlet pipe: Removal - Refitting K4M, and 858 or 866 136572 136576 a Using the (Mot. 1202-02) or (Mot. 1202-01) or (Mot. 1448) remove: - the heater matrix hose clip (9) , - the cooling radiator bottom hose clip (10) . a Disconnect the following from the coolant pump inlet pipe: - the heater matrix hose,...
  • Page 853 COOLING Water pump inlet pipe: Removal - Refitting REFITTING - the alternator strut nut on the cylinder block (25 N.m). I - REFITTING PREPARATION OPERATION a parts always to be replaced: seal between coo- a Refit the dipstick guide. lant pump inlet pipe and coolant pump (10,06,01, 22).
  • Page 854 COOLING Water pump inlet pipe: Removal - Refitting - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) Essential equipment (55A, Exterior protection), refrigerant charging station - the engine undertray bolts, - the engine undertray, Tightening torquesm - the front bumper (see Front bumper: Removal - coolant pump inlet pipe...
  • Page 855 COOLING Water pump inlet pipe: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: seal between coo- lant pump inlet pipe and coolant pump (10,06,01, 22). a parts always to be replaced: refrigerant pipe seal (30,02,02,52) a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu-...
  • Page 856 COOLING Water pump inlet pipe: Removal - Refitting a Remove: Essential special tooling - the front wheels (see Wheel: Removal - Refitting) Mot. 1448 Long nose pliers for hose (35A, Wheels and tyres), clips. - the front section of the front wheel arch liners (see Front wheel arch liner: Removal - Refitting) Essential equipment (55A, Exterior protection),...
  • Page 857 COOLING Water pump inlet pipe: Removal - Refitting - the coolant pump inlet pipe seal. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - the coolant pump inlet pipe offset fitted with a new seal, - the coolant pump inlet pipe offset bolt on the cylin- der block.
  • Page 858 COOLING Water pump inlet pipe: Removal - Refitting a Refit: - the engine cover, - the engine undertray. a Connect the battery (see Battery : Removal - Refit- ting) (80A, Battery). 19A-91...
  • Page 859 COOLING Water pump inlet pipe: Removal - Refitting a Remove: Essential special tooling - the front wheels (see Wheel: Removal - Refitting) Mot. 1448 Long nose pliers for hose (35A, Wheels and tyres), clips. - the front section of the front wheel arch liners (see Essential equipment Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),...
  • Page 860 COOLING Water pump inlet pipe: Removal - Refitting - the multifunction support (see 10A, Engine and cylinder block assembly, Multifunction sup- port: Removal - Refitting, page 10A-84) . II - OPERATION FOR REMOVAL OF PART CONCERNED 135645 115619 a Remove the clip (3) on the coolant pump inlet pipe hose using the tool (Mot.
  • Page 861 COOLING Water pump inlet pipe: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease: - the mating face of the coolant pump inlet pipe seal on the coolant pump inlet pipe in case of reuse, - the mating faces of the coolant pump inlet pipe seal if it is being reused,...
  • Page 862 COOLING Water pump inlet pipe: Removal - Refitting - the front panel, - the bonnet catch (see Bonnet latch: Removal - Refitting) (52A, Non-side opening element mecha- nisms), - the bolts for the engine wiring harness channel, - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-7) , - the front bumper supports (see Front bumper...
  • Page 863 COOLING Expansion bottle: Removal - Refitting Essential special tooling Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. Mot. 1202-01 Pliers for large hose clips. Mot. 1202-02 Pliers for small hose clips. IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns).
  • Page 864 COOLING Expansion bottle: Removal - Refitting F4R or K4M F9Q or K9K 136464 136606 a Move aside the fuel vapour absorber bleed solenoid a Unclip the manual priming pump from the expansion valve (4) . bottle at (5) . a Disconnect the fuel vapour absorber bleed solenoid a Remove the manual priming pump.
  • Page 865 COOLING Expansion bottle: Removal - Refitting F4R or K4M a Fit the fuel vapour absorber bleed solenoid valve. a Connect the wiring of the fuel vapour absorber bleed solenoid valve to the expansion bottle. II - FINAL OPERATION a Refit the expansion bottle nut onto the vehicle body.
  • Page 866 COOLING Electric water pump: Removal - Refitting Essential special tooling Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. REMOVAL 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 867 COOLING Electric water pump: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the electric coolant pump. a Connect - the electric coolant pump connector, - the electric coolant pump hoses. a Position the clips on the electric coolant pump hoses using the tool (Mot.
  • Page 868 COOLING Coolant temperature sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
  • Page 869 COOLING Coolant temperature sensor: Removal - Refitting III - FINAL OPERATION a Perform the following operations: - top up of the coolant level, - bleed the cooling system (see 19A, Cooling, Coo- ling circuit: Draining - Refilling, page 19A-17) . a Refit the engine cover.
  • Page 870 COOLING Coolant temperature sensor: Removal - Refitting 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). a Remove: - the engine cover, - the battery (see Battery : Removal - Refitting)
  • Page 871 COOLING Coolant temperature sensor: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant temperatu- re sensor seal (10,06,01,18). a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease: - the mating face of the coolant temperature sensor if it is to be reused, - the coolant outlet unit.
  • Page 872 COOLING Coolant temperature sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
  • Page 873 COOLING Coolant temperature sensor: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease the ma- ting face of the coolant temperature sensor on the coolant outlet unit.
  • Page 874 COOLING Coolant temperature sensor: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm coolant temperature 32 N.m sensor IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
  • Page 875 EXHAUST Exhaust: Parts and consumables for the repair work 19B-1...
  • Page 876 EXHAUST Exhaust: Parts and consumables for the repair work 138076 19B-2...
  • Page 877 EXHAUST Exhaust: Parts and consumables for the repair work Catalytic converter Expansion chamber Silencer (zc) Area to be cut 19B-3...
  • Page 878 EXHAUST Exhaust: Parts and consumables for the repair work K9K, and 830 or 832 138074 19B-4...
  • Page 879 EXHAUST Exhaust: Parts and consumables for the repair work Connecting pipe Silencer (zc) Area to be cut 19B-5...
  • Page 880 EXHAUST Exhaust: Parts and consumables for the repair work K9K, and 834 or 836 138078 19B-6...
  • Page 881 EXHAUST Exhaust: Parts and consumables for the repair work Particle filter Silencer (zc) Area to be cut 19B-7...
  • Page 882 EXHAUST Exhaust: Parts and consumables for the repair work 138077 19B-8...
  • Page 883 EXHAUST Exhaust: Parts and consumables for the repair work Particle filter Silencer (zc) Area to be cut 19B-9...
  • Page 884 EXHAUST Exhaust: Parts and consumables for the repair work 138075 19B-10...
  • Page 885 EXHAUST Exhaust: Parts and consumables for the repair work Connecting pipe Silencer (zc) Area to be cut 19B-11...
  • Page 886 EXHAUST Exhaust: Precautions for repair 2 - Identifying the area to be cut Essential special tooling Two marks on the exhaust pipe indicate the area to be Mot. 1199-01 35/50 mm diameter and 50/ cut (see 19B, Exhaust, Exhaust: Parts and consu- 95 mm diameter exhaust pipe mables for the repair work, page 19B-1) .
  • Page 887 EXHAUST Exhaust: Precautions for repair K9K, and 834 or 836 138164 138168 b - Rear area to be cut 138166 138161 19B-13...
  • Page 888 EXHAUST Exhaust: Precautions for repair K9K, and 830 or 832 138163 138167 K9K, and 834 or 836 138165 138169 19B-14...
  • Page 889 EXHAUST Exhaust: Precautions for repair As the cut is made, continue to tighten the two bolts of the tool (do not overtighten the tool against the pipe, to prevent deformation during the cutting operation). 4 - Positioning of the spare part 138173 100649 Before cutting the pipe, draw a line (D) between the...
  • Page 890 EXHAUST Exhaust: Precautions for repair Exhaust sleeve with two bolts 119681 138172 After tightening the sleeve, check that the cutting Apply EXHAUST MASTIC (see Vehicle: Parts and marks are correctly aligned. ingredients for the repairwork) (04B, Consumables - Products) inside the sleeve. To prevent any exhaust leaks, it is important to position the sleeve correctly on both lugs (1) .
  • Page 891 EXHAUST Catalytic converter: Removal - Refitting K9K, and 830 or 832 a Disconnect the battery (see Battery : Removal - Refitting) (80A, Battery). Tightening torquesm a Remove: turbocharger studs 9 N.m - the engine cover, catalytic converter nuts 28 N.m - the engine undertray bolts, on the turbocharger - the engine undertray.
  • Page 892 EXHAUST Catalytic converter: Removal - Refitting K9K, and 830 or 832 II - REMOVAL STAGE FOR THE PART CONCERNED. 134216 a Remove the catalytic converter downstream strut 136392 bolt (3) from the catalytic converter. a Remove the bolts from the exhaust flange (2) fitted a Undo: with their springs.
  • Page 893 EXHAUST Catalytic converter: Removal - Refitting K9K, and 830 or 832 REFITTING I - REFITTING PREPARATION OPERATION 109399 a Always replace the ring of the catalytic converter ex- haust flange. 135486 a Undo the catalytic converter upstream strut bolt (6) . a parts always to be replaced: seal between turbo- a Remove: charger and catalytic converter (10,09,01,08)
  • Page 894 EXHAUST Catalytic converter: Removal - Refitting K9K, and 830 or 832 II - REFITTING OPERATION FOR PART - the catalytic converter upstream strut bolt on the CONCERNED sump. a Refit a new ring on the catalytic converter exhaust a Refit: flange.
  • Page 895 EXHAUST Catalytic converter: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment a Cut the exhaust pipe (see 19B, Exhaust, Exhaust: component jack Precautions for repair, page 19B-12) in the desi- gnated area to be cut (see 19B, Exhaust, Exhaust: Parts and consumables for the repair work, page 19B-1) .
  • Page 896 EXHAUST Catalytic converter: Removal - Refitting a Degrease the bearing faces of the catalytic conver- a Check: ter using SURFACE CLEANER and clean cloths - that all the exhaust pipe heat shields are in place (see Vehicle: Parts and ingredients for the repai- and properly attached.
  • Page 897 EXHAUST Catalytic converter: Removal - Refitting F9Q, and 870 a The catalytic converter is not sold separately in the Parts Department. To replace it, the particle filter must be replaced (see 19B, Exhaust, Particle fil- ter: Removal - Refitting, page 19B-47) . 19B-23...
  • Page 898 EXHAUST Catalytic converter: Removal - Refitting F9Q, and 872 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) . WARNING To prevent the surrounding components from ove- rheating, do not damage (tear, pierce, bend, etc.) a...
  • Page 899 EXHAUST Catalytic converter: Removal - Refitting F9Q, and 872 II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new exhaust flange seal, - the catalytic converter. IMPORTANT Position the « nut and bolt securing the sleeve » assembly so that the assembly cannot come into contact with the underbody.
  • Page 900 EXHAUST Catalytic converter: Removal - Refitting - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Tightening torquesm Washing), - the scuttle panel grille (see Scuttle panel grille: catalytic converter studs 9 N.m Removal - Refitting) (56A, Exterior equipment), on the turbocharger - the scoop under the scuttle panel grille (see Scoop catalytic converter ups-...
  • Page 901 EXHAUST Catalytic converter: Removal - Refitting 137955 135754 a Remove: a Remove the clips (3) from the electric coolant pump. a Move aside the electric water pump. - the timing end lifting eye bolt (2) , - the lifting eye on the timing end, - the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres), - the front section of the front right-hand wheel arch...
  • Page 902 EXHAUST Catalytic converter: Removal - Refitting 135708 21926 a Remove: a Disconnect the downstream oxygen sensor connec- tor (8) . - the bolts (5) from the driveshaft relay bearing, a Unclip the downstream oxygen sensor wiring. - the driveshaft relay bearing. II - OPERATION FOR REMOVAL OF PART CONCERNED If replacing the catalytic converter...
  • Page 903 EXHAUST Catalytic converter: Removal - Refitting a parts always to be replaced: catalytic converter stud on the turbocharger (if loosened) (10,09,01, 04). Note: If a stud loosens during removal, coat it with HIGH RESISTANCE THREADLOCK (see Vehi- cle: Parts and ingredients for the repairwork) (04B, Consumables - Products).
  • Page 904 EXHAUST Catalytic converter: Removal - Refitting a Refit: - a new right-hand differential output seal (see Diffe- rential output seal: Removal - Refitting) (21A, - the connecting hose (see 19B, Exhaust, Connec- Manual gearbox), ting hose: Removal - Refitting, page 19B-60) , - the front right-hand wheel driveshaft (see Front ri- - the catalytic converter strut.
  • Page 905 EXHAUST Expansion chamber: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) WARNING...
  • Page 906 EXHAUST Expansion chamber: Removal - Refitting REFITTING I - OPERATION FOR REFITTING PART CONCERNED a Refit the expansion chamber using a component jack. IMPORTANT Position the « nut and bolt securing the sleeve » assembly so that the assembly cannot come into contact with the underbody.
  • Page 907 EXHAUST Expansion chamber: Removal - Refitting Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 908 EXHAUST Expansion chamber: Removal - Refitting IV - FINAL OPERATION a Check: - that there is no contact with the underbody, - all the exhaust pipe heat shields are in place and properly attached. a Start the vehicle. a Check that there are no leaks and deal with them if necessary.
  • Page 909 EXHAUST Connector pipe: Removal - Refitting K9K, and 830 or 832 II - CONNECTING PIPE REMOVAL OPERATION 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 910 EXHAUST Connector pipe: Removal - Refitting K9K, and 830 or 832 - the presence and correct positioning of all the ex- REFITTING THE EXHAUST DOWNPIPE haust pipe heat shields. I - PREPARATION OPERATION FOR REFITTING a Start the vehicle. THE EXHAUST DOWNPIPE a Check that there are no leaks and deal with them if necessary.
  • Page 911 EXHAUST Connector pipe: Removal - Refitting K9K, and 830 or 832 a Start the vehicle. a Check that there are no leaks and deal with them if necessary. 19B-37...
  • Page 912 EXHAUST Connector pipe: 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) . WARNING To prevent the surrounding components from ove- rheating, do not damage (tear, pierce, bend, etc.) a...
  • Page 913 EXHAUST Connector pipe: Removal - Refitting - that all exhaust pipe heat shields are present. a Start the vehicle. a Check that there are no leaks. 19B-39...
  • Page 914 EXHAUST Silencer: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 915 EXHAUST Silencer: Removal - Refitting REFITTING I - REFITTING OPERATION FOR PARTS CONCERNED a Fit the exhaust silencer using a component jack. a Refit: - the exhaust silencer bolt, - the expansion chamber bolt. a Fit a new After-Sales sleeve between the expansion chamber and the exhaust silencer (see 19B, Ex- haust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 916 EXHAUST Silencer: Removal - Refitting Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) . WARNING To prevent the surrounding components from ove- rheating, do not damage (tear, pierce, bend, etc.) a...
  • Page 917 EXHAUST Silencer: Removal - Refitting II - FINAL OPERATION a Check: - that all the exhaust pipe heat shields are in place and properly attached. - that there is no contact with the underbody. a Start the vehicle. a Check that there are no leaks and deal with them if necessary.
  • Page 918 EXHAUST Silencer: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 919 EXHAUST Silencer: Removal - Refitting a Check that there are no leaks. 19B-45...
  • Page 920 EXHAUST Silencer: Removal - Refitting Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) . WARNING To prevent the surrounding components from ove- rheating, do not damage (tear, pierce, bend, etc.) a...
  • Page 921 EXHAUST Particle filter: Removal - Refitting F9Q, and 870 Essential equipment component jack diagnostic tool 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 - Refitting) (80A, Battery).
  • Page 922 EXHAUST Particle filter: Removal - Refitting F9Q, and 870 REFITTING I - REFITTING PREPARATION OPERATION a Always replace the exhaust bracket seal. a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean and degrease the bea- ring faces between the exhaust flange and the particle filter.
  • Page 923 EXHAUST Particle filter: Removal - Refitting F9Q, and 870 a Check that there are no leaks and deal with them if necessary. a Refit the engine undertray. 19B-49...
  • Page 924 EXHAUST Exhaust gas temperature sensor: Removal - Refitting F9Q, and 870 II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Mot. 1807 Spanner tightening exhaust gas temperature sen- Tightening torquesm the exhaust gas tempe- 40 N.m rature sensor REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle:...
  • Page 925 EXHAUST Exhaust gas temperature sensor: Removal - Refitting F9Q, and 870 - the windscreen wiper arms (see Rear screen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), - the engine undertray, - the engine cover. 137667 a Remove the exhaust gas temperature sensor (3) using the tool (Mot.
  • Page 926 EXHAUST Particle filter pressure sensor: Removal - Refitting F9Q, and 870 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 927 EXHAUST Particle filter temperature sensors: Removal - Refitting F9Q, and 870 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 - Refitting) (80A, Battery).
  • Page 928 EXHAUST Exhaust fuel injector: Removal - Refitting F9Q, and 870 II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm the bolt of the exhaust 25 N.m fuel injector clamp 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 19B, Exhaust, Exhaust: Precautions...
  • Page 929 EXHAUST Exhaust fuel injector: Removal - Refitting F9Q, and 870 REFITTING I - REFITTING PREPARATION OPERATION 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 930 EXHAUST Exhaust fuel injector solenoid valve: Removal - Refitting F9Q, and 870 REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Re- fitting) (80A, Battery). a Remove: - the engine cover, - the fuel temperature sensor (see 13B, Diesel in- jection, Fuel temperature sensor: Removal - Refitting, page 13B-118) .
  • Page 931 EXHAUST Exhaust fuel injector solenoid valve: Removal - Refitting F9Q, and 870 a Connect: - the connector of the exhaust fuel injector solenoid valve, - the upper union of the fuel pipe of the exhaust fuel injector solenoid valve. III - FINAL OPERATION a Refit: - the fuel temperature sensor (see 13B, Diesel in- jection, Fuel temperature sensor: Removal -...
  • Page 932 EXHAUST Exhaust fuel injector cooler: Removal - Refitting F9Q, and 870 II - OPERATION FOR REMOVAL OF PART Essential special tooling CONCERNED Ms. 583 Hose clamp pliers. Mot. 1448 Long nose pliers for hose clips. Tightening torquesm the nuts of the exhaust 35 N.m fuel injector cooler REMOVAL...
  • Page 933 EXHAUST Exhaust fuel injector cooler: Removal - Refitting F9Q, and 870 REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the exhaust fuel injector cooler. a Torque tighten the nuts of the exhaust fuel injec- tor cooler (35 N.m). a Connect the hoses to the exhaust fuel injector coo- ler.
  • Page 934 EXHAUST Connecting hose: Removal - Refitting Essential equipment component jack 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 19B, Exhaust, Exhaust: Precautions for repair, page 19B-12) .
  • Page 935 EXHAUST Connecting hose: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: seal between cata- lytic converter and exhaust downpipe hose (10, 08,02,21). a Use SURFACE CLEANER (see Vehicle: Parts and ingredients for the repairwork) (04B, Consu- mables - Products) to clean the bearing faces of the catalytic converter and the exhaust connecting ho- II - REFITTING OPERATION FOR PART...
  • Page 936 EXHAUST Connecting hose: Removal - Refitting F9Q, and 870 a The connecting hose is not sold separately in the Parts Department. To replace it, the particle filter must be replaced (see 19B, Exhaust, Particle fil- ter: Removal - Refitting, page 19B-47) . 19B-62...

  • Page 937: Fuel Tank: Draining

    TANK Fuel tank: Draining II - DRAINING OPERATION Essential special tooling Mot. 1311-08 Union for measuring fuel F9Q or K9K pressure. Essential equipment pneumatic transfer pump for fuels 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 938 TANK Fuel tank: Draining 99641 99641 a Connect the pneumatic transfer pump for fuels on a Connect a pneumatic transfer pump for fuels to the fuel supply pipe of the fuel priming pump. the « T » union outlet. a Remove the front engine cover. a Remove the front engine cover.
  • Page 939 Connect the fuel supply pipe on the manual fuel pri- ming pump. a Refit the manual fuel priming pump. F4R or K4M a Disconnect the pneumatic transfer pump for fuels from the « T » union outlet. a Remove the « T » union (Mot. 1311-08).
  • Page 940 TANK Fuel tank: Removal - Refitting Essential special tooling WARNING Mot. 1352 Plastic fuel pipe cutter. To prevent the surrounding components from ove- rheating, do not damage (tear, pierce, bend, etc.) a Essential equipment heat shield. component support Any damaged heat shields must be replaced. REMOVAL Tightening torquesm fuel tank bolts...
  • Page 941 TANK Fuel tank: Removal - Refitting F9Q or K9K F4R or K4M 137742 138145 a Disconnect: a Unclip the fuel level sensor module connector (4) . a Disconnect: - the fuel level sensor module connector (2) , - the fuel pipe unions (3) on the fuel level sensor mo- - the fuel level sensor module connectors (4) and (5) dule.
  • Page 942 TANK Fuel tank: Removal - Refitting F9Q or K9K F4R or K4M 137741 136442 a Remove: a Remove: - the centre heat shield clips (7) , - the centre heat shield clips (8) , - the centre heat shield. - the centre heat shield.
  • Page 943 TANK Fuel tank: Removal - Refitting F9Q or K9K F4R or K4M 137733 136447 a Remove: a Remove: - the rear heat shield bolts (9) , - the rear heat shield bolts (10) , - the rear heat shield. - the rear heat shield.
  • Page 944 TANK Fuel tank: Removal - Refitting F9Q or K9K 137735 a Unclip the rigid brake pipes (13) . a Move the rigid brake pipes slightly to one side. 137732 137734 19C-8...
  • Page 945 TANK Fuel tank: Removal - Refitting F4R or K4M 136430 a Unclip the rigid brake pipes (14) . a Move the rigid brake pipes slightly to one side. 136425 F9Q or K9K 136419 137735 a Unclip the fuel pipes (15) from the fuel tank.
  • Page 946 Move aside the fuel vapour absorber outlet pipe. the tank to the wheel arch), disconnect the offset breather pipe (16) from the fuel tank. F4R or K4M 136419 a Unclip the fuel pipes (17) from the fuel tank. a Move the fuel pipesto one side.
  • Page 947 TANK Fuel tank: Removal - Refitting II - OPERATION FOR REMOVAL OF PART If the fuel tank is being replaced CONCERNED a Remove the fuel level sensor module (see 19C, Tank, Fuel level sensor module: Removal - Refit- ting, page 19C-16) . REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Fuel pipe clip...
  • Page 948 (A) with the tool (Mot. 1352). F4R or K4M a Fit the fuel vapour absorber outlet pipe. a Connect the union of the fuel vapour absorber outlet pipe.
  • Page 949 Connect: - the fuel pipe unions on the fuel level sensor modu- - the fuel level sensor module connector. F4R or K4M a Connect: - the fuel pipe union on the fuel level sensor module, - the fuel level sensor module connectors.
  • Page 950 TANK Filler neck: Removal - Refitting a Drain the fuel tank (see 19C, Tank, Fuel tank: Drai- ning, page 19C-1) . Tightening torquesm filler neck earth bolts 21 N.m 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 951 TANK Filler neck: Removal - Refitting II - OPERATION FOR REMOVAL OF PART REFITTING CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: Fuel pipe clip between the fuel tank filler neck and the fuel tank (11,08,01,05). II - REFITTING OPERATION FOR PART CONCERNED a Refit the filler neck.
  • Page 952 TANK Fuel level sensor module: Removal - Refitting Essential special tooling Mot. 1397 Universal petrol tank gauge nut wrench. 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 953 TANK Fuel level sensor module: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED F4R or K4M F9Q or K9K 138145 a Unclip the fuel level sensor module connector (4) . 137742 a Disconnect: a Disconnect: - the fuel level sensor module connectors (4) and (5)
  • Page 954 TANK Fuel level sensor module: Removal - Refitting II - REFITTING OPERATION FOR PART CONCERNED 138143 a Remove the fuel level sensor module nut (7) using 118996 the tool (Mot. 1397). a Position: a Let the fuel drain from the fuel level sensor module. - the new seal (8) in the neck correctly, - the fuel level sensor module (9) on the fuel tank.
  • Page 955 Connect: - the fuel pipe unions on the fuel level sensor modu- - the fuel level sensor module connector. F4R or K4M a Connect: - the fuel pipe union on the fuel level sensor module, - the fuel level sensor module connectors.
  • Page 956 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps. Mot. 1453-01 Additional winder nut on engine lift support Mot. 1453. Tightening torquesm gearbox mounting bolts 62 N.m suspended engine mounting bolts of the suspended...
  • Page 957 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 134620 a Remove: 134619 a Remove the central bolt (3) from the suspended en- - the gearbox mounting bolts (5) from the suspended engine mounting, gine mounting rubber pad support.
  • Page 958 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-4) , - the battery tray (see Battery tray: Removal - Re- fitting) (80A, Battery), - the battery (see Battery : Removal - Refitting)
  • Page 959 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps. Mot. 1453-01 Additional winder nut on engine lift support Mot. 1453. Tightening torquesm left-hand suspended 62 Nm engine mounting rubber pad support bolts bolts for the suspended 62 N.m...
  • Page 960 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K4M, and 858 or 866 135948 136622 a Remove the central bolt (4) from the support of the a Unclip the hydraulic clutch pipe from the left-hand left-hand suspended engine mounting rubber pad.
  • Page 961 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the cover from the left-hand suspended engine mounting rubber pad. K4M, and 858 or 866 135948 136554 a Remove: - the bolts (6) for the left-hand suspended engine mounting rubber pad cover, - the cover from the left-hand suspended engine mounting rubber pad.
  • Page 962 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting REFITTING - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing), I - REFITTING OPERATION FOR PART - the engine cover. CONCERNED a Refit the rubber pad support for the left-hand sus- pended engine mounting.
  • Page 963 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the battery tray (see Battery tray: Removal - Re- Essential special tooling fitting) (80A, Battery), Ms. 583 Hose clamp pliers. - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-4) , Mot.
  • Page 964 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment). K9K, and 832 135506 a Unclip the battery wiring channel from the left-hand suspended engine mounting (3) .
  • Page 965 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting K9K, and 832 135470 a Disconnect the hydraulic clutch pipe from the hy- draulic clutch release bearing by pulling on the clips 135469 (6) . a Unclip the hydraulic clutch pipe from the left-hand a Fit suitable blanking plugs on: suspended engine mounting at (7) .
  • Page 966 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting K9K, and 830 or 834 134485 a Remove the left-hand suspended engine mounting support bolt (11) on the gearbox. 136633 a Unclip the hydraulic clutch pipe from the left-hand a Detach the support on the gearbox from the left- suspended engine mounting at (8) .
  • Page 967 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the left-hand suspended engine mounting support on the body. K9K, and 830 or 834 K9K, and 832 135853 a Remove: 135483 a Remove: - the left-hand suspended engine mounting support bolts (14) on the gearbox, - the left-hand suspended engine mounting support bolts (13) on the gearbox,...
  • Page 968 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the support bolt for the left-hand suspended en- gine mounting on the gearbox62 (N.m). K9K, and 832 a Remove: a Refit the lower engine tie-bar. - the safety strap(s) from the (Mot. 1453), a Tighten to torque: - the (Mot.
  • Page 969 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the scoop under the scuttle panel grille (see Scoop Essential special tooling under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps.
  • Page 970 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the front section of the front left-hand wheel arch liner (see Front wheel arch liner: Removal - Re- fitting) (55A, Exterior protection). II - OPERATION FOR REMOVAL OF PART CONCERNED 136595 134247 a Fit the (Mot.
  • Page 971 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: seal between cata- lytic converter and exhaust downpipe hose (10, 08,02,21). II - REFITTING OPERATION FOR PART CONCERNED a Refit the left-hand suspended engine mounting sup- port on the gearbox.
  • Page 972 ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting a Refit: - the lower engine tie-bar (see 19D, Engine moun- ting, Lower engine tie-bar: Removal - Refitting, page 19D-33) , - the engine undertray. a Clip on the battery wiring channel. a Refit: - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting)
  • Page 973 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps. Mot. 1453-01 Additional winder nut on engine lift support Mot. 1453. Essential equipment safety strap(s) indelible pencil Tightening torquesm bolts for the suspended 62 N.m engine mounting rubber...
  • Page 974 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting a Remove: II - OPERATION FOR REMOVAL OF PART CONCERNED - the bolts (2) from the right-hand suspended engine mounting cover, - the bolt (3) from the rubber pad on the right-hand suspended engine mounting, - the right-hand suspended engine mounting.
  • Page 975 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting REMOVAL Essential special tooling Mot. 1453 Multiple-adjusting engine I - REMOVAL PREPARATION OPERATION mounting support with retai- ning straps. a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). Mot.
  • Page 976 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting K9K, and 832 K9K, and 830 134494 135412 a Disconnect the diesel fuel return pipe from the fuel a Disconnect the diesel fuel return pipe from the high return rail at (2) . pressure pump union at (2) .
  • Page 977 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 134172 a Remove the bonnet stop (5) . 134997 a Fit the (Mot. 1453) fitted with the (Mot. 1453-01) (6) with a safety strap(s) (7) . 19D-22...
  • Page 978 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED K9K, and 832 K9K, and 830 134221 135411 a Remove the bolts (9) for the right-hand suspended engine mounting « rubber pad - cover » assembly from the body.
  • Page 979 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting K9K, and 832 K9K, and 830 134495 135411 a Remove: a Remove: - the bolts (10) for the right-hand suspended engine - the bolts (10) for the right-hand suspended engine mounting « rubber pad - cover » assembly from the mounting «...
  • Page 980 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting - the bolts for the right-hand suspended engine mounting « rubber pad - cover » assembly on K9K, and 832 the body (62 N.m). a Remove the blanking plugs from: K9K, and 832 - the diesel return pipe opening, a Refit the upper engine tie-bar.
  • Page 981 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps. Mot. 1453-01 Additional winder nut on engine lift support Mot. 1453. Essential equipment safety strap(s) Tightening torquesm upper engine tie-bar 115 N.m bolts bolts for the right-hand...
  • Page 982 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 134645 134644 a Disconnect: - the petrol vapour rebreathing solenoid valve pipe (1) , - the fuel supply pipe (2) on the injector rail, a Insert the blanking plugs. a Unclip the pipes from the cover of the right-hand suspended engine mounting at (3) .
  • Page 983 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 136953 a Fit the tool (Mot. 1453) equipped with the tool (Mot. II - OPERATION FOR REMOVAL OF PART 1453-01) using a safety strap(s). CONCERNED 134646 a Remove: - the upper engine tie-bar bolts (4) , 19D-28...
  • Page 984 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting - the upper engine tie-bar (5) . II - FINAL OPERATION a Remove the tool (Mot. 1453) equipped with the tool (Mot. 1453-01) using the safety strap(s). a Refit: - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille:...
  • Page 985 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting Essential special tooling Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps. Mot. 1453-01 Additional winder nut on engine lift support Mot. 1453. Essential equipment indelible pencil Tightening torquesm right-hand suspended 62 N.m engine mounting bolts engine tie-bar bolt on...
  • Page 986 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED 133990 a Unclip the fuel pipes (3) . 136181 a Remove: - the right-hand suspended engine mounting bolts (5) on the body, - the bolts (6) from the right-hand suspended engine mounting on the engine, - the right-hand suspended engine mounting.
  • Page 987 ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting - the scoop under the scuttle panel grille (see Scoop under scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (56A, Exterior equipment), - the windscreen wiper arms (see Windscreen wi- per arm: Removal - Refitting) (85A, Wiping - Washing),...
  • Page 988 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting II - FINAL OPERATION a Refit the engine undertray. Tightening torquesm 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 989 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm lower engine tie-bar 62 N.m K9K, and 832 support bolts lower engine tie-bar bolt 180 N.m on the subframe lower engine tie-bar bolt 180 N.m on the lower engine tie- bar support...
  • Page 990 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting - the lower engine tie-bar bolt on the lower engi- ne tie-bar support (180 N.m). K9K, and 830 or 834 K9K, and 830 or 834 a Refit without tightening: - the lower engine tie-bar, - the lower engine tie-bar tie rod.
  • Page 991 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting Tightening torquesm engine tie-bar bolt on its 180 N.m support engine tie-bar bolt on 180 N.m the subframe REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
  • Page 992 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting - the gearbox lower engine tie-bar bolt (2) , - the lower engine tie-bar. Tightening torquesm lower engine tie-bar bolt 105 N.m on the gearbox lower engine tie-bar bolt 105 N.m on the front axle sub- K4M, and 858 or 866 frame reinforcement bolt secu-...
  • Page 993 ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting K4M, and 858 or 866 a Refit the lower engine tie-bar with its reinforcement. a Tighten to torque: - the lower engine tie-bar bolt on the gearbox (105 N.m), - the lower engine tie-bar bolt on the front axle subframe (105 N.m).

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