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Logan X90 Assembly

Engine and lower engine
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Engine
1
assembly
10A
11A
12A
13A
ANTIPOLLUTION
14A
16A
17A
17B
19A
19B
19C
"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."
and
lower
X90
APRIL 2004
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.
© Renault s.a.s. 2004
engine
Edition Anglaise

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Summary of Contents for Logan X90

  • Page 1: Fuel Mixture

    Engine lower engine assembly ENGINE AND LOWER ENGINE ASSEMBLY TOP AND FRONT OF ENGINE FUEL MIXTURE FUEL SUPPLY ANTIPOLLUTION STARTING - LOAD IGNITION PETROL INJECTION COOLING SYSTEM EXHAUST RESERVOIR APRIL 2004 Edition Anglaise "The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.

  • Page 2: Engine Mounting

    ENGINE MOUNTING APRIL 2004 Edition Anglaise "The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault. specifications current when it was prepared. The reproduction or translation in part of whole of the present document, as well as the use The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written production of the various component units and accessories from which his vehicles are...

  • Page 3: Table Of Contents

    L90 - Section 1 L90 - Section 1 ContentsPage Contents ENGINE AND LOWER ENGINE ASSEMBLY FUEL SUPPLY Engine identification Petrol supply circuit 13A-1 Oil filter 10A-1 Injector rail - Injectors 13A-2 Oil consumption 10A-3 Fuel pressure regulator:Checking 13A-6 Oil pressure 10A-4 Electric fuel: Checking 13A-7...

  • Page 4: Table Of Contents

    Contents PETROL INJECTION COOLING SYSTEM Location of components 17B-1 Water pump 19A-14 Oxygen sensors 17B-7 Thermostat 19A-18 Position and speed sensor 17B-11 Engine cooling fan assembly 19A-19 Fuel supply computer 17B-13 Computer: Connection 17B-19 EXHAUST Special notes 17B-21 General information 19B-1 Injection warning light 17B-23...

  • Page 5: Oil Filter

    ENGINE AND LOWER ENGINE ASSEMBLY Oil filter L90, and K7J, and 710 Essential special tooling Mot. 1329 Oil filter cover - 76 mm diameter REPLACING THE OIL FILTER 109223 Remove the oil filter using tool (Mot. 1329). Coat the sealing ring of the new oil filter with engine oil.
  • Page 6 ENGINE AND LOWER ENGINE ASSEMBLY Oil filter L90, and K7M, and 710 Essential special tooling Mot. 1329 Oil filter cover - 76 mm diameter REPLACING THE OIL FILTER 109223 Remove the oil filter using tool (Mot. 1329). Coat the sealing ring of the new oil filter with engine oil.

  • Page 7: Oil Consumption

    ENGINE AND LOWER ENGINE ASSEMBLY Oil consumption L90, and K7J or K7M PROCEDURE FOR MEASURING OIL CONSUMPTION 1 - Filling to the maximum level Note: The operation should be carried out with the engine warm after the fan assembly has cut in once.

  • Page 8: Oil Pressure

    ENGINE AND LOWER ENGINE ASSEMBLY Oil pressure L90, and K7J or K7M I -CHECKING Special tooling required Mot. 36-05 Oil pressure gauge kit Ensure that the engine oil level is between the "MIN" and "MAX" marks. 87363 Use the tool (Mot. 836-05) and a long dowel of 22 mm. The oil pressure check must be carried out with the en- gine warm (approximately 80˚C).
  • Page 9 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 Essential special tooling Tightening torquesm Mot. 1202-01 Clip pliers for cooling shock absorber base 10,5 daNm system hose clips bolts (large model) brake calliper mounting 10.5 daNm Mot. 1202-02 Clip pliers for cooling bolts system hose clips...
  • Page 10 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 107846 109184 Disconnect the battery, starting with the negative ter- minal. Remove: - fuse and relay cover (1), - the fuse holders and relays from their supports (2), - battery mounting clamp (3), - the battery.
  • Page 11 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 Drain: - the engine oil if necessary, - the gearbox oil if necessary, - the cooling circuit via the bottom hose, using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
  • Page 12 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 DIRECTION ASSISTEE, and BASIC HEATING 107924 Remove the power assisted steering pipe mounting bolts: - from the top of sub-frame (11), - on the multifunction support, - on the rear of the cylinder block. Disconnect: 109398 - the low pressure hose on the power assisted stee-...
  • Page 13 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 DIRECTION MANUELLE, and AIR CONDITIONING DIRECTION ASSISTEE, and AIR CONDITIONING 109396 109396 Disconnect connectors (14) of the fan assembly. Disconnect fan assembly connectors (12). 108107 Disconnect connector (13) from the refrigerant pres- sure sensor.
  • Page 14 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 Drain the air conditioning circuit using the filling sta- tion. Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to pre- vent moisture from getting into the circuit.
  • Page 15 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 107357 108565 Disconnect: Disconnect cooling hoses (22). - the petrol vapour absorber bleeding solenoid valve connector, - the brake servo pipe from the inlet manifold, - petrol vapour rebreather pipe (20) from the inlet manifold.
  • Page 16 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 107934 107935 Remove mounting bolt (24) from the earth strap on the gearbox. 99070 Remove: - brake callipers (25) and attach them to the shock absorbers, - track rod ends (26), - bolts (27) from the shock absorber bases, - upper mounting bolts (28) of the sub-frame tie rods, - the two mounting bolts from the steering rack.
  • Page 17 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 109494 109214 Remove: Remove mounting bolt (32) from the gear lever fork. - the clutch control cable from clutch fork (29), Attach the gearbox control linkage to the body. - the clutch control cable from sleeve stop (30).
  • Page 18 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 109495 Fit engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an ancho- ring point. 109229 Put a shim under the engine on the right-hand side of the sub-frame: - put a rubber shim under multifunction support (34), - fit tool (Mot.
  • Page 19 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 17765 Place tool (Mot. 1390) under the sub-frame. Lower the vehicle down onto the four pads of tool (Mot. 1390). 107929 Remove mounting nut (36) of the gearbox cover on the gearbox rubber mounting.
  • Page 20 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 REFITTING Torque tighten: - the gearbox rubber mounting mounting bolts (10.5 daNm), - the gearbox cover mounting nut on the gearbox rubber mounting (6.2 daNm), - the sub-frame mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2...
  • Page 21 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7J, and 710 DIRECTION ASSISTEE, and AIR CONDITIONING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running.
  • Page 22 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 Essential special tooling Tightening torquesm Mot. 1202-01 Clip pliers for cooling shock absorber base 10.5 daNm system hose clips bolts (large model) brake calliper mounting 10.5 daNm Mot. 1202-02 Clip pliers for cooling bolts system hose clips...
  • Page 23 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 107846 109184 Disconnect the battery, starting with the negative ter- minal. Remove: - fuse and relay cover (1), - the fuse holders and relays from their supports (2), - battery mounting clamp (3), - the battery.
  • Page 24 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 Drain: - the engine oil if necessary, - the gearbox oil if necessary, - the cooling circuit via the bottom hose, using tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot. 1448).
  • Page 25 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 DIRECTION ASSISTEE, and BASIC HEATING 107924 Remove the power assisted steering pipe mounting bolts: - from the top of sub-frame (11), - on the multifunction support, - on the rear of the cylinder block. Disconnect: 109398 - the low pressure hose on the power assisted stee-...
  • Page 26 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 DIRECTION MANUELLE, and AIR CONDITIONING DIRECTION ASSISTEE, and AIR CONDITIONING 109396 109396 Disconnect fan assembly connectors (14). Disconnect fan assembly connectors (12). 108107 Disconnect connector (13) from the refrigerant pres- sure sensor.
  • Page 27 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 Drain the air conditioning circuit using filling station. Disconnect the air conditioning pipe unions on the air conditioning compressor. WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to pre- vent moisture from getting into the circuit.
  • Page 28 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 107357 108565 Disconnect: Disconnect the cooling hoses (22). - the petrol vapour absorber bleeding solenoid valve connector, - the brake servo pipe from the inlet manifold, - petrol vapour rebreather pipe (20) from the inlet manifold, - fuel supply pipe (21) from the injection rail.
  • Page 29 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 107934 107935 Remove mounting bolt (24) from the earth strap on the gearbox. 99070 Remove: - brake callipers (25) and attach them to the shock absorbers, - track rod ends (26), - bolts (27) of the shock absorber bases, - upper mounting bolts (28) of the sub-frame tie rods, - the two mounting bolts from the steering rack.
  • Page 30 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 109494 109214 Remove: Remove mounting bolt (32) from the gear lever fork. - the clutch control cable from clutch fork (29), Attach the gearbox control linkage to the body. - the clutch control cable from sleeve stop (30).
  • Page 31 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 109495 Fit engine support tool (Mot. 1453) with the retaining belt, by taking the timing end lifting eye as an ancho- ring point. 109229 Put a shim under the engine on the right-hand side of the sub-frame: - put a rubber shim under multifunction support (34), - fit tool (Mot.
  • Page 32 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 17765 Place tool (Mot. 1390) under the sub-frame. Lower the vehicle onto the four pads of tool (Mot. 1390). 107929 Remove mounting nut (36) of the gearbox cover on the gearbox rubber mounting.
  • Page 33 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 REFITTING Torque tighten: - the gearbox rubber mounting mounting bolts (10.5 daNm), - the gearbox cover mounting nut on the gearbox rubber mounting (6.2 daNm), - the sub-frame mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2...
  • Page 34 ENGINE AND LOWER ENGINE ASSEMBLY Engine/gearbox assembly L90, and K7M, and 710 DIRECTION ASSISTEE, and AIR CONDITIONING Fill up the power assisted steering circuit. Bleed the power assisted steering circuit by turning the steering wheel fully in one direction then the other with the engine running.
  • Page 35 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7J, and 710 Essential special tooling Tav. 1747 Threaded rods for removing the sub- frame Tightening torquesm sump mounting bolts 1.4 daNm engine to gearbox cou- 4.4 daNm pling bolts sub-frame mounting (10.5 daNm) 108648 bolts...
  • Page 36 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7J, and 710 107934 108645 Remove mounting bolt (2) of the sub-frame tie-rods. 107924 Remove sub-frame mounting bolts (3) one at a time, then replace them by the threaded rods of tool (Tav. 1747).
  • Page 37 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7J, and 710 107936 Remove: - coupling bolts (4) of the engine and gearbox, - the sump mounting bolts, - the sump. REFITTING WARNING Replace: - the sump gasket, - the sub-frame mounting bolts. 10A-33...
  • Page 38 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7J, and 710 Note: Excess sealant could be squeezed out when the parts are tightened. The sealing compound/fluid mixture can cause damage to certain compo- nents (engine, radiator, etc.). 20166 20167 Apply: - four beads (5) of RHODORSEAL 56615 mm in dia- meter, - two spots (6) of RHODORSEAL 5661 of a diameter...
  • Page 39 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7J, and 710 - the steering rack mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm).
  • Page 40 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7M, and 710 Essential special tooling Tav. 1747 Threaded rods for removing the sub- frame Tightening torquesm sump mounting bolts 1.4 daNm engine to gearbox cou- 4.4 daNm pling bolts sub-frame mounting (10.5 daNm) 108648 bolts...
  • Page 41 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7M, and 710 107924 Remove sub-frame mounting bolts (3) one at a time, then replace them by one of the threaded rods of tool (Tav. 1747). IMPORTANT 108645 Make sure the threaded rod of tool (Tav . 1747) is sufficiently screwed into the threaded hole and that the nut of the tool is properly resting on the sub-frame.
  • Page 42 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7M, and 710 107936 Remove: - the coupling bolts (4) of the engine and gearbox, - the sump mounting bolts, - the sump. REFITTING WARNING Replace: - the sump gasket, - the sub-frame mounting bolts. 10A-38...
  • Page 43 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7M, and 710 Note: Excess sealant could be squeezed out when the parts are tightened. The sealing compound/fluid mixture can cause damage to certain compo- nents (engine, radiator, etc.). 20166 20167 Apply: - four beads (5) of RHODORSEAL 56615 mm in dia- meter, - two spots (6) of RHODORSEAL 5661 of a diameter...
  • Page 44 ENGINE AND LOWER ENGINE ASSEMBLY Sump L90, and K7M, and 710 - the steering rack mounting bolts (10.5 daNm), - the sub-frame tie-rod upper mounting bolts (2.1 daNm), - the sub-frame tie-rod lower mounting bolts (6.2 daNm), - the engine tie-bar mounting bolts (10.5 daNm), - the wheel bolts (10.5 daNm).

  • Page 45: Oil Pump

    ENGINE AND LOWER ENGINE ASSEMBLY Oil pump L90, and K7J, and 710 Tightening torquesm oil pump mounting bolts 2.5 daNm REMOVAL Place the vehicle on a two-post lift. Remove the sump (see 10A, Engine and periphe- rals, Sump). 108646 Remove: - the mounting (1) bolts of the oil pump, - the oil pump.
  • Page 46 ENGINE AND LOWER ENGINE ASSEMBLY Oil pump L90, and K7M, and 710 Tightening torquesm oil pump mounting bolts 2.5 daNm REMOVAL Place the vehicle on a two-post lift. Remove the sump (see 10A, Engine and periphe- rals, Sump). 108646 Remove: - the mounting (1)bolts of the oil pump, - the oil pump.
  • Page 47 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING - the power assisted steering pump mounting bolts (2.1 daNm). Tightening torquesm Refit the alternator (see 16A, Starting - Charge, Al- ternator). multifunction support 4.4 daNm mounting bolts...
  • Page 48 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING Tightening torquesm multifunction support 4.4 daNm mounting bolts air conditioning com- 2.1 daNm pressor mounting bolts REMOVAL Place the vehicle on a two-post lift. Remove the engine undertray.
  • Page 49 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING Tightening torquesm M10 mounting bolts of 4.4 daNm the multifunction sup- port M8 mounting bolts of the 2.1 daNm multifunction support REMOVAL Place the vehicle on a two-post lift.
  • Page 50 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the M8 mounting bolts of the multifunction sup- port (2.1 daNm)(2). Refit the alternator (see 16A, Starting - Charge, Al- ternator). Proceed in the reverse order to removal.
  • Page 51 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING - the power assisted steering pump mounting bolts (2.1 daNm). Tightening torquesm Refit the alternator (see 16A, Starting - Charge, Al- ternator). multifunction support 4.4 daNm mounting bolts...
  • Page 52 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING Tightening torquesm multifunction support 4.4 daNm mounting bolts air conditioning com- 2.1 daNm pressor mounting bolts REMOVAL Place the vehicle on a two-post lift. Remove the engine undertray.
  • Page 53 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING Tightening torquesm M10 mounting bolts of 4.4 daNm the multifunction sup- port M8 mounting bolts of the 2.1 daNm multifunction support REMOVAL Place the vehicle on a two-post lift.
  • Page 54 ENGINE AND LOWER ENGINE ASSEMBLY Multifunction support L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the two M8 mounting bolts of the multifunction support (2.1 daNm)(2). Refit the alternator (see 16A, Starting - Charge, Al- ternator). Proceed in the reverse order to removal.
  • Page 55 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING Essential special tooling Mot. 1505 Belt tension setting tool (frequency meter) Mot. 1715 Belt tension setting tool (frequency meter) Tightening torquesm alternator mounting bolt 2.1 daNm alternator mounting bolt 4.4 daNm...
  • Page 56 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING 16300 Crankshaft Alternator Measuring point Refit the accessories belt. Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 Hz ±...
  • Page 57 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING II - REMOVING THE ALTERNATOR BELT Essential special tooling Mot. 1505 Belt tension setting tool (frequency meter) Mot. 1715 Belt tension setting tool (frequency meter) Tightening torquesm alternator...
  • Page 58 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING II - REFITTING THE AIR CONDITIONING COMPRESSOR BELT Note: The air conditioning compressor belt does not have a tension wheel, as it is tensioned automati- cally, and it is refitted using a tool supplied with the belt.
  • Page 59 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING 109638 109640 Mount the belt and slide round the belt fitting tool by Rotate the crankshaft clockwise until the belt is in hand clockwise by approximately 90˚.
  • Page 60 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING REFITTING Tightening torquesm WARNING tension wheel mounting 2.1 daNm bolt Replace any belt that has been removed. pulley mounting bolt 2.1 daNm WARNING wheel bolts 10.5 daNm...
  • Page 61 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING 106001 109238 Refit the accessories belt. Remove the 6 mm Allen key. Turn the engine through three revolutions to position the belt correctly. WARNING Make sure that the inner tooth on all the pulleys Proceed in the reverse order to removal.
  • Page 62 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING REFITTING Essential special tooling Mot. 1505 Belt tension setting WARNING tool (frequency meter) Replace any belt that has been removed. Mot. 1715 Belt tension setting tool (frequency meter) WARNING...
  • Page 63 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING 105999 109235 Refit the accessories belt. Insert a long bolt (7) on the multifunction support. Tension the belt using the bolt (7). WARNING Set the belt tension using tool (Mot.
  • Page 64 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING II - REMOVING THE ALTERNATOR BELT Essential special tooling Mot. 1505 Belt tension setting tool (frequency meter) Mot. 1715 Belt tension setting tool (frequency meter) Tightening torquesm alternator...
  • Page 65 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING II - REFITTING THE AIR CONDITIONING COMPRESSOR BELT Note: The air conditioning compressor belt does not have a tension wheel, as it is tensioned automati- cally, and it is refitted using a tool supplied with the belt.
  • Page 66 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING 109638 109640 Mount the belt and slide round the belt fitting tool by Rotate the crankshaft clockwise until the belt is in hand clockwise by approximately 90˚.
  • Page 67 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING REFITTING Essential special tooling Mot. 1505 Belt tension setting WARNING tool (frequency meter) Replace any belt that has been removed. Mot. 1715 Belt tension setting tool (frequency meter) WARNING...
  • Page 68 TOP AND FRONT OF ENGINE Accessories belt L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING 105999 109235 Refit the accessories belt. Insert a long bolt (7) into the multifunction support. Tension the belt using bolt (7). WARNING Set the belt tension using tool (Mot.
  • Page 69 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING REFITTING Tightening torquesm WARNING tension wheel mounting 2.1 daNm bolt Replace any belt that has been removed. idler pulley mounting 2.1 daNm bolt WARNING When replacing the belt, be sure to replace the...
  • Page 70 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING 106001 109238 Refit the accessories belt. Remove the 6 mm Allen key. Turn the engine through three revolutions to position the belt correctly. WARNING Make sure that the inner tooth on all the pulleys Proceed in the reverse order to removal.
  • Page 71 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING Essential special tooling Mot. 1505 Belt tension setting tool (frequency meter) Mot. 1715 Belt tension setting tool (frequency meter) Tightening torquesm alternator mounting bolt 2.1 daNm alternator mounting bolt 4.4 daNm...
  • Page 72 TOP AND FRONT OF ENGINE Accessories belt L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING 16300 Crankshaft Alternator Measuring point Refit the accessories belt. Tension the belt by turning the alternator. Set the belt tension using tool (Mot. 1505) or (Mot. 1715) to a value of 305 Hz ±...

  • Page 73: Timing Belt

    TOP AND FRONT OF ENGINE Timing belt L90, and K7J, and 710 Remove: Essential special tooling - the engine undertray, Mot. 1453 Multiple-adjusting - the accessories belt (see 11A, Top and front of engine mounting sup- engine, Accessories belt ). port with retaining straps - the crankshaft accessories pulley by locking the...
  • Page 74 TOP AND FRONT OF ENGINE Timing belt L90, and K7J, and 710 107359 107498 Remove TDC pin plug (2). 4 4 4 107499 Remove: - lower timing cover (3), - upper timing cover (4). 11A-20...
  • Page 75 TOP AND FRONT OF ENGINE Timing belt L90, and K7J, and 710 ADJUSTING THE TIMING 107494 107497 Remove: Rescrew the crankshaft accessories pulley bolt with - tension wheel mounting nut (7), a spacer. - the timing belt, Turn the crankshaft clockwise to bring the camshaft sprocket one tooth before the vertical axle of the - the tension wheel.
  • Page 76 TOP AND FRONT OF ENGINE Timing belt L90, and K7J, and 710 107494 107493 Fit the timing belt by aligning the belt markings with those of the sprockets of camshaft (8) and cranks- haft (9). Rolling order: - crankshaft pulley, - tension wheel, - camshaft pulley, - water pump pulley.
  • Page 77 TOP AND FRONT OF ENGINE Timing belt L90, and K7J, and 710 Angle tighten to torque the crankshaft pulley mounting bolt (3 daNm + 80˚ ± ± ± ± 5), by blocking the flywheel with a screwdriver. 107492 Fit the auxiliary timing belt tensioner tool (Mot. 1135- 01)(12).
  • Page 78 TOP AND FRONT OF ENGINE Timing belt L90, and K7M, and 710 Remove: Essential special tooling - the engine undertray, Mot. 1453 Multiple-adjusting - the accessories belt (see 11A, Top and front of engine mounting sup- engine, Accessories belt ). port with retaining straps - the crankshaft accessories pulley by locking the...
  • Page 79 TOP AND FRONT OF ENGINE Timing belt L90, and K7M, and 710 107359 107498 Remove the TDC pin plug (2). 4 4 4 107499 Remove: - the lower timing cover (3), - the upper timing cover (4). 11A-25...
  • Page 80 TOP AND FRONT OF ENGINE Timing belt L90, and K7M, and 710 ADJUSTING THE TIMING 107494 107497 Remove: Rescrew the crankshaft accessories pulley bolt with - tension wheel mounting nut (7), a spacer. - the timing belt, Turn the crankshaft clockwise to bring the camshaft sprocket one tooth before the vertical axle of the - the tension wheel.
  • Page 81 TOP AND FRONT OF ENGINE Timing belt L90, and K7M, and 710 107494 107493 Fit the timing belt by aligning the belt markings with those of the camshaft sprockets (8) and crankshaft sprockets (9). Rolling order: - crankshaft pulley, - tension wheel, - camshaft pulley, - water pump pulley.
  • Page 82 TOP AND FRONT OF ENGINE Timing belt L90, and K7M, and 710 Angle tighten to torque the crankshaft pulley mounting bolt (3 daNm + 80˚ ± ± ± ± 5), by blocking the flywheel with a screwdriver. 107492 Fit timing auxiliary belt tensioner tool (Mot. 1135- 01)(12).

  • Page 83: Cylinder Head Gasket

    TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 Essential special tooling DIRECTION ASSISTEE, and AIR CONDITIONING Mot. 1672 Lower engine support Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Mot. 1202-02 Clip pliers for cooling system hose clips (small model) Mot.
  • Page 84 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 108423 107358 Remove mounting bolts (2) from of the air filter box. Disconnect connector (4) of the ignition coil. Remove the ignition spark plug leads. Note: The ignition spark plug leads are marked on the ignition coil (cylinder number 1 engine flywheel end).
  • Page 85 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 - pipe (12) from the brake servo on the inlet manifold, - petrol vapour rebreather pipe (13) from the inlet manifold. Disconnect: - ball joint (14) from the throttle valve control cable, - cable sleeve stop (15) from the throttle valve control cable.
  • Page 86 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 10016 Remove: - the rocker cover mounting bolts, - the rocker cover. 109493 Remove: - the earth cable from the lifting eye, - hose support mounting (17) on the lifting eye. 10015 Remove: - the cylinder head mounting bolts,...
  • Page 87 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 I -CLEANING THE CYLINDER HEAD REFITTING Clean the cylinder head. WARNING IMPORTANT In order to ensure that the bolts are correctly tigh- - Do not scratch the aluminium gasket faces. tened, use a syringe to remove any oil which may - Wear goggles.
  • Page 88 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7J, and 710 10016 Fit the rocker cover with a new gasket. Tightening the rocker cover: - pretighten in order and to torque the rocker cover mounting bolts (0.2 daNm). - Torque tighten in order the rocker cover moun- ting bolts (1 daNm).
  • Page 89 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 Essential special tooling DIRECTION ASSISTEE, and AIR CONDITIONING Mot. 1672 Lower engine support Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Mot. 1202-02 Clip pliers for cooling system hose clips (small model) Mot.
  • Page 90 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 108423 107358 Remove mounting bolts (2) from of the air filter box. Disconnect connector (4) of the ignition coil. Remove the ignition spark plug leads. Note: The ignition spark plug leads are marked on the ignition coil (cylinder number 1 engine flywheel end).
  • Page 91 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 - pipe (12) from the brake servo on the inlet manifold, - petrol vapour rebreather pipe (13) from the inlet manifold. Disconnect: - ball joint (14) from the throttle valve control cable, - cable sleeve stop (15) from the throttle valve control cable.
  • Page 92 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 10016 Remove: - the rocker cover mounting bolts, - the rocker cover. 109493 Remove: - the earth cable from the lifting eye, - hose support mounting (17) on the lifting eye. 10015 Remove: - the ten cylinder head mounting bolts,...
  • Page 93 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 I -CLEANING THE CYLINDER HEAD REFITTING Clean the cylinder head. WARNING IMPORTANT In order to ensure that the bolts are correctly tigh- - Do not scratch the aluminium sealing surfaces. tened, use a syringe to remove any oil which may - Wear goggles.
  • Page 94 TOP AND FRONT OF ENGINE Cylinder head gasket L90, and K7M, and 710 10016 Fit the rocker cover with a new gasket. Tightening of the rocker cover: - Pretighten in order and to torque the rocker cover mounting bolts (0.2 daNm), - Torque tighten in order the rocker cover moun- ting bolts (1 daNm).

  • Page 95: Specifications

    FUEL MIXTURE Specifications K7J, and 710 Test carried out at idle speed Fuel Engine Pollutant emissions (mini- Vehicle type Type Suffix Depol- Idling CO (%) Lambda octane lution speed (ppm) (λ) stan- rating) (rpm) dard LS0A 0.97 Super 14.5 752 +/- unleaded LS0C Euro 3...
  • Page 96 FUEL MIXTURE Specifications K7J, and 710 Description Brand - Type Special notes Manifold pressure sensor SIEMENS 5WK9681 Piezo-resistive sensor 3-track connector: - A: earth - B: signal - C: + 5 V supply Injection order 1, 3, 4, 2 (number 1 flywheel end) Fault finding Fault finding tool CLIP only...
  • Page 97 FUEL MIXTURE Specifications K7J, and 710 Description Brand - Type Special notes Downstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust gas temperature rises above 650˚C. Heating resistor: 6 Ω at 20˚C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal...
  • Page 98 FUEL MIXTURE Specifications K7M, and 710 Test carried out at idle speed Fuel Engine (mini- Pollutant emissions Vehicle type Type Suffix Emis- Idling CO (%) Lambda octane sion speed (ppm) (λ) control rating) (rpm) LS0B 0.97 Super 14.5 752 +/- unleaded LS0D Euro 3...
  • Page 99 FUEL MIXTURE Specifications K7M, and 710 Description Brand - Type Special notes Manifold pressure sensor SIEMENS 5WK9681 Piezo-resistive sensor 3-track connector: - A: earth - B: signal - C: + 5 V supply Injection order 1, 3, 4, 2 (number 1 flywheel end) Fault finding Diagnostic tool CLIP only...
  • Page 100 FUEL MIXTURE Specifications K7M, and 710 Description Brand - Type Special notes Downstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust gas temperature rises above 650˚C. Heating resistor: 6 Ω at 20˚C 4-track connector - A: heating resistor supply - B: heating resistor earth - C: + signal - D: - signal...
  • Page 101 FUEL MIXTURE Air inlet K7J, and 710 1202 Air filter unit Throttle valve intake manifold 12A-7...
  • Page 102 FUEL MIXTURE Air inlet K7M, and 710 1202 Air filter unit Throttle valve intake manifold 12A-8...
  • Page 103 FUEL MIXTURE Air filter: Replacement K7J, and 710 REMOVAL 107574 Remove the air filter unit cover mounting bolts. Unfasten the cover mounting clips. Remove: - the air filter unit cover, - the air filter. REFITTING Proceed in the reverse order to removal. 12A-9...
  • Page 104 FUEL MIXTURE Air filter: Replacement K7M, and 710 REMOVAL 107574 Remove the air filter unit cover mounting bolts. Unfasten the cover mounting clips. Remove: - the air filter unit cover, - the air filter. REFITTING Proceed in the reverse order to removal. 12A-10...
  • Page 105 FUEL MIXTURE Air filter unit K7J, and 710 REMOVAL 108423 Remove the air filter unit mounting bolts (1). 107361 Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter unit. REFITTING Proceed in the reverse order to removal. 12A-11...
  • Page 106 FUEL MIXTURE Air filter unit K7M, and 710 REMOVAL 108423 Remove the air filter unit mounting bolts (1). 107361 Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter unit. REFITTING Proceed in the reverse order to removal. 12A-12...
  • Page 107 FUEL MIXTURE Inlet manifold K7J, and 710 Tightening torquesm inlet manifold mounting 2.5 daNm bolts inlet manifold mounting 2.5 daNm nuts REMOVAL Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative ter- minal. 107356 Unclip the ball joints (3).
  • Page 108 FUEL MIXTURE Inlet manifold K7J, and 710 IMPORTANT During this operation, be sure to: - refrain from smoking or bringing very hot objects near the working area, - beware of fuel splashing when disconnecting the union, - protect sensitive areas from fuel outflow. Disconnect the injector connectors.
  • Page 109 FUEL MIXTURE Inlet manifold K7J, and 710 REFITTING Always replace all seals that have been removed. 107777 Refit the inlet manifold, starting with the centre lower mounting nut (13). 107486 Torque tighten: - the inlet manifold mounting bolts (2.5 daNm), - the inlet manifold mounting nuts (2.5 daNm).
  • Page 110 FUEL MIXTURE Inlet manifold K7M, and 710 Tightening torquesm inlet manifold mounting 2.5 daNm bolts inlet manifold mounting 2.5 daNm nuts REMOVAL Mount the vehicle on a two post lift. Disconnect the battery, starting with the negative ter- minal. 107356 Unclip the ball joints (3).
  • Page 111 FUEL MIXTURE Inlet manifold K7M, and 710 IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects near the working area, - beware of fuel splashing when disconnecting the union, - protect sensitive areas from fuel outflow. Disconnect the injector connectors.
  • Page 112 FUEL MIXTURE Inlet manifold K7M, and 710 REFITTING Always replace all seals that have been removed. 107777 Refit the inlet manifold, starting with the centre lower mounting nut (13). 107486 Torque tighten: - the inlet manifold mounting bolts (2.5 daNm), - the inlet manifold mounting nuts (2.5 daNm).

  • Page 113: Exhaust Manifold

    FUEL MIXTURE Exhaust manifold K7J, and 710 Tightening torquesm exhaust manifold moun- 2.5 daNm ting nuts e x h a u s t d ownpipe 0.7 daNm mounting studs e x h a u s t d ownpipe 2.1 daNm mounting nuts REMOVAL Mount the vehicle on a two post lift.
  • Page 114 FUEL MIXTURE Exhaust manifold K7J, and 710 108427 Torque tighten in order the exhaust manifold mounting nuts (2.5 daNm). Torque tighten: - the exhaust downpipe mounting studs (0.7 daNm) (if studs removed), - the exhaust downpipe mounting nuts (2.1 daNm). Proceed in the reverse order to removal.
  • Page 115 FUEL MIXTURE Exhaust manifold K7M, and 710 Tightening torquesm exhaust manifold moun- 2.5 daNm ting nuts e x h a u s t d ownpipe 0.7 daNm mounting studs e x h a u s t d ownpipe 2.1 daNm mounting nuts REMOVAL Mount the vehicle on a two-post lift.
  • Page 116 FUEL MIXTURE Exhaust manifold K7M, and 710 108427 Torque tighten in order the exhaust manifold mounting nuts (2.5 daNm). Torque tighten: - the exhaust downpipe mounting studs (0.7 daNm) (if studs removed), - the exhaust downpipe mounting nuts (2.1 daNm). Proceed in the reverse order to removal.
  • Page 117 FUEL MIXTURE Throttle valve K7J, and 710 REMOVAL 108423 Remove the air filter box (1) mounting bolts. 107356 Unclip the ball joint (3). 107361 Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter box. 107357 Disconnect: - the throttle position sensor connector (4),...
  • Page 118 FUEL MIXTURE Throttle valve K7M, and 710 REMOVAL 108423 Remove the air filter box (1) mounting bolts. 107356 Unclip the ball joint (3). 107361 Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter box. 107357 Disconnect: - the throttle position sensor connector (4),...
  • Page 119 FUEL MIXTURE Throttle body: Connection K7M, and 710 109393 To connect the throttle valve, see Technical Note Wi- ring Diagrams, Components 222 and 649. 12A-25...
  • Page 120 FUEL MIXTURE Throttle body: Connection K7J, and 710 109393 For information on connecting the throttle valve, see Technical Note: Wiring diagrams, Components 222 and 649. 12A-26...

  • Page 121: Petrol Supply Circuit

    FUEL SUPPLY Petrol supply circuit K7J, and 710 – K7M, and 710 Operating diagram of the petrol supply circuit 19310 The fuel system does not have a return. The fuel pressure does not vary with engine load. The circuit comprises: - a petrol "pump-gauge-filter"...
  • Page 122 FUEL SUPPLY Injector rail - Injectors K7J, and 710 Tightening torquesm injection rail mounting 0.7 daNm bolts REMOVAL Disconnect the battery, starting with the negative ter- minal. 107357 Disconnect: - the injector connectors, - the throttle position sensor connector (3). 108423 Remove the air filter box (1) mounting bolts.
  • Page 123 FUEL SUPPLY Injector rail - Injectors K7J, and 710 Proceed in the reverse order to removal. IMPORTANT WARNING During this operation, it is essential to: Connect the battery, starting with the positive ter- minal; carry out the necessary programming (see - refrain from smoking or bringing incandescent 80A, Battery, Battery: Remove and Refit).
  • Page 124 FUEL SUPPLY Injector rail - Injectors K7M, and 710 Tightening torquesm injection rail mounting 0.7 daNm bolts REMOVAL Disconnect the battery, starting with the negative ter- minal. 107357 Disconnect: - the injector connectors, - the throttle position sensor connector (3). 108423 Remove the air filter box (1) mounting bolts.
  • Page 125 FUEL SUPPLY Injector rail - Injectors K7M, and 710 Proceed in the reverse order to removal. IMPORTANT WARNING During this operation, it is essential to: Connect the battery, starting with the positive ter- minal; carry out the necessary programming (see - refrain from smoking or bringing incandescent 80A, Battery, Battery: Remove and Refit).
  • Page 126 FUEL SUPPLY Fuel pressure regulator:Checking K7J or K7M, and 710 Essential special tooling Mot. 1311-08 Union for measuring fuel pressure Mot. 1311-01 Fuel pressure pres- sure gauges and soc- ket unions IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects near the working area, - beware of fuel splashes when disconnecting the union,...
  • Page 127 FUEL SUPPLY Electric fuel: Checking K7J or K7M, and 710 Essential special tooling Mot. 1311-08 Union for measuring fuel pressure Mot. 1311-01 Fuel pressure pres- sure gauges and soc- ket unions IMPORTANT During this operation, be sure to: - refrain from smoking or bringing very hot objects close to the working area, - beware of fuel splashes when disconnecting the union,...
  • Page 128 FUEL SUPPLY Electric fuel: Checking K7J or K7M, and 710 109172 Connect the connector terminal (5 ) to + battery feed. Note the time taken for the measuring cylinder to fill 109174 Immerse the pipe (2) in a 2 l measuring cylinder. Note: The minimum pump flow is 60 l/h.
  • Page 129 ANTIPOLLUTION Petrol vapour rebreathing: Operation K7J or K7M, and 710 I -OPERATING DIAGRAM OF THE CIRCUIT 108415 97393 II - OPERATING PRINCIPLE Tank The tank is vented by means of the fuel vapour absor- ber. Fuel vapour absorber Fuel vapour is trapped by the active charcoal contained in the absorber as it passes through.
  • Page 130 ANTIPOLLUTION Fuel vapour rebreathing: Checking K7J or K7M, and 710 II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS Essential equipment The fuel vapour absorber bleed solenoid valve is diagnostic tool controlled by track 4 of the computer connector when: - the coolant temperature is above 60˚C, I -CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED - the air temperature is above 10˚C,...

  • Page 131: Fuel Vapour Canister

    ANTIPOLLUTION Fuel vapour canister K7J or K7M, and 710 Tightening torquesm fuel vapour absorber 21 Nm mounting nuts The fuel vapour absorber is located behind the front bumper on the right-hand side of the vehicle. REMOVAL Mount the vehicle on a lift. Remove the plastic screen from underneath the fuel vapour absorber.
  • Page 132 ANTIPOLLUTION Fuel vapour canister:Checking K7J or K7M, and 710 • No: there is an electrical fault, check the circuit. Essential special tooling - If not: under the conditions required for bleeding Mot. 1311-01 Fuel pressure pres- (see 14A, Antipollution, Fuel vapour rebrea- sure gauges and soc- thing), the vacuum pressure should increase (the ket unions...
  • Page 133 STARTING - LOAD Alternator: General information K7J or K7M, and 710 I -OPERATION - the light goes out when the engine is switched off, These vehicles are equipped with an internal ventilation - if the indicator light comes on while the engine is run- alternator with integrated regulator, and a warning light ning, it indicates a battery «...
  • Page 134 STARTING - LOAD Alternator K7J, and 710, and DIRECTION MANUELLE REFITTING Tightening torquesm WARNING alternator mounting bolt 2.1 daNm Replace any belt that has been removed. alternator mounting bolt 4.4 daNm WARNING REMOVAL When replacing the belt, be sure to replace the tension wheels and idler pulleys.
  • Page 135 STARTING - LOAD Alternator K7M, and 710, and DIRECTION MANUELLE REFITTING Tightening torquesm WARNING alternator mounting bolt 2.1 daNm Replace any belt that has been removed. alternator mounting bolt 4.4 daNm WARNING REMOVAL When replacing the belt, be sure to replace the tension wheels and idler pulleys.
  • Page 136 STARTING - LOAD Alternator K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING Tightening torquesm alternator mounting 2.1 daNm bolts power assisted steering 2.1 daNm pump mounting bolts REMOVAL Remove the accessories belt (see 11A, Top and front of engine, Accessories belt). 109225 109235 Remove:...
  • Page 137 STARTING - LOAD Alternator K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING 109217 Disconnect lead (4) from the alternator. Disconnect the connector (5). Remove: - alternator mounting bolts (3), - the alternator. REFITTING WARNING Replace any belt that has been removed. WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys.
  • Page 138 STARTING - LOAD Alternator K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING Tightening torquesm alternator mounting 2.1 daNm bolts power assisted steering 2.1 daNm pump mounting bolts REMOVAL Remove the accessories belt (see 11A, Top and front of engine, Accessories belt). 109225 109235 Remove:...
  • Page 139 STARTING - LOAD Alternator K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING 109217 Remove lead (4) from the alternator. Disconnect connector (5). Remove: - alternator mounting bolts (3), - the alternator. REFITTING WARNING Replace any belt that has been removed. WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys.
  • Page 140 STARTING - LOAD Alternator K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING Tightening torquesm alternator mounting 2.1 daNm bolts air conditioning com- 2.1 daNm pressor mounting bolts power assisted steering 2.1 daNm pump mounting bolts REMOVAL Remove: - the front bumper (see 55A, Exterior protection, Front bumper), - the accessories belt (see 11A, Top and front of engine, Accessories belt).
  • Page 141 STARTING - LOAD Alternator K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the alternator. REFITTING WARNING Replace any belt that has been removed. WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator.
  • Page 142 STARTING - LOAD Alternator K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING Tightening torquesm alternator mounting 2.1 daNm bolts air conditioning com- 2.1 daNm pressor mounting bolts power assisted steering 2.1 daNm pump mounting bolts REMOVAL Remove: - the front bumper (see 55A, Exterior protection, Front bumper), - the accessories belt (see 11A, Top and front of engine, Accessories belt).
  • Page 143 STARTING - LOAD Alternator K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING - the alternator. REFITTING WARNING Replace any belt that has been removed. WARNING When replacing the belt, be sure to replace the tension wheels and idler pulleys. Refit the alternator.
  • Page 144 STARTING - LOAD Starter: Identification K7J or K7M, and 710 Engine Starter MITSUBISHI M000T45171ZT 16A-12...

  • Page 145: Starter Motor

    STARTING - LOAD Starter motor K7J, and 710 Tightening torquesm starter mounting bolts 4.4 daNm REMOVAL Mount the vehicle on a lift. Disconnect the battery, starting with the negative ter- minal. 109214 Remove gearbox control linkage mounting bolt (2). WARNING The linkage is fitted with a spacer;...
  • Page 146 STARTING - LOAD Starter motor K7J, and 710 107486 109215 Remove: - the starter motor mounting bolts (4), - the starter. REFITTING Tighten to torque the starter mounting bolts (4.4 daNm). Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive ter- minal;...
  • Page 147 STARTING - LOAD Starter motor K7M, and 710 Tightening torquesm starter mounting bolts 4.4 daNm REMOVAL Mount the vehicle on a lift. Disconnect the battery, starting with the negative ter- minal. 109214 Remove gearbox control linkage mounting bolt (2). WARNING The linkage is fitted with a spacer;...
  • Page 148 STARTING - LOAD Starter motor K7M, and 710 107486 109215 Remove: - the starter motor mounting bolts (4), - the starter. REFITTING Tighten to torque the starter mounting bolts (4.4 daNm). Proceed in the reverse order to removal. WARNING Connect the battery, starting with the positive ter- minal;...
  • Page 149 IGNITION coils K7J, and 710 Tightening torquesm ignition coil unit moun- 1.5 daNm ting bolts REMOVAL 107358 Disconnect: - the spark plug leads, - ignition coil unit connector (1). Remove: - the ignition coil unit mounting bolts, - the ignition coil unit. 17A-1...
  • Page 150 IGNITION coils K7J, and 710 REFITTING 106640 When refitting coils or spark plug leads, it is essential to apply a bead of GRAISSE FLUOREE (part num- ber 82 00 168 855) with a diameter of 2 mm around the inner edge of the high voltage caps. Proceed in the reverse order to removal.
  • Page 151 IGNITION coils K7M, and 710 Tightening torquesm ignition coil unit moun- 1.5 daNm ting bolts REMOVAL 107358 Disconnect: - the spark plug leads, - ignition coil unit connector (1). Remove: - the ignition coil unit mounting bolts, - the ignition coil unit. 17A-3...
  • Page 152 IGNITION coils K7M, and 710 REFITTING 106640 When refitting coils or spark plug leads, it is essential to apply a bead of GRAISSE FLUOREE (part num- ber 82 00 168 855) with a diameter of 2 mm around the inner edge of the high voltage caps. Proceed in the reverse order to removal.

  • Page 153: Spark Plugs

    IGNITION Spark plugs K7J or K7M, and 710 - the spark plugs using tool (Ele. 1382). Engines Brand Type CHAMPION RYCLC87 SAGEM RFN58LZ CHAMPION RYCLC87 SAGEM RFN58LZ Flat skirt with seal Gap: 0.95 ± ± ± ± 0.05 mm 107358 Tightening: spark plugs (2.5 to 3 daNm) Remove: - the spark plug leads,...
  • Page 154 PETROL INJECTION Location of components K7J, and 710 108559 Ignition coil unit Air filter Throttle valve Air temperature sensor Air pressure sensor Injection computer Oil pressure sensor Upstream oxygen sensor Coolant temperature sensor (10) Engine position and speed sen- 108562 Injection computer 17B-1...
  • Page 155 PETROL INJECTION Location of components K7J, and 710 (11) Fuel pump relay (12) Injection locking relay 109211 Upstream oxygen sensor 107357 Oil pressure sensor Coolant temperature sensor (14) Throttle position potentiometer (10) Engine position and speed sen- (13) Idle speed regulator (15) Injectors 107356...
  • Page 156 PETROL INJECTION Location of components K7J, and 710 DIRECTION ASSISTEE Air pressure sensor Air temperature sensor 107358 Ignition coil unit 109397 (17) Power assisted steering pres- sure switch AIR CONDITIONING 109219 (16) Pinking sensor 108107 (18) Air conditioning pressostat 17B-3...
  • Page 157 PETROL INJECTION Location of components K7M, and 710 108559 Ignition coil unit Air filter Throttle valve Air temperature sensor Air pressure sensor Injection computer Oil pressure sensor Upstream oxygen sensor Coolant temperature sensor (10) Engine position and speed sen- 108562 Injection computer 17B-4...
  • Page 158 PETROL INJECTION Location of components K7M, and 710 (11) Fuel pump relay (12) Injection locking relay 109211 Upstream oxygen sensor 107357 Oil pressure sensor Coolant temperature sensor (14) Throttle position potentiometer (10) Engine position and speed sen- (13) Idle speed regulator (15) Injectors 107356...
  • Page 159 PETROL INJECTION Location of components K7M, and 710 DIRECTION ASSISTEE Air pressure sensor Air temperature sensor 107358 Ignition coil unit 109397 (17) Power assisted steering pres- sure switch AIR CONDITIONING 109219 (16) Pinking sensor 108107 (18) Air conditioning pressostat 17B-6...
  • Page 160 PETROL INJECTION Oxygen sensors K7M, and 710 REMOVAL Essential special tooling Mot. 1495 22 mm oxygen sensor I -UPSTREAM OXYGEN SENSOR removal / refitting soc- ket - 1/2" square drive and a 24 mm Allen key Tightening torquesm oxygen sensors 4.5 daNm heat shield mounting 2.5 daNm...
  • Page 161 PETROL INJECTION Oxygen sensors K7M, and 710 II - DOWNSTREAM OXYGEN SENSOR 108424 Mount the vehicle on a lift. Remove the downstream oxygen sensor connector from its support by sliding it (in the direction of the ar- row). Disconnect the connector of the downstream lamb- da sensor.
  • Page 162 PETROL INJECTION Oxygen sensors K7J, and 710 REMOVAL Essential special tooling Mot. 1495 22 mm oxygen sensor I -UPSTREAM OXYGEN SENSOR removal / refitting soc- ket - 1/2" square drive and a 24 mm Allen key Tightening torquesm oxygen sensors 4.5 daNm heat shield mounting 2.5 daNm...
  • Page 163 PETROL INJECTION Oxygen sensors K7J, and 710 II - DOWNSTREAM OXYGEN SENSOR 108424 Mount the vehicle on a lift. Remove the downstream oxygen sensor connector from its support by sliding it (in the direction of the ar- row). Disconnect the connector of the downstream lamb- da sensor.
  • Page 164 PETROL INJECTION Position and speed sensor K7J, and 710 Essential equipment diagnostic tool 109211 Program with the engine flywheel target after repla- cing the speed and position sensor (1) or the engine flywheel: - make a deceleration with injection cut-off in se- cond, third, fourth or fifth gear between 3,500 and 3,000 rpm, for at least 2 seconds, - make a second deceleration with injection cut-off in...
  • Page 165 PETROL INJECTION Position and speed sensor K7M, and 710 Essential equipment diagnostic tool 109211 Program with the engine flywheel target after repla- cing the speed and position sensor (1) or the engine flywheel: - make a deceleration with injection cut-off in se- cond, third, fourth or fifth gear between 3,500 and 3,000 rpm, for at least 2 seconds, - make a second deceleration with injection cut-off in...
  • Page 166 PETROL INJECTION Fuel supply computer K7J, and 710 Essential equipment diagnostic tool Tightening torquesm computer mounting nuts 0.8 daNm computer protector 0.8 daNm mounting bolts battery mounting clamp 1.2 daNm bolts REMOVAL 108564 Remove: - the computer protector mounting bolts, - the computer protector.
  • Page 167 PETROL INJECTION Fuel supply computer K7J, and 710 REFITTING Proceed in the reverse order to removal. Torque tighten: - the computer mounting nuts (0.8 daNm), - the computer protector mounting bolts (0.8 daNm), - the battery mounting clamp bolts (1.2 daNm). WARNING Connect the battery, starting with the positive ter- minal;...
  • Page 168 PETROL INJECTION Fuel supply computer K7J, and 710 1 - Immobiliser code The computers are supplied uncoded. When a com- puter is replaced it must be programmed with the ve- hicle code, and checked to ensure that the immobiliser function is working properly. Switch on the ignition for a few seconds then switch it off.
  • Page 169 PETROL INJECTION Fuel supply computer K7M, and 710 Essential equipment diagnostic tool Tightening torquesm computer mounting nuts 0.8 daNm computer protector 0.8 daNm mounting bolts battery mounting clamp 1.2 daNm bolts REMOVAL 108564 Remove: - the computer protector mounting bolts, - the computer protector.
  • Page 170 PETROL INJECTION Fuel supply computer K7M, and 710 REFITTING Proceed in the reverse order to removal. Torque tighten: - the computer mounting nuts (0.8 daNm), - the computer protector mounting bolts (0.8 daNm), - the battery mounting clamp bolts (1.2 daNm). WARNING Connect the battery, starting with the positive ter- minal;...
  • Page 171 PETROL INJECTION Fuel supply computer K7M, and 710 1 - Immobiliser code The computers are supplied uncoded. When a com- puter is replaced it must be programmed with the ve- hicle code, and checked to ensure that the immobiliser function is working properly. Switch on the ignition for a few seconds then switch it off.
  • Page 172 PETROL INJECTION Computer: Connection K7J, and 710 109395 To connect the injection computer (see wiring dia- gram suited to the vehicle subject to fault finding, com- ponent 120). 17B-19...
  • Page 173 PETROL INJECTION Computer: Connection K7M, and 710 109395 To connect the injection computer (see wiring dia- gram suited to the vehicle subject to fault finding, com- ponent 120). 17B-20...
  • Page 174 PETROL INJECTION Special notes L90, and K7J, and 710 SPECIAL NOTES FOR MULTIPOINT INJECTION 90-TRACK« EMS 31-32 » computer controlling injec- tion and ignition. Use of the diagnostic tool. Multipoint injection operating in sequential mode wi- thout a cylinder marking sensor or camshaft position sensor.
  • Page 175 PETROL INJECTION Special notes K7M, and 710 SPECIAL NOTES FOR MULTIPOINT INJECTION 90-TRACK« EMS 31-32 » computer controlling injec- tion and ignition. Use of the diagnostic tool. Multipoint injection operating in sequential mode wi- thout a cylinder marking sensor or camshaft position sensor.

  • Page 176: Injection Warning Light

    PETROL INJECTION Injection warning light K7J or K7M, and 710 PRINCIPLE FOR INJECTION WARNING LIGHT ON THE INSTRUMENT PANEL LIGHTING UP 1 - Vehicle not equipped with the engine immobiliser function The warning light is lit for approximately 3 seconds then goes out.

  • Page 177: Immobiliser Function

    PETROL INJECTION Immobiliser function L90, and K7J, and 710 – L90, and K7M, and 710 Essential equipment diagnostic tool These vehicles are equipped with second-generation engine immobiliser systems. The injection computers must be programmed with the immobiliser code for them to work. I -REPLACING AN INJECTION COMPUTER The computers are supplied uncoded.
  • Page 178 PETROL INJECTION Injection - air conditioning programming L90, and K7J, and 710 – L90, and K7M, and 710 I -SYSTEM OPERATION The air conditioning system is a cold loop which opera- tes the following components: - a control panel, - an injection computer, - a compressor.

  • Page 179: Throttle Body Potentiometer

    PETROL INJECTION Throttle body potentiometer K7J or K7M, and 710 REMOVAL 108423 Remove air filter unit mounting bolts (1). 107356 Unclip ball joint (3). 107361 Disconnect: - the oil vapour rebreather pipe (2), - the air inlet sleeve. Remove the air filter unit. 107357 Disconnect: - potentiometer connector (4),...
  • Page 180 PETROL INJECTION Throttle body potentiometer K7J or K7M, and 710 REFITTING Always replace all seals that have been removed. Proceed in the reverse order to removal. 17B-27...

  • Page 181: Idle Speed Correction

    PETROL INJECTION Idle speed correction L90, and K7J, and 710 – L90, and K7M, and 710 I -POWER ASSISTED STEERING PRESSOSTAT/ INJECTION COMPUTER CONNECTION (IF THE VEHICLE IS EQUIPPED WITH POWER ASSISTED STEERING) The injection computer receives a signal from the power assisted steering pressostat (can be seen on the diagnostic tool).

  • Page 182: Richness Regulation

    PETROL INJECTION Richness regulation L90, and K7J, and 710 – L90, and K7M, and 710 I -SENSOR HEATING upstream of the catalytic converter (the oxygen sensor in fact analyses the oxygen content of the exhaust fu- The sensors are heated by the computer: mes.
  • Page 183 PETROL INJECTION Central coolant temperature management K7J or K7M, and 710 The fan assembly is activated at high speed if the coo- lant temperature exceeds 102˚C or if the low speed is defective and is stopped when the temperature falls be- low 100˚C.
  • Page 184 PETROL INJECTION Special notes on the system (when driving) L90, and K7J, and 710 – L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: How the O.B.D. fault finding system works: when a fault Note: causing excessive pollution is detected, an instrument All electrical faults which result in exceeding the pol- panel warning light comes on (O.B.D warning light), lution limit cause the On Board Diagnostic warning...
  • Page 185 PETROL INJECTION Conditions for carrying out fault finding (when driving) L90, and K7J, and 710 – L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: 2 - Programming of richness adaptive parameters To carry out this programming, run the vehicle by res- pecting the pressure ranges laid down in section: "In- I -FAULT FINDING CONDITIONS jection: Adaptive richness correction".
  • Page 186 PETROL INJECTION Combustion misfire fault finding L90, and K7J, and 710 – L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: II - CONFIRMATION OF REPAIR The diagnostic can detect, for example: Make sure statuses: - a dirty spark plug, - ET014 «...
  • Page 187 PETROL INJECTION Catalytic converter fault finding L90, and K7J, and 710 – L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: I -CONDITIONS FOR ENTERING FAULT FINDING MODE The purpose of catalytic converter fault finding is to de- tect a malfunction which would cause hydrocarbon pol- Fault finding of the catalytic converter can only take pla- lutant emissions to exceed the On Board Diagnostic ce after the engine has been running for the time de-...
  • Page 188 PETROL INJECTION Oxygen sensor fault finding L90, and K7J, and 710 – L90, and K7M, and 710 FOR VEHICLES FITTED WITH O.B.D: I -TEST CONDITIONS The purpose of oxygen sensor fault finding is to detect Fault finding of the oxygen sensor can only take place a fault which would cause the On Board Diagnostic limit after the engine has been running for a while and under to be exceeded by hydrocarbon pollutant emissions.

  • Page 189: General Information

    COOLING SYSTEM General information Vehicles in the current range have cooling circuits with the following basic specifications: - hermetically-sealed pressurused circuit (expansion chamber valve), - circuit uses type « D » fluid, - passenger compartment heating system via a « heater matrix » radiator under the dashboard. GENERAL PRECAUTION IMPORTANT The circuits are designed to be pressurised, so be...
  • Page 190 COOLING SYSTEM Specifications K7J or K7M, and 710 I -GRADE AND QUANTITY OF COOLANT Engine Quantity (litres) Grade K7J 710 GLACEOL RX (TYPE D). Approximately 5.45 Use coolant only. K7M 710 - Protection down to- 40˚C ± 2 for very cold countries. Special notes: - Protection down to - 25˚C ±...
  • Page 191 COOLING SYSTEM Checking II - CHECKING THE VALVE Essential special tooling Ms. 554-01 Plug (spare) to test WARNING expansion bottle val- The expansion bottle valve must be replaced if coolant is leaking from the valve. Ms. 554-07 Equipment for chec- king coolant circuit and Fit the appropriate cap of tool (Ms.
  • Page 192 COOLING SYSTEM Diagram K7J, and 710 109415 Engine Water pump Thermostat Bleed screw Heater radiator Cooling radiator Expansion bottle Note: The expansion bottle degassing valve rating is 1.4 bar. 19A-4...
  • Page 193 COOLING SYSTEM Diagram K7M, and 710 109415 Engine Water pump Thermostat Bleed screw Heater radiator Cooling radiator Expansion bottle Note: The expansion bottle degassing valve rating is 1.4 bar. 19A-5...
  • Page 194 COOLING SYSTEM Bleeding and filling the cooling circuit. K7J, and 710 – K7M, and 710 FILLING Essential special tooling Mot. 1202-01 Clip pliers for cooling WARNING system hose clips (large model) The engine must be stopped and the air conditio- ning system must be switched off so that the Mot.
  • Page 195 COOLING SYSTEM Bleeding and filling the cooling circuit. K7J, and 710 – K7M, and 710 Fill the circuit through the expansion chamber. Close the bleed screw as soon as the fluid runs out in a continuous jet. Fill up the expansion bottle until the coolant over- flows.

  • Page 196: Bleeding The Cooling Circuit

    COOLING SYSTEM Bleeding the cooling circuit AUTOMATIC BLEEDING IMPORTANT - Do not open the bleed screw(s) while the engine is running or hot. - Never open the expansion bottle while the engine is hot (over 50˚C) or running. - Top up if necessary. - Retighten the expansion bottle cap while the engine is hot.
  • Page 197 COOLING SYSTEM Cooling radiator K7J or K7M, and 710, and AIR CONDITIONING Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Mot. 1448 Remote operation pliers for cooling sys- tem hose clips REMOVAL Mount the vehicle on a two-post lift. Remove the engine undertray.
  • Page 198 COOLING SYSTEM Cooling radiator K7J or K7M, and 710, and AIR CONDITIONING 108627 Remove bolts (4). Remove the bumper unit (this operation requires two workers). Disconnect the fog light connector (if fitted to vehi- 109396 cle). Disconnect: Remove the air filter unit air intake tube. - fan assembly connectors (5).
  • Page 199 COOLING SYSTEM Cooling radiator K7J or K7M, and 710, and AIR CONDITIONING 108104 Remove: - mounting pins (8) from the air deflector, - the air deflector. 108430 Remove radiator mounting nuts (10). Remove: - the upper radiator mounting brackets, - the fan assembly, - the radiator.
  • Page 200 COOLING SYSTEM Cooling radiator K7J or K7M, and 710, and BASIC HEATING Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Mot. 1448 Remote operation pliers for cooling sys- tem hose clips REMOVAL Mount the vehicle on a lift. Remove the engine undertray.
  • Page 201 COOLING SYSTEM Cooling radiator K7J or K7M, and 710, and BASIC HEATING REFITTING Proceed in the reverse order to removal. WARNING Ensure that the fins of the cooling radiator are not damaged as it is removed. Fill and bleed the cooling circuit (see 19A, Cooling, Draining - Filling the cooling circuit).

  • Page 202: Water Pump

    COOLING SYSTEM Water pump K7J, and 710 - the water pump. Essential special tooling Mot. 1202-01 Clip pliers for cooling CLEANING system hose clips (large model) IMPORTANT Mot. 1448 Remote operation - Do not scratch the aluminium sealing surfaces. pliers for cooling sys- tem hose clips - Wear goggles.
  • Page 203 COOLING SYSTEM Water pump K7J, and 710 109240 Torque tighten in order: - the water pump M8 bolt (2.2 daNm),(1) - the water pump M6 bolts (1 daNm). Remove the timing belt (see 11A, Top and front of engine, Timing belt). Fill up and bleed the cooling circuit (see 19A, Coo- ling, Draining - Filling the cooling circuit).
  • Page 204 COOLING SYSTEM Water pump K7M, and 710 - the water pump. Essential special tooling Mot. 1202-01 Clip pliers for cooling CLEANING system hose clips (large model) IMPORTANT Mot. 1448 Remote operation - Do not scratch the aluminium sealing surfaces. pliers for cooling sys- tem hose clips - Wear goggles.
  • Page 205 COOLING SYSTEM Water pump K7M, and 710 109240 Torque tighten in order: - the water pump M8 bolt (2.2 daNm),(1) - the water pump M6 bolts (1 daNm). Remove the timing belt (see 11A, Top and front of engine, Timing belt). Fill up and bleed the cooling circuit (see 19A, Coo- ling, Draining - Filling the cooling circuit).
  • Page 206 COOLING SYSTEM Thermostat K7J or K7M, and 710 Essential special tooling Mot. 1202-01 Clip pliers for cooling system hose clips (large model) Mot. 1448 Remote operation pliers for cooling sys- tem hose clips Tightening torquesm thermostat support unit 1 daNm mounting bolts REMOVAL Drain the coolant circuit via the lower radiator hose...
  • Page 207 COOLING SYSTEM Engine cooling fan assembly K7J or K7M, and 710, and BASIC HEATING - the fan assembly. Essential equipment IF REPLACING diagnostic tool Remove: - the retaining clip for the hose connecting the power Tightening torquesm assisted steering to the fan assembly (if fitted to the vehicle), fan assembly mounting 0.4 daNm...
  • Page 208 COOLING SYSTEM Engine cooling fan assembly K7J or K7M, and 710, and AIR CONDITIONING Essential equipment diagnostic tool REMOVAL Disconnect the battery, starting with the negative ter- minal. DIRECTION ASSISTEE Remove the air intake sleeve. Unclip the power assisted steering hose from the fan assembly.
  • Page 209 COOLING SYSTEM Engine cooling fan assembly K7J or K7M, and 710, and AIR CONDITIONING CHECKING OPERATION OF THE FAN ASSEMBLY Start the engine. Disconnect the coolant temperature sensor (see 17B, Petrol injection, Location of components). Check operation of the fan assembly. Reconnect the coolant temperature sensor connec- tor.
  • Page 210 EXHAUST General information K7J or K7M, and 710 The catalytic converter reaches high temperatures; do Cut zone 2 not park the vehicle close to flammable materials. WARNING - All damaged heat shields must be replaced. - The seal between the exhaust manifold gasket face and the catalytic converter (inclusive) must be perfect.
  • Page 211 EXHAUST General information K7J or K7M, and 710 3 - Operate tool Mot. 1199-01 102118 Position the tool on the pipe. Tighten the bolts on the cutting tool so that it grips the pipe. 100649 Turn the cutting tool with the handle while gripping the To prevent any exhaust leak, position the sleeve cor- pipe.
  • Page 212 EXHAUST Pipe assembly K7J, and 710 109861 Cut zone 1 Cut zone 2 19B-3...
  • Page 213 EXHAUST Pipe assembly K7M, and 710 109861 Cut zone 1 Cut zone 2 19B-4...

  • Page 214: Catalytic Converter

    EXHAUST Catalytic converter K7J, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter Mot. 1495 22 mm oxygen sensor removal / refitting soc- ket - 1/2" square drive and a 24 mm Allen key Tightening torquesm oxygen sensor 4.5 daNm c a t a l y t i c c o nverter 2.1 daNm...
  • Page 215 EXHAUST Catalytic converter K7J, and 710 REFITTING 109399 WARNING Be sure to replace the sealing ring between the 107926 exhaust manifold and the catalytic converter. Remove: Refit the oxygen sensor. - the catalytic converter mountings from the exhaust manifold, Tighten to torque the oxygen sensor (4.5 daNm) using tool (Mot.
  • Page 216 EXHAUST Catalytic converter K7M, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter Mot. 1495 22 mm oxygen sensor removal / refitting soc- ket - 1/2" square drive and a 24 mm Allen key Tightening torquesm oxygen sensor 4.5 daNm c a t a l y t i c c o nverter 2.1 daNm...
  • Page 217 EXHAUST Catalytic converter K7M, and 710 REFITTING 109399 WARNING Be sure to replace the sealing ring between the 107926 exhaust manifold and the catalytic converter. Remove: Refit the oxygen sensor. - the catalytic converter mountings from the exhaust manifold, Tighten to torque the oxygen sensor (4.5 daNm) using tool (Mot.

  • Page 218: Expansion Chamber

    EXHAUST Expansion chamber K7J or K7M, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter REMOVAL Mount the vehicle on a lift. 108927 Use tool (Mot. 1199-01) to cut the exhaust pipe in the centre of area to be cut (2). Remove the expansion chamber.
  • Page 219 EXHAUST Silencer K7J or K7M, and 710 Essential special tooling Mot. 1199-01 Exhaust pipe cutter REMOVAL Mount the vehicle on a lift. 108927 Use tool (Mot. 1199-01) to cut the exhaust pipe in the centre of area to be cut (1). Remove the silencer.

  • Page 220: Draining The Fuel Tank

    RESERVOIR Draining the fuel tank K7J or K7M, and 710 Essential special tooling Mot. 1311-08 Union for measuring fuel pressure Mot. 1311-01 Fuel pressure pres- sure gauges and soc- ket unions IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects close to the work area, - beware of fuel splashes when disconnecting the union,...
  • Page 221 RESERVOIR Draining the fuel tank K7J or K7M, and 710 109171 Disconnect engine/passenger compartment wiring harness (4). 109172 Connect connector terminal (5) to + battery feed to operate the fuel pump. Allow the fuel to run out until the flow is intermittent. Disconnect the + battery feed from terminal (5).

  • Page 222: Fuel Tank

    RESERVOIR Fuel tank K7J or K7M, and 710 Tightening torquesm fuel tank mounting bolts 2.1 daNm to torque c a t a l y t i c c o nverter 2.1 daNm mounting nuts REMOVAL Mount the vehicle on a two-post lift. Drain the fuel tank (see 19C, Fuel tank, Draining the fuel tank).
  • Page 223 RESERVOIR Fuel tank K7J or K7M, and 710 109177 109185 Remove the flap in the floor panel providing access Remove body earth cable (2). to the pump/gauge/filter assembly. Disconnect the fuel pump connector. 109183 Remove: - heat shield attachment pins, - the heat shield.
  • Page 224 RESERVOIR Fuel tank K7J or K7M, and 710 108650 Disconnect the fuel pipes coming from the fuel tank. IMPORTANT 108424 During this operation, be sure to: Remove the oxygen sensor connector by sliding it from its support (in the direction of the arrow). - refrain from smoking or bringing hot objects close to the work area, Disconnect the oxygen sensor connector.
  • Page 225 RESERVOIR Fuel tank K7J or K7M, and 710 REFITTING Refit the fuel tank. Tighten the fuel tank mounting bolts to torque (2.1 daNm). 109399 WARNING It is essential to replace the sealing ring between the exhaust manifold and the catalytic converter. Refit the exhaust line assembly.
  • Page 226 RESERVOIR Pump / sender unit / filter K7J or K7M, and 710 Essential special tooling Mot. 1397 Universal spanner for removing fuel gauge IMPORTANT During this operation, be sure to: - refrain from smoking or bringing hot objects close to the work area, - beware of fuel splashes when disconnecting the union, - protect sensitive areas from fuel outflow.
  • Page 227 RESERVOIR Pump / sender unit / filter K7J or K7M, and 710 109177 109176 Remove the flap providing access to the pump/gau- Remove the locking ring from the pump/gauge/filter ge/filter assembly. assembly using tool (Mot. 1397). Disconnect: Allow the fuel in the pump/gauge/filter assembly to run out.
  • Page 228 RESERVOIR Pump / sender unit / filter K7J or K7M, and 710 REFITTING 109179 109180 Tighten the locking ring on the pump/gauge/filter as- sembly using tool (Mot. 1397). It is essential to replace O-ring (1). WARNING WARNING The pump/gauge/filter assembly index and loc- Make sure that the seal is positioned correctly king ring index must be between the two mar- when the pump/gauge/filter assembly is refitted.
  • Page 229 RESERVOIR Fuel level sensor: Distinctive K7J or K7M, and 710 The fuel pump, the fuel filter and sender form an inse- Refit the pump/gauge/filter assembly (see 19C, Fuel parable assembly. tank, Pump/gauge/filter). I -CONNECTING THE PUMP/GAUGE/FILTER ASSEMBLY 108538 For information on connecting the pump/gauge/filter unit (see Technical Note Wiring diagrams, compo- nent 199).
  • Page 230 ENGINE MOUNTING Suspended engine mounting K7J, and 710 109231 Reference Tightening torque in daNm 10.5 10.5 19D-1...
  • Page 231 ENGINE MOUNTING Suspended engine mounting K7M, and 710 109231 Reference Tightening torque in daNm 10.5 10.5 19D-2...

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