MR364MEGANE1-1

© Renault s.a.s. 2005

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 318 022 FEBRUARY 2003 Edition Anglaise

X84, and B84 or C84 or G84 or S84

1 Engine and peripherals

10A ENGINE AND LOWER ENGINE ASSEMBLY

11A TOP AND FRONT OF ENGINE

12A FUEL MIXTURE

12B TURBOCHARGING

13A FUEL SUPPLY

13B DIESEL INJECTION

13C PREHEATING

14A ANTIPOLLUTION

16A STARTING - LOAD

17A IGNITION

17B PETROL INJECTION

© Renault s.a.s. 2005

"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.

77 11 318 022 FEBRUARY 2003 Edition Anglaise

X84, and B84 or C84 or G84 or S84

19A COOLING SYSTEM

19B EXHAUST

19C RESERVOIR

19D ENGINE MOUNTING

Mégane II - Section 1

Contents

Page

Mégane II - Section 1ContentsPage

10A ENGINE AND LOWER ENGINE ASSEMBLY

Engine identification 10A-1

Engine oil: Draining - Refilling 10A-2

Oil consumption Check 10A-3

Oil filter: Removal - Refitting 10A-4

Exchanger: Removal - Refitting 10A-10

Oil pressure 10A-16

Oil pressure sensor: Removal - Refitting 10A-17

Oil level sensor: Removal - Refitting 10A-20

Sump: Removal - Refitting 10A-21

Oil pump: Removal - Refitting 10A-42

Multifunction support: Removal - Refitting 10A-45

Engine/gearbox assembly: Removal - Refitting 10A-55

Engine speed and position sensor: Removal - Refitting 10A-131

Crankshaft seal at timing end Removal - Refitting 10A-132


Accessories belt: Removal - Refitting 11A-1

Timing belt: Removal - Refitting 11A-11

Timing chain: Removal - Refitting 11A-116

Cylinder head gasket : Removal - Refitting 11A-117

Tightening the cylinder head 11A-199

Cylinder head: Removal - Refitting 11A-205

12A FUEL MIXTURE

Specifications 12A-1

Air inlet 12A-11

Air resonator: Removal - Refitting 12A-22

Air filter: Replacement 12A-23

Air filter: Removal - Refitting 12A-25

Air filter unit: Removal - Refitting 12A-26

Air flowmeter: Removal - Refitting 12A-39

Air inlet flap: Removal - Refitting 12A-41

Air inlet duct: Removal - Refitting 12A-49

Inlet manifold: Removal - Refitting 12A-52

Injector holder shim: Removal - Refitting 12A-58

Manifolds: Removal - Refitting 12A-64


Contents

Exhaust manifold: Removal - Refitting 12A-67

Throttle valve: Removal - Refitting 12A-86

Throttle valve: Cleaning 12A-94

Engine stop device 12A-96

12B TURBOCHARGING

Turbocharging: Precautions for repair 12B-1

Turbocharger: Removal - Refitting 12B-6

Pressure regulator: Checking 12B-37

Turbocharging pressure regulation valve 12B-43

Intercooler: Removal - Refitting 12B-46

13A FUEL SUPPLY

Petrol supply circuit 13A-1

Diesel fuel supply circuit 13A-2

Petrol filter: General information 13A-6

Diesel filter: Removal - Refitting 13A-7

Injector rail - Injectors: Removal - Refitting 13A-14

Electric fuel: Checking 13A-20


Specifications 13B-1

Diesel injection: Specifications 13B-11

12A FUEL MIXTURE

Diesel injection: Precautions for repair 13B-16

Description 13B-31

Operation 13B-33

Location of components 13B-36

Immobiliser function 13B-61

Injection warning light 13B-62

Injection / air conditioning programming 13B-64

Idling speed 13B-67

Centralised coolant temperature management 13B-69

Computer configuration 13B-71

High pressure pipe: Checking 13B-73

High pressure pipe: Replacement 13B-76

Diesel injector: check 13B-83

High pressure pump: Removal - Refitting 13B-84

Diesel injector: Removal - Refitting 13B-113

Injectors: Configuration 13B-130

High-pressure pipe between the rail and injector: Removal - Refitting 13B-132

Injector rail: Removal - Refitting 13B-143

Rail pressure sensor 13B-160

Rail pressure sensor: Removal - Refitting 13B-161

Fuel flow actuator: Removal - Refitting 13B-164

Leak flow from injectors: Check 13B-170

Fuel pressure regulator: Removal - Refitting 13B-174


Contents

Diesel temperature sensor: Removal - Refitting 13B-179

Accelerometer: Removal - Refitting 13B-189

Venturi: Removal - Refitting 13B-190

Accelerator pedal potentiometer: General information 13B-194

Accelerator pedal potentiometer: Removal - Refitting 13B-195

Diesel injection computer: Removal - Refitting 13B-196

13C PREHEATING

Pre/postheating unit: Removal - Refitting 13C-1

Heater plugs Removal - Refitting 13C-2

Pre-postheating control 13C-11

14A ANTIPOLLUTION

Petrol vapour rebreathing: Operation 14A-1

Fuel vapour recirculation circuit: check 14A-3

Fuel vapour canister: Removal - Refitting 14A-4

Fuel vapour canister:Checking 14A-5

Oil vapour rebreathing 14A-6

Exhaust gas recirculation: Operating diagram

Exhaust gas recirculation: Description 14A-17

Exhaust gas recirculation unit 14A-23


Exhaust gas recirculation solenoid valve: Removal - Refitting 14A-29

Intercooler: Removal - Refitting 14A-31

Exhaust gas recirculation mounting: Removal - Refitting 14A-36

Exhaust gas recirculation rigid pipe: Removal - Refitting 14A-37

16A STARTING - LOAD

Alternator: General information 16A-1

Alternator: Removal - Refitting 16A-2

Alternator pulley: Removal - Refitting 16A-20

Starter: Identification 16A-24

Starter: Removal - Refitting 16A-25

17A IGNITION

Coils Removal - Refitting 17A-1

Spark plugs 17A-5


Location of components 17B-1

Oxygen sensors: Removal - Refitting 17B-14

Accelerator pedal potentiometer: Removal - Refitting 17B-16

Position and speed sensor 17B-17

14A ANTIPOLLUTION

Contents

Petrol injection computer: Removal - Refitting 17B-19

Special notes 17B-21

Injection warning light 17B-24

Immobiliser function 17B-25

Injection - air conditioning programming 17B-26

Throttle valve: Operating 17B-30

Idle speed correction 17B-31

Adaptive idle speed correction 17B-34

Richness regulation 17B-35

Adaptive richness correction 17B-39

Central coolant temperature management 17B-41

Camshaft dephaser: Description 17B-42

Fault finding warning light activation conditions (when driving) 17B-44

Conditions for carrying out fault finding (when driving) 17B-45

Combustion misfire fault finding 17B-46

Catalytic converter fault finding 17B-47

Oxygen sensor fault finding 17B-48

Speed limiter: Operating principle 17B-49

19A COOLING SYSTEM

General information 19A-1

Specifications 19A-2

Checking 19A-3

Diagram 19A-4


Cooling circuit: Draining - Refilling 19A-12

Engine cooling circuit: Cleaning 19A-14

Cooling circuit: Bleeding 19A-15

Cooling radiator: Removal - Refitting 19A-16

Water pump: Removal - Refitting 19A-22

Plenum chamber: Removal - Refitting 19A-40

19B EXHAUST

General information 19B-1

Pipe assembly 19B-5

Catalytic pre-converter: Removal - Refitting 19B-10

Catalytic converter: Removal - Refitting 19B-15

Expansion chamber: Removal - Refitting 19B-29

Silencer: Removal - Refitting 19B-30

Particle filter: Function 19B-31

Particle filter: Removal - Refitting 19B-32

Particle filter pressure sensor: Removal - Refitting 19B-38

Particle filter temperature sensors: Removal - Refitting 19B-42

Connecting hose: Removal - Refitting 19B-45

Particle filter: Cleaning 19B-46

19A COOLING SYSTEM

Contents

19C RESERVOIR

Draining the fuel tank 19C-1

Fuel tank: Description 19C-6

Fuel tank: Removal - Refitting 19C-12

Filler neck: Removal - Refitting 19C-15

Sender unit: Removal - Refitting 19C-17

Pump-sender unit-filter: Removal - Refitting 19C-20

Petrol filter: General information 19C-22

Fuel level sensor: Checking 19C-23

19D ENGINE MOUNTING

Suspended engine mounting 19D-1

Suspended engine mounting: Tightening torque 19D-9

Left-hand suspended engine mounting: Removal - Refitting 19D-12

Right-hand suspended engine mounting: Removal - Refitting 19D-14

Rear suspended engine mounting: Removal - Refitting 19D-16

10A-1

ENGINE AND LOWER ENGINE ASSEMBLYEngine identification 10A

List of engine Workshop Repair Manuals to be consul-ted depending on the engine type:

- K4J and K4M engine, Technical Note 3784A,

- K9K engine, Technical note 6006A,

- F9Q engine, Technical Note 3652A,

- F4R engine, Technical Note 3783 A.

Vehicle type Engine type Engine suf-fix

Cubic capa-city (cc)

Bore (mm) Stroke (mm) Compressionratio

XM0B

XM0H

XM1AK4J

730

1390 79.5 70 10/1

XM08 732

XM0C

XM0J

XM1B

K4M

760

1598 79.5 80.5 9.8/1761

XM05

XM0U

XM1M

XM1N

F4R

770

1998 82.7 939.8/1771

XNOW 776 9.5/1

XM0F

XM0T

K9K

722

1461 76 80.517.9/1XM02

XM13

728

XM02 729

XM1E 732 15.3/1

XM0G

XM1G

F9Q

800

1870 80 93

18.4/1

XM0L

XM1D

804 17/1

XM00 808 18.4/1

10A-2

ENGINE AND LOWER ENGINE ASSEMBLYEngine oil: Draining - Refilling

M9R, and 700

10A

I - OIL SERVICE

Remove the oil filler plug and the dipstick.

Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).

Remove the engine undertray.

Remove the drain plug (1) .

Let the oil run into a drain tray.

Copper seal

Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.

Tighten to torque the drain plug ( 44 Nm ) .

II - FILLING

When filling up the engine oil, always leave at least10 minutes for the oil to drain down before checkingwith a dipstick.

Fill up the engine with oil.

Refit the engine undertray.

Tightening torquesm

drain plug 44 Nm

Engine

Average oil capacity (check and adjust with

dipstick) (l)

Draining Oil changewith oil filterreplace-ment

M9R 6.4 6.7

114651

113764

WARNING

Always check the oil level using the dipstick.

Do not exceed the maximum level on the dipstick(as this could damage the engine).

Correct the engine oil level if necessary beforedelivering the vehicle to the customer.

10A-3

ENGINE AND LOWER ENGINE ASSEMBLYOil consumption Check 10A

PROCEDURE FOR MEASURING OIL CONSUMPTION

1 - Filling to the maximum level

Turn the engine off.

Wait two minutes for all of the oil to flow into the oilsump.

Check the level on the dipstick.

Top up to the "MAX" mark.

Make a paint mark on both the fuel filler cap and thesump drain plug in order to be able to check laterthat they have not been removed.

2 - Customer driving

Ask the customer to drive approximately 1,200 mi-les (2,000 km) in the vehicle without letting the oil le-vel reach the "MIN" mark.

3 - Topping up

Turn the engine off.

Wait two minutes for all of the oil to flow into the oilsump.

Check the level on the dipstick.

Top up to the "MAX" mark.

Note the quantity of oil added and the mileage cove-red since the last top-up to maximum level.

4 - Measurement of the oil consumption

Oil consumption = Quantity of topping up oil (inlitres) / number of kilometres (in thousands).

Note:

The operation should be carried out with theengine warm after the fan unit has started opera-ting.

Note:

The operation should be carried out with theengine warm after the fan assembly has startedoperating.

10A-4

ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting

K9K, and 722 or 728 or 729 or 732

10A

REMOVAL

I - REMOVAL PREPARATION OPERATION

Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).


Position (Mot. 1329) (1) on the oil filter.

II - OPERATION FOR REMOVAL OF PART CONCERNED

Remove the oil filter.

REFITTING

I - REFITTING PREPARATION OPERATION

Lubricate the oil filter seal with new engine oil.

II - REFITTING OPERATION FOR PART CONCERNED

Tighten the oil filter until it comes into contact withthe oil filter seal on the engine.

Tighten the oil filter three-quarters of a turn by hand.

III - FINAL OPERATION

Top up the engine oil.

Wipe any oil run-off with a cloth.


Special tooling required

Mot. 1329 76 mm diameter oil fil-ter removing tool

111850

10A-5


F4R, and 770 or 771 or 776

10A

REMOVAL

Position the vehicle on the two-post lift (see 02A,Lifting equipment, Underbody lift ).


Remove:

- the mounting bolts (1) from the air conditioningcompressor stay.

- the air conditioning compressor stay.

Position the (Mot. 1329) (2) on the oil filter.


REFITTING

Lubricate the oil filter seal with new engine oil.



Refit the air conditioning compressor stay.

Tighten to torque the air conditioning compressorstay mounting bolts ( 44 Nm ) .


Wipe any oil run-off with a cloth.




Tightening torquesm

air conditioning com-pressor stay mountingbolts

44 Nm

111851

11

111852

2

10A-6


K4M, and 760 or 761 – K4J, and 730 or 732

10A

REMOVAL



Position tool (Mot. 1329) (1) on the oil filter.


REFITTINGApply new engine oil to the oil filter seal.







110385

10A-7


M9R, and 700

10A

REMOVAL




Loosen the cover (1) slightly.

Let the engine oil flow out before removing the filterelement - cover assembly.

Remove the filter element - cover assembly.


Remove:

- the filter element (2) from the cover (3) ,

- the O-ring (4) from the cover (3) .

Tightening torquesm

cover 25 Nm

114653

114779

113320

10A-8


M9R, and 700

10AREFITTING


Clean the cover.

Position the new O-ring (5) correctly on the cover.

Apply new engine oil to the O-ring.


Refit:

- the new filter element (6) in the cover (7) ,

- the filter element - cover assembly.

Tighten to torque the cover ( 25 Nm ) .




113869

114780

10A-9


F9Q

10A

If the AC pipe is significantly deformed when the oil fil-ter is removed, there may be a refrigerant leak.

To reduce the risk of a leak in the MEGANE II andSCENIC II equipped with F9Q engine, the ADVICE inthis Technical Note relating to the removal of the oil fil-ter from the TOP OF THE ENGINE must be strictly fol-lowed.

REMOVAL



Remove:

- the engine covers,

- the engine undertray.

Drain the engine oil (see 05A, Draining/Filling-up ).

II - REMOVING THE OIL FILTER

From the top of the engine, position the (Mot. 1329)on the oil filter using an open-jawed spanner 27 mmin width.


REFITTING


Lubricate the new oil filter seal.

II - REFITTING THE OIL FILTER

Tighten the oil filter until it makes contact.



Top up the engine oil (see 05A, Draining - Filling-up ).

Refit:

- the engine undertray,

- the engine covers.



115078

10A-10

ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting

M9R, and 700

10AREMOVAL



Disconnect the battery (see 80A, Battery, Battery:Removal and Refitting )

Remove:

- the engine protectors,


- the oil filter (see 10A, Engine and peripherals, Oilfilter: Removal - Refitting ).

- the front bumper (see MR365 Bodywork, 55A Ex-terior protection, Front bumper )

Drain the coolant circuit using filling station (see62A, Air conditioning, Maintenance ).

Remove:

- the mounting bolts (1) from the Protection andSwitching Unit,

- the Protection and Switching Unit cover.


Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)

Mot. 1202-02 Pliers for small hoseclips

Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips

Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors

Equipment required

filling station

Tightening torquesm

oil cooler mountingbolts

25 Nm

coolant inlet unionmounting bolts

24 Nm

oil pressure sensor 44 Nm

intercooler downs-tream duct clip on theintercooler

5.5 Nm

intercooler downs-tream duct clip on thedamper valve

5.5 Nm

intercooler upstreamhose clip

5.5 Nm

front end panel uppermounting bolts

21 Nm

front end panel lowermounting bolts

44 Nm

112658

10A-11


M9R, and 700

10A

Disconnect the connectors (2) from the Protectionand Switching Unit.

Unfasten the bonnet opening cable (3) .

Remove:

- the clips (4) ,

- the front end panel upper mounting bolts (5) ,

Disconnect the screen washer tubes.

Unclip the air inlet scoop.

Remove:

- front end panel mounting bolts (7) ,

- the front end panel,

- the air inlet scoop.

Drain the engine cooling system (see 19A, Cooling,Engine cooling system: Draining-refilling ).

Loosen the clip (8) from the intercooler upstream ho-se.

Disconnect the intercooler upstream hose.

102504

114933

102365

102473

10A-12


M9R, and 700

10A

Remove the bolt (9) mounting the intercooler downs-tream duct on the cooling radiator.

Loosen:

- the clip (10) on the intercooler downstream duct onthe intercooler,

- the intercooler downstream duct clip on the dampervalve.

Move the downstream duct away from the intercoo-ler.

Disconnect:

- the cooling radiator top and bottom hose using(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,

- the fan unit resistor connector (11) ,

- the fan unit connector.

Unclip the wiring harness from the fan unit.

114649 112661

10A-13


M9R, and 700

10A

Disconnect:

- the hoses from the expansion bottle on the coolingradiator side (12) ,

- the pressure switch connector on the condenserlower air conditioning pipe (13) .

Unpick the wiring harness from the pressure switchconnector on the fan unit.

Remove the air conditioning pipes from the conden-ser (14) .

Remove the cooling assembly.

Disconnect the hose (15) from the oil cooler coolantoutlet union.

Remove:

- the oil pressure sensor using the (Mot. 1495-01) ,

- the mounting bolts (16) from the coolant inlet union,

- the coolant inlet union.

Disconnect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :

- the hose (17) from the coolant inlet union on theunion,

- the hose (18) from the cylinder block coolant inletpipe,

Remove the hose from the coolant inlet union.

109537

Note:

Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.

114929

10A-14


M9R, and 700

10AII - OPERATION FOR REMOVAL OF PART CONCERNED

Remove:

- the mounting bolts (19) from the oil cooler,

- the oil cooler.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

Refit:

- the oil cooler,

- the oil cooler mounting bolts.

Tighten to torque and in the order (1) - (3) - (2) - (4)the oil cooler mounting bolts ( 25 Nm ) .

114928

114928

10A-15


M9R, and 700

10AII - FINAL OPERATION

Connect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :

- the coolant inlet union hose on the cylinder block,

- the coolant inlet pipe hose on the union,

- the coolant outlet union hose to the oil cooler.

Refit:

- the coolant inlet union,

- the coolant inlet union mounting bolts,

- the oil pressure sensor.

Tighten to torque:

- the coolant inlet union mounting bolts ( 24 Nm ),

- using (Mot. 1495-01) the oil pressure sensor ( 44Nm ) .

Refit the cooling assembly.

Refit the air conditioning pipes to the condenser.

Attach the pressure switch connector wiring harnessto the fan unit.

Connect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :

- the expansion bottle hoses on the cooling radiatorside,

- the cooling radiator top and bottom hose.

Connect:

- the pressure switch connector on the condenserlower air conditioning pipe,

- the fan unit connector,

- the fan unit resistor connector,

Clip the fan unit wiring harness into place.

Refit:

- the intercooler downstream duct clip to the inter-cooler,


Tighten to torque:

- the intercooler downstream duct clip on the in-tercooler ( 5.5 Nm ) ,

- the intercooler downstream duct clip on thedamper valve ( 5.5 Nm ) .

Tighten the bolt mounting the intercooler downs-tream duct on the cooling radiator.

Connect the intercooler upstream hose.

Tighten to torque the intercooler upstream hoseclip ( 5.5 Nm ) .

Refit:

- the air inlet scoop,


- the clips,

- the front end panel mounting bolts.

Tighten to torque:

- the front end panel upper mounting bolts ( 21Nm ) ,

- the front end panel lower mounting bolts ( 44Nm ) .

Connect the Protection and Switching Unit connec-tors.

Clip the bonnet opening cable.


Refit:

- the Protection and Switching Unit cover,

- the Protection and Switching Unit cover mountingbolts,

- the oil filter (see 10A, Engine and peripherals, Oilfilter: Removal - Refitting ).


Refit:


- the front bumper (see MR365 Bodywork, 55A Ex-terior protection, Front bumper ).

Refill:

- the coolant circuit using the filling station (see62A, Air conditioning, Maintenance ),

- the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).

Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).

10A-16

ENGINE AND LOWER ENGINE ASSEMBLYOil pressure 10A

I - ADAPTERS FOR USE WITH VARIOUS ENGINES

II - PRECAUTIONS TO TAKE DURING CHECKS

The oil pressure check must be carried out with the en-gine warm (≈ 80˚C ).

III - CHECKING PROCEDURE

Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).

Remove the oil pressure sensor (see 10A, Engine andperipherals, Oil pressure sensor: Removal - Refit-ting ).

Position the (Mot. 836-05) with the appropriate adap-ters.


Start the vehicle.

Carry out the check.

Check the values.


Remove the (Mot. 836-05) and the adapters.

Refit the oil pressure sensor (see 10A, Engine and pe-ripherals, Oil pressure sensor: Removal - Refitting).



Mot. 836-05 Oil pressure gauge kit

Engine Adapters

K4J E + C + F

K4M E + C + F

F4R B + F

K9K E + C + F

F9Q B + F

M9R C + F

87363

EngineEnginesuffix

Minimum pressure (bar)

Idlespeed

3000 rpm

K4J 730 1 3

K4M760

1 3 782

F4R

770 1 3

771

776 1.2 3.5

K9K

722

1.2 3.5 728

732

F9Q804

1.2 3.5 812

M9R 700 0.9 4

10A-17

ENGINE AND LOWER ENGINE ASSEMBLYOil pressure sensor: Removal - Refitting

M9R, and 700

10A

REMOVAL



Remove:



- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ).

Remove:

- the engine accessories unit cover mounting bolts(1) ,

- the engine accessories unit cover.

Disconnect the connectors (2) from the engine ac-cessories unit.


Remove:

- the clips (4) ,



Unclip the air inlet scoop (6) .



Tightening torquesm

oil pressure sensor 44 Nm


21 Nm


44 Nm

112658

115585

114933

10A-18


M9R, and 700

10A

Remove:

- the front end panel lower mounting bolts (7) .

- the front end panel.


Disconnect the oil pressure sensor connector (8) .

Remove the oil pressure sensor using the (Mot.1495-01) (1) .

102365

114061

115022

115021

Note:

Be careful not to damage the air conditioningcompressor connector.

10A-19


M9R, and 700

10AREFITTING


Refit the oil pressure sensor.

Tighten to torque the oil pressure sensor ( 44 Nm )using the (Mot. 1495-01) .

Connect the oil pressure sensor connector.

II - FINAL OPERATION

Refit:


- the upper mounting bolts of the front end panel,

- the lower mounting bolts of the front end panel.

Tighten to torque:



Clip the air inlet scoop into place.

Connect the screen washer pipes.

Position the bonnet opening cable.

Connect the engine accessories unit connectors.

Refit:

- the clips,

- the engine accessories unit cover,

- the engine accessories unit cover mounting bolts,

- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),


- the engine protectors.

10A-20

ENGINE AND LOWER ENGINE ASSEMBLYOil level sensor: Removal - Refitting

M9R, and 700

10A

REMOVAL


Position the vehicle on a two-post lift (see 02A Lif-ting equipment, Underbody lift ).

Remove the front right-hand wheel.

Move the heat insulating material away from the oillevel sensor.


Disconnect the oil level sensor (1) .

Remove the oil level sensor.

REFITTING


Refit the oil level sensor.

Tighten to torque the oil level sensor ( 25 Nm ) .

Connect the oil level sensor.


Refit the heat insulating material around the oil levelsensor.

Refit the front right-hand wheel.

Tighten to torque the front right-hand wheel ( 110Nm ) .

Tightening torquesm

oil level sensor 25 Nm

front right-hand wheel 110 Nm

114932

10A-21

ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting

K4J, and 730 or 732 – K4M, and 760 or 761

10A

REMOVAL




Drain the engine oil (see 05A, Draining - Filling,Engine ).

Remove:


- the dipstick,

- the front wheels,

- the wheel arch liners,

Remove the half sub-frame side reinforcements (1) .

Attach the cooling assembly to the upper crossmember using a safety belt .

Equipment required

safety belt

Tightening torquesm

sump mounting bolts 14 Nm

sump mounting boltsare tightened to torque

14 Nm

gearbox - sump moun-ting bolts

44 Nm



14 Nm

gearbox - sump moun-ting bolts

44 Nm

bolt mounting the sumpon the multifunctionsupport

21 Nm

half sub-frame moun-ting bolts

105 Nm

half sub-frame moun-ting nuts

21 Nm

wheel bolts 110 Nm

battery cover bolts 4 Nm

101212

Note:

When positioning the safety belt , be careful not to:

- pinch the cooling hoses,

- strap the half sub-frame.

1

10A-22


K4J, and 730 or 732 – K4M, and 760 or 761

10A

Remove:

- the mounting nuts from the half sub-frame,

- the mounting bolts from the half sub-frame,

- the half sub-frame (2) .

Remove:

- the mounting bolts of the right-hand driveshaftbracket on the relay bearing,

- the bolts mounting the relay bearing on the sump.

Remove the mounting bolt of the sump on the multi-function support.

Remove:

- the sump mounting bolt,

- the sump.

REFITTING

Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.

Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.

102008

CA or CAREG

2

WARNING

The gasket faces must be clean, dry and freefrom grease (avoid finger marks).

WARNING

Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).

10A-23


K4J, and 730 or 732 – K4M, and 760 or 761

10A

Apply:

- four beads at (3) and (4) of SILICONE ADHESIVESEALANT which are 5 mm in diameter .

- two points of SILICONE ADHESIVE SEALANT at(5) which are 7 mm in diameter , at the jointbetween the crankshaft closure panel and the cy-linder block.

I - FIRST FITTING

Refit the oil splash plate onto the cylinder block.

20167

20166

3

4

5

5

20170

Note:

When refitting the sump, check that:

- the tabs (6) on the oil splash plate are positio-ned correctly in the notches (7) ,

- the cylinder block and the sump at the flywheelend are aligned to prevent deformation of theclutch housing.

77777

66666

10A-24


K4J, and 730 or 732 – K4M, and 760 or 761

10A

Refit the oil sump with a new seal.

Fit:

- the sump mounting bolts without tightening,

- the gearbox - sump mounting bolts without tighte-ning.

Tighten to torque and in order the sump mountingbolts ( 14 Nm ) .

Check that all the sump mounting bolts are tighte-ned to torque ( 14 Nm ) .

Tighten to torque the gearbox - sump mountingbolts ( 44 Nm ) .

20171

14

3

13

2

121110

1 20

9

19

8

18

7

17

6

16

5

15

4

10A-25


K4J, and 730 or 732 – K4M, and 760 or 761

10AII - SECOND FITTING


Fit:




Check that all the sump mounting bolts are tighte-ned to torque ( 14 Nm ) .

Tighten to torque the gearbox - sump mounting

bolts ( 44 Nm ) .

III - REFITTING (FOR FIRST AND SECOND FITTINGS)

Refit the bolt mounting the sump on the multifunctionsupport.

Tighten to torque the bolt mounting the sump onthe multifunction support ( 21 Nm ) .

Tighten to torque:

- the half sub-frame mounting bolts ( 105 Nm ) ,

- the half sub-frame mounting nuts ( 21 Nm ) ,

- the wheel bolts ( 110 Nm ) .

- the battery cover bolts ( 4 Nm ) .

Proceed in the reverse order to removal.

Top up the engine oil (see 05A, Draining - Filling,Engine ).


108881

20171

12345

6 7 8 9 10 11 12 13 14

15

16

17181920

CA or CAREG

10A-26


F9Q, and 800 or 804 or 808

10A

REMOVALPlace the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).




Remove:


- the dipstick,

- the front wheels,




Equipment required

safety belt

Tightening torquesm


105 Nm


21 Nm

wheel bolts 110 Nm

battery cover mountingbolts

4 Nm

101212

Note:




1

10A-27


F9Q, and 800 or 804 or 808

10A

Remove:




Remove:

- the engine tie-bar,

- the sump mountings,

- the sump.

REFITTING



102008

2

WARNING


WARNING


Note:

There are two fitting procedures for preparing the cylinder block gasket face when refitting:

- the first fitting procedure is used if SILICONEADHESIVE SEALANT has been used to sealthe crankshaft closure panel,

- the second fitting is used if a seal is used for thecrankshaft closure panel sealing.

10A-28


F9Q, and 800 or 804 or 808

10AI - FIRST FITTING

Apply a bead of SILICONE ADHESIVE SEALANT :

- at (A) , both sides of bearing No.1,

- at (B) , the joint between the cylinder block and thecrankshaft closure panel.

Refit the sump fitted with a new seal.

II - SECOND FITTING

Apply a bead of SILICONE ADHESIVE SEALANTat (A) , on the joint between the crankshaft closurepanel and the cylinder block.

Refit the sump fitted with a new seal.

15159

B

AA

B

15159

Note

Do not cut the two crankshaft closure panel sealtabs which sit higher than the cylinder block gas-ket face (B) .

A

B

10A-29


F9Q, and 800 or 804 or 808

10AIII - REFITTING (FOR THE FIRST AND SECOND FITTINGS)

Stage 1:

• Tighten to torque and in order, bolts (8) , (15) , (4), (19) , (11) , (12) to ( 18 Nm ).

- Stage 2:

• Tighten to torque and in order, bolts (10) , (13) ,(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (13), (18) , (3) , (20) , (2) , (21) , (1) and (22) to ( 15Nm ).

Refit the lower engine tie-bar (see 19D, Enginemounting, Suspended engine mounting ).

Tighten to torque:



- the wheel bolts ( 110 Nm ) ,

- the battery cover mounting bolts ( 4 Nm ) ,




15195

2 8

19 18

13

1

7

12

6

11

17

10

5

21

16

22

4

15

3 9

1420

10A-30


K9K, and 722 or 728 or 729 or 732

10AREMOVAL




Remove:


- the dipstick,


Remove:


- the front wheels,

- the wheel arch liners.


Equipment required

safety belt

Tightening torquesm

sump mounting bolts 14 NM


14 NM




14 NM


bolt mounting the sumpon the multifunctionsupport

21 Nm

catalytic converter ups-tream stay mountingbolts

21 Nm


105 Nm


21 Nm

half sub-frame sidereinforcement mountingbolts

21 Nm

wheel bolts 110 Nm

10A-31


K9K, and 722 or 728 or 729 or 732

10A



Move the diesel drain pipe away from the injectionrail protector.

Remove:




Remove:

- the lower engine tie-bar mounting bolts,

- the lower engine tie-bar,

- the lower engine tie-bar support lower mountingbolts.

Loosen the lower engine tie-bar upper bolt.

Remove:

- the bolts mounting the right-hand driveshaft brac-ket on the relay bearing,

- the bolts mounting the relay bearing on the sump,

- the relay bearing,

- the catalytic converter upstream stay mountingbolts,

- the catalytic converter upstream stay.

Disconnect the oil level sensor.

101212

Note:




K9K, and 732

1

102008

K9K, and 732

2

10A-32


K9K, and 722 or 728 or 729 or 732

10A

Remove the mounting bolt from the sump on themultifunction support.


Remove:

- the sump mounting bolt,

- the sump.

REFITTING


Clean the strainer with a soft, lint-free cloth.



Apply:

- four beads at (3) and (4) of SILICONE ADHESIVESEALANT which are 5 mm in diameter .

- two points of SILICONE ADHESIVE at (5) whichare, 7 mm in diameter , at the joint between thecrankshaft closure panel and the cylinder block.

CA or CAREG

K9K, and 732

WARNING


WARNING


20167

20166

33

5

4

5

4

10A-33


K9K, and 722 or 728 or 729 or 732

10AII - REFITTING OPERATION FOR PART CONCERNED

1 - FIRST FITTING

Refit the oil splash plate onto the cylinder block.


Fit:



Tighten to torque and in order the sump mountingbolts ( 14 NM ) .

Check that all the sump mounting bolts are tighte-ned to torque ( 14 NM ) .


20170

Note:

When refitting the sump, check that:

- the tabs (6) on the oil splash plate are positio-ned correctly in the notches (7) ,

- the cylinder block and the sump at the flywheelend are aligned to prevent deformation of theclutch housing.

7

66666

7777

20171

7

18

14

172

6 13

5

12

16

11

4

10

15

9

20

8

1913

10A-34


K9K, and 722 or 728 or 729 or 732

10A2 - SECOND FITTING


Fit:




Check that all the sump mounting bolts are tighte-ned to torque ( 14 NM ) .

Tighten to torque and in order the sump mounting

bolts ( 44 NM ) .


Connect the oil level sensor.

Refit the bolt mounting the sump on the multifunctionsupport.

Tighten to torque the bolt mounting the sump onthe multifunction support ( 21 Nm ) .

Refit the catalytic converter upstream stay.

Tighten the mounting bolts of the catalytic converterupstream stay until contact is made.

Tighten to torque the catalytic converter upstreamstay mounting bolts ( 21 Nm ) .

Refit:

- the relay bearing,

- the bolts mounting the relay bearing on the sump,

- the bolts mounting the right-hand driveshaft brac-ket on the relay bearing.

Refit the lower engine tie-bar support lower moun-ting bolts (see 19A, Engine mounting, Suspendedengine mounting ).

Tighten the lower engine tie-bar support lowermounting bolts (see 19A, Engine mounting, Sus-pended engine mounting ).

Refit the lower engine tie-bar (see 19A, Enginemounting, Suspended engine mounting ).

108881

20171

CA or CAREG

K9K, and 732

Note:

Apply a drop of LOCTITE FRENBLOC to the halfsub-frame mounting bolts.

10A-35


K9K, and 722 or 728 or 729 or 732

10ARefit:

- the half sub-frame mounting bolts,

- the half sub-frame mounting nuts,

- the half sub-frame.

Tighten to torque:


- the half sub-frame mounting nuts ( 21 Nm ) .

Fit the diesel drain pipe to the injection rail protector .

Remove the safety belt .

Refit:

- the half sub-frame side reinforcements,

- the half sub-frame side reinforcement mountingbolts.

Tighten to torque the half sub-frame side reinfor-cement mounting bolts ( 21 Nm ) .

Refit:

- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),



- the front wheels.

Tighten to torque the wheel bolts ( 110 Nm ) .



Refit:

- the dipstick,


K9K, and 732

10A-36


F4R, and 770 or 771 or 776

10A





Remove:


- the dipstick,

- the front wheels,


Remove:

- the half sub-frame side reinforcement mountingbolts,

- the side reinforcements (1) .

Attach the cooling assembly to the upper crossmember using the safety belt .

Equipment required

safety belt

Tightening torquesm


105 Nm


21 Nm

wheel bolts (F4R 776) 130 Nm

wheel bolts 110 Nm


4 Nm

101212

Note:




1

10A-37


F4R, and 770 or 771 or 776

10A

Remove:




Remove:

- the engine tie-bar,

- the sump mountings,

- the sump.

REFITTING



Apply a bead of SILICONE ADHESIVE SEALANTat (A) , at the joint between the crankshaft closurepanel and the cylinder block.

Refit the sump with a new gasket.

102008

WARNING


WARNING


2

15159

Note:

Do not cut the two tabs on the crankshaft closurepanel seal, which sit higher than the joint face ofthe cylinder block (B) .

BB

AA

10A-38


F4R, and 770 or 771 or 776

10A

Stage 1:

• Tighten to torque and in order, bolts (8) , (15) , (4), (19) , (11) , (12) ( 18 Nm ).

- Stage 2:

• Tighten to torque and in order, bolts (10) , (13) ,(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18), (3) , (20) , (2) , (21) , (1) and (22) ( 15 Nm ).


Tighten to torque:



- the wheel bolts (F4R 776) ( 130 Nm ) ,


- the battery cover mounting bolts ( 4 Nm ) .




15195

12

20 1517

21

2

1

65 94

1419 18

22

10

3 7

11

13

16

8

10A-39


M9R, and 700

10A

REMOVAL


Position the vehicle on a lift (see 02A, Lifting equi-pment, Underbody lift ).

Disconnect the battery (see 80A, Battery, Battery :Removal - Refitting ).

Remove:


- the dipstick,

- the front wheels,

- the front wheel arch liners,



Remove:

- the lower mounting bolts (1) from the side reinfor-cements,


Drain the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).


Mot. 1716 Removes housing withsilicone seals.

Tightening torquesm



105 Nm


21 Nm

the side reinforcementlower mounting bolts

21 Nm

102008

10A-40


M9R, and 700


Remove the sump mounting bolts.

Remove the sump using the (Mot. 1716) .

Remove the lower cover.

REFITTING


Check that the sump is not:

- scratched,

- deformed.

If this is the case, replace the sump.

Check that the base plate is not scratched.


Apply a bead of SILICONE ADHESIVE SEALANT(77 11 227 484) with a diameter of 5 mm ± 2 to thesump to make a seal.

Fit the sump.

Tighten the sump mounting bolts until contact is ma-de.


114997

IMPORTANT

- Do not scratch the aluminium sealing surfaces.

- Wear goggles.

- Wear gloves during the operation.

WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could cause damage tocer tain components (engine, radiator, etc.).

WARNING

The sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).

114410

10A-41


M9R, and 700

10AIII - FINAL OPERATION

Refit:

- the half sub-frame,


- the half sub-frame mounting nuts.

Tighten to torque:



Refit the side reinforcement lower mounting bolts.

Tighten to torque the side reinforcement lowermounting bolts ( 21 Nm ) .

Refit:



- the front wheel arch liners,

- the front wheels.

Connect the battery (see 80A, Battery, B attery :Removal - Refitting ).

Fill up the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).

Refit:

- the dipstick,


10A-42

ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting 10A

REMOVAL

Position the vehicle on a two-post lift.

Disconnect the battery, starting with the negativeterminal.

Remove the under-engine protectors

Drain the engine oil.

Remove the sump (see 10A, Engine and periphe-rals, Sump ).

Example for F9Q engine

Remove:

- the bolt (1) and the oil splash plate,

- the oil pump bolts (2) ,

- the oil pump.

REFITTING


Tighten to torque the oil pump mounting bolts ( 25Nm ) .

Refit the sump (see 10A, Engine and peripherals,Sump ).


Connect the battery, starting with the positive termi-nal.

Tighten to torque the battery cover bolts ( 4 Nm ) .

Tightening torquesm

oil pump mounting bolts 25 Nm


23224

1

2

WARNING

Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).

10A-43

ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting

M9R, and 700

10A

REMOVAL




Remove the sump (see 10A, Engine and periphe-rals, Sump: Removal - Refitting ).

Remove:

- the strainer mounting bolts ,

- the strainer.


Remove:

- the oil pump mounting bolts on the anti-splash pla-te,

- the oil pump mounting bolts on the cylinder block,

- the oil pump.

REFITTING


If necessary, use a locally-produced hook to fit theoil pump chain to the oil pump sprocket.


Finger tighten:

- the oil pump mounting bolts on the anti-splash pla-te,

- the oil pump mounting bolts on the cylinder block.

Tighten to torque the oil pump mounting bolts onthe cylinder block (5 Nm) .

Tighten to torque:

- the oil pump mounting bolts on the cylinderblock ( 25 Nm ) ,

- the oil pump mounting bolts on the anti-splashplate ( 10 Nm ) ,

Tightening torquesm

oil pump mounting boltson the cylinder block

25 Nm

oil pump mounting boltson the anti-splash plate

10 Nm

strainer mounting bolts 10 Nm

113156

113157

10A-44

ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting

M9R, and 700


Replace the oil strainer O-ring.

Fit the strainer to the oil pump and finger tighten thetwo mounting bolts in the following tightening order -.

Tighten the strainer mounting bolts ( 10 Nm ) inthe following tightening order -.

Remove:

- the sump (see 10A, Engine and peripherals,Sump: Removal - Refitting .


Fill up the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).


Start the engine and wait until the engine oil warninglight goes out.

Check the engine oil level.


113156

10A-45

ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting

K4J, and 730 or 732 – K4M, and 760 or 761

10A


Remove the engine protectors.

Disconnect the battery (see 80A, Battery, Battery :Removal - Refitting ).

Remove:

- the front wheels,

- the right and left-hand wheel arch liners,


- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ),

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ),

- the alternator (see 16A, Starting-Charging, Alter-nator: Removal - Refitting ).

Remove:

- the multifunction support mounting bolts (1) ,

- the bolt (2) mounting the multifunction support onthe sump,

- the multifunction support.

Tightening torquesm

multifunction supportmounting bolts

44 Nm

multifunction supportmounting bolt on thesump

21 Nm

CA or CAREG

102265

10A-46


K4J, and 730 or 732 – K4M, and 760 or 761

10A

Remove:



REFITTING

Refit:

- the multifunction support,

- the multifunction support mounting bolts.

Tighten to torque and in order:

- the multifunction support mounting bolts ( 44Nm ) ,

- the multifunction support mounting bolt on thesump ( 21 Nm ) .

CHAUFO

111057

CA or CAREG

102265

10A-47


K4J, and 730 or 732 – K4M, and 760 or 761

10A

Refit:



Tighten to torque and in order the multifunctionsupport mounting bolts (44 Nm) .

Refit:


- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ),

- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ),



- the front wheels.


Refit the engine protectors.

CHAUFO

111057

10A-48


K9K, and 722 or 724 or 728 or 729 or 732

10A

REMOVAL



Remove the engine covers.

Disconnect the battery (see 80A, Battery: Removal- Refitting ).

Remove:

- the front wheels,



- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).



Remove:


- the bolt (2) mounting the multifunction support onthe sump,


Tightening torquesm

multifunction supportmounting bolt on thesump

21 Nm


44 Nm

CA or CAREG

102265

10A-49


K9K, and 722 or 724 or 728 or 729 or 732

10A

Remove:



REFITTING


Refit:




- the multifunction support mounting bolt on thesump ( 21 Nm ) .


CHAUFO

111057

CA or CAREG

102265

10A-50


K9K, and 722 or 724 or 728 or 729 or 732

10A

Refit:



Tighten to torque and in order the multifunctionsupport mounting bolts (44 Nm) .


Refit:






- the front wheels.

Connect the battery (see 80A, Battery: Removal -Refitting ).

Refit the engine covers.

CHAUFO

111057

10A-51


F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG

10A


Drain the coolant circuit using the filling station(see 62A, Air conditioning, Maintenance ).


Remove the alternator (see 16A, Starting - Char-ging, Alternator ).

Disconnect:

- the air conditioning compressor connector,

- the pressure switch connector (1) .

Remove:

- the air conditioning compressor pipe (2) ,

- the air conditioning pipe between the compressorand the dehydration canister (3) .

Remove:

- the air conditioning compressor mounting bolts,

- the air conditioning compressor.

Equipment required

filling station

Tightening torquesm


44 Nm

air conditioning com-pressor mounting bolts

25 Nm

air conditioning com-pressor strut mountingbolts

44 Nm


109537

Note:


1

2

3

10A-52



10A

Remove:



REFITTING

Refit the multifunction support.

Tighten to torque:


- the air conditioning compressor mountingbolts ( 25 Nm ) .

- the air conditioning compressor strut mountingbolts ( 44 Nm )

Refit the alternator (see 16A, Starting - Charging,Alternator ).




Fill the coolant circuit using the filling station (62A,Air conditioning, Maintenance).

104337

44444

10A-53


M9R, and 700

10A

REMOVAL




Remove the alternator (see 16A, Starting-Char-ging, Alternator: Removal - Refitting ).

Disconnect the connector (1) from the air conditio-ning compressor.

Remove the air conditioning compressor mountingbolts (2) .

Move the air conditioning compressor to one side.

Attach the air conditioning compressor to the halfsub-frame.


Remove:



Tightening torquesm


44 Nm


25 Nm

114861

114862

10A-54


M9R, and 700

10AREFITTING


Position the multifunction support.

Finger tighten (until contact is made) the threemounting bolts in the following order ( (4) - (1) - (2) ).

Finger tighten the two remaining mounting bolts ( (3)(5) ) until contact is made.

Tighten to torque the multifunction support moun-ting bolts ( 44 Nm ) in the following tightening order( (4) - (1) - (2) - (3) - (5) ).


Fit the air conditioning compressor.

Tighten to torque the air conditioning compressormounting bolts ( 25 Nm )

Refit the alternator (see 16A, Starting-Charging,Alternator: Removal - Refitting ).


114862

10A-55

ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting

K4M, and 760 or 761

10AREMOVAL


Remove:


- the front wheels,



Drain:

- the gearbox (see 05A, Draining-Refilling, Gear-box ),

- the engine (see 05A, Draining-Refilling, Engine ).


Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).

Remove:

- the battery (see 80A, Battery, Battery: Removal -Refitting ),





Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm

front end panel uppermounting bolt

21 Nm

front end panel lowermounting bolt

44 Nm

half sub-frame frontmounting bolt

105 Nm

half sub-frame rearmounting bolt

21 Nm

wheel bolt 110 Nm


IMPORTANT

During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.

CA or CAREG

101212

1

10A-56


K4M, and 760 or 761

10A- the half sub-frame side reinforcements (1) ,

- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).

Disconnect the two connectors (2) .

Unclip the front bonnet opening cable (3) .

Remove:

- the clip (4) ,

- the fastening (5) .


Remove:

- the front end panel mounting bolts (6) ,


Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).

Disconnect:

- the petrol inlet pipe from the injector rail (7) ,

- the radiator top hose, using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) .

- the fan unit connectors,


Disconnect the hoses from the expansion bottle onthe cooling radiator side (8) .

102504

102365

54

3

22

666

101795

109537

7

988

11

1010

10A-57


K4M, and 760 or 761

10A

Disconnect the pressostat connector on the lower airconditioning pipe on the condenser (9) .

Remove:

- the air conditioning pipes from the condenser (10) .

- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (11),


Remove the air filter outlet duct (12) .

Disconnect the computer connectors (13) .

Remove the battery tray mounting bolts (14) .

Remove:

- the battery tray,

- the computer mounting.

Remove the air filter unit (15) .

CA or CAREG

Note:


101807

12

101822

104553

141414

131313

15

10A-58


K4M, and 760 or 761

10A

Disconnect the wiring harness connectors from therelay board.

Disconnect the earth strap on the body.

Remove the brake servo pipe (17) .

Disconnect:

- the hoses (18) and (19) using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,

- the downstream oxygen sensor connector.

101978

111051

16

101812

104240

17

1918

10A-59


K4M, and 760 or 761

10A

Unclip the lever cables on the gearbox:

- grip the gearbox control at (A) ,

- pull the pin at (B) ,

- raise the gearbox control at (C) .

Remove the gearbox controls (20) .

Remove:

- the multifunction switch cable ball joint (21) ,

- the multifunction switch cable (22) by unlocking thesleeve stop.

K4M, and 760

101743

101699

C

B

A

A

20

K4M, and 761

103409

22

21

10A-60


K4M, and 760 or 761

10A

Pull out clip (23) .

Disconnect the hydraulic clutch supply pipes.

Remove:

- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),

- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),

- the exhaust downpipe mountings,



Position the hydraulic crane fitted with a load posi-tioner or a chain.

K4M, and 760

101740

Note:

Plug the pipes to prevent fluid from escaping.

23

102008

24

10A-61


K4M, and 760 or 761

10A

Mark the suspended engine mounting in relation tothe body.

Remove the suspended engine mounting.

Remove the suspended gearbox mounting.


Rotate the « engine and gearbox » assembly in or-der to remove it.

REFITTING

To carry out a normal engine replacement operation(see Technical Note 3784A, Petrol engine - 4 cy-linders - K4, 10A, Engine and peripherals, Nor-mal replacement ).

Position the « engine and gearbox assembly » in thevehicle.

Refit:

- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),

- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),

- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),


- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ).


101866

K4M, and 760

102112

K4M, and 761

103273

10A-62


K4M, and 760 or 761

10ATighten to torque:

- the front end panel upper mounting bolt ( 21 Nm) ,

- the front end panel lower mounting bolt ( 44 Nm) ,

- the half sub-frame front mounting bolt ( 105 Nm) ,

- the half sub-frame rear mounting bolt ( 21 Nm ) ,

- the wheel bolt ( 110 Nm ) .

Add brake fluid to the brake fluid reservoir.

Bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ).

Perform the following operations:

- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),

- fill up the engine oil (see 05A, Draining-Refilling,Engine ),

- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).

Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).


Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).


Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment) .

K4M, and 760

CA or CAREG

IMPORTANTCorrectly attach the brake hose and the sensorwiring for the ABS system.

Do not twist the brake hose.

Note:

If the vehicle is fitted with xenon lamps, it isessential to initialise the system (see 80C,Xenon bulbs, Xenon headlights: Adjustment).

10A-63


F9Q, and 800 or 808

10A

REMOVAL


Remove:


- the front wheels,



Drain:






Car. 1363 Trim removal lever




Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm


21 Nm


44 Nm

wheel mounting bolt 110 Nm


105 Nm


321 Nm


WARNING

Procedure for removing the air inlet duct on the intercooler:

- detach the hose, using the (Car. 1363) ,

- do not use a degreaser, brake cleaning product, orany other product,

- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,

- refit the clip in the same recess in the event thatthe hoses are not replaced,

- it is essential to replace the hoses and/or the inter-cooler if they are damaged.

If this procedure is not followed the hoses may leakor come undone.

IMPORTANT


CA or CAREG

10A-64


F9Q, and 800 or 808

10A

Remove:

- the battery (see 80A, Battery, Battery: Removal -Refitting ).

- the half sub-frame side reinforcements (1) ,


Disconnect the connectors (2) .

Unclip the bonnet release cable (3) .

Remove:

- the clip (4) ,



Remove:




Remove:

- the fuel supply pipe (7) ,

- the fuel return pipe (8) .

Disconnect the electrical connector (9) .

Fit plugs into the openings.

101212

102504

1

54

3

2

102365

104338

WARNING

Follow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines).

Be aware of the residual pressure and the quan-tity of diesel fuel in the pipes.

66

8

79

10A-65


F9Q, and 800 or 808

10A

Disconnect:

- the intercooler hose (10) ,

- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

- the fan unit connectors.



Disconnect the pressostat connector on the lower airconditioning pipe from the condenser (12) .

Remove:


- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (14).

Disconnect the air duct from the intercooler (15) .


106275

109537

10

11 12

13

14

CA or CAREG

Note:


102473

15

10A-66


F9Q, and 800 or 808

10A



Remove:

- the battery tray mounting bolts (18) ,

- the battery tray,


Remove:

- the Protection and Switching Unit mounting bolt,

- the fuse box (19) ,

- the relay box (20) .

Disconnect the connectors from the Protection andSwitching Unit.

Remove:

- the earth strap (21) ,

- the pre-postheating unit (22) .

102500

101822

16

1717171818

104245

104340

19

20

21

22

10A-67


F9Q, and 800 or 808

10A

Remove the brake servo pipe (23) from the vacuumpump.

Disconnect the heater radiator top hose (24) on thescuttle panel side using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .



- clip the gearbox control at (A) ,



104322

101699

23

24

25

101743

C

B

A

A

10A-68


F9Q, and 800 or 808

10A

Press the clip (26) .

Disconnect the supply pipes.

Remove the clutch hydraulic control at the bulkhead.

Remove:





- the upper engine tie-bar.



102513

Note:


26

102008

27

10A-69


F9Q, and 800 or 808

10A


Remove:



- the suspended engine mounting,

- the gearbox suspended mounting,


REFITTING

To replace the engine (see Technical Note 3652A,High pressure diesel engine - Common Rail 4 cy-linder cast iron, 10A, Engine and peripherals,Normal replacement ).


Refit:

- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,


- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting )

- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),


- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).


Tighten to torque:



- the wheel mounting bolt ( 110 Nm ) ,


- the half sub-frame rear mounting bolt ( 321 Nm) .

Add the brake fluid to the brake fluid reservoir.


- bleed the clutch (see 37A, Mechanical compo-nent controls): bleed the clutch circuit



102742

102419IMPORTANT

Correctly attach the brake hose and the sensorwiring for the ABS system.


10A-70


F9Q, and 800 or 808

10A- fill up the coolant (see 19A, Cooling, Cooling sys-tem: Draining-refilling ).



Bleed the engine cooling circuit (see 19A, Cooling,Cooling circuit: Bleeding ).


Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).

CA or CAREG

Note:

Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).

10A-71


K9K, and 722 or 728

10A

REMOVAL


Remove:


- the front wheels,



Drain:










Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm


21 Nm


44 Nm

wheel mounting bolts 110 Nm


165 Nm


21 Nm


WARNING








IMPORTANT


CA or CAREG

10A-72


K9K, and 722 or 728

10A

Remove:


- the side reinforcements (1) from the half sub-framecross member,



Unclip the bonnet opening cable (3) .

Remove:

- the clip (4) ,



Remove:




101212

102504

1

54

3

22

102365

66

10A-73


K9K, and 722 or 728

10A

Remove:

- the fuel supply pipe (7)



Disconnect:




Remove the intercooler air ducts (9) and (10) .

102514

WARNING



7

8

106275

102473

9

10

10A-74


K9K, and 722 or 728

10A


Disconnect the pressostat connector on the lower airconditioning pipe on the condenser (12) .

Remove:

- the air conditioning pipes on the condenser (13) ,

- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (14),

Remove the cooling radiator assemblies.



Remove:

- the battery tray,


Move the turbocharger pressure regulation solenoidvalve to one side.

Disconnect:

- the air filter outlet duct,

- the flow meter connector (if fitted to the vehicle).

109537

CA or CAREG

Note:


11

14

13

1211

13

101822

K9K, and 728

151515

161616

10A-75


K9K, and 722 or 728

10A

Remove the air filter unit (17)


Disconnect:

- the pre-postheating unit (18) ,

- the earth strap on the body (19) .


Disconnect the heater radiator hoses from the scutt-le panel (21) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .

104553

101978

17

104340

102263

18

19

2121

20

10A-76


K9K, and 722 or 728

10A

Disconnect the heater radiator hoses from the scutt-le panel (22) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .






Remove the clutch hydraulic control (24) .

102264

101699

22

2323

101743

101701

A

C

B

A

24

10A-77


K9K, and 722 or 728

10A

Remove:








Remove:



- the gearbox suspended mounting,


102008

25

101866

102112

10A-78


K9K, and 722 or 728

10AREFITTING

To replace the engine (see Technical Note 6006A,High pressure diesel engine « Common Rail » - 4cylinder cast iron, 10A, Engine and peripherals,Normal replacement ).


Refit:







Tighten to torque:



- the wheel mounting bolts ( 110 Nm ) ,


- the half sub-frame rear mounting bolt ( 21 Nm ) .



- bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ),



- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-Refilling .





IMPORTANT

Correctly attach the brake hose and the sensorwiring for the ABS system.


CA or CAREG

Note:

Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).

10A-79


M9R, and 700

10A

REMOVAL



Remove:

- the engine undertrays,


- the front wheels,

- the right-hand and left-hand wheel arch liners,



Drain:


- the refrigerant circuit using the filling station (see62A, Air conditioning, Maintenance ).





Mot. 1390 Support for removingand refitt ing theengine and gearboxassembly

Equipment required

filling station

Tightening torquesm

rounded bracket boltswith their spring

21 Nm

half sub-frame rearmounting nuts

21 Nm

half sub-frame frontmounting bolts

105 Nm

intercooler upstreamhose

5.5 Nm

intercooler downs-tream pipe

5.5 Nm

intercooler downs-tream pipe on the airinlet valve

8 Nm

air conditioning pipeson the condenser

8 Nm

air conditioning pipebetween the air condi-tioning compressor andthe dehydration canister

8 Nm


21 Nm


44 Nm

battery tray bolts 21 Nm

wiring harness moun-ting nuts

8 Nm

Tightening torquesm

10A-80


M9R, and 700

10A

Remove:

- the Protection and Switching Unit cover mountingbolts (1) ,




Remove:

- the clips (4) ,

- upper mounting bolts from the front end panel (5) ,

- the fuse box,

- the relay box.


Remove:


- the mounting nut (8) from the wiring harness.

Move the wiring harness to one side.

Remove the battery tray.


112658

102504

112659

114933

10A-81


M9R, and 700

10A

Remove:

- the mounting bolts from the lower front end panel(10) ,



Remove the air resonator (11) .

Remove the air inlet duct (12) .

Remove the air filter unit.

102365

114659

115019

115020

10A-82


M9R, and 700

10A

Loosen the intercooler upstream hose clip (13) .

Disconnect the intercooler upstream hose.

Disconnect:




102473

112661

10A-83


M9R, and 700

10A

Remove the bolt (1 5) mounting the intercoolerdownstream pipe on the cooling radiator.

Loosen:

- the clip (16) securing the intercooler downstreampipe on the intercooler,

- the clip securing the intercooler downstream pipeon the air inlet valve.

Move aside the intercooler downstream pipe on theintercooler.

Disconnect:

- the cooling radiator top and bottom hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .

- the hoses from the expansion bottle on the coolingradiator side (17) ,

- the pressostat connector on the condenser lowerair conditioning pipe (18) .

Release the wiring harness from the pressostat con-nector on the fan unit.

Remove:




Disconnect:

- the fuel supply pipe,

- the fuel return pipe from the diesel filter,

- the fuel return pipe.

Insert plugs into the openings.

Disconnect:

- the pre-postheating unit connector (21) ,

- the earth strap on the body (22) .

115023

Note:


WARNINGFollow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines:Precautions dur ing repair ).

Watch out for diesel fuel splashing when discon-necting the supply union.

104340

10A-84


M9R, and 700

10A

Remove the clutch hydraulic control pipe at the bulk-head (23) .

Remove the brake assistance pipe from the vacuumpump.

Disconnect:

- the heater radiator hose from the scuttle panel out-let,

- the heater radiator hose from the scuttle panel out-let using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .






Remove:

- the side reinforcement mounting bolts (25) ,

- the side reinforcements,

- the half sub-frame mounting bolts (26) ,

- the half sub-frame mounting nuts (27) ,

115003

115001

101743

102008

10A-85


M9R, and 700

10A- the half sub-frame.

Remove:

- the rear mounting (28) (see 19D, Engine moun-ting, Rear mounting: Removal and Refitting )

Remove the rounded bracket bolts with their springs(29) .

Remove:



114650

114991

10A-86


M9R, and 700


Position the (Mot. 1390) .

Remove:

- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ).

- the mounting nut on the left-hand suspendedmounting (see 19D, Engine mounting, Left-handsuspended mounting: Removal - Refitting ).


REFITTING


Position:

- the right-hand suspended mounting in its housing,

- the « Engine and gearbox » assembly in the vehi-cle.

Refit:

- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ).

- the mounting nut on the left-hand suspendedmounting (see 19D, Engine mounting, Left-handsuspended mounting: Removal - Refitting ).

114989

10A-87


M9R, and 700


Refit:

- the rear mounting (see 19D, Engine mounting,Rear mounting: Removal - Refitting ).


- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),

- the rounded bracket bolts with their spring.

Tighten to torque the rounded bracket bolts withtheir spring ( 21 Nm ) .

Refit:



- the half sub-frame mounting nuts.

Tighten to torque:

- the half sub-frame rear mounting nuts ( 21 Nm ),

- the half sub-frame front mounting bolts ( 105Nm ) .

Refit:

- the gearbox controls,

- the fuse box,

- the relay box,

- the earth strap on the body,

Connect:

- the pre-postheating unit connector,

- the brake servo pipe from the vacuum pump,

- the clutch hydraulic control pipe at the bulkhead,

- the heater radiator hose from the scuttle panel out-let,

- the heater radiator hose from the scuttle panel out-let using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) ,


- the fuel return pipe on the diesel filter,



Connect:

- the cooling radiator top and bottom hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,

- the mounting bolt to the intercooler downstream pi-

pe,

- the intercooler upstream hose,

- the intercooler downstream pipe.

Tighten to torque:

- the intercooler upstream hose ( 5.5 Nm ) ,

- the intercooler downstream pipe ( 5.5 Nm ) ,

- the intercooler downstream pipe on the air inletvalve ( 8 Nm ) .

Refit:

- the air conditioning pipes to the condenser.

- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister.

Tighten to torque:

- the air conditioning pipes on the condenser ( 8Nm ) ,

- the air conditioning pipe between the air condi-tioning compressor and the dehydration canis-ter ( 8 Nm ) .

Secure the wiring harness to the pressostat connec-tor on the fan unit.

Connect

- the hoses from the expansion bottle on the coolingradiator side,

- the pressostat connector on the condenser lowerair conditioning pipe.



Clip the fan unit wiring harness into place.

Refit:


- the air inlet duct,

- the air resonator,


- the front end panel lower mounting bolts,

- the front end panel upper mounting bolts,

- the clips.

Tighten to torque:



Clip on the air inlet scoop.

10A-88


M9R, and 700

10ARefit:

- the battery tray, the injection computer and itsmounting,

- the battery tray mounting bolts,

- the wiring harness,

- the wiring harness mounting nut.

Tighten to torque:

- the battery tray bolts ( 21 Nm ) ,

- the wiring harness mounting nuts ( 8 Nm ) .

Connect

- the computer connectors,

- the Protection and Switching Unit connectors.

Clip the bonnet opening cable.

Refit:

- the rounded bracket mounting bolts with theirspring (see 19A, Exhaust ),

- the rear mounting (see 19D, Engine mounting,Rear mounting: Removal - Refitting ).




- fill up the engine oil if necessary,

- fill up the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ),

- fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).

Refit:




- the side reinforcement mounting bolts,

- the front wheels,


- the battery (see 80A, Battery, Battery: Removaland Refitting )

- the engine protector.

10A-89


F4R, and 770 or 771 or 776

10A

REMOVAL


Remove:


- the front wheels,



Drain:










Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm


21 Nm


44 Nm

wheel bolts 110 Nm

wheel bolt (F4R 776) 130 Nm


105 Nm


21 Nm


4 Nm

WARNING

Procedure for removing the air inlet duct on the intercooler (F4R 776):




- refit the clip in the same recess if the hoses arenot replaced,



Note:

During this operation, strap the vehicle to the liftusing a safety belt , to avoid any imbalance.

CA or CAREG

10A-90


F4R, and 770 or 771 or 776

10A

Remove:






Remove:

- the clip (4) ,



Remove:




Disconnect the fuel supply pipe (7) from the injectorrail.

101212

102504

1

54

3

22

102365

F4R, and 770 or 771

101795

666

7

10A-91


F4R, and 770 or 771 or 776

10A

Disconnect:

- the injector rail (8) from the fuel supply pipe

- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,



Disconnect the intercooler hose (9) .

Disconnect:

- the turbocharging pressure sensor connector (10) ,

- the air temperature sensor connector (11) ,


Move the air duct (13) to one side.


F4R, and 776

106271

F4R, and 776

106275

8

9

109536

F4R, and 770 or 771

101807

1312

11

10

14

10A-92


F4R, and 770 or 771 or 776

10A

Disconnect the hoses from the cooling radiator ex-pansion bottle (15) .


Remove:







109537

CA or CAREG

Note:


18

17

1615

101822

20191919 2020

10A-93


F4R, and 770 or 771 or 776

10A

Move the fuel vapour recirculation solenoid valve toone side (21) .

Undo the bolt (22) .

Pull the mounting bracket away from the electriccoolant pump.

Move the electric water pump (23) to one side.

Remove the electric pump mounting (24) .

Remove the computer and its mounting (25) .


F4R, and 776

106278

106632

21

22

24

23

106280

104553

25

10A-94


F4R, and 770 or 771 or 776

10A


Disconnect the earth strap (26) .


Disconnect the downstream oxygen sensor connec-tor.


101978

111051

26

F4R, and 770 or 771

101812

F4R, and 776

106787

27

28

10A-95


F4R, and 770 or 771 or 776

10A

Disconnect hoses (29) and (30) using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) .

Remove the control cables from the gearbox (31) .

Unclip the two gear lever cables on the gearbox:




Remove:


104240

F4R, and 770 or 776

101699

2930

3131

101743

F4R, and 771

103409

B

C

A

A

33

32

10A-96


F4R, and 770 or 771 or 776

10A- the multifunction switch cable (33) by loosening thesleeve stop.

Place a cloth under the master cylinder.

Remove the clip (33) from the union on the mastercylinder return.

Disconnect the pipes from the slave cylinder.


Withdraw the slave cylinder feed pipes.

Remove:








F4R, and 770 or 776

101740

33

102008

34

10A-97


F4R, and 770 or 771 or 776

10A






REFITTING

To carry out a normal engine replacement operation(see Technical Note 6027A, Petrol engine - 4 cy-linders - F4, 10A, Engine and peripherals, Nor-mal replacement ).


Refit:






102742

F4R, and 770 or 776

102112

F4R, and 771

103273

10A-98


F4R, and 770 or 771 or 776

10A- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).


Tighten to torque:




- the wheel bolt (F4R 776) ( 130 Nm ) ,




Bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ).


- fill up the gearbox oil (see 05A, Draining-refilling,Gearbox ),

- fill up the engine oil (see 05A, Draining-refilling,Engine ),





Tighten to torque the battery cover mounting bolts( 4 Nm ) .


IMPORTANT

Correctly attach the flexible brake pipe and ABSsensor wiring.

Do not twist the brake hoses.

F4R, and 770 or 776

CA or CAREG

Note:

Be sure to initialise the xenon bulb system (if fit-ted to the vehicle) see 80C, Xenon bulbs,Xenon headlights: Adjustment ).

10A-99


K9K, and 729, and DP0

10A

REMOVAL


Remove:


- the front wheels,



Drain:










Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm


21 Nm


44 Nm


105 Nm


210 Nm

wheel bolts 110 Nm


4 Nm

WARNING








IMPORTANT


CA or CAREG

10A-100



10A

Remove:






Remove:

- the clip (4) ,



Remove:




101212

102504

1

54

3

22

102365

666

10A-101



10A

Remove:




Disconnect:




Disconnect the intercooler hoses (9) and (10) .

102514

WARNING



78

106275

102473

9

10

10A-102



10A



Remove:

- the air conditioning hoses from the condenser (13),

- the air conditioning hose between the air conditio-ning compressor and the dehydration canister (14).





Move the turbocharger pressure solenoid valve toone side.

Remove:

- the battery tray,

- the computer and its support.

Disconnect the flowmeter connector (if fitted to thevehicle).

109537

CA or CAREG

Note:


1112

14

1313

101807

101822

15

161616171717

10A-103



10A

Disconnect:

- the relay plate harness connectors,

- the relay,

- the fuse box,

- the earth strap from the body,

Remove the brake servo pipe from the vacuumpump (18) .

Disconnect the heater radiator hose from the scuttlepanel (19) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .


Remove:


- the multifunction switch cable (21) by unlocking thesleeve stop.

Disconnect:

- the engine speed sensor,

- the connector by releasing the slide from the con-nector.

104245

102263

18

19

104553

103409

2120

10A-104



10A

Disconnect:

- the pre-postheating unit (22) ,

- the automatic transmission computer connector(23) .

Open the gearbox computer wiring harness moun-ting bracket (24) .

Remove:

- the exhaust mounting nuts (25) ,

- the lower engine tie-bar (26) .

110681

103413

23

22

24

103749

262626

2525

10A-105



10A

Remove:




Position the hydraulic crane fitted with a load posi-tioner .


Remove:



- the suspended gearbox mounting,


102008

27

102114

103273

10A-106



10AREFITTING



Refit:



- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ).




Tighten to torque:




- the half sub-frame rear mounting bolt ( 210 Nm) .






- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ),


Bleed the engine cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).




IMPORTANTCorrectly attach the flexible brake pipe and ABSsensor wiring.


CA or CAREG

Note:

Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlights: Adjustment ).

10A-107


K4J, and 730 or 732

10AREMOVAL


Remove:


- the front wheels,



Drain:





Remove:






Equipment required

safety belt

filling station

hydraulic crane

load positioner

Tightening torquesm


21 Nm


44 Nm


105 Nm


21 Nm

wheel bolt 110 Nm


IMPORTANT


CA or CAREG

101212

1

10A-108


K4J, and 730 or 732

10A- the half sub-frame side reinforcements (1) ,




Remove:

- the clip (4) ,



Remove:




Disconnect the fuel supply union (7) .

Disconnect:





102504

102365

54

3

22

666

101802

109537

7

8 9

10

11

10A-109


K4J, and 730 or 732

10A


Remove:




Remove:

- the air resonator mounting bolt (12) ,

- the air resonator.



Remove:

- the battery tray,



CA or CAREG

Note:


101103

12

101822

101978

131313141414

10A-110


K4J, and 730 or 732

10A

Disconnect the earth strap from the body.


Disconnect:

- the hoses (17) and (18) using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,

- the downstream oxygen sensor connector.





111051

101812

15

16

104240

101743

1817

C

B

A

A

10A-111


K4J, and 730 or 732

10A


Pull out clip (20) .


Remove:







101699

101740

Note:


1919

20

102008

21

10A-112


K4J, and 730 or 732

10A


Remove:




Remove the « engine and gearbox assembly » .

REFITTING

To carry out a normal engine replacement operation(see Technical Note 3784A, Petrol engine - 4 cy-linders - K4, 10A, Engine and peripherals, Nor-mal replacement ).


Refit:







Tighten to torque:











- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ).

101866

102112

IMPORTANTCorrectly attach the brake hose and the sensorwiring for the ABS system.


10A-113


K4J, and 730 or 732

10AConnect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).

Bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit: ).



Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment) .

CA or CAREG

Note:

If the vehicle is fitted with xenon bulbs, it isessential to initialise the xenon bulb system (see80C, Xenon bulbs, Xenon headlights: ).Adjustment ).

10A-114


F9Q, and 804

10A

REMOVAL


Remove:


- the front wheels,



Drain:












Equipment required

safety belt

filling station

Tightening torquesm


21 Nm


44 Nm


105 Nm


21 Nm

wheel bolt 130 Nm


4 Nm

WARNING








IMPORTANT

During this operation, strap the vehicle to the liftusing a safety belt , to avoid any imbalance.

CA or CAREG

10A-115


F9Q, and 804

10ARemove:


- the scuttle panel grille (see MR 371 Bodywork,55A, Exterior protection, Scuttle panel grille ).



Remove:

- the clip (3) ,


Remove:


- the front bumper (see MR 371, Bodywork, 55A,Exterior protection, Front bumper ).

Disconnect the pressostat connector from the lowerair conditioning pipe on the condenser.

Remove:

- the two air conditioning pipes from the condenser,



Remove:



102504

101212

2

11

43

5

CA or CAREG

Note:


102365

666

10A-116


F9Q, and 804

10A

Remove:



Disconnect the electrical connector (9) .

Insert plugs into the openings.

Disconnect.

Disconnect:

- the intercooler hose (10)



- the hoses from the expansion bottle on the coolingradiator side.


Disconnect the duct (11) .

104338

WARNING


Watch out for diesel fuel splashing when discon-necting the supply union.

9

8

7

106275

102473

10

11

10A-117


F9Q, and 804

10A

Disconnect the connector (12) .



Remove:


- the battery tray,


Remove:


- the fuse box (16) ,

- the relay box (17) .

Disconnect the connectors from the Protection andSwitching Unit.

Remove:

- the earth strap (18) ,

- the pre-postheating unit (19) .

102500

101822

13

12

151515

141414

104245

104340

17

16

19

18

10A-118


F9Q, and 804

10A


Disconnect the heater radiator hoses (21) from thescuttle panel side using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .

Remove the gearbox controls (2 2) , using ascrewdriver.

Pull the clip (23) from the clutch pipes.


Remove:



104322

104085

21212121

20

22

101740

Note:


102008

23

24

10A-119


F9Q, and 804

10A- the exhaust downpipe mountings,






Remove:




Remove the « engine and gearbox assembly » .

111879

111880

102742

102419

10A-120


F9Q, and 804

10AREFITTING

To replace the engine (see Technical Note 3652A,High pressure diesel engine - Common Rail 4 cy-linder cast iron, 10A, Engine and peripherals,Normal replacement ).


Refit:








Tighten to torque:











- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ).



Bleed the engine cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).



IMPORTANT



CA or CAREG

Note:

If the vehicle is fitted with xenon bulbs, it isessential to initialise the system (see 80C,Xenon bulbs, Xenon headlights: ). Adjust-ment ).

10A-121


K9K, and 732

10A

REMOVAL



Remove:


- the front wheels,



Drain:

- the gearbox, if necessary,

- the engine, if necessary.


Drain the coolant circuit using the filling station .







Equipment required

filling station

Tightening torquesm


105 Nm


21 Nm


21 Nm


44 Nm

wheel bolts 110 Nm

WARNING

Procedure for removing the air inlet duct on the intercooler (there is a danger of leakage and dislo-cation if this procedure is not complied with):

- detach the hose using the (Car. 1363) ,


- clean the bearing face on the intercooler and onthe hose with a dry, lint-free cloth,

- always replace the clip with a new one,

- replace the new clip in the same position if thehose is not replaced,

- it is essential to replace the hose and/or the inter-cooler if they are damaged,

IMPORTANT

During this operation, secure the vehicle to thelift with a strap, to avoid any imbalance.

CA or CAREG

10A-122


K9K, and 732

10A

Remove:

- the battery,

- the side reinforcements (1) ,


Remove:

- the relay plate cover mounting bolts.

- the relay plate cover.

Disconnect the connectors (2) from the relay board.

Unclip the bonnet opening cable (3) ,

Remove:

- the clip (4) ,



Remove:



Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).

101212

102504

102365

10A-123


K9K, and 732

10A

Remove:



Place plugs in the holes (see 13B, Diesel injection,Cleanliness guidelines ).

Disconnect:

- the hoses from the intercooler (9) ,





112656

WARNING

- Follow the cleanliness guidelines closely.

- Beware of diesel fuel splashing when discon-necting the supply unions.

106275

112661

10A-124


K9K, and 732

10A


Disconnect the pressostat connector from the lowerair conditioning pipe on the condenser. (12)

Remove:





Unclip:

- the wiring harness from the battery negative termi-nal,

- the wiring harness.

Remove:


- the battery tray with the computer and its support.

Move the turbocharger pressure solenoid valve toone side.

Disconnect:

- the connector from the flowmeter,

- the air duct between the air filter unit and the turbo-charger.

109537

CA or CAREG

Note:


101822

10A-125


K9K, and 732

10A

Loosen the air filter unit upstream air duct retainingtabs slightly (17) .

Remove:

- the air filter unit upstream air duct,

- the air filter unit (18) .


Disconnect:

- the pre-postheating unit connector (19) ,

- the earth strap from the body (20) .

112657

104553

101978

104340

10A-126


K9K, and 732

10A


Disconnect:

- the heating radiator hose from the scuttle panel(22) using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) ,

- the heating radiator hose (23) using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) .

Remove the gearbox controls.

Pull clip (24) .

Disconnect the clutch hydraulic control.

Remove:



112946 101743

WARNING

Do not touch the gearbox control slides.

101740

10A-127


K9K, and 732

10A- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),





112814

112813

10A-128


K9K, and 732

10A


Remove:

- the rear suspended mounting (see 19D, Enginesuspension, Rear suspended mounting: Remo-val - Refitting ),

- the left-hand suspended mounting (see 19D, Engi-ne mounting, Left-hand suspended mounting:Removal - Refitting ),

- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ),

Rotate the engine and gearbox assembly in order toremove it.

Remove the engine and gearbox assembly.

REFITTING




Position the engine and gearbox assembly in the ve-hicle.

Refit:

- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ),

- the left-hand suspended mounting (see 19D, Engi-ne mounting, Left-hand suspended mounting:Removal - Refitting ),

- the rear suspended mounting (see 19D, Enginesuspension, Rear suspended mounting: Remo-val / Refitting ).

Remove the (Mot. 1390) .


Refit:


- the half sub-frame mounting bolts.

Tighten to torque:



Refit:



113927

112655

IMPORTANT


10A-129


K9K, and 732

10AConnect:

- the clutch hydraulic control.

- the heater radiator hose using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) .

- the heater radiator hose from the scuttle panelusing the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .

Refit the gearbox controls.

Connect:

- the pre-postheating unit connector,

- the earth strap on the body,

- the relay plate harness connectors.

Refit:

- the air filter unit,

- the air duct upstream of the air filter.

Connect:

- the air duct between the air filter unit and the turbo-charger.

- the connector from the flowmeter.

Reposition the turbocharging pressure regulatingsolenoid valve.

Refit:

- the battery tray,

- the battery tray bolts,

Connect the computer connectors.

Refit:

- the negative terminal wiring harness,


Connect:



Prime the diesel circuit using the priming pump.


Connect:

- the cooling radiator hoses,

- the intercooler hoses,


Connect:

- the air conditioning pipes to the condenser.


- the pressostat connector on the condenser lowerair conditioning pipe

Refit the fan unit wiring harness.

Refit:


- the front end panel mounting bolts,

- the two cooling assembly guide clips.

- the mounting bolts,

- the front bonnet opening cable clip.

Tighten to torque:


- the front end panel lower mounting bolt ( 44 Nm) .

Connect:

- the connectors to the relay board,

- the screen washer tubes.

Refit:

- the front bumper (see Workshop Repair Manual365 Bodywork, 55A, Exterior protection, Frontbumper ),



- the front wheels,



- the relay plate cover,

- the relay plate cover mounting bolts.


Connect the battery ( 80A, Battery, Battery: Remo-val - refitting) .

CA or CAREG

10A-130


K9K, and 732

10A



- bleed the clutch system (see 37A, Mechanicalcomponent controls, Clutch system: Bleeding),




Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Draining-refilling ).

Adjust the headlights (see, depending on equip-ment, 80B, Headlights, Halogen headlights: Ad-justment or 80C, Xenon bulbs, Xenon headlights:Adjustment ).


CA or CAREG

You must initialise the xenon bulb system (if fittedto the vehicle).

10A-131

ENGINE AND LOWER ENGINE ASSEMBLYEngine speed and position sensor: Removal - Refitting

M9R, and 700

10A

REMOVAL



Move the heat insulating material to one side.


Disconnect the engine speed and position sensor.

Remove:

- the engine speed and position sensor mountingbolt (1) ,

- the engine speed and position sensor (2) .

III - REFITTING OPERATION FOR PART CONCERNED

Refit the engine speed and position sensor.

Tighten the engine speed and position sensormounting bolt until contact is made.

Tighten to torque the engine speed and positionsensor mounting bolt ( 10 Nm ) .

IV - FINAL OPERATION

Refit:

- the heat insulating material around the enginespeed and position sensor,


Tightening torquesm

engine speed and posi-tion sensor mountingbolt

10 Nm

114979

10A-132

ENGINE AND LOWER ENGINE ASSEMBLYCrankshaft seal at timing end Removal - Refitting

M9R, and 700

10A

REMOVAL




Remove:

- the front right-hand wheel,

- the front right-hand wheel arch liner.

Remove:

- the right-hand side reinforcement mounting boltson the half sub-frame cross member,

- the right-hand side reinforcement from the half sub-frame cross member (1) ,



Remove the crankshaft sealing ring using the (2)supplied in the spare parts kit for the new gasket.

Tightening torquesm

the crankshaft timingend sealing ring

47 Nm

101212

114853

10A-133


M9R, and 700

10AREFITTING



Position the sealing ring notches opposite the not-ches in the timing cover.

Engage the sealing ring notches in the timing covernotches.

Tighten the sealing ring by hand using the tool sup-plied in the new gasket spare parts kit.

113656

WARNING


114850

114851

10A-134


M9R, and 700

10A

Using tool supplied in the new gasket spare parts kittighten to torque the crankshaft timing end sea-ling ring ( 47 Nm ) .


Refit:


- the right-hand side reinforcements on the half sub-frame,

- the front right-hand wheel arch liner,

- the front right-hand wheel.


114852

11A-1

TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting

K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, andK9K, and 722 or 728 or 729 or 732, and CA or CAREG

11A

REMOVAL



Remove:




Remove the right-hand side reinforcement (1) .

Turn the accessories belt auto tensioner clockwiseusing a 16 mm spanner.

Remove:

- the accessories belt,

- the tensioning roller.

Tightening torquesm

tensioning roller moun-ting bolt

40 Nm

wheel bolts 110 Nm


IMPORTANT

Wear protective gloves during every operation.

WARNING

Never turn the engine in the opposite direction to itsnormal operation.

WARNING

It is imperative to replace the accessories belt andthe tensioning rollers.

WARNING

Do not run the engine without the accessories beltto avoid damaging the crankshaft and the accesso-ries pulley.

101212

101878

1

11A-2


K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, andK9K, and 722 or 728 or 729 or 732, and CA or CAREG

11A

REFITTING

Use a brush to remove any deposits from thecrankshaft pulley V-grooves.

Refit the tensioning roller.

Tighten to torque the tensioning roller mountingbolt ( 40 Nm ) .

Refit the accessories belt.

Rotate the crankshaft twice to position the accesso-ries belt correctly.



Tighten to torque:



106000

WARNING

The accessories belt has five teeth, but the airconditioning compressor pulley has six grooves.When fitting the accessories belt, it is essential tocheck that the groove (2) remains free.

22

11A-3


K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, andCHAUFO

11A

REMOVAL



Remove:




Remove the side reinforcement (1) .

Loosen the tensioning roller bracket mounting bolts.

Remove:



REFITTING



Refit the tensioning roller fitted with new bolts.


Mot. 1638 Accessories belt ten-sioning tool

Mot. 1505 Belt tension settingtool (frequency meter)


Tightening torquesm


35 Nm

wheel bolts 110 Nm


4 Nm

IMPORTANT

Wear protective gloves during the operation.

WARNING


WARNING


WARNING


101212

WARNING

- The two Torx mounting bolts of the tensioningroller must be replaced by M8 x 20 bolts (partnumber 77 03 002 059 ).

11A-4


K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, andCHAUFO

11A

Tension the accessories belt using the (Mot. 1638)by tightening nut (3) (with the two tensioning rollermounting bolts loosened).

Check (4) and using the (Mot. 1505) or the (Mot.1715) , that the accessories belt tension is between223 and 245 Hz .

It is essential to turn the engine through two revolu-tions to position the accessories belt correctly.

Check that the accessories belt tension is between223 and 245 Hz at the measuring point (4) . If not,readjust the tension.


Proceed in the reverse order to removal


Tighten to torque:



20845

WARNING

The accessories belt has five teeth, but the pul-leys have six grooves. It is essential to check thatgroove (2) remains free when the belt is fitted. 21861

11A-5



11A

REMOVAL



Remove:




Remove the right-hand side reinforcement (1) .

Turn the accessories belt auto tensioning roller anti-clockwise using a 16 mm spanner.

Remove:



REFITTING


Tightening torquesm


50 Nm

wheel bolts 110 Nm


IMPORTANT

Wear gloves throughout the operation.

WARNING


WARNING


WARNING


101212

104339

1

11A-6



11ATighten to torque the tensioning roller mountingbolt ( 50 Nm ) .

Rotate the crankshaft twice to position the accesso-ries belt correctly.



Tighten to torque:



11A-7


M9R, and 700

11A

REMOVAL





Remove:


- the front right-hand wheel arch liner;


- the right-hand side reinforcement from the half sub-frame cross member (1) .


Place a 3 mm Allen key in the tensioning roller hole(2) .

Move accessories belt tensioning pulley clockwiseuntil the Allen key is fully inserted.

Remove the accessories belt.


Mot. 1770 Crankshaft pulley loc-king tool

Tightening torquesm


44 Nm


25 Nm

crankshaft accessoriespulley mounting bolt

50 Nm + 85˚ ±±±±6˚

101212

114854

11A-8


M9R, and 700

11A

Remove:

- the tensioning roller mounting bolts (3) ,


Remove:

- the fixed roller mounting bolt plastic cover (4) ,

- the fixed roller mounting bolts (5) ,

- the fixed roller (6) .

Remove:

- the crankshaft accessories pulley mounting boltusing the (Mot. 1770) (1) ,

- the washer,

- the crankshaft accessories pulley.

114856

114857

114849

11A-9


M9R, and 700

11AREFITTING




Refit the fixed roller.

Tighten to torque the tensioning roller mountingbolt ( 44 Nm )

Refit the plastic cover on to the fixed roller mountingbolt.


.


Refit the crankshaft accessories pulley by inserting itonto the two crankshaft flat surfaces.

Refit the washer inside the crankshaft accessoriespulley by inserting it onto the two crankshaft flat sur-faces.

Finger tighten the crankshaft accessories pulleymounting bolt.

Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 50 Nm + 85˚ ±±±± 6˚ )using the (Mot. 1770) .


Remove the tensioning roller pin.

Turn the crankshaft twice.

Check that the accessories belt V-blocks are wellpositioned in the V-grooves of all the pulleys.

WARNING

Only use brushes with plastic or non-corrosivemetal (brass) bristles.

WARNING

Do not run the engine without the accessoriesbelt so as not to damage the crankshaft accesso-ries pulley.

WARNING

When replacing the accessories belt recommen-ded by the manufacturer, always replace:


- the tensioning roller and fixed roller,

- the crankshaft accessories pulley bolt,

- the crankshaft accessories pulley.

Note:

The Parts Department supplies the tensioningroller pin.

WARNING

Check that the washer fits properly on thecrankshaft flat surfaces.

11A-10


M9R, and 700


Refit:

- the right-hand side reinforcement from the half sub-frame cross member.


- the front right-hand wheel arch liner;



11A-11

TOP AND FRONT OF ENGINETiming belt: Removal - Refitting

K4J, and 730 or 732

11A


Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps

Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453

Mot. 1489 TDC locating pin

Mot. 1368 Tool for tightening ten-sioner bolt. 8 mm Torxwrench 12.7 mmsquare

Mot. 799-01 Timing gear wheelimmobiliser

Mot. 1496 Camshaft setting tool

Mot. 1750 Adapter for camshaftsetting tool Mot. 1496

Mot. 1490-01 Locking and adjustingcamshaft pulleys

Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)


Tightening torquesm

fixed roller mountingbolt

45 Nm

tensioning roller moun-ting nut

27 Nm


40 Nm + 145˚±±±± 15˚


27 Nm


27 Nm


45 Nm


27 Nm


40 Nm + 145˚±±±± 15˚


27 Nm


27 Nm


45 Nm


27 Nm


27 Nm

accessories pulleymounting bolt

40 Nm + 115˚±±±± 15˚

new camshaft pulleynuts

30 Nm + 84˚ ±±±±4˚


27 Nm

TDC setting pin plug 20 Nm

upper timing cover boltsand nuts

41 Nm

wheel bolts 110 Nm


4 Nm

IMPORTANT

Wear protective gloves during every operation.

WARNING


WARNING

The belt must be replaced with a new one if it hasbeen removed.

Tightening torquesm

11A-12


K4J, and 730 or 732

11A

REMOVAL



Remove:



Position the (Mot. 1453) and the (Mot. 1453-01) withretaining straps.

WARNING

When replacing the belt, be sure to replace the ten-sioning rollers and fixed rollers.

Note:

The timing belt procedure is the same for engineswith or without camshaft dephasers

102450

102451

11A-13


K4J, and 730 or 732

11A


Remove:

- the « engine and suspended engine mounting »assembly,

- the lower engine tie-bar.

Remove:

- the air resonator mounting,


Pierce the middle of the plugs on the end of thecamshaft using a screwdriver.

Remove:

- the sealing plugs at the camshaft end with ascrewdriver,

- the TDC pin plug (1) ,

- the engine lifting eye (flywheel end),

101866

WARNING

Do not damage the air conditioning pipe.

101103

14491

1

11A-14


K4J, and 730 or 732

11AADJUSTING THE TIMING

Position the camshaft grooves (2) almost horizontal-ly and offset downwards, turning the crankshaft in itsnormal operating direction (timing end clockwise).

Screw in the TDC setting pin (3) (Mot. 1489) .

Turn the crankshaft in its operating direction (timingend clockwise), until the crankshaft comes into con-tact with TDC setting pin.

Check that the camshaft grooves are horizontal andoffset downwards.

Remove:

- the crankshaft accessories pulley (4) , locking theflywheel with a screwdriver,

- the upper timing cover (5) ,

- the lower timing cover (6) .

14491-1

14489

3

2

14490

14487

5

4

6

11A-15


K4J, and 730 or 732

11A

Undo the nut (7) on the tensioning roller to slackenthe timing belt.

Remove:

- the fixed roller (8) using the (Mot. 1368) ,

- the timing belt, taking care not to drop the cranks-haft sprocket,

- the timing sprocket,


REFITTING - PROCEDURE 1

I - PROCEDURE FOR ENGINES FITTED WITH A TIMING COVER WITHOUT FLAP

1 - ADJUSTING THE TIMING

The first procedure is used when replacing any timi-ng component that does not require one or morecamshaft pulleys to be loosened.

Set the camshaft grooves horizontally and below thecentre line by turning the camshafts with the (Mot.799-01) if necessary.

101872

8

7 WARNING

Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.

WARNING

Be sure to degrease:

- the end of the crankshaft (timing end),

- the timing sprocket bore and contact surfaces,

- the contact surfaces of the crankshaft andaccessories pulley.

This is to avoid timing slippage.

This slippage causes engine damage.

14490

11A-16


K4J, and 730 or 732

11A

Fit the (Mot. 1496) with the (Mot. 1750) (9) .

Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts.

Position the TDC setting pin (Mot. 1489) (10) .

Check that the crankshaft is in contact with the TDCsetting pin (Mot. 1489) (10) (crankshaft groove (11)should be at the top).

111337

111336

14489

108875

11A-17


K4J, and 730 or 732

11A2 - REFITTING

Refit the tensioning roller by positioning the tensio-ning roller lug in rib (12) .

Refit:

- the crankshaft timing sprocket (13) ,

- the timing belt,


Tighten to torque the fixed roller mounting bolt (45 Nm ) using the (Mot. 1368) .

3 - BELT TENSION

Using a 6 mm Allen key, bring the adjustable index(15) opposite the notch (16) , by turning the eccen-tric (17) clockwise.

108879

14487-3

14487-2

103263

11A-18


K4J, and 730 or 732

11ATighten to torque the tensioning roller mountingnut ( 27 Nm ) .

Refit the crankshaft accessories pulley.

Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 145˚ ±±±± 15˚ )(crankshaft in contact with TDC setting pin)

Remove:

- the camshaft setting tool (Mot. 1496) ,

- the TDC setting pin (Mot. 1489) .

Rotate the crankshaft clockwise (timing end) throu-gh two revolutions and before completing the se-cond revolution.

Screw the TDC setting pin (Mot. 1489) into the cylin-der block.

Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.

Remove the TDC setting pin (Mot. 1489) .

Check that adjustable index (18) is opposite thenotch (19) .

Loosen the tensioning roller nut by up to one turn,holding the adjustable index with a 6 mm Allen key.

Gradually move the adjustable index (18) facing thenotch (19) turning the eccentric (20) in a clockwisedirection.

Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .

4 - CHECKING THE TIMING AND TENSION

a - Checking the tension

Rotate the crankshaft clockwise through two revolu-tions (timing end).

Screw in the TDC setting pin (Mot. 1489) .

Move the crankshaft slowly and smoothly to rest onthe TDC setting pin (Mot. 1489) .

Remove the TDC setting pin.

Check the tensioning roller indexes are aligned; ifnot readjust the tension by loosening the tensioningroller eccentric by a single turn.

Correctly align the adjustable index with the fixed in-dex or the notch (depending on the type of tensio-ning roller).


b - Checking the timing

Check that the tensioning roller indexes are correctlypositioned before checking the timing setting.


Move the crankshaft slowly and smoothly until it isresting against the pin.

103263

11A-19


K4J, and 730 or 732

11A

Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland below the centre line).


II - PROCEDURE FOR ENGINES FITTED WITH TIMING COVER WITH FLAP



Set the camshaft grooves horizontally and below thecentre line by turning the camshafts with the (Mot.799-01) , if necessary.

14490

WARNING

The timing adjustment and tensioning operationmust be repeated if the camshaft setting tooldoes not engage.

WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.

WARNING




- the contact surfaces of the crankshaft andaccessories pulley.



14490

11A-20


K4J, and 730 or 732

11A


Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts

Position the TDC setting pin (Mot. 1489) (22) .


111337

111336

14489

108875

11A-21


K4J, and 730 or 732

11A2 - REFITTING

Refit the tensioning roller by positioning the tensio-ning roller lug in rib (24) .

Refit the crankshaft timing sprocket.

Refit:

- the timing belt,

- the timing fixed roller (25)


3 - TIMING BELT TENSION

Bring the adjustable index (26) opposite the notch(27) , by turning the eccentric (28) clockwise using a6 mm Allen key.


Refit the lower timing cover.

108879

14487-3

103263

109054

11A-22


K4J, and 730 or 732

11A


Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 145˚ ±±±± 15˚ )(crankshaft in contact with TDC setting pin).

Remove the cover plate from the lower timing cover.

Remove:



Rotate the crankshaft twice in a clockwise direction,on the timing end, before aligning the markings (onthe camshaft dephaser) already made by the opera-tor.


Move the crankshaft slowly and smoothly to rest onthe TDC setting pin.


109055

109052

11A-23


K4J, and 730 or 732

11A

Check through the lower timing cover window thatthe adjustable index (30) is opposite the notch (29) ,if not, loosen the timing tensioning roller screw by asingle turn while holding the eccentric using a 6 mmAllen key.



Check that dephaser marking is in alignment withmarking already made by the operator.







Check through the lower timing cover window thatthe index and the notch of the timing tensioning rol-ler are aligned; if not, readjust the tension by loose-ning the tensioning roller nut on the eccentric by asingle turn.

Align the adjustable index with the notch.



Ensure that the index and the notch on the timingtensioning roller are in the correct position beforechecking the timing.


Move the crankshaft slowly and smoothly to rest onthe TDC setting pin.

109051

103263

11A-24


K4J, and 730 or 732

11A

Fit (without forcing) the camshaft setting tool (Mot.1496) (the camshaft grooves must be horizontal andoffset towards the bottom).

Refit the lower timing cover plate, checking that thelocating pin (32) fits properly in the notch (33) .

REFITTING -PROCEDURE 2

I - ADJUSTING THE TIMING

The second procedure is used for the replacementof all components requiring the slackening of one ormore of the camshaft pulleys.

Refit the camshaft pulleys and the old nuts, tighte-ning to a torque of 15 Nm .

14490

Note:


109052

WARNINGIf the stud is loosened with the nut (see NT3887A, Replacing camshaft pulley studs K9 -K4, 11A, Top and front of engine, Camshaft ).

WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.

WARNING




- the crankshaft accessories pulley bearingfaces,

- the camshaft ends (timing end),

- the camshaft sprocket bores and contact surfa-ces.



11A-25


K4J, and 730 or 732

11A

Position the camshaft grooves horizontally and off-set downwards, by turning the camshafts with the(Mot. 1496) if necessary.



Remove the old camshaft pulley nuts and replacethem with new ones (without tightening the nuts: 0.5to 1 mm play between nuts and pulleys).

14490

103261

111337

111336

11A-26


K4J, and 730 or 732

11A


Position the RENAULT badge (37) etched on thecamshaft pulley spokes vertically at the top.

II - REFITTING

Refit the tensioning roller by positioning the tensio-ning roller lug in groove (38) .

Refit:

- the timing sprocket (39) ,

- the timing belt on the camshaft pulleys (without mo-ving the camshaft pulleys).

14489

14487-1

108879

14487-3

11A-27


K4J, and 730 or 732

11A

Fit the camshaft pulley locking tool (Mot. 1490-01)(40) (use the timing cover mountings to mount thetool).

Refit the fixed roller (41) .


Refit the crankshaft accessories pulley (without tigh-tening the bolt, 2 to 3 mm play between bolt and pul-ley).

III - BELT TENSION

Using a 6 mm Allen key, bring the adjustable index(42) in line with the notch (43) , by turning the eccen-tric (44) clockwise.


Remove camshaft pulley locking tool (Mot. 1490-01).

Rotate the timing system through six revolutionswith the exhaust camshaft sprocket, using the (Mot.799-01) .

101876

14487-3

103263

Note:

Check that the camshaft pulley nuts and bolt donot come into contact with their respective pul-leys. In addition, from time to time, press thecamshaft pulleys against the camshafts.

11A-28


K4J, and 730 or 732

11A

Check that adjustable index (45) is opposite thenotch (46) .




Position the camshaft pulley locking tool (Mot. 1490-01) .

Tighten to torque and angle:

- the accessories pulley mounting bolt ( 40 Nm +115˚ ±±±± 15˚ ) (crankshaft in contact with TDC settingpin)

- the new camshaft pulley nuts ( 30 Nm + 84˚ ±±±± 4˚) starting with the exhaust pulley

Remove:


- the camshaft pulley locking tool (Mot. 1490-01) ,


IV - CHECKING THE TIMING AND TENSION

1 - Checking the tension


screw the TDC setting pin (Mot. 1489) into the cylin-der block.

slowly and smoothly position the crankshaft in con-tact with the TDC setting pin (Mot. 1489) .


103263

14839

14489

WARNING

Check that the crankshaft is in contact with theTDC setting pin (Mot. 1489) .

11A-29


K4J, and 730 or 732

11ACheck the tensioning roller indexes are aligned; ifnot readjust the tension by loosening the tensioningroller eccentric by a single turn.

Correctly align the adjustable index with the fixed in-dex or the notch (depending on the type of tensio-ning roller).


2 - Checking the timing

Check that the timing pulley indexes are correctlypositioned before checking the timing setting.


Move the crankshaft slowly and smoothly and rest iton the TDC setting pin (Mot. 1489) .

Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland offset downwards).


REFITTING

Refit the TDC setting pin plug, applying a drop ofJOINT SILICONE ADHERENT onto the thread hole.

Tighten to torque the TDC setting pin plug ( 20 Nm) .


Refit the upper timing cover.

Tighten to torque the upper timing cover bolts andnuts ( 41 Nm ) .

Refit:



- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),

- new inlet camshaft sealing plugs (Mot. 1487) ,

- new exhaust camshaft sealing plugs (Mot. 1488) .



Tighten to torque:

- the wheel bolts ( 110 Nm )


14490

Note:


15103-1

11A-30


K9K, and 722 or 728 or 729

11AREMOVAL



Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting ).

Position the (Mot. 1453) and (Mot. 1453-01) with re-taining straps.





Mot. 1430 Set of 5 crankshaftand camshaft pulleytiming pins

Tightening torquesm

tensioning roller bolt 25 Nm

crankshaft accessoriespulley M12 mountingbolt

60 Nm + 100˚±±±± 10˚

crankshaft accessoriespulley M14 mountingbolt

120 Nm + 95˚±±±± 15˚


25 Nm


cylinder head suspen-ded mounting bolts

21 Nm

wheel bolts 110 Nm


4 Nm

WARNING


102450

102451

11A-31


K9K, and 722 or 728 or 729

11A

Remove the lower tie-bar bolts (1) .

Remove the lower engine tie-bar.

Mark the position of the suspended engine moun-ting.

Slacken the bolt (2)


102115

102114

WARNING


1

2

11A-32


K9K, and 722 or 728 or 729

11A

Remove the upper timing cover by unclipping thetabs (3) .

19654

3

11A-33


K9K, and 722 or 728 or 729

11A

Remove:

- the cylinder marking sensor on the high pressurepump (4) ,

- the plastic bolt (6) .

Unclip the tabs (5) .

Remove the lower timing cover.

19654-1

11A-34


K9K, and 722 or 728 or 729

11A

Remove the cylinder head suspended mounting.

Remove the TDC setting pin plug.

Positioning the timing at the adjustment point

Rotate the crankshaft clockwise (timing end) to posi-tion the hole (8) in the camshaft pulley partially inline with the hole (9) in the cylinder head.

19654-2

19650

7

19702

9

8

11A-35


K9K, and 722 or 728 or 729

11A


Turn the crankshaft clockwise (timing end) smoothlyuntil the crankshaft comes in contact with the TDCsetting pin (Mot. 1489) .

Insert the pin (2) (Mot. 1430) in the camshaft pulleyand cylinder head holes.

Remove:

- the pin (Mot. 1430) ,


19650-1

14489-1

1

19655

2

11A-36


K9K, and 722 or 728 or 729

11A

Remove the crankshaft accessories pulley, lockingthe flywheel with a screwdriver.

19656

11A-37


K9K, and 722 or 728 or 729

11A

Undo the tensioning roller bolt (10) to slacken the ti-ming belt.

Remove:

- the timing belt (take care not to drop the crankshaftsprocket),



REFITTING19656-1

10

WARNING

It is imperative to replace the timing belt, the ten-sioning roller and the accessories pulley bolt.

WARNING




- the contact surfaces of the crankshaft accesso-ries pulley.



11A-38


K9K, and 722 or 728 or 729

11A

Refit the crankshaft timing sprocket.

19710

11A-39


K9K, and 722 or 728 or 729

11AI - ADJUSTING THE TIMING


Insert the pin (2) (Mot. 1430) in the camshaft pulleyand cylinder head holes.

Screw the TDC setting pin into the cylinder block.

Check that the mark (13) on the high pressure pumppulley is in line with the bolt head (14) .

Check that the crankshaft is hard against the TDCsetting pin (Mot. 1489) (crankshaft groove (15) fa-cing upwards).

19656-2

15

1413

12

11

2

Note:

Check that the tensioning roller lug (11) is cor-rectly positioned in the groove (12) .

14489

11A-40


K9K, and 722 or 728 or 729

11A

Fit the new timing belt, aligning the marks on the beltwith those on the camshaft sprockets and the highpressure pump.

Position the tensioning roller adjustable index (16)opposite the lug using a 6 mm Allen key, turning itanticlockwise.

Tighten to torque the tensioning roller bolt ( 25 Nm) .


Tighten to torque and angle (crankshaft in contact with the TDC setting pin):

- crankshaft accessories pulley M12 mountingbolt ( 60 Nm + 100˚ ±±±± 10˚ ) ,

- crankshaft accessories pulley M14 mountingbolt ( 120 Nm + 95˚ ±±±± 15˚ ) .

Remove:

- the TDC setting pin (Mot. 1489) ,

- the camshaft pulley timing pin (Mot. 1430) .

19657

Note:

19 belt tooth spaces between the camshaftsprocket and pump marks.

19658

16

11A-41


K9K, and 722 or 728 or 729

11A


Before the camshaft pulley hole (17) comes in linewith the cylinder head hole (18) , screw the TDC set-ting pin (Mot. 1489) into the cylinder block.

Bring the crankshaft slowly and smoothly into con-tact with the pin.

Check:

- that the timing pin (Mot. 1430) engages properly inthe camshaft and cylinder head holes,

- that there are 19 belt tooth spaces between thecamshaft sprocket mark (19) and the high pressurepump sprocket mark (20) .

Remove:



19702

18

17

19655

After two turns, the tensioning roller indexes maybe in two different positions.

The rotation of the tensioning roller eccentricdepends on the position.

2019

11A-42


K9K, and 722 or 728 or 729

11AFirst position

Loosen the tensioning roller bolt by no more thanone turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (21) , turningthe Allen key anticlockwise, to the middle of the timi-ng window (22) .

Second position

Loosen the tensioning roller bolt by no more thanone turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (23) , turningthe key clockwise, to the middle of the timing window(24) .

111083

111081

21

111082

111081

23

23

24

11A-43


K9K, and 722 or 728 or 729

11AII - REFITTING


Refit the TDC setting pin plug, applying JOINT SILI-CONE ADHERENT to the thread hole.


Refit the cylinder head suspended mounting.

Tighten to torque the cylinder head suspendedmounting bolts ( 21 Nm ) .

19654-2

11A-44


K9K, and 722 or 728 or 729

11A

Refit the lower timing cover, positioning the tab (25)in the lower timing cover aperture (26) .

19654-1

19659

26

25

11A-45


K9K, and 722 or 728 or 729

11A

Refit:

- the upper timing cover,





.

Tighten to torque:



19654

11A-46


F9Q, and 800 or 804 or 808

11A

REMOVAL



Remove:


- the accessories belt (see 11A, Cylinder head, Ac-cessories belt: Removal - Refitting ).





Mot. 1054 TDC setting pin

Mot. 1543 Tool for pretensioningtiming belt

Mot. 1705 Adapter for timing beltpretensioning tool



Tightening torquesm



45 Nm


40 Nm + 110˚±±±± 10˚

wheel bolts 110 Nm


WARNING


102450

102451

11A-47


F9Q, and 800 or 804 or 808

11A

Remove:



Mark the position of the suspended engine mountingin relation to the body.

Slacken the bolt (1)


Remove:

- the TDC setting pin plug.

- the flywheel guard cover plate.

Remove:

- the crankshaft accessories pulley, locking theflywheel with a screwdriver,

- the timing cover mounting bolts (2) ,

- the timing cover.

102420

WARNING

Do not damage the air conditioning pipes (if fittedto the vehicle).

1

15102

104739

22

11A-48


F9Q, and 800 or 804 or 808

11AADJUSTING THE TIMING

Rotate the crankshaft clockwise (timing end); bringthe camshaft pulley mark to half a tooth before themark on the guard.

When the mark on the camshaft pulley is half a toothbefore the mark on the guard, press in the TDC set-ting pin (Mot. 1054) until the crankshaft is timed.

Undo the tensioning roller mounting nut (3) to slac-ken the tensioning roller.

Remove the timing belt.

REFITTING

104329

104330

104326

WARNING

Replace the timing belt, the tensioning roller, thecrankshaft accessories pulley and bolt.

3

11A-49


F9Q, and 800 or 804 or 808

11A

Refit the tensioning roller, taking care to position itcorrectly on the locating pin (4) .

Check that the TDC setting pin (Mot. 1054) is in pla-ce.

Fit the new timing belt, aligning the marks on the beltwith those on the crankshaft, camshaft and highpressure pump sprockets (count 28 belt tooth spa-ces between the mark on the camshaft sprocket andthe mark on the high pressure pump sprocket).

Press the tensioning roller against the belt by tighte-ning the bolt (8) on the tensioning roller mounting.


Position the crankshaft accessories pulley bolt.

104336

16187

Note:

The crankshaft groove (5) must be in the middleof the two ribs (6) on the crankshaft guard plate.The crankshaft timing sprocket mark (7) shouldbe offset one tooth to the left of the vertical axisof the engine.

4

66

7

5

104327

Note:

The bolt (8) is manufactured locally.

8

11A-50


F9Q, and 800 or 804 or 808

11A

Mount the timing belt pretensioning tool (Mot. 1543)fitted with the cover (Mot. 1705) (9) on the cranks-haft accessories pulley bolt.

Pretension the timing belt between the crankshaft ti-ming sprocket and the tensioning roller using the(Mot. 1543) and a torque wrench set to a torque of(11 Nm) .

16563

104331

9

104332

11A-51


F9Q, and 800 or 804 or 808

11A

Position the sensor of the (Mot. 1505) or (Mot.1715) between the crankshaft sprocket and the ten-sioning roller.

Tension the belt to obtain the recommended value90 ±±±± 3 Hz by turning the bolt (10) .

Tighten to torque the tensioning roller mountingnut (10 Nm) .

Turn the crankshaft through two revolutions.

Reposition the TDC setting pin (Mot. 1054) .

Position the timing at its setting point (start pressingon the pin half a tooth before alignment of the cams-haft pulley mark and the cover plate mark, to avoidgoing into a camshaft balancing hole).


Refit the TDC setting pin plug, applying a drop ofRHODORSEAL 5661 onto the thread.


Apply a pretensioning force between the crankshafttiming sprocket and the tensioning roller using the(Mot. 1543) and a torque wrench set to a torque of11 Nm .

Place the sensor of the (Mot. 1505) between thecrankshaft sprocket and the tensioning roller.

Check that the tension value is 80 ±±±± 5 Hz ; if not, rea-djust.



Remove the crankshaft accessories pulley bolt.

Refit the crankshaft accessories pulley, without se-parating its two component parts.

Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 110˚ ±±±± 10˚ ).

Refit:





To refit, proceed in the reverse order to removal.


Tighten to torque:



104333

10

105435

11A-52


F4R, and 770 or 771 or 776

11A




Mot. 1672 Lower engine support

Mot. 1054 TDC setting pin

Mot. 1509 Camshaft sprocketlocking tool

Mot. 1509-01 Conversion kit for Mot.1509





Tightening torquesm

toothed sprocket nuts 80 Nm



50 Nm

tensioning roller nut 7 Nm

toothed sprocket nuts (80 Nm)

old inlet camshaftdephaser mounting bolt

(30 Nm)

old exhaust camshaftpulley nut

30 Nm

toothed sprocket nuts (80 Nm)

old inlet and exhaustcamshaft pulley nuts

(30 Nm)



tensioning roller nut 28 Nm


inlet camshaft depha-ser mounting bolt

(30 Nm)

exhaust camshaft pul-ley nut

(30 Nm)

inlet camshaft depha-ser mounting bolt

100 Nm

camshaft pulley depha-ser blanking cover

25 Nm


86˚ ±±±± 6˚


inlet and exhaust cams-haft pulley nuts

86˚ ±±±± 6˚

nuts 80 Nm

inlet and exhaust cams-haft pulley nuts

30 Nm + 86˚ ±±±±6˚

crankshaft accessoriespulley bolt

40 Nm + 110˚±±±± 10˚

M6 lower timing coverbolts

80 Nm

M8 lower timing coverbolts

20 Nm

M8 upper timing coverbolts

18 Nm

M10 upper timing coverbolts

38 Nm

wheel bolts 110 Nm


4 Nm

Note

The timing belt procedure is the same for engineswith or without camshaft dephasers.

Tightening torquesm

11A-53


F4R, and 770 or 771 or 776

11A

REMOVAL



Remove:






WARNING


WARNING

Do not run the engine without the accessories beltto avoid damaging the crankshaft accessories pul-ley.

WARNINGOn the F4R engine, it is essential to fit the cranks-haft sprocket with the integral key.

WARNING

Replace the following parts when they are removed:

- the camshaft pulley nuts,

- the crankshaft accessories pulley,

- the crankshaft accessories pulley bolt.

WARNING

When replacing the belt, it is imperative to replacethe tensioning roller and the fixed roller.

102450

102451

11A-54


F4R, and 770 or 771 or 776

11A

Remove:

- the radiator cross member right-hand side reinfor-cement (1) ,




Remove:

- the clip (4) ,

- the fastening (5) ,



Remove:




Position the (Mot. 1672) with retaining straps.

106077

F4R, and 776

102504

1

54

3

22

102365

105432

666

11A-55


F4R, and 770 or 771 or 776

11A


Remove the suspended mounting assembly.


Remove:

- the air filter outlet duct (7) ,

- the throttle valve (8) ,

- the connector on the lifting bracket.

Remove the fuel vapour recirculation solenoid valve(9) .

102742

Note:

Be careful not to bend the air conditioning pipe.

F4R, and 770 or 771

101807

7

8

F4R, and 776

106278

9

11A-56


F4R, and 770 or 771 or 776

11A

Loosen the nut (10) .

Pull the mounting bracket away from the electriccoolant pump.

Move the electric coolant pump (11) to one side.

Remove the wiring harness mounting bracket.

Remove the TDC setting pin plug (12) .

Remove the camshaft sealing plugs.


Rotate the engine clockwise (timing end) so that thecamshaft grooves are offset below the centre lineand almost horizontal, as shown in the drawing.

Insert the TDC setting pin (Mot. 1054) so that it isbetween the balancing hole and the crankshaft set-ting groove.

106632

15102

1011

12

15105

15106

11A-57


F4R, and 770 or 771 or 776

11A

Turn the engine slightly in the same direction,pushing in the TDC setting pin (Mot. 1054) until thesetting point is reached.

At the setting point, the camshaft grooves must behorizontal and offset below the centre line, as shownin the drawing.

Correct position

Incorrect position


15163-2

15106-1

15163-1

15163

11A-58


F4R, and 770 or 771 or 776

11A

Remove:

- the flywheel guard,

- the crankshaft pulley, locking the flywheel with ascrewdriver.

Refit the TDC setting pin (Mot. 1054) .

106519

15303

11A-59


F4R, and 770 or 771 or 776

11A

Remove:



F4R, and 770 or 771

18433

14

13

11A-60


F4R, and 770 or 771 or 776

11A

Remove:

- the heat shield (15) ,


F4R, and 776

106338

15

104719

16

17

11A-61


F4R, and 770 or 771 or 776

11A- the lower timing cover (17) .

Slacken the timing belt by loosening the tensioningroller nut (18) .

Remove:

- the fixed roller (19) ,

- the timing belt,

- the crankshaft timing sprocket.

18433-2

18

19

WARNING

When replacing the timing belt, it is imperative toreplace the tensioning roller and the fixed roller.

WARNING

A belt which has been removed MUST be repla-ced.

WARNING

Never turn the engine in the opposite direction toits normal operation.

11A-62


F4R, and 770 or 771 or 776

11AII - ADJUSTING THE TIMING

104703

WARNING



- the timing sprocket bore and contact surfaces(20) ,

- the contact surfaces of the crankshaft accesso-ries pulley,

This is to prevent slippage between the timinggear and the crankshaft.


WARNING


WARNING

In this case, the old camshaft pulley nuts must beremoved in order to correctly set the belt tension.

2020

11A-63


F4R, and 770 or 771 or 776

11A

Check that the camshaft dephaser wheel is correctlylocked (no rotation of the wheel to the left or to theright).

F4R, and 770 or 771

15815-3

11A-64


F4R, and 770 or 771 or 776

11A

Position the (Mot. 1509) with sprocket (Mot. 1509-01) .

Position the spacer (21) of the (Mot. 1509-01) on thestud (22) .

Fit the upper bolt (23) , positioning the spacer (24)(Mot. 1509-01) between the tool and the rocker co-ver (do not tighten the bolt).

Tighten the bolt and the shouldered nut (25) .

Bring the toothed sprockets of the (Mot. 1509) intocontact with the camshaft pulleys.

Tighten the toothed sprocket nuts ( 80 Nm ) (26) .

Remove:

- the inlet camshaft dephaser blanking cover (27) ,

- the inlet camshaft dephaser mounting bolt,

- the exhaust camshaft pulley nut,

- the (Mot. 1509) ,

- the camshaft pulleys.

Loosen the stud with the nut (see NT 3884A, Repla-cing F4 camshaft pulley studs, Top and front ofengine, Camshaft ).

16019

16019-1

22

21

23

24

16019-3

26 252526

27

11A-65


F4R, and 770 or 771 or 776

11A

Install the (Mot. 1509) with its toothed sprocket(Mot. 1509-01) .


Bring the toothed sprockets into contact with thecamshaft pulleys.


Remove:

- the camshaft pulley nuts,

- the (Mot. 1509) ,

- the camshaft pulleys.

Loosen the stud with the nut (see NT 3884A, Repla-cing F4 camshaft pulley studs, Top and front ofengine, Camshaft ).

Refit the degreased camshaft pulleys with the oldmountings.

Tighten to torque the old mountings (15 Nm max.)using the (Mot. 799-01) .

Position the grooves offset horizontally below thecentre-line as shown above by turning the cams-hafts using the (Mot. 799-01) .

F4R, and 776

104711

28

29

28

29

WARNING

When removing the timing belt, it is essential to replace:

- the crankshaft accessories pulley,

- the tensioning roller and fixed roller,

- the accessories and timing belts.

15106-1

11A-66


F4R, and 770 or 771 or 776

11A

Position the (Mot. 1496) , attaching it to the end ofthe camshafts.

Loosen:


- the inlet camshaft dephaser pulley bolt,

Loosen the camshaft pulley nuts.

Correct position

15104

F4R, and 770 or 771

F4R, and 776

15114

15163-1

WARNING

Check that the crankshaft is correctly centered.

The crankshaft groove (30) must be between thetwo ribs (31) .

31

30

11A-67


F4R, and 770 or 771 or 776

11A

Refit the tensioning roller, correctly positioning the(32) of the tensioning roller in the groove (33) .

Refit:


- the timing belt,


Tighten to torque the fixed roller mounting bolt (50 Nm ) .

15201

33

32

15815-1

34

11A-68


F4R, and 770 or 771 or 776

11AIII - ADJUSTING THE TENSION

Align the marks (35) and (36) on the tensioning rollerusing an Allen key (6 mm) in (37) .

Tighten to torque the tensioning roller nut ( 7 Nm ).

Position the (Mot. 1509) with the toothed sprocket(Mot. 1509-01) for locking the camshaft pulleys.


Bring the toothed sprocket nuts into contact with thecamshaft pulleys.

Tighten to torque:

- the toothed sprocket nuts ( (80 Nm) ) (39) ,

- the old inlet camshaft dephaser mounting bolt ((30 Nm) ) ,

- the old exhaust camshaft pulley nut ( 30 Nm ) .

Remove the (Mot. 1509) fitted with the (Mot. 1509-01) .

15256

Note:

Do not rotate the tensioning roller anticlockwise.

37

36

35

F4R, and 770 or 771

104728

38

39

38

39

11A-69


F4R, and 770 or 771 or 776

11A

Position the (Mot. 1509) for locking the camshaftpulley.



Tighten to torque:

- the toothed sprocket nuts ( (80 Nm) ) (40) ,

- the old inlet and exhaust camshaft pulley nuts ((30 Nm) ) (41) ,


Make a pencil mark (42) between the camshaft pul-leys and the camshaft bearing cap.

Remove the following tools:

- TDC setting pin (Mot. 1054) ,

- camshaft setting tool (Mot. 1496) .


F4R, and 776

104711

41

4040

41

21877

42424242

11A-70


F4R, and 770 or 771 or 776

11AIV - CHECKING THE TIMING AND THE TENSION


Before the end of the second revolution (i.e. half atooth before alignment of the marks made previouslyby the operator), insert the crankshaft TDC settingpin (Mot. 1054) (so that it is between the balancinghole and the timing hole).

Bring the timing to its adjustment point.

Position the camshaft adjustment tool (Mot. 1496) .

15163-2

15163-1

15104

11A-71


F4R, and 770 or 771 or 776

11A

Position the (Mot. 1509) with the toothed sprockets(Mot. 1509-01) for locking the camshaft pulleys.


Offer up the toothed sprocket nuts against the cams-haft pulleys.


Loosen:

- the old inlet camshaft dephaser pulley mountingbolt,

- the old exhaust camshaft pulley nut.

Remove the (Mot. 1509) with the sprocket (Mot.1509-01) for locking the camshaft pulleys.



Offer up the toothed sprocket nuts against the cams-haft pulleys.


Loosen:

- the old inlet camshaft pulley nut,


Remove the (Mot. 1509) for locking the camshaftpulley.

F4R, and 770 or 771

104728

444343

44

F4R, and 776

104711

46

4545

46

11A-72


F4R, and 770 or 771 or 776

11A

Align mark (47) with mark (48) by loosening the ten-sioning roller nut by up to one turn, while holding it inposition with a 6 mm (49) Allen key.

Final tighten the tensioning roller nut ( 28 Nm ) .

15256

49

48

47

11A-73


F4R, and 770 or 771 or 776

11A

Position the (Mot. 1509) with toothed sprockets tolock the camshaft pulleys.


Bring the toothed sprockets into contact with thecamshaft pulleys.


Remove:

- the old inlet camshaft pulley dephaser bolt,

- a new nut on the exhaust camshaft pulley.

Refit:

- a new bolt on the inlet camshaft pulley,

- a new nut on the exhaust camshaft pulley.

Tighten to torque:

- the inlet camshaft dephaser mounting bolt ( (30Nm) ) ,

- the exhaust camshaft pulley nut ( (30 Nm) ) .

Remove the camshaft adjustment tool (Mot. 1496) .

Tighten to torque:

- the inlet camshaft dephaser mounting bolt ( 100Nm ) ,

- the camshaft pulley dephaser blanking cover (25 Nm )

Tighten to angle the exhaust camshaft pulley nut (86˚ ±±±± 6˚ ) .



- camshaft pulley locking tool (Mot. 1509) with too-thed sprockets (Mot. 1509-01) .


F4R, and 770 or 771

104728

50

51

11A-74


F4R, and 770 or 771 or 776

11A





Remove:

- the old inlet camshaft pulley nut,


Refit a new nut onto the inlet and exhaust camshaftpulley.

Tighten to torque the inlet and exhaust camshaftpulley nuts 30 Nm .

Remove the camshaft adjustment tool (Mot. 1496) .

Tighten to angle the inlet and exhaust camshaftpulley nuts ( 86˚ ±±±± 6˚ ) .



- camshaft pulley locking tool (Mot. 1509) .


Position the camshaft locking tool (Mot. 1509) , tor-que tightening the nuts ( 80 Nm ) (54) .


Remove the old camshaft pulley nuts and replacethem with new ones.

Tighten to torque and angle the inlet and exhaustcamshaft pulley nuts ( 30 Nm + 86˚ ±±±± 6˚ ) .


- (Mot. 1496) ,

- camshaft pulley locking tool (Mot. 1509) .


Rotate the crankshaft clockwise through two revolu-tions.

F4R, and 776

104711

52

53

104711

5454

55

11A-75


F4R, and 770 or 771 or 776

11A2 - Checking the timing

Before the end of the second revolution (i.e. half atooth before alignment of the marks made previouslyby the operator), insert the crankshaft TDC settingpin ( (Mot. 1054) so that it is between the balancinghole and the timing hole).

Check that mark (56) is aligned with mark (57) onthe tensioning roller before checking the timing ad-justment.

The offset grooves (58) should be horizontal and be-low the centre line.

Position the camshaft setting tool (Mot. 1496) wi-thout forcing it. If the tool does not engage, repeatthe timing and tensioning procedure.

REFITTING

Refit:

- the lower timing cover,

- the upper timing cover.

15649

15106-1

56

57

58

15104

WARNING

It is imperative to replace the crankshaft acces-sories pulley and bolt.

11A-76


F4R, and 770 or 771 or 776

11A

Lock the flywheel using a large screwdriver.

Tighten to torque and angle the crankshaft acces-sories pulley bolt ( 40 Nm + 110˚ ±±±± 10˚ ) .

Refit:

- the crankshaft accessories belt (see 11A, Top andfront of engine, Accessories belt ),

- the TDC setting pin plug, applying a drop of RHO-DORSEAL 5661 to the thread hole.

Refit:

- the new sealing plugs:

• on the inlet camshaft (Mot. 1487) ,

• on the exhaust camshaft (Mot. 1448) ,

- the right-hand suspended mounting (see 19D, En-gine mounting, Suspended mounting ) in accor-dance with the marks.


Tighten to torque:

- the M6 lower timing cover bolts ( 80 Nm ) ,

- the M8 lower timing cover bolts ( 20 Nm ) ,

- the M8 upper timing cover bolts ( 18 Nm ) ,

- the M10 upper timing cover bolts ( 38 Nm ) ,




15303

WARNING

To avoid damaging the crankshaft accessoriespulley, do not start the engine without the acces-sories belt.

15103-1

11A-77


K4M, and 730 or 732

11A

REMOVAL



Remove:







Mot. 1368 Tool for tightening ten-sioner bolt. 8 mm Torxwrench 12.7 mmsquare



Mot. 1750 Adapter for camshaftsetting tool Mot. 1496




Tightening torquesm

crankshaft accessoriespulley bolt

40 Nm + 145˚±±±± 15˚

timing tensioning rollernut

27 Nm

pulley mounting bolt 45 Nm


30 Nm + 84˚ ±±±±4˚

inlet camshaft pulleydephaser bolt

75 Nm

TDC pin plug 20 Nm

upper timing cover nutsand bolts

41 Nm

wheel bolts 110 Nm


4 Nm

WARNING


Tightening torquesm

11A-78


K4M, and 730 or 732

11A

Fit the (Mot. 1453) and the (Mot. 1453-01) and theretaining straps.


Remove:

- the « engine/suspended engine mounting » as-sembly,


Remove:


- the throttle valve (2) ,

- the connector from the lifting bracket,

- the lifting eye (flywheel end).

102450

102451

101866

WARNING


101807

1

2

11A-79


K4M, and 730 or 732

11A

Pierce the centre of the plugs on the end of thecamshaft using a screwdriver.

Remove:

- the sealing plugs at the camshaft end with ascrewdriver,

- the TDC setting pin plug (3) .

ADJUSTING THE TIMING

Position the camshaft grooves (5) almost horizontal-ly and offset towards the bottom while turning thecrankshaft in its operating direction (clockwise timi-ng end).


Turn the crankshaft in its operating direction (timingend clockwise), until the crankshaft comes into con-tact with TDC setting pin.

14491

3

14491-1

14489

5

4

5

11A-80


K4M, and 730 or 732

11A

Check that the camshaft grooves are horizontal andoffset downwards.

Remove:

- the crankshaft accessories pulley (6) , locking theflywheel with a screwdriver,



Undo the tensioning roller bolt (9) to slacken the timi-ng belt.

Remove:

- the pulley (10) using the (Mot. 1368) ,

- the timing belt, taking care not to drop the cranks-haft sprocket,



14490

14487

6

8

7

101872

10

9

11A-81


K4M, and 730 or 732

11AREFITTING - PROCEDURE 1

I - PROCEDURE FOR AN ENGINE FITTED WITH A TIMING COVER WITHOUT A FLAP



Position the camshaft grooves horizontally and be-low the centre line by turning the camshafts usingthe (Mot. 799-01) if necessary.

Fit the (Mot. 1496) with (Mot. 1750) (11) .


WARNING

Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.

WARNING




- the accessories pulley contact surfaces,



This is to avoid slippage between:

- the timing,

- the crankshaft,

- the camshaft sprockets.


111337

111336

11A-82


K4M, and 730 or 732

11A

Check that the mark (12) on the dephaser is verticaland pointing upwards.

Make a mark (13) with a pencil between the depha-ser wheel and the rocker cover.

103269

11A-83


K4M, and 730 or 732

11A

Check:

- that the crankshaft is correctly in contact with theTDC setting pin (Mot. 1489) (15) with the cranks-haft groove (14) facing upwards,

- that the inlet camshaft dephaser wheel is correctlylocked (wheel does not rotate right or left).

.

2 - REFITTING

Refit the tensioning roller by positioning the tensio-ning roller lug in the groove (16) .

Refit:


- the timing belt,

- the pulley (17) .

Tighten to torque the pulley mounting bolt (45 Nm)using (Mot. 1368) .

3 - BELT TENSION

Using a 6 mm Allen key, bring the adjustable indexmarker (19) opposite the notch (20) , by turning theeccentric (21) clockwise.

14489

108879

14487-3

103263

11A-84


K4M, and 730 or 732

11ATighten to torque the tensioning roller mountingnut (7 Nm)


Tighten to torque and angle the crankshaft acces-sories pulley bolt ( 40 Nm + 145˚ ±±±± 15˚ ) (cranks-haft in contact with the TDC setting pin).

Remove:



Rotate the crankshaft through two clockwise revolu-tions (timing end) before aligning the marks (on thecamshaft dephaser).




Check that the adjustable index marker (22) is oppo-site the notch (23) .


Gradually move the adjustable indexing marker (22)opposite the notch (23) turning the eccentric (24) ina clockwise direction.

103263

11A-85


K4M, and 730 or 732

11A

Tighten to torque the timing tensioning roller nut(27 Nm) (25) .

Check that the dephaser mark (26) is aligned withthe mark (27) .



Rotate the crankshaft through two clockwise revolu-tions (timing end) before aligning the marks (on thecamshaft dephaser).

Screw in the TDC setting pin (Mot. 1489) .

Move the crankshaft slowly and smoothly to rest onthe TDC setting pin (Mot. 1489) .


Check that the tensioning roller markers are aligned.If not, repeat the tensioning procedure.


Check that the timing pulley index markers are cor-rectly positioned before checking the timing setting.


Move the crankshaft slowly and smoothly until it isresting against the pin.

Fit the camshaft adjusting the (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland below the centre line).

103267

WARNING

If the tool cannot be engaged, readjust the timingand the tension.

11A-86


K4M, and 730 or 732

11AII - PROCEDURE FOR AN ENGINE FITTED WITH A TIMING COVER WITH A FLAP



Set the camshaft grooves horizontally and below thecentre line by turning the camshafts using the (Mot.799-01) if necessary.



WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.

WARNING







This is to avoid slippage between:

- the timing,

- the crankshaft,

- the camshaft sprockets.


111337

111336

11A-87


K4M, and 730 or 732

11A

Check that the mark (29) on the dephaser is verticaland pointing upwards.


103269

11A-88


K4M, and 730 or 732

11A

Check:

- that the crankshaft is correctly in contact with theTDC setting pin (Mot. 1489) (32) with the cranks-haft groove (48) facing upwards,

- that the inlet camshaft dephaser wheel is correctlylocked (wheel does not rotate right or left).

.

2 - REFITTING

Refit the tensioning roller by positioning the tensio-ning roller lug in the groove (33) .

Refit:


- the timing belt,

- the pulley (34) .

Tighten to torque the pulley mounting bolt (45 Nm)using (Mot. 1368) .

14489

108879

14487-3

14487-2

11A-89


K4M, and 730 or 732

11A3 - BELT TENSION

Move the adjustable index marker (36) opposite thenotch (37) , by turning the eccentric (38) clockwiseusing a 6 mm Allen key.



Tighten to torque and angle the crankshaft acces-sories pulley bolt (40 Nm + 145˚ ±±±± 15˚) .

103263

109054

109055

11A-90


K4M, and 730 or 732

11A

Remove the timing flap from the lower timing cover.

Remove:







Using the lower timing cover window, check that theadjustable index marker (40) is opposite the notch(39) .

Loosen the timing tensioning roller nut by up to oneturn while holding the eccentric with a 6 mm Allenkey.

Gradually move the adjustable indexing marker (40)opposite the notch (39) turning the eccentric (41) ina clockwise direction.

Tighten to torque the timing tensioning roller nut(27 Nm) .

109052 109051

103263

11A-91


K4M, and 730 or 732

11A4 - CHECKING THE TIMING AND TENSION






Using the lower timing cover window, check that theindex marker and the timing tensioning roller notchare aligned.

Reset the tension by loosening the tensioning rollereccentric nut by up to one turn.

Align the adjustable indexing marker with the notch.

Tighten to torque the timing tensioning roller nut (27 Nm ) .


Check that the index marker and the timing tensio-ning roller notch are correctly positioned beforechecking the timing.



Position (without forcing) the camshaft timing tool(Mot. 1496) (the camshaft end grooves must be ho-rizontal and offset towards the bottom).

Refit the lower timing cover flap, checking that thepin (42) fits into the notch properly (43) .

14490

WARNING


109052

11A-92


K4M, and 730 or 732

11AREFITTING -PROCEDURE 2


The second procedure is used for the replacementof all components requiring the loosening of one ormore of the camshaft pulleys.

Refit the camshaft pulleys and the old nuts, tighte-ning them to a torque of 15 Nm .

Position the camshaft grooves horizontally and off-set downwards, by turning the camshafts using the(Mot. 1496) if necessary.

WARNINGIf the stud is loosened with the nut (see Techni-cal Note 3887A, Replacement of K9 -K4 cams-haft pulley studs, 11A, Top and front ofengine, Camshaft ).

WARNING

Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.

WARNING









14490

103261

11A-93


K4M, and 730 or 732

11A



111337

111336

11A-94


K4M, and 730 or 732

11A


14489

103269

11A-95


K4M, and 730 or 732

11A

Fit the camshaft dephaser into a vice with jaws.

Fit a bolt in the dephaser hub.

Check that the dephaser hub is mechanically secu-red correctly using a tubular hexagon box spanner(the hub must not be able to rotate towards the left orright).

Refit:

- the exhaust camshaft pulley with a new nut,

- the inlet camshaft dephaser with a new bolt.

Position:

- the RENAULT logo (47) engraved on the camshaftpulley spokes vertically at the top,

- the dephaser marking (48) vertically and at the top.


111338

111339

111340

11A-96


K4M, and 730 or 732

11AII - REFITTING

When refitting the tensioning roller, ensure that thetensioning roller lug fits correctly into the groove (50).

Refit:


- the timing belt on the camshaft pulleys (without mo-ving the camshaft pulleys).

Fit the camshaft pulley locking tool (Mot. 1490-01)(52) (use the timing cover mountings to fit the tool).

Refit the pulley (53) .

Tighten to torque the pulley mounting bolt ( 45 Nm) using the (Mot. 1368) .

Refit the crankshaft accessories pulley (without tigh-tening the bolt, leaving 2 to 3 mm play between boltand pulley).

108879

14487-3

103265

14487-3

11A-97


K4M, and 730 or 732

11AIII - BELT TENSION

Using a 6 mm Allen key, bring the adjustable indexmarker (54) opposite the notch (55) , by turning theeccentric (56) clockwise.

Tighten to torque the tensioning roller mountingnut (7 Nm).

Remove the camshaft pulley immobilising tool (Mot.1490-01) .

Rotate the timing system through six revolutionswith the exhaust camshaft pulley, using the (Mot.799-01) .

Check that the adjustable index marker (57) is ali-gned with the fixed index marker (58) .


Gradually move the adjustable index marker (57)opposite the notch (58) , turning the eccentric (59) ina clockwise direction.

103263

Note:

Check that the camshaft pulley nuts and bolt donot come into contact with their respective pul-leys. In addition, from time to time, press thecamshaft pulleys against the camshafts.

103263

11A-98


K4M, and 730 or 732

11A

Tighten to torque the tensioning roller mountingnut (27 Nm) .

Check that:

- the RENAULT logo (60) engraved on the camshaftpulley spokes is positioned vertically at the top,

- the dephaser mark (61) is aligned with the mark(62) already made by the operator.

Fit the camshaft pulley immobilising tool (Mot. 1490-01) .

103268

14839

11A-99


K4M, and 730 or 732

11A

Tighten to torque and angle the crankshaft acces-sories pulley bolt (40 Nm + 145˚ ±±±± 15˚) (crankshaftin contact with the TDC setting pin).

Tighten to torque and angle the exhaust camshaftpulley nut ( 30 Nm + 84˚ ±±±± 4˚ ) .

Tighten to torque the inlet camshaft pulley depha-ser bolt ( 75 Nm ) .

Refit the new inlet camshaft dephaser blanking co-ver (64) .

Remove:

- (Mot. 1496) ,

- the camshaft pulley immobilising tool (Mot. 1490-01) ,


IV - CHECKING THE TIMING AND TENSION




Slowly and smoothly position the crankshaft so thatis in contact with TDC setting pin (Mot. 1489) .


Check that the pulley indexes are aligned, otherwisecontinue with the tensioning process.

14489

WARNING

Check that the crankshaft is pressing against theTDC setting pin (Mot. 1489) (63) .

103265

11A-100


K4M, and 730 or 732

11A2 - Checking the timing

Check that the tensioning roller indexes are correctlypositioned before checking the timing setting.


Move the crankshaft slowly and smoothly into posi-tion against the pin.

Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland offset downwards).

REFITTING

Refit the TDC pin plug, applying a drop of SILICONEADHESIVE SEAL onto the threading.

Tighten to torque the TDC pin plug ( 20 Nm ) .


Refit the upper timing cover.

Tighten to torque the upper timing cover nuts andbolts ( 41 Nm ) .

Refit:

- the suspended engine mounting (see 19D, Enginemounting, Suspended engine mounting ),

- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting ),


- the new inlet camshaft sealing plugs (Mot. 1487) ,

- the new exhaust camshaft sealing plugs (Mot.1488) .



Tighten to torque:

- the wheel bolts ( 110 Nm )


14490

WARNING

If the tool cannot be engaged, readjust the timingand the tension.

15103-1

WARNING


11A-101


K9K, and 732

11AI - PRECAUTIONS FOR REPAIR

II - PARTS AND CONSUMABLES FOR THE REPAIR

Parts always to be replaced:

- timing belt,

- timing belt tensioning roller,

- crankshaft accessories pulley bolts.

Consumables:

- Silicone adhesive seal part no. 77 11 227 484 .

III - ESSENTIAL EQUIPMENT

Equipment:

- Protective gloves,

- Large screwdriver,

- female torx socket ( 14 ),

- Allen key ( 6 mm ),

- Offset spanner ( 18 mm ),

- bolt tightening gauge,

- Torque wrench.





Mot. 1430 Set of 5 crankshaftand camshaft pulleytiming pins

Tightening torquesm

camshaft pulley wheelbolts

14 Nm

tensioning roller bolt 27 Nm

camshaft pulley wheelbolts

14 Nm

crankshaft pulley M14bolt

120 Nm + 95˚±±±± 15˚

TDC pin plug cap 20 Nm

cylinder head suspen-ded mounting bolts

21 Nm

ball joint bracket moun-ting bolts with theirsprings

21 Nm

wheel bolts 110 Nm

IMPORTANTWear protective gloves during all operations.

WARNING

The belt must be replaced with a new one if ithas been removed.


Do not run the engine without the accessoriesbelt so as not to break the crankshaft accesso-ries pulley.

When replacing the belt, be sure to replace thetensioning rollers and pulleys.

11A-102


K9K, and 732

11AIV - REMOVAL

1 - REMOVAL PREPARATION OPERATION



Remove:


- the scuttle panel grille (see MR 365 Bodywork,55A, Exterior protection, Scuttle panel grille ),


- the right-hand wheel arch liners,


- the accessories belt (see 11A, Top and front ofengine, Accessories belt ).

Fit the (Mot. 1453) and the (Mot. 1453-01) with theretaining straps.

Remove:

- the exhaust ball joint bracket mounting bolts,

- the lower engine tie-bar mounting bolts.

Detach the manual priming pump.

102450

102451

WARNING

Be careful not to damage the air conditioningpipes.

11A-103


K9K, and 732

11A

Remove the right-hand suspended mounting (1) and(2) (see 19D, Engine mounting, Right-hand sus-pended mounting: Removal - Refitting ).


Remove:

- the upper timing cover,

- the plastic bolt (4) .



Undo the cylinder head suspended mounting bolts.

Twist the timing belt slightly (to remove the cylinderhead suspended mounting).

Remove the cylinder head suspended mounting (6) .

113927

112990

112998

112989

11A-104


K9K, and 732

11A

Remove the TDC pin plug (7) using a torx socket(14).

2 - OPERATION FOR REMOVAL OF PART CONCERNED

Turn the crankshaft to position the hole (8) of thecamshaft pulley almost opposite the hole (9) in thecylinder head.


Turn the crankshaft clockwise (timing end) smoothlyuntil the crankshaft is pressed against the TDC set-ting pin.

19650

107270

19650-1

14489

11A-105


K9K, and 732

11A

Engage the pin (11) (Mot. 1430) in the camshaftpulley and cylinder head holes.

Remove:

- the timing pin from the camshaft pulley (Mot. 1430),


Remove the crankshaft accessories pulley, lockingthe engine flywheel using a screwdriver passing itthrough orifice under the starter motor.

Undo the tensioning roller bolt (12) to slacken the ti-ming belt.

Remove:

- the timing belt,

- the timing tensioning roller.

109049

107260

109046

11A-106


K9K, and 732

11AV - REFITTING

1 - REFITTING PART CONCERNED

Refit the timing tensioning roller.

Place the tensioning roller lug (13) in the cylinderhead groove (14) .

Engage the pin (15) (Mot. 1430) in the holes of thecamshaft pulley and cylinder head, turning thecamshaft using an 18 mm offset spanner if necessa-ry.

Check that:

- the mark on the high-pressure pump (16) is offsetby one tooth to the right of the vertical axis (17) ,

- the crankshaft is in contact with the TDC setting pin(Mot. 1489) (crankshaft timing sprocket collet (18)at the top).

Remove one bolt from the camshaft pulley wheel.

Loosen the two other camshaft pulley wheel bolts(19) by one turn.

109042

109043

14489

109042

11A-107


K9K, and 732

11A

Fit the timing belt, starting with the crankshaft sproc-ket, aligning the marks on the belt with those on thecrankshaft sprockets, the camshaft and the high-pressure pump. There should be 19 tooth spacesbetween the sprocket marks and 51 tooth spacesbetween the crankshaft sprockets and the high pres-sure pump.

109044

11A-108


K9K, and 732

11A

Position the tensioning roller adjustable index mar-ker (20) opposite the lug (21) using a 6 mm Allenkey, turning it anti-clockwise.

Tighten to torque the tensioning roller bolt (27Nm) .

Check that the camshaft pulley hub bolts are not ful-ly up against the camshaft pulley wheel.

19658

109047

11A-109


K9K, and 732

11A

Refit camshaft pulley wheel bolt (22) .

Tighten to torque the camshaft pulley wheel bolts( 14 Nm ) .

Remove:


- the timing pin from the camshaft pulley (Mot. 1430),

Tighten the old crankshaft accessories pulley bolt fit-ted with a spacer (23) (which does not cover the timi-ng sprocket mark) onto the crankshaft.

109045

107272

11A-110


K9K, and 732

11A

Rotate the crankshaft twice in a clockwise direction(timing end) before the camshaft pulley hole (24) isopposite the cylinder head hole (25) .


Bring the crankshaft slowly and smoothly against theTDC setting pin.

Set the camshaft pulley using the (Mot. 1430) .

If the (Mot. 1430) does not engage:

loosen the camshaft pulley wheel bolts by one turn,

Turn the camshaft pulley hub using an offset span-ner to facilitate setting of the camshaft pulley hub.

Do not retighten the camshaft pulley wheel bolts.

107270

109049

109048

11A-111


K9K, and 732

11A

Check that the crankshaft timing sprocket collet (26)is positioned vertically facing upwards.

109045

Note:

After two turns, the tensioning roller markers maybe in two different positions.

The rotation of the tensioning roller eccentricdepends on the position.

11A-112


K9K, and 732

11Aa - First position

Loosen the tensioning roller bolt by a maximum ofone turn, holding the tensioning roller using a 6 MMAllen key.

Gradually align the adjustable index marker (27) tothe middle of the timing window (28) , turning the keyanti-clockwise.

b - Second position

Loosen the tensioning roller bolt by a maximum ofone turn, holding the tensioning roller using a 6 MMAllen key.

Gradually align the adjustable index marker (29) tothe middle of the timing window (30) , turning the keyclockwise.

Tighten to torque:

- the tensioning roller bolt ( 27 Nm ) ,

- the camshaft pulley wheel bolts ( 14 Nm ) .

111083

111081

111082

111081

11A-113


K9K, and 732

11ARemove:



Rotate the crankshaft twice in a clockwise direction(timing end) before the camshaft pulley hole is oppo-site the cylinder head hole.


Bring the crankshaft slowly and smoothly against theTDC setting pin.

Set the camshaft pulley using the (Mot. 1430) .

If this is not possible, repeat the operation for refit-ting the timing belt.

Refit the accessories crankshaft pulley with a newbolt.

Tighten to torque and angle (crankshaft in contactwith the TDC setting pin) the crankshaft pulley M14bolt ( 120 Nm + 95˚ ±±±± 15˚ )



- timing pin from camshaft pulley (Mot. 1430) .

2 - FINAL OPERATION

Refit the TDC pin plug, coating the thread with SILI-CONE ADHESIVE SEAL .

Tighten to torque the TDC pin plug cap ( 20 Nm ) .

109049

107260

11A-114


K9K, and 732

11A

Refit the cylinder head suspended mounting (31) .

Tighten to torque the cylinder head suspendedmounting bolts ( 21 Nm )

Refit:

- the lower timing cover (32) , positioning the tab (33)in the hole (34) in the inner timing cover,

- the timing cover plastic bolt (35) .

112989 112990

19659

11A-115


K9K, and 732

11A

Refit the upper timing cover (36) Refit the right-hand suspended mounting support(see 19D, Engine mounting, Right-hand suspen-ded engine mounting: Removal - Refitting ).

Remove the (Mot. 1453) and the (Mot. 1453-01) .

Refit the manual priming pump

Refit:

- the rear suspended engine mounting (see 19D,Engine mounting, Right-hand suspended engi-ne mounting: Removal - Refitting ).

- the exhaust ball joint bracket mounting bolts

Tighten to torque the ball joint bracket mountingbolts with their springs ( 21 Nm )

Refit:


- the right-hand wheel arch liner,





Tighten to torque the wheel bolts ( 110 Nm )


112990 113927

11A-116

TOP AND FRONT OF ENGINETiming chain: Removal - Refitting

M9R, and 700

11AREMOVAL

Removing the timing chain requires the engine andgearbox assembly to be removed (see 10A, Engineand peripherals, Engine and gearbox assembly:Removal - Refitting ).

To remove the timing chain (see Technical Note6017A, M9R diesel engine ).

REFITTINGTo refit the timing chain (see Technical Note6017A, M9R diesel engine ).

Refit the engine and gearbox assembly (see 10A,Engine and peripherals, Engine and gearbox as-sembly: Removal - Refitting ).

11A-117

TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting

K4J, and 730 or 732

11A

REMOVALPosition the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).


Remove:





- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).


Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).






Mot. 1573 Cylinder head support

Mot. 104 Cylinder head ali-gning tool

Ele. 1382 Spark plug spannertoolkit 16 & 21 mm tor-que 1.75 & 28 Nm +square adapter 9-9.52for spanner Ele. 1086

Mot. 1491 Camshaft oil seal fit-ting tool

Mot. 1632 Tool for fitting thecamshaft seal



Equipment required

cylinder head testing tool

Tightening torquesm

rocker cover mountingbolts 22, 23, 20, 13

12 Nm

oil separator mountingbolts (new) in the non-threaded housings

15 Nm

(new or original) oilseparator mount ingbolts in the pre-threadedhousings

10 Nm

plugs 25 to 30 Nm

coil mounting bolts (ifthe holes are alreadythreaded)

12 Nm

coil mounting bolts (ifthe holes are not threa-ded)

15 Nm

inlet manifold mountingbolts

9 Nm


Tightening torquesm

11A-118


K4J, and 730 or 732

11A

Set up the engine stand (1) (Mot. 1672)

Remove the (Mot. 1453) and (Mot. 1453-01) .

Remove the camshaft pulleys using camshaft pulleylocking tool (2) (Mot. 1490-01) .

Loosen the stud with the nut if necessary (see Tech-nical Note 3887A, Replacement of K9 - K4 cams-haft pulley studs, 11A, Top and front of engine,Camshaft ).

Remove:

- the injection rail protector,

- the fuel supply pipe from the injection rail.

Move the fuel supply pipe aside.

Remove bracket mounting bolt (1) .

Move the bracket to one side.

Remove the wiring harness bracket mounting bolt(2) .

Disconnect:

- the brake servo vacuum pipe (3) from the inlet ma-nifold.

- the connector (4) from the coolant temperaturesensor,

- the water unit hoses,

105432

101876

IMPORTANT

Be careful of petrol splashing out when discon-necting the fuel supply union.

1

218699

14889

1

3

4

2

11A-119


K4J, and 730 or 732

11AMove the bracket/wiring harness assembly aside.

Disconnect:

- the ignition coil connectors (5) ,


- the inlet manifold pressure sensor connector (7) ,

- the fuel vapour recirculation solenoid valve pipe (8),

- the catalytic converter upstream oxygen sensorconnector.

Disconnect the connector (9) from the injectors

Unfasten the clip (10) .


Remove:

- the ignition coils,

- the plugs,

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting ).

- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting ).

18666

5

5

8 7

6

104240

10

9

11A-120


K4J, and 730 or 732

11A

Remove:

- the lifting bracket (11) ,

- the inlet manifold mounting bolts (12)

- the inlet manifold.

Remove:

- the catalytic converter/gearbox stay mounting bolts(13) ,

- the catalytic converter/gearbox stay

- the exhaust pipe mounting nuts (14) .

Detach the exhaust pipe.

Remove:

- the oil separator mounting bolts (15) ,

- the oil separator.

Remove:

- the rocker cover mounting bolts,

- detach the rocker cover vertically, tapping the lugs(16) with a copper hammer.

18706

101793

12121212

11

13

141414

18431

103256

WARNING

Do not damage the aluminium surfaces.

151515

16

16

11A-121


K4J, and 730 or 732

11A

Remove the inlet and exhaust camshafts.

14498

11A-122


K4J, and 730 or 732

11A

Remove:

- the valve rockers (17) ,

- the hydraulic tappets (18) .

Remove:

- the cylinder head mounting bolts,

- the cylinder head.

Mount the cylinder head on the cylinder head moun-ting (Mot. 1573) .

Remove the cylinder head gasket from the cylinderblock.

I - CLEANING THE CYLINDER HEAD

Clean the gasket faces with DÉCAPJOINT to dissol-ve any parts of the seal still attached to the lower co-ver and the cylinder block.

Apply the product to the section to be cleaned; Waitapproximately ten minutes, then remove the residueusing a wooden spatula.

II - CHECKING THE GASKET FACE

Use a ruler and feeler gauge to check that there isno gasket face bow.

Maximum bow: 0.05 mm

Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .

For the cylinder head stripping procedure (seeTechnical Note 3784A, K4 4-cylinder petrol engi-ne, 10A, Engine and peripherals, Rebuilding thecylinder head) .

Position the pistons at mid-stroke to prevent anycontact with the valves when refitting the camshafts.


- the cylinder head combustion face,

- the cylinder block combustion face.

14499

Note:

To prevent any risk of unpriming the hydraulictappets make sure that they are vertical.

IMPORTANT

Do not scratch the aluminium gasket faces.

During the operation, wear:

- goggles,

- gloves.

18

17

WARNING

Do not allow this product to drip onto the pain-twork.

Clean the cylinder head carefully to preventforeign bodies from entering the oil supply andreturn pipes.

Failure to follow this guideline could lead to bloc-kage of the oilways, resulting in rapid and seriousdamage to the engine.

WARNING

No regrinding of the cylinder head is permitted.

11A-123


K4J, and 730 or 732

11A

Check that the centring dowel is present (19) on thecylinder block.

Fit the (Mot. 104) (20) onto the cylinder block.

REFITTING

Fit the new cylinder head gasket.

Refit the cylinder head.

Check the cylinder head tightening bolts (see 11A,Top and front of engine, Cylinder head gasket:Removal - Refitting ).

Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ).

Reprime the hydraulic tappets (hydraulic tappetsmay empty after a long down time).

To check if repriming is necessary, press the top ofthe tappet (21) with your thumb.

If the tappet piston depresses:

- immerse the tappets in a container full of dieselfuel,

- refit the hydraulic tappets.

Refit:

- the valve rockers,

- the camshafts, oiling the bearings.

14689

20 19

14499

21

11A-124


K4J, and 730 or 732

11AI - CAMSHAFT MARKINGS

Inlet camshaft

Position the groove (22) on the end of the camshafthorizontally (groove below the centre line of thecamshaft).

The cams (23) for cylinder 1 must be located to theright of the vertical axis (24) , flywheel end view.

101880

11A-125


K4J, and 730 or 732

11AExhaust camshaft

Position groove (25) horizontally on the end of thecamshaft (groove below the centre line of the cams-haft).

The cams (26) for cylinder 1 must be located to theleft of the vertical axis (27) , flywheel end view.

101881

11A-126


K4J, and 730 or 732

11A

Position the camshaft grooves horizontally and off-set downwards.

Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it turns red-dish.

Using a cloth, remove the LOCTITE 518 from (28)the six camshaft rocker cover bearings.

Refit the rocker cover.

15106-1

WARNING

The sealing faces must be clean, dry and free ofgrease.

WARNING

Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould damage certain components (engine,radiator).

WARNING

Do not apply oil to the rocker cover gasket faces.

14517

28

11A-127


K4J, and 730 or 732

11AII - TIGHTENING PROCEDURE


- rocker cover mounting bolts 22, 23, 20, 13 , 8Nm ,

- rocker cover mounting bolts 1 to 12, 14 to 19,21 to 24 (12 Nm) .

Loosen bolts 22, 23, 20 and 13, in order.

Tighten to torque and in order rocker cover moun-ting bolts 22, 23, 20, 13 ( 12 Nm ) .

14497

11A-128


K4J, and 730 or 732

11A

Using a stipple roller, apply LOCTITE 518 to thegasket face until it is reddish in colour.

Refit the oil separator.

Torque tighten in order

- the oil separator mounting bolts (new) in thenon-threaded housings ( 15 Nm )

- the (new or original) oil separator mountingbolts in the pre-threaded housings ( 10 Nm )

101869

WARNING

the gasket faces must be clean, dry and free ofgrease.

WARNING


18431

8

7

6

54

3

2

1

11A-129


K4J, and 730 or 732

11A

On the four ignition coils, apply a bead (2 9) ofFLUORINATED GREASE 82 00168 855 2 mm indiameter to the inner circumference of the high-ten-sion cap.

Refit the plugs.

Tighten to torque the plugs ( 25 to 30 Nm ) usingthe plug spanner set (Ele. 1382) .

Refit the coils.

Tighten to torque:

- the coil mounting bolts (if the holes are alreadythreaded) ( 12 Nm ) ,

- the coil mounting bolts (if the holes are notthreaded) ( 15 Nm ) ,

Always replace all the inlet manifold seals.

106443

29

11A-130


K4J, and 730 or 732

11A

Tighten to torque and in order the inlet manifoldmounting bolts ( 9 Nm ) .

Refit:

- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting ).

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting ).

III - REPLACING THE CAMSHAFT SEALS

There are two types of elastomer camshaft sealwhich are easy to identify.

The first type of elastomer seal is fitted with a spring(30) with a lip seal (31) in the shape of a « V »

14497-1

20256

31

30

11A-131


K4J, and 730 or 732

11A

The second type of elastomer seal is fitted with a flatlip seal (32) and a protector (33) (which also assistsin fitting the seal to the engine).

1 - Fitting the first seal type to the inlet camshaft

Fit the seals using the (Mot. 1491) (34) and the oldnuts (35) .

20257

Note:

Both seal versions can be fitted on the sameengine. They are not interchangeable. It isessential to use the same version when replacingan old seal, except when one or more camshaftsare replaced.

3332

14892

35

34

11A-132


K4J, and 730 or 732

11A2 - Fitting the seal to the exhaust camshaft

Screw the stud of (38) the (Mot. 1632) onto thecamshaft.

18687

WARNING

It is very important to hold the protector (36)when handling the seal, as this type of seal isvery fragile. It is strictly forbidden to touch theelastomer seal (37) in order to prevent any oilleaks once the seal is fitted to the engine.

3736

105531

21687

38

38

11A-133


K4J, and 730 or 732

11A

Fit the protector, with a seal, to the camshaft.

Fit cover (39) and the collar nut (40) of the (Mot.1632) .

Screw in the collar nut until the cover comes intocontact with the cylinder head.

Remove the nut, cover, protector and threaded rod.

IV - REFITTING

Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting ).

21687-1

21687-2

39

40

21687-3

WARNING

Follow the second procedure in the timing beltrefitting procedure.

11A-134


K4J, and 730 or 732

11A

Refit:


- new inlet camshaft sealing plugs using the (Mot.1487) ,

- new exhaust camshaft sealing plugs using the(Mot. 1488) ,


Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining-refilling ).




15103-1

11A-135


K9K, and 722 or 728 or 729

11A









Equipment required

diagnostic tool


angular tightening wrench

Tightening torquesm

rocker cover mountingbolts

10 Nm

turbocharger oil returnpipe

9 Nm

intercooler hose clip 5.5 Nm


IMPORTANT

Before any operation:

- connect the diagnostic tool ,

- establish dialogue with the injection computer,

- check that the injection rail is depressurised,

- be aware of the fuel temperature,

- order the special high-pressure injection circuitplug kit.

WARNING

Procedure for removing the air inlet duct (K9K 728 and 729):

- make a mark on the inlet duct between the stain-less steel pipe and the hose,



- clean the stainless steel pipe and the hose with adry, lint-free cloth,


- rotate the clip around its axis to make torque tigh-tening easier,

- it is essential to replace the hose and/or the stain-less steel pipe in the event of damage.

There is a risk of leaks or dislodging if this proce-dure is not followed.

11A-136


K9K, and 722 or 728 or 729

11AREMOVAL


Remove:




Remove:

- the battery,





Fit the engine stand (Mot. 1672) .


Disconnect:

- the air temperature and pressure sensor connector(1) ,

- the exhaust gas recirculation valve control connec-tor (2) ,

- the air hoses (3) ,

- the air hose (4) ,

- the turbocharging pressure regulation valve rubberpipe,

- the air sleeve from the air filter unit,

- the oil vapour rebreathing pipe from the rocker co-ver.

Remove the air resonator unit mounting stay (5) .

105432

K9K, and 722

102081

2

1

5

4 33

11A-137


K9K, and 722 or 728 or 729

11A

Disconnect:

- the air temperature and pressure sensor connector(6) ,

- the exhaust gas regulation valve control connector(7) ,

- the engine speed and position sensor connector(8) ,

- the air hose (9) ,

- the rubber hose from the turbocharging pressurecontrol valve.

Pull out the clip.

Make a mark on the inlet duct between the stainlesssteel pipe and the hose (10) .

Undo the bolt (11) .

Remove the air duct (12) .

K9K, and 728 or 729

110326

9

87

6

110325

110322

11

10

12

11A-138


K9K, and 722 or 728 or 729

11A

Disconnect:

- the injector connectors,

- the heater plug connectors,

- the rail pressure sensor connectors,

- the diesel fuel supply pipe from the pump,

- the diesel return pipe from the pump,

- the fuel temperature sensor (13) ,

- the fuel flow actuator connector (14) .

Remove the wiring and diesel return pipe support(15) .

Disconnect:

- the water unit hoses (16) using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) ,

- the brake servo vacuum pipe (17) on the vacuumpump side,

- the coolant temperature sensor connector on thewater unit.

- the radiator top hose from the cylinder head wateroutlet using the (Mot. 1202-01) or (Mot. 1202-02)or (Mot. 1448) .

Unclip the heater radiator hose (18) .

Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).

102086

13

1515

14

102263

17

16

18

11A-139


K9K, and 722 or 728 or 729

11A

Disconnect the turbocharger oil return pipe (19) .

Remove the inner timing cover (20) .

Remove:

- the rocker cover mounting bolts (21) ,

- the rocker cover.

Remove:

- the cylinder head mounting bolts (22) ,


104175

19710

19

2020

19711

19712

21212121

222222

222222

11A-140


K9K, and 722 or 728 or 729

11AI - CLEANING

Clean the cylinder head.

Clean the gasket faces with DÉCAPJOINT to dissol-ve the section of the gasket which is still attached.

Apply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.


Check for gasket face bow using a ruler and a feelergauge.

The maximum bow is 0.05 mm .


For the cylinder head stripping procedure (seeTechnical Note 6006A, 4 cast iron cylinder HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead ).

REFITTINGProceed in the reverse order to removal.

Fit the new cylinder head gasket, centred by twodowels.

Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.


Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) usingthe angular tightening wrench .

Fit the new rocker cover gasket.

Apply beads (23) of SILICONE ADHESIVE SEAL 2mm in diameter.

IMPORTANT



- goggles,

- gloves.

WARNING

Please make sure, during this operation, that noforeign bodies enter the oilways (galleries in boththe cylinder block and the cylinder head).

WARNING

Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply galle-ries.

Failure to follow this advice could lead to the pipeblocking, quickly damaging the camshaft.

WARNING


WARNING


WARNINGThe sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).

WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct-fluid mix may damage some components(engine, radiator).

19712-1

23

23

2323

11A-141


K9K, and 722 or 728 or 729

11A


Tighten to torque and in order the rocker covermounting bolts ( 10 Nm ) .

Reconnect the turbocharger oil return pipe, fittedwith new seals.

Tighten to torque the turbocharger oil return pipe( 9 Nm ) .

Reconnect:

- the oil vapour rebreather pipe,

- the new turbocharger air sleeves.

Reconnect the air duct by aligning the marks.

Tighten to torque the intercooler hose clip ( 5.5Nm ) .

Refit:

- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).



Fill the cooling circuit (see 19D, Cooling, Coolingcircuit: Draining-refilling ).

Reprime the diesel circuit (see 13B, Fuel supply,Diesel fuel supply circuit ).



Tighten to torque the battery cover bolts ( 4 Nm ) .19711

19709

K9K, and 728 or 729

3

2

1

8

7

65

4

11A-142


F9Q, and 800 or 808

11A

REMOVAL


Remove:




Remove:


- the battery tray,














Equipment required

diagnostic tool



Tightening torquesm

oil supply pipe bolt onthe turbocharger

22.5 Nm

oil supply pipe bolt onthe cylinder block

22.5 Nm

oil return pipe bolts 12 Nm


IMPORTANT


- connect the diagnostic tool ,





WARNING

Fit plugs in the openings.

Be sure to follow the safety instructions.

Refer to (see 13B, Diesel injection, Cleanlinessguidelines ).

105432

11A-143


F9Q, and 800 or 808

11A

Disconnect:


- the air duct (2) towards the turbocharger,

- the oil vapour rebreathing pipe (3) ,

- the engine damping device valve pipe (4) .

Remove:

- the air duct (5) from the inlet manifold,

- the oil vapour rebreathing canister (6) .

Remove the vacuum tank mounting bolts (7) .

Disconnect:

- the turbocharger pressure regulation solenoid val-ve pipes,

- the engine damping device solenoid valve connec-tor (8) ,

- the camshaft sensor connector (9) .

Remove the vacuum tank.

105511

1

2

3

4

5

6

18983

7

89

11A-144


F9Q, and 800 or 808

11A

Disconnect:

- the exhaust gas recirculation solenoid valve con-nector (10) ,

- the injector connectors (11) ,

- the heater plug connectors (12) ,

- the rail pressure sensor connector (13) ,

- the high-pressure pump pressure regulator con-nector (14) ,

- the diesel return temperature sensor connector(15) ,

- the diesel filter connector,

- the diesel fuel supply pipe (16) ,

- the diesel return pipe (17) .

Insert the blanking plugs.

Move the wiring harnesses to one side.

Disconnect:

- the cylinder head outlet water unit hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,

- the connector (18) from the coolant temperaturesensor.

Remove the three high-pressure pump supportmounting bolts (19) .

105512

10

11

1112

12

13

14

1516

17

104323

102348

18

19

11A-145


F9Q, and 800 or 808

11A

Remove:

- the catalytic converter (20) (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).

- the oil supply pipe (21) ,

- the oil return pipe mountings (22) on the turbochar-ger.

Remove the cylinder head mounting bolts (23) .

Remove the cylinder head. This operation requirestwo people.

I - CLEANING


Clean the gasket faces with DÉCAPJOINT to dissol-ve the section of the gasket which is still attached.

18997

20

21

22

16189

WARNING

When removing the cylinder head, take care notto cause any damage to its gasket face as it pas-ses the turbocharger above it.

IMPORTANTDo not scratch the aluminium gasket faces.


- goggles,

- gloves.

2323232323

11A-146


F9Q, and 800 or 808

11AApply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.





For the cylinder head stripping procedure (seeTechnical Note 3652A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead ).

REFITTING


Fit the cylinder head gasket.


Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) using aangular tightening wrench .

Tighten to torque:

- the oil supply pipe bolt on the turbocharger (22.5 Nm ) ,

- the oil supply pipe bolt on the cylinder block (22.5 Nm ) ,

- the oil return pipe bolts ( 12 Nm ) .

Refit:





Reprime the diesel circuit (see 13A, Fuel supply,Diesel fuel supply circuit ).




WARNING

To prevent any foreign bodies from entering theoil pipes (pipes in both the cylinder block andcylinder head).

WARNING


Failure to follow this advice could block the oilsupply pipes, causing rapid camshaft damage.

WARNING

The cylinder head bolts must be replaced eachtime they are removed and must not be oiledbefore being fitted.

WARNING


11A-147


F4R, and 770 or 771

11A

REMOVAL


Remove:




Remove









Mot. 1509 Camshaft sprocketlocking tool

Mot. 1509-01 Conversion kit for Mot.1509





Mot. 1517 Camshaft seal fittingtool

Mot. 1512 Camshaft oil seal fit-ting tool (28 x 47)



Equipment required



Tightening torquesm

rocker cover bolts 22,23, 20, 13

(8 Nm)

rocker cover bolts 1 to12, 14 to 19, 21 to 24

(12 Nm)

new or original oil sepa-rator mounting bolts (inthreaded holes)

10 Nm

new oil separatormounting bolts (in non-threaded holes)

15 Nm

plugs 25 to 30 Nm

coils (if holes alreadythreaded)

12 Nm

coils (if holes not threa-ded)

15 Nm

inlet manifold 9 Nm


4 Nm

105432

Tightening torquesm

11A-148


F4R, and 770 or 771

11A

Fit the (Mot. 1509) with the gear (Mot. 1509-01) .

Tighten the collar nut (1) and the bolt (2) , then bringthe gears of (Mot. 1509) into contact with the cams-haft pulleys while torque tightening the nuts (80Nm) (3) .

Remove the inlet camshaft dephaser blanking coverusing a 14 mm Allen key.

Remove:


- the inlet camshaft dephaser mounting bolt,

Loosen the nut stud if necessary (see TechnicalNote 3887A, Replacement of F4 camshaft pulleystuds, 11A, Top and front of engine, Camshaft ).

Remove the bracket mounting bolts (4) .

Move the bracket to one side.

16019-4

3

2

1

3

16019-4

18699

4

11A-149


F4R, and 770 or 771

11A

Remove the wiring harness bracket mounting bolts(5) .

Disconnect:


- the water unit hoses using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,

- the brake servo vacuum pipe (7) on the inlet mani-fold side.

Move the bracket/wiring harness assembly aside.

Disconnect:



- the camshaft dephaser connector (10) ,


- the fuel vapour recirculation solenoid valve pipe(12) ,


- the upstream oxygen sensor connector.

Unclip the wiring harness clip.


Remove:


- the plugs,

- the dephaser solenoid valve.

14889

102735

5

6

7

18666

8

8

9

101112

11A-150


F4R, and 770 or 771

11A

Remove:

- the lifting bracket (13) at the timing end,

- the inlet manifold mounting bolts (14) ,


Remove:

- the catalytic converter/gearbox stay mounting bolts(15) ,

- the catalytic converter/gearbox stay,


Remove:

- the oil separator mounting bolts.

- the oil separator (17) ,

- the lifting bracket at the flywheel end (18) .

102939

101793

13

14141414

1515

161616

102940

1817

11A-151


F4R, and 770 or 771

11A

Remove the rocker cover bolts.

Remove the rocker cover vertically, tapping the lugs(19) with a copper hammer.

Remove the camshaft seals.

102941

WARNING


19

19

11A-152


F4R, and 770 or 771

11A

Remove the inlet and exhaust camshafts (20)

15151

20

11A-153


F4R, and 770 or 771

11A

Remove:



14499

Note:


21

22

11A-154


F4R, and 770 or 771

11A

Remove:

- the cylinder head bolts,



Remove the cylinder head gasket from the cylinderblock

I - CLEANING

Clean the gasket faces with DÉCAPJOINT to dissol-ve any sections where the seal is still attached.

Apply the product to the section to be cleaned; Waitfor approximately ten minutes, then remove it usinga wooden spatula.




Test the cylinder head to detect any cracks using thecylinder head testing tool (see Technical Note3783A, F4 4-cylinder petrol engine, 10A, Engineand peripherals, Rebuilding the cylinder head)for the cylinder head stripping procedure.

Position the pistons at mid-stroke to prevent anycontact with the valves when the camshafts arebeing refitted.

15153

IMPORTANT



- goggles,

- gloves.

WARNING

To prevent any foreign bodies from entering theoil pipes (pipes in the cylinder block and cylinderhead).

WARNING


11A-155


F4R, and 770 or 771

11ABe sure to degrease:

- The combustion face of the cylinder head,

- the combustion face of the cylinder block.

REFITTING



Check the bolts (see 11A, Top and front of engine,Tightening the cylinder head ).

Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) using aangular tightening wrench .

Re-prime the hydraulic tappets (hydraulic tappetsmay empty if they have been removed for some ti-me).

To check or reprime them, press the top of the tap-pet at (23) with your thumb.




Refit:



The camshafts are identified by the pulley moun-tings.

Detailed view of the pulley mountings:

- (24) : exhaust camshaft,

- (25) : inlet camshaft.

14499

23 15152

2524

11A-156


F4R, and 770 or 771

11A

Position the camshaft grooves as shown in the dia-gram.

Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it is reddishin colour.


15106-1

WARNING


WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).

WARNING

Do not apply oil to the sealing face of the cams-haft bearing cap cover.

14517

Note:

Using a cloth, remove the LOCTITE 518 from(26) the camshaft rocker cover bearings.

26

11A-157


F4R, and 770 or 771

11A


- rocker cover bolts 22, 23, 20, 13 ( (8 Nm) ) ,

- rocker cover bolts 1 to 12, 14 to 19, 21 to 24 ((12 Nm) ) .


Tighten to torque and in order mounting bolts 22,23, 20, 13 (12 Nm) .

14497

11A-158


F4R, and 770 or 771

11A

Using a stipple roller, apply LOCTITE 518 to the jointface of the oil separator until it is reddish in colour.



- the new or original oil separator mounting bolts(in threaded holes) ( 10 Nm ) ,

- the new oil separator mounting bolts (in non-threaded holes) ( 15 Nm ) .

102738

WARNING


WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).

102729

11A-159


F4R, and 770 or 771

11A

On the four ignition coils, apply a bead (2 7) ofFLUORINATED GREASE 82 00 169 855 2 mm indiameter to the lower circumference of the high-ten-sion cap.

106443

27

11A-160


F4R, and 770 or 771

11A

Refit the plugs.

Tighten to torque the plugs ( 25 to 30 Nm ) .

Refit the coils.

Tighten to torque:

- the coils (if holes already threaded) ( 12 Nm ) ,

- the coils (if holes not threaded) ( 15 Nm ) .

Refit the inlet manifold with its new gasket.

Tighten to torque and in order the inlet manifold ( 9Nm ) .

Refit the camshaft offset timer solenoid valve, with anew seal.

Replace the camshaft seals.

- use the (Mot. 1517) for the inlet camshaft seal.

- use the (Mot. 1512) for the exhaust camshaft seal.

Refit:

- the timing belt (it is essential to follow the procedu-re (see 11A, Top and front of engine, Timingbelt: Removal - Refitting ).


Refit:

- the new sealing plugs:

• on the inlet camshaft (Mot. 1487) ,

• on the exhaust camshaft (Mot. 1488) ,

- the right-hand suspended engine mounting (see19D, Engine mounting, Suspended enginemounting ).






102939 15103-1

11A-161


K4M, and 760 or 761

11A


Remove:




Remove:









Mot. 1669 Fitting cam followertappet




Mot. 104 Cylinder head ali-gning tool

Mot. 1513 Tool for refitting cams-haft dephaser solenoidvalve lip seal

Ele. 1382 Spark plug spannertoolkit 16 & 21 mm tor-que 1.75 & 28 Nm +square adapter 9-9.52for spanner Ele. 1086

Mot. 1632 Tool for fitting thecamshaft seal



Equipment required


Tightening torquesm

rocker cover mountingbolts 22, 23, 20, 13

12 Nm

oil separator mountingbolts

15 Nm

camshaft dephasersolenoid valve bolt

10 Nm

plugs 25 to 30 Nm

coil mounting bolts (ifholes already threaded)

12 Nm

coil mounting bolts (ifholes not threaded)

15 Nm

camshaft position sen-sor mounting bolt

10 Nm


9 Nm


Tightening torquesm

11A-162


K4M, and 760 or 761

11A

Set up the engine stand (1) (Mot. 1672) .

Remove the (Mot. 1453) and (Mot. 1669) .

Remove the wiring harness support mounting bolt(1) .

Disconnect:


- the water unit hoses using the (Mot. 1453) or (Mot.1453-01) or (Mot. 1490-01) ,

- the brake servo vacuum pipe (3) on the inlet mani-fold side.

Move the bracket/wiring harness assembly aside.

105432

1

14889

102735

2

1

3

11A-163


K4M, and 760 or 761

11A

Disconnect:



- the camshaft dephaser solenoid valve connector(6) ,


- the fuel vapour recirculation solenoid valve pipe (8),

Disconnect:

- the camshaft position sensor connector (9) ,

- the catalytic converter upstream oxygen sensorconnector.

Disconnect the connector (10) from the injectors

Unfasten the clip (11) .


Remove:


- the plugs,

- the dephaser solenoid valve,

- the camshaft position sensor.

18666

101809

5

4

4

87 6

9

104240

11

10

11A-164


K4M, and 760 or 761

11A

Remove:

- the lifting bracket (12) ,

- the inlet manifold mounting bolts (13) ,


Remove:

- the catalytic converter-gearbox stay mounting bolts(14) ,

- the catalytic converter/gearbox strut,


Move the exhaust pipe aside.

Remove the camshaft pulleys using the (Mot. 1490-01) .

103272

131313

12

101793

151515

14

11A-165


K4M, and 760 or 761

11A

Remove:

- the oil separator mounting bolts (17) ,

- the oil separator.

Remove:

- the rocker cover mounting bolts,

- detach the rocker cover vertically, tapping the lugs(18) with a copper hammer.

Remove the inlet and exhaust camshafts.

103255

WARNING

Do not remove the bolt (16) as it acts as a stopfor the squared cam tappet.

1717171717

16

103256

WARNING


103258

18

18

11A-166


K4M, and 760 or 761

11A

Remove:



Remove:

- the cylinder head mounting bolts,



Remove the cylinder head gasket from the cylinderblock.

I - CLEANING THE CYLINDER HEAD

Clean the gasket faces with DECAPJOINT to dissol-ve any parts of the seal still attached to the lower co-ver and the cylinder block.



Use a ruler and feeler gauge to check that there isno gasket face bow.



For the cylinder head stripping procedure (seeTechnical Note 3784A, K4 4-cylinder petrol engi-ne, 10A, Engine and peripherals, Rebuilding thecylinder head) .

Position the pistons at mid-stroke to prevent anycontact with the valves when refitting the camshafts.


- the cylinder head combustion face,

- the cylinder block combustion face.

14499

Note:


IMPORTANT



- goggles,

- gloves.

20

19

WARNING

Do not allow this product to drip onto the pain-twork.

Clean the cylinder head carefully to preventforeign bodies from entering the oil supply andreturn pipes.

Failure to follow this guideline could lead to bloc-kage of the oilways, resulting in rapid and seriousdamage to the engine.

WARNING


11A-167


K4M, and 760 or 761

11A

Check that the centring dowel is present (21) on thecylinder block.

Fit the (Mot. 104) (22) on the cylinder block.

REFITTING



Check the cylinder head tightening bolts (see 11A,Top and front of engine, Cylinder head gasket:Removal - Refitting ).

Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ).

Reprime the hydraulic tappets (hydraulic tappetsmay empty after a long down time).

To check if repriming is necessary, press the top ofthe tappet (23) with your thumb.




Refit:



14689

22 21

14499

23

11A-168


K4M, and 760 or 761

11AI - CAMSHAFT MARKINGS

Inlet camshaft

Exhaust camshaft

Position the pin (26) of the (Mot. 1669) against thebottom of the groove by loosening bolt (27) .

Mount the (Mot. 1669) on the rocker cover, correctlypositioning the pin (28) in the rocker cover hole (29) .

Fit the rocker cover tool (Mot. 1669) using the bolts(30) .

102507

(24) The inlet camshaft is fitted withthe camshaft sensor target.

102506

(25) The exhaust camshaft is fittedwith the square cam.

24

25

103685

103684

26

29

28

27

303030

11A-169


K4M, and 760 or 761

11A

Tighten the bolt (31) until the pin (32) is hard upagainst the bottom of the groove.

Position the bolt of the (Mot. 1669) in place of theoriginal bolt at (33) to hold the tappet in the com-pressed position.

Turn the bolt (34) until the pin (35) is hard up againstthe bottom of the groove.

Remove the (Mot. 1669) from the rocker cover.

103687

103688

32

31

33

103686

35

34

11A-170


K4M, and 760 or 761

11A

Position the camshaft grooves horizontally and off-set downwards.

Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it turns red-dish.

Using a cloth, remove the LOCTITE 518 from (36)on the six camshaft rocker cover bearings.

Refit the camshaft rocker cover.

15106-1

WARNING

The sealing faces must be clean, dry and free ofgrease. (do not leave any finger marks).

WARNING


14517

36

11A-171


K4M, and 760 or 761

11AII - TIGHTENING PROCEDURE


- rocker cover mounting bolts 22, 23, 20, 13 (8Nm) ,

- rocker cover mounting bolts 1 to 12, 14 to 19,21 to 24 (12 Nm) .


Tighten to torque and in order rocker cover moun-ting bolts 22, 23, 20, 13 ( 12 Nm ) .

14497

11A-172


K4M, and 760 or 761

11A

Using a stipple roller, apply LOCTITE 518 to thegasket face until it is reddish in colour.


Tighten to torque and in order the oil separatormounting bolts ( 15 Nm ) .

Remove the bolt (10) of the (Mot. 1669) to releasethe tappet.

Refit the original bolt, applying a drop of LOCTITEFRENETANCH .

Refit:

- the camshaft dephaser solenoid valve seal usingthe (Mot. 1513) (37) ,

- the camshaft dephaser solenoid valve.

Tighten to torque the camshaft dephaser solenoidvalve bolt ( 10 Nm ) .

102073

WARNING

the sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).

WARNING


101820

16016

54

32

110 9

8

7

6

37

11A-173


K4M, and 760 or 761

11A

On the four ignition coils, apply a bead (3 8) ofFLUORINATED GREASE 82 00168 855 2 mm indiameter to the inner circumference of the high-ten-sion cap.

106443

38

11A-174


K4M, and 760 or 761

11A

Refit the plugs.

Tighten to torque the plugs ( 25 to 30 Nm ) usingthe plug spanner set (Ele. 1382) .

Refit the coils.

Tighten to torque

- the coil mounting bolts (if holes already threa-ded) ( 12 Nm ) ,

- the coil mounting bolts (if holes not threaded) (15 Nm )

.

Refit the cylinder reference sensor (39) with a newseal.

Tighten to torque the camshaft position sensormounting bolt ( 10 Nm ) .

Always replace all the inlet manifold seals.


III - REPLACING THE CAMSHAFT SEALS

The elastomer seal on these engines is fitted with aflat lip seal (40) and a protector (41) (also assists infitting the seal to the engine).

103257

39

103272

20257

2

1

8

7

6

5

4

3

4140

11A-175


K4M, and 760 or 761

11A1 - Fitting the seal to the exhaust camshaft

Screw the stud (44) of the (Mot. 1632) onto thecamshaft.

18687

WARNING

It is very important to hold the protector (42)when handling the seal, as this type of seal isvery fragile. It is strictly forbidden to touch theelastomer seal (43) in order to prevent any oilleaks once the seal is fitted to the engine.

4342

105531

21687

44

44

11A-176


K4M, and 760 or 761

11A

Fit the protector, with a seal, to the camshaft.

Fit the cover (45) and the collar nut (46) of the (Mot.1632) .



2 - Fitting the inlet camshaft seal

21687-1

21687-2

4645

21687-3

WARNING

It is very important to hold the protector whenhandling the seal, as this type of seal is very fra-gile. In order to prevent any oil leaks once theseal is fitted to the engine, it is strictly forbiddento touch the elastomer seal.

11A-177


K4M, and 760 or 761

11A

Fit the protector (47) , with a seal, to the camshaft.

Push the centre of the protector to force the seal intoits housing.

Remove the seal protector, taking care not to dropthe seal.

Screw the stud (48) of the (Mot. 1632) onto thecamshaft.

105532

105533

47

105531

105534

48

48

11A-178


K4M, and 760 or 761

11A

Fit the cover (49) and the collar nut (50) of the (Mot.1632) .



IV - REFITTING

Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal and Refitting )

Refit:

- the accessories belt (see Top and front of engine,Accessories belt: Removal - Refitting ).

- new inlet camshaft sealing plugs using the (Mot.1487) ,

- new exhaust camshaft sealing plugs using the(Mot. 1488) ,


Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining - refilling ).

Connect the battery (see 80A, Battery, Battery: Re-moval - refitting ).



105535

WARNING

Follow the second procedure in the timing beltrefitting procedure.

50

49

15103-1

11A-179


F4R, and 776

11A

Removing the cylinder head gasket requires the en-gine and transmission assembly to be removed (see10A, Engine and peripherals, Engine and gear-box assembly: Removal - Refitting ).

To remove the cylinder head gasket (see TechnicalNote 3784A, F4 4-Cylinder Petrol Engine, 10A,Engine and peripherals, Cylinder head: Strip-ping - Refitting .

WARNING

Removing and refitting the turbocharger requirescareful application of the repair procedures toensure the system is properly sealed.

FAILURE TO COMPLY WITH THESE INSTRUC-TIONS MAY HAVE SERIOUS SAFETY-RELATEDCONSEQUENCES FOR THE DRIVER.

11A-180


F9Q, and 804

11A

REMOVING - REFITTING


Remove:




Drain the cooling circuit through the cooling radiatorusing (Mot. 1202-01) or (Mot. 1202-02) or (Mot.1448) .

Remove the scuttle panel grille (see MR 371 Bo-dywork, 55A, Exterior Protection, Scuttle PanelGrille ).

Remove:

- air filter access panel mounting bolts,

- the scuttle panel partition mounting bolt,

- the scuttle panel partition mounting bolts,

- the scuttle panel partition,


- the battery,

- the battery tray,


Remove the catalytic pre-converter (see 19B, Ex-haust, Catalytic Pre-converter: Removal - Refit-ting ).

Remove:

- the timing belt (see 11A, Top and front of engine:Timing belt ).

- the accessories belt (see 11A, Top and front ofengine, Accessories belt ) ,








Equipment required

cylinder head testing equipment


Tightening torquesm

battery cover mountingbolts.

4 Nm .

IMPORTANT


- connect the diagnostic tool (After-Sales),


- check that the injector rail is depressurised,

- watch out for the fuel temperature,


WARNING

Plug the orifices.

Make sure that you follow all the safety instruc-tions.

Refer to 13B, Diesel injection, Cleanliness ins-tructions).

11A-181


F9Q, and 804

11A

Fit the engine support with (Mot. 1672) .

Remove (Mot. 1453) and (Mot. 1453-01) .

Disconnect:

- the oil vapour rebreathing pipe (4)

- the air inlet duct (see 12A, Fuel mixture, Air inta-ke: Removal - Refitting ) (5) .

- the turbocharging pressure connector (7) ,

- the throttle valve connector (8) ,

- the turbocharging pressure solenoid valve connec-tor (9) ,

- the flowmeter connector (10)


- the diesel pressure regulator connector (12) .

Remove:

- the injector rail protector (13) (see 13B, Diesel in-jection, Injector rail protector ).

105432

111887

111888

11A-182


F9Q, and 804

11A

Disconnect:

- the vacuum pipe (14) from the vacuum pump,


- the exhaust gas recirculation connector (16) ,

- the coolant temperature sensor (17) ,

- the turbocharger vacuum pipes (18) .

Disconnect:

- the camshaft sensor connector (19) ,




Disconnect:

- the diesel return temperature sensor connector,

- the high-pressure pump pressure regulator con-nector,


- the diesel return pipe (22) ,

- the diesel fuel supply pipe.

Remove the starter (see 16A, Starting-Charging,Starter: Removal - Refitting .

Remove:

- the turbocharger air duct,

- the turbocharger oil return pipe

- the coolant hoses.

- the turbocharger oil supply pipe.

Disconnect the scuttle panel hoses from the cylinderhead outlet.

111886

111965

111889

11A-183


F9Q, and 804

11A

Remove:

- the high-pressure pump rear mounting bolts (23) ,

- the windscreen wiper mounting,

- the bonnet,

- the cylinder head mounting bolts.

Remove the cylinder head.

Remove exhaust gas recirculation pipe mountingbolts (24) .

Remove the exhaust gas recirculation pipe moun-ting clip.

Remove the cylinder head mounting bolts.


102348

WARNING


111861

111863

11A-184


F9Q, and 804

11AI - CLEANING



Check for gasket face bow using a ruler and a set ofshims.

The maximum deformation is 0.05 mm .

Test the cylinder head to detect any possible cracksusing a cylinder head testing equipment .

(see TN 3652A, 4-cylinder Cast Iron High Pressu-re Common Rail Diesel Engine, 10A, Engine andperipherals, Rebuilding the cylinder head) for thecylinder head stripping procedure.

REFITTING


Degrease the gasket faces.

Refit the cylinder head with a new cylinder head gas-ket.

Refit new cylinder head bolts.

Tighten the cylinder head (see 11A, Top and frontof engine, tightening the cylinder head) using aangular tightening wrench .

Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter ).

Refit the timing belt (see 11A, Top and front of en-gine, Timing belt ).

Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt ).

Fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit .

Reprime the diesel circuit (see 13B, Fuel supply,Diesel supply circuit ).


Tighten to torque the battery cover mountingbolts. ( 4 Nm . )

IMPORTANT


Wear protective goggles.

Wear gloves during the operation.

Clean the gasket faces with DECAPJOINT clea-ning product to dissolve the part of the gasketwhich is stuck to the sump and cylinder cover.

Apply the product to the section to be cleaned;Wait approximately ten minutes, then remove theresidue using a wooden spatula.

WARNING


WARNING

Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply pipes.

Failure to follow this instruction could lead to thepipes becoming blocked, causing rapid camshaftdamage.

WARNING

No regrinding is permitted.

WARNING

carry out the necessary programming (see 80A,Battery: Removal - Refitting ).

11A-185


F9Q, and 804

11A

REMOVING - REFITTING


Remove:





Always respect the repair precautions (see 13B,Diesel injection, Diesel injection: Precautionsduring repair ).

Remove:



- the battery tray,

- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).


Remove:

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting) ,


Fit the engine support using the (Mot. 1672) .






Equipment required

diagnostic tool

cylinder head testing equipment


Tightening torquesm


4 Nm

IMPORTANT


- connect the diagnostic tool (After-Sales),





WARNING

Fit plugs in the openings.

105432

11A-186


F9Q, and 804

11A

Disconnect:


- the air inlet duct (see 12A, Fuel mixture, Air inlet:Removal - Refitting ) (2) ,

- the turbocharging pressure connector (4) ,


- the turbocharging pressure solenoid valve connec-tor (6) ,

- the air flowmeter sensor connector (7) ,


- the diesel pressure regulator connector (9) .

Remove:

- the injection rail protector (10) (see 13B, Diesel in-jection, Injection rail protector ).

Disconnect:

- the vacuum pipe from the vacuum pump (11) ,


- the exhaust gas recirculation connector (13) ,

- the coolant temperature sensor (14) ,

- the turbocharger vacuum pipes (15) .

Disconnect:

- the camshaft sensor connector (16) ,

- the injector connectors (17) .


Move the electric wiring harness to one side.

111887

111888

7

5

4

3

21

6

10

9

8

111886

111965

12

11

14

13

1515

1617171717

11A-187


F9Q, and 804

11A

Disconnect:

- the diesel return temperature sensor connector,

- the high-pressure pump pressure regulator con-nector,


- the diesel return pipe (19) ,

- the diesel fuel supply pipe.

Remove:

- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting .

- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).

- the water hoses.

Disconnect the cylinder head outlet water unit ho-ses.

Remove:

- the high pressure pump rear mounting bolts (20) ,

- the windscreen wiper mounting,

- the bonnet,

- the cylinder head mounting bolts.

111889

19

18181818

102348

WARNING


2020

11A-188


F9Q, and 804

11A

Remove the mounting bolts (21) from the exhaustgas recirculation pipe.

Remove the mounting clip from the exhaust gas re-circulation pipe.

Remove the cylinder head mounting bolts.


I - CLEANING


Clean the gasket faces with DECAPJOINT to dissol-ve any part of the gasket which is attached to thelower cover and cylinder block.

Apply the product to the section to be cleaned; waitapproximately 10 minutes, then remove residueusing a wooden spatula.




Test the cylinder head to detect any possible cracksusing a cylinder head testing equipment .

For the cylinder head stripping procedure (seeTechnical Note 3652A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead) .

111861

111863

2121

2121

IMPORTANT

Do not scratch the aluminium sealing surfaces.


- goggles,

- gloves.

WARNING


WARNING


Failure to follow this instruction could lead to thepipes becoming blocked, causing rapid camshaftdamage.

WARNING

No regrinding is permitted.

11A-189


F9Q, and 804

11AREFITTING


Degrease the gasket faces.

Refit the cylinder head with a new cylinder head gas-ket.

Refit new cylinder head bolts.

Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head) using aangular tightening wrench .

Refit the catalytic pre-converter (see 19B, Exhaust,Catalytic Pre-converter: Removal - Refitting ).

Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting ).

Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt: Removal - Refitting).


Reprime the diesel circuit (see 13B, Fuel supply,Diesel fuel supply circuit ).




11A-190


K9K, and 732

11A

REMOVAL







Ele. 1552 Tool for removing rearscreen wiper arm







Equipment required

diagnostic tool

hydraulic crane

load positioner



Tightening torquesm

rocker cover mountingbolts

10 Nm

alternator mountingbolts

21 Nm

hose clip on the stain-less steel pipe

5.5 Nm


9 Nm


WARNING

Before starting work on the vehicle, obtain:

- a new plug kit ( PART NO. 77 01 476 857) ,

- some cleaning cloths ( PART NO. 77 11 211 707) ,

- cleaning product ( PART NO. 77 11 24 188) .

IMPORTANT

Before carrying out any work on the injection sys-tem, check using the diagnostic tool :

- that the injection rail is not under pressure,

- that the fuel temperature is not too high.

It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, Cleanliness guidelines).

WARNING

Procedure for removing the air inlet duct (risk of leaking and dislodging if this procedure is not res-pected):


- do not use degreaser, brake cleaning agents, orany other products,

- clean the bearing face on the intercooler with adry, lint-free cloth,


- place the clip in the same position if the hose isnot replaced,

- it is essential to replace the hose and/or the rigidpipe in the event of damage.

11A-191


K9K, and 732

11ARemove the engine undertray.

Unclip the trim (1)

Remove:

- the seal (2) ,

- the plastic rivets (3) ,

- the wiper arms (4) using the (Ele. 1552) ,

- the scuttle panel grille.

- the scuttle panel partition.

Remove:


- the timing belt (see 11A, Top and front of engine,Timing belt ),

- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ).

- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ).

Remove the turbocharger oil return pipe (5) .

Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Draining-refilling ).

Remove:

- the alternator upper mounting bolt (26) ,

- the alternator lower mounting bolt (27) ,

102101

102100

104175

102267

11A-192


K9K, and 732

11A

Remove:

- the inner timing cover mounting bolts (6) ,

- the inner timing cover.



Disconnect the air inlet pressure sensor connector(7) .

Loosen the clips (8) and (9) .


19710

19626

112815

102473

11A-193


K9K, and 732

11A

Pull out the clip.

Make a mark (11) on the air inlet duct between thestainless steel pipe and the hose using an indeliblepen.

Detach the hose from the stainless steel pipe.

Remove:

- the mounting bolt (12) from the stainless steel pipe,

- the stainless steel pipe (13) .

Unclip the injection rail protector cover (14) .

Remove:

- the injection rail protector cover,

- the injection rail protector cover mounting bolt andmounting nut (15) ,

- the dipstick,

- the dipstick guide tube mounting bolts (16) .

Remove the dipstick guide tube.

Disconnect:


112811

112991

112992

112993

11A-194


K9K, and 732

11A- the injector connectors (18) ,

Disconnect:

- the connector (19) from the damper valve,

- the cylinder reference sensor connector (20) ,

- the pressure regulation solenoid valve connector(21) ,

- the flow regulation solenoid valve connector (22) ,

- the diesel temperature sensor connector (23) ,

- the rail pressure sensor connector.

Unclip the wiring harness retaining clip (24) .

Remove the wiring harness clip mounting nut (25) .

Remove the wiring harness.

Tilt the alternator against the radiator assembly.

Clean the fuel return and supply pipe unions (see13A, Diesel injection, Repair precautions ).

Disconnect:



Fit plugs.

112994

112656

WARNING

Do not blast compressed air once the fuel circuitis open, otherwise impurities may enter the sys-tem. Use wipes if necessary.

Note:

Make preparations for fuel outflow. Clean withnew wipes.

11A-195


K9K, and 732

11A

Remove:

- the retaining bracket mounting bolts from the ex-haust gas recirculation cooler,

- the bracket from the exhaust gas recirculation coo-ler.

Remove the injection rail protector cover supportmounting bolt and mounting nuts (30) .

Unclip the drain pipe from the injection rail protectorcover support.

Remove:

- the injection rail protector cover support,

- the damper valve (see 12A, Damper valve: Re-moval - Refitting .

Disconnect the oil vapour rebreathing pipe on therocker cover side (31) .


Disconnect:

- the exhaust gas recirculation solenoid valve con-nector,

- the scuttle panel hoses (33) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,

- the brake servo vacuum pipe (34) on the vacuumpump side,

- the temperature sensor connector from the scuttlepanel,

- the radiator top hose from the cylinder head outletwater unit (35) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) ,

- the turbocharging pressure regulation solenoid val-ve hose on the vacuum pump side,

- the turbocharging pressure regulation solenoid val-ve hose on the pressure regulation valve side.

113475

111748

112996

112997

11A-196


K9K, and 732

11A

Remove:

- the rocker cover mounting bolts (36) ,

- the rocker cover.


Remove:

- the cylinder head mounting bolts (37) ,

- the cylinder head using a hydraulic crane fittedwith a load positioner .

REFITTING

I - CLEANING


Clean the gasket faces with DECAPJOINT to dissol-ve any parts of the seal still attached.

Apply the product to the part to be cleaned. Wait ap-proximately ten minutes, then remove the residueusing a wooden spatula.




For the cylinder head stripping procedure see Tech-nical Note 6006A, 4-cylinder cast iron High Pres-sure Common Rail Diesel Engine, 10A, Engineand peripherals, Rebuilding the cylinder head . .


113476

19712

IMPORTANT


Wear goggles.


WARNING

Please make sure, during this operation, that noforeign bodies enter the oil pipes (pipes in boththe cylinder block and the cylinder head).

WARNING

Protect the oil duct to prevent any foreign bodiesfrom entering the cylinder head oil supply pipes.

Failure to follow this procedure could lead to theoil supply pipes becoming blocked, quicklydamaging the camshaft.

WARNING


11A-197


K9K, and 732

11AIII - REFITTING OPERATION FOR PART CONCERNED


Fit the new cylinder head gasket, centred by twodowels.

Refit the cylinder head using the hydraulic crane fit-ted with the load positioner .

Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) usingangular tightening wrench .

IV - FINAL OPERATION

Fit the new rocker cover gasket.

Apply beads (38) of SILICONE ADHESIVE SEAL 2mm in diameter.


Tighten to torque and in order the rocker covermounting bolts ( 10 Nm ) .

Connect:

- the turbocharging pressure regulation solenoid val-ve hose on the pressure regulation valve side.

- the turbocharging pressure regulation solenoid val-ve hose on the vacuum pump side,

- the radiator top hose from the cylinder head wateroutlet unit using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,

- the temperature sensor connector to the scuttle pa-nel,

- the brake servo vacuum pipe on the vacuum pumpside,

- the scuttle panel hoses using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,

Refit:

- the air inlet duct between the air filter unit outletand the turbocharger inlet,

- the oil vapour rebreathing pipe;

- the damper valve (see 12A, Damper valve: Re-moval - Refitting ).

- the injection rail protector cover support,

- the injection rail protector cover support mountingbolt and mounting nuts.

Clip the drain pipe onto the injection rail protector co-ver support.

WARNING


19712-1

WARNING


WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.)

113476

11A-198


K9K, and 732

11ARefit:

- the injection rail protector cover mounting bracket,

- the injection rail protector cover retaining bracketmounting bolts,

Remove the blanking plugs.

Connect:



Torque tighten the alternator mounting bolts ( 21Nm ) .

Connect:

- the rail pressure sensor connector,

- the diesel fuel temperature sensor connector.

- the flow regulation solenoid valve connector,

- the pressure regulation solenoid valve connector,

- the cylinder reference sensor,

- the connector on the damper valve,

- the heater plugs connector,


Position the wiring harness.

Refit the mounting nut of the wiring harness clip.

Clip the retaining clip of the wiring harness.

Refit:

- the dipstick guide tube mounting bolts to the injec-tion rail protector cover support,

- the diesel anti-splash device cover,

- the injection rail protector cover bolt and nuts,

Clip on the injection rail protector cover.

Refit:

- the clip to the stainless steel pipe,

- the stainless steel pipe between the intercoolerhose and the turbocharger, aligning the marks,

- the pipe between the intercooler and the dampervalve.

Tighten to torque the hose clip on the stainlesssteel pipe ( 5.5 Nm )

Clip the stainless steel pipe to the turbocharger.

Refit the air duct between the damper valve and theintercooler

Tighten the clips.

Connect:

- the air pressure sensor,

- the exhaust gas recirculation solenoid valve con-nector.

Fit the (Mot. 1453) with the (Mot. 1453-01) .


Refit:

- the inner timing cover,

- the alternator upper mounting bolt,

- the alternator lower mounting bolt,

- the turbocharger oil return pipe.

Tighten to torque the turbocharger oil return pipe( 9 Nm ) .

Refit:

- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ),





- the battery,

Fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).

Reconnect the battery (see 80A, Battery, Removal- Refitting ).



11A-199

TOP AND FRONT OF ENGINETightening the cylinder head

K4J, and 730 or 732 – K4M, and 760 or 761

11ACYLINDER HEAD TIGHTENING PROCEDURE

Tighten to torque and in order the cylinder headmounting bolts ( 20 Nm ) .

Check that all of the cylinder head mounting boltsare tightened to the correct torque of 20 Nm .

Angle-tighten in order the cylinder head mountingbolts ( 240˚ ±±±± 6˚ ) .

Tightening torquesm

cylinder head moun-ting bolts

20 Nm


240˚ ±±±± 6˚

14500

WARNING

Reuse the bolts if the length under the headdoes not exceed 117.7 mm (otherwise replaceall the bolts with new ones).

In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.

Do not oil the new bolts. The bolts must be oiledif reused.

WARNING


WARNING

Do not retighten the cylinder head bolts afterapplying this procedure.

11A-200


K9K, and 722 or 728 or 729

11A

CYLINDER HEAD TIGHTENING PROCEDURE


Check that all of the cylinder head mounting boltsare tightened to the correct torque (25 Nm) .

Angle-tighten in order the cylinder head mountingbolts ( 255˚ ±±±± 10˚ ) .

Tightening torquesm


25 Nm


255˚ ±±±± 10˚

19712

WARNING


WARNING

Always replace all of the cylinder head bolts withnew ones after removal.

In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil thatmay be in the cylinder head mounting holes.

Do not oil the new bolts.

WARNING


3

4

102

918

7 6

5

11A-201


F9Q, and 800 or 804 or 808




Angle-tighten in order the cylinder head mountingbolts ( 230˚ +/- 6˚ ) .

Tightening torquesm


30 Nm


230˚ +/- 6˚

16189

WARNING


WARNING

Systematically replace all cylinder head boltsafter removal.

To ensure correct tightening, use a syringe toremove any oil that may be in the cylinder headmounting holes.


WARNING


1

2 3

45

6 7

89

10

11A-202


F4R, and 770 or 771 or 776



Check that all of the cylinder head bolts are tighte-ned to the correct torque (20 Nm) .

Step 1

Angle-tighten in order the cylinder head mountingbolts ( 100˚ ±±±± 6˚ )

Tightening torquesm


20 Nm


100˚ ±±±± 6˚


100˚ ±±±± 6˚

15153

2

1 10

9

8

7

6

5

4

3

WARNING


In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil thatmay be in the cylinder head mounting holes.


WARNING


11A-203


F4R, and 770 or 771 or 776

11AStep 2

Angle-tighten in order the cylinder head mountingbolts ( 100˚ ±±±± 6˚ )

WARNING


11A-204


K9K, and 732


Tighten to torque and in order the cylinder headmounting bolts ( 25 Nm ) with the low torquewrench .


Angle-tighten in order the cylinder head mountingbolts ( 255˚ ±±±± 10˚ ) using the angular tighteningwrench .

Equipment required

low torque wrench


Tightening torquesm


25 Nm


255˚ ±±±± 10˚

19712

WARNING


WARNING


In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.


WARNING


11A-205

TOP AND FRONT OF ENGINECylinder head: Removal - Refitting

M9R, and 700

11AREMOVAL

Removing the cylinder head requires the engine andgearbox assembly to be removed (see 10A, Engineand peripherals, Engine and gearbox assembly:Removal - Refitting ).

To remove the cylinder head (see Technical Note6017A, M9R Diesel engine ).

REFITTINGTo refit the cylinder head (see Technical Note6017A, M9R Diesel engine ).

Refit the engine and gearbox assembly (see 10A,Engine and peripherals, Engine and gearbox as-sembly: Removal - Refitting ).

12A-1

FUEL MIXTURESpecifications

F4R, and 770 or 771 or 776

12A

(1)for a coolant temperature above 80˚C and after theengine speed has stabilised at 2,500 rpm for approxi-mately 30 seconds .

(2)octane rating 91 unleaded compatible

(3)for the legal values, see specifications by country

(4)at 2,000 rpm CO should be a maximum of 0.3 %

Equipment required

diagnostic tool

VehicleGear-

box

Engine

Type Suffix Bore

(mm)

Stroke

(mm)

Cubiccapacity

(cc)

Compression

ratio

XM0UND0

F4R

770

82.7 93 1,998 9.8/1

DP0 771

XN0W ND0 776 9.5 ± 0.3

EngineTest carried out at idle speed(1)

Fuel (2)

(minimum

octane

rating)

Pollutant emissions(3)

Type Suffix Idlingspeed

(rpm)

CO (%)(4) CO2 (%) HC (ppm) Lambda (λ)

F4R 770 /771 /776

750 ±±±± 50 0.5

maximum

14.5

maximum

100

maximum

0.97< λ <1.03 Superunleaded(Octanerating 95)

Temperatures in ˚C ±±±± 1 - 10 25 50 80 110 120

Negative temperature coefficient air tem-perature sensor (resistance in Ω)

10,454to 8,623

2,174 to1,928

857 to763

326 to292

143 à127

112 to98

Negative temperature coefficient coolanttemperature sensor (resistance in Ω)

13,588t o 11,332

2,364 to2,140

850 to772

290 to275

117 to111

90 to 86

12A-2


F4R, and 770 or 771 or 776

12A

Description Brand-Type Special notes

Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer

128-track computer

- connector A: 48-track

- connector B: 32-track

- connector C: 48-track

Fuel pump - It is part of a « pump - sender - filter » assemblyincorporating the pressure regulator

Pressure: 3.5 ±±±± 0.06 bar

Minimum flow: 80 to 120 l/h

Ignition coils SAGEM Four coils

Primary resistance: tracks 1 and 2 approximately 0.5Ω

Secondary resistance: track 1 and high voltage out-put: 10.5 +/- 1.5 kΩ

2-track connector:

- 1: + 12 V supply

- 2: earth control

Ignition coils BERU (F4R 776) only Four coils



2-track connector:

- 1: + 12 V supply

- 2: earth control

Injectors

SIEMENS - DEKA 4 Bi-jet solenoid injector

Resistance: 14.5 +/- 0.7 Ω at 20˚C

2-track connector:

- 1: + 12 V supply

- 2: earth control

SIEMENS - DEKA 7(F4R 776) only

Bi-jet solenoid injector

Resistance: 12 ±±±± 0.5 Ω at 20˚C

2-track connector:

- 1: + 12 V supply

- 2: earth control

12A-3


F4R, and 770 or 771 or 776

12A

Manifold pressure sensor

SIEMENS - MAP03 Piezoelectric type sensor

Replace the seal each time it is removed.

3-track connector:

- A: earth

- B: signal

- C: + 5 V supply

BOSCH (F4R 776) only Piezoelectric type sensor


3-track connector:

- 1: + 5 V supply

- 2: earth

- 3: signal

Injection order - 1-3-4-2

no. 1 flywheel end

Fault finding diagnostic tool CLIP only

Accelerator pedal potentio-meter

CTS Dual gang potentiometer

Resistance values:

- circuit 1: tracks 3 and 5: 1,700 ±±±± 900 Ω

- gang 2: tracks 2 and 6: 2,850 ±±±± 2,050 Ω

6-track connector:

- 1: gang 2 signal

- 2: 5 V supply, gang 2


- 4: gang 1 signal

- 5: gang 1 earth

- 6: gang 2 earth

Pinking sensor SAGEM Piezoelectric type sensor

Tightening torque: 20 Nm

Engine speed and positionsensor

SIEMENS Variable reluctance type sensor

Resistance: 200 to 270 Ω at 23˚C



12A-4


F4R, and 770 or 771 or 776

12A

Upstream and downstreamoxygen sensors

BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaustgas temperature rises above 850˚C .

Heating resistor: 9 Ω at 20˚C

4-track connector:

- A: + heating resistor

- B: - heating resistor

- C: + signal

- D: - signal

Warm engine:

- Rich mixture > 800 mV

- Lean mixture < 50 mV

Fuel vapour absorber sole-noid valve

SAGEM Resistance: 26 ±±±± 4 Ω to 23˚C

2-track connector:

- 1: + 12 V supply

- 2: earth control

Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-vious table)

Coolant temperature sensor JAEGER ELTH

or SILEA

Negative temperature coefficient thermistor (see pre-vious table)

Refrigerant sensor TEXAS

INSTRUMENTS

3-track connector:

- A: earth

- B: + 5 V supply

- C: signal


12A-5


F4R, and 770 or 771 or 776

12A

Throttle valve

VDO EGAS 5

Diameter 60 mm (F4R770 and 771)

Direct current geared electric motor.

6-track connector:

- 1: potentiometer gang no. 1 signal

- 2: 5 V potentiometer supply

- 3: + motor


- 5: - motor

- 6: common earth

Engine resistance: approximately 2.3 Ω at 23˚C

Potentiometer resistance:

tracks 2 and 6: 1000 ±±±± 250 Ω

VDO EGAS - T

Diameter 40 mm (F4R776) only

Direct current geared electric motor.

6-track connector:

- 1: earth


- 3: + motor

- 4: - motor



Engine resistance: approximately 1.57 Ω to 23˚C

Potentiometer resistance:

tracks 1 and 5: 1,000 ±±±± 250 Ω

Camshaft dephaser solenoidvalve

AISIN (F4R 770 and771)

It is controlled by the opening cyclic ratio.

Resistance: 7.2 ±±±± 0.5 Ω to 20˚C

2-track connector:

- 1: + 12 V supply

- 2: earth

Spark plug

CHAMPION

RC 87 YCL (F4R 770and 771

Single electrode spark plugs

Gap: 0.90 ±±±± 0.05 mm

Torque: 25 to 30 Nm

NGK PFR6G - 9

(F4R 776) only


Gap: 0.900--0.1mm

Torque: 25 to 30 Nm

Catalytic converter EBERSPÄCHER C175


12A-6


K4J, and 730 or 732 – K4M, and 760 or 761

12A

(1)for a coolant temperature above 80˚C and after theengine speed has stabilised at 2,500 rpm for approxi-mately 30 seconds .

(2)octane rating 91 unleaded compatible

(3)for the legal values, see specifications by country

(4)at 2,000 rpm CO should be a maximum of 0.3 %

Equipment required

diagnostic tool

VehicleGear-

box

Engine

Type Suffix Bore

(mm)

Stroke

(mm)

Cubiccapacity

(cc)

Compression

ratio

XM0B JH3 K4J730

79.5 70 1390

10 / 1732

XM0CJH3

K4M760

79.5 80.5 1,598 DP0 761

EngineTest carried out at idle speed(1)

Fuel (2)

(minimum

octane

rating)

Pollutant emissions(3)


(rpm)

CO (%)(4) CO2 (%) HC (ppm) Lambda (λ)

K4J 730 /732

750 ±±±± 50 0.5

maximum

14.5

maximum

100

maximum0.97<λ<1.03

Superunleaded(Octanerating 95)

K4M 760 /761

700 ±±±± 40

Temperatures in ˚C ±±±± 1 - 10 25 50 80 110 120

Negative temperature coefficient air tem-perature sensor (resistance in Ω)

10,454to 8,623

2,174 to1,928

857 to763

326 to292

143 à127

112 to98

Negative temperature coefficient coolanttemperature sensor (resistance in Ω)

13,588t o 11,332

2,364 to2,140

850 to772

290 to275

117 to111

90 to 86

12A-7


K4J, and 730 or 732 – K4M, and 760 or 761

12A

Description Brand -Type Special notes

Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer

128-track computer

- connector A: 48-track

- connector B: 32-track

- connector C: 48-track

Fuel pump - It is part of a « pump - sender - filter » assemblyincorporating the pressure regulator

Pressure: 3.5 ±±±± 0.06 bar

Minimum flow: 80 to 120 l/h

Ignition coils SAGEM Four coils



2-track connector:

- 1: + 12 V supply

- 2: earth control

Injectors SIEMENS - DEKA 4 Bi-jet solenoid injector

Resistance: 14.5 +/- 0.7 Ω at 20˚C

2-track connector:

- 1: + 12 V supply

- 2: earth control

Manifold pressure sensor SIEMENS - MAP03 Piezoelectric type sensor


3-track connector:

- A: earth

- B: signal

- C: + 5 V supply

Injection order - 1-3-4-2

no. 1 flywheel end

Fault finding diagnostic tool CLIP only

12A-8


K4J, and 730 or 732 – K4M, and 760 or 761

12A

Accelerator pedal potentio-meter

CTS Dual gang potentiometer

Resistance values:

- gang 1: tracks 3 and 5: 1,700 ±±±± 900 Ω

- gang 2: tracks 2 and 6: 3,875 ±±±± 1,025 Ω

6-track connector:

- 1: gang 2 signal



- 4: gang 1 signal

- 5: gang 1 earth

- 6: gang 2 earth

Pinking sensor SAGEM Piezoelectric type sensor


Engine speed and positionsensor

SIEMENS Variable reluctance type sensor

Resistance: 200 to 270 Ω at 23˚C


Upstream and downstreamoxygen sensors

BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaustgas temperature rises above 850˚C .

Heating resistor: 9 Ω at 20˚C

4-track connector:

- A: + heating resistor

- B: - heating resistor

- C: + signal

- D: - signal

Warm engine:

- Rich mixture > 800 mV

- Lean mixture < 50 mV

Fuel vapour absorber sole-noid valve

SAGEM Resistance: 26 ±±±± 4 Ω to 23˚C

2-track connector:

- 1: + 12 V supply

- 2: earth control

Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-vious table)


12A-9


K4J, and 730 or 732 – K4M, and 760 or 761

12A

Coolant temperature sensor JAEGER ELTH

or SILEA

Negative temperature coefficient thermistor (see pre-vious table)

Refrigerant sensor TEXAS

INSTRUMENTS

3-track connector:

- A: earth

- B: + 5 V supply

- C: signal


K4J


Throttle valve VDO EGAS T

60 mm diameter

6-way connector

- 1: common earth


- 3: - motor

- 4: + motor



Engine resistance: approximately 1.6Ω to 23˚C

Potentiometer resistance; tracks 1 and 5: 1,000 ±±±± 250 Ω

K4M


Throttle valve VDO EGAS 5

57 mm diameter

Direct current geared electronic motor

6-way connector



- 3: + motor


- 5: - motor

- 6: common earth

Potentiometer resistance; tracks 2 and 6: 1,000 ±±±± 250 Ω

12A-10


K4J, and 730 or 732 – K4M, and 760 or 761

12A

K4M


Camshaft dephaser solenoid valve DELPHI It is controlled by the opening cyclic ratio.

Resistance: 7.2 ±±±± 0.5 Ω to 20˚C

2-track connector:

- 1: + 12 V supply

- 2: earth

Camshaft position sensor SAGEM Hall effect sensor

3-track connector:

- 1: earth

- 2: signal

- 3: + 12 V supply


Spark plug EYQUEM RFN 58 LZ

or CHAMPION RC 87 YCL


Gap: 0.95 ±±±± 0.05 mm

Torque: 25 to 30 Nm

Catalytic converter EBERSPÄCHER C150

12A-11

FUEL MIXTUREAir inlet

K4J, and 730 or 732

12ADiagram of the air inlet circuit

102071

(1) Air inlet sleeve

(2) Air resonator

(3) Air filter unit

(4) Air unit

(5) Throttle valve

(6) Inlet manifold

(7) Injector holder plate

(8) Air inlet

12A-12


K4M, and 760 or 761

12ADiagram of the air intake circuit

101190

7

2

22

6

5 4

3

1

(1) Air intake sleeve

(2) Air resonators

(3) Air filter unit

(4) Throttle valve

(5) Inlet manifold

(6) Injector holder shim

(7) Air inlet

12A-13


K9K, and 722

12ADiagram of the air intake circuit

102070

3

2

1

8

7

6

54

(1) Air intake sleeve

(2) Air filter unit

(3) Exhaust gas recirculation unit

(4) Air resonator

(5) Metal air intake tube

(6) Intercooler

(7) Turbocharger

(8) Air inlet

12A-14


F9Q, and 800

12AAir intake circuit diagram

102482

1

2

34 5

6

7

(1) Air inlet

(2) Air filter

(3) Flowmeter

(4) Turbocharger

(5) Inlet manifold

(6) Engine shut-off flap

(7) Air-to-air intercooler

12A-15


F4R, and 770 or 771

12AAir intake circuit diagram

102744

1

2

23

45

6

7

(1) Air intake trunking

(2) Resonators

(3) Air filter unit

(4) Throttle body

(5) Intake manifold

(6) Injector mounting plate

(7) Air intake

12A-16


F4R, and 776

12A

107841

6

5

4

3

2

1

(1) Air intake

(2) Air resonator

(3) Air filter unit

(4) Turbocharger

(5) Intercooler

(6) Inlet manifold

12A-17


K9K, and 728 or 729

12A

110316

1

2

34

5

6

7

8

(1) Air inlet sleeve

(2) Air filter unit


(4) Air resonator

(5) Metal air inlet tube

(6) Intercooler

(7) Turbocharger

(8) Air inlet

12A-18


F9Q, and 804


112269

(1) Air inlet

(2) Air filter unit

(3) Flowmeter

(4) Turbocharger

(5) Inlet manifold

(6) Throttle valve

(7) Intercooler

(8) Air filter

(9) EGR unit

12A-19


K9K, and 732

12A

112302

1

2

3

4

56

7

8

(1) Air inlet

(2) Air filter unit

(3) Flowmeter

(4) Turbocharger

(5) Damper flap

(6) Air filter

(7) Intercooler

(8) Air resonator

12A-20


F9Q, and 808


114617

(1) Air inlet

(2) Air filter

(3) Flowmeter

(4) Turbocharger

(5) Inlet manifold

(6) Engine stop flap

(7) Intercooler

12A-21


M9R, and 700


114472

(1) Air inlet scoop

(2) Noise-reducing air duct

(3) Air resonator

(4) Air filter unit

(5) Air filter

(6) Air flowmeter

(7) Turbocharger

(8) Intercooler

(9) Damper flap

(10) EGR solenoid valve

12A-22

FUEL MIXTUREAir resonator: Removal - Refitting

M9R, and 700

12AREMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED


Remove the front bumper (see MR 365, Bodywork,55A, Exterior protection, Front bumper ).

Remove:

- the left-hand headlight upper mounting bolt (1) ,

- the left-hand headlight lower mounting bolt (2) .

Disconnect the left-hand headlight connectors.

Remove the left-hand headlight.


Remove the air resonator (3) starting with the endpiece side of the duct that is upstream of the air filter.

REFITTING


Refit the air resonator starting with the end pieceside of the duct that is upstream of the air filter.


Refit the left-hand headlight.

Tighten:

- the left-hand headlight upper mounting bolt,

- the left-hand headlight lower mounting bolt.

Disconnect the left-hand headlight connectors.

Refit the front bumper (see MR 365, Bodywork,55A, Exterior protection, Front bumper ).


115726

115725

114659

12A-23

FUEL MIXTUREAir filter: Replacement

K4J, and 730 or 732

12AREPLACING THE FILTER ELEMENT

Remove:


- the air resonator housing.

Disconnect brake servo vacuum pipe (2) from the in-let manifold.

Remove:

- the two air filter cover mounting bolts (3) ,

- the filter element.

101103

1

101104

WARNING

Do not damage the vacuum outlet on the inletmanifold. If it is broken the inlet manifold willneed to be replaced.

2

3

12A-24

FUEL MIXTUREAir filter: Replacement

F4R, and 770 or 771 or 776 – F9Q, and 800 or 804 or 808 – K4M, and 760 or 761 – K9K, and 722 or 728 or 729 or732

12A

REPLACING THE FILTER ELEMENT

Remove the mounting bolts (1) from the air filter co-ver.

Remove:

- the cover (2) ,


.

REFITTING


Tightening torquesm


4 Nm

106277

11 106276

2

12A-25

FUEL MIXTUREAir filter: Removal - Refitting

F4R or F9Q or K4M or K9K or M9R

12AREMOVAL


Remove the mounting bolts (1) from the air filter co-ver.


Remove:

- the cover (2) ,

- the air filter.

REFITTING


Clean the air filter unit.

Refit:

- the air filter,

- the cover.


Tighten the air filter unit mounting bolts.

106277

106276

12A-26

FUEL MIXTUREAir filter unit: Removal - Refitting

K4J, and 730 or 732

12A

REMOVALRemove the engine covers.


Remove:

- the seal (1) ,

- the plastic rivets (2) .

Unclip the trim (3) .

Remove wiper arms (4) using tool (Ele. 1294-01) .

Remove the scuttle panel grille.


Ele. 1294-01 Windscreen wiper armremoving tool

Tightening torquesm

air filter unit mountingbolts

9 Nm


4 Nm

102100

12

102101

102105

3

4

12A-27


K4J, and 730 or 732

12A

Remove:

- the bulkhead soundproofing mountings (5) ,

- the bulkhead soundproofing material.

Remove:


- the air resonator.

Disconnect brake servo vacuum pipe (7) from the in-let manifold.

Remove:

- air filter cover mounting bolts (8) ,


101487

101103

5

5

55

6

101104

WARNING

Do not damage the vacuum outlet on the inletmanifold. If it is damaged, the inlet manifold willneed to be replaced.

7

8

12A-28


K4J, and 730 or 732

12A

Disconnect the oxygen sensor connector. (9)

Remove the retaining bracket (10) .

Remove:

- air filter mounting bolts (11) ,

- the air filter unit.

REFITTING

Replace:

- the throttle valve seal each time it is removed usinggrease to make fitting easier,

- the plastic rivets and clips every time they are re-moved.


Torque tighten the air filter unit mounting bolts ( 9Nm ) .


Torque tighten the battery cover mounting bolts (4 Nm ) .101494

101488

9

10

11

WARNINGcarry out the necessary programming (see 80A,Battery: Removal - refitting ).

12A-29


M9R, and 700

12A

REMOVAL


Remove





Remove:




Unpick the bonnet opening cable (3) .

Remove:

- the clips (4) ,

- the front end panel upper mounting bolts (5) .


Mot. 1608 Torque screwdriver

Tightening torquesm

air flowmeter mountingbolts

4 Nm

air duct clip mountingbolt between the air fil-ter unit and the turbo-charger

5.5 Nm


44 Nm


21 Nm

battery tray mountingbolts

21 Nm

wiring harness moun-ting nut

8 Nm

112658

102504

12A-30


M9R, and 700

12A

Disconnect the injection computer connectors (6) .

Remove:


- the wiring harness mounting nut (8) .


Unpick the battery negative terminal wiring harness(9) .

Remove the battery tray and the injection computer.

Move the turbocharger regulation solenoid valve(10) to one side.

Remove the air duct between the air filter unit andthe turbocharger.


112659 104555

114933

12A-31


M9R, and 700

12A

Remove:

- the lower front end panel mounting bolts (12) .


Remove the air resonator (13) .



Remove the air filter unit (15)

102365

114659

115019

115020

12A-32


M9R, and 700

12A

Remove

- the air flowmeter mounting bolts (16) ,

- the air flowmeter (17) .

REFITTING


Refit the air flowmeter onto the air filter unit.

Tighten to torque the air flowmeter mounting bolts( 4 Nm ) using the (Mot. 1608) .

Refit the air filter unit.


Refit:




- the front end panel clips,


Tighten to torque:

- the air duct clip mounting bolt between the airfilter unit and the turbocharger ( 5.5 Nm ) ,

- the front end panel lower mounting bolts ( 44Nm ) ,

- the front end panel upper mounting bolts ( 21Nm ) .

Clip on:

- the air inlet scoop to the front end panel,

- the bonnet opening cable

Fit the turbocharger regulation solenoid valve ontothe air filter unit.

Refit the battery tray and the computer.

Tighten to torque the battery tray mounting bolts (21 Nm ) .

Refit the wiring harness mounting nut.

Tighten to torque the wiring harness mounting nut( 8 Nm ) .

Connect:

- the injection computer connectors,

- the air flowmeter connector,

- the connectors to the Protection and Switching Unitbox.

Refit:





114993

12A-33


K4M, and 760 or 761 – F4R, and 770 or 771 or 776

12A



Remove the battery (see 80A, Battery: Removal -Refitting ).


Remove:


- the wiring harness strap (3) .

Unclip the wiring harnesses from the battery tray.


Remove the injection computer (4) and its mounting.

Remove:

- the air inlet sleeve (5) ,

- the air ducts (6) ,


Tightening torquesm


21 Nm


4 Nm

101822

21

3

1122

101811

101737

4

6

5

6

12A-34


K4M, and 760 or 761 – F4R, and 770 or 771 or 776

12AREFITTING





WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).

12A-35


K9K, and 722 or 728 or 729

12A





Remove:






Remove:




Tightening torquesm


21 Nm


4 Nm

101822

101811

101737

12A-36


K9K, and 722 or 728 or 729

12AREFITTING






12A-37


F9Q, and 800 or 804 or 808 – K9K, and 732

12A





Remove:






Remove:




Tightening torquesm


21 Nm


4 Nm

101822

101811

101737

12A-38


F9Q, and 800 or 804 or 808 – K9K, and 732

12AREFITTING






12A-39

FUEL MIXTUREAir flowmeter: Removal - Refitting

M9R, and 700

12A

REMOVAL



Unclip:

- the turbocharger regulation solenoid valve hose (1)from the turbocharger - air filter unit air inlet duct,

- the oil vapour rebreathing duct (2) from the turbo-charger - air filter unit air inlet duct.

Unpick the turbocharger regulation solenoid valveon the air filter unit.

Disconnect the air flowmeter connector.

Move the turbocharger regulation solenoid valveand air flowmeter connector aside.

Loosen:

- the air inlet duct clip (3) on the air filter unit side,

- the air inlet duct clip on the turbocharger side.

Remove the turbocharger - air filter unit duct.


Remove:

- the air flowmeter mounting bolts (4) from the air fil-ter unit,


Mot. 1608 Torque screwdriver

Tightening torquesm

air flowmeter mountingbolts on the air filter unit

4 Nm

air inlet duct clip on theair filter unit side

5.5 Nm

air inlet duct clip on theturbocharger side

5.5 Nm

114846

114990

114993

12A-40

FUEL MIXTUREAir flowmeter: Removal - Refitting

M9R, and 700

12A- the air flowmeter (5) .

REFITTING


Refit:

- the air flowmeter,

- the bolts securing the air flowmeter.

Tighten to torque the air flowmeter mounting boltson the air filter unit ( 4 Nm ) using the (Mot. 1608) .


Refit the air filter unit - turbocharger air inlet duct.

Tighten to torque:

- the air inlet duct clip on the air filter unit side (5.5 Nm ) ,

- the air inlet duct clip on the turbocharger side (5.5 Nm ) .

Clip:

- the oil vapour rebreathing duct onto the air filter unit- turbocharger air inlet duct,

- the turbocharger regulation solenoid valve hoseonto the air filter unit - turbocharger air inlet duct,

Refit the turbocharger regulation solenoid valve ontothe air filter unit.

Connect:



Note:

Be sure not to damage the air flowmeter seal.

Replace the seal if necessary.

12A-41

FUEL MIXTUREAir inlet flap: Removal - Refitting

K9K, and 732

12A

REMOVAL





Loosen the clip and (2) and move the air inlet duct(3) to one side.


Disconnect:

- the connector (4) from the damper flap,

- the vacuum pipe from the brake servo.

Remove:

- the damper flap mounting nuts (5) ,

- the damper flap,

- the damper flap seal.

REFITTING


Refit:

- the damper flap with a new seal,

- the damper flap mounting nuts.

Tighten to torque the damper flap mounting nuts (12 Nm ) .

Connect:

- the vacuum pipe from the brake servo,

- the connector to the damper flap.


Refit the air inlet duct onto the damper flap.

Tighten the clip.

Connect:

- the connector of the air inlet pressure sensor,


Tightening torquesm

damper flap mountingnuts

12 Nm

112815

112810

12A-42


K9K, and 732

12ARefit the engine covers.

12A-43


F9Q, and 804

12A



Loosen the air inlet hose clip (1) .

Disconnect the air inlet hose,

Move the air inlet hose to one side,

Disconnect:

- the connector (2) from the damper flap,

- the turbocharging pressure sensor connector (3) .

Remove the damper flap.

REFITTING


Replace the seal.

Tighten to torque the damper flap mounting bolts( 8 Nm ) .



Tightening torquesm

damper flap mountingbolts

8 Nm


4 Nm

111887

WARNING


12A-44


M9R, and 700

12A

REMOVAL



Remove:





Remove:



Disconnect the Protection and Switching Unit con-nectors (2) .


Remove:

- the clips (4) ,

- the upper front end panel mounting bolts (5) ,

Disconnect the screen washer pipes.

Tightening torquesm

damper flap retainingstrut mounting bolts onthe inlet manifold

12 Nm

damper flap retainingstrut mounting bolts onthe exhaust gas recircu-lation solenoid valve

12 Nm

downstream intercoo-ler duct clip on the inter-cooler

5.5 Nm

downstream intercoo-ler duct clip on the dam-per flap

5.5 Nm


21 Nm


44 Nm


21 Nm

wiring harness moun-ting nut on the batterytray

8 Nm

112658

115585

12A-45


M9R, and 700

12A


Remove:




Unpick the battery negative terminal wiring harness(9) .



Disconnect the turbocharger pressure sensor con-nector (11) .

Remove the turbocharger pressure sensor mountingnut (12) on the damper flap strut.

Remove:

- the lower front end panel mounting bolts (13) .


112659

114933

115701

102365

12A-46


M9R, and 700

12A

Remove the mounting bolt (14) from the intercoolerduct (downstream) on the cooling radiator.

Loosen:

- the downstream intercooler duct clip (15) on the in-tercooler,

- the downstream intercooler duct clip (16) on thedamper flap.

Remove the downstream intercooler duct.


Disconnect the damper flap connector (17) .

Remove:

- the mounting bolts (18) from the damper flap retai-ning strut on the inlet manifold,

- the mounting bolts (19) from the damper flap retai-ning strut on the exhaust gas recirculation solenoidvalve,

- the damper flap,

- the seal between the damper flap and the exhaustgas recirculation solenoid valve

REFITTING


Replace the seal between the damper flap and theexhaust gas recirculation solenoid valve.

114649

115702

114406

12A-47


M9R, and 700


Finger tighten until contact:

- the damper flap retaining strut mounting bolts onthe inlet manifold,

- the damper flap retaining strut mounting bolts onthe exhaust gas recirculation solenoid valve,

Tighten to torque:

- the damper flap retaining strut mounting boltson the inlet manifold ( 12 Nm ) ,

- the damper flap retaining strut mounting boltson the exhaust gas recirculation solenoid valve( 12 Nm ) .

12A-48


M9R, and 700


Refit:

- the downstream intercooler duct clip onto the inter-cooler and the damper flap,

- the downstream intercooler duct mounting boltonto the cooling radiator.

Tighten to torque:

- the downstream intercooler duct clip on the in-tercooler ( 5.5 Nm ) ,

- the downstream intercooler duct clip on thedamper flap ( 5.5 Nm ) .

Refit:


- front end panel mounting bolts.

Tighten to torque:



Clip:


- the bonnet opening cable.

Refit:

- the battery tray,


- the wiring harness mounting nut onto the batterytray.

Tighten to torque:

- the battery tray mounting bolts ( 21 Nm ) ,

- the wiring harness mounting nut on the batterytray ( 8 Nm )

Clip the battery negative terminal wiring harness.

Connect:

- the screen washer pipes,

- the Protection and Switching Unit connectors,

- the injection computer connectors.

Refit:

- the clips,


- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ),




Carry out programming by following command sce-nario SC036 if replacing or removing - refitting thedamper flap (see MR 366 Fault finding, 13B, Faultfinding - Interpretation of commands ) and (seeMR 366 Fault finding, 13B, Fault finding - Repla-cement of components ).

12A-49

FUEL MIXTUREAir inlet duct: Removal - Refitting

F9Q, and 800 or 808

12A

REMOVAL

Disconnect:

- the battery, starting with the negative terminal,

- the turbocharging pressure sensor (1) .

Loosen the clip (2) .

Disconnect the air inlet hose.

Separate the air inlet hose.

Disconnect the vacuum hose from the (3)diaphragm.

Remove:

- inlet duct mounting bolts (4) ,

- the air inlet duct mounting nut (5) ,

- the air inlet duct.

Tightening torquesm

inlet duct mountingbolts

8 Nm

inlet duct nut 21 Nm

battery cover mountingbolt

4 Nm

101893

1

101892

101884

2

3

4

5

12A-50


F9Q, and 800 or 808

12AREFITTING

Replace the seal.

Refit the inlet duct.

Tighten to torque in order:

- the inlet duct mounting bolts ( 8 Nm ) ,

- the inlet duct nut ( 21 Nm ) .



Torque tighten the battery cover mounting bolt ( 4Nm ) .

101884

WARNING

carry out the necessary programming (see 80A,Battery: Removal - refitting ).

6

7

8

12A-51


F9Q, and 804

12A

REMOVAL



Disconnect:


- the pressure sensor connector (2) ,

- the inlet duct air duct (3) (4) ,

- the oil vapour rebreather pipe (5) :

• on the oil separator,

• on the turbocharger upstream air duct.

Remove:

- the inlet duct mounting bolts (6) ,


REFITTING

Replace the seals.

Refit the inlet duct.


- the inlet duct mounting bolts ( 25 Nm ) ,

- the inlet duct mounting nut ( 21 Nm ) ,




Tightening torquesm

inlet duct mountingbolts

25 Nm

inlet duct mounting nut 21 Nm


4 Nm

111887

WARNING


12A-52

FUEL MIXTUREInlet manifold: Removal - Refitting

K4J, and 730 or 732

12A

REMOVAL


Remove:

- the air filter unit (see 12A, Fuel mixture, Air filterunit ),

- the throttle valve (see 12A, Fuel mixture, Throttlevalve ).

Disconnect:

- the manifold pressure sensor (1) ,

- the ignition coils (2) ,

- the air temperature sensor (3) .


Remove:

- the plenum chamber mounting bolts,

- the plenum chamber.

REFITTING

Always replace all of the seals.


Tightening torquesm

plenum chamber moun-ting bolts

9 Nm

throttle valve bolts 13 Nm

air unit bolts 9 Nm


4 Nm

101100

3

221

101794

12A-53


K4J, and 730 or 732

12A

Tighten to torque and in order the plenum chambermounting bolts ( 9 Nm )

Tighten to torque:

- the throttle valve bolts ( 13 Nm ) ,

- the air unit bolts ( 9 Nm ) ,



101794

WARNING

Carry out the necessary programming (see 80A,Battery: Removal - Refitting

7

1

4

6

3

5

2

12A-54


F4R, and 770 or 771 – K4M, and 760 or 761

12A

REMOVAL


Remove:


- air duct (1) .

Disconnect:

- throttle valve connector (2) ,

- brake servo vacuum pipe (3) to the inlet manifold.

Disconnect fuel vapour recirculation pipe (4) to thethrottle valve.

Tightening torquesm

inlet manifold bolts 9 Nm

motorised throttle valvebolts

13 Nm


4 Nm

101807

1

102735

Note:

Do not damage the vacuum outlet on the inletmanifold. If it is damaged, the inlet manifold willneed to be replaced.

4

3

2

12A-55


F4R, and 770 or 771 – K4M, and 760 or 761

12A

Disconnect electrical wiring harness (5) .

Pull the electric wiring harness to one side.

Disconnect fuel inlet pipe (6) from the injector rail.

Unclip fuel vapour recirculation pipe (7) from the in-let manifold.

Remove the inlet manifold bolts.

ON THE WORKBENCH

Remove the throttle valve.

REFITTING

Always replace all of the seals with new ones.


Tighten to torque and in order the inlet manifoldbolts ( 9 Nm ) .

Tighten to torque the motorised throttle valvebolts ( 13 Nm ) , tightening each bolt evenly.



101795

IMPORTANT

Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.

102726

55

6

7

102726

WARNING

Carry out the necessary programming (see 80A,Battery: Removal - refitting ).

1

8

7

3

6

2

5

4

12A-56


F4R, and 776

12A

REMOVAL



Remove air duct (1) .

Remove petrol vapour rebreathing pipe (2) .

Disconnect the motorised throttle valve connector.

Remove air pipe (3) between the turbocharger andthe intercooler.

Remove:

- motorised throttle valve mounting bolts (4) ,

- the motorised throttle valve.

Disconnect:

- turbocharging pressure sensor connector (5) ,

- vacuum pipe (6) from the brake servo,

- oil vapour recirculation pipe (7) .

Tightening torquesm


21 Nm

motorised throttle valvemounting bolts

21 Nm


4 Nm

106270

106272

2

1

3

106633

106787

44

57

6

12A-57


F4R, and 776

12A

Disconnect:

- injection rail petrol supply pipe (8) ,

- the injector connectors.

Pull the electric wiring harness to one side.

Remove the inlet manifold bolts.

REFITTING



Tighten to torque the motorised throttle valvemounting bolts ( 21 Nm ) .



106271

WARNING


106337

WARNING

Be sure to replace all the sealing joints with newones when they are removed.

8

106337

WARNING


12A-58

FUEL MIXTUREInjector holder shim: Removal - Refitting

K4J, and 730 or 732

12A

REMOVAL


Remove the inlet manifold (see 12A, Fuel mixture,Inlet manifold ).

Remove injector rail protector mounting nuts (1) .


Disconnect:

- fuel supply union (2) ,

- injectors (3) ,

- pinking sensor (4) .

Remove the two injection rail bolts (5)

Pull the injection rail gently towards yourself to re-move it.

Remove:

- nut (6) securing the electrical wiring harness,

- oil gauge well (7) .

Tightening torquesm

injector holder shimmounting bolts 11 and12

25 Nm

injector holder shimmounting bolts 13 to 20

21 Nm

upper timing cover bolt 44 Nm

suspended mountingbolt

44 Nm


4 Nm

IMPORTANT


WARNING

Protect the alternator against fuel spills from therail or supply duct.

101801

1

101802

101493

2

3 43

5

6

7

12A-59


K4J, and 730 or 732

12A

Remove the injector holder shim mounting bolts.

REFITTING

The injector holder shim seal must always be repla-ced.

Insert all the mounting bolts.

Secure:

- the injector holder shim against the upper timingcover, by tightening bolt (8) by hand,

- the injector holder shim against the engine suspen-ded mounting by tightening bolt (9) by hand.

Position the injector mounting plate against thecross pieces (10) on the cylinder head cover.


- injector holder shim mounting bolts 11 and 12( 25 Nm ) ,

- injector holder shim mounting bolts 13 to 20 (21 Nm ) .

Tighten to torque:

- the upper timing cover bolt ( 44 Nm ) ,

- the suspended mounting bolt ( 44 Nm ) .

Refit the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).



Torque tighten the battery cover mounting bolts (4 Nm ) .

101792

101792

WARNING


8

9 10

11 12

1314

15

16

1718

19

20

12A-60


K4M, and 760 or 761

12A

REMOVALDisconnect the battery, starting with the negativeterminal.


Disconnect injectors (1) .


Remove:

- injector rail mounting bolts (2) ,

- the injector rail, pulling it carefully towards you.

Remove injector mounting plate mounting bolts (3) .

Tightening torquesm

bolts 5 and 6 on theinjector holder shim

25 Nm

bolts 7 to 14 on theinjector holder shim

21 Nm

suspended mountingbolt

44 Nm

upper timing cover bolt 44 Nm


4 Nm

IMPORTANT


WARNING


101810

102303

11

2

33

3

33

12A-61


K4M, and 760 or 761

12AREFITTING



Secure:

- the injector holder shim against the upper timingcover, by tightening bolt (3) by hand,

- the injector holder shim against the engine suspen-ded mounting by tightening bolt (4) by hand.


- bolts 5 and 6 on the injector holder shim ( 25Nm ) ,

- bolts 7 to 14 on the injector holder shim (21 Nm ) .

Tighten to torque:

- the suspended mounting bolt ( 44 Nm ) ,

- the upper timing cover bolt ( 44 Nm ) .




Torque tighten the battery cover mounting bolts (

4 Nm ) .

102303

WARNING


3

4

5 6

78

910

1112

13

14

12A-62


F4R, and 770 or 771

12A

REMOVAL



Remove injector rail protector mounting nuts (1) .


Disconnect:

- fuel supply union (2) ,

- injection wiring harness (3) .

Remove:

- injector rail mounting bolts (4) ,


Tightening torquesm

bolts 7 and 8 of theinjector holder shim

25 Nm

bolts 9 to 16 on theinjector holder shim

21 Nm

suspended mountingbolt 6

44 Nm

upper timing cover bolt5

44 Nm


4 Nm

IMPORTANT


WARNING


101801

1

102728

102730

3

2

4

12A-63


F4R, and 770 or 771

12A

Remove the injector holder shim mounting bolts.

REFITTING



Secure:

- the injector holder shim against the upper timingcover, by tightening bolt (5) by hand

- the injector holder shim against the suspended en-gine mounting by tightening bolt (6) by hand.


- bolts 7 and 8 of the injector holder shim ( 25Nm ) ,

- bolts 9 to 16 on the injector holder shim (21 Nm ) .

Tighten to torque:

- suspended mounting bolt 6 ( 44 Nm ) ,

- upper timing cover bolt 5 ( 44 Nm ) .





101792

101792

WARNING


10 9

87

6

5

1615

14

13

1211

12A-64

FUEL MIXTUREManifolds: Removal - Refitting

F9Q, and 800 or 808

12A

REMOVAL


Remove:

- the inlet duct (see 12A, Fuel mixture, Inlet duct ),

- the turbocharger (See 12B, Turbocharging, Tur-bocharger ).

Disconnect:

- the air inlet pipe from the damper (1) ,

- the engine stop solenoid valve (2) connector.

Remove:

- the pipe mountings (3) ,

- the vacuum canister (4) ,

- the engine stop solenoid valve (5) .

Disconnect the exhaust gas recirculation solenoidvalve.

Remove:

- the exhaust gas recirculation solenoid valve (6) ,

- the exhaust gas recirculation pipe (7)

- the engine lifting bracket (8)

- the manifold mounting nuts,

- the manifolds.

REFITTING


Replace the gaskets:

- on the manifolds,

- the exhaust gas recirculation solenoid valve,

- on the air inlet duct.

Tighten to torque:

- the Manifold mounting stud ( 8 Nm ) ,

- the manifold mounting nuts, ( 28 Nm ) ,

- the exhaust gas recirculation valve mountingbolt ( 8 Nm ) .

Tighten to torque the engine cover mounting bolts( 4 Nm ) .

Tightening torquesm

Manifold mounting stud 8 Nm

manifold mounting nuts, 28 Nm

exhaust gas recircula-tion valve mounting bolt

8 Nm

engine cover mountingbolts

4 Nm

102486

1

2

3

4

5

102478

WARNING


6

7

8

12A-65


F9Q, and 804

12A

REMOVAL


Position the vehicle on a lift.

Remove:

- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting).


- the exhaust gas recirculation unit (see 14A, Emis-sion control, Exhaust gas recirculation unit ),

- the exhaust gas recirculation pipe,

- the catalytic pre-converter (see 19B, Exhaust, Ca-talytic pre-converter: Removal - Refitting ).

- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting ).


Disconnect the exhaust gas temperature before tur-bocharger sensor (1) .

Remove:

- the manifold mounting nuts

- the exhaust manifold (2) .

Remove the inlet manifold (3) .

Tightening torquesm

manifold mountingstuds

8 Nm

manifold mounting nuts 28 Nm


4 Nm

111872

111873

12A-66


F9Q, and 804

12AREFITTING


Replace the manifold gaskets.

Refit the manifolds.

Tighten to torque:

- the manifold mounting studs ( 8 Nm ) ,

- the manifold mounting nuts ( 28 Nm ) ,

Refit:


- the exhaust gas recirculation solenoid valve (see14A, Emission control, Exhaust gas recircula-tion unit ),

- the turbocharger (see 12B, Turbocharging, Tur-bocharger ).


Refit the engine lifting bracket.


WARNING


12A-67

FUEL MIXTUREExhaust manifold: Removal - Refitting

M9R, and 700

12A

REMOVAL



Remove:




Disconnect:

- the injection computer connectors (1) ,


- the turbocharger regulation solenoid valve connec-tor.

Unclip:

- the battery negative terminal wiring harness (2) ,

- the injection computer connector wiring harness,

- the turbocharger regulation solenoid valve wiringharness.

Remove:



Unpick the wiring harness from the injection compu-ter connectors.

Remove the battery tray with the injection computermounting.

Tightening torquesm

exhaust manifold studs 9 Nm

exhaust manifoldmounting nuts

30 Nm

EGR duct mountingbolts on the EGR cooler

30 Nm

EGR duct mountingbolts on the exhaustmanifold

30 Nm

EGR duct mountingbolt on the cylinderhead

10 Nm

EGR duct heat shieldmounting bolt on thecylinder head

10 Nm

EGR duct heat shieldmounting bolt on theexhaust manifold

10 Nm

lower mounting bolts ofthe front end panel

44 Nm

upper mounting bolts ofthe front end panel

21 Nm

air inlet duct clip 5.5 Nm


21 Nm

IMPORTANT

Wear protective gloves during all operations.

112659

12A-68


M9R, and 700

12A

Loosen the air inlet duct clip (5) on the air flowmeterside.

Remove:

- the air inlet duct on the air flowmeter side,



Remove:





Remove:

- the clips (10) ,

- the upper mounting bolts (11) .


114990

114933

112658

102504

12A-69


M9R, and 700

12A

Remove:



Remove:

- the EGR duct heat shield mounting bolt (13) on theexhaust manifold,

- the EGR duct heat shield mounting bolt (14) on thecylinder head,

- the EGR duct mounting bolts (15) on the cylinderhead.

Move the EGR duct heat shield to one side.

Remove the EGR duct mounting bolts (16) on theEGR cooler.

Remove the EGR duct mounting bolts (17) on theexhaust manifold.

Move the EGR duct to one side.

Remove:

- the gasket between the EGR cooler and the EGRduct,

- the gasket between the EGR duct and the exhaustmanifold.

102365

113280

113295

113311

113281

12A-70


M9R, and 700


Remove:

- the exhaust manifold mounting nuts,

- the exhaust manifold spacers,

- the exhaust manifold,

- the exhaust manifold gasket.

REFITTING


Clean and degrease the bearing faces:

- the exhaust manifold in case of reuse,

- the cylinder head face,

- the EGR duct,

Check that the exhaust manifold studs are correctlytorque tightened (9 Nm) ; if not, replace any looseexhaust manifold studs.

Tighten to torque the exhaust manifold studs ( 9Nm ) .

Refit the new seal on the exhaust manifold.


Refit:


- the spacers.

Finger tighten the new mounting nuts until they arein contact with the exhaust manifold.

Tighten to torque and in order the exhaust manifoldmounting nuts (18 Nm) .

Tighten to torque and in order the exhaust manifoldmounting nuts ( 30 Nm ) .

113279

113279

Note:

Check that the manifold gasket is positioned cor-rectly.

The tab must be positioned as (18) .

113279

12A-71


M9R, and 700


Refit:

- the new gasket between the EGR duct and the ex-haust manifold,

- the new gasket between the EGR cooler and theEGR duct.

Finger tighten until contact:

- the EGR duct mounting bolts on the exhaust mani-fold,

- the EGR duct mounting bolts on the EGR cooler,

- the EGR duct mounting bolts on the cylinder head.

Tighten to torque:

- the EGR duct mounting bolts on the EGR cooler( 30 Nm ) ,

- the EGR duct mounting bolts on the exhaustmanifold ( 30 Nm ) ,

- the EGR duct mounting bolt on the cylinderhead ( 10 Nm ) .

Fit the heat shield.

Refit:

- the EGR duct heat shield mounting bolt to the cylin-der head,

- the EGR duct heat shield mounting bolt to the ex-haust manifold.

Tighten to torque:

- the EGR duct heat shield mounting bolt on thecylinder head ( 10 Nm ) ,

- the EGR duct heat shield mounting bolt on theexhaust manifold ( 10 Nm ) .

Refit:


- the upper mounting bolts of the front end panel,


Tighten to torque:

- the lower mounting bolts of the front end panel( 44 Nm ) ,

- the upper mounting bolts of the front end panel( 21 Nm ) .



Refit the clips.

Fit the bonnet opening cable.

Connect the Protection and Switching Unit connec-tors.

Refit:

- the Protection and Switching Unit cover,



- the air inlet duct to the air flowmeter,

- the air inlet duct clip on the air flowmeter side.

Tighten to torque the air inlet duct clip ( 5.5 Nm ) .

Refit the battery tray with the injection computermounting.

Fit the computer connector wiring harness.

Refit:

- the wiring harness mounting nut,

- the battery tray mounting bolts.


Fit:

- the turbocharger regulation solenoid valve wiringharness,

- the battery negative terminal connector wiring har-ness,

- the injection computer connector wiring harness.

Connect:

- the turbocharger regulation solenoid valve connec-tor,



Refit:




12A-72


K9K, and 722 or 728 or 729

12A

REMOVAL

Put the vehicle on a two-post lift.


Remove:

- the lifting eye (2) ,

- the air inlet metal tube (3) ,

- the turbocharger (see 12B, Turbocharging, Tur-bocharger ),

- the exhaust gas recirculation metal tube (1) ,

- the exhaust gas recirculation unit mounting bolts(4) ,

- the exhaust gas recirculation unit,

- the manifold mounting nuts (5) ,

- the manifold.


Mot. 1567 Remote operationpliers for EGR clips

Tightening torquesm

exhaust manifold studs 9 Nm


26 Nm

exhaust gas recircula-tion unit mounting bolts

21 Nm

air inlet metal tubemounting bolts

21 Nm

lifting eye 21 Nm


4 Nm

102074

1

2

3

4

55

55

12A-73


K9K, and 722 or 728 or 729

12AREFITTING

Replace the manifold gasket.

Tighten to torque the exhaust manifold studs ( 9Nm ) .

Refit the manifold.


Fit:

- the exhaust gas recirculation unit,

- the new exhaust gas recirculation unit tube,

- the new clips on the new exhaust gas recirculationunit tube.

Tighten the new clips using the (Mot. 1567) .

Tighten to torque:

- the exhaust gas recirculation unit mountingbolts ( 21 Nm ) ,

- the air inlet metal tube mounting bolts ( 21 Nm ),

- the lifting eye ( 21 Nm ) .


Refit the turbocharger (see 12B, Turbocharging,Turbocharger ).



20848-1

3

2

1

8

76

5

4

WARNING


12A-74


K4J, and 730 or 732 – K4M, and 760 or 761

12A

REMOVALPosition the vehicle on a two-post lift.


Remove the air filter unit (see 12A, Fuel mixture,Air filter unit ).


Disconnect downstream oxygen sensor (1) .

Remove:

- exhaust bracket mounting nuts (2) ,

- exhaust manifold strut (3) .



Tightening torquesm

manifold nuts. 23 ±±±± 3 Nm

heat shield bolts 10 Nm

oxygen sensors 45 Nm

mounting bolts for theexhaust pipe brackets tothe body

21 Nm

bolt on the inlet mani-fold strut

8 Nm

exhaust bracket nuts 20 Nm


4 Nm

K4J

K4M

101501

101793

Note:

Mark with a pen the position of the exhaustsilentbloc supports on the vehicle body.

1

2333

12A-75


K4J, and 730 or 732 – K4M, and 760 or 761

12A

Remove mounting bolt (4) from the exhaust pipe si-lentbloc supports on the body.

Remove mounting bolt (5) from the silencer silent-bloc bracket on the body.

Withdraw the exhaust pipe towards the rear of thevehicle.

Remove oxygen sensor (6) using tool (Mot. 1495-01) .

Remove upper heat shield (7) from the exhaust ma-nifold.

Remove:

- the nine exhaust manifold securing nuts,

- the exhaust manifold.

102116

102117

4

5

101798

101797

6

77

777

12A-76


K4J, and 730 or 732 – K4M, and 760 or 761

12AON THE WORKBENCH

Remove the lower heat shield.

REFITTING

Always replace:

- the manifold gaskets,

- the exhaust bracket gaskets,

- the manifold nuts.



- the manifold nuts. ( 23 ±±±± 3 Nm ) ,

- the heat shield bolts ( 10 Nm ) ,

- the oxygen sensors ( 45 Nm ) ,

- the mounting bolts for the exhaust pipe brac-kets to the body ( 21 Nm ) ,

- the bolt on the inlet manifold strut ( 8 Nm ) ,

- the exhaust bracket nuts ( 20 Nm ) .



101502

101797

WARNING


5

4

9

8

17

6

32

12A-77


F4R, and 770 or 771

12A

REMOVAL



Disconnect downstream oxygen sensor (1) .

Remove:

- exhaust bracket mounting nuts (2) ,

- the exhaust manifold strut (3) .

Remove mounting bolt (4) from the exhaust pipe si-lentbloc supports on the body.



Tightening torquesm

manifold nuts 18 Nm

heat shield bolts 10 Nm


mounting bolts for theexhaust pipe brackets tothe body

21 Nm

bolt on the exhaustmanifold strut on thegearbox

21 Nm



4 Nm

101501

1

101793

Note:

Mark with a pen the position of the exhaustsilentbloc supports on the vehicle body.

102116

2

3

22

4

12A-78


F4R, and 770 or 771

12A

Remove mounting bolt (5) from the silencer silent-bloc bracket on the body.


Remove oxygen sensor (6) using tool (Mot. 1495-01) .

Remove upper heat shield (7) from the exhaust ma-nifold.

Remove:



ON THE WORKBENCH

Remove the lower heat shield.

REFITTING

Always replace:

- the manifold gaskets,

102117

101798

5

7

6

7

101797

101502

12A-79


F4R, and 770 or 771

12A- the exhaust bracket gaskets,

- the manifold nuts.



- the manifold nuts ( 18 Nm ) ,

- the heat shield bolts ( 10 Nm ) ,


- the mounting bolts for the exhaust pipe brac-kets to the body ( 21 Nm ) ,

- the bolt on the exhaust manifold strut on thegearbox ( 21 Nm ) ,




101797

WARNING


3

97

25

14

6

8

12A-80


F4R, and 776

12A


Remove:

- the engine and transmission assembly (see 10A,Engine and peripherals, Engine - gearbox ),


Remove:



REFITTING

Proceed in the reverse order to removal.Tightening torquesm


20 Nm

the battery cover moun-ting bolts

4 Nm

21936

WARNING

Always replace:

- the exhaust manifold sealing ring,

- the exhaust manifold mounting nuts.

12A-81


F4R, and 776

12A


Refit:


- the engine and transmission assembly (see 10A,Engine and peripherals, Engine - gearbox ),


Tighten to torque the battery cover mountingbolts ( 4 Nm ) .

21936

WARNING


WARNING

Strict adherence to the repair procedures isrequired for the removal and refitting of the turbo-charger in order to seal the system FAILURE TOCOMPLY WITH THESE INSTRUCTIONS MAYHAVE SERIOUS SAFETY-RELATED CONSE-QUENCES .

87

65

43

2

1

12A-82


K9K, and 732

12A

REMOVAL


Put the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).




Move aside the air inlet duct between the intercoolerand the damper valve on the damper valve.

Remove the mounting bolt (3) from the damper val-ve.

Remove:




- the lifting eye mounting bolts on the timing end,

- the lifting eye on the timing end.



Tightening torquesm

exhaust manifoldmounting studs

9 Nm


26 Nm


25 Nm

exhaust gas recircula-tion rigid pipe mountingbolts

35 Nm

112815

112810

12A-83


K9K, and 732

12A

Remove the mounting bolts (4) from the injection railcover mounting bracket.

Remove:

- the clip (5) from the EGR rigid pipe using the (Mot.1567) ,

- the mounting bolts (6) from the exhaust gas recir-culation pipe,

- the exhaust gas inlet pipe .

Loosen the mounting bolts (7) on the EGR unit by afew turns.

Move the EGR unit to one side without removing it.

II - REMOVAL OF PART CONCERNED

Remove:

- the mounting nuts (8) from the exhaust manifold,


REFITTING


Always clean the joint faces thoroughly.

113475

113842

113558

113561

12A-84


K9K, and 732


Tighten to torque and in order the exhaust manifoldmounting studs ( 9 Nm ) .

Position the new exhaust manifold gasket.

Refit:


- the exhaust manifold mounting nuts.

Tighten to torque the exhaust manifold mountingnuts ( 26 Nm ) .


Fit the exhaust gas recirculation unit.

Torque tighten the exhaust gas recirculation unitmounting bolts ( 25 Nm ) .

Refit:

- the new exhaust gas recirculation rigid pipe with anew seal,

- the mounting bolts on the exhaust gas recirculationpipe,

Fit the new snap-on clip.

Tighten the bolts of the exhaust gas recirculation ri-gid pipe on the manifold until they make contact.

Adjust the exhaust gas recirculation rigid pipe in re-lation to the cooler support.

Lock the snap-on clip of the exhaust gas recircula-tion rigid pipe using the (Mot. 1567) .

Tighten to torque the exhaust gas recirculation ri-gid pipe mounting bolts ( 35 Nm ) .

Refit:

- the lifting eye mounting bolts on the timing end,

- the timing end lifting eye,

- the injection rail protector cover retaining bracketmounting bolts,

20848-1

WARNING

Ensure that you do not constrain the exhaust gasrecirculation rigid pipe before fitting the snap-onclip.

12A-85


K9K, and 732

12A- the inlet throttle valve mounting bolt,




Connect the damper valve connector.

Refit the air inlet duct between the intercooler andthe inlet throttle valve on the inlet throttle valve.

Tighten the clip on the air inlet duct.

Connect the air inlet pressure sensor connector.



12A-86

FUEL MIXTUREThrottle valve: Removal - Refitting

K4J, and 730 or 732

12A

REMOVAL


Remove air filter unit (1) (see 12A, Fuel mixture,Air filter unit ).

Disconnect:


- fuel vapour recirculation pipe (3) on the control so-lenoid valve.

Remove:

- mounting bolts (4) ,

- the throttle valve.

Equipment required

diagnostic tool

Tightening torquesm

throttle valve bolts 13 Nm

air filter unit bolts 9 Nm


4 Nm

101489

1

2

3

101800

44

12A-87


K4J, and 730 or 732

12AREFITTING


Replace the throttle valve seal each time it is remo-ved (use grease to make it easier to fit).

Tighten to torque:

- the throttle valve bolts ( 13 Nm ) ,

- the air filter unit bolts ( 9 Nm ) .



In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g r a m m i n g u s i n g c o m m a n d RZ005« Programming » .

When the ignition is switched on, the throttle valveshould go through a cycle of programming the MINand MAX throttle stop positions.

Using the diagnostic tool « CLIP » , check that theprogramming has been performed correctly ET051« Throttle stop programming » .

WARNING


12A-88


F9Q, and 800 or 808

12A

REMOVAL

Disconnect:


- turbocharging pressure sensor (1) .

Unscrew air inlet hose clip (2) .

Disconnect the air inlet hose.

Separate the air inlet hose.

Disconnect vacuum hose (3) from the diaphragm.

Remove:

- the three mounting bolts (4) ,

- the « throttle valve / diaphragm » assembly.

REFITTING


Replace the seal.

Tighten to torque the throttle valve mounting bolts( 8 Nm ) .



Tightening torquesm

throttle valve mountingbolts

8 Nm


4 Nm

101893

1

101892

WARNING


2

3

44

12A-89


K4M, and 760 or 761

12A

REMOVAL



Disconnect:



Remove:

- the four throttle valve mounting bolts (4) ,


Equipment required

diagnostic tool

Tightening torquesm


13 Nm


4 Nm

101807

1

102735

4

3

2

4

4

4

12A-90


K4M, and 760 or 761

12AREFITTING

Replace the throttle valve seal with a new one eachtime it is removed.


Tighten to torque the throttle valve mounting bolts( 13 Nm ) , tightening them evenly.



In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g r a m m i n g u s i n g c o m m a n d RZ005« Programming » .


Check using the diagnostic tool « CLIP » that theprogramming has been performed correctly ET051« Throttle stop programming » .

WARNING


12A-91


F4R, and 770 or 771 or 776

12A

REMOVAL



Remove fuel vapour recirculation pipe (2) .

Disconnect the motorised throttle valve connector.

Remove:

- motorised throttle valve mounting bolts (3) ,

- the motorised throttle valve.



Equipment required

diagnostic tool

Tightening torquesm

throttle valve mountingbolts (F4R 776)

10 Nm


13 Nm


4 Nm

F4R, and 776

106270

2

1

106633

101807

333

4

12A-92


F4R, and 770 or 771 or 776

12A

Disconnect:



Remove:

- the four throttle valve mounting bolts (7) ,


REFITTING

Replace the throttle valve seal each time it is remo-ved.


Tighten to torque the throttle valve mounting bolts(F4R 776) ( 10 Nm ) , tightening them evenly.

Tighten to torque the throttle valve mounting bolts( 13 Nm ) , tightening them evenly.



In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g ramming us ing command R Z 0 0 5« Programming » .


Using the diagnostic tool « CLIP » , check that theprogramming has been performed correctly ET051« Throttle stop programming » .

102735

5

6

7

7

WARNING


12A-93


F9Q, and 804

12A



Undo the air inlet hose clip (1) .

Disconnect the air inlet hose,

Move the air inlet hose to one side,

Disconnect:


- the turbocharging pressure sensor connector (3) .

Remove the throttle valve.

REFITTING


Replace the seal.

Torque tighten the throttle valve mounting bolts (8 Nm ) .



Tightening torquesm


8 Nm


4 Nm

111887

1

32

WARNING


12A-94

FUEL MIXTUREThrottle valve: Cleaning

F4R or K4J or K4M

12A

Remove the throttle valve (see 12A, Fuel mixture,Throttle valve ).

Remove the external O-ring seals from the throttlevalve.

Hold the throttle valve flap open manually.

Spray the cleaning product onto the inside of the val-ve until all traces of clogging disappear.

Remove the cleaning product residue and the dirt re-sidue using a cloth, part number 77 11 211 707

Equipment required

diagnostic tool

WARNING

Wear protective goggles and gloves during the ope-ration. Be sure to work in a clean environment soas not to allow any contamination of the throttlevalve.

106899

Note:

The Renault carburettor cleaning agent, partnumber 77 11 171 437 can damage the seals.

106901

WARNING

Do not apply cleaning agent, part number 77 11171 437 , to the outside of the valve, in the springhousing or on the connector.

106900

12A-95

FUEL MIXTUREThrottle valve: Cleaning

F4R or K4J or K4M

12A

Use a nozzle to direct compressed air at the edgesand outside of the throttle valve.

Refit the throttle valve (see 12A, Fuel mixture,Throttle valve ).


Using tool diagnostic tool , reinitialise the program-ming of the throttle stops via the delete commandRZ005 « Programming » .


Check, using the diagnostic tool , that this pro-gramming has been carried out using the commandET051 « Throttle stop programming » .

106902

WARNING

It is essential to replace the throttle valve O-ringseals.

Note:

If the throttle valve is dropped or receives anyother impact, it will need to be replaced.

WARNING


12A-96

FUEL MIXTUREEngine stop device

F9Q, and 800 or 808

12AI - OBJECTIVE

The system is intended to stop the engine quickly afterthe ignition is switched off.

II - DESCRIPTION

The system consists of:

- a diaphragm (1) acting on the throttle,

- a throttle (2) ,

- a solenoid valve (3) ,

- a vacuum (4) .

III - OPERATING PRINCIPLE

When the ignition is switched off, the solenoid valveconnects the vacuum and the diaphragm.

The diaphragm is submitted to the vacuum; this closesthe air inlet flap.

The engine can no longer take in air and stops runningimmediately.

101892

101894

2

1

2

1

102486

3

4

12B-1

TURBOCHARGINGTurbocharging: Precautions for repair

F9Q

12BInstructions that must be followed when turbochargers are replaced due to mechanical damage:

- damage to the bearing system,

- broken shaft,

- compressor wheel rubbing against the turbochargercasing,

- broken compressor wheel.

Damage of the kind listed above can lead to impuritiesentering the circuits to which the turbocharger is con-nected.

FOR THE AIR CIRCUIT:

- Consequences:

• swarf and metal objects in the ducts upstream anddownstream of the turbocharger,

• large volumes of oil in the air circuit (collected in theintercooler).

- Risks (after replacing the turbocharger):

• metal objects found in the compressor wheel (des-truction of turbocharger),

• engine racing (oil sucked up in the intercooler).

FOR THE LUBRICATION CIRCUIT:

- Consequences:

• swarf found in the engine oil circuit,

• circulation of swarf within the circuit.

- Risks (after replacing the turbocharger):

• premature wear on the bearing system (destructionof turbocharger).

The following must be replaced:

- intercooler,

- turbocharger upstream air duct,

- engine oil,

- oil filter,

- turbocharger oil supply and return pipes,

- all seals that have been removed.

DESCRIPTION OF OPERATION

- Replace the intercooler

- Replace the turbocharger upstream duct (see dia-gram)

- Clean the turbocharger ducts

- Drain the engine oil

- Replace the oil filter

- Replace the oil return and supply pipes and theirseals

I - INSTRUCTIONS FOR THE AIR CIRCUIT

Diagram of the air circuit

Remove intercooler (3) if the vehicle is fitted with one(refer to the Workshop Repair Manual of the vehicle af-fected 12B, Turbocharging, Intercooler ).

WARNINGMetal objects may enter the oil and air circuits as aresult of a broken turbocharger.

Failure to follow the INSTRUCTIONS listed will leadto the turbocharger breaking again.

112666

(1) air filter

(2) compressor wheel

(3) intercooler

(4) turbocharger pressure sensor

(5) inlet manifold

(6) turbine wheel

WARNING

Always replace the intercooler.

5

4

3

2

1

C

B

A6

7

12B-2


F9Q

12B

Damage to the compressor wheel results in metal ob-jects entering the air duct (A) between the air filter andthe turbocharger.

Replace the air duct (A) between the air filter and theturbocharger.

Check that there are no metal objects inside the flow-meter (7) .

Clean the ducts

Remove:

- the air circuit duct (between the turbocharger and theintercooler) for section (B) ,

- the air circuit duct (between the intercooler and the in-let manifold) for section (C) .

Remove the turbocharger pressure sensor (4) for sec-tion (C) , if the duct is fitted with one.

For ducts comprising several components:

- mark the duct (11) so that you can identify whereeach component should be positioned when refitting,

- separate all the duct components.

Clean the removed ducts one by one using a cleaning spray:

- brush as much of the duct interior as possible (onlyuse brushes with plastic bristles),

- wash the duct with plenty of cleaning liquid,

- let the cleaned duct drain by standing it up verticallyand then start cleaning the next duct.

110738 112772

112770

11

12B-3


F9Q

12B

Dry the ducts one by one using a compressed air spraygun.

For ducts comprising several components:

- assemble the components in the correct order usingthe markings (11) that you have previously made.

Refit:

- the turbocharger pressure sensor (4) for section (C) ,if the duct is fitted with one.

- the air circuit duct (between the turbocharger and theintercooler) for section (B) ,

- the air circuit duct (between the intercooler and the in-let manifold) for section (C) ,

Refit the new intercooler (3) , if the vehicle is fitted withone (refer to the Workshop Repair Manual of the vehi-cle affected 12B, Turbocharging, Intercooler ,).

II - INSTRUCTIONS FOR THE LUBRICATION CIRCUIT


Replace the oil filter.

Replace:

- the turbocharger oil supply pipe,

- the turbocharger oil return pipe(s).

112771 102480

111870

WARNING

Always replace all seals that have been removed.

12B-4


F9Q

12B

WARNING

When starting the engine:

- let the engine run at idle speed for 1 minute sothat the oil circuit pressure can reach the requiredlevel,

- accelerate several times under no load.

12B-5


M9R, and 700

12B

WARNING

With a marker, mark the position of the exhaust rub-ber mounting bush supports on the bodywork.

WARNING

- Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.

- Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Checkthat it is not leaking; if it is, replace it.

12B-6

TURBOCHARGINGTurbocharger: Removal - Refitting

K9K, and 722 or 728 or 729

12B

REMOVALPut the vehicle on a two-post lift.




Disconnect air duct (1) .

Remove air duct (2) from the turbocharger.

Disconnect:

- the turbocharger pressure sensor (3) ,

- the exhaust gas recirculation solenoid valve (4) ,

- the turbocharging duct (5) on the turbocharger,

- the pipe (6) from the turbocharging pressure regu-lation valve on the air duct.

Equipment required

diagnostic tool

Tightening torquesm

turbocharger mountingstuds on the turbochar-ger

7 Nm

turbocharger mountingstuds on the exhaustmanifold

7 Nm

turbocharger mountingnuts on the exhaustmanifold

26 Nm

turbocharger oil inletpipe union on the cylin-der head

22.5 Nm

turbocharger oil inletduct socketed bolt onthe turbocharger

22.5 Nm

turbocharger oil returnpipe mounting bolts onthe turbocharger

12 Nm

exhaust gas recircula-tion solenoid valve heatshield mounting bolts

12 Nm


4 Nm

K9K, and 722

102081

4

6

5

3

2

1

12B-7


K9K, and 722 or 728 or 729

12B

Pull out the clip.

Undo bolt (7) .


Disconnect:

- the turbocharging pressure sensor connector (9) ,

- the exhaust gas recirculation solenoid valve mani-fold (10) ,

- the turbocharging duct (11) on the turbocharger,

- the pipe from the turbocharging pressure regula-tion valve on the turbocharging pressure regulationsolenoid valve.

K9K, and 728 or 729

110325

110323

8

7

110326

11

10

9

12B-8


K9K, and 722 or 728 or 729

12B

Remove:

- the exhaust flange mountings (12) ,

- the stay mounting (13) on the catalytic converter.

Loosen the other stay mountings on the gearbox.

Remove stay (13) .

Remove mounting bolt (14) from the exhaust piperubber mounting bush support on the body.

Remove mounting bolt (15) from the silencer rubbermounting bush support on the body.


102076

Note:

Mark the position of the exhaust rubber mountingbush supports on the vehicle body with a pen.

13

1212

102116

102117

14

15

12B-9


K9K, and 722 or 728 or 729

12B

Remove:

- the catalytic converter stay (16) ,

- the four mounting nuts (17) securing the catalyticconverter to the turbocharger,

- the catalytic converter.

Remove:

- the bracket (18) ,

- the exhaust gas recirculation solenoid valve heatshield (19) .

Remove:

- the oil supply pipe (20) ,

- the oil return pipe (21) ,

- the two upper mounting nuts (22) from the turbo-charger,

- the lower mounting nut from below,

- the turbocharger.

102077

102119

16

17171717

19 18

102079

22

21

20

22

12B-10


K9K, and 722 or 728 or 729

12BREFITTING

Tighten to torque:

- the turbocharger mounting studs on the turbo-charger ( 7 Nm ) ,

- the turbocharger mounting studs on the ex-haust manifold ( 7 Nm ) .

Position the turbocharger on the exhaust manifold.

Tighten to torque the turbocharger mounting nutson the exhaust manifold ( 26 Nm ) .

Apply LOCTITE FRENTANCH to the threads of theturbocharger oil inlet pipe union on the cylinderhead.

Position the turbocharger oil supply pipe on the tur-bocharger and on the cylinder head, applying newseals in the process.

Tighten to torque:

- the turbocharger oil inlet pipe union on the cy-linder head ( 22.5 Nm ) ,

- the turbocharger oil inlet duct socketed bolt onthe turbocharger ( 22.5 Nm ) .

Position the turbocharger oil return pipe on the tur-bocharger and on the cylinder block, applying newseals in the process.

Torque tighten the turbocharger oil return pipemounting bolts on the turbocharger ( 12 Nm )

Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).


Tighten to torque the exhaust gas recirculationsolenoid valve heat shield mounting bolts ( 12Nm ) .


Before starting, disconnect the 4 injectors (startingthe engine is prohibited).

Run the starter motor until the oil pressure warninglight goes out (wait for a few seconds).

Switch off the ignition.

Reconnect the 4 injector connectors.

Start the engine.

Let the engine idle then depress the accelerator se-veral times with no load.


Make sure that there are no oil leaks.

Connect the diagnostic tool and clear the storedfaults.

Make sure that all the exhaust pipe heat shields arein place and properly secured.

Make sure that there is no contact with the underbo-dy.


WARNING

Ensure that no impurities enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Alsocheck that the sealing is perfect; if not, replace it.

WARNINGCheck that the intercooler is not full of oil. If thisis the case, remove it, rinse with a cleaning agentand then let it dry.

WARNING

Always replace:

- all the O-rings and both copper seals on the tur-bocharger oil inlet duct,

- the exhaust flange seal.

- any damaged heat shield.

WARNING


12B-11


F9Q, and 800

12B





Disconnect the turbocharger air inlet and outlet pi-pes.

Disconnect the tube (1) from the turbocharging pres-sure regulation valve control diaphragm.

Remove:

- the turbocharger oil supply pipe (2) ,

- the turbocharger oil return pipe (3) ,

- the turbocharger mounting nuts (4) ,

- the turbocharger.

Tightening torquesm

turbocharger mountingstuds

8 Nm

turbocharger union endpiece

26 Nm

turbocharger mountingnuts

26 Nm

oil supply pipe moun-ting nuts

22.5 Nm

oil supply pipe moun-ting bolt on the cylinderblock

12 Nm

turbocharger oil returnpipe mounting bolts

12 Nm


4 Nm102481

102480

12B-12


F9Q, and 800

12BREFITTING


Be sure to replace the seals:

- on the turbocharger oil supply pipe,

- on the turbocharger oil return pipe,

- the turbocharger,

WARNINGEnsure that no impurities enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale.

check that the sealing is perfect; if not, replace it.

12B-13


F9Q, and 800

12B

Always replace the end piece seal on the union (5) ,if the end piece has been removed.

Tighten to torque:

- the turbocharger mounting studs ( 8 Nm ) ,

- the turbocharger union end piece ( 26 Nm ) , ifthe studs have been removed.

Refit the turbocharger.

Tighten to torque the turbocharger mounting nuts( 26 Nm ) .

Fit the oil supply pipe:

- screw on (without tightening) the oil supply pipenuts,

- screw on (without tightening) the oil supply pipemounting bolt on the cylinder block.

Refit the oil return pipe.

Tighten to torque:

- the oil supply pipe mounting nuts ( 22.5 Nm ) ,

- the oil supply pipe mounting bolt on the cylin-der block ( 12 Nm ) ,

- the turbocharger oil return pipe mounting bolts( 12 Nm ) .




Refit the exhaust pipe, aligning it with the marks

made previously.



Check that there are no leaks:

- start the engine,

- check that the oil pressure warning light has goneout,

- let the engine run at idle speed,

- accelerate several times at no load,

- switch off the ignition,

- check that there are no oil leaks.


114467

12B-14


F4R, and 776

12B

REMOVAL


Removal of the turbocharger requires the engine tobe removed (see 10A, Engine and peripherals,Engine - Gearbox ).

Remove the catalytic converter (see 19B, Exhaust,Catalytic converter ).

Disconnect:

- the wastegate control solenoid valve pipe (1) ,

- the solenoid valve - turbocharger pipe (2) ,

- the braking solenoid valve pipe (3) .

Remove the air filter - turbocharger pipe (4) .

Fit hose clamps and remove the turbocharger coo-ling hoses (5) .

Equipment required

diagnostic tool

Tightening torquesm

bolts of the oil returnpipe towards the cylin-der block

12 Nm

turbocharger coolingduct bolts (initial torque)

12 Nm

turbocharger coolingduct bolts

27 Nm

turbocharger mountings 15 Nm + 75˚

oil supply pipe hollowmounting bolt

45 Nm

oil supply pipe union 25 Nm

oil return pipe mountingbolts

8 Nm

mounting bolts of the oilreturn and supply pipes

21 Nm

Note:

To loosen the turbocharger mounting nuts on theexhaust manifold, spray some releasing agentonto the nuts while they are still warm, justbefore removal.

21927

21928

32

1

4

55

12B-15


F4R, and 776

12B

Remove:

- the heat shield bolt (6) ,

- the engine cover mounting and the turbochargerstrut (7) ,

- the turbocharger - intercooler air pipe.

Remove the starter motor heat shield.

Remove:

- the turbocharger oil return pipe mounting bolts (8) ,

- the turbocharger oil return pipe (10) ,

- the turbocharger oil supply pipe (9) .

Remove:

- the nuts (11) securing the turbocharger to the ma-nifold,

- the turbocharger.

21929

21930

21931

21933

12B-16


F4R, and 776

12BREFITTING

The turbocharger mounting nuts and studs must bereplaced along with the seals.

On the workbench, refit and tighten to torque:

- the two bolts of the oil return pipe towards thecylinder block ( 12 Nm ) (13) ,

- the oil return pipe bolt (14) .

Pre-tighten the turbocharger cooling duct bolts(initial torque) ( 12 Nm ) (15) ,

Tighten to torque the turbocharger cooling ductbolts ( 27 Nm ) .

Fit and finger tighten:

- the turbocharger mountings on the exhaust mani-fold,

- the oil supply pipe mountings on the turbocharger,

- the return pipe to the cylinder block,

- the turbocharger - intercooler air pipe,

- the turbocharger strut mounting.

Tighten:

- the clip (16) from the intercooler - turbochargerpipe to position the turbocharger,

- the turbocharger strut (17) .

WARNING


If there has been a fault in the turbocharger,check that the intercooler is not full of oil. If this isthe case, remove it, rinse with a cleaning agentand then let it dry.

Check that the turbocharger oil return pipe is notpartially or completely blocked by scale. Alsocheck that it is perfectly sealed. If not, replace it.

22809

14

13

15

13

1521931

106273

17

16

12B-17


F4R, and 776

12B

Tighten to torque:

- the turbocharger mountings ( 15 Nm + 75˚ ) (18),

- the oil supply pipe hollow mounting bolt ( 45Nm ) (19) ,

- the oil supply pipe union ( 25 Nm ) (20) ,

- the oil return pipe mounting bolts ( 8 Nm ) (21) ,

- the mounting bolts of the oil return and supplypipes ( 21 Nm ) (22) .


All removed seals must be replaced including thoseon the cooling pipe as well as the intercooler - turbo-charger air pipe.

Fill and bleed the cooling circuit (see 19A, Cooling,Filling - Bleeding ).


21933

21931

181818

18


WARNING- Before starting the engine, connect the dia-

gnostic tool and lock the injection system.

- Run the starter motor until the oil pressure war-ning light goes out (wait a few seconds) thenunlock the injection system.

- Start the engine then accelerate with no loadseveral times.

- Switch off the ignition and check that there areno oil leaks.

- Run the engine at idle speed until the enginecooling fan starts up:

- Accelerate several times with no load then per-form a road test.

- Clear the faults using the diagnostic tool .

- Switch off the ignition and check that there areno oil leaks.

12B-18


F9Q, and 804

12B




Remove the battery.

Remove:


- the nut (2) ,

- the battery tray.

Bleed the cooling system (see 19A, Cooling, Coo-ling system: Draining - filling ).




Equipment required

diagnostic tool

Tightening torquesm


37 Nm

turbocharger oil supplypipe hollow mountingbolts

22.5 Nm

oil supply pipe hollowmounting bolt on thehousing

44 Nm

oil supply pipe moun-ting bolt on the housing

25 Nm


12 Nm


4 Nm

112659

12B-19


F9Q, and 804

12B

Remove, using the (Mot. 1448) :

- the « hose - rigid pipe assembly » (3) . betweenthe EGR cooler (4) and the water outlet unit,

- the « hose - rigid pipe assembly » (5) between theEGR coolant and the heater matrix hose.

Disconnect the upper cooling hose on the turbochar-ger.

Remove the air duct (6) from the turbocharger.

Remove the duct between the turbocharger and theair filter.

Disconnect the turbocharger (7) vacuum pipe.


111866

111860

111869

111865

12B-20


F9Q, and 804

12B

Remove the starter motor (see 16A, Starting-Char-ging, Starter motor: Removal - Refitting ).

Remove the heat shield (9) .

Remove the turbocharger oil supply pipe (10) .

Remove the turbocharger mounting nuts (11) .

111868

111867

111870

111871

12B-21


F9Q, and 804

12B

Remove the turbocharger (12) .

REFITTING


Always replace:

- the turbocharger oil supply pipe,

- the oil supply pipe hollow mounting bolts,

- the seals on the turbocharger oil return pipe,

- the seal between the turbocharger and the exhaustmanifold,

Tighten to torque:

- the turbocharger mounting nuts ( 37 Nm ) ,

- the turbocharger oil supply pipe hollow moun-ting bolts ( 22.5 Nm ) ,

- the oil supply pipe hollow mounting bolt on thehousing ( 44 Nm ) ,

- the oil supply pipe mounting bolt on the hou-sing ( 25 Nm ) ,

- the turbocharger oil return pipe ( 12 Nm ) .

Refit:

- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting ).

- the catalytic pre-converter (see 19B, Catalyticpre-converter: Removal - Refitting ).

112457

112458

WARNINGEnsure that no impurities enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Alsocheck that it is perfectly sealed. If not, replace it.

Note:

Pay attention to the direction of fitting of themanifold - turbocharger seal.

The seal tab must be on the turbocharger side.

12B-22


F9Q, and 804

12BMake sure that all the exhaust pipe heat shields arein place and properly secured.




- start the engine,






Connect the diagnostic tool and clear the storedfaults.


Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining - filling ).



12B-23


K9K, and 732

12B

REMOVAL






Pull out the clip.

Loosen the mounting bolt (1) on the air inlet rigidduct.

Move the air inlet rigid duct to one side (see (2) .

Disconnect:


- the air inlet duct (4) on the turbocharger,



Disconnect the turbocharging pressure regulationvalve hose on the regulation valve side.

Tightening torquesm


9 Nm


26 Nm

bolts mounting the oilinlet pipe on the turbo-charger

22.5 Nm

bolts mounting the oilinlet pipe on the cylinderhead

22.5 Nm

bolts mounting the oilreturn pipe on the turbo-charger

12 Nm

112811

112991

112816

12B-24


K9K, and 732

12B

Remove:

- the bolt (6) mounting the oil inlet pipe on the turbo-charger,

- the bolt mounting the oil inlet pipe on the cylinderhead,

- the oil supply pipe ,

- the oil return pipe mounting bolts,

- the oil return pipes (5) ,

- the upper mounting nuts (7) from the turbocharger,

- the lower mounting nut from the turbocharger,

- the turbocharger.

REFITTING


Always clean the joint faces thoroughly.

102079

WARNING

Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Checkthat there are no leaks. If there are, replace thepart.

WARNING

Check that the intercooler is not full of oil. If it is,remove and rinse it with the cleaning agent, thenlet it dr ip dry.

WARNING

Replace any damaged heat shield.

12B-25


K9K, and 732

12BII - REFITTING OPERATION FOR PART CONCERNED

Tighten to torque the turbocharger mountingstuds ( 9 Nm )

Fit the new turbocharger seal.

Refit:

- the turbocharger.

- the turbocharger mounting nuts.


Refit:

- the new oil inlet pipe,

- the oil inlet pipe mounting bolt on the turbocharger

- the bolt mounting the oil inlet pipe on the cylinderhead.

Tighten to torque:

- the bolts mounting the oil inlet pipe on the tur-bocharger ( 22.5 Nm ) ,

- the bolts mounting the oil inlet pipe on the cy-linder head ( 22.5 Nm )

Fit new seals on the oil return pipe.

Refit:

- the oil return pipe,

- the oil return pipe mounting bolts.

Tighten to torque the bolts mounting the oil returnpipe on the turbocharger ( 12 Nm ) .

Connect the vacuum pipe to the pressure regulationsolenoid valve on the turbocharger.

Refit:

- the oil inlet pipe on the turbocharger,

- the turbocharger oil inlet pipe union on the turbo-charger,


Connect:

- the turbocharging pressure regulation valve hose,

- the air inlet duct on the turbocharger side,

- the oil vapour rebreathing pipe on the rocker coverside.


Refit the clip on the air inlet duct if necessary.

Clip the air inlet rigid pipe on the turbocharger.

Refit the air inlet rigid duct mounting bolt.

Connect:

- the air inlet duct on the turbocharger,

- the oil vapour rebreathing pipe.




Note:

Make sure there is no contact between the cata-lytic converter and the turbocharger oil returnpipe.

12B-26


F9Q, and 808

12B

REMOVAL




Disconnect:


- the turbocharging pressure regulation valve (2) pi-pe.


Mot. 1566 Wrench for removinghigh-pressure pipes

Tightening torquesm


8 Nm


26 Nm

hollow mounting bolt onthe turbocharger oil sup-ply pipe

22.5 Nm

nut mounting the oilsupply pipe on the cylin-der block

22.5 Nm

bolt mounting the oilsupply pipe on the cylin-der block

25 Nm


12 Nm


8 Nm

turbocharger union endpiece

26 Nm


26 Nm

oil supply pipe moun-ting nut on the turbo-charger side

22.5 Nm

oil supply pipe moun-ting nut on the cylinderblock

22.5 Nm


12 Nm


4 Nm

104424

12B-27


F9Q, and 808

12B

Disconnect the turbocharger air inlet and outlet pi-pes (3) .


I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE)

Remove:

- the mounting bolt (4) from the oil supply pipe,

- the hollow mounting bolt (5) from the oil supply pipeunion on the turbocharger.

Loosen the union (6) on the cylinder block.

Remove the oil supply pipe by passing it through theturbocharger wheels.

Remove:



- the turbocharger bracket mounting nuts,

- the turbocharger.

104421

Note:

During factory fitting, 2 types of oil supply pipecan be fitted to the turbocharger.

The way in which a turbocharger is removeddepends on the type of pipe.

114207

12B-28


F9Q, and 808

12BII - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)

Remove the bolt (7) mounting the oil supply pipe tothe cylinder block.

Undo the oil supply pipe unions on:

- the cylinder block,

- the turbocharger (8) using the (Mot. 1566) .

Remove the turbocharger oil supply pipe.

Remove:



- the turbocharger bracket mounting nuts,

- the turbocharger.

In the event that the oil supply pipe is replaced:

- remove the oil supply union end piece (9) . Thisstep prepares the turbocharger for the supply pipeto be refitted with the hollow bolt union.

REFITTING


Always replace:

- the oil supply pipe with hollow bolt union on the tur-bocharger side (depending on version),

- the oil supply pipe seals with nut unions on the tur-bocharger side (depending on version),

- the seals on the turbocharger oil return pipe,

104417

Note:

There is only one supply pipe part numberavailable as a replacement part. Only the oil sup-ply pipe with a hollow bolt union is available.

114467

Note:

During factory fitting, 2 types of oil supply pipecan be fitted to the turbocharger.

The way in which a turbocharger is refitteddepends on the type of pipe.

WARNING


Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale.

Also check that it is perfectly sealed. If not,replace it.

12B-29


F9Q, and 808

12B- the turbocharger seals.

I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE)

Tighten to torque the turbocharger mountingstuds ( 8 Nm ) .




- screw on (without tightening) the oil supply unionmounting nut on the cylinder block,

- screw on (without tightening) the supply pipe hol-low mounting bolt,



Tighten to torque:

- the hollow mounting bolt on the turbochargeroil supply pipe ( 22.5 Nm ) ,

- the nut mounting the oil supply pipe on the cy-linder block ( 22.5 Nm ) ,

- the bolt mounting the oil supply pipe on the cy-linder block ( 25 Nm )

- the turbocharger oil return pipe mounting bolts( 12 Nm ) .

II - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)

Always replace the end piece seal on the union (10), if the end piece has been removed.

Tighten to torque:

- the turbocharger mounting studs ( 8 Nm ) ,

- the turbocharger union end piece ( 26 Nm ) , if ithas been removed.




- screw on (without tightening) the oil supply pipemounting nuts,



Tighten to torque:

- using the tool, the oil supply pipe mounting nuton the turbocharger side ( 22.5 Nm ) ,

- the oil supply pipe mounting nut on the cylinderblock ( 22.5 Nm ) ,

- the turbocharger oil return pipe mounting bolts( 12 Nm )

III - CONTINUATION OF REFITTING PROCEDURE


114467

12B-30


F9Q, and 808

12BTo refit, proceed in the reverse order to removal.


Refit the exhaust pipe, aligning it with the marksmade previously.




- start the engine,







12B-31


M9R, and 700

12BREMOVAL





Remove:

- the bolts (1) mounting the oil pipe on the turbochar-ger,

- the oil pipe mounting bolts (2) on the cylinder block,

- the hollow bolt (3) securing the turbocharger oilpipe to the cylinder block,

- the turbocharger oil pipe.

Equipment required

roller-type stud removal tool

tweezers

diagnostic tool

Tightening torquesm

stud on the exhaustmanifold

9 Nm

studs on the turbochar-ger

14.5 Nm

turbocharger strutmounting bolt on theflywheel end

25 Nm

lower mounting nuts onthe turbocharger

28 Nm

upper mounting nut onthe turbocharger

28 Nm

turbocharger transversemounting bolt

25 Nm

turbocharger strutmounting bolt on thetiming side

25 Nm

air inlet duct mountingbolts

8 Nm

air inlet duct clip on theturbocharger side

5.5 Nm

bolts mounting the oilpipe on the turbochar-ger

10 Nm

hollow bolt securing theoil pipe on the cylinderblock

16 Nm

bolt mounting the oilpipe on the cylinderblock

25 Nm

IMPORTANT

Wear protective gloves during the operation.

114982

12B-32


M9R, and 700

12B

Remove the lower mounting nuts (4) from the turbo-charger.

Disconnect:

- the hose (5) from the turbocharging pressure regu-lator on the control diaphragm,

- the oil vapour rebreathing hose (6) on the oil sepa-rator.

Loosen the air duct clip on the turbocharger side.

Disconnect the air inlet duct on the turbocharger si-de.

Rotate the air duct retaining clip (7) on the turbo-charger.

Remove the mounting bolts (8) for the air duct on theinlet manifold.

Move to one side the air duct towards the intercoo-ler.

113277

114846

113282

113155

12B-33


M9R, and 700

12BII - OPERATION FOR REMOVAL OF PART CONCERNED

Remove:

- the turbocharger upper mounting nut (9) on the ex-haust manifold,

- the turbocharger mounting bolt (10) ,

- the turbocharger.

- the gasket between the turbocharger and the ex-haust manifold.

Remove:

- the mounting bolts (11) from the turbocharger strut,

- the turbocharger strut.

REFITTING



- of the exhaust manifold,

- of the turbocharger if reused.

Remove the stud on the exhaust manifold using aroller-type stud removal tool .

Refit a new stud to the exhaust manifold using a rol-ler-type stud removal tool .

Tighten to torque the stud on the exhaust mani-fold ( 9 Nm ) .

Remove the turbocharger studs in the event that theturbocharger is reused.

Refit the new studs on the turbocharger in the eventthat the turbocharger is reused.

Tighten to torque the studs on the turbocharger (14.5 Nm ) .

Remove the air inlet duct seal at the turbochargeroutlet using a tweezers .

113277

114471

115068

12B-34


M9R, and 700

12B

Refit the new seal to the turbocharger air inlet duct.

115069

Note:

Check that the turbocharger air inlet duct seal(12) is fitted in the correct direction.

12B-35


M9R, and 700


Fit the new turbocharger strut.

Finger tighten the mounting bolts (13) and (14) of theturbocharger strut.

Fit the turbocharger without its seal and hold the tur-bocharger flat against the exhaust manifold.

Move the turbocharger strut until it is against the tur-bocharger at the flywheel end.

Gently tighten the turbocharger strut mounting bolton the timing end (13) .

Move the turbocharger to one side.

Tighten to torque the turbocharger strut mountingbolt on the flywheel end ( 25 Nm ) (14) .

Fit a new seal between the turbocharger and the ex-haust manifold.


Finger tighten the new turbocharger transversemounting bolt by a few turns.

Tighten until contact is made:

- the new upper mounting nut on the turbocharger,

- the new lower mounting nuts on the turbocharger.

Tighten to torque:

- the lower mounting nuts on the turbocharger (28 Nm ) ,

- the upper mounting nut on the turbocharger (28 Nm ) .

Undo the turbocharger strut mounting bolt on the ti-ming end (13) .

Tighten to torque:

- the turbocharger transverse mounting bolt ( 25Nm ) ,

- the turbocharger strut mounting bolt on the ti-ming side ( 25 Nm ) (13) .


Rotate the retaining clip of the air inlet duct to refitthe retaining clip in its recess.

Clip the air inlet duct on to the turbocharger.

Refit the air inlet duct mounting bolts on the inlet ma-nifold.

Tighten to torque the air inlet duct mounting bolts( 8 Nm ) .

Connect:

- the air inlet duct to the turbocharger,

- the oil vapour rebreathing hose to the oil separator.

Tighten to torque the air inlet duct clip on the tur-bocharger side ( 5.5 Nm ) .

Connect the turbocharging pressure regulator on thecontrol diaphragm.

114471

WARNING

The turbocharger strut must move freely.

WARNING

Do not tighten the bolt too quickly to prevent theturbocharger strut from rotating.

12B-36


M9R, and 700

12B

Lubricate the new turbocharger oil pipe O-ring onthe cylinder block side.

Remove the protective plug from the oil supply unionon the cylinder block side.

Fit the turbocharger oil pipe, first positioning it in thecylinder block (14) .

Finger tighten:

- the bolts (15) mounting the oil pipe on the turbo-charger,

- the oil pipe hollow bolt (16) on the cylinder block,

- the bolts (17) mounting the oil pipe on the cylinderblock.

Tighten to torque:

- the bolts mounting the oil pipe on the turbo-charger ( 10 Nm ) (15) ,

- the hollow bolt securing the oil pipe on the cy-linder block ( 16 Nm ) (16) ,

- the bolt mounting the oil pipe on the cylinderblock ( 25 Nm ) (17) .



114982

WARNING

Check for the gasket between the turbochargerand the turbocharger oil pipe.

WARNING

Do not rotate the turbocharger oil pipe O-ring onthe cylinder block side when inserting.

After fitting, check that the turbocharger oil pipeO-ring, on the cylinder block side, has not comeout of its housing.

Check for two copper seals on the oil supplyunion on the cylinder block side.

WARNING

Disconnect the injection rail pressure regulatorconnector (disables engine starting).

Run the starter motor until the oil pressure war-ning light goes out (do this for a few seconds).


Connect the injection rail pressure regulator con-nector.

Start the engine.

Let the engine idle then depress the acceleratorseveral times under no load.


Make sure that there are no oil leaks.

Connect the diagnostic tool and clear the sto-red faults.

12B-37

TURBOCHARGINGPressure regulator: Checking

K9K, and 722 or 724 or 728 or 729 or 732

12B

TURBOCHARGING PRESSURE REGULATION VALVE

1 - Check

Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger ).

Use a magnetic holder fitted with a dial gauge loca-ted at the end of the regulation valve rod (as far aspossible on the rod shaft).

Gradually apply pressure to the regulation valveusing the pressure and vacuum pump.

2 - Value

For a pressure value of 1.4 bar , the rod movementmust be 4.3 mm .

3 - Check




4 - Value

For a vacuum value of 0.6 bar , the rod movementmust be 7 mm ±±±± 0.5 .

WARNING

It is strictly prohibited to adjust the turbochargingpressure regulation valve rod in the turbocharger.

K9K, and 722

21869

Note:

The check cannot be carried out with the turbo-charger in place.

K9K, and 724

21869

Note:


12B-38


K9K, and 722 or 724 or 728 or 729 or 732

12B

5 - Check


Use a feeler gauge between the regulation valve rodand the stop (as far as possible into the rod shaft).


6 - Value

For a vacuum value of 0.5 bar , the rod movementmust be 1.7 mm .

K9K, and 728 or 729 or 732

110748

Note:


12B-39


F9Q, and 800 or 808

12B

TURBOCHARGING PRESSURE CONTROL VALVE

1 - CHECKING

Remove the turbocharger (See 12B, Turbochar-ging, Turbocharger ).

Use a magnetic holder fitted with a dial gauge pla-ced on the end of the control valve stem (as far aspossible in the axis of the stem).

Gradually apply pressure to the regulation valveusing a vacuum/pressure pump.

2 - Value

For a pressure value of 265 mbar , the stem move-ment must be between 0.5 and 3.5 mm .

For a vacuum value greater than 600 mbar , thestem is at the stop.

WARNING

Adjusting the turbocharger pressure regulationvalve rod is strictly prohibited.

21869

Note:

The turbocharger cannot be tested in situ.

12B-40


F4R, and 776

12B


1 - CHECKING

Remove the turbocharger (See 12B, Turbochar-ging, Turbocharger ).

Use a magnetic holder fitted with a dial gauge pla-ced on the end of the control valve stem (as far aspossible in the axis of the stem).

Gradually apply pressure to the regulation valveusing a vacuum/pressure pump.

2 - Value

For a pressure value of 331 mbar , the stem move-ment should be 1 mm .

For a pressure value of 544 mbar , the stem move-ment must be 5 mm .

WARNING

Adjusting the turbocharger pressure regulationvalve rod is strictly prohibited.

22807

Note:

The turbocharger cannot be tested in situ.

12B-41


F9Q, and 804

12B


1 - Checking


Connect a pressure and vacuum pump (1) to thepressure regulator (2) .


Gradually apply a vacuum to the pressure regulatorusing the pressure and vacuum pump.

2 - Value

Test points:

- For a pressure value of 200 mbar , the rod move-ment should be between 2 and 4 mm .

- for a pressure value of 550 mbar , the rod move-ment should be between 8 and 11 mm. .

WARNING

It is strictly prohibited to adjust the turbochargingpressure regulation valve rod in the turbocharger.

21869

Note:


12B-42


M9R, and 700

12B

TURBOCHARGING PRESSURE REGULATOR

1 - Check

Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger: Removal - Refitting ).

Connect a pressure-vacuum pump (1) to the pressu-re regulator (2) .


Gradually apply a vacuum to the pressure regulatorusing the pressure-vacuum pump.

2 - Value

Test points:

- For a vacuum value of 250 mbar , the rod move-ment should be between 3 and 6 mm .

- for a vacuum value greater than 600 mbar , the rodshould not move.

WARNING

The turbocharging pressure regulator rod must notbe adjusted.

21869

Note:


12B-43

TURBOCHARGINGTurbocharging pressure regulation valve

F9Q, and 800 or 808

12B

The turbocharging pressure regulation valvediaphragm (1) is controlled by a solenoid valve (2)which is in turn controlled by the injection computer.This solenoid valve varies the vacuum as a function ofthe engine operating ranges, which allows the turbo-charging pressure to be regulated.

The turbocharging pressure regulation valve is open inthe rest position. The engine operates as normally as-pirated.

The solenoid valve, closed in the rest position, is sup-plied after the engine is started following a delay whichvaries according to the coolant temperature.

WARNING

If the turbocharger solenoid valve is removed, it isessential to mark the supply and return pipes onthe solenoid valve.

102480

101889

2

1

2

103128

Shaft Description

X Time in seconds

Y Coolant temperature in ˚C

12B-44


F4R, and 776

12B

Pressure regulation valve diaphragm (1) is controlledby a solenoid valve (2) , which is in turn controlled bythe injection computer.

The pressure adjustment valve is closed at rest posi-tion.

Solenoid valve (2) is open in the rest position.

In the open position, solenoid valve (2) compares theturbocharger outlet (turbocharging pressure) anddiaphragm (1) .

Because of this, the turbocharging pressure acts di-rectly on the diaphragm and the pressure adjustmentvalve opens.

When solenoid valve (2) is controlled, the turbochar-ging pressure signal (taken at the turbocharger outlet)is diverted to the turbocharger inlet. Consequently, thediaphragm is not submitted to turbocharging pressure,the pressure adjustment valve closes.

The solenoid valve is open at rest and is energisedwhen the engine is started. However, during a timedperiod which depends on coolant temperature, the tur-bocharging pressure is limited and the engine speedcannot exceed 2500 rpm.

This ensures that the oil has sufficient time to reach theturbocharger bearings.

21927

2

1

107010

Shaft Description

X Time in seconds


12B-45


K9K, and 728 or 732

12B

The turbocharging pressure regulation valvediaphragm (1) is controlled by a turbocharging pressu-re regulator solenoid valve (2) attached to a bracketfixed onto the air filter unit. This solenoid valve is con-trolled by the injection computer.

This solenoid valve may, according to engine operatingranges, vary the vacuum pressure used to regulate theturbocharging pressure delivered by a variable geo-metry turbocharger.

The pressure regulation valve is open in the rest posi-tion; the engine is therefore naturally aspirated.

The turbocharging pressure regulation solenoid valveis closed in the rest position; it is powered once the en-gine is started and a delay according to the coolanttemperature.

114184

114185

WARNING

When removing the turbocharging pressure regula-tion solenoid valve, it is essential to mark the supplyand return pipes on the solenoid valve.

12B-46

TURBOCHARGINGIntercooler: Removal - Refitting

K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700

12BREMOVAL




Remove:




Remove the Protection and Switching Unit covermounting bolts (1) .



Tightening torquesm


5.5 Nm

intercooler upstreamhose clip

5.5 Nm


5.5 Nm


21 Nm


44 Nm


21 Nm


8 Nm

WARNING



- do not use a degreaser, brake cleaning product orany other product,


- replace the clip in the same position if the hose isnot replaced,


- always replace the hose and/or the intercooler ifthey have been damaged.

There is a danger of leakage and dislocation if thisprocedure is not followed.

F9Q, and 804 – K9K, and 732 – M9R, and 700

112658

12B-47



12B

Remove the Protection and Switching Unit cover.



Remove:

- the clips (4) ,

- the upper mounting bolts (5) of the front end panel,





Remove:



Undo the hose clip (8) upstream of the intercooler.

Disconnect the hose upstream of the intercooler.

102504

M9R, and 700

114933

102473

12B-48



12B

Remove the intercooler downstream duct mountingbolt (9) on the cooling radiator.

Loosen:

- the intercooler downstream duct clip (10) on the in-tercooler,


Loosen the intercooler downstream duct clip (11) onthe intercooler.

Move the intercooler downstream duct away fromthe intercooler.

Remove the intercooler.

REFITTING


M9R, and 700

114649

102474

WARNING

If there has been a fault in the turbocharger,check that the intercooler is not full of oil.

In this is the case:

- remove the intercooler.

- rinse the intercooler with a cleaning agent,

- allow the intercooler to drain.

12B-49




Connect:

- the intercooler upstream hose,

- the intercooler downstream duct onto the intercoo-ler.

Tighten to torque:


- the intercooler upstream hose clip ( 5.5 Nm ) .

Refit the intercooler downstream duct mounting boltonto the cooling radiator.

Tighten to torque the intercooler downstream ductclip on the damper valve ( 5.5 Nm ) .


Refit:



Tighten to torque:




Clip on the bonnet opening cable.

Refit:

- the battery tray,


- the wiring harness mounting nut on the battery tray.

Tighten to torque:



Clip on the battery terminal wiring harness.

Connect:




Refit the Protection and Switching Unit cover.

Refit the Protection and Switching Unit cover moun-ting bolts.

Refit:

- the clips,






M9R, and 700

M9R, and 700

M9R, and 700

Note:

You must initialise the xenon bulb system (if fittedto the vehicle).

12B-50


B84 or C84, and F4R, and 774

12B

REMOVAL


Remove:

- the front bumper,

- the headlights.

Remove the air deflectors (1) .

Disconnect the inlet (2) and outlet (3) ducts from theintercooler.

Tightening torquesm


4 Nm

102476

102474

102473

12B-51



12B

Lift the intercooler upwards to release it from themounting brackets (4) .

REFITTING

Check that the intercooler is not full of oil.

If it is, it must be rinsed with a cleaning agent andthen left to drain properly.




102475

13A-1

FUEL SUPPLYPetrol supply circuit

F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761

13AOperating diagram of the fuel supply circuit

The fuel system does not have a return.

The fuel pressure does not vary with engine load.

The circuit comprises:

- a rail (1) without a union to return pipes and without asupply pressure regulator,

- a single pipe (2) coming from the tank,

- from a supply assembly « pump - dipstick - fuel filter »fitted with a pressure regulator (3) , pump (4) and fuelfilter (5) (all located in the reservoir),

- a fuel vapour recirculation tank (6) .

19310

3

2

1

6

5

4

13A-2

FUEL SUPPLYDiesel fuel supply circuit

C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732

13AOperating diagram of the diesel fuel supply circuit


- a gauge (1) ,

- a manual priming pump (2) ,

- a fuel filter (3) that may be fitted with a water detectionsensor,

- a high-pressure pump (4) with a built-in mechanicallow-pressure pump (transfer pump),

- a fuel flow actuator (5) ,

- an injector rail (6) fitted with a diesel pressure sensor(7) ,

- four solenoid injectors (8) fitted with discharge valves,

- a Venturi tube (9) ,

- various sensors,

- an injection computer.

102847

IMPORTANT

Loosening a high-pressure pipe union when theengine is running is strictly prohibited.

WARNING

It is not permitted to remove the pressure sensorfrom the fuel rail (because this may cause circuitcontamination problems). If the pressure sensorfails, the pressure sensor, the rail and the five high-pressure pipes must be replaced.

K9K, and 722 or 728 or 729

WARNING

Dismantling the interior of the high-pressure pumpand the injectors is prohibited. DELPHI Only theflow actuator, the diesel fuel temperature sensorand the Venturi tube can be replaced.

13A-3


C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732

13A

K9K, and 732

WARNING

Removing the flow regulator solenoid valve and thepressure regulating solenoid valve from the high-pressure pump is prohibited. SIEMENS .

13A-4


F9Q, and 800

13AOperating diagram of the fuel supply circuit


- a priming bulb (1) (located in the engine compart-ment),

- a fuel filter (2) that may be fitted with a water detectionsensor,

- a high-pressure regulator (3) mounted on the pump,

- a high-pressure pump (4) ,

- an injection rail (5) fitted with a diesel pressure sensorand a pressure limiter (6) ,

- four solenoid injectors (7) ,

- various sensors,


100821

654321 7

IMPORTANT

It is strictly forbidden to uncouple a high-pressurepipe union when the engine is running.

WARNING

Dismantling the interior of a high-pressure pump orthe injectors is prohibited.

13A-5


F9Q, and 800 or 804 or 808

13AOperating diagram of the diesel fuel supply circuit


- a gauge (1)

- a manual priming pump, (2)

- a diesel filter (3) consisting of:

• a fuel heater,

• a water detection sensor (4) , depending on the ver-sion,

- a high-pressure pump (5) consisting of:

• a mechanical low-pressure pump,

• a pressure regulator, (6)

- an injector rail (7) fitted with a pressure regulator (8) ,

- four solenoid injectors (9) ,

- a diesel fuel temperature sensor (10) for the diesel re-turn circuit,


102307

IMPORTANT


WARNING

Dismantling the interior of the high-pressure pumpand the injectors is prohibited.

Outside the warranty period for the pump, only thepump pressure regulator can be replaced.

During the pump warranty period, the high-pressurepump should be completely replaced if the pressureregulator fails.

13A-6

FUEL SUPPLYPetrol filter: General information


13A

The fuel filter is located in the fuel tank; it is built intothe « pump-sender-filter » assembly and cannot be re-moved.

The filter is intended to have a long service life.

Checking the fuel supply pressure and the pump deli-very rate is the equivalent of running fault finding on the« pump-sender-filter » assembly.

102299

WARNING

The « pump-sender-filter » assembly must be repla-ced if one of the components is faulty.

13A-7

FUEL SUPPLYDiesel filter: Removal - Refitting

K9K, and 722 or 728 or 729

13A

Order a set of blanking plugs, part number 77 01 206804 .


Remove:


- the wheel arch liner mounting bolts (1) .

- the wheel arch liner clips using an unclipping tool,

- the wheel arch liner (2) ,

- the right-hand engine side cover,

- the diesel filter from its mounting by pushing itupwards.

Disconnect all the filter pipe unions.

Place blanking plugs over the open fuel supply pi-pes.

Remove the diesel filter.

REFITTING

Take the blanking plugs off the fuel supply pipes.

Reconnect the pipe unions.

Clip the diesel filter onto the mounting.

Tightening torquesm

wheel bolts 110 Nm

WARNING

Follow the cleanliness instructions closely (see13B, Diesel injection, Cleanliness guidelines ).

The cartr idge assembly must be replaced (the die-sel filter is contained in a non-removable cartridge).

101539

WARNING

Keep the pipe unions away from contaminatedareas.

13A-8


K9K, and 722 or 728 or 729

13A

Prime the fuel system with the priming pump (3)(automatic degassing).




102124

WARNING


21749

Regular ly bleed out the water in the diesel filtervia the bleed plug (4) .

Some vehicles have a sensor for detecting waterin the diesel fuel (5) , located on the filter. If wateris detected in the circuit, the injection fault war-ning light on the instrument panel comes on.

13A-9


F9Q, and 800 or 804 or 808

13A

The diesel filter is located behind the right-hand headli-ght. It is contained in a removable cartridge. This car-tridge has a built-in diesel fuel heater, comprising aresistor and temperature switch.

REMOVAL


Remove:


- the wheel arch liner mounting bolts (1) ,

- the wheel arch liner clips using an unclipping tool,

- the wheel arch liner (2) .

Unclip the diesel filter from its mounting by pushing itupwards.

Tightening torquesm


4 Nm

wheel bolts 110 Nm

IMPORTANT


- watch out for diesel fuel splashing when discon-necting the supply union,

- order the special high pressure injection circuitplug kit.

WARNING

- Protect sensitive areas from fuel leakage.

- Strictly observe the cleanliness guidelines.

Note:

Remove the diesel filter assembly to remove thecartr idge.

101539

104560

13A-10


F9Q, and 800 or 804 or 808

13A

Disconnect the diesel heater connector (3) from thediesel heater.

Disconnect from the diesel filter:

- the pipe (4) coming from the tank,

- the engine supply pipe (5) .

fit plugs to the pipes and filter.

Remove the diesel filter.

Mark the position of the diesel filter cover in relationto the bowl (6) .

Remove the mounting bolt (7) from the cover on thebowl.

Open the diesel filter and replace:

- the filter element,

- the seal,

REFITTING

Always replace the filter element O-ring.

Refit the cover over the bowl.

Tighten the mounting bolt on the cover over thebowl.

Clip the diesel filter onto the mounting.

Reconnect to the diesel filter:

- the fuel supply pipes,

- the diesel fuel heater connector,

102477

WARNING

Keep the pipe unions away from contaminatedareas.

19317

WARNING

Align the marking on the cover, fitted with blan-king plugs, with the marking on the bowl.

13A-11


F9Q, and 800 or 804 or 808

13A

Reprime the supply circuit:

- Turn the air bleed screw (8) 360 degrees,

- operate the manual priming pump (9) until the fuelruns without air bubbles,

- retighten the bleed screw (8) ,

- operate the manual priming pump (9) one last time.





19317

102124

WARNING


Note:

Regular ly bleed out water that has accumulatedin the diesel filter through the bleed plug.

Some vehicles have a sensor for detecting waterin the diesel fuel, located in the diesel filter. Ifwater is detected in the circuit, the injection faultwarning light on the instrument panel comes on.

13A-12


K9K, and 724 or 732 – M9R, and 700

13A

REMOVAL




Remove:


- the front right-hand wheel arch liner (1) .


Remove the diesel filter from its mounting on thebody by pushing the « filter - metal strap » assemblyupwards.

Disconnect all the fuel pipe unions on the diesel fil-ter.

Remove the diesel filter from the vehicle.

REFITTING


Connect the fuel pipes onto the new diesel filter.

Tightening torquesm

wheel bolts 110 Nm

WARNING

During this operation:

- refrain from smoking or bringing red hot objectsclose to the working area,

- beware of fuel splashes when disconnecting theunion,

- protect sensitive areas from fuel outflow.

Note:

Make sure you have a new diesel filter before ope-ning the fuel circuit.

104544

114559

Note:

Make preparations for the fuel outflow.

WARNING

Prevent the hose unions from coming into con-tact with a polluted environment.

Note:

Only use wipes part number 77 11 211 707 toclean the filter and pipes once the fuel circuit isopened.

13A-13


K9K, and 724 or 732 – M9R, and 700

13ARefit the « filter - metal strap » assembly on itsmounting on the body.


Prime the fuel circuit using the manual priming pump(2) (automatic degassing).

Check there are no leaks from the unions on the fil-ter.

Refit:





Note:

Check that the filter is correctly positioned andsecure in its mounting by shaking it: the filtermust not move.

If necessary, remove the filter and gentlysqueeze the metal strap retaining bracket on itsmounting.

102124

Note:

Regularly bleed out water that has accumulatedin the diesel filter through the bleed plug.

Some vehicles have a sensor for detecting waterin the diesel fuel, located at the bottom of the fil-ter. If water is detected in the circuit, a fault war-ning light on the instrument panel comes on.

13A-14

FUEL SUPPLYInjector rail - Injectors: Removal - Refitting

K4M, and 760 or 761

13A

The injectors are secured to the injector rail by clips.

The fuel circulates constantly around the circumferen-ce of the injector body. This sweeping by the fuel pre-vents the formation of petrol vapour bubbles and helpswarm starting.


Remove:


- the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).

Disconnect injector electrical harness (1) .

Remove:

- the two injector rail mounting bolts (2) ,


ON THE WORKBENCH

Remove:

- injector clips (3) ,

- injectors (4) .

Tightening torquesm

injector rail mountingbolts

9 Nm


4 Nm

IMPORTANT


WARNING


101810

101816

2

1

34

13A-15


K4M, and 760 or 761

13AREFITTING

Fit the injector rail.

Torque tighten the injector rail mounting bolts ( 9Nm ) .




WARNINGThe O-rings and the injector mounting clips mustalways be replaced with new ones.

WARNING


13A-16


B84 or C84 or G84, and K4J, and 730 or 732

13A





Remove mounting nuts (1) from the injection rail pro-tector.


Disconnect:

- fuel supply pipe (2)

- injector and pinking sensor electrical harness (3) .

Remove:



Tightening torquesm


9 Nm


4 Nm

101801

1

101802

IMPORTANT


WARNING


101493

332

4

13A-17


B84 or C84 or G84, and K4J, and 730 or 732

13AON THE WORKBENCH

Remove:


- injectors (6) .

REFITTING






101492

WARNING

The O-rings and the injector mounting clips mustalways be replaced with new ones.

WARNING


56

13A-18


F4R, and 770 or 771 or 776

13A





Remove the two injection rail guard mounting nuts(1) .


Disconnect:

- fuel supply pipe (2) ,

- injector and pinking sensor electrical harness (3) .

Disconnect:

- turbocharging pressure sensor connector (4)

- the vacuum pipe from brake servo (5) ,

- oil vapour recirculation pipe (6) .

Tightening torquesm


9 Nm


4 Nm

F4R, and 770 or 771

101801

11

102728

F4R, and 776

106787

3

2

5

4

6

13A-19


F4R, and 770 or 771 or 776

13A

Disconnect fuel supply pipe (7) from the injector rail.

Remove:



ON THE WORKBENCH

Remove:


- injectors (10) .

REFITTING





Torque tighten the battery cover mounting bolts (4 Nm )

106271

IMPORTANT

Be careful of petrol splashing out when discon-necting the fuel supply union.

WARNING

Protect sensitive areas from fuel spillage.

102730

7

88

102737

WARNING

The O-rings and the injector mounting clips mustalways be replaced with new ones.

WARNING


9

10

13A-20

FUEL SUPPLYElectric fuel: Checking

K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776

13A

Disconnect the petrol inlet pipe from the injectionrail.

Disconnect the petrol inlet pipe from the injectionrail.

Connect:

- pipe (1) fitted with a pressure gauge and located intest kit (Mot. 1311-01) , to the « T » union of tool(Mot. 1311-08) (2) ,

- the « T » union to the rail,

- petrol inlet pipe (3) to the « T » union.

Insert pipe (1) into a 2000 ml measuring cylinder.

Remove the Protection and Switching Unit cover.


Mot. 1311-01 Fuel pressure test kit

Mot. 1311-08 Union for measuringfuel pressure

IMPORTANT

During this operation, be sure to:

- refrain from smoking or bringing hot objects closeto the working area,



K4J, and 730 or 732 – F4R, and 770 or 771 or 776

101496

12

3

K4M, and 760 or 761

101803

IMPORTANT

This procedure must be carried out with the igni-tion off.

1

2

3

13A-21

FUEL SUPPLYElectric fuel: Checking


13A

Place the electrical connector (4) to one side withoutdisconnecting it.

Disconnect the brown connector (5) from the Protec-tion and Switching Unit.

Connect terminal (5) of the brown connector to thebattery positive feed

102502

102503

4

5

102501

Note:

The flow reading should be between 80 and 120l/h .

5

1

12

13B-1

DIESEL INJECTIONSpecifications

K9K, and 722 or 728 or 729

13B

Equipment required

diagnostic tool

Vehicle type

Engine Engine speed (rpm) Smoke opacity


Maximumunladen

Maximumladen

Homologa-tion value(m-1)

Legal maxi-mum (m-1)

XM0F

XM0T

K9K

722 805 ±±±± 50 5000 ±±±± 150 4800 ±±±± 100

1.5

3

XM1F 724 800 ±±±±50 4900 ±±±± 150 4900 ±±±± 150 2

XM02

XM13

728

805 ±±±± 50 4950 ±±±± 150 4800 ±±±± 100 3

XM02 729

Description Make - type Special notes

High pressure pump DELPHI Pressure from 0 to 1,400 bar

Low pressure pump DELPHI Integrated in the high pressurepump

Injection computer DELPHI 112-track computer (A 32, B 48, C32)

Diesel rail pressure sensor DELPHI Integrated in the rail

Resistance not measurable

Supply voltage: + 5 V

3-track connector:

- 1: signal

- 2: diesel rail pressure sensorearth

- 3: + 5 V supply

Injectors DELPHI / MNS HP Solenoid injector

Maximum pressure 1,600 bar



2-track connector:

- 1: injector + control

- 2: injector - control

13B-2


K9K, and 722 or 728 or 729

13B

Diesel flow actuator DELPHI Located on the high pressurepump

Resistance: 5.3 Ω ± 0.5 at 20˚C


2-track connector:

- 1: + battery feed via Protectionand Switching Unit

- 2: actuator control

Engine speed and position sensor MGI Var iable reluctance sensor

Resistance: 760 Ω (K9K 722)

Resistance: 680 Ω (K9K 724,728, 729)

2-track connector

- A: + signal

- B: - signal

Pre-postheating unit NAGARES BED 7-12 Pre-postheating function mana-ged by the computer

9-track connector

- 1: heater plug no. 3 supply


- 3: + battery supply



- 8: injection computer control

- 9: fault finding

Heater plugs CHAMPION or BERU Resistance: 0.6 Ω


13B-3


K9K, and 722 or 728 or 729

13B

Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance

- gang 1: tracks 3 and 5: 1700 ±900 Ω

- gang 2: tracks 2 and 6: 3875 ±1025 Ω

6-track connector:

- 1: gang 2 signal

- 2: gang 2 + 5 V supply


- 4: gang 1 signal

- 5: gang 1 earth

- 6: gang 2 earth

Cylinder reference sensor SAGEM Hall effect sensor

3-track connector:

- 1: cylinder reference sensorearth

- 2: signal

- 3: + battery feed via Protectionand Switching Unit

Diesel temperature sensor DELPHI Located on the high pressurepump

Negative temperature coefficientthermistor

Resistance: 2.2 kΩ at 25˚C

2-track connector:

- 1: signal

- 2: diesel temperature sensorearth

Accelerometer SAGEM Resistance not measurable

2-track connector:

- 1: signal

- 2: accelerometer earth


13B-4


K9K, and 722 or 728 or 729

13B

Engine coolant temperature sen-sor

ELTH Negative temperature coefficientthermistor

Resistance:

- 75780 ± 7000 Ω at - 40˚C

- 12460 ± 1128 Ω at - 10˚C

- 2252 ± 112 Ω at 25˚C

- 811 ± 38 Ω at 50˚C

- 282 ± 8 Ω at 80˚C

- 115 ± 3 Ω at 110˚C

- 88 ± 2 Ω at 120˚C

4-track connector:

- 3: signal

- 4: engine coolant temperaturesensor earth

Turbocharging air temperatureand pressure sensor

BOSCH / LDF6T 20-250 Pressure sensor with a negativetemperature coefficient thermistor


Resistance:

- 20376 ± 1110.5 Ω at - 25˚C

- 15614 ± 829 Ω at - 20˚C

- 9426 ± 475 Ω at - 10˚C

- 5887 ± 281.5 Ω at 0˚C

- 3791 ± 172.5 Ω at 10˚C

- 2511 ± 109 Ω at 20˚C

- 1715.5 ± 71 Ω at 30˚C

- 1200 ± 47 Ω at 40˚C

- 851 ± 32 Ω at 50˚C

- 612 ± 22 Ω at 60˚C

- 446 ± 15 Ω at 70˚C

- 330 ± 11 Ω at 80˚C

4-track connector:

- 1: earth

- 2: air temperature sensor signal

- 3: + 5 V supply

- 4: pressure sensor signal

Exhaust gas recirculation sole-noid valve (K9K 722, 728 and729)

PIERBURG Supply voltage: + 13.5 V

Resistance: tracks 1 and 5: 8 ±0.5 Ω at 20˚C


13B-5


K9K, and 722 or 728 or 729

13B

Exhaust gas recirculation sole-noid valve (K9K 724)

PIERBURG Supply voltage: 13.5 V

Resistance: tracks 2 and 6: 2.3 Ωat 20˚C

Exhaust gas recirculation sole-noid valve position potentiometer(K9K 724)

PIERBURG Integrated in the exhaust gasrecirculation solenoid valve


6-track connector:

- 1: potentiometer supply

- 2: solenoid valve supply

- 3: potentiometer earth

- 4: not used

- 5: potentiometer signal

- 6: solenoid valve earth

Exhaust gas recirculation sole-noid valve position potentiometer(K9K 722 728 and 729)

PIERBURG Integrated in the exhaust gasrecirculation solenoid valve


Resistance:

- tracks 2 and 4: 4 ± 1.6 kΩ at20˚C

6-track connector:

- 1: solenoid valve + battery feedvia Protection and Switching unit

- 2: potentiometer supply + 5 V

- 3: not used




Refrigerant pressure sensor TEXAS INSTRUMENTS Supply voltage: + 5 V

3-track connector:

- A: earth

- B: + 5 V supply

- C: signal


13B-6


K9K, and 722 or 728 or 729

13B

Fault finding - diagnostic tool : CLIP only

Turbocharging pressure regula-tion solenoid valve (K9K 724, 728and 729)

BITRON Proportional solenoid valve

Supply voltage: 13.5 V

Resistance: 16.5 Ω ±±±± 1.6 at 23˚C

2-track connector:

- 1: signal

- 2: supply


13B-7


F9Q, and 800 or 808

13B

Equipment required

diagnostic tool

Vehicles Gearbox

Engine

Type Suffix Bore(mm)

Stroke(mm)

Cubic capa-city (cc)

Compres-sion ratio

XM0G

XM1G ND0 F9Q

800

80 93 1870 19:1

XM00 808

Engine speed (rpm) Smoke opacity

Idling speed Maximum unladen Maximum laden Homologation

value (m-1)

Legal maximum

(m-1)

800 ± 50 4850 ± 150 4500 ± 100 1.9 (54%) 3 (70%)

Description Make - Type Special notes

High pressure pump BOSCH CP3 Pressure from 250 to 1,350 bar

Diesel fuel pressure sensor BOSCH Bolted onto the rail

Injectors BOSCH Solenoid injector

Operating pressure up to: 1300bar

Pressure regulator BOSCH Bolted onto the high pressurepump

Resistance: 3 ± 0.1 Ω at 20˚C

Injection computer BOSCH EDC 16 112-track computer

Pre-postheating unit (locatedbehind the front left-hand wheelarch liner)

NAGARES BED/7-12 With pre-postheating functionmanaged by computer

Heater plugs BERU ou CHAMPION Resistance: 0.6 Ω connector dis-connected

Engine speed sensor MGI Resistance: 720 at 880 Ω at 20˚C

Camshaft sensor ELECTRIFIL -

Accelerator potentiometer CTS Dual gang potentiometer

Resistance:

- gang 1: 1700 ± 900 Ω

- gang 2: 3875 ± 1025 Ω

13B-8


F9Q, and 800 or 808

13B

Air inlet temperature sensor SIEMENS Integrated in the air flowmeter

Diesel fuel temperature sensor ELTH Resistance: 2,050 Ω at 25˚C

Engine coolant temperature sen-sor

ELTH Resistance: 2252 Ω ± 112 at 25˚C

Air flowmeter SIEMENS Air flowmeter with integrated airtemperature sensor

- track 1: air temperature

- track 2: earth

- track 3: 5 V reference feed

- track 4: + 12 V after injectionrelay feed

- track 5: air flow signal

- track 6: earth

Turbocharger pressure sensor BOSCH Output voltage with ignition on andengine stopped (between tracks 2and 3):

- = 1.6 V for an atmospheric pres-sure of 1,013 mbar

- > 1.6 V for an atmospheric pres-sure > 1,013 mbar

- < 1.6 V for an atmospheric pres-sure < 1,013 mbar

Replace the seal each time it isremoved

Atmospheric pressure sensor - Integrated in the computer

Exhaust gas recirculation solenoidvalve

PIERBURG Gang resistance: 8 ± 0.5 Ω at20˚C (tracks 1 and 5)

Sensor resistance: 4 kΩ at 20˚C(tracks 2 and 4)

Damper valve solenoid valve(engine stop solenoid valve)

BITRON ou EATON Resistance: 46 ± 3 Ω at 25˚C

Turbocharging pressure regulationsolenoid valve

PIERBURG Resistance: 15.4 ± 0.7 Ω at 20˚C

Fault finding diagnostic tool : CLIP only


13B-9


F9Q, and 804

13B

Equipment required

diagnostic tool

Vehicle type

Engine Engine speed (rpm) Smoke opacity


Maximumunladen

Maximumladen

Homologa-tion value(m -1)

Legal maxi-mum (m-1)

XM0L

XM1D

XM17

XM14

F9Q 804 800 ± 50 4850 ±150

4500 ±100

1.9 (54%) 3 (70%)


High pressure pump BOSCH CP3.2 Pressure 1600 bar Max

Diesel fuel pressure sensor BOSCH Bolted onto the rail

Tightening torque: 3.5 ± 5 Nm

Injectors BOSCH Solenoid injector

Operating pressure up to: 1600 bar

Pressure regulator BOSCH Screwed onto the high pressurepump

Resistance: 3 ± 0.1 Ω at 20˚C

Injection computer BOSCH EDC 16 112-track computer

Pre-postheating unit (locatedbehind the front left-hand wheelarch liner)

NAGARES BED/7-12 With pre-postheating functionmanaged by computer

Heater plugs BERU ou CHAMPION Resistance: 0.6 Ω connector dis-connected

Engine speed and TDC sensor MGI Resistance: 800 Ω at 20˚C

Camshaft sensor ELECTRIFIL Hall effect type

Accelerator potentiometer CTS Dual gang potentiometer

Resistance:

- gang 1: 1700 ± 900 Ω

- gang 2: 2850 ± 2050 Ω

Air inlet temperature sensor SIEMENS Integrated in the air flowmeter

Engine coolant temperature sensor ELTH Resistance: 2252 Ω ± 112 at 25˚C

13B-10


F9Q, and 804

13B

Air flowmeter SIEMENS Air flowmeter with integrated airtemperature sensor

- track 1: air temperature

- track 2: earth

- track 3: 5 V reference feed

- track 4: + 12 V after injection relayfeed

- track 5: air flow signal

- track 6: earth

Turbocharger pressure sensor BOSCH Output voltage with ignition on andengine stopped (between tracks 2and 3):

- = 1.6 V for an atmospheric pres-sure of 1,013 mbar

- > 1.6V for an atmospheric pres-sure > 1013 mbar

- < 1.6 V for an atmospheric pres-sure < 1013 mbar

Replace the seal each time it isremoved

Atmospheric pressure sensor - Integrated in the computer


SIEMENS Gang resistance: 2.96 ± 10 % at20˚C (tracks 1 and 5)

Sensor resistance: 6.5 kΩ ± 40% at20˚C (tracks 2 and 4)


PIERBURG Resistance: 15.4 ± 0.7 Ω at 20˚C

Turbocharger GARRET Calibration

- For an underpressure 265 mbar ,the rod should have a stroke ofbetween 0.5 and 3.5 mm

- for a vacuum greater than 600mbar the rod should be at thestop

Fault finding diagnostic tool : CLIP only


13B-11

DIESEL INJECTIONDiesel injection: Specifications

K9K, and 732

13B

Equipment required

diagnostic tool

Vehicletype

Engine Engine speed (rpm) Smoke opacityDepollutionstan-dard


Maximumunladen

Maximumladen

Homo-loga-tionvalue

Legalmaxi-mum

X84 K9K 732 800 ± 50 5000 ±150

5000 ±150

1.5 m -1 2 m -1 EuroIV


High pressure pump SIEMENS VDO Pressure from 0 to 1600 bar

Low pressure pump SIEMENS VDO Integrated in the high pressurepump

Injection computer SIEMENS VDO 128-track computer (A 32, B 48, C48)

Diesel rail pressure sensor SIEMENS VDO Integrated in the rail



3-track connector:

- 1: signal

- 2: diesel rail pressure sensorearth

- 3: supply +

Injectors SIEMENS VDO 6-hole piezoelectric injector


Supply voltage: 150 V

2-track connector:

- 1: supply

- 2: earth

Flow regulation solenoid valve SIEMENS VDO Integrated in the high pressurepump

Cannot be removed


13B-12


K9K, and 732

13B

Pressure regulation solenoid valve SIEMENS VDO Integrated in the high pressurepump

Cannot be removed


Engine speed and position sensor SIEMENS VDO Variable reluctance sensor

Resistance: 680 Ω ± 6.8 at 20˚C

2-track connector

- 1: + signal

- 2: - signal

Pre-postheating unit NAGARES With pre-postheating function con-trolled by the injection computer

8-track connector


- 2: spark plug no. 1 supply

- 3: fault finding

- 4: + battery supply

- 6: spark plug no. 4 supply


- 8: injection computer control

Heater plugs CHAMPION ou BERU Resistance: 0.6 Ω

Accelerator pedal potentiometer CTS Dual gang potentiometer

Resistance

- gang 1: tracks 3 and 5: 1700 Ω ±900

- gang 2: tracks 2 and 6: 3875 Ω ±1025

6-track connector:

- 1: gang 2 signal



- 4: gang 1 signal

- 5: gang 1 earth

- 6: gang 2 earth


13B-13


K9K, and 732

13B

Cylinder reference sensor JCAE Hall effect sensor

3-track connector:

- 1: earth

- 2: signal

- 3: supply

Diesel temperature sensor ELTH Located on the diesel return rail onthe high pressure pump outlet

2-track connector:

- 1: signal

- 2: earth

Atmospheric pressure sensor SIEMENS VDO Integrated in the computer

Air temperature sensor SIEMENS VDO Integrated in flowmeter

Negative temperature coefficientthermistor

Resistance:

- 44373 Ω ± 3118 at - 40˚C

- 15141 Ω ± 871 at - 20˚C

- 9202 Ω ± 486 at 10˚C

- 5774 Ω ± 276 at 0˚C

- 3714 Ω ± 161 at 10˚C

- 2448 Ω ± 95 at 20˚C

- 1671 Ω ± 58 at 30˚C

- 1150 Ω ± 36 at 40˚C

- 817 Ω ± 22 at 50˚C

- 583 Ω ± 14 at 60˚C

- 316 Ω ± 6 at 80˚C

- 183 Ω ± 2 at 100˚C

Turbocharger pressure sensor BOSCH / LDF6 20-300 Supply voltage: + 5 V

3-track connector:

- 1: supply

- 2: earth

- 3: signal

Damper valve JCAE Solenoid valve position potentiome-ter built into the damper valve

Solenoid valve supply voltage: +13.5V

Potentiometer supply voltage: + 5V


13B-14


K9K, and 732

13B

Engine coolant temperature sensor ELTH Negative temperature coefficientthermistor

Resistance:

- 75780 Ω ± 7000 at - 40˚C

- 12460 Ω ± 1128 at - 10˚C

- 2,252 Ω ± 112 at 25˚C

- 811 Ω ± 38 at 50˚C

- 282 Ω ± 8 at 80˚C

- 115 Ω ± 3 at 110˚C

- 88 Ω ± 2 at 120˚C

4-track connector:

- 1: not used

- 2: engine coolant temperaturesensor signal

- 3: engine coolant temperaturesensor earth

- 4: not used


PIERBURG Supply voltage: + 13.5 V

Resistance: tracks 2 and 6: 2.3 Ω

Exhaust gas recirculation solenoidvalve position potentiometer

PIERBURG Integrated in the exhaust gas recir-culation solenoid valve


6-track connector:

- 1: potentiometer supply

- 2: solenoid valve supply


- 4: not used



Refrigerant pressure sensor TEXAS INSTRUMENT

BIRTON


3-track connector:

- A: earth

- B: supply

- C: signal


13B-15


K9K, and 732

13B

Water in diesel sensor PRESSAC Located on the diesel filter

3-track connector:

- 1: supply

- 2: signal

- 3: earth

Air inlet flowmeter SIEMENS VDO Air flowmeter with integrated airtemperature sensor

6-track connector:

- 1: air temperature signal

- 2: earth

- 3: Not used

- 4: + 12 V supply

- 5: supply: + 5 V

- 6: air flow signal


BIRTON Proportional solenoid valve

supply voltage + 12 V

2-track connector:

- 1: computer output

- 2: supply

Fault finding - diagnostic tool : CLIP only


13B-16

DIESEL INJECTIONDiesel injection: Precautions for repair

K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700

13BI - RISKS LINKED TO CONTAMINATION

The high pressure direct injection system is highly sen-sitive to contamination. The risks caused by contami-nation are:

- damage to or destruction of the high pressure injec-tion system,

- a component seizing,

- a component not being properly sealed.

All After-Sales operations must be performed undervery clean conditions. Having carried out an operationin good conditions means that no impurities (particles afew microns in size) have penetrated the system duringdismantling.

The cleanliness principle must be applied from the filterto the injectors.

What are the sources of contamination?

- metal or plastic chips,

- paint,

- fibres from:

• cardboard,

• brushes,

• paper,

• clothing,

• cloth,

- foreign bodies such as hair,

- ambient atmosphere,

- etc.

1 - Cleaning cloths

Use lint free cleaning cloths (part number 77 11 211707 ).

The use of rags or ordinary paper towels is prohibited:these produce lint and lose fibres, which then contami-nate the fuel circuit.

Each cloth must only be used once.

2 - Blanking plugs

The blanking plugs are used to cap the fuel circuit onceit is opened and to therefore prevent contaminantsfrom entering.

A set of blanking plugs should be used once only andused plugs must be discarded after use: once used,the plugs are soiled and cleaning them is not sufficientto make them reusable.

Unused plugs must also be discarded and not usedagain for any other operation on an injection system.

Blanking plug set part number:

- F9Q: 77 01 208 229

- K9K ( DELPHI injection): 77 01 206 804

- K9K ( SIEMENS injection): 77 01 476 857

- M9R: 77 01 209 062

3 - Protective bags

Use hermetically-resealable plastic bags, using adhe-sive tape, for example, to store components which willbe refitted and reused. Stored parts will therefore beless subject to the risk of contamination.

These bags must be used once only: once they havebeen used, they are to be discarded.

4 - Cleaning products

Two cleaning products can be used:

- an injector cleaner (part number 77 11 224 188 ),

- an aerosol spray brake cleaner (part number 77 11226 128 ).

To use the injector cleaner, be sure to have a cleanbrush in good condition (the brush must not lose anybristles) as well as a clean container which has no im-purities in it.

II - ADVICE TO BE FOLLOWED BEFORE ANY OPERATION

1) Carry out the work in a clean working area and takecare to protect removed components from dust usingplastic bags which are hermetically-resealable, forexample.

WARNING

Cleaning the engine using a high pressure washeris prohibited because of the risk of damaging con-nections. In addition, moisture may collect in theconnectors and create electrical connection faults.

Note:

Use a new injector cleaner each time work is car-ried out (a used cleaning agent will contain impuri-ties).

13B-17



13B2) Always order the following from the Parts Depart-ment before carrying out work:

- une collection de bouchons de propreté neuve ,specific to the engine,

- a sufficient number of lint-free lingettes de nettoya-ge .

- one of the two produits de nettoyage for the fuelpipe unions,

- les pièces à remplacer systématiquement aftereach removal and which are mentioned in the workprocedures specific to each vehicle (see the relevantWorkshop Repair Manual).

3) Wear safety goggles fitted with side shields to pre-vent the cleaning product from splashing the eyes.

4) Wear latex safety gloves to avoid prolonged contactwith the skin.

5) Before any operation on the injection system protect (using plastic bags or clean cloths for example):

- the accessories and timing belts,

- the electrical accessories (starter motor, alternator,power-assisted steering pump, sensors and electricalconnectors),

- the flywheel face.

III - INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

Wash your hands before and while carrying out thework.

Change the latex safety gloves if they become soiled ordamaged.

All components removed from the injection systemmust be stored in a hermetically sealed plastic bagonce they have been capped.

Reseal the bag hermetically using adhesive tape, forexample, even if the bag must be opened shortly afte-rwards: ambient atmosphere can be a source of pollu-tion.

After opening the fuel circuit, the use of brushes, clea-ning agents, air blow guns, rifle-type brushes or stan-dard cloths is strictly prohibited: These items are likelyto allow impurities to enter the system.

When replacing a component with a new one or whenrefitting it after storing it in a plastic bag, do not unpackit until it is time to fit it on the vehicle.

IV - CLEANING

There are currently two procedures for cleaning thefuel circuit before opening it in order to carry out work inthe workshop.

These procedures enable the fuel circuit to be cleanedto prevent contamination: they both have the same endresult and neither is preferred over the other.

1 - Using the injector cleaning agent

Clear the access to the unions that need opening, fol-lowing the work procedures specific to the vehicle (seethe relevant Workshop Repair Manual).

Protect sections which are sensitive to fuel leaks.

Pour the injector cleaning agent into a container whichis free from impurities.

Dip a clean brush, which is not shedding bristles, intothe container of injector cleaning agent.

Clean the unions carefully using the brush and the in-jector cleaning agent.

Blast the components that have been cleaned withcompressed air (tools, workbench, and also parts,unions and around the injection system). Make surethere are no brush bristles remaining and that the areais clean.

Wipe the sections that were cleaned with fresh clea-ning cloths.

Open the circuit at the unions and immediately fit therelevant blanking plugs.

Note:

If wearing leather protective gloves, cover thesewith latex protective gloves.

IMPORTANT

Wear latex safety gloves when using the cleaningagent.

IMPORTANT

Wear safety goggles fitted with side shields duringthis operation.

WARNINGDo not blast with compressed air once the fuel cir-cuit is open, otherwise impurities may enter the sys-tem. Use cleaning cloths only, if necessary.

13B-18



13B2 - Using the brake cleaning agent

Clear the access to the unions that need opening, fol-lowing the work procedures specific to the vehicle (seethe relevant Workshop Repair Manual).

Protect sections which are sensitive to fuel leaks.

Spray the brake cleaning agent onto the unions to beopened.

Clean the unions carefully using fresh cleaning cloths.

Blast the components that have been cleaned withcompressed air (tools, workbench, and also parts,unions and around the injection system). Make surethere are no brush bristles remaining and that the areais clean.

Open the circuit at the unions and immediately fit therelevant blanking plugs.

IMPORTANT

Wear latex safety gloves when using the cleaningagent.

IMPORTANT

Wear safety goggles fitted with side shields duringthis operation.

WARNING

Do not blast with compressed air once the fuel cir-cuit is open, otherwise impurities may enter the sys-tem. Use cleaning cloths only, if necessary.

13B-19



13BV - INSTRUCTIONS FOR FITTING THE PLUGS

K9K, and 722 or 724 or 728

13B-20



13Bpart no. 77 01 206 804

13B-21



13B20977

13B-22



13B

K9K, and 732

13B-23



13Bpart no. 77 01 476 857

13B-24



13B113430

13B-25



13B

F9Q, and 804

13B-26



13Bpart no. 77 01 208 229

13B-27



13B104561

13B-28



13B

M9R, and 700

13B-29



13Bpart no. 77 01 209 062

13B-30



13B113737

13B-31

DIESEL INJECTIONDescription

F9Q, and 800 or 808

13BThe high pressure direct injection system is intended todeliver a specific volume of diesel fuel to the engine ata specific time.

The system comprises:

- a priming pump on the low pressure circuit,

- a diesel filter,

- a pressure regulator mounted on the pump,

- a high pressure pump,

- an injection rail fitted with a diesel fuel pressure sen-sor and a pressure limiter,

- four solenoid injectors,

- various sensors,


13B-32

DIESEL INJECTIONDescription

K9K, and 722 or 728 or 729

13BThe high pressure direct injection system is intended todeliver a specific volume of diesel fuel to the engine ata specific time.

The system comprises:

- a priming pump on the low pressure circuit,

- a diesel filter,

- a high pressure pump combined with a low pressurepump (transfer pump),

- a pressure regulator mounted on the pump,

- a spherical injection rail,

- a pressure sensor incorporated into the rail,

- four solenoid injectors,

- a diesel fuel temperature sensor,

- a coolant temperature sensor,

- a turbocharging air temperature and pressure sensor,

- a cylinder marking sensor,

- an engine speed sensor,

- an accelerometer,

- an exhaust gas recirculation solenoid valve,

- an accelerator pedal potentiometer,

- an atmospheric pressure sensor,


13B-33

DIESEL INJECTIONOperation

F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732

13B

The « common rail » high pressure injection systemoperates in sequential mode (based on the multipointinjection principle for petrol engines).

Through its pre-injection process, this injection system can provide:

- reduced operating noise,

- a reduction in the amount of pollutant gases and par-ticles,

- a high engine torque at low engine speeds.

The high pressure pump generates the high pressuretransmitted to the injection rail. The actuator on thehigh pressure pump controls the volume of diesel fuelsupplied according to the demand determined by theinjection computer. The rail supplies each injectorthrough a steel pipe.

The computer:

- determines the injection pressure value necessary forthe engine to operate correctly and then operates thefuel flow actuator. It checks that the pressure value iscorrect by analysing the value transmitted by thepressure sensor located on the rail,

- determines the injection time necessary to deliver theright volume of diesel fuel and the moment when in-jection should be started,

- electrically actuates each injector individually afterdetermining these two values.

The flow injected into the engine is determined accor-ding to:

- the duration of injector actuation,

- the injector opening and closing speed,

- the needle stroke (determined by a constant for an in-jector type),

- the nominal hydraulic flow of the injector (specific toeach injector),

- the high pressure rail pressure regulated by the com-puter.

The computer manages:

- idle speed regulation,

- the exhaust gas flow reinjected into the inlet,

- the fuel supply (timing, flow and rail pressure),

- the fan assembly actuation request (function: centra-lised coolant temperature management),

- the air conditioning,

- the cruise control-speed limiter function,

- the pre/postheating actuation.

The high pressure pump is supplied at low pressure bya mechanical low pressure pump (transfer pump).

The high pressure pump supplies the rail which is pres-sure-controlled:

- for loading by the fuel flow actuator,

- for discharge by the injector valves.

Drops in pressure may also be compensated for.

The fuel flow actuator allows the high pressure pump tosupply the exact volume of diesel fuel required to main-tain the pressure in the rail. This feature allows heatgeneration to be minimised and engine output to be im-proved.

To discharge the rail, the injection valves are controlled by small electrical pulses:

- short enough not to open the injector (passing throu-gh the return circuit from the injectors),

- long enough to open the valves and discharge therail.

The injection computer actuates the fan assembly andthe coolant temperature warning light on the instru-ment panel (function: centralised coolant temperaturemanagement).

The various vehicle computers communicate via multi-plex links. The fault warning lights on the instrumentpanel are therefore activated via the multiplex network.

In the event of an impact, the function that cuts off thediesel fuel supply circuit is managed by the airbagcomputer. It gives the command via the multiplexnetwork to the injection computer to lock the injectionlocking relay control.

Equipment required

diagnostic tool

IMPORTANT

Before carrying out any work on the injection circuit, check using the diagnostic tool :

- that the rail is not pressurised,


Every time work is carried out, be sure to follow thesafety and cleanliness advice specified in this docu-ment.

Loosening a high pressure pipe union when theengine is running is strictly prohibited.

13B-34



13BUnlocking is only enabled after the ignition is switchedoff for 10 seconds . This operation causes the faultwarning light to come on for longer than usual whenswitching on the ignition. The warning light will not re-turn to normal operation until the fault has been clearedusing the diagnostic tool .

The vehicle speed signal is transmitted to the instru-ment panel by the ABS computer or the gearbox (vehi-cle without ABS system) via the multiplex network.

Some vehicles have a sensor for detecting water in thediesel fuel, which is located in the filter. If there is waterpresent in the diesel fuel, the orange injection warninglight comes on.

Automatic configuration for cruise control - speed limi-ter operation and for air conditioning operation.

Injection computer actuating the air conditioning com-pressor clutch via the UPC.

A new electronics casing called the « UPC » has beenadded to the vehicles wiring diagram.

The UPC supplies the following with power:

- the air conditioning compressor,

- the fan assembly,

- the electrical heating resistors.

The UPC is located in the engine compartment nearthe battery. It contributes to the protection of certainelectrical components.

In this capacity, it comprises:

- fuses,

- several internal relays including:

• the « + after ignition feed » relay,

• the fan assembly control relays,

• the air conditioning compressor relay.

These relays cannot be removed.

If the UPC is replaced, it must be configured using thediagnostic tool (see 87G, Motor exchange unit,UPC: Configuration ).

The injection computer receives a continuous signalvia the multiplex network regarding the electrical poweravailable from the alternator. This therefore preventsthe vehicle's electrical consumption from being in ex-cess of the alternator's capacity. The aim is to givepriority to charging the battery.

Reprime the circuit using the priming pump.

The system can inject the diesel fuel into the engine upto a pressure of 1350 bar . Before each operationcheck that the injection rail is no longer pressurised.

Be sure to observe the tightening torque:

- for the high pressure pipes,

- for the injector on the cylinder head,

- for the pressure sensor and pressure regulator.

WARNING

- The engine must not be run with diesel fuel contai-ning more than 10% diester or petrol, even inminute quantities.

- Dismantling the interior of the high pressure pumpand the injectors is prohibited. Only the fuel flowactuator, the diesel fuel temperature sensor andthe Venturi tube can be replaced.

- It is prohibited to remove the pressure sensor fromthe injection rail as this could cause contaminationof the circuit. If the pressure sensor is faulty,replace the assembly consisting of the pressuresensor, rail, and the five high pressure pipes.

- It is strictly prohibited to remove any injectionpump pulley bearing the number 070 575. If thepump is being replaced also replace the pulley.

- Supplying any system component directly with the+ 12 V is prohibited.

- Ultrasonic decarbonisation and cleaning are prohi-bited.

- Never start the engine unless the battery is pro-perly connected.

- Never turn the engine against its operating direc-tion.

IMPORTANT

The engine should not be run with diesel fuel con-taining more than 10% diester.

Note:

After any operation, check that there is no dieselfuel leakage. Let the engine idle until the enginecooling fan starts up, then accelerate several timesat no load.

13B-35



13BWhen the high pressure pump, injectors and high pres-sure supply, outlet and return unions are removed orrepaired, all apertures should be capped with suitablenew blanking covers to prevent contamination.

When replacing a high pressure pipe, follow the proce-dure below:

- remove the high pressure pipe, holding the filter rodon the injector with a lock spanner,

- fit anti-contamination plugs,

- loosen the high pressure rail,

- fit the new high pressure pipe,

- finger tighten the unions until they touch,

- torque tighten the high pressure rail mountings,

- torque tighten the union at the injector end,

- torque tighten the high pressure rail end union.

WARNING

Any pipe removed must be replaced.

WARNING

Dismantling the interior of the pump is prohibited.

The fuel return pipe fitted to the injectors must bereplaced when removed.

The diesel fuel temperature sensor cannot beremoved. It is part of the fuel return rail.

Loosening a high pressure pipe union when theengine is running is prohibited.

13B-36

DIESEL INJECTIONLocation of components

K9K, and 722

13B

102072

(1) Pr iming pump

(2) Cylinder reference sensor

(3) Turbocharger

(4) Exhaust gas recirculation sole-noid valve

(5) Injector

(6) Turbocharging air temperatureand pressure sensor

(7) Injection computer

(8) Air filter unit

(9) Protection and Switching Unit

(10) Coolant temperature sensor

(11) Engine speed and position sen-sor

(12) Rail pressure sensor

(13) Spherical injection rail

(14) Accelerometer

(15) Diesel temperature sensor

(16) Diesel flow actuator

(17) High pressure pump

101811


13B-37


K9K, and 722

13B

101105


102085


102084

(21) Venturi

(22) Flow actuator




(26) Accelerometer

(27) Injector

102082

13B-38


K9K, and 722

13B



(30) Wastegate valve

19654-1


13B-39


K9K, and 722

13B

20796



102204

(34) Accelerator pedal potentiometer

102125

(35) Pre-postheating unit

102121

(36) Diesel filter

13B-40


K9K, and 722

13B

102124

(37) Pr iming pump

102128

(38) Refrigerant pressure sensor

102077

(39) Turbocharger

(40) Catalytic converter

13B-41


F9Q, and 800 or 808

13B

101883

(1) Diesel filter

(2) Manual priming pump



(5) Solenoid injectors

(6) Engine stop system vacuumreserve

(7) Engine stop system solenoidvalve

(8) Exhaust gas recirculation sole-noid valve (F9Q 800)

(9) Turbocharger regulation sole-noid valve

(10) Flowmeter with air temperaturesensor



(13) Engine stop valve diaphragm

(14) Engine stop valve

(15) Pressure limiter (on injectionrail)

(16) Turbocharging pressure sensor

(17) Diesel temperature sensor (fuelreturn)


(19) Diesel pressure regulator

13B-42


F9Q, and 800 or 808

13B

18297-1


(21) Injection rail

(22) Injector

(23) Pressure regulator

(24) Pressure sensor


(26) Pressure limiter

102485

(27) TDC sensor

27

13B-43


F9Q, and 800 or 808

13B

16181


102479

(29) Turbocharger


28

29

30

101891

(31) Preheating unit

101889

(32) Turbocharging pressure regula-tion solenoid valve

31

32

13B-44


F9Q, and 800 or 808

13B

101892

(33) Engine stop valve

(34) Engine stop valve controldiaphragm

102486

(35) Engine stop valve vacuumreserve

(36) Engine stop valve solenoid valve

(37) Exhaust gas recirculation sole-noid valve (F9Q 800)

34

33

37

36

35

101886


102121

(39) Diesel filter

38

39

13B-45


F9Q, and 800 or 808

13B

102352


102204


40

13B-46


K9K, and 728 or 729

13B

106343

(1) Pr iming pump


(3) Turbocharger


(5) Injector



(8) Air filter unit

(9) UPC





(14) Accelerometer

(15) Diesel fuel temperature sensor

(16) Diesel fuel flow actuator


(18) Turbocharging pressure sole-noid valve

101811


13B-47


K9K, and 728 or 729

13B

101105

(20) UPC

102085


102084

(22) Venturi

(23) Fuel flow actuator




(27) Accelerometer

(28) Injector

110327

13B-48


K9K, and 728 or 729

13B

110319




(32) Turbocharging pressure regula-tion valve

101889


13B-49


K9K, and 728 or 729

13B

19654-1


20796


102204


13B-50


K9K, and 728 or 729

13B

102125


104954

(38) Diesel filter

102124

(39) Priming pump

102128

(40) Refrigerant pressure sensor

13B-51


K9K, and 728 or 729

13B

102077

(41) Turbocharger


13B-52


F9Q, and 804

13B

101883

(1) Diesel filter

(2) Pr iming pump



(5) Solenoid injectors

(6) Exhaust gas recirculation sole-noid valve unit

(7) Turbocharger regulation sole-noid valve

(8) Flowmeter with air temperaturesensor


(10) UPC





(15) Diesel pressure regulator

13B-53


F9Q, and 804

13B

18297-1


(17) Injection common rail

(18) Injectors

(19) Pressure regulator

(20) Pressure sensor



102485

(23) TDC sensor

13B-54


F9Q, and 804

13B

16181


111864

(25) Turbocharger


101891

(27) Preheating unit

101889


13B-55


F9Q, and 804

13B

111856

(29) Throttle valve.

(30) Exhaust gas recirculation sole-noid valve unit.

101886

(31) Pr iming pump

102121

(32) Diesel filter

102204


13B-56


K9K, and 732

13B

114186




(4) Turbocharger

(5) Injectors


(7) Turbocharging air pressure sen-sor

(8) Air flowmeter

(9) Air filter unit





(14) Injection rail

(15) Injection rail pressure sensor


(17) Diesel filter

101811


13B-57


K9K, and 732

13B

101105


111748


112994


(22) Air inlet valve

(24) Pressure regulation solenoidvalve

(23) Flow regulation solenoid valve

13B-58


K9K, and 732

13B

114348

(25) Diesel injector fuel return rail


(27) High pressure pipe between therail and injector

(28) High pressure pipe between thepump and rail

(29) High pressure rail


(31) Diesel injector

(32) Injector bracket

(33) Spacer between the cylinderhead and injector bracket

102204


13B-59


K9K, and 732

13B

102125


114559

(36) Diesel filter

102124

(37) Priming pump

113840


(39) Turbocharger

13B-60


K9K, and 732

13B

114185


13B-61

DIESEL INJECTIONImmobiliser function

K9K, and 722 or 728 or 729 – F9Q, and 800 or 804 or 808

13BThese vehicles are fitted with an engine immobilisersystem, controlled by a RENAULT card random rollingcode recognition system, which requires a special pro-cedure for replacing the computer.

REPLACEMENT

For the removal/refitting procedure, (see 13B, Die-sel injection, Diesel injection computer ).

For the engine immobiliser functions (see 82A, En-gine immobiliser, Operation ).

Injection computers are supplied without a code, butthey can all be programmed with one.

When replacing the computer, program it with thevehicle code, then check that the engine immobiliserfunction is operational.

Switch on the ignition for a few seconds without star-ting the engine.


Note:

The immobiliser function operates after roughly10 seconds (the red immobiliser warning lightblinks on the instrument panel).

WARNING

- The injection computer retains the immobilisercode for life.

- The system has no security code.

- Running tests with computers borrowed fromthe Parts Department or from another vehiclewhich must then be returned is prohibited.

- These computers are permanently coded.

13B-62

DIESEL INJECTIONInjection warning light

K9K, and 722 or 728 or 729 or 732

13B

Vehicles fitted with the Delphi DDCR high-pressurediesel fuel system use fault warning symbols and textwarning messages, depending on the level of severityof the faults detected, to inform the customer and de-termine the correct fault finding procedure.

The injection computer controls the illumination of war-ning lights and message displays on the instrument pa-nel. The fault warning lights come on:

- during the preheating phase,

- if there is an injection fault,

- if the engine is overheating.

The warning signals are sent to the instrument panelvia the multiplex network.

WARNING LIGHT ACTIVATION PRINCIPLE.

During the starting phase (press the « Start » button,the orange preheating symbol is lit during the prehea-ting phase, then goes out) (see 13C, Preheating, Pre-postheating control ).

In the event of an injection fault (level 1), the message« Check injection » is displayed and then the« Service » warning light comes on. This means a re-duced level of operation and a limited safety level.

Repairs should be carried out as soon as possible.

These faults are associated with:

- the engine immobiliser,

- a C2l (individual injector correction) coding error,

- an injector,

- the injector controls,

- the diesel fuel supply (injector leak, etc.),

- an engine speed sensor target fault,

- the injection locking relay,

- the exhaust gas recirculation solenoid valve or posi-tion sensor,

- the accelerator pedal potentiometer (gangs 1 and 2),

- the accelerator pedal potentiometer supply,

- the turbocharging pressure sensor (in the event ofoverpressure),

- water in the diesel fuel or a water detection sensorfault (if fitted on vehicle.

If there is a serious injection fault (level 2), the red en-gine symbol and the word « Stop » appears (only on in-formation display), with the message « Injectionfaulty » , followed by the « Stop » warning light andbuzzer.

The faults relate to:

- with delayed stop: the fuel flow actuator (loop discre-pancy and overpressure),

- with immediate stop:

• the engine speed sensor,

• the diesel flow actuator,

• the rail pressure sensor,

• the supply to all the injectors,

• the sensor supply voltage,

• an internal computer fault.

If the engine overheats, the engine temperature faultsymbol appears with the message « Engineoverheating » (only on information display) followed bythe « Stop » warning light and buzzer. If this happens,the vehicle will stop immediately.

« On Board Diagnostic » excess pollution orange warning light

The orange warning light, represented by an engine,comes on for approximately 5 seconds then goes out.It is never displayed when the engine is running (notoperational).

Note:

For vehicles fitted with K9K 732 engines (see MR370 Mechanics, Scénic II ).

13B-63

DIESEL INJECTIONInjection warning light

F9Q, and 800 or 804 or 808

13BVehicles fitted with the Bosch EDC16 high pressurediesel fuel system use fault warning symbols and textwarning messages, depending on the level of severityof the faults detected, to inform the customer and de-termine the correct fault finding procedure.

The injection computer controls the illumination of war-ning lights and message displays on the instrument pa-nel. The fault warning lights and error messages are visible:

- during the preheating phase,

- if there is an injection fault,

- if the engine is overheating.

The warning signals are sent to the instrument panelvia the multiplex network.

WARNING LIGHT PRINCIPLE

During the starting phase (press on the « Start » but-ton, the orange preheating symbol is lit during the pre-heating phase then it goes out) (see 13C, Preheating,Pre-postheating control ).

In the event of an injection fault (level 1), the message« Check injection » is displayed and then the« Service » warning light comes on. This means a re-duced level of operation and a limited safety level.


- an internal computer fault,

- an immobiliser system fault,

- a speed synchronisation fault,

- an accelerator pedal potentiometer fault,

- an air flowmeter fault,

- a speed sensor fault (see ABS system),

- an EGR solenoid valve fault,

- a fault in the turbocharging pressure regulation sole-noid valve,

- a fault in the main relay of the Protection and Swit-ching Unit,

- an injector fault,

- an injector flow correction fault (IMA),

- a sensor power feed fault.

If there is a serious injection fault (level 2), the red en-gine symbol and the word « Stop » appears (only on in-formation display), with the message « Injectionfaulty » , followed by the « Stop » warning light andbuzzer.


- an internal computer fault,

- an injector fault,

- a rail pressure sensor fault,

- a rail pressure regulator fault.

If the engine overheats, the engine coolant temperatu-re fault symbol appears with the message « Engineoverheating » (only on information display) followed bythe « Stop » warning light and buzzer. In this case thevehicle must be stopped immediately.

« On Board Diagnostic » excess pollution orange warning light

The orange engine symbol comes on when the ignitionis switched on for around 5 seconds then goes out. Itis never displayed when the engine is running (not ope-rational).

13B-64

DIESEL INJECTIONInjection / air conditioning programming

K9K, and 722 or 728 or 729

13B

The air conditioning management is shared betweenseveral computers that communicate via the multiplexnetwork.

It is of the « cold loop » type.

The injection computer is responsible for:

- managing the cooling request according to passengercompartment commands and the circuit pressure va-lue,

- calculating the power absorbed by the compressorfrom the circuit pressure value,

- authorising engine cooling fan control in accordancewith vehicle speed and circuit pressure,

- authorising or inhibiting engagement of the compres-sor clutch.

When the air conditioning is switched on, the air condi-tioning control panel requests authorisation to engagethe compressor clutch.

The injection computer authorises or inhibits compres-sor clutch engagement, controls the fan assembly viathe UPC and imposes an increased idle speed.

This engine speed is 900 rpm depending on how muchpower is absorbed by the compressor.

The injection computer authorises operation of the air conditioning compressor and the fan unit (both sup-plied by the UPC), according to the following condi-tions:

- engine coolant temperature,

- vehicle speed,

- climate control.

The signals used for the air conditioning function are transmitted via:

- track A A4 « CAN HIGH » multiplex connection,

- track A A3 « CAN LOW » multiplex connection.

The connections between the injection computer and the refrigerant pressure sensor are:

- C C3 refrigerant pressure sensor signal,

- C C4 refrigerant pressure sensor supply,

- C G3 refrigerant pressure sensor earth.

I - COMPRESSOR OPERATION PROGRAMMING

During certain operating phases, the injection compu-ter disables the operation of the compressor.

1 - Engine starting programming

The operation of the air conditioning compressor is in-hibited for 1 second after the engine has started.

2 - Thermal protection programming

The air conditioning compressor is not engaged if theengine temperature is above 115˚C or above 110˚C athigh engine speeds, 4500 rpm for more than 10 se-conds .

3 - Fan unit control programming

With the engine idling or when driving, with the air con-ditioning on, the fan unit is activated at high or lowspeed, according to the refrigerant pressure and thevehicle speed.

4 - Recovery of performance

If the accelerator pedal is depressed firmly (more than75 % of its travel), the compressor is disengaged for 5seconds .

5 - Recovery of power when moving off

To assist the vehicle moving away, the air conditioningcompressor is disengaged if the accelerator pedal tra-vel is greater than 30 % and the engine speed is lessthan 1250 rpm .

6 - Anti-stalling function

The air conditioning compressor is disengaged if theengine speed is less than 740 rpm .

Note:

For vehicles fitted with engine concerned (see MR370 Mechanics, Scénic II ).

Note:

The value of parameter ( PR044 ) « power absor-bed by the air conditioning compressor » is never 0,whatever the status of the air conditioning compres-sor. The minimum reading is approximately 250 W .

The air conditioning compressor is of the « variabledisplacement » type.

13B-65


K9K, and 722 or 728 or 729

13B7 - Engine overspeed timed protection programming

The air conditioning compressor is disengaged if theengine speed is above 4500 rpm for more than 3 se-conds .

II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING

To reduce the heating time, fit air heating resistorsknown as « passenger compartment heatingresistors » in the passenger compartment heating cir-cuit.

The UCH determines the need to actuate the heatingresistors, according to the user's request.

The injection computer determines:

- the number of heating resistors supplied (power con-trol limitation) depending on the alternator charge,

- whether resistor operation should be disabled, accor-ding to engine speed, load and vehicle speed.

The heating resistors are supplied by the UPC.

At the request of the resistors, the fast idle speed beco-mes 900 rpm .

III - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING

During certain operating phases, the injection compu-ter disables the passenger compartment heating resis-tors.

1 - Engine start programming

Operation of passenger compartment heating resistorsis prohibited for 20 seconds after the engine is started.

2 - Performance return programming under heavy load

Under heavy load at low engine speeds the heating re-sistors are temporarily disabled.

Input conditions:

- engine speed less than 3000 rpm ,

- and vehicle speed less than 78 mph (130 km/h) .

Output conditions:

- engine speed above 3500 rpm ,

- and vehicle speed greater than 90 mph (150 km/h)(by way of information).

3 - Performance return programming for hill starts

To assist hill starts, the heating resistors are tempora-rily disabled.

Input conditions:

- engine speed less than 900 rpm ,

- and vehicle speed less than 2.4 mph (4 km/h) ,

- and gearbox in neutral.

Output conditions:

- engine speed greater than 2500 rpm ,

- or vehicle speed greater than 3.6 mph (6 km/h)

- or a gear is engaged.

4 - Stalling prevention programming

When the engine speed falls below 760 rpm , opera-tion of passenger compartment heating resistors is in-terrupted. When engine speed rises above 750 rpm ,the passenger compartment heating resistors are re-enabled.

Note:

There is always a delay of more than 10 secondsafter the air conditioning compressor is disengagedbefore it can be disengaged again.

13B-66


F9Q, and 800 or 804 or 808

13BThe air conditioning management is shared betweenseveral computers that communicate via the multiplexnetwork.

When the air conditioning is switched on, the air condi-tioning control panel requests authorisation to engagethe compressor clutch.

The injection computer authorises or inhibits the com-pressor clutch, and controls the fan assembly via theUPC.

When the air conditioning function is selected, theidling speed is not altered.

The signals used for the air conditioning function are transmitted via:

- track A A4 « CAN HIGH » multiplex connection,

- track A A3 « CAN LOW » multiplex connection.

This compressor is the variable output type.

I - AIR CONDITIONING COMPRESSOR OPERATION PROGRAMMING

During certain operating phases, the injection compu-ter disables the compressor.


Air conditioning compressor operation is inhibited for 2seconds after the engine has started.


The air conditioning compressor is not engaged if theengine coolant temperature is above 115 ˚C , it is re-engaged if the engine coolant temperature falls below115 ˚C .

This vehicle is equipped with heating resistors locatedin the air conditioning unit.

These heating resistors are designed to heat up the airwhich is then directed to the passenger compartment.

When the heating resistors are activated, the injectioncomputer adopts a fast idling speed. This enginespeed is 900 rpm .

3 - Recovery of power when moving off

To help the vehicle start moving, the air conditioningcompressor is engaged if the accelerator pedal posi-tion is above 25 % , the engine speed is below 1350rpm and the vehicle speed is below 3 mph (5 km/h) .

4 - Anti-stalling function

The air conditioning compressor is disengaged if theengine speed is below 750 rpm .

It is re-engaged if the engine speed exceeds 780 rpm .

II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING

During certain operating phases, the injection compu-ter disables the heating resistors.


The heating resistors are disabled while the heaterplugs are in operation.

When the engine starts, the heating resistor supply isauthorised after a delay that depends on the enginecoolant temperature.

2 - Stalling prevention programming

When the engine speed falls below 800 rpm , opera-tion of the heating resistors is interrupted. When theengine speed falls below 875 rpm , operation of theheating resistors is authorised.

Engine coolant tem-perature

(˚C +/- 1)

Delay

(s)

- 30 30

- 20 25

- 10 15

0 15

10 15

20 15

30 10

13B-67

DIESEL INJECTIONIdling speed

K9K, and 722 or 728 or 729 or 732

13B

The injection computer calculates the idling speed nee-ded to maintain it at the recommended level and tocompensate for any variation in the mechanical orelectrical torque as a function of:

- the coolant temperature,

- the battery voltage,

- the gear selected,

- the electrical consumers (climate control, fan unit,passenger compartment heating electrical resistors,etc.),

- any faults found.

I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

X: Engine idle speed (rpm)

Y: Engine coolant temperature (˚C)

II - IDLE SPEED CORRECTION IN THE EVENT OF AN ACCELERATOR PEDAL POTENTIOMETER FAULT

- If one of the two accelerator pedal potentiometertracks is faulty, the injection computer forces an idlespeed of 1300 rpm . This defect mode limits perfor-mance. The « Check injection » message lights up,followed by the « Service » warning light.

- If the accelerator pedal potentiometer is jammed, nolonger supplied, or is no longer sending an output si-gnal, the injection computer imposes an idle speed of1300 rpm . This defect mode limits performance. The« Check injection » message lights up, followed bythe « Service » warning light.

- If there is inconsistency between the accelerator pe-dal potentiometer signal and the brake switch signal,the injection computer imposes an idle speed of 1300rpm .

III - IDLE SPEED CORRECTION IN THE EVENT OF AN INJECTOR C2I CODING ERROR

In the event of an injector C2I coding error (individualadjustment of the injector flow), the injection computerforces an idle speed of 1300 rpm . This defect mode li-mits performance. The « Check injection » message li-ghts up, followed by the « Service » warning light.

IV - IDLE SPEED CORRECTION WHEN THE VEHICLE IS BEING DRIVEN

At normal engine operating temperature, the idle speed is modified according to the gear engaged:

- in neutral, the speed is 805 rpm ,

- in 1stand 2ndgear, the speed is 875 rpm ,

- in 3rdand 4thgear, the speed is 900 rpm ,

- in 5thgear, the speed is 950 rpm .

Note:


Note:

At normal engine operating temperature, withoutmajor electrical consumers, the engine idling speedis 805 ±±±± 50 rpm .

103122

13B-68

DIESEL INJECTIONIdling speed

B84 or C84 or S84, and F9Q, and 800 or 804

13BI - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE

In all cases, this engine idling speed correction is deac-tivated 10 minutes after engine start and adopts a va-lue of 800 rpm .

X: Engine idling speed (rpm)

Y: Engine coolant temperature (˚C)

II - IDLE SPEED CORRECTION IN THE EVENT OF AN ACCELERATOR PEDAL POTENTIOMETER FAULT

If the two accelerator pedal potentiometer tracks aredefective, the injection computer sets the idling speedat 1400 rpm . By pressing on the brake pedal, theidling speed falls back to 1000 rpm .

If there is inconsistency between the accelerator pedalpotentiometer signals and the brake switch, the idlingspeed increases to 1400 rpm .

III - ENGINE IDLE SPEED CORRECTION WHEN THE VEHICLE IS BEING DRIVEN

The engine idling speed when the vehicle is being dri-ven is:

- 870 rpm when the 1stor the 2ndgear is engaged,

- 900 rpm when a higher gear than 2ndis engaged.

103129

13B-69

DIESEL INJECTIONCentralised coolant temperature management

K9K, and 722 or 728 or 729 or 732

13B

The coolant temperature sensor (injection and coolanttemperature indicator on the instrument panel) is a 3-track sensor:

- 2 tracks for the coolant temperature signal to the com-puter (tracks B H2 and B H3),

- 1 track for instrument panel indicators.

This system allows the engine cooling fan to be con-trolled by the injection computer. It consists of a singletemperature sensor serving injection, the engine coo-ling fan, the temperature indicator and the instrumentpanel engine coolant temperature warning light.

The request to operate the engine cooling fan is madeby the injection computer through the multiplexnetwork.

I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING

The fan assembly is controlled:

- at low speed if the engine coolant temperature ex-ceeds 99 ˚C or in the event of a coolant temperaturesensor fault and stops when the temperature falls be-low 96 ˚C ,

- at high speed if the engine coolant temperature ex-ceeds 102 ˚C or if the low speed is faulty and stopswhen the temperature falls below 99 ˚C .

The fan assembly low and high speeds are controlledwhen the air conditioning function is selected on theinstrument panel.

The fan will operate at high speed under the low speedoperating conditions if low speed is faulty.

II - OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT

The warning light is actuated by the injection computervia the multiplex network.

The warning light is continuously lit if the coolant tem-perature exceeds 118˚C . It goes out when the tempe-rature drops below 115 ˚C .

Note:


13B-70

DIESEL INJECTIONCentralised coolant temperature management

F9Q, and 800 or 804 or 808

13BThe coolant temperature sensor (injection and coolanttemperature indicator on the instrument panel) is a 3-track sensor:

- 2 tracks for the coolant temperature signal to the com-puter (tracks B E1 and B K3),

- 1 track for instrument panel indicators.

This system allows the engine cooling fan to be con-trolled by the injection computer. It consists of a singletemperature sensor serving injection, the engine coo-ling fan, the temperature indicator and the instrumentpanel engine coolant temperature warning light.

The request to operate the engine cooling fan is madeby the injection computer through the multiplexnetwork.

I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING

The fan assembly is controlled:

- at low speed if the engine coolant temperature ex-ceeds 99˚C and stops when the temperature dropsbelow 96˚C ,

- at high speed if the engine coolant temperature ex-ceeds 102˚C and stops when the temperature dropsbelow 99˚C ,

- The fan assembly low and high speeds are controlledwhen the air conditioning function is selected on theinstrument panel.

II - ENGINE COOLANT TEMPERATURE WARNING LIGHT

The warning light is actuated by the injection computervia the multiplex network.

The warning light is lit continuously if the coolant tem-perature exceeds 120˚C . It goes out if the temperaturefalls below 115˚C .

13B-71

DIESEL INJECTIONComputer configuration

K9K, and 722 or 728 or 729 or 732

13B

The system can be programmed and reprogrammedvia the diagnostic socket using the diagnostic tool .

PROGRAMMING, REPROGRAMMING OR REPLACING THE COMPUTER

Before programming, reprogramming or replacing the computer, save to the diagnostic tool the fol-lowing data:

- the C2I parameters (individual injector correction),

- the engine adaptives using command SC003« Save computer data » .

After programming, reprogramming or replacing the computer:


- start and then stop the engine (to initialise the com-puter) and wait for 30 seconds ,

- switch on the ignition again.

- Use the diagnostic tool :

• use command SC001 « Write saved data » torestore the C2I and engine adaptives,

• enter the VIN using command VP010 « WriteVIN » ,

• rectify any faults in computers indicated by thediagnostic tool ,

• clear the computer memory,

• carry out a road test,

• carry out a new check using the diagnostic tool .

Equipment required

diagnostic tool

WARNING- Connect (to the mains or the cigarette lighter) the

diagnostic tool .

- Check the condition of the battery.

- Connect a battery charger (throughout the dura-tion of computer (re)programming, the engine coo-ling fan is automatically engaged).

- Comply with the engine coolant temperaturevalues given in the diagnostic tool beforecarrying out any (re)programming.

WARNING



- Running tests with computers borrowed fromthe Parts Department or from another vehiclewhich must then be returned is prohibited.

- The computers are permanently coded.

Note:

If commands SC001 and SC003 are not run orcannot be run following programming, repro-gramming or replacement of the computer, theC2I of each injector must be written manually,reading the C2Is on the injectors (see 13B, Die-sel Injection, Injectors: Configuration ).

13B-72

DIESEL INJECTIONComputer configuration

F9Q, and 800 or 808

13B

The system can be programmed and reprogrammedvia the diagnostic socket using the diagnostic tool (re-fer to Technical Note 3585A ).

PROGRAMMING, REPROGRAMMING OR REPLACING THE COMPUTER

When a computer is reprogrammed or replaced, it isnecessary to reprogram it with the IMA (InjectorFlow Correction) codes of the four injectors.

There are two possibilities:

- If it is possible to enter into dialogue with the computer:

• download the data from the old computer into thediagnostic tool ,

• replace the computer,

• transfer the data from the diagnostic tool to thenew computer,

• using the diagnostic tool , ensure that the com-puter has not detected any faults relating to the in-jector codes and that the instrument panelwarning light is off.

- If it is not possible to enter into dialogue with the computer:


• read the data from the injectors,

• enter it into the computer using the diagnostictool ,

• reconfigure the computer for the equipment (airconditioning),

• using the diagnostic tool , ensure that the com-puter has not detected any faults relating to the in-jector codes and that the instrument panelwarning light is off.

Equipment required

diagnostic tool

WARNING

- Connect the diagnostic tool (to the mains or thecigarette lighter).

- Check the condition of the battery.

- Connect a battery charger (the engine coolingfans are automatically activated for the entireduration of the computer (re)programming ).

- Keep to the engine coolant temperature guidelinessupplied in the diagnostic tool before carryingout any (re)programming.

13B-73

DIESEL INJECTIONHigh pressure pipe: Checking

K9K, and 722 or 728 or 729

13B

Reprime the diesel circuit using the manual primingpump.


Run command AC029 « high pressure circuit sea-ling test » , in the « LPG/fuel circuit » tab.

Check that there are no leaks in the high pressurecircuit.

Deal with the causes of any leaks.


Equipment required

diagnostic tool

WARNING

After any operation, check that there are is no die-sel fuel leakage.

Note:

The diagnostic tool can be used for testing thehigh pressure circuit with the engine running.

This command can be used for finding a leak dueto an incorrectly fitted or tightened union. Thiscommand only works if the engine coolant tem-perature is above 60˚C . The fault finding proce-dure will not reveal small leaks due to incorrecttightening.

WARNING

Do not leave anything in the engine bay duringthe test phase (significant vibration).

Note:

The engine automatically runs a cycle of fouraccelerations and decelerations to lower the railpressure.

13B-74


K9K, and 732

13B

Reprime the diesel circuit using the manual primingpump.




Loosen the clip and (2) move the air inlet duct aside(3) .

Pull out the clip.

Remove the stainless steel pipe mounting bolt (4) .

Move the air inlet duct to one side (5) .

Equipment required

diagnostic tool

WARNING

After any operation, check that there are is no die-sel fuel leakage.

112815

112811

112991

13B-75


K9K, and 732

13B


Remove:

- the mounting nut and bolt (7) from the injection railprotector cover,


Refit the clip onto the stainless steel pipe if necessa-ry.

Clip the stainless steel pipe to turbocharger.

Refit the air inlet duct on the damper valve.

Tighten the clip.

Connect:



Run command AC029 « high pressure circuit sea-ling test » , in the « LPG/fuel circuit » tab.

Check that there are no leaks in the high pressurecircuit.

Deal with the causes of any leaks.

Disconnect:


- the air inlet pressure sensor connector.

Loosen the clip and move the air inlet duct aside.

Pull out the stainless steel pipe clip.

Remove the air inlet duct.

Refit:


- the injection rail protector cover mounting nut andbolt,

Clip the injection rail protector cover.


Clip the stainless steel pipe to the turbocharger.

Refit:

- the stainless steel pipe mounting bolt,

- the air inlet duct on the damper valve.

Tighten the clip.

Connect:




112992

Note:

The diagnostic tool can be used for testing thehigh pressure circuit with the engine running.

This command can be used for finding a leak dueto an incorrectly fitted or tightened union. Thiscommand only works if the engine coolant tem-perature is above 60˚C . The fault finding proce-dure will not reveal small leaks due to incorrecttightening.

WARNING

Do not leave anything in the engine bay duringthe test phase (significant vibration).

Note:

The engine automatically runs a cycle of fouraccelerations and decelerations to lower the railpressure.

13B-76

DIESEL INJECTIONHigh pressure pipe: Replacement

K9K, and 722 or 728 or 729 or 732

13B



Disconnect air inlet duct (1) .



Equipment required

diagnostic tool

pipe socket for tightening the pump-rail high-pres-sure pipe (19-17 mm Crowfoot spanner)

high-pressure pipe wrench (DM19)

pipe socket for tightening injector-rail high pressurepipes ("Crowfoot 18-17" wrench)

low torque wrench

Tightening torquesm

rail mounting nuts 28 Nm

« pump-rail » high-pressure pipe nuts

38 Nm

« rail-injectors » high-pressure pipe nuts

38 Nm

filler neck nut on the rail 21 Nm


4 Nm

Note:


IMPORTANT


• that the injector rail is not under pressure,

• that the fuel temperature is not too high.

- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.

- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.

WARNING

- Ensure that you have a special high-pressureinjection circuit blanking plugs kit.

- Ensure that any high-pressure pipe or high-pres-sure pipe clips that have been removed are repla-ced.

K9K, and 722

102120

1

13B-77


K9K, and 722 or 728 or 729 or 732

13B

Pull out clip (2) .

Loosen bolt (3) .

Move aside the air duct (4) .

Remove diesel fuel splash plate (5) .

Remove dipstick guide tube (6) .

Fit blanking plugs into the openings.

Carefully disconnect:

- the heater plugs (7) ,

- the injectors,

- the high-pressure pump electrical connectors (8) ,

- the diesel supply and return pipes (9) .

K9K, and 728 or 729

110325

110323

2

3

4

102362

102361

5

7777

8996

13B-78


K9K, and 722 or 728 or 729 or 732

13B


- the diesel return pipe (10) connecting the injectorsto the high-pressure injection pump,

- the spherical injector rail pressure sensor (11) ,

- the accelerometer (12) ,

- the oil level sensor (13) ,

- the timing cover cylinder marking sensor (14) .

Shift the electrical harness to one side.

Remove filler neck (15) located on the spherical in-jector rail.

102360

WARNING- Be sure to hold the intermediate injector union(18) in place with a spanner when loosening thehigh-pressure pipes.

- Do not damage injector leak return nozzle (19) .

12 11

10

15

14

13

13B-79


K9K, and 722 or 728 or 729 or 732

13B

Loosen mounting nuts (16) on the spherical injectorrail by several turns.

Remove clips (17) connecting the high-pressure pi-pes.

Loosen:

- the high-pressure pipe nut at the injector end usingtool (Mot. 1566) ,

- the high-pressure pipe nut at the injector rail endusing tool (Mot. 1566) .

Move the nuts along the tube, keeping the olive incontact with the taper.

Remove high-pressure pipes (20) one by one.


20803

19724

1717

1616

19

18

Note:

Loosen the nuts pipe by pipe.

20803

20

13B-80


K9K, and 722 or 728 or 729 or 732

13BREFITTING

I - REFITTING THE « PUMP - RAIL » HIGH PRESSURE PIPE

Remove the plugs.

Insert the high-pressure pipe olive in the high-pres-sure pump high-pressure outlet taper.

Insert the high-pressure pipe olive in the sphericalinjector rail inlet taper.

Finger tighten the high-pressure pipe nuts, startingwith the one at the rail end.

Slightly pretighten the high-pressure pipe nuts.

II - REFITTING THE « RAIL - INJECTORS » HIGH-PRESSURE PIPES

Remove the plugs.

Insert the high-pressure pipe olive in the injectorhigh-pressure inlet taper.

Insert the high-pressure pipe olive in the rail high-pressure outlet taper.

Tighten the high-pressure pipe nuts by hand, star-ting with the nut at the injector end.


Fit a new clip provided with the new high-pressure pipe:

- insert the first half-shell using adjustable pliers,

- insert the second half-shell using adjustable pliers.

20960

WARNING

- Before fitting a new high-pressure pipe, lightlylubricate the nut threads with the oil from theapplicator provided in the new parts kit.

- Be careful not to allow oil into the high-pressurepipe.

- Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.

WARNING

Do not remove the caps from each componentuntil the last moment.

WARNING

When tightening the high-pressure pipes, it isessential to support the injector central union(18) .

Note:

The order of fitting the injector rail pipes is notimportant.

19723

Note:

Follow the direction of fitting (the lugs onlyengage in one position).

13B-81


K9K, and 722 or 728 or 729 or 732

13BIII - REFITTING THE « PUMP - RAIL » HIGH PRESSURE PIPE AND THE « RAIL - INJECTOR » HIGH PRESSURE PIPES

Tighten to torque the rail mounting nuts ( 28 Nm ) .

WARNING

- Do not touch the high-pressure pipes with thespanner when tightening.

- Be sure to hold the injector central union inplace with a spanner when tightening.

13B-82


K9K, and 722 or 728 or 729 or 732

13B

Tighten to torque and in order the « pump-rail » high-pressure pipe nuts ( 38 Nm ) :

- pump end,

- rail end.

Use the pipe socket for tightening the pump-railhigh-pressure pipe (19-17 mm Crowfoot span-ner) or the high-pressure pipe wrench (DM19) .

Tighten to torque and in order the « rail-injectors » high-pressure pipe nuts ( 38 Nm ) :

- injectors end,

- rail end.

Use the pipe socket for tightening injector-railhigh pressure pipes ("Crowfoot 18-17" wrench)or the high-pressure pipe wrench (DM19) .


Prime the diesel circuit using the priming pump.

Tighten to torque the filler neck nut on the rail ( 21Nm ) using a low torque wrench .

Connect the battery, starting with the negative termi-nal.


110404

Note:

Tighten each pipe fully before moving on to thenext pipe.

WARNING


WARNING

Confirm that there is no diesel fuel leak:

- check the sealing after repair (see 13B, Dieselinjection, High-pressure pipe: Sealing check,

- let the engine run at idle speed until the enginecooling fan starts to operate,


- carry out a road test,


- check that there is no diesel fuel escaping.

13B-83

DIESEL INJECTIONDiesel injector: check

K9K, and 722 or 728 or 729

13BCommand AC029 « High pressure circuit sealingtest » in the « Fuel/LPG » tab also enables the lea-kage rate of each injector to be checked in order todetermine an internal leak in one or several injec-tors. This test only works when the engine tempera-ture is greater than 60˚C .


Disconnect the return pipes of the four injectors.

Connect the four transparent hoses with an internaldiameter of 4 mm and a length of 50 cm in the placeof the return pipes.

Immerse these hoses into four graduated measuringcylinders (or use the measuring tool found in the« capped rail » kit).

Start the engine.

Allow the engine to run for 2 minutes at idle speed.

Run command AC029 « High pressure circuit sea-ling test » in the « Fuel/LPG » tab. The engine willautomatically carry out a cycle of four accelerations /decelerations to increase the pressure in the rail andcheck whether there are internal leaks on the injec-tors' return circuit.

When the cycle is complete, the test must be runagain, to obtain a correct reading of the flow of eachinjector.

After two cycles the flow of each injector should be35 ml .

Replace the faulty injector.

IMPORTANT

Never leave a tool or other object on the side ofthe engine housing during the four cycles (signifi-cant vibration).

13B-84

DIESEL INJECTIONHigh pressure pump: Removal - Refitting

K9K, and 722 or 728 or 729

13B


Mot. 1367-02 Engine support

Mot. 1367 Engine support tool forreplacing cyl inderhead

Mot. 1606 High pressure pump-pulley retaining tool

Mot. 1525 Extractor for timinggear with tapered hub

Mot. 1525-02 Adaptor claws for Mot.1525

Equipment required

diagnostic tool

Tightening torquesm

high pressure injectionpump mounting bolts

21 Nm

high pressure injectionpump pulley mountingnut

55 Nm

rail mounting nuts 28 ±±±± 3 Nm

union at the rail end 24 Nm

union at the pump end 24 Nm


4 Nm

WARNING


- a new set of blanking plugs (part no.: 77 01 206804 ),

- cleaning cloths (part no.: 77 11 211 707 ),

- cleaning product (part no.: 77 11 224 188 ).

WARNING

Tighten to torque 38 Nm the « pump-rail » and « injection rail » high pressure pipes with the fol-lowing part numbers:

- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .

for high pressure pipes with other part numbers,tighten to a torque of 24 Nm .

IMPORTANT


• that the injection rail is not under pressure,



- Loosening a high pressure pipe union when theengine is running is strictly prohibited.

WARNING

- Obtain a set of special high pressure injection cir-cuit plugs.

- Always replace any high pressure pipe or highpressure pipe clip removed with a new one.

WARNING

Never turn the engine against its operating direc-tion.

13B-85


K9K, and 722 or 728 or 729

13BREMOVAL

I - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING NUMBER 070 575

Replace the « pump-pulley » assembly, followingthe removal procedure for the high pressure pumpnot fitted with a pulley 070 575 .

Remove:



- the « pump-pulley » assembly.

II - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING A NUMBER OTHER THAN 070 575


Disconnect:


- the air inlet duct (1) .

21265

WARNING

Removing any high pressure pump pulley bea-ring the number 070 575 is strictly prohibited.

21265

K9K, and 722

102120

13B-86


K9K, and 722 or 728 or 729

13B

Pull out the clip.

Undo the bolt (2) .


Remove dipstick guide tube (4) .

Plug the opening on the engine block.



- the injectors,

- the fuel flow actuator electrical connectors (6) ,


- the supply and return pipes (8) .

Remove the diesel fuel splash plate (9) .

K9K, and 728 or 729

110325

110323

102361

102362

4

55

55

6

7

88

13B-87


K9K, and 722 or 728 or 729

13B

Disconnect:

- the fuel return pipe connecting the injectors to thepump (10) ,

- the rail pressure sensor (11) ,

- the accelerator (12) ,

- the oil level sensor (13) ,

- the cylinder reference sensor (14) on the timing co-ver.

Unclamp the electrical harness and move it to oneside.

Remove the channel located on the spherical injec-tion rail.

Remove the (16) « pump-rail » high pressure pipe(see 13B, Diesel injection, High pressure pipe:Replacing ).

Slacken the rail mounting nuts (15) by a few turns.

Loosen the nut at the pump end, then the nut at therail end.

Slide the nut down the tube, keeping the olive in con-tact with the taper.

Plug the openings on the injection circuit.

Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .

102360 102083

19626

13B-88


K9K, and 722 or 728 or 729

13B

Remove:

- the right-hand suspended mounting support andcover,

- the tie-bar and make a mark.

Remove the upper timing cover by unclipping both tabs (17) .

102114

19654

13B-89


K9K, and 722 or 728 or 729

13B

Remove the engine tie-bar mounting bolts (18) onthe gearbox and sub-frame.

Raise the engine a few centimetres for access to thesuspended mounting attachments on the cylinderhead and the high pressure pump pulley.

Remove the mounting bolts securing (19) the enginetie-bar on the gearbox and on the engine sub-frame.

Raise the engine a few centimetres for access to thesuspended mounting attachments on the cylinderhead and the high pressure pump pulley.

102115

WARNING

Do not dislodge the right-hand driveshaft whenlifting the engine.


103749

WARNING

Do not dislodge the right-hand driveshaft whenlifting the engine.

13B-90


K9K, and 722 or 728 or 729

13B

Remove:

- the cylinder reference sensor (20) ,

- the plastic bolt (21) ,

Unclip the three tabs (22) .


19654-1

13B-91


K9K, and 722 or 728 or 729

13B

Remove the suspended mounting (23) from the cy-linder head.

Position the engine at Top Dead Centre. The cams-haft pulley hole (24) should be opposite the cylinderhead hole (25) .

19654-2

23167

13B-92


K9K, and 722 or 728 or 729

13B

Position the (Mot. 1606) (3) .

If necessary, turn the engine slowly to adjust the po-sition of the locking tool on the pump pulley teeth.

Remove the high pressure pump pulley nut (26) ,holding the pulley with an open-jawed spanner.

Fit the (Mot. 1525) (4) fitted with the (Mot. 1525-02).

23168 23169

WARNING

Ensure that the tool pushrod is correctly orientedand is pressing against the high pressure pumpshaft.

13B-93


K9K, and 722 or 728 or 729

13B

Remove the high pressure pump mounting bolts(27) .

Screw down the pushrod of the (Mot. 1525) .

Detach the « pulley - pump » assembly.

Remove:

- the high pressure pump,

- the high pressure pump extractor tool.

REFITTING

Ensure that the pulley clamping pin is still in place.

Fit the high pressure injection pump.

Tighten to torque the high pressure injectionpump mounting bolts ( 21 Nm ) .

Fit the high pressure injection pump pulley nut.

Tighten to torque the high pressure injectionpump pulley mounting nut ( 55 Nm ) , holding thepulley with an open-jawed spanner.


Before fitting the new high pressure pipe, lightly lu-bricate the union threads with the oil from the appli-cator provided in the new parts kit.

102085

WARNING

Do not remove the blanking plugs from eachcomponent until the last moment.

WARNING

Always replace all high pressure pipes removed.

WARNING

Some pipes are supplied with applicator andsome without.

The pipes supplied without applicator are self-lubricating pipes.

13B-94


K9K, and 722 or 728 or 729

13B

Refit the high pressure pipe - to do this:

- remove the protective plugs,

- insert the high pressure pipe olive in the pump out-let taper,

- insert the high pressure pipe olive in the rail inlet ta-per.

Finger tighten the high pressure pipe unions, star-ting with the one located at the rail end.

Tighten to torque the rail mounting nuts ( 28 ±±±± 3Nm ) .


- the union at the rail end ( 24 Nm ) ,

- the union at the pump end ( 24 Nm ) .


Prime the diesel fuel supply circuit with the primingpump (automatic degassing).



If replacing the high pressure pump, reprime the die-sel circuit using the diagnostic tool .

Connect the diagnostic tool to the vehicle.

Establish dialogue with the diesel injection compu-ter.

Run command AC212 « FILLING NEW PUMPCHAMBER » .

Follow the instructions on the diagnostic tool untilthe command is completed.

Start the engine.

If the engine does not start or if the start-up sequen-ce is interrupted:


- wait for 30 seconds ,

- restart the engine.

Using the diagnostic tool clear any faults stored bythe injection computer.

Check the high pressure circuit sealing after the re-pair operation (see 13B, Diesel injection, Highpressure pipe: Test ).

110404

Note:

For VDiag numbers earlier than VDiag 48 , it is essentialthat the injection computer is reprogrammed.

If the reprogramming is not carried out, do not apply theprocedure detailed below but prime the fuel circuit usingthe priming bulb.

WARNINGNever start the engine until the pump has been reprimed.

Also comply with the operation instructions provided toprevent the high pressure pump from being damagedinternally, due to running with no load and no diesel lubri-cation.

Note:

The star ting phase can last up to 20 seconds .

WARNING


- let the engine run at idle speed until the engine coolingfan starts to operate,




13B-95


F9Q, and 800 or 808

13B

It is essential to read the repair precautions (see 13A,Diesel injection, Repair precautions ).



Remove:


- the timing belt (see 11A, Top and front of engine,Timing belt ).

- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting), if fitted to the vehicle.


Mot. 1668 Locking high pressurepump sprocket


Mot. 1525-03 Adapter claws for Mot.1525 (for 33-tooth pul-ley)

Mot. 1746 Offset spanner fortightening high pres-sure pump pipe


Equipment required

diagnostic tool

Tightening torquesm

high-pressure pumpmounting bolts on thepump supports

30 Nm

high-pressure pumppulley nut

50 Nm

high-pressure pumpsupport mounting boltson the cylinder head

20 Nm + 80˚

high-pressure pumprear support mountingbolts on the cylinderblock

44 Nm


22 Nm

pump-rail high-pressurepipe nut on the pumpside

29 Nm

pump-rail high-pressurepipe nut on the rail side

25 Nm


4 Nm

IMPORTANT


- that the injector rail is not under pressure,



WARNING

Ensure that any high-pressure pipe removed isreplaced.

WARNING


13B-96


F9Q, and 800 or 808

13B

Disconnect:

- the diesel fuel heater from the diesel filter,

- the heater plugs,

- the pressure regulator (1) ,

- the pressure sensor (2) (version without injector railprotector).

Disconnect the diesel supply and return pipes.

Plug the openings.

Remove the diesel pipes retaining clip.

Remove the pump-rail high-pressure pipe.

Plug the openings.

Remove the two mounting bolts (3) from the high-pressure pump on the high-pressure pump rear sup-port.

102352

102351

102353

102348

13B-97


F9Q, and 800 or 808

13B

Remove:

- the three mounting bolts (4) from the high-pressurepump front support,

- the high-pressure pump, with the high-pressurepump support.


Remove the nut (5) from the high-pressure pumppulley.

Fit the pulley extractor (Mot. 1525) (2) with claws(Mot. 1525-03) for pulleys with thirty-three teeth.

Remove the pulley by tightening the pulley extractorthrust bolt (6) .

Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.1668) .

Remove:

- the three mounting bolts (7) from the high-pressurepump,

- the high-pressure pump.

102350

102893

102894

102345

13B-98


F9Q, and 800 or 808

13BREFITTING

Refit the high-pressure pump on the pump support.

Tighten to torque:

- the high-pressure pump mounting bolts on thepump supports ( 30 Nm ) ,

- the high-pressure pump pulley nut ( 50 Nm ) byimmobilising the pulley with (Mot. 1668) .

Push the ring (8) back as shown in the diagram.

Undo the two mounting bolts (9) on the high-pressu-re pump rear support on the cylinder block.

Refit the high-pressure pump assembly and thepump support.

Tighten to torque the high-pressure pump supportmounting bolts on the cylinder head ( 20 Nm +80˚ ) .

I - REFITTING THE HIGH-PRESSURE INJECTION PUMP REAR SUPPORT

Finger tighten the mounting bolts to press the sup-port against the high-pressure pump and the cylin-der block.

Tighten to torque the high-pressure pump rearsupport mounting bolts on the cylinder block (44 Nm ) .

II - REFITTING THE PUMP - RAIL HIGH-PRESSURE PIPE

Undo the injector rail mounting bolts (the injector railshould be « loose » ).

Insert the high-pressure pipe olive in the pump outlettaper

Insert the high-pressure pipe olive into the injectorrail inlet taper.



Tighten to torque the injector rail mounting bolts (22 Nm ) .

Tighten to torque using (Mot. 1746) or (Mot. 1566) :

- the pump-rail high-pressure pipe nut on thepump side ( 29 Nm ) ,

- the pump-rail high-pressure pipe nut on the railside ( 25 Nm ) .


WARNING


102349

WARNING

- Be careful not to allow oil into the high-pressurepipe.

- Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.

WARNINGDo not remove the plugs from each componentuntil the last moment.

13B-99


F9Q, and 800 or 808

13BRefit:


- the accessories belt (see 11A, Top and front ofengine, Accessories belts ).

For versions with injector rail protector covers:

- Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).

Prime the diesel circuit using the manual primingpump.




- Remove the air inlet duct,

- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).


Note:

Refit the inlet duct without refitting the injector railprotector or replacing the duct seal.

WARNING

Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).

WARNING


- Run the engine at idle speed,

- accelerate several times under no load,

- Switch off the ignition,

- Check that there is no diesel fuel escaping.

13B-100


F9Q, and 804

13B

It is essential to read the repair precautions (see 13A,Diesel injection, Repair precautions ).



Remove:

- the accessories belt (see 11A, Top and front ofengine, Accessories belts ),

- the timing belt (see 11A, Top and front of engine,Timing belt ).


Mot. 1668 Locking high pressurepump sprocket


Mot. 1525-03 Adapter claws for Mot.1525 (for 33-tooth pul-ley)



Equipment required

diagnostic tool

Tightening torquesm

high-pressure pumpmounting bolts on thepump supports

30 Nm

high-pressure pumppulley nut

50 Nm

high-pressure pumpsupport mounting boltson the cylinder head

20 Nm + 80˚

high-pressure pumprear support mountingbolts on the cylinderblock

44 Nm

high-pressure pumpmounting bolts on therear pump support

30 Nm


25 Nm

pump-rail high-pressurepipe nut on the pumpside

29 Nm

pump-rail high-pressurepipe nut on the rail side

25 Nm


4 Nm

IMPORTANT





WARNING


WARNING


13B-101


F9Q, and 804

13B

Remove the injector rail protector (see 13B, Dieselinjection, Injector rail protector: Removal - Refit-ting ).

Disconnect:

- the diesel fuel heater from the diesel filter,

- the heater plugs,

- the pressure regulator (1) ,

Disconnect the diesel supply and return pipes (2) .

Plug the openings.

Remove the diesel pipes retaining clip.

Remove the pump - rail high-pressure pipe (3) .

Plug the openings.

Remove the bolts mounting the high-pressure pumpto the high-pressure pump rear support.

111888

102351

102353

102348

13B-102


F9Q, and 804

13B

Remove:

- the bolts (5) mounting the high-pressure pumpfront support,

- the high-pressure pump, with the high-pressurepump support.


Remove the nut (7) from the high-pressure pumppulley.

Set the pulley extractor (Mot. 1525) in place; fittedwith claws (Mot. 1525-03) (8) for pulleys with thirty-three teeth.

Remove the pulley by tightening the pulley extractorthrust bolt (9) .

Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.1668) .

Remove:

- the high-pressure pump mounting bolts (10) ,


102350

102893

102894

102345

13B-103


F9Q, and 804

13BREFITTING

Refit the high-pressure pump on the pump support.

Tighten to torque:

- the high-pressure pump mounting bolts on thepump supports ( 30 Nm ) ,

- the high-pressure pump pulley nut ( 50 Nm ) byimmobilising the pulley with (Mot. 1668) .

Push the ring (11) back as shown in the diagram.

Undo the two mounting bolts on the high-pressurepump rear support on the cylinder block.

Refit the « high-pressure pump - pump support » as-sembly.

Tighten to torque the high-pressure pump supportmounting bolts on the cylinder head ( 20 Nm +80˚ ) .

I - REFITTING THE HIGH-PRESSURE PUMP REAR SUPPORT

Finger tighten the mounting bolts to press the sup-port against the high-pressure pump and the cylin-der block.

Tighten to torque:

- the high-pressure pump rear support mountingbolts on the cylinder block ( 44 Nm ) ,

- the high-pressure pump mounting bolts on therear pump support ( 30 Nm ) .

II - REFITTING THE PUMP-RAIL HIGH-PRESSURE PUMP

Undo the injector rail mounting bolts (the injector railshould be « loose » ).

Refit a new pump-rail high-pressure pipe.


Tighten to torque the injector rail mounting bolts (25 Nm ) .


- the pump-rail high-pressure pipe nut on thepump side ( 29 Nm ) ,

- the pump-rail high-pressure pipe nut on the railside ( 25 Nm ) .


WARNING


102349

WARNING- Be careful not to allow oil into the high-pressure

pipe.

- Do not put high-pressure pipes under stress.

WARNING

Do not remove the plugs from each componentuntil the last moment.

13B-104


F9Q, and 804

13BRefit:


- the accessories belt (see 11A, Top and front ofengine, Accessories belts ),

- the air inlet duct (see 12A, Fuel mixture, Air inletduct: Removal - Refitting ).




Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).

Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).


Note:


WARNING


WARNING


- Run the engine at idle speed,


- Switch off the ignition,


13B-105


K9K, and 732

13B

REMOVAL



Switch off the ignition and wait 30 seconds beforestarting work on the injection system.


Disconnect the battery (see 80A, Battery: Removal- Refitting .

Pull the clip

Remove the air inlet duct mounting bolt.

Move the air inlet duct to one side.

Remove:

- the rigid air duct between the intercooler hose andthe turbocharger,


Mot. 855 Timing gear lockingstrap.

Mot. 1768 SIEMENS injectionpump pulley extractorclaws



Equipment required

diagnostic tool

Tightening torquesm

high-pressure pumppulley mounting bolt

55 Nm

high-pressure pumpmounting bolts

21 Nm

high-pressure pipe nuts 24 Nm

WARNING

Before starting work on the vehicle, have to hand:

- a new plug kit (part no. 77 01 476 857) ,

- some cleaning cloths (part no. 77 11 211 707) ,

- cleaning product (part no. 77 11 224 188) .

WARNING


- the high-pressure pipe between the high-pressurepump and the injector rail.

IMPORTANT




It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, cleanliness guidelines ).

112811

13B-106


K9K, and 732

13B- the injector rail protector cover

Disconnect:




- the fuel flow actuator connector,

- the fuel temperature sensor connector.

Clean (see 13B, Diesel injection, Repair precau-tions ):

- the fuel return pipe connecting the injectors,

- the fuel inlet pipe.

Disconnect:

- the fuel return pipe connecting the injectors to thehigh-pressure pump,

- the fuel inlet pipe.

Fit blanking plugs into the openings (see 13B, Die-sel injection, Cleanliness guidelines ).

Remove:

- the accessories belt (see section 10A, Accesso-ries belt: Removal - Refitting ).

- the timing belt (see section 10A, Timing belt: Re-moval - Refitting ).

Remove:

- the mounting bolts (3) from the dipstick guide onthe mounting of the diesel anti-splash device.

- the bolt (4) and mounting nuts (5) from the injectorrail protector cover support.


Unpick the drain pipe on the injector rail protectorcover support.

Clean the high-pressure pipe between the high-pressure pump and injector rail (see 13B, Diesel in-jection, Repair precautions ).

Remove:

- the injector rail protector cover support,

- the high-pressure pipe between the high-pressurepump and rail.

Fit the correct blanking plugs on:

- the high-pressure pump,

- the injector rail.

Note:

Make preparations for the fuel outflow,

Clean with new wipes.

WARNING

- Strictly observe the cleanliness guidelines.

- Beware of diesel fuel splashing when discon-necting the supply unions.

111748

Note:

Make preparations for fuel outflow,

Clean with new wipes.

WARNING

When loosening the union of the high-pressurepipe on the high-pressure pump, the interme-diate nut must be secured on the high-pressurepump using a lock wrench.

13B-107


K9K, and 732


REMOVAL OF THE HIGH-PRESSURE PUMP

Remove:

- the high-pressure pump mounting bolts,


REMOVAL OF THE HIGH-PRESSURE PUMP PULLEY

Hold the high-pressure pump in a vice, using thelower securing point on the pulley side.

Hold the high-pressure pump pulley with a 32 mmoffset wrench then remove the mounting nut fromthe pulley.

Fit (Mot. 1768) on the high-pressure pump pulleythen extract the pulley.

REFITTING

WARNING

If the high-pressure pump is to be reused, keep itin a sealed plastic bag all the time it is discon-nected.

WARNING

When replacing a high-pressure pump, retain thehigh-pressure pump pulley and refit on the newpump.

111743

111744

Note:

The high-pressure pump pulley can also beimmobilised using the (Mot. 855) .

WARNING

Ensure that you do not mark the high-pressurepulley when extracting it using the tool.

You must replace any damaged high-pressurepump pulleys.

WARNING

- Remove the blanking plugs only before recon-necting the fuel circuit pipes

- The plugs are single-use. Do not reuse themand throw away the complete kit after opening.

13B-108


K9K, and 732

13BI - REFITTING OPERATION FOR PART CONCERNED

1 - REFITTING THE HIGH-PRESSURE PULLEY

Take the high-pressure pump out of its plastic bag.

Finger tighten the mounting nut of the high-pressurepump pulley.

Lock the high-pressure pump pulley with the toolsused previously.

Tighten to torque the high-pressure pump pulleymounting bolt ( 55 Nm ) .

2 - REFITTING THE HIGH-PRESSURE PUMP

Position the high-pressure pump on the cylinderhead.

Tighten to torque the high-pressure pump moun-ting bolts ( 21 Nm )

Remove: the blanking plugs from the injector rail andhigh-pressure pump.

Fit a new high-pressure pipe between the injectorrail and the high-pressure pump.

Hand-tighten the nut on the high-pressure pipe onthe pump end, then the one on the rail end.

Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1746) or (Mot. 1566) and startingwith the high-pressure pump side.

WARNING

When replacing an injector rail, only remove itfrom its packaging just before it is refitted.

Note:

If the new parts kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).

13B-109


K9K, and 732

13BII - FINAL OPERATION

Refit:

- the injector rail protector cover support,

- the injector rail protector cover support mountingnuts and bolt,

- the dipstick guide,

- the dipstick guide mounting bolts.

Connect:

- the drain pipe to the injector rail protector coversupport




- the fuel flow actuator connector,

- the fuel return pipe connecting the injectors to thehigh-pressure pump,


- the fuel temperature sensor connector.

Reposition the wiring harness.

Refit:

- the mounting nut to the wiring harness retainingclip,

- the timing belt (see section 10A, Timing belt: Re-moval - Refitting ),

- the accessories belt (see section 10A, Accesso-ries belt: Removal - Refitting ).

- the injector rail protector cover,

Clip the air inlet duct onto the turbocharger.

Refit the inlet duct mounting bolt.

Refit the battery (see 80A, Battery: Removal - Re-fitting ).

Reprime the fuel circuit using the priming pump.

Using the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.

Using diagnostic tool , check that there are no sto-red faults. Clear them if necessary.

Note:

Ensure that the injector rail protector supportmounting bolt does not fall under the high-pres-sure pump.

WARNING

Confirm that there are no diesel fuel leaks:

- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: test ),

- run the engine at idle speed,


- Check that there are no diesel fuel leaks

13B-110


M9R, and 700

13BREMOVAL


It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this system(see 13B, Diesel injection, Repair precautions).


Remove:

- the engine protector,


Remove the high-pressure pipe between the high-pressure pump and the injector rail (see 13B, Dieselinjection, High-pressure pipe: Replacing ).

Disconnect the fuel inlet quick-release union on thehigh-pressure pump.

Plug the openings.

Disconnect the fuel return union.

Plug the openings.

Disconnect the pressure regulator connector on thehigh-pressure pump.


Remove:

- the high-pressure pump mounting bolts,





Equipment required

diagnostic tool

Tightening torquesm

high-pressure pumpmounting bolts

25 Nm

high-pressure pipeunion on the high-pres-sure pump

32 Nm

high-pressure pipeunion on the injector rail

32 Nm

high-pressure piperetaining bracket moun-ting bolts on the bea-ring cap casing

10 Nm

clips on the air filterduct at the turbochar-ger inlet

5.5 Nm

bolts securing the tur-bocharger outlet air ducton the inlet manifold

8 Nm

IMPORTANT





WARNING

Obtain a set of special high-pressure injectioncircuit plugs.


13B-111


M9R, and 700

13BREFITTING


Always replace:

- the high-pressure pump O-ring seal,

- the high-pressure pump mounting bolt.

Lubricate the new high-pressure pump seal with en-gine oil.


Fit the high-pressure pump.

Finger tighten the high-pressure pump mountingbolts as far as possible.

Tighten to torque and in order the high-pressurepump mounting bolts ( 25 Nm ) (1-2-3-4).

WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.

WARNING

Do not apply pressure to the high-pressure pumpgear teeth.

WARNING

Check that the high-pressure pump is in contactwith the cylinder head before positioning thebolts.

13B-112


M9R, and 700

13BIII - FINAL OPERATION


Remove the « wiring harness and fuel pipe » as-sembly.

Check that the seal is correctly positioned on thehigh-pressure pipe.

Finger tighten as far as possible and in order:

- the high-pressure pipe union on the high-pressurepump,

- the high-pressure pipe union on the injector rail,

- the bolt mounting the high-pressure pipe retainingbracket on the bearing cap casing.


- the high-pressure pipe union on the high-pres-sure pump ( 32 Nm ) , using (Mot. 1566) ,

- the high-pressure pipe union on the injector rail( 32 Nm ) , using (Mot. 1746) ,

- the high-pressure pipe retaining bracket moun-ting bolts on the bearing cap casing ( 10 Nm ) .

Tighten to torque:

- the clips on the air filter duct at the turbochar-ger inlet ( 5.5 Nm ) ,

- the bolts securing the turbocharger outlet airduct on the inlet manifold ( 8 Nm ) .




WARNING

Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.

Do not allow oil into the high-pressure pipe.

WARNING


WARNING







13B-113

DIESEL INJECTIONDiesel injector: Removal - Refitting

K9K, and 722 or 728 or 729

13B

It is essential to read the repair precautions wheneverwork is carried out (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).

REMOVAL




Disconnect:

- the heater plugs,

- the connectors to injectors no. 3 and no. 4.

- injector connectors no. 1 and no. 2.


Equipment required

diagnostic tool

Tightening torquesm

injector mounting brac-ket

28 Nm

rail mounting nuts 28 Nm

high-pressure pipe nutsof the « pump-rail »

24 Nm

high-pressure pipe nutsof the « injector rail »

24 Nm

of the neck on the rail 21 Nm

IMPORTANT

Before any operation on the injection circuit, use thediagnostic tool to check that the injector rail is nolonger under pressure, and that the fuel tempera-ture is not too high.

It is essential to respect the safety and cleanlinessadvice specified in this document whenever work iscarried out on this system.


WARNING

Tighten to torque 38 Nm the « pump-rail » and « injector-rail » high-pressure pipes with one of the following part numbers:

- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .

For high-pressure pipes with different part numbers,tighten to torque 24 Nm .

WARNING





102362

13B-114


K9K, and 722 or 728 or 729

13B

Disconnect the injector diesel return pipe (2) .


Disconnect the high-pressure pump electrical con-nectors (3) .

Remove the mounting bolts from the neck (4) fixedto the spherical injector rail.

Pull the electric wiring harness to one side with theneck on the side.

Loosen the injector rail mounting nuts by severalturns.

Remove the clips connecting the high-pressure pi-pes.

Clean the high-pressure pipe (see 13B, Diesel in-jection, Diesel injection: Precautions during re-pair ).

Remove the « injector-rail » high-pressure pipe con-cerned.

109463 109467

13B-115


K9K, and 722 or 728 or 729


Undo the injector bracket (5) .

Remove the injector (6) .

If an injector is reused, always mark a removed in-jector in relation to its cylinder.

Pull off the compression washer.

REFITTING

I - CLEANING THE INJECTORS

Soak the injectors in degreaser.

Wipe with new cloths (part no.: 77 11 211 707 ).


If removing the four injectors, loosen the mountingnuts of the injector rail by a few turns (the rail shouldbe loose).

Using cloths (part no.: 77 11 211 707 ) soaked in fresh solvent, clean:

- the injector wells,

- the injector bodies,

- the injector brackets.

Use a new cloth to dry components that have beencleaned.

Replace the compression washer with a new one.

Position the injector.

Tighten to torque the injector mounting bracket (28 Nm ) .

109462

Note:

an injector corresponds to a cylinder.

WARNING

It is strictly forbidden to clean the injectors with:

- a wire brush,

- an emery cloth,

- an ultrasonic cleaner.

WARNING

Do not remove the plugs from each componentuntil the last moment.

19724

Note:

If one or more injectors are replaced, note thealphanumeric code (C2I) (7) and the cylinder onwhich it is fitted.

13B-116


K9K, and 722 or 728 or 729

13BIII - FINAL OPERATION


Insert the high-pressure pipe olive into the rail high-pressure conical outlet.

Finger tighten the high-pressure pipe nuts, startingwith the nut at the injector end.


Fit the new clip provided with the new high-pressurepipe.

If removing the four injectors, torque tighten the railmounting nuts ( 28 Nm ) .

Tighten to torque and in order the high-pressure pipe nuts of the « pump-rail » ( 24 Nm ) :

- high-pressure pump end,

- rail end.

Tighten to torque and in order the high-pressure pipe nuts of the « injector rail » ( 24 Nm ) :

- injectors end,

- rail end.

Refit the neck on the injector rail.

Torque tighten the nuts of the neck on the rail ( 21Nm )

Connect:

- the injector diesel fuel return pipe,

- the connectors to injectors no. 1 and no. 2,

- the connectors to injectors no. 3 and no. 4.

- the heater plugs.



Program the alphanumeric code (C2I) for the repla-ced injector(s) using diagnostic tool (see 13B, Die-sel injection, Injectors: configuration ).

20960

WARNING

Before fitting a new high-pressure pipe, lightlylubricate the nut threads with oil from the applica-tor provided with the new part.

Be careful not to allow oil into the high-pressurepipe.

Do not lubricate high-pressure pipes suppliedwithout an applicator; these pipes are self-lubri-cating.

WARNING


Note:

The assembly order of the « injector-rail » high-pressure pipes is not important.

Note:

Tighten a pipe fully before moving on to the nextpipe.

WARNING


- Run the engine until the fan starts up.

- Accelerate several times at no load.

- Switch off the ignition.


13B-117


F9Q, and 800 or 804 or 808

13B

It is essential to read the repair precautions wheneverwork is carried out (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).

Injectors may be replaced individually. Only removethe high-pressure pipe concerned.

REMOVAL



Remove the injector rail protector (see 13B, Dieselinjection, Injector rail protector: Removal - Refit-ting ), if fitted to the vehicle.

For versions without injector rail protectors:

- remove the inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ), if necessary.




Equipment required

diagnostic tool

Tightening torquesm

injector bracket bolt 25 Nm

nut on the injector side 25 Nm

nut on the rail side 29 Nm


4 Nm

IMPORTANT





WARNINGOpening the injectors is prohibited.

13B-118


F9Q, and 800 or 804 or 808

13B

Disconnect the injector connector.

Do not remove the injector clip.

Press the injector clip.

Pull the return rail end piece vertically.

Remove the return rail.


18297-1

13B-119


F9Q, and 800 or 804 or 808

13B

Remove the « injector-rail » high-pressure pipeusing (Mot. 1566) or (Mot. 1746) .


If an injector is reused, always mark a removed in-jector in relation to its cylinder.

Remove:

- the injector bracket mounting bolt,

- the injector and its bracket,

- the compressor washer.

REFITTING

I - CLEANING INJECTORS (IF THEY ARE TO BE REUSED)

Clean, using new cloths soaked in cleaning product (see 13B, Diesel injection, Diesel injection: Re-pair precautions ) clean:

- the injector wells,

- the injector bodies,

- the injector brackets.

Use a new cloth to dry components that have beencleaned.

II - REFITTING THE INJECTOR

1327

WARNING

The injector filter rod must not be removed.

WARNING

When loosening the injector pipe unions (2) onthe injectors, be sure to hold the filter rod retai-ning nuts (3) with a lock wrench.

Note:

an injector corresponds to a cylinder.

WARNING


- a wire brush,

- an emery cloth,


WARNING

Do not remove the protective caps from eachcomponent until the last moment.

13B-120


F9Q, and 800 or 804 or 808

13B

Replace the heat shield washer (4) with a new one.

Refit the injector with its bracket.

Tighten to torque the injector bracket bolt ( 25 Nm) .

Screw, by hand, the high-pressure pipe nuts on therail and injector.


- the nut on the injector side ( 25 Nm ) ,

- the nut on the rail side ( 29 Nm ) ,

1326

Note:

If one or more injectors have been replaced, notedown the alphanumeric code (IMA) that is writtenon the new injector and the cylinder it is fitted on.

WARNING

Do not fit high-pressure pipes without mountings.

WARNING

Always replace any high-pressure pipe removedwith a new one.

WARNING

Always hold the filter rod mounting nuts on theinjector holder with a lock wrench when tighte-ning.

13B-121


F9Q, and 800 or 804 or 808

13B

Refit the return rail (5) .



Push the return rail end piece vertically.

Throw away the plug set upon completion of theoperation.


Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ), if removed.


Program the alphanumeric code (IMA) for the injec-tor(s) replaced using the diagnostic tool (see MR366 Fault finding, 13B, Diesel injection, Fault fin-ding - Replacement of components ).




- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).

- Refit the inlet duct (see 12A, Fuel mixture, Air in-let duct: Removal - Refitting ).

18297-1

Note:


- Refit the inlet duct without refitting the injectorrail protector or replacing the duct seal.

WARNING


WARNING


- Run the engine at idle speed.




13B-122


K9K, and 732

13B

REMOVAL










Equipment required

diagnostic tool

Tightening torquesm

injector bracket moun-ting bolt

30 Nm

injector rail mountingnuts

28 Nm



WARNING





WARNING


- all the high-pressure pipes which have been remo-ved.

- any injector that has been opened, contrary to ins-tructions,

- Any damaged mounting clips for the fuel returnpipe on the injector must be replaced.

- the compressor washer.

IMPORTANT





112815

13B-123


K9K, and 732

13B

Pull out the clip.



Unclip injector rail protector cover (6) .

Remove:

- the mounting nut and bolt (7) from the injector railprotector cover,

- the dipstick,

- the dipstick tube mounting bolts (8) .

Move the dipstick tube to one side.

Protect the alternator from fuel outflow.

Clean (see 13B, Repair precautions ). :

- the high-pressure pipes between the injector railand the injectors,

- the fuel return connectors of the injectors.

112811

112991

112992

13B-124


K9K, and 732

13B

Disconnect the injector connector (9) .

Remove:

- the nut of the high-pressure pipe between the injec-tor rail and the injector on the rail end,

- the nut of the high-pressure pipe between the injec-tor rail and the injector on the injector end,

Remove the high-pressure pipe in question and dis-card it.

Fit blanking plugs,

Using a fine, flat-blade screwdriver, push the lowersection of the clip (12) holding the fuel return con-nector on the injector towards the rocker cover.

Extract the fuel return connector from the injectorwhile pushing the lower bracket of the retaining clipdownwards.

114075

1327

WARNING

When the high-pressure pipe unions (10) on theinjector holder are loosened, it is imperative tohold the filter rod retaining nut (11) with a lockwrench.

Note:

Make preparations for the fuel outflow. Clean withnew wipes.

111749

WARNING

Ensure that the clip is not fully removed from itshousing to prevent it from being twisted whentouching the rocker cover.

111751

13B-125


K9K, and 732

13BFit the correct blanking plug.

Remove the fuel return pipe from the injector.


Remove:

- the injector bracket mounting bolt (13) ,

- the injector bracket,

- the spacer between the cylinder head and the in-jector bracket,

- the injector,

- the compression washer located at the bottom ofthe injector well in the cylinder head.

Fit the appropriate blanking plug on the injector's no-se.

Remove four injectors

111746

114010

Note:

If the injector is jammed in its well and does notcome out, turn the injector at the flat support sur-faces of the injector bracket using a 13 mm openend wrench.

WARNING

If it is to be reused, keep the injector(s) in a sea-led plastic bag until required.

WARNING

Ensure that no impurities enter into the cylindervia the injector well in the cylinder head: plug theorifice using a clean cloth.

Note:

This procedure only applies if removing all theinjectors and, after having removed them all, inpreparation for refitting them.

13B-126


K9K, and 732

13B

Disconnect:

- the injector connector (14) ,

- the heater plugs connector (15) .

Disconnect:


- the cylinder marking sensor connector (17) ,








112993 112994

13B-127


K9K, and 732

13B

Clean the fuel supply and return pipe unions (see13B, Repair Precautions ).

Disconnect:



Fit blanking plugs,

Unclip the diesel evacuation pipe.

Remove:

- the injector rail protector support bolt and mountingnuts (25) ,

- the injector rail protector support.

Undo the injector rail mounting nuts by a few turns(the injector rail should be loose).

REFITTING


Cleaning the injectors

Leave the injectors to soak in cleaner fluid.

Clean using new wipes.

Remove the injector from its plastic bag.

Remove the blanking plugs on the nose of the injec-tor.


Refit:

- a new compression washer at the bottom of the in-jector well in the cylinder head,

- the injector,

- the spacer between the cylinder head and the in-jector bracket,

- the injector bracket,

- the injector bracket mounting bolt.

112656

Note:


111748

WARNING


- a wire brush,

- an emery cloth,


WARNING

Only remove the blanking plugs immediatelybefore connecting the fuel circuit pipes.

The plugs are single-use. Do not reuse them;dispose of the whole set after use.

WARNING

If replacing the injector, do not remove it (them)from its (their) packaging until just before you refitit (them).

13B-128


K9K, and 732

13BTighten to torque the injector bracket mountingbolt ( 30 Nm ) .


Fit the new high-pressure pipe(s) between the injec-tor rail and the injector.

Finger tighten the high-pressure pipe nuts, startingwith the one at the injector rail side.

1 - Refit the four high-pressure pipes

Tighten to torque the injector rail mounting nuts (28 Nm ) .

Refit:

- the injector rail protector support,

- the mounting nuts and bolt of the injector rail pro-tector support.

Clip the diesel evacuation pipe.


Connect:


- fuel return pipe.

Fit the wiring harness.


Clip on the retaining clip of the wiring harness.

Connect:


- the diesel fuel temperature sensor connector,

- the connector of the flow regulation solenoid valve,

- the connector of the pressure regulation solenoidvalve,

- the cylinder marking sensor connector,



- the injectors' connector.

2 - All types

Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1566) or (Mot. 1746) and startingat the injector rail end.


Push the retaining clip of the fuel return connectoron the injector to the front of the vehicle in order toplace it in its initial position.

Clip on the fuel return connector of the injector.


Refit:

- the dipstick tube mounting bolts.

- the dipstick,

- the injector rail protector cover mounting nut andbolt,

Clip injector rail protector cover.

Refit:

- the clip on the stainless steel pipe if necessary,

- the stainless steel pipe on the hose, aligning themarkings,

- the air inlet duct clip between the turbocharger andthe intercooler.

Tighten the air inlet duct clip ( 5.5 Nm ) .


Refit:



Tighten the clip.

Connect:



Reprime the fuel circuit with the manual primingpump.


Note:

If the new pipes kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).

WARNING

Check the condition of the seal on the fuel returnconnector of the injector.

Change the diesel return rail if one of its compo-nents is damaged.

13B-129


K9K, and 732

13BUsing the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.

Using diagnostic tool , check that there are no sto-red faults; clear if necessary.

WARNING


- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Check ),




- check for leaks and for diesel fuel outflow.

13B-130

DIESEL INJECTIONInjectors: Configuration

K9K, and 722 or 728 or 729 or 732

13BREPLACING THE INJECTORS

The correction values are written on a label affixed toeach injector then entered in the computer which canthen control each injector by taking account of their dif-ferences in manufacture.

The system can be configured at the diagnostic socketusing the RENAULT CLIP diagnostic tools.

The C2I parameters must be renewed after an injector is replaced. To do this, the C2I parameters must be re-entered into the computer using the following com-mands:

- To enter the four C2Is when replacing the computer,run the SC002 « Enter injector codes » .

- To enter an individual C2I parameter, when replacing one or more injectors, enter the following commands:

• cylinder 1 injector: control VP001 (flywheel end cy-linder),

• cylinder 2 injector, command: control VP002 ,

• cylinder injector 3: control VP003 ,

• cylinder injector 4: control VP004 .

By using the relevant command, the technician can re-enter the new C2I parameters for the injector replacedand delete the old C2I parameters.

Note:

The C2I (individual injector correction) parametersare a factory calibration carried out on each injectorto adjust the flow of each injector precisely, takinginto account differences in manufacture.

Note:

Only after replacing all four injectors at once, resetthe injector programming adaptives using theRZ004 « Pressure regulation adaptives » .

13B-131

DIESEL INJECTIONInjectors: Configuration

F9Q, and 800 or 808

13B

INJECTORS

A 6-character « alphanumeric » code known as theIMA (Injector Flow Correction) is marked on the injec-tors. This code is specific to each injector, and takesinto account manufacturing dispersion and specifiesthe flow of the injector.

When one or more injectors is replaced, the code of thenew injector(s) must be programmed into the compu-ter. If this operation is not carried out then the enginespeed will be limited to 1800 rpm .

Follow the procedure described below:

- Replace the faulty injector(s) and establish dialogue with the computer:

• read the data on the replaced injector(s),

• enter them into the computer using the diagnostictool CLIP,

• make sure, using the diagnostic tool CLIP, that thecomputer has not detected any faults relating to theinjector codes and that the instrument panel warninglight is off.

- When a computer is reprogrammed or replaced, it isnecessary to program the codes of the four injectorsinto the new computer.

There are two possibilities:

- if it is possible to enter into dialogue with the computer again:

• download the data from the old computer into thediagnostic tool CLIP,


• transfer the data from the diagnostic tool CLIP tothe new computer,


- if it is not possible to establish dialogue with the computer:


• read the data from the injectors,

• enter them into the computer using the diagnostictool CLIP,

• reconfigure the computer for the equipment (air con-ditioning),


Equipment required

diagnostic tool

13B-132

DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting

K9K, and 732

13BREMOVAL






Loosen the clip (2) and move the air inlet duct aside(3) .

Pull out the clip.




Equipment required

diagnostic tool

Tightening torquesm


28 Nm


WARNING





WARNING



IMPORTANT





112815

112811

13B-133


K9K, and 732

13B

Remove:

- the stainless steel pipe mounting bolt (4) ,


Unclip the injector rail protector cover (6) .

Remove:



- the dipstick,

- the dipstick pipe mounting bolts (8) .

Move the dipstick pipe to one side.


Clean the high-pressure pipe unions between the in-jector rail and injectors (see 13B, Repair precau-tions ).


Remove:

- the nut of the high-pressure pipe between the injec-tor rail and the injector on the rail end,

- the nut of the high-pressure pipe between the injec-tor rail and the injector on the injector end,

Remove the high-pressure pipe in question and dis-card it.

Fit blanking plugs,

112991

112992

1327

WARNING

When the high-pressure pipe unions (9) on theinjector holder are loosened, it is imperative tohold the filter rod retaining nut (10) with a lockwrench.

Note:


13B-134


K9K, and 732

13BRemoving the four high-pressure pipes

Disconnect:


- the heater plugs connector (12) .

Disconnect:










Note:

This procedure only applies if removing all thehigh-pressure pipes and, after having removedthem all, in preparation for refitting them.

112993

112994

13B-135


K9K, and 732

13B


Clean the fuel supply and return pipes unions (see13B, Repair Precautions ).

Disconnect:

- the fuel inlet pipe (20) ,


Fit blanking plugs,


Remove:

- the injector rail protector support bolt and mountingnuts (22) ,


- the fuel supply and return pipes.

Clean the unions (see 13B, Repair precautions ):

- of the fuel return pipe on the high-pressure pumpand injector rail,

- on the high-pressure pipe between the high-pres-sure pump and the injector rail,

REFITTING


Take the new high-pressure pipe out of its plasticbag.


112656

Note:


111748

WARNING



13B-136


K9K, and 732


Fit the new high-pressure pipe between the injectorrail and the injector.


1 - Refit the four high-pressure pipes


Refit:





Connect:


- fuel return pipe.



Clip the retaining clip of the wiring harness into pla-ce.

Connect:



- the connector of the flow regulation solenoid valve,

- the connector of the pressure regulation solenoidvalve,





2 - All types

Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1566) or (Mot. 1746) and startingwith the injector rail side.


Refit:


- the dipstick,






Refit:



Tighten the clamp.

Connect:






Use diagnostic tool to check for stored faults. Clearthem if necessary.

Note:


WARNING







13B-137


K9K, and 722 or 724 or 728 or 729

13B

REMOVAL



Remove the turbocharging duct retaining pin (1)from the turbocharger.

Remove the duct mounting bolt on the cylinderhead.

Move the duct to one side.

Disconnect the inlet air pressure sensor (2)

Loosen the clip (3) and remove the inlet duct (4) .

Equipment required

diagnostic tool

Tightening torquesm


28 Nm

« pump-rail » high-pressure pipe nuts

24 Nm

high-pressure pipe nutsof the « injector rail »

24 Nm

nuts of the neck on therail

21 Nm

IMPORTANT




It is essential to respect the safety and cleanlinessadvice whenever work is carr ied out on this system.

Loosening a high-pressure pipe union when theengine is running is prohibited.

WARNING





WARNING


- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .


112331

13B-138


K9K, and 722 or 724 or 728 or 729

13B

Remove the dipstick mounting bolts (5) .

Place the dipstick to one side.

Remove the injector rail protector cover (6) .


Remove the connectors (8) :

- the heater plugs,

- the injectors.

K9K, and 724

109473

109470

K9K, and 722 or 728 or 729

102362

109466

13B-139


K9K, and 722 or 724 or 728 or 729

13B

Disconnect the high-pressure pump electrical con-nectors (9) .

Remove the mounting bolts from the neck (10) fixedto the spherical injector rail.

Move the electric wiring harness and neck to theside as shown by the arrow.

Loosen the injector rail mounting nuts by severalturns.

Remove the clips connecting the high-pressure pi-pes.


Clean the pipe(s) to be removed (see 13B, Dieselinjection, Diesel injection: Repair precautions .

Loosen:

- the high-pressure nut at the injector end,

- the high-pressure pipe nut at the injector rail end.


Throw away the pipe.

REFITTING


If replacing the four high-pressure pipes:

- remove the anti-splash cover mounting,

- Undo the injector rail mounting nuts by a few turns(the injector rail should be loose).




109467

20960

WARNING

Before fitting a new high-pressure pipe, lightlylubricate the nut threads with oil from the applica-tor provided in the new part.

Be careful not to allow oil into the high-pressurepipe.

Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.

WARNING

Leave removal of the blanking plugs from anycomponent until last.

13B-140


K9K, and 722 or 724 or 728 or 729

13BInsert the high-pressure pipe olive in the rail high-pressure outlet taper.

Finger tighten the high-pressure pipe nuts, startingwith the nut at the injector end.


Fit the new clip provided with the new high-pressurepipe.

If replacing the four high-pressure pipes, torque tigh-ten the injector rail mounting nuts ( 28 Nm ) .

Tighten to torque and in order the « pump-rail » high-pressure pipe nuts ( 24 Nm ) :

- pump end,

- rail end.

Tighten to torque and in order the high-pressure pipe nuts of the « injector rail » ( 24 Nm ) .

- injectors end,

- rail end.


Refit the neck to the injector rail and torque tightenthe nuts of the neck on the rail ( 21 Nm ) .

Connect the connectors:

- on the accelerometer

- of the injectors,

- of the heater plugs.

Refit the injector rail protector cover.

Insert the dipstick.

Refit the dipstick mounting bolts.

Refit the inlet duct and tighten its clip.

Connect the inlet air pressure sensor

Fit the turbocharger air duct.

Lock the air duct between the turbocharger and theintercooler air inlet pipe.

Tighten the bolt of the air duct on the rocker cover.


Prime the diesel circuit using the priming pump.Note:

The assembly order of the « injector-rail » high-pressure pipes is not important.

Note:

Tighten a pipe fully before moving on to the nextpipe.

K9K, and 724

WARNING


- check the seal after repair,




- confirm that there is no diesel fuel leak.

13B-141


M9R, and 700

13B

REMOVAL



Remove:



- the oil separator (see 13B, Diesel injection, Oilseparator: Removal - Refitting ).

Remove the bolt mounting the diesel return pipe onthe rocker cover.

Disconnect the quick-release union from the dieselreturn pipe.

Lift the mobile section of the diesel return pipe on theinjectors.

Remove the diesel return pipe.



Equipment required

diagnostic tool

Tightening torquesm

« rail-injector » high-pressure pipe mountingnuts

32 Nm

diesel return pipemounting bolt on therocker cover

10 Nm

WARNING

Before carrying out any work on the injection sys-tem, use the diagnostic tool to check that:

- the rail is not under pressure,


The cleanliness and safety advice specified in thisdocument must be followed during each operation.


WARNING

Obtain the special high-pressure injection circuitplug kit.

Always replace any high-pressure pipe or high-pressure pipe clip removed with a new one.

113142

13B-142


M9R, and 700


Using (Mot. 1566) , loosen:

- the high-pressure nut at the injector end,

- the high-pressure pipe nut at the injector rail end.

Move the nuts along the tube, keeping the olive incontact with the taper.

Remove the high-pressure pipes one by one.

Plug the openings.

REFITTING




Fit:

- the high-pressure pipe olive in the injector taper,

- the high-pressure pipe olive into the injector railoutlet taper.

Finger tighten until contact the high-pressure pipenuts, starting with the nut at the injector rail side.

Tighten to torque and in order, using (Mot. 1566) , the « rail-injector » high-pressure pipe mounting nuts ( 32 Nm ) :

- on the injectors,

- on the injector rail.


Refit:

- the diesel return pipe,

- the bolt mounting the diesel return pipe on the roc-ker cover

Drive the mobile section of the diesel return pipe intothe injectors.

Tighten to torque the diesel return pipe mountingbolt on the rocker cover ( 10 Nm ) .

Connect the quick-release union to the diesel returnpipe.

Refit:

- the oil separator (see 13B, Diesel injection, Oilseparator: Removal - Refitting ).




113134

Note:

Loosen the nuts pipe by pipe.

WARNING

Do not lubricate the high-pressure pipes suppliedwithout an applicator, these high-pressure pipesare self-lubricated.

Do not allow oil into the high-pressure pipe.

WARNING


13B-143

DIESEL INJECTIONInjector rail: Removal - Refitting

K9K, and 722 or 728 or 729

13B

REMOVAL


Position the vehicle on a lift (see 02A, Lifting equi-pment, Underbody lift ).

It is essential to read the repair precautions whene-ver work is carried out (see 13B, Diesel injection,Diesel injection: Precautions during repair ).







Equipment required

diagnostic tool

Tightening torquesm


28 Nm

high-pressure pipe nutsbetween the injector railand the injectors

24 Nm

high-pressure pipe nutsbetween the injector railand the high-pressurepump

24 Nm

WARNING

Before starting work on the vehicle, make sure you have:

- a new blanking plug kit ( PART NO. 77 01 206 804),

- some wipes ( PART NO. 77 11 211 707 ),

- cleaning product ( PART NO. 77 11 224 188 ).

WARNING



WARNING


- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .


WARNING


- that the rail is not under pressure,


13B-144


K9K, and 722 or 728 or 729

13B

Disconnect the injector connectors (1) and the hea-ter plugs (2) .


Disconnect:

- the connectors (4) for the flow actuator and the die-sel fuel temperature sensor,

- the spherical rail pressure sensor (5) .

Move the electric wiring harness and channel to theside as shown by the arrow.

Remove the mountings from the channel (6) fixed onthe spherical rail.


Clean the high-pressure pipes (see 13B, Diesel in-jection, Diesel injection: Precautions during re-pair ).

109466

102362

109467

WARNING

Do not blast with compressed air once the fuelcircuit is open, otherwise impurities may enterthe system. Use wipes if necessary.

13B-145


K9K, and 722 or 728 or 729

13B

Remove the clips between the high-pressure pipes.

Loosen the nuts securing the high-pressure pipesbetween the injector rail and the injector.

Remove the four high-pressure pipes and discard.


Remove the high-pressure pipe between the high-pressure pump and the injector rail (7) .



Remove:

- the injector rail mounting nuts (8) ,


REFITTING


Take the injector rail out of its plastic bag.

20803

Note:


Note:


20803

WARNING

If the injector rail is to be reused, keep it in a sea-led plastic bag all the time it is disconnected.

WARNING


The plugs are single-use. Do not reuse them andthrow away the complete kit after opening.

WARNINGIf an injector rail is being replaced, only removethe new one from its original packaging when it isabout to be fitted.

13B-146


K9K, and 722 or 728 or 729



Tighten the injector rail mounting bolts (the injectorrail should be loose).


Remove the blanking plugs from:

- the high-pressure pump,

- the injector rail fuel inlet opening.

Fit a new high-pressure pipe between the injectorrail and the high-pressure pump.

Finger tighten the high-pressure pipe nuts until theymake contact.

Remove the blanking plugs from:

- the rail injector fuel return openings,

- the injector fuel inlet.

Fit the new high-pressure pipes between the rail andthe injectors.

Finger tighten the high-pressure pipe nuts until theymake contact.

Tighten to torque:

- the injector rail mounting nuts ( 28 Nm ) ,

- the high-pressure pipe nuts between the injec-tor rail and the injectors ( 24 Nm ) using (Mot.1746) or (Mot. 1566) starting at the injector end,

- the high-pressure pipe nuts between the injec-tor rail and the high-pressure pump ( 24 Nm )using (Mot. 1746) or (Mot. 1566) starting at thehigh-pressure pump end.

Refit:

- the wiring harness with the neck,

- the neck mountings.

Connect the electrical connectors.

Reprime the fuel circuit.



- check the seal after repair (see 13B, Diesel injec-tion, Diesel injection: Repair precautions ),




Use diagnostic tool to check for stored faults. Clearthem if necessary.

Note:

If the new pipe kit does not contain an applicator,lubrication of the pipe threads will be unneces-sary (as they are self-lubricating pipes).

Note:

If the new pipe kit does not contain an applicator,lubrication of the pipe threads will be unneces-sary (as they are self-lubricating pipes).

13B-147


F9Q, and 800 or 808

13B

It is essential to read the repair precautions (see 13B,Diesel injection, Repair precautions ).

REMOVAL

Disconnect the battery, starting with the positive ter-minal.

Remove:


- the air inlet duct (see 12A, Fuel mixture, Air inletduct: Removal - Refitting ).

- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting), if fitted to the vehicle.




Equipment required

diagnostic tool

Tightening torquesm


25 Nm

nuts on the injector endand the nut on the injec-tion pump end

25 Nm

nuts on the rail end 29 Nm


4 Nm

IMPORTANT





13B-148


F9Q, and 800 or 808

13B

Disconnect:

- the pressure sensor connector (1) ,


- the fuel temperature sensor connector,


- the fuel return pipe on the injection pump side,

- the fuel return pipe on the diesel temperature sen-sor side.


Move the diesel temperature sensor (3) to one side.




Remove the diesel return pipe (4) .

Plug the openings.

18297-1

Note:

The diesel temperature sensor is an integral partof the fuel return pipe; these two components areconnected and cannot be removed separately.

13B-149


F9Q, and 800 or 808

13B

Remove the high-pressure diesel pipes using (Mot.1566) or (Mot. 1746) .

Plug the openings.

Remove:

- the injector rail bolts,

- the injector rail (5) .

REFITTING

Position the injector rail.


Pretighten the injector rail bolts, leaving clearancebetween the bolt heads and the rail.

Refit the injector rail pipes and the rail pump pipe:

- screw, by hand, the high-pressure pipe nuts ontothe pump and injector side,

- screw, by hand, the high-pressure pipe nuts ontothe rail side.


- the injector rail mounting bolts ( 25 Nm ) ,

- the nuts on the injector end and the nut on theinjection pump end ( 25 Nm ) ,

- the nuts on the rail end ( 29 Nm )

1327

WARNING


76

WARNING



WARNING

Do not put high-pressure pipes under stress.

Always hold the filter rod retaining nuts on theinjector holder when tightening.

13B-150


F9Q, and 800 or 808

13B

Refit the return rail (4) :

- do not remove the clip from the injector,

- press the injector clip,

- push the return rail end piece vertically.









- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ), if fitted to the vehicle,


18297-1

Note:

Refit the inlet duct without refitting the injector railprotector or refitting the duct seal.

WARNING


WARNING






13B-151


F9Q, and 804

13B

It is essential to read the repair precautions (see 13B,Diesel injection, Repair precautions ).

REMOVAL


Remove:



Disconnect:




Plug the openings.




Remove the diesel return pipe (3) .

Plug the openings.




Equipment required

diagnostic tool

Tightening torquesm


25 Nm

nuts on the injector sideand the nut on the injec-tor pump side

25 Nm

nuts on the rail side 29 Nm


4 Nm

IMPORTANT





111965

3

2 1111

13B-152


F9Q, and 804

13B

Remove the high-pressure diesel pipes using (Mot.1566) or (Mot. 1746) .

Plug the openings.

Remove the oil separator.

Remove:

- the injector rail bolts (6) ,

- the injector rail (7) .

REFITTING


Tighten the injector rail bolts, leaving clearancebetween the bolt heads and the rail.

Refit the injector rail pipes and the rail pump pipe:

- screw, by hand, the high-pressure pipe nuts ontothe pump and injector side,

- screw, by hand, the high-pressure pipe nuts ontothe rail side.


- the injector rail mounting bolts ( 25 Nm )

- the nuts on the injector side and the nut on theinjector pump side ( 25 Nm )

- the nuts on the rail side ( 29 Nm )

1327

WARNING


111859

5

4

7

66

WARNING



WARNING

Do not put high-pressure pipes under stress.

Do not touch the high-pressure pipes with thespanner when tightening them.

Always hold the filter rod retaining nuts on theinjector holder when tightening.

13B-153


F9Q, and 804

13B

Refit the return rail (8) :

- do not remove the clip from the injector,

- press the injector clip,

- push the return rail end piece vertically.







Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).


111965

Note:


WARNING


WARNING






8

13B-154


K9K, and 732

13B

REMOVAL



Remove the engine covers







Equipment required

diagnostic tool

Tightening torquesm


28 Nm

high-pressure pipe nutsbetween the injector railand the injectors

24 Nm

high-pressure pipe nutsbetween the injector railand the high-pressurepump

24 Nm


WARNING





WARNING



IMPORTANT





112815

13B-155


K9K, and 732

13B

Pull out the clip.

Remove the stainless steel pipe mounting bolt (4)



Remove:



- the dipstick,



Disconnect:


112811

112991

112992

112993

13B-156


K9K, and 732

13B- the heater plugs connector (10) .

Disconnect:











Clean (see 13B, Repair precautions ):



Disconnect:



Fit blanking plugs,

112994

112656


13B-157


K9K, and 732

13B


Remove:

- the injector rail protector support mounting bolt andmounting nuts,

- the injector rail protector support.

Clean (see 13B, Repair precautions ):

- the high-pressure pipes between the injector railand the injectors,

- the high-pressure pipes (19) between the high-pressure pump and the injector rail.

Remove:

- the nuts from the four high-pressure pipes betweenthe injector rail and the injector on the rail end,

- the nuts from the four high-pressure pipes betweenthe injector rail and the injector on the injector end,

Remove the four high-pressure pipes and dispose ofthem in a bin.

Fit blanking plugs,

111748

1327

WARNING

When loosening the high-pressure pipe unions(21) on the injector holder, it is essential to holdthe filter rod mounting nut (22) with a lockwrench.

Note:


13B-158


K9K, and 732

13BRemove the high-pressure pipe between the high-pressure pump and the injector rail and dispose of itin a bin.


Remove:

- the injector rail mounting nuts (23) ,


REFITTING


Take the injector rail out of its plastic bag.



Finger tighten the injector rail mounting bolts.


Fit the new high-pressure pipe between the injectorrail and the high-pressure pump.



Fit the new high-pressure pipes between the injectorrail and the injectors.



WARNING

When loosening the connector of the high-pres-sure pipe, the intermediate nut must be securedon the pump using a lock wrench.

Note:


111745

WARNING

If the injector rail is to be reused, keep it in a sea-led plastic bag all the time it is disconnected.

WARNING



WARNING

If an injector rail is being replaced, only removethe new one from its original packaging when it isabout to be fitted.

Note:


Note:

If the new pipes kit does not contain an applica-tor, lubrication of the nut threads will be unneces-sary (as they are self-lubricating pipes).

13B-159


K9K, and 732

13BTighten to torque:

- the high-pressure pipe nuts between the injec-tor rail and the injectors ( 24 Nm ) using (Mot.1566) or (Mot. 1746) starting with the rail end.

- the high-pressure pipe nuts between the injec-tor rail and the high-pressure pump ( 24 Nm )using (Mot. 1566) or (Mot. 1746) starting with thehigh-pressure pump end.


Refit:





Connect:


- fuel return pipe.



Clip the retaining clip of the wiring harness.

Connect:



- the connector of the flow control solenoid valve,

- the connector of the pressure control solenoid val-ve,





Refit:


- the dipstick,




Refit:


- the stainless steel pipe on the hose, aligning themarkings,

- the clamp of the air inlet duct between the turbo-charger and the intercooler.

Tighten the air inlet duct clip ( 5.5 Nm ) .


Refit:



Tighten the clamp.

Connect:

- the connector to the air inlet pressure sensor,





Using diagnostic tool , check that there are no sto-red faults; clear if necessary.

Note:

Ensure that the injector rail protector supportmounting bolt does not fall under the high-pres-sure pump.

WARNING







13B-160

DIESEL INJECTIONRail pressure sensor

K9K, and 722 or 724 or 728 or 729 or 732

13B

Pressure sensor (1) cannot be removed from the sphe-rical injector rail.

In the event of a pressure sensor fault, the « rail pres-sure sensor and high-pressure pipe » assembly mustbe replaced (see 13B, Diesel injection, Injector rail ).

102086

1

13B-161

DIESEL INJECTIONRail pressure sensor: Removal - Refitting

F9Q, and 800

13B

Equipment required

diagnostic tool

Tightening torquesm

pressure sensor to tor-que

3.5 daNm +/-0.5

battery cover mountingbolts to torque

0.4 daNm

IMPORTANT

Before starting any work on the injection circuit, use the diagnostic tool to check that:

• the injection rail is no longer pressurised,

• the fuel temperature is not too high.

- Whenever work is carried out, it is essential to res-pect the safety and cleanliness advice given in thisdocument.

- It is strictly forbidden to undo a high-pressure pipeunion when the engine is running.

WARNING

- Obtain a set of special high-pressure injection cir-cuit plugs.

- All high-pressure pipes must be replaced and anyremoved high-pressure pipe clips.

13B-162


F9Q, and 800

13BREMOVAL

Disconnect:

- the battery, starting with the negative terminal.

- the pressure sensor.

Unscrew the pressure sensor.

18297-5

13B-163


F9Q, and 800

13BREFITTING

Replace the seal.

Screw in the sensor.

Tighten the pressure sensor to torque ( 3.5 daNm+/- 0.5 ) .

Connect the connector.

Tighten the battery cover mounting bolts to tor-que ( 0.4 daNm ) .

WARNINGConnect the battery; carry out the necessary pro-gramming (see (see 8, Electrical equipment) ).

WARNING

Check that there are no diesel leaks:

- run the engine at idle speed until the fan startsup,




- check that there is no diesel leak:

13B-164

DIESEL INJECTIONFuel flow actuator: Removal - Refitting

K9K, and 722

13B


Disconnect:


- the air intake duct (1) .

Remove diesel splash plate (2) .

Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

fuel flow actuatormounting bolts

5.5 ±±±± 0.6 Nm

battery cover securingbolts

4 Nm

IMPORTANT

Before carrying out any work on the injection circuit, check using the diagnostic tool CLIP:

• that the injection rail is no longer under pressure,




WARNING


- Always replace any high pressure pipe and highpressure pipe clips removed with new ones.

102120

102362

1

2

13B-165


K9K, and 722

13B

Disconnect:

- the heater plugs,

- the injector connectors (3) from cylinders no. 3 andno. 4,

- the pump electrical connectors (4) ,


Remove the high-pressure pipe (6) on injector no. 4(see 13B, Diesel injection, High pressure pipes:Replacement ).

Cap the openings.

Undo bracket bolts (7) .

Withdraw the fuel flow actuator (by hand using smallsuccessive turns).

102514

3

45

102315

WARNING

Do not use the electrical connector as a leverarm.

6

7

13B-166


K9K, and 722

13BREFITTING

Only unpack the new component when you are rea-dy to fit it.

Fit the actuator.

Finger-tighten the two mounting bolts.

Tighten to torque the two fuel flow actuator moun-ting bolts ( 5.5 ±±±± 0.6 Nm ) using tool low torquewrench .

Refit a new high-pressure pipe to injector no. 4 (see13B, High pressure pipes: Replacement ) and anew clip.

Reconnect:

- the diesel fuel supply and return pipes,

- the electrical connectors.



Tighten to torque the battery cover securing bolts( 4 Nm ) .

WARNINGDo not remove the blanking plugs from any com-ponent until the last moment.

WARNING

Do not damage the seal when refitting.

Note:

Do not lubricate the seals with grease or useddiesel fuel. Use the applicator provided in the kitfor the new part.

WARNING


WARNING

Confirm that there is no diesel fuel leakage:

- check the sealing after repair (see 13B, Highpressure pipe: Fuel-tightness check ).

- Let the engine run at idle speed until the enginecooling fan starts up.

- Accelerate several times under no load.

- Carry out a road test.



13B-167


K9K, and 728 or 729

13B

REMOVAL



Pull the clip.

Undo bolt (1) .


Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

flow actuator mountingbolts

5.5 ±±±± 0.6 Nm


4 Nm

Note:

For vehicles with a K9K 732 engine (see MR 370Mechanical, Scénic II ).

IMPORTANT

Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :





WARNING


- Always replace any high-pressure pipe or high-pressure pipe clip removed with a new one.

110325

110323

1

2

13B-168


K9K, and 728 or 729

13B

Remove the diesel splash plate (3) .

Disconnect:

- the heater plugs,

- the injector connectors (6) from cylinders n˚3 andn˚4,

- the pump electrical connectors (4) ,


Remove the high-pressure pipe (7) from injector no.4 (see 13B, Diesel injection, High-pressure pi-pes: Replacing ).


Undo bracket bolts (8) .

Withdraw the fuel flow actuator (by hand using smallsuccessive turns).

102362

102514

3

4

6

5

6

102315

WARNING

Do not use the electrical connector as a leverarm.

7

88

13B-169


K9K, and 728 or 729

13BREFITTING

Only unpack the new component when you are rea-dy to fit it.

Fit the actuator.

Finger tighten the mounting bolts.

Tighten to torque the two flow actuator mountingbolts ( 5.5 ±±±± 0.6 Nm ) using low torque wrench .

Refit a new high-pressure pipe on injector no. 4 (see13B, High-pressure pipes: Replacement ) and anew clip.

Reconnect:

- the diesel fuel supply and return pipes,

- the electrical connectors.





WARNING

Do not damage the seal when refitting.

Note:

Do not lubricate the seals with grease or useddiesel fuel. Use the applicator provided in the kitfor the new part.

WARNING


WARNING


- Check the tightness after repair (see 13B,High-pressure pipe: Sealing check ).

- Let the engine run at idle speed until the enginecooling fan starts to operate.


- Carry out a road test.



13B-170

DIESEL INJECTIONLeak flow from injectors: Check

K9K, and 722 or 728 or 729

13B



Connect the four transparent hoses of (Mot. 1711)to the injectors instead of the injector fuel return pi-pes.

Fit the correct blanking plugs, in particular onto theventuri pipe to prevent depriming the circuit.

Insert these hoses in the four graduated measuringcylinders of the (Mot. 1711) .


Follow the procedures described in the Fault findingMR (see MR 372 Fault finding, 13B, Diesel injec-tion, Fault finding - Tests ).

Disconnect:


- the four transparent hoses of (Mot. 1711) .


Refit the injector fuel return pipes.




Mot. 1711 Kit for measuringinjector leak rate

IMPORTANT

Do not leave any object (tools or other) on theside of the engine housing during the entire ope-ration.

Position the tools so that they do not fall duringthe « engine running » phase of the test.

13B-171


K9K, and 732

13B






Pull out the clip.




Mot. 1771 Kit for measuring SIE-MENS injector leakrate

Mot. 1711 Kit for measuringinjector leak rate

112815

112811

112991

13B-172


K9K, and 732

13B


Remove:



- the dipstick,



Disconnect the four fuel return pipes of the four in-jectors (see 13B, Diesel injector fuel return rail:Removal - Refitting ).

Connect the transparent hoses of (Mot. 1771) to theinjectors instead of the injector fuel return pipes.

Fit the correct blanking plug to the injector fuel returnconnectors.

Insert these hoses in the four graduated measuringcylinders of the (Mot. 1711) .

Refit:


- the dipstick.



Refit the air inlet duct on the damper valve.

Tighten the clamp.

Connect:



Follow the procedures described in the Fault findingMR (see MR 372 Fault finding, 13B, Diesel injec-tion, Fault finding - Tests ).

Disconnect:


- the air inlet pressure sensor connector.

Loosen the clip and move the air inlet duct aside.

Pull out the clip from the stainless steel pipe.


Remove:

- the dipstick,



Disconnect the four transparent pipes from (Mot.1771) .

Refit:


- the dipstick,






Refit:



Tighten the clamp.

112992

IMPORTANT

Do not leave any object (tools or other) on theside of the engine housing during the entire ope-ration.

Position the tools so that they do not fall duringthe « engine running » phase of the test.

13B-173


K9K, and 732

13BConnect:





13B-174

DIESEL INJECTIONFuel pressure regulator: Removal - Refitting

F9Q, and 800 or 808

13B

Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

regulator bolts 6 Nm


4 Nm

IMPORTANT






WARNING


- Be sure to replace any high pressure pipe andhigh pressure pipe clips that have been removed.

13B-175


F9Q, and 800 or 808

13BREMOVAL


Blow the area with compressed air to clean impuri-ties away from the fuel pressure regulator.

Disconnect the fuel pressure regulator connector.

Clean the area with brake degreaser.

Remove:

- fuel pressure regulator bolts (1) ,

- the fuel pressure regulator manually (do not useany tool for leverage).

18297-1

1

13B-176


F9Q, and 800 or 808

13BREFITTING

Clean the fuel pressure regulator bearing face onthe high pressure pump, taking care not to introduceany impurities.

Wipe the fuel pressure regulator bearing face on thehigh pressure pump, taking care not to introduce anyimpurities.

Connect the battery.

Rinse the fuel pressure regulator housing in the highpressure pump, with the ignition on for a few se-conds.

Disconnect the battery.

Prepare the new regulator:

- remove the protective cap,

- check the seal positions,

- lubricate the O-rings with clean diesel fuel.

Offer up the regulator, rotating it slightly.

Push the regulator gently in until it engages fully.

Pretighten the new regulator bolts to 3 Nm .

Tighten to torque the three regulator bolts ( 6 Nm )using a low torque wrench .

Clean the area with cleaning cloths.

Fit the fuel pressure regulator connector.



Switch on the ignition.

Clear the fault shown in the diagnostic tool CLIP ifnecessary.

Note:

Lubrication is very important to avoid externalleakage.

WARNING


WARNING


- let the engine run at idle speed until the enginecooling fan starts up,





13B-177


F9Q, and 804

13BREMOVAL


Blow compressed air into the area to clean dirt fromaround the fuel pressure regulator.

Disconnect the fuel pressure regulator connector.

Clean the area with brake degreaser.

Remove:

- fuel pressure regulator bolts (1) ,

- the fuel pressure regulator manually (do not useany tool for leverage).

Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

regulator bolts 6 Nm


4 Nm

IMPORTANT






WARNING

- Obtain the special high-pressure injection cap kit.

- Be sure to replace any high-pressure pipe remo-ved.

111887

1

13B-178


F9Q, and 804

13BREFITTING

Clean the fuel pressure regulator bearing face onthe high-pressure pump, taking care not to introduceany impurities.

Wipe the fuel pressure regulator bearing face on thehigh-pressure pump, taking care not to introduceany impurities.


Flush the fuel pressure regulator housing in thehigh-pressure pump, with the ignition on for a fewseconds.


Prepare the new regulator:

- remove the protective cap,

- check the seal positions,

- lubricate the O-rings with clean diesel fuel.

Offer up the regulator, rotating it slightly.

Push the regulator gently in until it engages fully.

Pretighten the new regulator bolts (3 Nm) .

Tighten to torque the regulator bolts ( 6 Nm ) usinglow torque wrench .

Clean the area with cleaning cloths.

Fit the fuel pressure regulator connector.



Switch on the ignition.

Clear the fault indicated on the diagnostic tool ifnecessary.

Note:

Lubrication is very important to avoid externalleaks.

WARNING


WARNING







13B-179

DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting

K9K, and 722

13B

REMOVAL



Disconnect air aspiration hose (1) .

Equipment required

diagnostic tool

Tightening torquesm

diesel temperature sen-sor

15 Nm

batter cover mountingbolts

4 Nm

IMPORTANT






WARNING


- Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.

WARNING

Tighten to torque 38 Nm the « pump-rail » and « injector rail » high-pressure pipes with one of the following part numbers:

- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .


WARNING





102120

1

13B-180


K9K, and 722

13B

Disconnect:

- the heater plugs from cylinders n˚ 3 and 4,

- the injectors (2) on cylinders 3 and 4,

- the diesel fuel temperature sensor connector (3) .

Clean the sensor (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).

Remove the fuel temperature sensor (4) .


REFITTING

Lubricate the O-ring with the lubricant from the appli-cator supplied with the new part.

Fit the diesel fuel temperature sensor.

Tighten to torque the diesel temperature sensor (15 Nm ) .

Reconnect the electrical connector.


Tighten to torque the batter cover mounting bolts( 4 Nm ) .

Check the sealing after repair (see 13B, Diesel in-jection, High-pressure pipe: Check sealing ).

102514

102317

3

2

4

WARNING


WARNING

Do not damage the O-ring when refitting.

WARNING






13B-181


K9K, and 728 or 729

13B

REMOVAL



Pull the clip.

Equipment required

diagnostic tool

Tightening torquesm


15 Nm


4 Nm

IMPORTANT






WARNING


- Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.

WARNING

Tighten to torque 38 Nm the « pump-rail » and « injector rail » high-pressure pipes with one of the following part numbers:

- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 .


WARNING





110325

13B-182


K9K, and 728 or 729

13B

Unscrew bolt (1)


Disconnect:

- the heater plugs from cylinders n˚ 3 and 4,

- the injectors (3) on cylinders 3 and 4,

- the fuel temperature sensor connector (4) .

Clean the sensor (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).

Remove the diesel fuel temperature sensor (5) .


REFITTING

Lubricate the O-ring with the lubricant from the appli-cator supplied with the new part.

Fit the diesel fuel temperature sensor.


Reconnect the electrical connector.



110323

102514

1

2

4

33

102317

WARNING


WARNING


5

13B-183


K9K, and 728 or 729

13BCheck the sealing after repair (see 13B, Diesel in-jection, High-pressure pipe: Check sealing ).

WARNING






13B-184


K9K, and 732

13B

The diesel temperature sensor (1) is attached to thediesel injector fuel return rail.

Replace the diesel injector fuel return rail and dieseltemperature sensor assembly if there is a diesel tem-perature sensor fault (see 13B, Diesel injection, Die-sel injector fuel return rail: Removal - Refitting ).

111747

13B-185


K9K, and 724

13B

During each operation, always read the precautions forrepair (see 13B, Diesel injection, Diesel injection:Precautions for repair ).

REMOVAL




Remove the pin securing the turbocharger pipe onthe turbocharger (1) .

Remove the bolt mounting the pipe on the cylinderhead.

Move the pipe to one side.

Disconnect the inlet air pressure sensor (2)


Move the inlet air duct to one side (4) .

Equipment required

diagnostic tool

Tightening torquesm


15 Nm

IMPORTANT


- that the injection rail is not under pressure,


It is essential to respect the safety and cleanlinessadvice whenever work is carr ied out on this system.

Loosening a high pressure pipe union when theengine is running is strictly prohibited.

WARNING

Tighten to a torque of 38 Nm the « pump-rail » and « rail-injectors » high pressure pipes with the fol-lowing part numbers:

- 77 01 207 025 ,

- 77 01 207 026 ,

- 77 01 207 027 ,

- 77 01 207 028 ,

- 77 01 207 029 ,

For high pressure pipes with different part numbers,tighten to a torque of 24 Nm .

WARNING


- a new blanking plug kit ( PART NUMBER 77 01206 804 ),

- cleaning cloths ( PART NUMBER 77 11 211 707 ).

112331

13B-186


K9K, and 724

13B

Remove:

- the dipstick,

- the dipstick pipe mounting bolts.


Unclip the clips (5) from the injection rail protector.

Remove:

- the mounting bolts (6) from the injection rail protec-tor,

- the injection rail protector (7) .

Remove the high pressure pump protectors (8) and(9)

Clean the pipes (see 13B, Diesel injection, Dieselinjection: Precautions for repair ).

Disconnect the diesel supply and return pipes (10) .

Fit the correct blanking plugs.

109470 109465

102514

Note:

Make preparations for fuel outflow. Clean withnew cloths.

13B-187


K9K, and 724

13B

Disconnect the diesel temperature sensor connector(11) .


Clean the diesel temperature sensor (see 13B, Die-sel injection, Diesel injection: Precautions for re-pair ).

Remove the diesel temperature sensor (12) .

REFITTING


Lubricate the O-ring with lubricant from the applica-tor supplied with the new part.

II - REFITTING PART CONCERNED

Refit the diesel temperature sensor.



Connect:


- the diesel supply and return pipes.

Refit:

- the high pressure pump protectors,

- the injection rail protector.

Refit the air inlet duct and tighten the clip.

Connect the inlet air pressure sensor

Fit the turbocharger air duct.

Lock the air duct onto the turbocharger and the inter-cooler inlet air pipe.

Tighten the bolt of the air duct on the rocker cover.



102514

102317

Note:

Do not lubricate the diesel temperature sensorseals with grease or used diesel. Use the appli-cator supplied with the kit.

WARNING



13B-188


K9K, and 724

13BCheck the sealing after repair (see 13B, Diesel in-jection, High pressure pipe: check ).

WARNING





- check that there is no diesel fuel leaking.

13B-189

DIESEL INJECTIONAccelerometer: Removal - Refitting

K9K, and 722 or 728 or 729

13B

REMOVAL

Disconnect the accelerometer connector (1) .

Remove the accelerometer using tool (Emb. 1596) .

REFITTING


Tighten to torque the accelerometer ( 20 Nm )using tool low torque wrench .


Tighten to torque the battery cover securing bolts( 4 Nm ) .


Emb. 1596 24 mm socket forremoving/refittingclutch master cylinder

Equipment required

low torque wrench

Tightening torquesm

accelerometer 20 Nm


4 Nm

102086

1

WARNINGcarry out the necessary programming (see 80A,Battery: Removal - refitting ).

13B-190

DIESEL INJECTIONVenturi: Removal - Refitting

K9K, and 722

13B

REMOVAL


Disconnect:


- the intake duct (1) .

Disconnect the fuel supply and return pipes (2) .

Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

Venturi mounting bolt 5.5 Nm ±±±± 0.6


4 Nm

IMPORTANT




- It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this sys-tem.


WARNING


- Always replace any high pressure pipe and highpressure pipe clips removed with new ones.

102120

102514

1

2

13B-191


K9K, and 722

13B

Disconnect the return pipe (3) connecting the injec-tor to the pump.

Remove:

- the Venturi mounting bolt (4) ,

- the Venturi.

REFITTING

Lubricate the O-ring with the lubricant from the appli-cator provided with the new part.

Do not damage the O-ring when fitting the Venturi.

Fit the Venturi.

Tighten to torque the Venturi mounting bolt ( 5.5Nm ±±±± 0.6 ) using tool low torque wrench .

Reconnect the various pipes.

Tighten to torque the battery cover securing bolts( 4 Nm )

102316

3

4

WARNINGDo not remove the blanking plugs from any com-ponent until the last moment.

WARNING


WARNING


- check the sealing after repair (see 13B, Dieselinjection, High pressure pipe: Fuel tightnesscheck ),

- let the engine run at idle speed until the enginecooling fan starts up,





13B-192


K9K, and 728 or 729

13B

REMOVAL


Pull the clip.

Undo bolt (1) .


Equipment required

diagnostic tool

low torque wrench

Tightening torquesm

Venturi mounting bolt 5.5 Nm ±±±± 0.6


4 Nm

IMPORTANT




- It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this sys-tem.


WARNING


- Be sure to replace any high-pressure pipe andhigh-pressure pipe clips that have been removed.

110325

110323

1

2

13B-193


K9K, and 728 or 729

13B

Disconnect the fuel supply and return pipes (3) .

Disconnect the return pipe (4) connecting the injec-tor to the pump.

Remove:

- the Venturi mounting bolt (5) ,

- the Venturi.

REFITTING

Lubricate the O-ring with the lubricant from the appli-cator provided with the new part.

Do not damage the O-ring when fitting the Venturi.

Fit the Venturi.

Tighten to torque the Venturi mounting bolt ( 5.5Nm ±±±± 0.6 ) using tool low torque wrench .

Reconnect the various pipes.

Connect the battery, starting with the positive termi-nal

Tighten to torque the battery cover mounting bolts( 4 Nm )

102514

102316

33

5

4


WARNING


WARNING


- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Sealingcheck ),






13B-194

DIESEL INJECTIONAccelerator pedal potentiometer: General information


13BThe accelerator pedal potentiometer is incorporated inthe accelerator pedal. If it is replaced, the acceleratorpedal must also be replaced.

There are two types of pedal: with or without a kic-kdown point.

Vehicles fitted with cruise control / speed limiter havean accelerator pedal with a kickdown point at the endof their travel ( « kick-down » ).

This kickdown point makes it possible to exit the speedlimiter function if the driver has to increase speed.

WARNING

A pedal fitted with a kickdown point may be fitted inplace of a pedal without a kickdown point. However,fitting a pedal without a kickdown point in place of apedal with a kickdown point is prohibited.

13B-195

DIESEL INJECTIONAccelerator pedal potentiometer: Removal - Refitting


13B

REMOVAL

Disconnect:


- the accelerator pedal connector.

Remove:

- pedal mounting bolts (1) ,

- the pedal.

REFITTING




Tightening torquesm


4 Nm

102204

11

WARNING


Note:

A fault on the accelerator pedal position potentio-meter results in changes in the idle speed orengine operation (see 13B, Diesel injection,Idle speed ).

13B-196

DIESEL INJECTIONDiesel injection computer: Removal - Refitting

K9K, and 722 or 728 or 729 – F9Q, and 800 or 808

13B

There are two procedures for doing this (see 13B, Die-sel Injection, Injectors: Configuration and pro-gramming ):

- an automatic procedure which can be used if it is pos-sible to read the information contained in the old com-puter,

- a manual procedure for when it is not possible to readthe information contained in the old computer.



Remove the battery.


Remove:


- the wiring harness bracket (3) .

Detach the wiring harnesses from the battery tray.


Remove the injection computer and its support (4) .

Equipment required

diagnostic tool

Tightening torquesm


21 Nm


4 Nm

Note:

When programming, reprogramming or replacing acomputer, it is necessary to program the C2I para-meters (individual injector correction) and theengine parameters into the new computer using thediagnostic tool RENAULT CLIP tool. 101822

101811

3

221

4

13B-197


K9K, and 722 or 728 or 729 – F9Q, and 800 or 808

13B

Remove:

- the computer mounting bolts (5) ,

- the computer.

REFITTING



Make sure you refit the battery tray correctly on thecomputer support.



Respect the programming instructions for the C2Iparameters (individual injector correction) and engi-ne adaptives (see 13B, Diesel injection, Computerconfiguration ).

Switch on the ignition and read the fault codes usingthe diagnostic tool .

If necessary, repair the faults indicated.

Clear the faults.

Check that the vehicle is operating correctly.

101890

55

101887

WARNING


13B-198


K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700

13B

When replacing the computer (see MR 372 Fault fin-ding, Diesel injection, Fault finding - Replacementof components ).

REMOVAL



Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting ).


Unclip:

- the wiring harness (2) from the battery negative ter-minal,


Remove:

- the upper mounting bolt (3) from the computer sup-port,

- the mounting bolt (4) from the computer support

- the mounting nut (6) from the wiring harness,

- the computer (5) and its support.


Remove:

- the computer mounting nuts,

- the computer from its support.

REFITTING


Refit:

- the computer on its support,

- the computer mounting nuts.

Tightening torquesm

mounting bolt on thecomputer support

21 Nm

WARNING



- It is forbidden to perform tests with computers bor-rowed from the Parts Department or from anothervehicle, that must then be returned. These compu-ters are permanently coded.

115720

13B-199


K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700

13BII - FINAL OPERATION

Refit the mounting bolt to the computer support.

Tighten to torque the mounting bolt on the compu-ter support ( 21 Nm ) .

Refit the upper mounting bolt to the computer sup-port.

Clip on:

- the wiring harness to the battery negative terminal,


Connect the computer connectors.

Refit:



13C-1

PREHEATINGPre/postheating unit: Removal - Refitting

F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732 – M9R, and 700

13C


Remove:

- the front left-hand wheel,

- the front left-hand wheel arch liner.

Disconnect the pre-postheating unit connector.

Remove:

- the pre-postheating unit mounting bolt,

- the pre-postheating unit.

REFITTING



Tighten to torque:



.

Tightening torquesm


4 Nm

wheel bolts 110 Nm

Note:

It is located behind the front left-hand wheel archliner.

101823

102125


13C-2

PREHEATINGHeater plugs Removal - Refitting

K9K, and 722

13C

The resistance of a heater plug is 0.6 Ω (connector dis-connected).

The heater plugs are removed without opening thehigh pressure diesel circuit.



Disconnect the air duct.

Disconnect the electrical connector from the heaterplugs.

Clean around the outside of the heater plugs with acompressed air gun to prevent contamination of thecylinders.

Undo then remove the plugs using a 10 mm diame-ter long radio socket connected to a universal joint.

Use a hose to unscrew the plugs completely.

REFITTING


Tighten to torque the heater plugs ( 15 Nm ) .



Tightening torquesm

heater plugs 15 Nm


4 Nm

102120

15762

WARNING

Ensure that no foreign bodies enter the cylinderduring this operation.

WARNING


13C-3


K9K, and 728 or 729

13C



Pull the clip.

Undo the bolt (1) .

Move the air duct aside (2) .





Tightening torquesm

heater plugs 15 Nm


4 Nm

110325

110323

15762

WARNING


1

2

13C-4


K9K, and 728 or 729

13CREFITTING





WARNING


13C-5


F9Q, and 800 or 804 or 808

13C

The resistance of a heater plug is 0.6 Ω (connector dis-connected).

The heater plugs are removed without opening thehigh pressure diesel circuit.



Remove:

- the inlet duct (see 12A, Fuel mixture, Inlet duct:Removal - Refitting ).

- the injection rail protector (see 13B, Diesel injec-tion, Injection rail protector: Removal - Refitting)





REFITTING





Tightening torquesm

heater plugs 15 Nm


4 Nm

F9Q, and 804

15762

WARNING


WARNING


13C-6


F9Q, and 804

13CUD replaced with 11,05,08,02-01,37-001,016 on 08/06/2005

13C-7


K9K, and 732

13C

REMOVAL





Loosen the clip (2) and move the air inlet duct aside(3) .

Pull out the clip.



Tightening torquesm

heater plugs 15 Nm

WARNING

Procedure for removing the air inlet duct (risk of leaking and slipping if this procedure is not obser-ved):



- clean the bearing face on the intercooler and onthe hose with a dry, lint-free cloth,


- place the clip in the same position if the hose isnot replaced,

- always replace the hose and/or the intercooler ifdamaged.

112815

112811

13C-8


K9K, and 732

13C

Make a marking (4) on the air inlet duct between thestainless steel pipe and the hose.

Detach the hose from the stainless steel pipe.

Remove:

- the mounting bolt (5) from the stainless steel pipe,



Remove:

- the mounting nut and bolt (8) from the injection railprotector cover,


- the dipstick,

- the dipstick pipe mounting bolts (9) .



Disconnect the connector from the heater plug.




REFITTING


Refit the heater plugs using the hose.

112991

112992

112993

Note:

Do not pull on the plug cable.

WARNING


13C-9


K9K, and 732

13CTighten to torque the heater plugs ( 15 Nm ) .

Connect the connector to the heater plugs.


Refit:

- the mounting bolts to the dipstick pipe,

- the dipstick,


- the injection rail protector mounting bolt and moun-ting nut.

Clip on the injection rail protector cover.

Refit:


- the stainless steel pipe on the hose, aligning themarking,

Clip the stainless steel pipes onto the turbocharger.

Refit:



Tighten the clip.

Connect:




13C-10


M9R, and 700

13C

REMOVAL


Remove the front engine cover.


Disconnect the heater plug connectors.

Clean and blast the outside of the plugs to preventany contamination of the cylinders.


Unscrew then remove the plugs using a socketwrench for removing/refitting preheating plugsor a 1/4-inch square drive long 10 mm socket with auniversal joint.

If necessary, use a hose to unscrew the plugs com-pletely.

REFITTING


Refit the heater plugs.

Bring the heater plugs just into contact.

Tighten to torque the heater plugs ( 16.5 Nm ) usinga socket wrench for removing/refitting prehea-ting plugs or a 1/4-inch square drive long socket 10mm in diameter connected to a universal joint.


Connect



Refit the engine cover.

Equipment required

socket wrench for removing/refitting preheatingplugs

Tightening torquesm

heater plugs 16.5 Nm

WARNING


WARNING

The heater plugs are damaged by being tighte-ned to any torque greater than 19 Nm .

13C-11

PREHEATINGPre-postheating control

F9Q, and 800 or 808

13CThe pre/post heating function is controlled by the injec-tion computer.

PRE/POST HEATING OPERATING PRINCIPLE

1 - Switching on the ignition « preheating »

a - Variable preheating

The duration the indicator light is lit and of the supply tothe heater plugs depends on the coolant temperatureand the battery voltage.

X: Time in seconds

Y: Coolant temperature in ˚C

In all cases the preheating warning light should light upfor more than 12 seconds .

b - Fixed preheating

After the warning light goes out the plugs remain sup-plied for a fixed period of 10 seconds .

2 - Starting

The plugs continue to be supplied while the starter isbeing activated.

3 - Engine running « postheating »

During this phase the plugs are supplied continuouslyaccording to coolant temperature.

At idling speed with no depression of the acceleratorpedal.

X: Time in seconds


101189

101188

13C-12

PREHEATINGPre-postheating control

K9K, and 722 or 728 or 729 or 732

13CThe pre-postheating function is controlled by the injec-tion computer.

PRE-POSTHEATING OPERATING PRINCIPLE

1 - Ignition on « preheating »

a - Variable preheating

The time taken for the warning light to come on and forsupply to the heater plugs depends on the coolant tem-perature and the battery voltage.

X: Time in seconds


Whatever the situation, the heater plug warning lightcannot remain lit for more than 12 seconds (except inthe event of a coolant temperature sensor fault).

b - Fixed preheating

After the warning light goes out, the heater plugs conti-nue to be supplied for a fixed period of 5 seconds .

2 - Starting

The plugs remain supplied while the starter motor isbeing activated.

3 - Engine running « postheating »

During this phase the plugs are supplied continuouslyaccording to the coolant temperature.

At idling speed with no depression of the acceleratorpedal.

X: Time in seconds


103123

103124

14A-1

ANTIPOLLUTIONPetrol vapour rebreathing: Operation


14AI - OPERATING DIAGRAM OF THE CIRCUIT

106679

(1) Inlet manifold

(2) Fuel vapour absorber bleedsolenoid valve

(3) Fuel vapour absorber

(4) Tank

(5) Breather

(6) Anti-return valve (F4R 776 only)

102724


12

34

5

6

6

7

F4R, and 776

106278


102734


(10) Fuel vapour recirculation comingfrom the tank

8

9

10

1112

14A-2

ANTIPOLLUTIONPetrol vapour rebreathing: Operation


14A

II - OPERATING PRINCIPLE

The tank is vented by means of the fuel vapour absor-ber.

Fuel vapour is trapped by the active charcoal contai-ned in the absorber as it passes through.

Fuel vapour trapped in the absorber is eliminated andburnt by the engine.

To do this, connect the fuel vapour absorber and the in-let manifold via the solenoid valve. This solenoid valveis located on the shock absorber cup.

The principle behind the solenoid valve is to open apassage of variable size (according to the opening cy-clic ratio signal sent by the injection computer).

The variation in the passage opened for fuel vapour inthe solenoid valve results from the balance betweenthe magnetic field created by the supply to the windingand the return spring force attempting to close the so-lenoid valve.

(11) Recirculation of fuel vapoursgoing to the engine

(12) Tank breather

WARNING

The breather should not be blocked during normalengine operation.

14A-3

ANTIPOLLUTIONFuel vapour recirculation circuit: check


14AI - CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED

Check the conformity of the circuit (see 14A, Anti-pollution, Fuel vapour rebreathing Operation ).

Check the condition of the pipes to the tank.

II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS

The fuel vapour absorber bleed solenoid valve is controlled by track C-E1 of the computer if:

- the coolant temperature is above 55˚C ,

- the air temperature is above 10˚C ,

- the engine is not at idle speed,

- a given load threshold is reached,

- the throttle potentiometer is not in the « no load »position.

During « on board diagnostic » fault finding, fuel va-pour absorber bleeding is not authorised.

The opening cyclic ratio of the fuel vapour absorberbleed solenoid valve can be displayed using the dia-gnostic tools by referring to parameter PR102: Fuelvapour absorber bleed solenoid valve OCR .

The solenoid valve is closed for values below 1.2 % .

Note:

A fault with this system may result in rough idlingor the engine stalling.

106679

(1) Inlet manifold



(4) Tank

(5) Breather

(6) Anti-return valve (F4R 776 only)

12

34

5

6

6

14A-4

ANTIPOLLUTIONFuel vapour canister: Removal - Refitting


14AThe absorber is located on the fuel tank under the ve-hicle.

REMOVAL

Release absorber (1) from the fuel tank retainingnotch by pushing it in the direction of the arrow.

Disconnect:

- pipe (2) bringing the fuel vapour from the tank,

- pipe (3) taking the fuel vapours to the solenoid val-ve,

- breather pipe (4) .

Remove the absorber.

REFITTING


102483

1

102734

2

3 4

14A-5

ANTIPOLLUTIONFuel vapour canister:Checking


14A

CHECKING THE FUEL VAPOUR ABSORBER

On the fuel vapour absorber, cap the circuit comingfrom the tank.

Connect a pressure gauge on tool (Mot. 1311-01) tothe absorber breather outlet.

With the engine at idle speed, check that there is novacuum at the absorber breather outlet (under thesame conditions, the command value read by thediagnostic tool in parameter: Fuel vapour absorberbleed solenoid valve OCR remains minimal ( Xlower than or equal to 1.5 % ).

Is there a vacuum?

- Yes: with the ignition off, use a vacuum pump to apply a vacuum of 500 mbar to the solenoid valve outlet . The vacuum pressure should not vary by more than 10 mbar over 30 seconds .

Does the pressure vary?

• Yes: the solenoid valve is faulty, replace it.

• No: there is an electrical fault, check the circuit.

- No: under bleeding conditions (see « bleedingconditions » ), the vacuum should increase (at thesame time the parameter value on the diagnostictool should also increase).

CHECKING THE FUEL VAPOUR ABSORBER TANK CONNECTION

Check this connection by connecting a vacuumpump to the pipe going to the absorber.


Mot. 1311-01 Fuel pressure test kit

14A-6

ANTIPOLLUTIONOil vapour rebreathing

B84 or C84 or S84, and K4J, and 730 or 732

14AI - LOCATION OF COMPONENTS

101495

1

(1) Oil vapour breather port

101499

3

2

(2) Oil vapour recovery plate loca-ted on the cylinder head cover

(3) Sized port

101869

2

14A-7


B84 or C84 or S84, and K4J, and 730 or 732

14AFor information on removing oil vapour recovery plate(2) , (see 11A, Top and front of engine, Tighteningthe cylinder head ).

II - OPERATING DIAGRAM

A: At low loads, small quantities of oil vapour are sucked back in via sized opening (7).

B: At medium and high loads, large quantities of oil vapour are sucked in by the gas throttle.

III - CHECKING

To ensure the antipollution system works properly, theoil vapour rebreathing circuit must be kept clean and ingood condition.

101956

101957

(1) Engine

(2) Oil vapour recovery plate

7

65

4 3

2

1

7

65

43

2

1

(3) Air unit

(4) Motorised throttle valve

(5) Inlet manifold

(6) Air inlet

(7) Sized port

14A-8


K4M, and 760 or 761

14AI - LOCATION OF COMPONENTS

For information on removing oil vapour recovery plate(3) , (see 11A, Top and front of engine, Cylinderhead gasket ).

102305

2

1

(1) Oil vapour breather pipe

(2) Sized opening

101820

(3) Oil vapour recovery plate on thecylinder head cover


43

102073

3

14A-9


K4M, and 760 or 761

14AII - OPERATING DIAGRAM

A: At low loads, the oil vapours are rebreathed in small quantities through the sized opening (6)

B: Under average and heavy loads, the oil vapours are rebreathed in large quantities through the gas throttle valve.

III - CHECKING


102308

102309

(1) Engine


(3) Motorised throttle

(4) Inlet manifold

3

2

1

6

5

4

3

2

1

6

5

4

(5) Air inlet

(6) Sized opening

14A-10


K9K, and 722 or 728 or 729 or 732

14AI - PRESENTATION OF THE CIRCUIT

A : Under low load, the vacuum in the air inlet duct isbelow the spring calibration. The oil vapours are re-breathed in large volumes by the vacuum in the air inletduct.

B : Under medium or high load, the pressure in the airinlet duct pulls the valve diaphragm, the oil vapours arerebreathed in small quantities via a sized opening.

II - CHECK

To ensure the correct operation of the anti-pollutionsystem, the oil vapour rebreathing circuit must be keptclean and in good condition.

20965

20965-1

(1) Cylinder head cover


(3) Oil vapour rebreathing valve

(4) Air inlet duct

(5) Turbocharger

(6) Atmospheric pressure

3

2

1

6 54

3

2

1

654

14A-11


F9Q, and 800 or 808

14AI - CIRCUIT PRESENTATION

II - CHECK

To ensure the correct operation of the anti-pollutionsystem, the oil vapour rebreathing circuit must be keptclean and in good condition.

100053

(1) Engine

(2) Oil separator

(3) Air filter unit

(4) Air duct

(5) Turbocharger

(6) Inlet manifold

4

3

2

1

6

5

100054

(1) Oil vapour rebreathing pipe con-nected to the intake pipes

(2) Cylinder block outlet oil vapourrebreathing pipe

(3) Separator filter oil return pipe

(4) Oil separator

4

3

2

1

14A-12


F4R, and 770 or 771 or 776

14AI - PRESENTATION OF COMPONENTS

102723

1

2


(2) Oil vapour recirculation valve

102729

3

(3) Oil vapour recovery plate on thecylinder head cover

14A-13


F4R, and 770 or 771 or 776

14A

Oil vapour recovery plate located on the rocker cover

F4R, and 776

106629

B A

(A) Circuit upstream of turbochar-ger, used for medium and highloads. The vapour is suckedback in by the prevailing vacuumpressure in the inlet manifold

(B) Circuit downstream of throttlevalve, used for low loads. Thevapour is sucked back in by theprevailing vacuum pressurebetween the throttle and engine

106588

14A-14


F4R, and 770 or 771 or 776

14AFor removal, (see 11A, Top and front of engine, Cy-linder head gasket ).

II - OIL VAPOUR RECIRCULATION CIRCUIT

102738

(4) Throttle upstream oil vapourrecirculation aperture

4

3

102745

10

9

8

5

7

6

14A-15


F4R, and 770 or 771 or 776

14A

III - CHECKING


(5) Air duct

(6) Throttle valve

(7) Inlet manifold

(8) Throttle valve upstream oilvapour rebreathing port


(10) Oil vapour rebreathing valve

14A-16


F9Q, and 804

14AI - THE CIRCUIT

II - CHECK


100053

(1) Engine

(2) Oil separator

(3) Air filter unit

(4) Air duct

(5) Turbocharger

(6) Inlet manifold

100054

(1) Oil vapour rebreathing pipe con-nected to the inlet pipes

(2) Cylinder block outlet oil vapourrebreathing pipe

(3) Oil separator filter return pipe

(4) Oil separator

14A-17

ANTIPOLLUTIONExhaust gas recirculation: Description

K9K, and 722 or 728 or 729

14AI - THE CIRCUIT

II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM

Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOx) content of the exhaust gases.

The computer regulates the passage of gases by ac-tuating a solenoid valve.


The solenoid valve is controlled by an opening cyclicratio signal issued by the injection computer. The ope-ning cyclic ratio signal modulates the opening of thesolenoid valve, and consequently the quantity of ex-haust gas directed back to the inlet manifold.

The computer runs a constant test to keep track of theposition of the exhaust gas recirculation solenoid val-ve.

IV - OPERATING CONDITIONS

The following parameters determine actuation of the exhaust gas recirculation solenoid valve:

- coolant temperature,

- air temperature,

- atmospheric pressure,

- accelerator pedal position,

- diesel injected,

- engine speed.

Operating point for checking the exhaust gas recirculation solenoid valve

The exhaust gas recirculation solenoid valve is actua-ted if:

- the air temperature is between -30˚C and 67 ˚C , in-clusive,

- or the coolant temperature is between 0˚C and 127˚Cinclusive,

- the engine speed is above 500 rpm ,

- the diesel fuel injection flow is between 10 and 31mg/stroke inclusive,

- the atmospheric pressure is above 421 mbar .

If so, the diagnostic tool indicates an exhaust gas recir-culation solenoid valve position opening cylinder ratiovalue equal to 4 and 60% .

Exhaust gas recirculation is cut off if:

- the battery voltage is below 9 V ,

- the engine speed is below 500 rpm ,

- the mapping (engine speed - load) exceeds a thres-hold,

- the air conditioning compressor is actuated.

The exhaust gas recirculation solenoid valve is notsupplied after starting for 2 seconds .

The exhaust gas recirculation solenoid valve is no lon-ger supplied if there is a fault on:

- the exhaust gas recirculation solenoid valve,

- the turbocharging pressure sensor,

102364

(1) Engine

(2) Air filter unit

(3) Plenum chamber

(4) Exhaust manifold

(5) Exhaust gas recirculation unitwith solenoid valve

(6) Turbocharger


(8) Intercooler

(A) Air inlet

(B) Exhaust gas outlet

A

8

1

7 6

5

4

3Note:

The position of the exhaust gas recirculation sole-noid valve is a determining factor in the calculationof the quantity of air admitted by the engine.

14A-18


K9K, and 722 or 728 or 729

14A

15761

Track Description

1 Solenoid supply

2 Position potentiometer supply

3 Not used

4 Position potentiometer earth

5 Solenoid earth control

6 Position potentiometer signal

14A-19


F9Q, and 800 or 808

14AI - THE CIRCUIT


Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOx) content of the exhaust gases.

The injection computer allows gas to pass by actuatinga solenoid valve.





The following parameters determine activation of the exhaust gas recirculation solenoid valve:


- the air temperature,


- the injection flow,

- the engine speed.

Exhaust gas recirculation is cut off if:

- the battery voltage is below 9 V ,

23244

11

2

10

1

9

84

7

3

6

5

(1) Engine


(3) Inlet manifold


(5) Turbocharger


(7) Air flowmeter

(8) Air inlet

(9) Exhaust gas outlet

(10) Intercooler inlet

(11) Intercooler outlet

14A-20


F9Q, and 800 or 808

14A- If the engine speed is above 2,950 rpm when the pe-

dal is released (low pedal value),

- if the mapping (engine speed/load) exceeds a giventhreshold,

- after 40 seconds if

• the vehicle speed is below 7 mph (12 km/h) ,

• the engine speed is below 1,000 rpm .

• the coolant temperature is above 60 ˚C .

The exhaust gas recirculation solenoid valve is notcontrolled after engine start-up depending on coolanttemperature mapping.

The exhaust gas recirculation solenoid valve is no lon-ger supplied if there is a fault on:

- the coolant temperature sensor,

- the air temperature sensor,

- the turbocharging pressure sensor,

- the atmospheric pressure sensor.

Note:

There is no exhaust gas recirculation at altitude (>1,200m).

103127

X Time in seconds


15761

Track Description

1 Solenoid supply

2 Sensor feed

4 Sensor earth

5 Solenoid earth

6 Sensor output

14A-21


F9Q, and 804

14AI - DIAGRAM


Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOX) content of the exhaust gases.

The injection computer authorises gas passage by run-ning an electric motor which actuates a valve linkingthe exhaust manifold and the inlet manifold.


The principle of the exhaust gas recirculation consistsof reintroducing some of the exhaust fumes into the en-gine air breathing cycle.

The EGR valve is controlled by a direct current motor.

114451

(1) Engine

(2) Exhaust gas cooler


(4) Inlet manifold


(6) Turbocharger

14A-22


K9K, and 732

14AI - THE CIRCUIT


Exhaust gas recirculation is used to reduce the con-centration of nitrogen oxides (NOx) in exhaust fumes.

The computer regulates the passage of gases by ac-tuating a solenoid valve.





The following parameters determine actuation of the exhaust gas recirculation solenoid valve:


- air temperature,


- accelerator pedal position,

- diesel injected,

- engine speed.

102364

(1) Engine

(2) Air filter unit

(3) Plenum chamber


(5) Exhaust gas recirculation unitwith solenoid valve

(6) Turbocharger


(8) Intercooler

(A) Air inlet

(B) Exhaust gas outlet

Note:

The position of the exhaust gas recirculation sole-noid valve is a determining factor in the calculationof the quantity of air admitted by the engine.

14A-23

ANTIPOLLUTIONExhaust gas recirculation unit

K9K, and 722

14A


Remove:


- the air duct (1) .

Disconnect the wiring harness (2) .


Disconnect:

- turbocharging pressure regulation valve pipe (3)from the air duct,

- air inlet pipe (4) on the exhaust gas recirculationunit.

Remove:

- bracket (5) ,

- engine lifting eye (6) ,

- air intake metal pipe (7) .



Tightening torquesm

exhaust gas recircula-tion unit mounting bolt

21 Nm

metal air inlet tubemounting bolt

21 Nm

lifting eye (timing end) 21 Nm

mounting bolts for theheat shield on theexhaust gas recircula-tion solenoid valve

12 Nm


4 Nm

102120

1

102126

102119

2

3

4

56

7

14A-24


K9K, and 722

14A

Remove:

- exhaust gas recirculation solenoid valve heatshield (8) ,

- exhaust gas recirculation pipe (9) ,

- the two exhaust gas recirculation unit mountingbolts (10) ,

- the exhaust gas recirculation unit.

REFITTING

Replace the exhaust gas recirculation tube completewith new clips.

Tighten the new clips using tool (Mot. 1567) .

Replace the O-rings on the air inlet metal tube.

Tighten to torque:

- the exhaust gas recirculation unit mountingbolt ( 21 Nm ) ,

- the metal air inlet tube mounting bolt ( 21 Nm ) ,

- the lifting eye (timing end) ( 21 Nm ) ,

- the mounting bolts for the heat shield on the ex-haust gas recirculation solenoid valve ( 12 Nm ).



Tighten to torque the engine cover mounting bolts( 4 Nm ) .

102074

WARNING


8

9

10

14A-25


K9K, and 728 or 729 or 732

14A

REMOVAL


Pull the clip.

Undo bolt (1) .


Disconnect the wiring harness (3) .




Tightening torquesm


21 Nm

metal inlet air tubemounting bolts

21 Nm

lifting eye (timing end) 21 Nm

exhaust gas recircula-tion solenoid valve heatshield mounting bolts

12 Nm

front engine covermounting bolts

4 Nm

Note:

For vehicles fitted with the K9K 732 engine (seeWorkshop Repair Manual 370 Mechanics, Scé-nic II ).

110325

110323

102126

1

2

3

14A-26


K9K, and 728 or 729 or 732

14A

Disconnect:

- the turbocharging pressure regulation valve pipe(4) from the air duct,

- the air inlet pipe (5) on the exhaust gas recircula-tion unit.

Remove:

- the bracket (6) ,

- the engine lifting eye (7) ,

- the air inlet metal tube (8) .

Remove:

- the exhaust gas recirculation solenoid valve heatshield (9) ,

- the exhaust gas recirculation pipe (10) ,

- the two exhaust gas recirculation unit mountingbolts (11) ,

- the exhaust gas recirculation unit.

REFITTING

Replace the exhaust gas recirculation tube completewith new clips.

Tighten the new clips using (Mot. 1567) .

Replace the O-rings on the metal air inlet tube.

Tighten to torque:


- the metal inlet air tube mounting bolts ( 21 Nm ),

- the lifting eye (timing end) ( 21 Nm ) ,

- the exhaust gas recirculation solenoid valveheat shield mounting bolts ( 12 Nm ) .



Tighten to torque the front engine cover mountingbolts ( 4 Nm ) .

102119

102074

6

5

4

8

7

11

10

911

WARNING


14A-27


F9Q, and 804

14A

REMOVAL


Remove the battery.

Remove the air duct (see 12A, Fuel mixture, Inletduct: Removal - Refitting ).

Remove the mounting bolts (1) from the exhaust gasrecirculation pipe.

Remove the mounting bolts (2) from the exhaust gasrecirculation unit.

REFITTING


Tightening torquesm


25 Nm

exhaust gas recircula-tion pipe mounting bolts

18 Nm


4 Nm

111861

111964

113177

WARNING

Never remove the exhaust gas recirculation sole-noid valve from the unit.

14A-28


F9Q, and 804

14ATighten to torque:


- the exhaust gas recirculation pipe mountingbolts ( 18 Nm ) .


Reconnect the connectors.


WARNING


14A-29

ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting

K9K, and 722 or 728 or 729 or 732

14A

The exhaust gas recirculation solenoid valve is fittedinto the exhaust gas recirculation unit.

REMOVALRemove:

- the heat shield,

- the exhaust gas recirculation solenoid valve moun-ting bolts,

- the exhaust gas rebreathing solenoid valve by uns-crewing it gradually,

- the exhaust gas recirculation solenoid valve by gra-dually turning it using tool (Mot. 1729) .

REFITTING


Tighten to torque the exhaust gas recirculationsolenoid valve mounting bolts ( 9 Nm ) .


Mot. 1729 Pin spanner for remo-ving the EGR valve

Tightening torquesm

exhaust gas recircula-tion solenoid valvemounting bolts

9 Nm

Note:

For vehicles fitted with the K9K 732 engine (seeWorkshop Repair Manual 370 Mechanics, Scé-nic II ).

WARNING

Always replace the exhaust gas recirculationsolenoid valve seal with a new one

14A-30

ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting

F9Q, and 800 or 808

14A

The exhaust gas recirculation solenoid valve is fittedinto the exhaust gas recirculation unit.

REMOVALRemove:

- the inlet and exhaust manifolds (see 12A, Fuelmixture, Manifold ),

- the bolts securing the exhaust gas recirculation so-lenoid valve,

- the exhaust gas recirculation solenoid valve by gra-dually turning it using tool (Mot. 1729) .

REFITTING


Tighten to torque the mounting bolts on the ex-haust gas recirculation solenoid valve ( 9 Nm ) .


Mot. 1729 Pin spanner for remo-ving the EGR valve

Tightening torquesm

mounting bolts on theexhaust gas recircula-tion solenoid valve

9 Nm

WARNING

Always replace the exhaust gas recirculationsolenoid valve gasket with a new one

14A-31

ANTIPOLLUTIONIntercooler: Removal - Refitting

K9K, and 732

14A

REMOVAL



Remove:




Remove the oil vapour rebreather pipe (1) .

Disconnect the connector (2) from the oil vapour re-circulation solenoid valve.

Pull out the clip.


Ms. 583 Hose clamps


Equipment required

diagnostic tool

Tightening torquesm

bolts mounting theexhaust gas cooler onits two supports

12 Nm

bolt mounting theexhaust gas cooler sup-ports on the cylinderhead

25 Nm

mounting bolts of therigid exhaust gas recir-culation pipe

35 Nm

coolant circulationcover mounting bolts

10 Nm

bolts mounting the lif-ting bracket on thetiming end

10 Nm

112816

112811

14A-32


K9K, and 732

14A

Remove the mounting bolt (3) from the stainlesssteel pipe.

Move the air inlet duct (4) to one side.

Disconnect the connector (5) from the air inlet pres-sure sensor.

Loosen the clip (6) and move the air inlet duct aside.

Remove the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting ).

Remove the mounting bolts (7) from the injection railprotector cover mounting bracket.

112991

112815

113475

14A-33


K9K, and 732

14A

Position the (Ms. 583) on the exhaust gas cooler in-let and outlet hoses.

Remove the mounting bolts (8) from the exhaust gascoolant recirculation cover.

Move the exhaust gas coolant recirculation cover toone side.

Remove the seals from the cover.

Remove:

- the lifting bracket mounting bolts (9) from the timingend,

- the lifting bracket on the timing end (10) ,

- the air inlet metal tube (11) ,


- the mounting bolts from the exhaust gas inlet pipe(12) ,

- the mounting bolts from the exhaust gas recircula-tion unit assembly (13) ,

- the exhaust gas recirculation unit assembly.


At the workbench, remove:

- the bolt mounting the exhaust gas cooler on its twosupports,

- the exhaust gas cooler,

- the exhaust gas inlet pipe snap-fit clamp,

- the exhaust gas inlet pipe.

114341

Note:

Make preparations for coolant outflow.

112329

112326

14A-34


K9K, and 732

14AREFITTING


All the bearing faces on each removed part must becarefully cleaned.


Refit the exhaust gas cooler on its two supports fit-ted with new seals.

Refit:

- the mounting bolts to the cooler, without makingcontact so that the cooler can move,

- the exhaust gas recirculation unit assembly, with itscooler, onto the cylinder head.

- the mounting bolts for the two exhaust gas coolersupports.

Tighten the bolts mounting the two exhaust gas coo-ler supports on the cylinder head until they makecontact.

Adjust the exhaust gas cooler on its two supports sothat it is immobilised.

Tighten the mounting bolts of the exhaust gas cooleron its two supports until they make contact, in orderto immobilise it.

Remove the exhaust gas recirculation unit assemblywith its cooler.

At the workbench, tighten to torque the bolts moun-ting the exhaust gas cooler on its two supports (12 Nm ) .

Refit the exhaust gas recirculation unit assembly onthe cylinder head with its cooler.

Refit the bolts mounting the exhaust gas cooler sup-ports on the cylinder head.

Tighten to torque the bolt mounting the exhaustgas cooler supports on the cylinder head ( 25Nm ) .

WARNING

Take care not to damage the bearing faces toprevent any risk of coolant leaks.

WARNING

Always replace:

- the metal air inlet tube and its O-rings,

- the exhaust gas inlet pipe, its mounting bolts, itsseal and its snap-fit clamp,

- the cooler seals and its supports,

- the seals of the coolant circulation cover withinthe exhaust gas cooler,

- the seal between the downstream duct of thecut-off valve and the exhaust gas cooler sup-port,

- the seal between the catalytic converter and theturbocharger.

WARNING

Ensure that the seals between the cooler and itstwo supports are correctly positioned to avoidany coolant leaks.

112326

WARNING

Ensure that the seals between the cooler and itstwo supports are correctly positioned to avoidany coolant leaks.

14A-35


K9K, and 732

14ARefit:

- the new rigid exhaust gas recirculation pipe with anew seal,

- the new exhaust gas recirculation pipe mountingbolts,

Fit the new snap-fit clamp.

Tighten the rigid exhaust gas recirculation pipemounting bolts until they make contact.

Adjust the rigid exhaust gas recirculation pipe in re-lation to the cooler support on the timing end.

Lock the snap-fit clamp of the rigid exhaust gas re-circulation pipe using the (Mot. 1567) .

Tighten to torque the mounting bolts of the rigidexhaust gas recirculation pipe ( 35 Nm ) ).

III - FINAL OPERATIONS

Refit:


- the coolant circulation cover

- the coolant circulation cover mounting bolts

Tighten to torque the coolant circulation covermounting bolts ( 10 Nm )

Refit:

- the lifting bracket on the timing end,

- the bolts mounting the lifting bracket on the timingend.

Tighten to torque the bolts mounting the liftingbracket on the timing end ( 10 Nm )

Loosen the nut mounting the rail protector on themounting bracket.

Refit the bolts mounting the rail protector mountingbracket on the exhaust gas cooler assembly.

Tighten:

- the bolts mounting the rail protector mounting brac-ket on the exhaust gas cooler assembly,

- the nut mounting the rail protector on the mountingbracket.

Refit the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting ).

Connect the air inlet pressure sensor connector.

Refit the clip on the air inlet duct if necessary.

Position the air inlet duct.

Clip the air inlet duct onto the turbocharger.

Refit the air inlet duct mounting bolt.

Tighten the air inlet duct bolt.

Connect the exhaust gas recirculation solenoid val-ve connector.

Refit the oil vapour rebreathing pipe.

Connect the battery (see 80A, Battery: Removal -Refitting).

Bleed the coolant (see 19A, Cooling, Cooling cir-cuit: Bleeding ).

Refit:



Clear any faults stored by the computer using thediagnostic tool .

WARNING

Ensure that you do not squeeze the exhaust gasinlet pipe before fitting the snap-fit clamp.

WARNING

Ensure that the water inlet and outlet hoses ofthe exhaust gas cooler are correctly aligned sothat they do not bend.

14A-36

ANTIPOLLUTIONExhaust gas recirculation mounting: Removal - Refitting

K9K, and 732

14AFor removing and refitting the supports for the exhaustgas recirculation (see 14A, Emission control, Ex-haust gas cooler: Removal - Refitting ).

14A-37

ANTIPOLLUTIONExhaust gas recirculation rigid pipe: Removal - Refitting

K9K, and 732

14A

REMOVAL




Disconnect the battery (see 80A, Battery: Removal -Refitting

Remove:


- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - refitting ).


Remove:

- the mounting bolts (1) from the exhaust gas recir-culation pipe,

- the snap-fit clamp (2) using the (Mot. 1567) ,

- the rigid exhaust gas recirculation pipe (3) .

REFITTING


All the bearing faces must be carefully cleaned.


Refit:

- the rigid exhaust gas recirculation pipe with a newseal,

- the new exhaust gas recirculation pipe mountingbolts,

Fit a new snap-fit clamp.

Tighten the mounting bolts of the rigid exhaust gasrecirculation pipe on the manifold until they makecontact.

Adjust the exhaust gas inlet pipe in relation to thecooler support on the timing end.

Lock the snap-fit clamp of the rigid exhaust gas re-circulation pipe using the (Mot. 1567) .

Tighten to torque the mounting bolts of the rigidexhaust gas recirculation pipe on the manifold (35 Nm ) .


Refit:

- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ),






Tightening torquesm

mounting bolts of therigid exhaust gas recir-culation pipe on themanifold

35 Nm

113842

WARNING

Always replace:

- the exhaust gas inlet pipe, its seal on the cylin-der head and its snap-fit clamp,

- the seals between the catalytic converter andthe turbocharger.

WARNINGEnsure that you do not squeeze the exhaust gasinlet pipe before fitting the snap-fit clamp.

16A-1

STARTING - LOADAlternator: General information

F4R or F9Q or K4J or K4M or K9K or M9R

16AI - OPERATION

These vehicles are fitted with an alternator with internal ventilation and incorporated regulator, plus a warning light on the instrument panel, which operates as fol-lows:

- when the ignition is switched on, the warning light co-mes on,

- when the engine starts, the warning light goes out,

- if the warning light comes on while the engine is run-ning, this indicates a « charge » fault.

II - IDENTIFICATION

Engine Alternator Currentstrength

K4J and

K4M

VALEO : TG11 C011 110 A

VALEO : TG11 C027

BOSCH : LIE8 0 124 525028

150 A

F4R

VALEO : TG11 C040 110 A

VALEO : TG11 C049

VALEO : SG12 B092 125 A

VALEO : SG12 B098

K9K

VALEO : TG11 C041 110 A

VALEO : TG11 C034

BOSCH : LIE8 0 124 525082

150 A BOSCH : LIE8 0 124 525081

MELCO : 8GM A004 TJ0581

210 A MELCO : 8GM A004 TJ0481

F9Q

VALEO : TG11 C018

110 A VALEO : TG11 C040

VALEO : TG11 C049

VALEO : SG12 B078

125 A VALEO : SG12 B081

VALEO : SG15 B092

VALEO : SG15 B098

BOSCH : LIE8 0 124 525101 150 A

BOSCH : 0 124 525 044

VALEO : SG15 L027 155A

M9R

BOSCH : LIE6 0 124 0AC473B

120A

VALEO : TG15 C059 150 A

MELCO : 8GM A004 TJ0281

210 A

Note:

There is a configuration in the Protection and Swit-ching Unit for the alternator fitted to the vehicle (see87G, Engine compartment connection unit, Pro-tection and Switching Unit ).

Engine Alternator Currentstrength

16A-2

STARTING - LOADAlternator: Removal - Refitting

K9K, and 722 or 724 or 728 or 729 or 732

16A

REMOVAL

REMOVAL PREPARATION OPERATION


Remove the engine cover.

Disconnect:


- the electrical connections.

Remove the alternator harness.

Remove:

- the front wheels,



- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).

Fit the cooling assembly to the upper cross memberusing the safety belt .

Remove:

- the side stiffener mounting bolts,

- the side reinforcements (1) .

Remove:

- the half sub-frame mounting nuts and bolts (2) ,


Equipment required

safety belt

Tightening torquesm


21 Nm


21 Nm

free pulley supportmounting bolts

21 Nm


105 Nm


21 Nm

wheel bolts 110 Nm

Note:

When fitting the safety strap, take care:

- not to crush the cooling hoses,

- not to strap up the half sub-frame.

101212

102008

16A-3


K9K, and 722 or 724 or 728 or 729 or 732

16A

Disconnect:

- the pressostat connector (3) ,

- the air conditioning compressor connector (4) ,

Move the electric wiring harness to one side.Remove the air conditioning compressor mountingbolts (5) .

Remove the air conditioning compressor and attachit using a safety belt .

CA or CAREG

109537

19703

Note:

Take care not to constrain the compressor airconditioning pipes during this operation.

16A-4


K9K, and 722 or 724 or 728 or 729 or 732

16A

Remove:

- the free pulley support mounting bolts (6) ,

- the idler pulley support.

OPERATION FOR REMOVAL OF PART CONCERNED

Remove:

- the alternator mounting bolts (7) ,

- the alternator.

CHAUFO

11107919703

WARNING

Do not damage the cooling unit vanes (radiator,condenser, etc.) during handling.

Note:

To ease alternator removal, slightly move thecooling system towards the front.

16A-5


K9K, and 722 or 724 or 728 or 729 or 732

16AREFITTING


Refit the rings (8) using pliers or a vice.


Refit:

- the alternator,

- the alternator mounting bolts.



Refit:

- The air conditioning compressor,

- the air conditioning compressor mounting bolts.

Tighten to torque the air conditioning compressormounting bolts ( 21 Nm )

Connect:

- the pressostat connector,

- the air conditioning compressor connector.

Refit:

- the free pulley support,

- the free pulley support mounting bolts.

Tighten to torque the free pulley support moun-ting bolts ( 21 Nm ) .


Apply a drop of LOCTITE - FRENEBLOC on thesub-frame mounting bolts.

Refit:


- the side reinforcements.

Tighten to torque:



Refit:




- the front wheels.


Connect:

- the electrical connections,



18987

CA or CAREG

CHAUFO

16A-6


F4R, and 770 or 771 or 776

16A

REMOVAL



Remove:




- radiator cross member side reinforcement (1) ,

- the bumper.

Disconnect:

- the fog lights connector (if fitted on vehicle),

- the headlight washer pipes (if the fitted on vehicle)at the windscreen washer fluid reservoir end.

Remove:

- the bumper mountings,

- the bumper.

Disconnect the windscreen washer fluid reservoir pi-pes.

Tightening torquesm


25 Nm


4 Nm

wheel bolts 110 Nm

101212

1

16A-7


F4R, and 770 or 771 or 776

16A



Remove:

- the clip (4) ,

- mounting (5) ,

- impact cross member mounting bolts (6) ,


- the accessories belt (See 11A, Top and front ofengine, Accessories belt ).

Disconnect the alternator electrical connections.

Remove:

- intercooler air duct (7) ,

- the accessories belt tension wheel.

102504

102365

4

3

2

5

2

666

F4R, and 776

104342

7

16A-8


F4R, and 770 or 771 or 776

16A

Remove:


- the alternator using a screwdriver.

REFITTING

Refit the rings (9) using pliers or a vice to facilitate fit-ting.


Replace the accessories belt.

Tension the accessories belt (see 11A, Top andfront of engine, Accessories belt ).



Tighten to torque:



19703

WARNING

Do not force it against the air conditioning hose:there is a risk of refrigerant fluid escaping.

Note:

To facilitate removal of the alternator, shift thecooling assembly gently forward (be careful notto deform the condenser pipes).

88

18987

WARNING

When replacing the belt, be sure to replace thetension wheels and idler pulleys.

WARNING


99

16A-9


F9Q, and 800 or 804 or 808

16A

REMOVAL



Remove:


- the front wheels,


- the half sub-frame side reinforcement (1) ,

- the bumper (see MR 365 Bodywork, 55A, Exte-rior protection, Front bumper ).




Remove:

- the clip (4) ,

- the mounting (5) ,





Remove the accessories belt tensioning roller.

Tightening torquesm


25 Nm

wheel bolts 110 Nm


4 Nm

101212

1

102504

102365

54

322

666

16A-10


F9Q, and 800 or 804 or 808

16A

Remove:

- the alternator mountings (7) ,


To facilitate removal of the alternator, shift the coo-ling assembly forward gently (be careful not to da-mage the condenser pipes).

REFITTING

Refit the rings (8) using a vice to facilitate fitting.

Refit the alternator.







19703

77

18987


88

16A-11


K4J, and 730 or 732 – K4M, and 760 or 761

16A



Remove:




- radiator cross member side reinforcement (1) ,

- the bumper.

Disconnect:

- the fog lights connector (if fitted on vehicle),

- the headlight washer pipes (if the fitted on vehicle)at the windscreen washer fluid reservoir end.

Remove:


- the bumper.

Disconnect the windscreen washer fluid reservoir pi-pes.

Tightening torquesm


21 Nm

alternator strut moun-ting bolts

21 Nm

nut securing the strut tothe stud on the engineside

21 Nm


4 Nm

wheel bolts 110 Nm

101212

1

16A-12


K4J, and 730 or 732 – K4M, and 760 or 761

16A



Remove:

- the clip (4) ,

- mounting (5) ,

- impact cross member mounting bolts (6) ,


- the accessories belt (See 11A, Top and front ofengine, Accessories belt ).


Remove the alternator retaining strut.

Remove:



102504

102365

4

3

2

5

2

666

19703

WARNING

Do not force it against the air conditioning hose:there is a risk of refrigerant fluid escaping.

Note:

To facilitate removal of the alternator, shift thecooling assembly gently forward (be careful notto deform the condenser pipes).

77

16A-13


K4J, and 730 or 732 – K4M, and 760 or 761

16AREFITTING


Tighten to torque:

- the alternator mounting bolts ( 21 Nm ) ,

- the alternator strut mounting bolts ( 21 Nm ) .

- the nut securing the strut to the stud on the en-gine side ( 21 Nm ) ,

Replace the accessories belt.

Tension the accessories belt (see 11A, Top andfront of engine, Accessories belt ).



Tighten to torque:



18987

WARNING

When replacing the belt, be sure to replace thetension wheels and idler pulleys.

WARNING


99

16A-14



16A

REMOVAL



Remove:



- the right-hand wheel arch liner,

- the side stiffener (1) ,

- the fog lights connector,




Remove:

- the clip (4) ,

- the mounting (5) ,

- the impact cross member mounting bolt (6) ,



Remove the accessories belt tensioning roller.

Tightening torquesm


25 Nm



4 Nm

Note:

The tensioning roller and the inertia reel must bereplaced when the accessories belt is replaced.

106077

102504

102365

16A-15



16A

Remove:

- the alternator mountings (7) ,


To ease alternator removal, slightly move the coo-ling system toward the front (be careful not to bendthe condenser pipes).

REFITTING


Refit:

- the alternator,

- the alternator mounting bolts.

Tighten to torque the alternator mounting bolts (25 Nm ) .

Refit the new accessories belt.

Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt: Removal - Refitting).

Tighten to torque the wheel mounting bolts ( 130Nm ) .


Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting .


19703

WARNING

The belt must be replaced with a new one if ithas been removed.

18987

16A-16


M9R, and 700

16A

REMOVAL

I - REMOVAL PREPARATION STAGE



Remove:




Remove:

- the right-hand sub-frame side stiffener (1) ,



Tightening torquesm


25 Nm

positive terminal moun-ting nut

8 Nm

air inlet hose clip on thedamper valve

5.5 Nm

air inlet hose clip on theintercooler

5.5 Nm

turbocharger pressuresensor mounting nut

8 Nm


21 Nm


44 Nm 101212

114855

16A-17


M9R, and 700

16A





Remove:

- the clip (6) ,

- the front end panel upper mounting bolt (7) .


Remove:

- the front end panel lower mounting bolts (8) ,


Remove the « cooling radiator - condenser -intercooler » assembly from its housing and push itforwards.

114933

112658

102504

102365

16A-18


M9R, and 700

16A

Disconnect the turbocharging pressure sensor con-nector (9) .

Remove the turbocharger pressure sensor mountingnut on the air inlet valve stay.

Undo the air inlet hose clip on the damper valve.

Remove:

- the air inlet duct clip (10) from the intercooler,

- the air inlet clip mounting bolt (11) from the conden-ser,



Disconnect the alternator's electrical connector (12).

Remove the positive terminal mounting nut (13) .

Remove the alternator mounting bolts (14) .

Remove the alternator.

114409

114649

114860

114859

16A-19


M9R, and 700

16AREFITTING


Refit the rings (15) using pliers or a vice to facilitatefitting.

Fit the alternator in place.

Tighten to torque

- the alternator mounting bolts ( 25 Nm ) ,

- the positive terminal mounting nut ( 8 Nm ) .

Connect the alternator electrical connector.


Refit the « Cooling radiator - condenser -intercooler » group in its housing.

Refit the air inlet duct.

Tighten to torque:

- the air inlet hose clip on the damper valve ( 5.5Nm ) ,

- the air inlet hose clip on the intercooler ( 5.5 Nm) .

Tighten the air inlet clip mounting bolt on the con-denser.

Refit the turbocharger pressure sensor on the dam-per valve stay.

Tighten to torque the turbocharger pressure sen-sor mounting nut ( 8 Nm ) .

Connect the turbocharging pressure sensor connec-tor.


Refit:


- front end panel mounting bolts,

Tighten to torque:



Clip:

- the bonnet opening cable,


Refit clips.

Refit:


- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting )

- the half sub-frame side stiffener,





18987

16A-20

STARTING - LOADAlternator pulley: Removal - Refitting

K4J or K4M or K9K, and CA

16A



- the tensioning roller,

- the tensioning roller mounting bolts.

essential equipment

- tool box for removing and refitting the alternator pulley(Mot. 1732)

It is essential to replace an alternator decouplingpulley with a decoupling pulley.

REMOVAL


Remove the alternator (see 16A, Starting - Char-ging, Alternator: Removal - Refitting ).

Hold the alternator in a vice.


Fit the hexagon socket (1) from the tool box for re-moving and refitting the alternator pulley (Mot. 1732)into the alternator pulley.


Mot. 1732 Tool for removing andrefitting the alternatorpulley

Tightening torquesm

alternator decouplingpulley

80 Nm

110276

110266

110267

16A-21



16A

Fit the drive (2) from the tool box for removing andrefitting the alternator pulley (Mot. 1732) (correspon-ding to the alternator mark) into the hexagon socket(3) .

Position the drive adapter (4) in socket (5) .

Hold the hexagon socket (6) using an open-jawedspanner (7) .

Loosen the decoupling pulley (8) using a ratchet (9)(turning the ratchet clockwise).

Remove the decoupling pulley.

110268

110269

110270

16A-22



16AREFITTING


Screw the new decoupling pulley onto the alternatorrotor.

Fit:

- the hexagon socket (10) in the alternator,

- the drive (11) (corresponding to the socket in thealternator rotor),

- the drive adapter (12) onto the drive (11) .

110266

110269

Note:

Check that the torque wrench is capable of tigh-tening in an anticlockwise direction.

16A-23



16A

Tighten to torque the alternator decoupling pulley( 80 Nm ) using a torque wrench.


Refit the alternator to the vehicle (see 16A, Starting- Charging, Alternator: Removal - Refitting ).

110266

16A-24

STARTING - LOADStarter: Identification 16A

Engine Starter motor

K4J and K4M VALEO : D7E27

K9K MITSUBISHI

F9Q and F4R VALEO : D7R49

16A-25

STARTING - LOADStarter: Removal - Refitting

F4R, and 770 or 771

16A




Disconnect:

- the oil level sensor connector,

- the starter connections,

Remove:

- the starter motor mounting bolts,

- the starter motor.

REFITTING

Check that the centring dowel (1) is in place.



Tighten to torque:

- the starter mounting bolts ( 38 Nm ) ,


Tightening torquesm

starter mounting bolts 38 Nm


4 Nm

14853

101482

WARNING


16A-26


F9Q, and 800 or 808

16A



Remove:


- the front right wheel,

- the battery,

- the battery tray,

- the air hose between the air filter and turbochargerduct,

Remove:

- the air hose (1) and gently separate the hose (2) ,

- the engine tie-bar.

Remove:

- the bracket (3) ,

- the catalytic converter (4) mounting plate on thegearbox,

- the catalytic converter (5) (see 19B, Exhaust, Ca-talytic converter ).

Disconnect the starter motor electrical connections.

Remove:

- the starter motor mounting bolts (6) ,


Tightening torquesm

wheel bolts 110 Nm


4 Nm

102421

21

101120

102427

3

4

5

6

16A-27


F9Q, and 800 or 808

16AREFITTING

Check that the centring dowel is in place.




Tighten to torque:


- the engine cover mounting bolts ( 4 Nm ) .

WARNING


16A-28


K9K, and 722

16A



Remove:



Remove:


- catalytic converter stay (2) on the gearbox,

- the catalytic converter (3) (see 19B, Exhaust, Ca-talytic converter ).

Disconnect the starter motor electrical connections.

Remove:

- the starter mountings (4) ,

- the starter (5) .

REFITTING



Tighten to torque the starter mounting bolts ( 44Nm ) .



Tighten to torque:



Tightening torquesm


wheel bolts 110 Nm


4 Nm

104175

1

2

3

102268

WARNING


5

4

16A-29


K4J, and 730 or 732 – K4M, and 760 or 761

16A

REMOVAL



Remove:


- the air resonator mounting (K4J),

- the air filter outlet duct (K4M),

Disconnect:


- the starter connections,

Remove:

- the starter motor mounting bolts,


REFITTING




Tighten to torque:



Tightening torquesm



4 Nm

14853

101482

WARNING

carry out the necessary programming (see 80A,Battery: Removing - refitting ).

1

16A-30


F4R, and 776

16A

REMOVALThe engine needs to be removed if the starter motoris being replaced (see 10A, Engine and periphe-rals, Engine - gearbox ).


Remove:

- the heat shield mountings (1) ,

- the heat shield,

- the catalytic converter downstream strut (2) .

Disconnect the starter supply.

Remove:



Tightening torquesm


the catalytic converterdownstream strut nut

21 Nm

heat shield mountingbolts

8.5 Nm


4 Nm

106249

2 111

21921

333

16A-31


F4R, and 776

16AREFITTING



Tighten to torque:


- the the catalytic converter downstream strutnut ( 21 Nm ) ,

- the heat shield mounting bolts ( 8.5 Nm ) .



21935

WARNING


4

16A-32


K9K, and 728 or 729

16A




Disconnect:

- the starter electrical connections (1)

- the rail pressure sensor (2) .

Disconnect the gearbox earth.

Disconnect the oil level sensor.

Tightening torquesm



4 Nm

106205

1

2

106203

106201

16A-33


K9K, and 728 or 729

16A

Remove:

- the starter mountings,


REFITTING



Tighten to torque the starter mounting bolts ( 44Nm ) .



106191

WARNING


16A-34


F9Q, and 804

16A



Remove:



- the battery,

- the battery tray,

- the air hose between the air filter and turbochargerduct,

Remove the catalytic pre-converter. (see 19B; Ex-haust, Catalytic pre-converter: Removal - Refit-ting ).

Remove the air duct (1) from the turbocharger.


Disconnect the wiring harness from the starter mo-tor.

Remove the starter motor mounting bolts (3) .

Remove the starter motor.

REFITTING


Tighten to torque the starter motor mounting bolts( 44 Nm ) .

Tightening torquesm

starter motor mountingbolts

44 Nm


12 Nm


4 Nm

wheel bolts 110 Nm

111860

111865

111868

16A-35


F9Q, and 804

16AProceed in the reverse order to removal.

Replace the turbocharger oil return pipe seals.

Tighten to torque the turbocharger oil return pipemounting bolts ( 12 Nm ) .



Tighten to torque:



WARNING


16A-36


M9R, and 700

16A

REMOVAL



Remove:





Drain the coolant circuit using the filling station(see 62A, Air conditioning, Maintenance ).

Remove:





Remove:

- the clips (4) ,



Equipment required

filling station

Tightening torquesm


44 Nm

starter base mountingnut

8 Nm

solenoid excitationmounting nut

5 Nm


5.5 Nm


5.5 Nm


21 Nm


44 Nm


21 Nm


8 Nm

112658

102504

16A-37


M9R, and 700

16A

Disconnect the injection computer connector (6) .

Remove:




Unclip the wiring harness (9) from the battery - termi-nal.



Remove:



Remove the intercooler downstream duct mountingbolt (12) on the cooling radiator.

Loosen:

- the intercooler downstream duct clip (13) on the in-tercooler,


Remove the intercooler downstream duct from theintercooler.

Remove the cooling assembly from its housing andpush the assembly forwards.

112659

114933

102365

114649

16A-38


M9R, and 700

16A

Remove the air dehydration canister conditioningpipe mounting bolt (14) from the air conditioningcompressor.

Remove the air dehydration canister conditioningpipe from the air conditioning compressor.


Remove:

- the mounting nut (15) from the starter base,

- the mounting nut (16) from the solenoid excitation.

Remove the earth wire mounting bolt (17) on thestarter.

Move the starter motor wiring harness to one side.

109537

Note:

Plugs must be fitted to the pipe and the compres-sor to prevent moisture from entering the system.

114628

114998

16A-39


M9R, and 700

16A

Remove:

- the starter mounting bolts (18) .


REFITTING


Fit the starter.


Refit:

- the starter base wire,

- the starter base mounting nut,

- the solenoid excitation wire,

- the solenoid excitation mounting nut,

- the earth wire,

- the earth wire mounting bolt.

Tighten to torque:

- the starter base mounting nut ( 8 Nm ) ,

- the solenoid excitation mounting nut ( 5 Nm ) .

113312

16A-40


M9R, and 700


Refit:

- the air dehydration canister conditioning pipe ontothe air conditioning compressor,

- the air dehydration canister conditioning pipemounting bolt onto the air conditioning compressor(see 62A, Air conditioning, Compressor: Remo-val - Refitting ).

Fit the cooling assembly.

Refit:

- the intercooler downstream duct onto the intercoo-ler and damper valve,

- the intercooler downstream duct mounting boltonto the cooling radiator.

Tighten to torque:


- the intercooler downstream duct clip on thedamper valve ( 5.5 Nm ) .

Refit:



Tighten to torque:



Clip:


- the bonnet opening cable.

Refit:

- the battery tray,


- the wiring harness mounting nut onto the batterytray.

Tighten to torque:



Clip the battery - terminal wiring harness.

Connect:




Refit:

- the clips,






Fill the coolant circuit using the filling station (see62A, Air conditioning, Maintenance ).

16A-41


K9K, and 732

16A

REMOVAL


Position the vehicle on a two-post lift (see 02A, Lif-ting equipment; underbody lift ).

Remove the engine cover.



Disconnect:

- the oil pressure sensor connector (1) ,

- the oil level sensor connector (2) .

Unclip the diesel fuel drain pipe.

Tightening torquesm


44 Nm

113863

106201

16A-42


K9K, and 732

16A

Remove the starter electrical connections (3) .

Disconnect the injector rail pressure sensor connec-tor.

Move the wiring harness against the cylinder block.


Remove:

- the starter mounting bolts (4) .


REFITTING




Refit:

- the starter motor,

- the starter mounting bolts.



Refit the starter nuts.

Clip on the diesel fuel drain pipe.

Connect:

- injection rail pressure sensor connector,


- the oil pressure sensor connector.




106205

106191

16A-43



16A

REMOVALDisconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).

Removal of the starter requires the engine to be re-moved (see 10A, Engine and peripherals, Gear-box - motor assembly: Removal - Refitting ).


Remove:


- the heat shield,

- the catalytic converter downstream strut (2) .

Disconnect the starter supply.

Remove:



Tightening torquesm

starter mountings 38 Nm

catalytic converterdownstream stay nut

44 Nm

heat shield mountings 8.5 Nm

106249

21921

16A-44



16AREFITTING



Tighten to torque:

- the starter mountings ( 38 Nm ) ,

- the catalytic converter downstream stay nut (44 Nm ) ,

- the heat shield mountings ( 8.5 Nm ) .


21935

17A-1

IGNITIONCoils Removal - Refitting

F4R, and 770 or 771 – K4J, and 730 or 732 – K4M, and 760 or 761

17A

The power module is incorporated in the injection com-puter. The ignition system uses the same sensors asthe injection system.

There are four ignition coils secured directly onto thespark plugs by bolts on the cylinder head cover.

The coils are in series in pairs by the injection com-puter:

- track C M4 for cylinders 1 and 4,

- track C M3 for cylinders 2 and 3.

REMOVAL


Disconnect:

- the battery starting with the negative terminal.

- the connectors (1) from the ignition coils.

Remove the coil mounting screws (2) .

REFITTING

To refit, proceed in the reverse order of removal.

If necessary, replace the coil O-rings.

Tighten the ignition coil mounting screws to tor-que ( 1.5 daNm ) .

Tighten the battery cover mounting bolts to ( 0.4daNm ) .

Tightening torquesm

ignition coil mountingscrews to torque

1.5 daNm

the battery cover moun-ting bolts to

0.4 daNm

14851

101490

WARNING

Damaged connectors must be replaced.

WARNINGConnect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).

2

1

17A-2



17A

The power module is built into the injection computer.The ignition system uses the same sensors as the in-jection system.

There are four ignition coils, and they are mounteddirectly onto the spark plug by a bolt on the rockercover.

The coils are supplied in series two by two by the in-jection computer:

- track C M4 for cylinders 1 and 4,

- track C M3 for cylinders 2 and 3.

REMOVAL


Disconnect:


- the ignition coil connectors (1) .

Remove the coil mounting bolts (2) .

Tightening torquesm

ignition coil mountingbolts

15 Nm


4 Nm

14851

101490

17A-3



17A

Remove the coil mounting bolts (3) .

REFITTING


F4R, and 776

106589

WARNING

Be sure to replace any damaged connectors.

3333

17A-4



17A

Apply to the four ignition coils a bead (4) of FLUORI-NE GREASE (PART NO. 82 00 168 855) , 2 mm indiameter around the inner edge of the high tensioncap.

If necessary, replace the coil O-rings.

Tighten to torque:

- the ignition coil mounting bolts ( 15 Nm ) ,


106443

4

17A-5

IGNITIONSpark plugs


17A

Remove:

- the ignition coils (see 17A, Ignition, Coils ),

- the spark plugs.


Ele. 1382 Spark plug kit

Tightening torque

Spark plugs

25 to 30 Nm

Engines Brand Type

K4J and K4M EYQUEM RFN58LZ

CHAMPION RC87YCL

Flat skirt with seal

Gap: 0.95 ( ±±±± 0.05 mm )

F4R 770 / 771 CHAMPION RC87YCL


Gap 0.90 ( ±±±± 0.05 mm )

F4R 776 NGK PFR6G-9


Gap 0.85 ( ±±±± 0.05 mm )

17B-1

PETROL INJECTIONLocation of components

K4J, and 730 or 732 – K4M, and 760 or 761

17B

K4J, and 730 or 732

101099

31

10 9 8 7

2 654

(1) Fuel vapour recirculation sole-noid valve

(2) Manifold pressure sensor


(4) Ignition coil




(8) Pinking sensor

(9) Air temperature sensor

(10) Injector rail and injectors

17B-2


K4J, and 730 or 732 – K4M, and 760 or 761

17B

K4M, and 760 or 761

101804

11

22 21 20 19

1817

16

15141312


(12) Camshaft dephaser solenoidvalve


(14) Ignition coil

(15) Camshaft position sensor





(20) Pinking sensor



K4J, and 730 or 732

102107


2323

17B-3


K4J, and 730 or 732 – K4M, and 760 or 761

17B

101493

(24) Injector rail

(25) Injectors

101800


2525

2525

24

26

101101




(30) Ignition coils

101498


(32) Pinking sensor

29

28

30

27

3231

17B-4


K4J, and 730 or 732 – K4M, and 760 or 761

17B

K4M, and 760 or 761

101810

(33) Injector rail

(34) Injectors

101796




(38) Ignition coils

33

3434

3434

3635

37

3838

3838

101809

(39) Pinking sensor




101811


39

40

42

41

43

17B-5


K4J, and 730 or 732 – K4M, and 760 or 761

17B

K4M, and 760 or 761

102735


101105


44

45

102144


102204


46

47

17B-6


K4J, and 730 or 732 – K4M, and 760 or 761

17B

101798

(48) Upstream oxygen sensor

101501

(49) Downstream oxygen sensor


48

50

49

102483

(51) Fuel vapour recirculation absor-ber

51

17B-7


F4R, and 770 or 771 or 776

17B

F4R, and 770 or 771

102722

21

11 10 9 8

76543




(4) Ignition coil





(9) Pinking sensor



17B-8


F4R, and 770 or 771 or 776

17B

F4R, and 776

106078

21 20 19 18 17 16

1514132312

22

(12) Ignition coil









(21) Pinking sensor


(23) Electric water pump

106280


24

17B-9


F4R, and 770 or 771 or 776

17B

F4R, and 770 or 771

101809

(25) Pinking sensor




102730

(29) Injector rail

(30) Injectors

25

26

27

28

29

3030

3030

102732

(31) Pinking sensor


102724

(33) Fuel recirculation solenoid valve



(36) Ignition coil

31

32

33

34

35

3636

3636

17B-10


F4R, and 770 or 771 or 776

17B

102735

(37) Throttle valve

102144


37

38

F4R, and 776

101809

(39) Pinking sensor


106269

(41) Injector rail

(42) Injectors

4039

42424242

41

17B-11


F4R, and 770 or 771 or 776

17B

106633


106278


43

44

106787


(46) Ignition coils

106279



46

45

48

47

17B-12


F4R, and 770 or 771 or 776

17B

101105


102204


49

50

102483

(51) Fuel vapour recirculation absor-ber

F4R, and 770 or 771

101798


51

52

17B-13


F4R, and 770 or 771 or 776

17B

101501



F4R, and 776

106244


53

54

55

106253


56

17B-14

PETROL INJECTIONOxygen sensors: Removal - Refitting

F4R, and 770 or 771 – K4M, and 760 or 761 – K4J, and 730 or 732

17B

REMOVAL

I - UPSTREAM OXYGEN SENSORS

Remove lambda sensor (1) using the tool (Mot.1495-01) .

II - DOWNSTREAM OXYGEN SENSOR

Remove lambda sensor. (2)

REFITTING


Tighten to torque the oxygen sensor ( 45 Nm )using a 24 mm fork socket for the downstream sen-sor and tool (Mot. 1495-01) for the upstream oxygensensor.



Tightening torquesm

oxygen sensor 45 Nm

101798

1

101501

2

17B-15

PETROL INJECTIONOxygen sensors: Removal - Refitting

F4R, and 776

17B

REMOVAL

I - UPSTREAM OXYGEN SENSORS

Remove the front engine cover.

Disconnect the oxygen sensor.

Remove the oxygen sensor (1) using the tool (Mot.1495-01) .

II - DOWNSTREAM OXYGEN SENSOR

Remove:


- the oxygen sensor (2) using (Mot. 1495-01) .

REFITTING


Tighten to torque the oxygen sensors ( 34 Nm )using tool (Mot. 1495-01) .



Tightening torquesm


106244

1

21926

2

17B-16

PETROL INJECTIONAccelerator pedal potentiometer: Removal - Refitting

F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732

17B

The accelerator pedal potentiometer is incorporated inthe accelerator pedal. If it is replaced, the acceleratorpedal must also be replaced.

There are two types of pedal: with or without a resis-tance point .

Vehicles equipped with cruise control/speed limiterhave an accelerator pedal with a point of resistance atthe end of their travel (kickdown)

This kickdown point is used for exiting the speed limiterfunction if the driver has to increase his speed.

REMOVAL

Disconnect:


- the accelerator pedal connector.

Remove:

- pedal mounting bolts ,

- the pedal.

REFITTINGProceed in the reverse order to removal.



Tightening torquesm


4 Nm

WARNING

A pedal fitted with a kickdown point may be fitted inplace of a pedal without a kickdown point. Fitting apedal without a resistance point in place of a pedalwith a resistance point is not permitted.

102204

WARNINGCarry out the necessary programming (see 80A,Battery: Removal - refitting ).

Note:

A fault on the accelerator pedal position potentio-meter results in changes in the idle speed orengine operation (see 17B, Petrol injection, Idlespeed correction ).

17B-17

PETROL INJECTIONPosition and speed sensor


17B

Program the engine flywheel target, after replacingspeed and position sensor (1) or the engineflywheel.

Program with the engine flywheel target after repla-cing speed and position sensor (1) or the engineflywheel

In third gear, accelerate twice in succession to 4000rpm , then decelerate to power take-up speed.

Power take-up speed is the moment when, duringdeceleration under no load with the injection cut out,the computer authorises injection again.

Use the diagnostic tool to check that programminghas been carried out correctly ET089: « Programengine flywheel target » .

Read the fault codes.

Repair if necessary.

Clear the fault codes.

Check that the vehicle is working correctly.

Equipment required

diagnostic tool

F4R, and 770 – K4M, and 760 – K4J, and 730 or732

102144

1

F4R, and 776

102485

1

17B-18

PETROL INJECTIONPosition and speed sensor

F4R, and 771 – K4M, and 761

17B

Program the engine flywheel target, after replacingspeed and position sensor (1) or the engineflywheel.







Check that the vehicle is operating correctly.

Equipment required

diagnostic tool

102144

Note:

Do not shift the gear lever to « D »

1

17B-19

PETROL INJECTIONPetrol injection computer: Removal - Refitting


17B




Remove:

- the bolts securing the computer to the mounting,

- the computer.

Remove the battery.


Remove:

- the battery tray (3) mounting bolts,

- the electrical wiring harness (4) .



Equipment required

diagnostic tool

Tightening torquesm


21 Nm


4 Nm

K4M, and 760 or 761 – K4J, and 730 or 732

102107

1

F4R, and 770 or 771 or 776

101822

222

4

333

17B-20

PETROL INJECTIONPetrol injection computer: Removal - Refitting


17B


Remove the four computer mounting bolts.

REFITTING




Use the diagnostic tool to check that this program-ming has been completed correctly ET051: Throttlestop programming .

Perform flywheel target programming during a roadtest.







Check that the vehicle is functioning correctly.


101811

101890

5 WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).

Note:

When the ignition is switched on, the motorisedthrottle valve should go through a cycle of pro-gramming for its minimum and maximum posi-tions.

17B-21

PETROL INJECTIONSpecial notes


17BSPECIAL NOTES FOR MULTIPOINT INJECTION SAGEM « S3000 »

1 - 128-track computer

It is marked SAGEM and is a type « S3000 » FLASHEEPROM controlling the injection and ignition.

2 - Multipoint injection functioning in sequential mode.

Without cylinder n˚1 marking sensor on the camshaftTherefore, engine phasing is carried out by softwareusing the TDC sensor. Starting the engine in semi-se-quential mode (for engine phasing) then enteringphased sequential mode.

With cylinder n˚1 marking sensor on the camshaft The-refore, engine phasing (cylinder n˚1 recognition) is car-ried out using the cylinder marking sensor signal.Starting the engine in semi-sequential mode (for engi-ne phasing) then entering phased sequential mode.

3 - Injection warning light on the instrument panel

Installation of a special injection warning light (OBD in-dicator light « On Board Diagnostic » ) warning light. Itis part of the « on board diagnostic » OBD fault findingsystem.

4 - Special notes relating to the engine immobiliser

Installation of a third generation engine immobiliser, in-volving a specific computer replacement procedure.

5 - Fuel circuit without return to the tank.

The pressure regulator is located on the « pump/sen-der unit » assembly.

6 - Idle speed (warm engine)

Nominal idle speed

The idle speed is corrected depending on:

- the engine coolant temperature,

- the battery voltage,

- the air conditioning,

- the engine oil pressure (K4M engine).

- the position of the automatic gearbox selector lever(F4R engine).

7 - Maximum speed

a - Engine overspeed protection, cold engine

When the coolant temperature is below 60˚C or for 10seconds after starting, the cut-off value is 5800 rpm .

When the coolant temperature is below 75˚C or for 10seconds after starting, the cut-off value is 5800 rpm .

When the coolant temperature is below 75˚C or for amaximum of 17 minutes after starting, the cut-off valueis 5900 rpm .

F4R, and 770 or 771 or 776 – K4J, and 730 or 732

K4M, and 760 or 761

Engine Engine speed (rpm)

K4J 730 /732

750 +/- 50

K4M 760

K4M 761

700 +/- 30

F4R 770

F4R 771

F4R 776

750 +/- 50

K4J, and 730 or 732

K4M, and 760 or 761

F4R, and 770 or 771 or 776

17B-22



17Bb - Engine overspeed protection, warm engine

Once the engine is warm, the cut-off returns to its nor-mal value:

The cut-off speed is 6500 rpm whichever gear is enga-ged (manual or automatic gearbox).

The cut-off speed is 6000 rpm whichever gear is enga-ged (manual gearbox), and 6300 rpm (automatic gear-box).

8 - Camshaft dephaser

It is continuously varied from 0 to 43˚ of the crankshaft.It is controlled by a solenoid valve supplied by an ope-ning cyclic ratio signal operated by the injection com-puter.

It is controlled by a solenoid valve which is supplied byan all or nothing system from the injection computer.

9 - Operation of the engine cooling fan and the coolant temperature warning light

The request is made from the injection computer throu-gh the multiplex network (coolant temperature centra-lised control function). The engine cooling fan issupplied by the Protection and Switching Unit.

10 - Air conditioning compressor operation

The request is made by the injection computer throughthe multiplex network. The request depends on the airconditioning , but also the coolant temperature. The airconditioning compressor is supplied by the Protectionand Switching Unit.

11 - Operation of the fuel pump

The request is made by the injection computer. It recei-ves its power supply from the Protection and SwitchingUnit.

12 - Cruise control / speed limiter

The configuration of the cruise control / speed limiterand the air conditioning is automatic.

13 - Oxygen sensor

Use of two oxygen sensors located upstream anddownstream of the catalytic converter.

14 - Throttle valve

Correction of the air flow and the idle speed is carriedout by the motorised throttle valve.

15 - Protection and switching unit

It supplies:


- the fuel pump,

- the air conditioning compressor,

- the fan assembly,

- various injection actuators (injectors, fuel vapour ab-sorber solenoid valve, etc.).

The protection and switching unit is located in the engi-ne compartment near the battery. It contributes to theprotection of certain electrical components.

In this capacity, it comprises:

- fuses,

- several internal relays including:

• the « + after ignition feed » relay,

• the fuel pump relay,

• the air conditioning compressor relay

• the engine cooling fan relays,

• the starter relay (starter motor solenoid operation)

These relays cannot be removed.

16 - Injection computer

It constantly receives from the multiplex network, thesignal indicating the electrical power available from thealternator. This is to prevent the vehicle's electricalconsumption from exceeding the capacity of the alter-nator. The aim is to give priority to charging the battery.

K4J, and 730 or 732 – K4M, and 760 or 761

F4R, and 770 or 771 or 776

K4M, and 760 or 761

F4R, and 770 or 771 or 776

17B-23



17B17 - Accelerator pedal

Replacement of the accelerator pedal poses no parti-cular problems.

The computer adopts the value read when the ignitionwas switched on as the no load position reference va-lue.

A twin-track potentiometer is used to inform the com-puter of the accelerator pedal position. It has two trackswith different resistance values. The first track suppliesa voltage of ( 0 to 5 V ) which is double the secondtrack ( 0 to 2.5 V ). The comparison between the twoprovides a check on the consistency of the signal sup-plied.

18 - Idle speed

It is increased by a maximum of 160 rpm if the batteryvoltage is below 12.7 V .

If a manifold pressure sensor fault is present or stored, the idle speed setpoint is:

- 896 rpm (K4J and K4M engines),

- 1024 rpm (F4R engine).

17B-24

PETROL INJECTIONInjection warning light


17BThe S 3000 injection system manages the lighting ofthree warning lights and the display of warning messa-ges according to the severity of the faults detected,with the aim of informing the customer and directingfault finding.

The injection computer controls the lighting of warninglights and message displays on the instrument panel.These warning lights are lit during the starting phase, inthe event of an injection fault or engine overheating.

The signals to light up the warning lights reach the ins-trument panel via the multiplex network.

WARNING LIGHT OPERATING PRINCIPLE

1 - During the starting phase, press the starter button ( « start » )

The « on board diagnostic » indicator light comes onfor approximately 3 seconds , then goes out.

2 - When there is an injection fault (level 1)

The « check injection » message lights up, followed bythe « service » warning light. This means a reduced le-vel of operation and a limited safety level. Repairsshould be carried out as soon as possible.

These faults are linked to:

- the motorised throttle valve,

- the accelerator pedal potentiometer,

- the inlet pressure sensor,

- the computer,

- the actuator supply,

- the computer supply.

3 - When there is a severe injection fault (level 2)

The red symbol depicting an engine and the « stop »message (display with matrix only) appears with the« faulty injection » text message followed by the« stop » warning light and a buzzer.

4 - When the engine is overheating

The engine temperature fault symbol (display with ma-trix only) lights up with the « engine overheating » textmessage followed by the « stop » warning light and abuzzer. If this happens, the vehicle will stop immedia-tely.

5 - When a fault causing excessive exhaust gas pollution levels is detected

The « on board diagnostic » indicator light depicting an engine lights up:

- « flashing » in the event of a fault which might causedestruction of the catalytic converter (destructive mis-fires). If this happens, the vehicle will stop immedia-tely.

- « continuously » in the event that depollution stan-dards have not been adhered to (polluting enginemisfires, catalytic converter fault, oxygen sensor fault,inconsistency between the oxygen sensors and fuelvapour absorber fault).

17B-25

PETROL INJECTIONImmobiliser function


17BThis vehicle is equipped with an immobiliser which re-quires a specific procedure for replacing the computer.

REPLACING AN INJECTION COMPUTER

To program the immobiliser code (see 82A, Engineimmobiliser, Injection computer: Programming:).

WARNING- The injection computer retains its immobilisercode for life.


- It is forbidden to perform tests with computersborrowed from the Parts Department or fromanother vehicle which must then be returned.

- These computers are permanently coded.

17B-26

PETROL INJECTIONInjection - air conditioning programming

F4R, and 770 or 771 or 776

17BI - INJECTION COMPUTER - AIR CONDITIONING COMPUTER CONNECTION

Climate control is managed by several computers.


- managing the request for cold air in response to pas-senger compartment controls and the circuit pressurelevel.

- determining the power absorbed by the air conditio-ning compressor based on the pressure of the circuit,

- authorising the fan assembly control according to ve-hicle speed and circuit pressure.

- authorising or disables the compressor clutch.

When climate control is activated, the climate controlpanel requests authorisation for air conditioning com-pressor operation.

The injection computer authorises or prevents:

- air conditioning compressor operation,

- fan assembly operation,

- an accelerated idle speed.

This speed depends on the power absorbed by the compressor:

- 900 rpm .

The request to run the fan assembly and compressor ismade by the injection computer via the multiplexnetwork. This request depends on the air conditioningbut also on the coolant temperature and vehicle speed.

The engine cooling fan and the compressor are sup-plied by the Protection and Switching Unit.

The data used for the function is exchanged via the multiplex network:

- Track A A4 « CAN HIGH » multiplex connection,

- Track A A3 « CAN LOW » multiplex connection.

The injection computer also receives the refrigerant pressure sensor signal on tracks:

- B J3 refrigerant pressure sensor signal,

- B J2 refrigerant pressure sensor + 5 V supply,

- B K2 refrigerant pressure sensor earth.

The compressor is of variable displacement type.

II - COMPRESSOR FUNCTION PROGRAMMING

In certain operating phases, the injection computer di-sables the air conditioning compressor.


To facilitate starting on a hill, operation of the air condi-tioning compressor is prevented for 20 seconds .

2 - Maximum engine speed protection programming

Operation of the air conditioning compressor is preven-ted if:

- the instantaneous engine speed is above 6300 rpm ,

- the constant engine speed is above 5760 rpm formore than 10 seconds .


Operation of the air conditioning compressor is preven-ted if the coolant temperature is above 115˚C at highspeed and high load.

Entry conditions:

- Engine speed greater than 4512 rpm ,

- « and » inlet manifold pressure below 700 mbar .

Exit conditions:

- for a time of 10 seconds ,

- « and » certain conditions of the coolant temperaturecentralised management function.

WARNING

The value of parameter PR044: « power absorbedby the AC compressor » is never 0 , irrespectiveof the status of the compressor. The minimum valuereading is approximately 250 to 300 W .

17B-27


K4J, and 730 or 732





- determining the power absorbed by the air conditio-ning compressor based on the pressure value of thecircuit,









- 850 rpm .














To facilitate starting on a hill, operation of the air condi-tioning compressor is prevented for 10 seconds .


The compressor does not work if:

- the instantaneous engine speed is above 6688 rpm ,

- the constant engine speed is above 6112 rpm formore than 10 seconds .


The compressor does not work if the coolant tempera-ture is above 119˚C at high speed and high load.

Entry conditions:

- engine speed greater than 6496 rpm ,


Exit conditions:

- engine speed below 6496 rpm ,

- « and » coolant temperature below 119˚C ,


4 - Performance return programming

The compressor is prevented from operating for 5 se-conds .

Entry conditions:

- throttle fully open,

- « and » engine speed below 2016 rpm ,

- « and » engine speed below 10 mph (16 km/h) .

Exit conditions:

- throttle not fully open,

- « or » for a time of 5 seconds ,

- « or » engine speed at or above 2048 rpm ,

- « or » vehicle speed greater than 16 mph (26 km/h) .


To facilitate hill-starting, under certain load and engineoperating conditions, operation of the air conditioningcompressor is prevented for 5 seconds .

WARNING


17B-28


K4J, and 730 or 732

17B6 - Maximum engine speed protection programming

The air conditioning compressor does not work if theengine speed is above 6496 rpm .


The air conditioning compressor does not work if thecoolant temperature is above 119˚C at high speed andhigh load.

17B-29


K4M, and 760 or 761





- determining the power absorbed by the air conditio-ning compressor based on the pressure value of thecircuit,









- 850 rpm .














The compressor is prevented from operating for 10 se-conds after engine start.

2 - Performance return programming

The compressor is prevented from operating for 5 se-conds .

Entry conditions:

- throttle fully open,

- « and » engine speed below 2016 rpm ,

- « and » engine speed below 10 mph (16 km/h) .

Exit conditions:

- throttle not fully open,

- « or » for a time of 5 seconds ,

- « or » engine speed at or above 2048 rpm ,

- « or » vehicle speed greater than 16 mph (26 km/h) .


To facilitate hill-starting, under certain load and engineoperating conditions, operation of the air conditioningcompressor is prevented for 5 seconds .


The air conditioning compressor does not work if theengine speed is above 6496 rpm .


The air conditioning compressor does not work if thecoolant temperature is above 119˚C at high speed andhigh load.

WARNING


17B-30

PETROL INJECTIONThrottle valve: Operating


17BI - THROTTLE BODY

The throttle valve ensures that idle speed regulationand engine air intake modulation are performed cor-rectly. It is composed of an electric motor and twothrottle position potentiometers.

When the engine is idling, the throttle position is regu-lated according to the idle speed setpoint. This setpointtakes into account the major power consumers (airconditioning) and operating conditions (air temperatureand coolant temperature).

When the driver depresses the accelerator pedal, hisrequest is translated into an angle of throttle opening.

However, to improve driving pleasure, the throttle ope-ning is not directly proportional to the driver’s request.

To eliminate misfires, facilitate gear changes and per-form the safety functions, the throttle valve modulatesthe engine torque.

II - THROTTLE VALVE DEFECT MODES

There are four types of defect mode for the throttle val-ve.

1 - Reduced performance mode

This mode covers electrical faults for which there is aviable backup solution for the injection system (loss ofone of the two tracks on the pedal potentiometer or thethrottle valve). This mode limits acceleration and res-tricts maximum throttle opening (maximum speed of 56mph (90 km/h) (manual gearbox) and 62 mph (100km/h) (automatic transmission).

2 - Loss of driver intervention mode:

This mode is also known as « electrical defect mode ». This mode is applied when the accelerator pedal si-gnal disappears completely, but the injection computerstill controls the intake of air to the engine (automaticthrottle control is still operational). In this mode, the in-jection computer imposes a set accelerator pedal posi-tion for each gear ratio and imposes the idle speedwhen the brake pedal is depressed. In this case themaximum engine speed in neutral is 2500 rpm .

3 - Mechanical limp home mode

This mode covers faults resulting in loss of automaticthrottle control (ie it is impossible to operate the thrott-le). In this case, the throttle is returned to its mechani-cal rest position, the injection computer limits theengine speed by cutting injection and limits torque bycutting out the cylinders (ignition and injection) accor-

ding to the position of the accelerator. Therefore, themaximum engine speed under full load or in neutral is2500 rpm .

4 - Pedal information mode

If the signal from the inlet manifold vacuum is lost, ope-ning of the throttle is directly proportional to pressureon the accelerator pedal.

Note:

Each of these modes results in the injection faultwarning light on the instrument panel lighting up.

17B-31

PETROL INJECTIONIdle speed correction

F4R, and 770 or 771 or 776


(1) Except when starting between 15˚C and 30˚C .

II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE

The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. 910 rpm .

III - IDLE SPEED ADJUSTMENT WHEN THERE IS A MANIFOLD PRESSURE SENSOR FAULT

In the event of a manifold pressure sensor fault is set at1024 rpm .

Coolant temperature

( ˚C )

Engine speed

( rpm )

- 20 1072

20 976 (1)

40 896

80 752

100 752

120 848

Note:

If the engine is started when the coolant tempera-ture is between 15˚C and 30˚C and, as a result, theengine speed remains at idle speed, the enginespeed will decrease progressively. This drop inengine speed is due to an antipollution functionwhen the engine is started (oxygen sensor heatingresistors starting).

17B-32


K4J, and 730 or 732




The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. 910 rpm .


If the manifold pressure sensor is faulty, the idle speedis set at 896 rpm .

Coolant temperature

( ˚C )

Engine speed

( rpm )

- 20 1152

20 1008 (1)

40 960

80 752

100 752

120 896

Note:


17B-33


K4M, and 760 or 761




The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. to 860 rpm .


If the manifold pressure sensor is faulty, the idle speedis set at 896 rpm .

Coolant temperature

( ˚C )

Engine speed

rpm )

- 20 1150

20 944 (1)

40 850

80 700

100 700

120 752

Note:


17B-34

PETROL INJECTIONAdaptive idle speed correction


17BI - ADAPTIVE IDLE SPEED CORRECTION

Principle

In normal warm-engine operating conditions, the idlespeed OCR PR091 varies between a high and low va-lue to obtain the nominal idle speed.

It is possible that following variations in the operation ofthe vehicle (running in, fitting the engine, etc.), that theidle speed opening cyclic ratio could approach to thehighest or lowest values.

Adaptive correction PR090 on the idle speed OCRenables the engine's air requirement to be variedslowly by bringing the opening cyclic ratio back to anaverage nominal value.

This adjustment only takes effect if the coolant tempe-rature is above 75˚C and for 1 minute after enginestart and during the idle speed regulation phase.

II - IDLE SPEED OPENING CYLIC RATIO AND ITS ADAPTIVE CORRECTION

- PR055: « engine speed »

• 750 rpm

- PR032: « Intake pressure »

• 300 mbar < or = X < or = 400 mbar

- PR091: « idle speed regulation theoretic opening cyclic ratio »

• 6 % < or = X < or = 22 %

- PR090: « Idling speed regulation programmed value »

• minimum stop: - 6.25 %

• maximum stop: + 6.25%

III - INTERPRETATION OF THESE PARAMETERS

« If there is excess air » (air leak, incorrectly adjustedthrottle stop, etc.), the engine speed increases at idlingspeed. The idle opening cyclic ratio value decreases toreturn to nominal idle speed; the idle opening cyclic ra-tio adaptive correction decreases to recentre the idleopening cyclic ratio.

« If there is insufficient air » (clogging, etc.), the logic isreversed: the idle opening cyclic ratio and the adaptivecorrection increase, to refocus operation of the idlespeed regulation.

WARNING

After the computer memory has been cleared, it isimperative to start the engine, stop it, then leave itrunning at idle speed so that the adaptive correctioncan recalibrate itself correctly.

17B-35

PETROL INJECTIONRichness regulation

F4R, and 770 or 771 or 776 – K4M, and 760 or 761

17B

An engine operating with the S 3000 computer is fittedwith two oxygen sensors called the upstream sensorand the downstream sensor after their position on thecatalytic converter.

I - SENSOR HEATING

Oxygen sensor heating is controlled by the computer if all of the following conditions are met:

- the inlet manifold pressure is below a threshold whichdepends on a function table of the engine speed,

- the road speed is below ( 84 mph (135 km/h) ,

- after a certain mapped engine operating time whichdepends on the engine's top dead centre (excludingno load operation) and the coolant temperature.

Oxygen sensor heating is stopped if the following con-ditions are met:

- the vehicle speed is greater than 85 mph (140 km/h)(value given for information only),

- when the engine is under heavy load.

II - UPSTREAM SENSOR VOLTAGE

Reading parameter PR098: « upstream oxygen sensor voltage » on the diagnostic tool

The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter. It is expressed in millivolts. Witha « looped engine » (when the engine corrects the rich-ness according to the two sensors, the engine is said tobe « looped » ); the voltage should oscillate quicklybetween two values:

- 100 mV and 450 mV for a lean mixture,

- 450 mV and 900 mV for a rich mixture.

III - DOWNSTREAM SENSOR VOLTAGE

Reading parameter PR099: « downstream oxygen sensor voltage » on the diagnostic tool

The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter, expressed in millivolts.

The function of this sensor is to locate faults on the ca-talytic converter and to perform a second, more preci-se, check on the richness. This second richness checkis called the « slow regulation loop » . This function isactivated only after the engine has been operating for acertain time.

When the engine is « looped » (when the computercorrects the richness according to the two sensors, theengine is said to be « looped » ), the voltage should bein the region of 600 mV (except at idle speed when itmay be difficult to stabilise). When the vehicle is dece-lerating, the voltage should be approximately 100 mV .

IV - RICHNESS CORRECTION

The richness correction value read on the diagnostictool i n p a r a m e t e r PR 138: « RICHNESSCORRECTION » represents the average of the rich-ness corrections applied by the computer dependingon the richness of the fuel mixture as determined bythe oxygen sensor located upstream of the catalyticconverter (the oxygen sensor in fact analyses the oxy-gen content of the exhaust gas).

The centre point of the correction value is 50% and theend value 0 to 100% .

- value less than 50% : request for decrease in rich-ness,

- value above 50% : request for increase in richness.

V - ENTERING RICHNESS REGULATION MODE

1 - Loop mode

Richness regulation starts after a maximum delay of 10seconds and if the coolant temperature is above 10˚C(manual gearbox) and 2.5˚C (automatic gearbox).

Equipment required

diagnostic tool

Note:

The smaller the difference between the minimumand maximum values, the poorer the signal fromthe sensor.

If the difference is small, check the sensor heater.

Note:

Do not take into account the voltage on the dia-gnostic tool at idle speed.

17B-36


F4R, and 770 or 771 or 776 – K4M, and 760 or 761

17B2 - Non-loop mode

In mixture regulation mode, the phases of operation during which the computer ignores the value of the vol-tage from the sensor are:

- at full load,

- under significant loads and at high engine speeds,

- when decelerating with a no load signal,

- when the oxygen sensor is faulty.

VI - DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT

When the voltage from the oxygen sensor is incorrect(varying only slightly or not at all) during mixture regu-lation, the computer will only enter defect mode if thefault has been recognised as present for 3 minutes .When this happens, parameter PR138: « RICHNESSCORRECTION » is 45 or 60% .

If an oxygen sensor fault is present and recognisedand if the fault has already been stored, the system en-ters the open loop mode directly.

17B-37


K4J, and 730 or 732

17B

An engine operating with the S 3000 computer is fittedwith two oxygen sensors called the upstream sensorand the downstream sensor after their position on thecatalytic converter.

I - SENSOR HEATING

Oxygen sensor heating is controlled by the computer if all of the following conditions are met:

- the inlet manifold pressure is below a threshold whichdepends on a function table of the engine speed,

- the speed is below ( 84 mph (135 km/h) ,

- after a certain mapped engine operating time whichdepends on the engine's top dead centre (excludingno load operation) and the coolant temperature.

Oxygen sensor heating is stopped if the following con-ditions are met:

- the vehicle speed is greater than 85 mph (140 km/h)(value given for information only),

- when the engine is under heavy load.

II - UPSTREAM SENSOR VOLTAGE

Reading parameter PR098: « upstream oxygen sensor voltage » on the diagnostic tool

The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter. It is expressed in millivolts. Witha « looped engine » (when the engine corrects the rich-ness according to the two sensors, the engine is said tobe « looped » ); the voltage should oscillate quicklybetween two values:

- 100 mV and 450 mV for a lean mixture,

- 450 mV and 900 mV for a rich mixture.

III - DOWNSTREAM SENSOR VOLTAGE

Reading parameter PR099: « downstream oxygen sensor voltage » on the diagnostic tool

The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter, expressed in millivolts.

The function of this sensor is to locate faults on the ca-talytic converter and to perform a second, more preci-se, check on the richness. This second richness checkis called the « slow regulation loop » . This function isactivated only after the engine has been operating for acertain time.

When the engine is « looped » (when the computercorrects the richness according to the two sensors, theengine is said to be « looped » ), the voltage should bein the region of 600 mV (except at idle speed when itmay be difficult to stabilise). When the vehicle is dece-lerating, the voltage should be approximately 100 mV .

IV - RICHNESS CORRECTION

The richness correction value read on the diagnostictool i n p a r a m e t e r PR 138: « RICHNESSCORRECTION » represents the average of the rich-ness corrections applied by the computer dependingon the richness of the fuel mixture as determined bythe oxygen sensor located upstream of the catalyticconverter (the oxygen sensor in fact analyses the oxy-gen content of the exhaust gas).

The centre point of the correction value is 50% and theend value 0 to 100% .

- value less than 50% : request for decrease in rich-ness,

- value above 50% : request for increase in richness.

V - ENTERING RICHNESS REGULATION MODE

1 - Loop mode

The start of richness regulation is effective following aperiod which depends on the engine coolant tempera-ture when the engine is started. At 20˚C , the start ofthe richness loop is effective after approximately 8 se-conds .

Equipment required

diagnostic tool

Note:

The smaller the difference between the minimumand maximum values, the poorer the signal fromthe sensor.

If the difference is small, check the sensor heater.

Note:

Do not take into account the voltage on the dia-gnostic tool at idle speed.

17B-38


K4J, and 730 or 732

17B2 - Non-loop mode

In mixture regulation mode, the phases of operation during which the computer ignores the value of the vol-tage from the sensor are:

- at full load,

- under significant loads and at high engine speeds,

- when decelerating with a no load signal,

- when the oxygen sensor is faulty.

VI - DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT

When the voltage from the oxygen sensor is incorrect(varying only slightly or not at all) during mixture regu-lation, the computer will only enter defect mode if thefault has been recognised as present for 3 minutes .When this happens, parameter PR138: « RICHNESSCORRECTION » is 45 or 60% .

If an oxygen sensor fault is present and recognisedand if the fault has already been stored, the system en-ters the open loop mode directly.

17B-39

PETROL INJECTIONAdaptive richness correction

K4J, and 730 or 732 – K4M, and 760 or 761

17BI - PRINCIPLE

In looping phase, the richness regulation corrects theinjection time to obtain fuel dosing as close as possibleto a richness of 1. Richness correction value PR138 isclose to 50% , with stop values of 0 and 100% .

Adaptive richness corrections PR143 and PR144 allowthe injection map to be shifted to recentre richness re-gulation at 50 % .

Adaptive corrections take 50% as the average valueafter reinitialising the computer (clearing the memory),and have end values.

Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine

If the coolant temperature is above 90˚C while idling formore than 10 minutes (K4M engine) and 1 minute(K4J engine), the adaptives are fixed until the end ofidling.

Programming conditions for adaptive richness correction

- Warm engine: coolant temperature above 80˚C ,

- do not exceed an engine speed of 4640 rpm

- disconnect the fuel vapour absorber by the solenoidvalve or block the inlet pipe on the engine.

Following this test the adjustments will be operational.The test should be followed by normal, smooth and va-ried driving over a distance of 3 to 6 miles (5 to 10 km). After the test, read the adaptive values. Initially 50% ,they should have changed. If not, take the readingsagain, taking care to observe the test conditions strict-ly.

Pressure zones which must be passed through during the test

There are five pressure zones to scan during road tes-ting. These zones are defined by the following calibra-tions:

II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST

In the event of a lack of fuel (injectors clogged, pressu-re and fuel flow too low, etc), the richness regulation in-creases to obtain a richness as close as possible to 1and the richness adaptive corrections increase until therichness correction is again fluctuating around 50% .

If there is an excess of fuel, the logic is inverted.

PR138 Richness correction 30%

< or = X < or =

98%

PR143 Richness adaptivegain

25%

< or = X < or =

63%

PR144 Richness adaptiveoffset

25%

< or = X < or =

63%

Range mbar

N˚1 258 to 458 Average 358

N˚2 458 to 536 Average 497

n˚3 536 to 614 Average 575

N˚4 614 to 692 Average 653

N˚5 692 to 813 Average 752

17B-40

PETROL INJECTIONAdaptive richness correction

F4R, and 770 or 771 or 776

17BI - PRINCIPLE

In looping phase, the richness regulation corrects theinjection time to obtain fuel dosing as close as possibleto a richness of 1. Richness correction value PR138 isclose to 50% , with stop values of 0 and 100% .

Adaptive richness corrections PR143 and PR144 allowthe injection map to be shifted to recentre richness re-gulation at 50 % .

Adaptive corrections take 50% as the average valueafter reinitialising the computer (clearing the memory),and have end values.

Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine

If the coolant temperature is above 80˚C while idling formore than 1 minute , the adaptives are fixed until theend of idling.

Programming conditions for adaptive richness correction

- Warm engine: coolant temperature above 80˚C ,

- Do not exceed an engine speed of 4512 rpm .

- disconnect the fuel vapour absorber by the solenoidvalve or block the inlet pipe on the engine.

Following this test the adjustments will be operational.The test should be followed by normal, smooth and va-ried driving over a distance of 3 to 6 miles (5 to 10 km). After the test, read the adaptive values. They shouldhave changed from their original value of 50 % . If not,take the readings again, taking care to observe the testconditions strictly.

Pressure zones which must be passed through during the test

There are five pressure zones to scan during road tes-ting. These zones are defined by the following calibra-tions:

II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST

In the event of a lack of fuel (injectors clogged, pressu-re and fuel flow too low, etc), the richness regulation in-creases to obtain a richness as close as possible to 1and the richness adaptive corrections increase until therichness correction is again fluctuating around 50% .

If there is an excess of fuel, the logic is inverted.

PR138 Richness correction 23%

< or = X < or =

74%

PR143 Richness adaptivegain

12.5%

< or = X < or =

87.5%

PR144 Richness adaptiveoffset

32%

< or = X < or =

87.5%

Range mbar

N˚1 276 to 398 Average 337

N˚2 398 to 516 Average 457

n˚3 516 to 637 Average 576

N˚4 637 to 753 Average 695

N˚5 753 to 872 Average 812

17B-41

PETROL INJECTIONCentral coolant temperature management 17B

The fan assembly is controlled by the injection compu-ter.

I - ANTI-PERCOLATION FUNCTION

The anti-percolation function is controlled by the injec-tion computer.

The coolant temperature signal used is that from the in-jection system.

After switching the ignition off, the system enters moni-toring mode. If the coolant temperature exceeds thethreshold 103˚C for 5 minutes after the engine hasbeen switched off, the low-speed fan assembly is acti-vated.

After switching the ignition off, the system enters moni-toring mode. If the coolant temperature exceeds 110˚Cfor 2 minutes after the engine has been switched off,the low-speed fan assembly is activated.

If the coolant temperature falls below 100˚C again, thefan assembly relay is cut-out (the fan assembly cannotbe activated for more than 10 minutes ).

II - FAN ASSEMBLY OPERATION

The fan unit is operated at low speed if the coolant tem-perature exceeds 98˚C and stops when the temperatu-re falls below 96˚C .

The fan assembly is operated at high speed if the coo-lant temperature exceeds 102˚C and stops when thetemperature falls below 99˚C .

III - OPERATION OF THE TEMPERATURE WARNING LIGHT

The temperature warning light comes on if the coolanttemperature exceeds 119˚C and goes out when thetemperature falls below 115˚C .

K4J, and 730 or 732 – K4M, and 760 or 761

F4R, and 770 or 771 or 776

17B-42

PETROL INJECTIONCamshaft dephaser: Description

F4R, and 770 or 771 – K4M, and 760 or 761

17BI - SPECIAL NOTES

Its role is to modify the valve timing.

To improve cylinder filling at all speeds, K4M and F4Rengines are fitted with an inlet camshaft dephaser (1) .

Dephasing at the moment when the inlet valves closeoptimises filling according to engine speed. Midrangetorque and output are improved.

Leaving the inlet valves open for longer at high enginespeed allows the mixture to be continually admittedowing to its high speed.

However, at lower engine speeds the gases do nothave a high level of inertia. It is therefore preferable toclose the inlet valves earlier to avoid incorrect fillingand a loss of torque due to the reflux of fresh gases.

The higher the engine speed, the later the inlet valvesmust be closed.

II - OPERATION AND PROGRAMMING

The oil is supplied to the dephaser by a solenoid valve(2) located on the cylinder head.

The supply by a variable opening cyclic ratio signal(amplitude 12 V , frequency 250 Hz ) enables oil to bedistributed to the mechanism and the dephaser angleto be adjusted.

The operation of the camshaft dephaser varies conti-nuously.

The computer supplies the solenoid valve with a varia-ble opening cyclic ratio proportional to the desired de-phasing.

Dephasing is varied continuously from 0 to 43˚ of thecrankshaft.

The camshaft dephaser control solenoid valve is con-trolled if the following conditions are met:

- no speed sensor fault,

- no camshaft position sensor fault,

- no injection system faults,

- after the engine has started,

- outside idling speed and no load,

- threshold of mapping according to load and enginespeed reached,

F4R, and 770 or 771 – K4M, and 760 or 761

102943

K4M, and 760 or 761

1

15200

101814

2

17B-43

PETROL INJECTIONCamshaft dephaser: Description

F4R, and 770 or 771 – K4M, and 760 or 761

17B- coolant temperature between 10 and 120˚C ,

- engine oil temperature too high.

Defect modes:

- dephaser returns to initial position,

- zero dephasing.

III - OPERATION AND PROGRAMMING

The dephaser is controlled in an all or nothing systemby the injection computer using a solenoid valve (3) lo-cated on the rocker cover.

From 1,500 to 4,300 rpm , the computer supplies thesolenoid valve.

Above 4,300 rpm , the solenoid valve is not supplied.The position of the mechanism improves filling at highspeeds. In this position, a locking piston locks the me-chanism.

At rest, the solenoid valve is in the closed position. It authorises the flow of oil to control the dephaser when the following conditions are met:

- no speed sensor fault,

- no camshaft position sensor fault,

- no injection system faults,

- after the engine has started,

- outside idling speed,

- battery voltage > 11.4 V ,

- coolant temperature above 30˚C ,

- engine speed between 1,500 and 4,300 rpm ,

- charge > 87% (approximately 900 mbar ).

WARNING

A solenoid valve jammed open causes an unstableidle speed, manifold pressure which is too high atidle speed and significant engine operating noise.

F4R, and 770 or 771

102732

3

Note:

Up to 1,500 rpm , the solenoid valve is no longersupplied. The mechanism is locked by the piston.As soon as the solenoid valve is supplied, atspeeds above 1,500 rpm , the oil pressure pushesthe locking piston and releases the mechanism.

102736

WARNING

A solenoid valve which is blocked open leads to anunstable idle speed and too high a pressure in themanifold at idling speed.

17B-44

PETROL INJECTIONFault finding warning light activation conditions (when driving) 17B

I - FAULTS CAUSING ACTIVATION OF THE ONBOARD DIAGNOSTIC WARNING LIGHT

1 - Electrical fault

Continuous illumination of the light after several conse-cutive detections of a fault (depending on the compo-nent).

2 - Combustion misfiring that could destroy the catalytic converter

Immediate illumination and flashing of the warning li-ght.

3 - Catalytic converter or oxygen sensor fault, polluting misfires

Continuous illumination of the light after a fault is de-tected three times consecutively.

II - MANAGEMENT OF THE ONBOARD DIAGNOSTIC (OBD) WARNING LIGHT

1 - Warning light comes on

If the same OBD fault is detected during three conse-cutive journeys or there is an electrical fault.

2 - Warning light flashes

If misfires that could destroy the catalytic converter aredetected.

3 - Light goes out

If the OBD fault does not reappear in three consecutivejourneys the warning light goes out, but the fault will bestored in the injection computer.

The fault must not be detected for 40consecutive journeys for the a stored fault to be clea-red from the computer without using the fault finding to-ol.

WARNING

The diagnostics of the catalytic converter and ups-tream oxygen sensor are sequential and are run:

- once when driving (they take several seconds pertest),

- only under certain specific driving conditions.

Under certain driving conditions, it may be the casethat fault finding for certain functions are not perfor-med (e.g. when in a traffic jam).

Note:

The fault may not be re-detected:

- if the fault is fleeting in nature,

- due to the driving style of the customer, which maynot always cover all of the fault detection condi-tions.

17B-45

PETROL INJECTIONConditions for carrying out fault finding (when driving) 17B

I - CONDITIONS FOR ENTERING FAULT FINDING MODE

If, when the ignition is switched on and when driving,the air temperature read by the temperature sensor isnot between -7.5˚C and 119.39˚C , if the coolant tem-perature read by the sensor is not between -7.5˚C and119.39˚C , or if the difference between 1046 mbar andthe manifold pressure is greater than 273 mbar (altitu-de of about 2500 metres), OBD is not authorised untilthe ignition is switched on again.

In order for the On Board Diagnostic system to functioncorrectly, there must be no electrical fault in the injec-tion system, even if the OBD warning light does notcome on.

Fault finding of the oxygen sensor and the catalyticconverter can never be performed at the same time.

When the catalytic converter and oxygen sensor faultfinding procedures are in progress, the fuel vapour ab-sorber bleed is closed and the richness adaptive para-meters are frozen at their last value.

II - TEST PROCEDURE

Before performing the tests, carry out the following in the sequence shown:

- repair all electrical faults,

- clear all faults,

- carry out injection system programming,

- check the OBD system.

III - COMPLETE INITIALISATION OF THE OBD

In order to reinitialise the OBD function, it is necessary to carry out following operations:

- clear stored faults,

- clear OBD faults,

- clear all programming.

IV - PROGRAMMING NECESSARY FOR OBD

Programming must be reinitialised when replacing:

- an injection computer,

- an engine flywheel target,

- an engine speed sensor.

1 - Engine flywheel target programming


Power take-up speed is the moment when, during de-celeration under no load and the injection cut out, thecomputer authorises injection again.

2 - Programming of richness adaptive parameters

To perform this programming, the vehicle must be dri-ven within the pressure ranges (see 17A, Petrol injec-tion, Adaptive richness correction ).

17B-46

PETROL INJECTIONCombustion misfire fault finding 17B

The purpose of detecting misfiring is to detect any mal-functions which could cause hydrocarbon pollutantemissions to exceed the OBD limit, or cause damageto the catalytic converter.

I - THE FAULT FINDING SYSTEM CAN DETECT:

- clogging or flooding of a spark plug,

- clogging of the injectors or an injector flow fault,

- incorrect operation of the supply system (pressure re-gulator, fuel pump, etc.),

- a faulty connection in the petrol or injection circuits(coil secondary, etc.).

II - MEASUREMENT OF ENGINE MISFIRINGS

Fault finding is performed by measuring the instanta-neous variations in engine rotation speed.

If a drop in torque is detected, this is an indication ofmisfiring. Misfiring results in a drop in engine torquebelow a predetermined threshold.

This fault finding is practically continuous while the caris being driven. If it is not carried out, or if a fault is de-tected, all other OBD fault finding (catalytic converterand upstream oxygen sensor) will be prevented.

III - THE FAULT FINDING STRATEGY ENABLES TWO TYPES OF FAULT TO BE DISTINGUISHED:

- Destructive misfiring - over 15% - resulting in catalyticconverter damage. It causes the injection warning li-ght to flash immediately.

- Pollutant misfiring - below 15% - causing the OBDpollution limit to be exceeded. It causes the injectionwarning light to come on if it is detected during threeconsecutive journeys.

IV - CONDITIONS FOR DETECTION

Check that programming has been correctly carriedout.

Check that the prerequisites for switching on the igni-tion and for detecting misfiring correspond.

Detection is carried out as soon as the coolant tempe-rature is above 7.5˚C , in three operating rangesbetween idle speed and 4,500 rpm .

The pollutant misfiring test can also be carried out bymaintaining the engine at idle speed with all the powerconsumers on for 10 minutes .

V - REPAIR CONFIRMATION

Using the tool diagnostic tool , check:

Following this test, if the diagnostic tool has indicatedmisfiring faults DF065 , DF059 , DF060 , DF061 , orDF062 , refer to the appropriate fault finding procedurefor the symptom concerned.

Equipment required

diagnostic tool

Note:

- In comparison to the Sagem 2000 injection, Sagem 3000 has the following functions:

• injection cut-off to cylinders causing misfiring,

• appearance of a fault indicating non-conformityof the flywheel target.

- If distortion of the target is too marked, the compu-ter cannot implement an adjustment that is suffi-cient to detect misfiring correctly.

WARNING

At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching the ignition off will lead tothe results being misinterpreted.

ET 057 Misfiring on cylinder 1 No




17B-47

PETROL INJECTIONCatalytic converter fault finding 17B

The purpose of catalytic converter fault finding is to de-tect a fault which could cause hydrocarbon pollutantemissions to exceed the OBD limit.

The catalytic converter's capacity to store oxygen is in-dicative of its condition. As the catalytic converterages, its capacity to store oxygen reduces along withits ability to treat pollutant gases.

I - CONDITIONS FOR STARTING FAULT FINDING

Fault finding on the catalytic converter can only be car-ried out after the engine has been running for about 16.5 minutes , and if all the necessary conditions for switching on the ignition are still met:

- no electrical faults,

- no misfiring detected,

- no catalytic converter fault finding performed sincethe ignition was switched on,

- programming has been carried out,

- main loop and double loop active,

- coolant temperature higher than 75˚C ,

- engine speed read by the diagnostic tool as between1472 rpm and 3868 rpm .

II - FAULT DETECTION

Fault finding is carried out when driving under stabi-lised conditions.

When the conditions for starting fault finding are met,richness excitation peaks are applied, which has theeffect of sending bursts of oxygen into the catalyticconverter.

1 - If the catalytic converter is functioning normally

It absorbs oxygen and the voltage of downstream oxy-gen sensor PR099 remains at an average value.

2 - If it needs replacing

It rejects the oxygen and downstream oxygen sensorPR099 starts to pulse. The voltage of the oxygen sen-sor fluctuates (the OBD warning light comes on afterthree journeys).

III - REPAIR CONFIRMATION

If after the test, the diagnostic tool has detected a cata-lytic converter fault DF110: « Catalytic converter »refer to the fault finding procedure for this fault.

WARNING

At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching off the ignition will lead tothe results being misinterpreted.

17B-48

PETROL INJECTIONOxygen sensor fault finding 17B

The purpose of fault finding on the upstream oxygensensor is to detect faults that would cause emissions ofhydrocarbon, carbon monoxide or nitrogen oxide to ex-ceed the OBD limit. It is carried out by measuring andcomparing periods of upstream oxygen sensor vibra-tion.

I - POSSIBLE CAUSES OF FAULTS

There are possible types of fault in the upstream oxy-gen sensor:

- mechanical damage to an electrical component(breakage, cut in wire) which leads to an electricalfault,

- chemical damage to the component, which causesthe response time of the sensor to slow down, thus in-creasing its switching period.

II - CONDITIONS FOR STARTING FAULT FINDING

When test conditions are reached, the computer takesan average of sensor cycle readings PR121« Average upstream oxygen sensor cycle » , takingaway the effects of interference, which is compared toan average OBD limit cycle.

III - TEST CONDITIONS

Fault finding on the oxygen sensor can only be carried out after the engine has been running for about 15 mi-nutes , and if all the necessary conditions for switching on the ignition are still met:

- no electrical faults detected,

- programming has been carried out,

- no oxygen sensor fault finding performed since theignition was switched on,

- no misfiring detected,

- coolant temperature higher than 75˚C ,

- engine speed given by the diagnostic tool as between1472 rpm and 3868 rpm .

- manifold pressure between 292 mbar and 900 mbar .

IV - FAULT DETECTION

Fault finding is carried out when driving, according tothe conditions previously outlined, and prevents fuelvapours bleeding from the absorber.

V - REPAIR CONFIRMATION

If, after the test, the diagnostic tool has detected anupstream oxygen sensor fault DF092: « Upstreamoxygen sensor circuit » refer to the fault finding pro-cedure for this fault.

Equipment required

diagnostic tool

WARNING

At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching off the ignition will lead tothe results being misinterpreted.

17B-49

PETROL INJECTIONSpeed limiter: Operating principle 17B

Entry conditions:

- switch in speed limiter position,

- 19 mph (30 km/h) minimum, 125 mph (200 km/h)maximum (guideline only),

- « + » , « - » or « R » buttons pressed.

Exit conditions:

- accelerator depressed firmly (beyond the safety resis-tance point),

- switch in the « off » position,

- « 0 » button depressed,

- injection computer intervention (fault or overspeed),

Note:

If the warning light on the instrument panel flashes,it informs to the driver that the cruising speed can-not be maintained.

19A-1

COOLING SYSTEMGeneral information 19A

When a faulty vehicle arrives, check:

- the condition and tension of the water pump drivebelt,

- that the fan, the radiator and the radiator grille are notobstructed by an object which may impede the flow ofair.

Vehicles in the current range have cooling circuits with the following basic specifications:

- Pressurised sealed circuit (expansion bottle valve),

- circuit using type « D » coolant only.

IMPORTANT

The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious scalding).

Never remove the valve from the expansion bottlewhile the engine is hot.

Similarly, take care when working under the bonnet,as the radiator fan(s) may start up unexpectedly.

Do not open the bleed valve(s) while the engine isrunning.

WARNING

The coolant helps to keep the engine running pro-perly (heat exchange).

The system does not operate using pure water.

WARNING

Drain with the engine warm.

Flushing and refilling should be carried out with awarm or cold engine.

Never flush a hot engine (risk of serious thermalshock).

WARNING

When carrying out a repair that requires a the cir-cuit to be completely drained, it is essential to flushthe circuit with clean water, blow compressed airthrough the circuit to eliminate water, fill and drainthe circuit and then measure the effective protec-tion.

The criteria to be met are:

- Protection down to - 25˚C ±±±± 2 for cold and tempe-rate climates,

- Protection down to - 40 ˚C ±±±± 2 for very cold clima-tes

Note:

Refer to the vehicle's maintenance service bookletfor information on cooling circuit service intervals.

For any further information, refer to the WorkshopRepair Manual of the vehicle concerned.

Note:

Summary of expansion bottle valve ratings.

Expansion bottle valve with:

• a yellow hand: 1.4 bar

• a white hand: 1.6 bar

• a grey hand: 1.8 bar

Note:

Ready-to-use coolant or antifreeze must be dilutedwith distilled water in accordance with the guideli-nes marked on the container.

19A-2

COOLING SYSTEMSpecifications 19A

Grade and quantity of coolant

Thermostat

Engine Suffix Quantity(litres)

Grade

K4J730

6

GLACEOL RX

(type D).

Only use

coolant

fluid

732

K4M760 6

761 6.5

K9K

722 5.3

728 6.5

729 6.8

732 7.5

F4R

770 6

771 6.5

776

F9Q

800 7.2

804 7.6

808 7.2

M9R 700 7.5

Engine Start of ope-ning (˚C)

End of ope-ning (˚C)

K4J 89 99 ±±±± 2

K4M 89 99 ±±±± 2

K9K 89 99 ±±±± 2

F9Q 89 99 ±±±± 2

F4R 89 99 ±±±± 2

M9R 89 99 ±±±± 2

19A-3

COOLING SYSTEMChecking 19A

I - RECOMMENDATIONS FOR REPAIR II - CHECKING THE CIRCUIT SEALING

Checking the cooling system and the expansion bottle valve

Check the cooling system and the expansion bottlevalve using the cooling system diagnostic and fillingtool (mot. 1700) . For guidance on the use of thistool see NT 3857A, How to use the cooling circuitdiagnostic and filling tool .

IMPORTANT

The circuits are designed to be pressurised; takecare at high temperatures (risk of serious scal-ding).

Never remove the valve from the expansionbottle while the engine is hot.

Similarly, take care when working under the bon-net, as the radiator fan(s) may start up unexpec-tedly.

Do not open the bleed valve(s) while the engineis running.

Note:

The expansion bottle valve must be replaced ifcoolant is leaking from the valve.

107138

Note:

For any further information, refer to the Works-hop Repair Manual of the vehicle concerned.

19A-4

COOLING SYSTEMDiagram

K4J, and 730 or 732 – K4M, and 760 or 761

19A

105003

7

9

9

6

5

8

4

3

2

1

10

(1) Engine

(2) Cooling radiator

(3) Heating radiator

(4) Expansion tank

(5) Water pump

(6) Thermostat

(7) 9 mm choke

(8) 16 mm choke

(9) Bleed screws

(10) Automatic gearbox coolant-oilintercooler (if fitted to the vehi-cle)

Note:

The expansion bottle degassing valve rating is 1.4bar .

19A-5


K9K, and 722 or 728 or 729

19A

110741

1

8

2

7

11

10

99

6

5

4

3

(1) Engine


(3) Heater radiator

(4) Expansion bottle

(5) Water pump

(6) Thermostat

(7) 11 mm choke (K9K 722)

(8) 9 mm by-pass choke (K9K 728 /729)

(9) Bleed screws

(10) Coolant-engine oil intercooler

(11) Coolant-oil intercooler (K9K729)

Note:


19A-6


F9Q, and 800 or 808

19A

102269

5

4

3

2

1

8

7

10

9

9

6

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) 8 mm choke

(8) 9 mm choke

(9) Bleed screws

(10) Coolant-oil intercooler

Note:


19A-7


F4R, and 770 or 771

19A

102740

6

11

54

3

2

1

8

7

10

9

9

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) 8.3 mm choke

(8) 16 mm choke

(9) Bleed screws

(10) Coolant-oil intercooler

(11) Automatic gearbox coolant-oilintercooler (if fitted to the vehi-cle)

Note:


19A-8


F4R, and 776

19A

106628

13

96

5

7

11

3

2

8

1

4

10

129

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) 9 mm choke

(8) 16 mm choke

(9) Bleed screws

(10) Water-oil intercooler

(11) Thermostat mounting

(12) Turbocharger


Note

The expansion bottle valve rating is 1.4 bar .

19A-9


F9Q, and 804

19A

112266

139

9

10

12

14

6

2

37

5 1

4

11

8

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) 8 mm choke

(8) 16 mm choke

(9) Bleed screws


(11) Cylinder head coolant outlet unit

(12) Turbocharger



Note

The expansion bottle valve rating is 1.4 bar .

19A-10


K9K, and 732

19A

112268

1

2

3

4

5

6

7

77

8

9

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) Bleed screws



Note:


19A-11


M9R, and 700

19A

114452

(1) Engine


(3) Heater radiator


(5) Water pump

(6) Thermostat

(7) Choke

(8) Choke

(9) Bleed screws

(10) Water-oil heat exchanger


Note:


19A-12

COOLING SYSTEMCooling circuit: Draining - Refilling 19A

DRAINING

Use the following tools:

- (Car. 1363) ,

- (Mot. 1202-01) ,

- (Mot. 1202-02) ,

- (Mot. 1448) .

Remove the expansion bottle cap.

Open the cooling system at the cooling radiator bot-tom hose using the (Car. 1363) .

Blast compressed air into the circuit through the ex-pansion bottle cap orifice to remove as much wateras possible.

CLEANING

For cleaning (see 19A, Cooling, Cooling system:cleaning).

FILLING

Use GLACEOL RX (TYPE D) coolant.



Mot. 1202-01 Clip pliers for hose clips (largemodel)

Mot. 1202-02 Clip pliers for hose clips (smallmodel)

Mot. 1448 Remote operation pliers for coo-ling system hose clips

Mot. 1700 Cooling system filling and dia-gnostic tool

IMPORTANT

The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious burns).

Never remove the cap from the expansion bottlewhile the engine is hot.



WARNING

The coolant helps to keep the engine running pro-perly (heat exchange).

The system does not operate using pure water.

WARNING

Drain the fluid with the engine warm.



WARNING

When carrying out a repair that requires a completechange, it is essential to flush the circuit with cleanwater, blast compressed air through the circuit todrive out the water, fill and bleed the circuit andthen measure the effective protection.

The parameters to be observed are:

- Protection down to - 25˚C ±±±± 2 for cold and tempe-rate climates,

- Protection down to - 40 ˚C ±±±± 2 for very cold clima-tes.

Note:

Before carrying out any operation, protect electricalequipment using plastic bags.

Note:

The engine must be switched off and the air condi-tioning system deactivated to prevent the enginecooling fans operating as soon as the engine isstarted.

19A-13

COOLING SYSTEMCooling circuit: Draining - Refilling 19A

Refill the cooling system using the cooling systemdiagnostic and filling tool (Mot. 1700) . For guidanceon the use of this tool see Technical Note 3857A,Using the cooling system diagnostic and fillingtool .

Fill up the expansion bottle until the coolant over-flows.

Refit the expansion bottle cap.

Bleed the circuit (see 19A, Cooling system, Coo-ling circuit: Bleeding, page 19A-15) .

19A-14

COOLING SYSTEMEngine cooling circuit: Cleaning 19A

CLEANING THE COOLING SYSTEM

To clean the cooling system, fill with water via theexpansion bottle.

Blast compressed air into the circuit through the ex-pansion bottle cap orifice to remove as much wateras possible.

Connect the top and bottom hoses.

IMPORTANT

The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious burns).

Do not remove the cap from the expansion bottlewhile the engine is hot.



WARNING

Drain the fluid with the engine warm.



Note:

In some cases it will be necessary to disconnectthe radiator top hose to correctly flush the enginecooling radiator.

19A-15

COOLING SYSTEMCooling circuit: Bleeding 19A

BLEEDING

Run the engine at 1500 rpm , rapidly varying the en-gine speed (until you reach maximum speed) 2 to 3times approximately every 2 minutes until the engi-ne cooling fan starts up for a second time.

Run the engine at 2500 rpm , until the engine coo-ling fan has run three times (time required for auto-matic degassing).

IMPORTANT

Do not open the bleed screw(s) while the engineis running or hot.

Do not open the expansion bottle while theengine is running or hot (above 50˚C ).

Adjust the level, if necessary.

Retighten the expansion bottle cap while theengine is hot.

Using approved equipment, measure the degreeof coolant protection.

Check for any leaks.

Make sure the passenger compartment heatingis working properly.

K9K, and 722 or 728 or 729 or 732

F4R, and 770 or 771 or 776 – F9Q, and 800 or 804or 808 – K4J, and 730 or 732 – K4M, and 760 or761

19A-16

COOLING SYSTEMCooling radiator: Removal - Refitting 19A

REMOVAL



Remove:


- the front wheels,



Disconnect:

- the fog lights connector (if fitted to vehicle),

- the headlight washer pipes (if fitted).

Remove:


- the bumper.



Remove:

- the clip (3) ,

- the mounting (4) .

Disconnect the windscreen washer pipes.






Tightening torquesm

intercooler hose clip 5.5 Nm


4 Nm


F4R, and 776 – F9Q, and 800 or 804 or 808 – K9K,and 722 or 728 or 729 or 732

WARNING


- risk of leaks and of coming loose if this proce-dure is not adhered to.

- detach the hose using tool (Car. 1363) ,

- do not use degreaser, brake cleaner, or anyother product,

- clean the bearing face on the intercooler andthe hose with a dry, lint-free cloth,

- always replace the clip with a new one.

- replace the new clip in the same position if thehose is not replaced,

- it is essential to replace the hose and/or theintercooler if they are damaged,

102504

43

2

11

19A-17


Remove the cross member (5) .

Drain the cooling circuit through the radiator bottomhose.

Disconnect:

- the radiator top hose,

- the expansion bottle hoses on the radiator,


Disconnect the intercooler inlet ducts (6) and outletducts (7) .


102365

5


102473

102474

6

7

19A-18


Separate the condenser from the radiator.

Remove the radiator.

Separate the fan unit from the radiator.

REFITTING


Tighten to torque the intercooler hose clip ( 5.5Nm ) .

For refitting plastic clips, use:

- hose clip pliers (Mot. 1202-01) ,

- hose clip pliers (Mot. 1202-02)

- remote operation hose clip pliers (Mot. 1448) .


- fill the cooling circuit (see 19A, Cooling, Draining- filling the cooling circuit ),

- bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit ),


Tighten to torque:


- the wheel mounting bolts ( 110 Nm ) .WARNING

Be careful not to damage the air conditioningpiping.


WARNING

Ensure that the fins of the cooling unit (radiator,condenser) are not damaged when moved.

WARNING


Note

Be sure to initialise the xenon bulb system (if fit-ted on vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).

19A-19

COOLING SYSTEMCooling radiator: Removal - Refitting

K9K, and 732

19A



Disconnect the battery (see 80A, Battery: Removal- fitting ).

Remove:


- the front wheels,




Disconnect the connectors (1) from the relay board,

Unclip the bonnet opening cable (2) ,

Remove:

- the clip (3) ,



Remove:

- the front end panel bolts (5) ,


Drain the cooling system via the radiator bottom ho-se, using tool (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .





Tightening torquesm


21 Nm


44 Nm

wheel bolts 110 Nm

102504

102365

19A-20


K9K, and 732

19A

Disconnect the ducts (6) and (7) from the intercoo-ler.


Disconnect:

- the cooling radiator top hose,

- the expansion bottle hoses (8) ,

- the fan unit resistor connector (9) .

- the fan unit connector

102473

102474

109537

112661

19A-21


K9K, and 732

19A

Separate the condenser from the cooling radiator.


Remove the radiator assembly from the fan unit.

Separate the cooling radiator from the fan unit.

REFITTING


Position the fan unit on the cooling radiator.

Refit the cooling radiator assembly and the fan unit.


Reposition the condenser on the cooling radiator.

Connect:

- the hoses onto the cooling radiator,

- the fan unit connectors;


Refit the intercooler.

Connect the intercooler ducts.

Refit the front end panel.

Tighten to torque:

- the front end panel upper mounting bolts ( 21Nm )

- the front end panel lower mounting bolts ( 44Nm )

Clip the bonnet opening cable

Reconnect:

- the connectors to the relay board,

- the screen washer pipes.

Fill with and bleed the coolant (see 37A, Cooling,Bleeding the cooling circuit ).

Refit:



- the front wheels,




CA or CAREG

WARNING


CA or CAREG

WARNING


19A-22

COOLING SYSTEMWater pump: Removal - Refitting

C84 or G84 or S84, and F9Q, and 800 or 804 or 808

19A

REMOVAL


Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting .

Remove:




Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining - Refilling ).

Remove:



Remove:

- the water pump mounting bolts (6) ,

- the water pump.

REFITTING



Replace the water pump seal every time the waterpump is removed.

Refit:

- the water pump,

- the water pump mounting bolts.

Tightening torquesm

water pump mountingbolts

9 Nm

front right-hand wheelmounting bolts

110 Nm

102422

IMPORTANTDo not scratch the aluminium sealing surfaces.

Wear goggles.


WARNING


Note:

Apply two drops of LOCTITE FRENETANCH tothe water pump mounting bolts.

19A-23


C84 or G84 or S84, and F9Q, and 800 or 804 or 808

19A

Tighten to torque and in order the water pumpmounting bolts ( 9 Nm ) .

Refit:



Fill the cooling system (see 19A, Cooling, Draining- Filling the cooling system ).


Bleed the cooling system (see 19A, Cooling, Blee-ding the cooling system ).

Refit:



- the front right-hand wheel mounting bolts.

Tighten to torque the front right-hand wheelmounting bolts ( 110 Nm ) .

102422

19A-24


K4J, and 730 or 732 – K4M, and 760 or 761

19A

REMOVAL



Remove



- the engine undertray


Remove:



Remove:

- the timing tensioning roller,

- the water pump.

REFITTING



Tightening torquesm

water pump M8 moun-ting bolt

22 Nm

water pump M6 moun-ting bolts

10 Nm


110 Nm

14505

IMPORTANT


Wear goggles.


WARNING


WARNING

Applying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct-fluid mix may cause damage to some com-ponents (engine, radiator, etc.).

19A-25


K4J, and 730 or 732 – K4M, and 760 or 761

19A

Apply at (1) a bead of LOCTITE 518 mastic 0.6 mmto 1 mm wide.

10063

1

19A-26


K4J, and 730 or 732 – K4M, and 760 or 761

19A

Refit:

- the water pump,


Pretighten the water pump M6 mounting bolts to 8Nm and the water pump M8 mounting bolts to 8Nm .


- the water pump M8 mounting bolt ( 22 Nm ) ,

- the water pump M6 mounting bolts ( 10 Nm ) .

Refit:






Refit the front right-hand wheel

Refit:





14505

Note:

Apply one to two drops of LOCTITE FRENE-TANCH to the mounting bolts (1) and (4) of thewater pump.

6

5

4

3

2

1

8

7

19A-27


K9K, and 722 or 728 or 729 or 732

19A



Remove:





Remove:




Remove the alternator upper mounting (1) .

Undo the alternator lower mounting (2) .

Tilt the alternator forward.

Remove:

- the inner timing cover mounting bolts (3) ,

- the inner timing cover.

Tightening torquesm


11 Nm


110 Nm

102267

102266

1

2

33

19A-28


K9K, and 722 or 728 or 729 or 732

19A

Remove:


- the water pump.

REFITTING

Clean the gasket faces using DECAPJOINT to dis-solve any sealant still adhering.



Refit:

- the water pump,

- the water pump mounting bolts (1) to (5) .


102262

IMPORTANT


Wear goggles.


44

102262

WARNING


Note:


1

5

4

3

2

19A-29


K9K, and 722 or 728 or 729 or 732

19A

Refit:

- the inner timing cover (5) ,






Refit:




Tighten to torque:

- the front right-hand wheel mounting bolts ( 110Nm )

102266

5

19A-30


F4R, and 770 or 771 or 776

19A

REMOVAL


Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting .

Remove:




Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).

Remove:



Remove:


- the water pump.

REFITTING




Refit:

- the water pump,


Tightening torquesm


9 Nm


110 Nm

102422

66666

IMPORTANTDo not scratch the aluminium sealing surfaces.

Wear goggles.


WARNING


Note:


19A-31


F4R, and 770 or 771 or 776

19A


Refit:






Refit:





102422

5

4

32

1

19A-32


K9K, and 732

19A

REMOVAL




Remove:



Drain the cooling circuit via the radiator bottom hose,using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.1448) .

Remove:

- the accessories belt (see 11A, Top and Front ofEngine, Accessories belt ).

- the timing belt (see 11A, Top and front of engine,Timing belt

Loosen the alternator lower mounting bolt by threeturns.

Remove the alternator upper mounting bolt.

Tilt the alternator against the radiator assembly.

Remove:

- the inner timing cover mounting bolts,

- the timing cover.





Tightening torquesm


11 Nm



4 Nm 102267

102266

19A-33


K9K, and 732


Remove:

- the water pump mounting bolts

- the water pump.

III - CLEANING

REFITTING

I - OPERATION FOR REFITTING PART CONCERNED

Refit:

- the water pump,



102262

IMPORTANT

- Do not scratch the aluminium sealing surfaces.

- Wear goggles.

- Clean the gasket faces with DECAPJOINT todissolve the part of the gasket still present.

Apply the product to the part to be cleaned, waitapproximately 10 minutes, then remove residueusing a wooden spatula.

WARNING

The water pump seal every time the water pumpis removed.

Note:

Apply one or two drops of LOCTITE FRENE-TANCH to the water pump mounting bolts.

102262

19A-34


K9K, and 732


Refit:

- the inner timing cover,

- the alternator,

- the timing belt (see 11A, Top and front of engine:Timing belt ),



- fill the cooling circuit (see 19A, Cooling, Draining- Filling the cooling circuit ),

- bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit ),

Connect the battery starting with the positive termi-nal (see 80A Battery: Removal - Refitting ).

Tighten to torque:

- the wheel mounting bolts ( 130 Nm )

- the battery cover mounting bolts ( 4 Nm )

102266

WARNING

Carry out the necessary programming.

19A-35


M9R, and 700

19AREMOVAL




Remove:







Tightening torquesm


25 Nm

water pump pulleymounting bolts

21 Nm


21 Nm


44 Nm

WARNING

When carrying out a repair that requires a com-plete change, it is essential to flush the circuitwith clean water, blast compressed air throughthe circuit to drive out the water, fill and bleed thecircuit and then measure the effective protection.


- protection down to - 25 ˚C ± 2 for cold and tem-perate countries,

- protection down to - 40 ˚C ± 2 for very coldcountries.

IMPORTANT

The circuits are designed to be pressurised, sobe careful at high temperatures (risk of seriousburns).


When working under the bonnet, be aware thatthe radiator cooling fan(s) may start without war-ning.

Do not open the bleed screw(s) with the enginerunning.

19A-36


M9R, and 700

19A

Remove:

- the right-hand side stiffener mounting bolts,

- the right-hand side stiffener (1) ,

- the rear mounting (see 19D, Suspended enginemounting, Rear mounting: Removal - Refitting).





101212

114855

114933

112658

19A-37


M9R, and 700

19A



Remove:

- the clip (6) ,



Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining - Filling ).

Remove:



Remove the « Cooling radiator - condenser -intercooler » assembly from its housing and move itforwards.

Fit the (Mot. 1390) on two pads.

Undo

- the right-hand suspended mounting support moun-ting bolts,

- the upper engine tie-bar mounting bolts.

Remove the upper engine tie-bar.

102504 102365

19A-38


M9R, and 700

19A

At the same time, turn the (Mot. 1390) forwards, lif-ting the right-hand suspended engine mounting (9)and bring the compressor pulley (10) level.


Remove:

- the water pump pulley mounting bolts (11) ,

- the water pump pulley (12) .

114863

114858

19A-39


M9R, and 700

19A

Remove:

- the water pump mounting bolts,

- the water pump (13) .

REFITTING


The water pump seal must be replaced.

Apply soapy water to the seal before refitting the wa-ter pump.

Refit the water pump.

Check that the water pump is supported by the cylin-der block before tightening the bolts.


Tighten to torque the water pump pulley mountingbolts ( 21 Nm ) .


Position

- the « Engine - Gearbox » assembly on the vehicle,

- the « Cooling radiator - condenser - intercooler »assembly on the half sub-frame.

Refit:

- the right-hand suspended engine mounting (see19D, Engine mounting, Right-hand suspendedengine mounting: Removal - Refitting ).



Tighten to torque:



Clip:

- the bonnet opening cable,


Refit the clips.


Refit:


- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting )

- the rear suspended engine mounting (see 19D,Engine mounting, Rear suspended enginemounting: Removal - Refitting ).

- the half sub-frame cross member side stiffener,




114863

WARNING

Clean the pump shaft cooling hole on the cylin-der block.

19A-40

COOLING SYSTEMPlenum chamber: Removal - Refitting

M9R, and 700

19AREMOVAL



Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting ).


Remove:




Unpick the wiring harness (4) from the battery - ter-minal.


Drain the cooling system via the radiator bottomhose using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) (see 19A, Cooling, Cooling system:Draining - Filling).





Mot. 1700 Cooling circuit fillingand diagnostic tool

Tightening torquesm

coolant outlet unitmounting bolts on thecylinder head

11 Nm


21 Nm

wiring harness moun-ting nut

8 Nm

WARNING

When carrying out a repair that requires a completechange, it is essential to flush the circuit with cleanwater, blast compressed air through the circuit todrive out the water, fill and bleed the circuit andthen measure the effective protection.


- protection down to -25˚C ±2 for cold and tempe-rate countries,

- protection up to -40˚C ±2 for countries with extre-mely cold climates.

IMPORTANT

The circuits are designed to be pressurised, so becareful at high temperatures (risk of serious burns).


During an operation under the bonnet, be awarethat one (or several) of the radiator cooling fan(s)may operate unexpectedly.

Do not open the bleed screw(s) with the engine run-ning.

112659

19A-41


M9R, and 700

19A

Disconnect the coolant temperature sensor connec-tor (5) .


Remove the cooling hose clips using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) on thecoolant outlet unit.

Disconnect the cooling hoses from the coolant outletunit.

Unpick the wiring harness on the coolant outlet unit.

Remove:

- the coolant outlet unit mounting bolts,

- the coolant outlet unit.

REFITTING


replace the seal of the coolant outlet unit.

II - REFITTING PART CONCERNED

Remove:

- the coolant outlet unit.

- the coolant outlet unit mounting bolts,

114934

113293

113291

WARNING

The seal faces must be clean, dry and free fromgrease (avoid finger marks).

19A-42


M9R, and 700

19A

Tighten to torque and in order the coolant outletunit mounting bolts on the cylinder head ( 11 Nm) .

Connect the coolant outlet unit cooling hoses.

Refit the cooling hose clips using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) on the coolant out-let unit.


Connect the coolant temperature sensor connector.

Refit the battery tray.

Remove:


- the wiring harness,

- the wiring harness mounting nut.

Tighten to torque:


- the wiring harness mounting nut ( 8 Nm ) .

Connect the injection computer connectors.

Clip on the battery - terminal wiring harness.

Refit the battery (see 80A, Battery, Battery: Remo-val - Refitting ).

Fill the cooling system using the (Mot. 1700) (see19A, Cooling, Cooling system: Draining - Refil-ling ).

113291

19B-1

EXHAUSTGeneral information 19B

The whole exhaust pipe is made of stainless steel.

The catalytic converter reaches high temperatures; donot park the vehicle close to flammable materials.

SPECIAL NOTES ON THE EXHAUST PIPE

1 - Exhaust pipe cutting line

The exhaust pipe is a single unit type.

When replacing one of the components, cut the ex-haust pipe:

- correctly identify the area to be cut.

- use the cutting tool correctly (Mot. 1199-01) ,

- correctly position the After-Sales sleeve.

2 - Identifying the cut zone

Two punch marks on the exhaust pipe indicate thearea to be cut (see 19B, Exhaust, General informa-tion on exhausts ).

Before cutting the pipe between the catalytic converterand the expansion chamber, remove the protectiveplate.


Mot. 1199-01 35/50 mm diameterand 50/95 mm diame-ter exhaust pipe cut-ting tool. Completeassembly in kit.

WARNING

Any damaged heat shields must be replaced.

The sealing between the exhaust manifold and thecatalytic converter must be perfect.

All seals removed must be replaced.

Take care not to damage the catalytic converterduring removal and refitting.

F4R, and 776

109581

109580

19B-2


Cut zone 1

Cut zone 2Before cutting the pipe, mark the halfway point (D)between marks (P1) and (P2) .

The distance between the two marks is 80 mm

3 - Using tool Mot. 1199-01

Position the tool on the pipe.

Tighten the two bolts on the cutting tool so that it gripsthe exhaust pipe.

Turn the cutting tool with the handle while gripping thepipe.

As the cut is made, continue to tighten the two bolts ofthe tool (do not overtighten the tool against the pipe, toprevent deformation during the cutting operation).

101504

101503

100649

102118

P1

80 mm

D

P2

19B-3


4 - Special notes on the replacement part

5 - Fitting the After-Sales sleeve

Apply exhaust pipe mastic inside the sleeve.

To prevent any exhaust leaks, position the sleeve cor-rectly on both lugs.

Place the sleeve on the worn section of the pipe. Adjustthe clip diameter by tightening slightly.

Place the sleeve end on the worn section of the pipe.

Adjust the sleeve diameter by tightening gently.

Cut zone 1

Cut zone 2

6 - Special feature of cut zone 2

Remove the bolt securing the rubber mounting bush(2) onto the body.

Lower the exhaust pipe.

Position tool (Mot. 1199-01) on the pipe.

Cut the exhaust pipe .

101960

WARNING

When replacing the middle section of the exhaustpipe (pipe on diesel version, expansion chamber onpetrol versions), the replacement part needs to beshortened by 60 mm .

95478

60 mm

1

101501

101500

19B-4


Tighten to torque the nut (1) on the exhaust sleeve(25 Nm) .

When tightening to torque, a click indicates that the tor-que of (25 Nm) has been reached.

Check that:

- there is no contact with the underbody,

- the presence and correct positioning of all the ex-haust pipe heat shields.

WARNING

Do not reuse a used bracket.

WARNING

Do not reuse an old sleeve.

The « sleeve tightening nuts and bolts » must bepositioned so that they cannot come into contactwith the underbody.


19B-5

EXHAUSTPipe assembly


19B

K4J, and 730 or 732

112063

2

1

(1) Cut zone 1

(2) Cut zone 2

K4M, and 760 or 761

112062

1

2

19B-6



19B

(1) Cut zone 1

(2) Cut zone 2

F4R, and 770 or 771 or 776

112061

1

2

(1) Cut zone 1

(2) Cut zone 2

19B-7


K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808

19B

K9K, and 722

112060

1

2

(1) Cut zone 1

(2) Cut zone 2

K9K, and 728 or 729 or 732

112059

1

2

19B-8



19B

(1) Cut zone 1

(2) Cut zone 2

F9Q, and 800 or 808

112059

1

2

(1) Cut zone 1

(2) Cut zone 2

F9Q, and 804

112058

1

2

19B-9



19B

(1) Cut zone 1

(2) Cut zone 2

19B-10

EXHAUSTCatalytic pre-converter: Removal - Refitting

F4R, and 776

19B

Remove the engine in order to remove the catalyticpre-converter (see 10A, Engine and peripherals, En-gine - gearbox ).

REMOVAL

Remove:


- the heat shield.

Disconnect the oxygen sensor connectors (2) .

Remove:

- the upper bracket (3) and upstream stays (4) ,

- the catalytic converter/gearbox stay mounting (5) ,

- the catalytic converter mounting nuts, (6) on theturbocharger,


Remove the oxygen sensor on the workbench.

REFITTING

Refit the oxygen sensors.

Tighten to torque the upstream stay mountingbolts (on the engine) ( 38 Nm ) .

Pretighten in order:

- the upper bracket mounting bolts,

- the nuts securing the catalytic converter to the tur-bocharger,

- the upstream catalytic converter stay mountingbolt.


- the catalytic converter mounting bolt (on theupstream stay) ( 8.5 Nm ) ,

Tightening torquesm

upstream stay moun-ting bolts (on theengine)

38 Nm

catalytic convertermounting bolt (on theupstream stay)

8.5 Nm

upper bracket moun-ting bolt (on the exhaustmanifold)

8.5 Nm

upper bracket moun-ting bolt (on the catalyticconverter)

8.5 Nm

catalytic converter nuts(on the turbocharger)

40 Nm


exhaust flange studs 8.5 Nm

106246

111

21926

WARNING

Be sure to replace all the exhaust flange and tur-bocharger sealing joints.

5

3

666

2

4

19B-11


F4R, and 776

19B- the upper bracket mounting bolt (on the ex-haust manifold) ( 8.5 Nm ) ,

- the upper bracket mounting bolt (on the cataly-tic converter) ( 8.5 Nm ) ,

- the catalytic converter nuts (on the turbochar-ger) ( 40 Nm ) ,


- the exhaust flange studs ( 8.5 Nm ) .


19B-12


F9Q, and 804

19B

Remove:



- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).

Remove:


- the exhaust mounting bolts,

- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft: Removal -Refitting ).

- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).

Remove:

- the catalytic pre-converter lower stay mountingbolts (1)

- the catalytic pre-converter lower stay.

Tightening torquesm

connector clip betweenthe turbocharger andthe catalytic pre-conver-ter

20 Nm

catalytic pre-converterupstream stay moun-ting nuts on the engine

30 Nm

catalytic pre-converterupstream stay moun-ting nuts on the cataly-tic pre-converter

30 Nm

catalytic pre-convertergearbox-side downs-tream stay mountingbolts on the engine

50 Nm

catalytic pre-convertergearbox-side downs-tream stay mountingbolts on the catalyticpre-converter

50 Nm

catalytic pre-convertertiming-end downstreamstay mounting bolts onthe engine

50 Nm

catalytic pre-convertertiming-end downstreamstay mounting nuts onthe catalytic pre-conver-ter

30 Nm

catalytic pre-converteroutlet exhaust flangestuds

7 Nm

exhaust flange nuts 21 Nm


4 Nm

111864

11

19B-13


F9Q, and 804

19B

Remove:

- the catalytic pre-converter upper stay mountingbolts (2) ,

- the catalytic pre-converter upper stay,

- the turbocharger and catalytic pre-converter moun-ting clip bolt (3) ,

- the catalytic pre-converter.

111862

22

3

19B-14


F9Q, and 804

19BREFITTING

On the workbench, refit the gearbox-side downs-tream stay to the catalytic pre-converter.

Tighten the gearbox-side downstream stay moun-ting bolts on the catalytic pre-converter so that theymake contact.

Fit the catalytic pre-converter to the engine.

Tighten the gearbox-side downstream stay moun-ting bolts on the engine so that they make contact.

Refit:

- the connector clip between the turbocharger andthe catalytic pre-converter,

- the catalytic pre-converter upstream stay.


- the catalytic pre-converter upstream stay mountingnuts on the engine,

- the catalytic pre-converter upstream stay mountingnuts on the catalytic pre-converter,

Loosen then tighten in order and until they make contact:

- the catalytic pre-converter gearbox-side downs-tream stay mounting bolts on the engine,

- the catalytic pre-converter gearbox-side downs-tream stay mounting bolts on the catalytic pre-con-verter.

Refit the catalytic pre-converter downstream stay onthe timing end.


- the catalytic pre-converter timing-end downstreamstay mounting bolts on the engine,

- the catalytic pre-converter timing-end downstreamstay mounting nuts on the catalytic pre-converter,

- the connector clip between the turbocharger andthe catalytic pre-converter.

Tighten to torque:

- the connector clip between the turbocharger

and the catalytic pre-converter ( 20 Nm ) ,

- the catalytic pre-converter upstream staymounting nuts on the engine ( 30 Nm ) ,

- the catalytic pre-converter upstream staymounting nuts on the catalytic pre-converter (30 Nm ) ,

- the catalytic pre-converter gearbox-sidedownstream stay mounting bolts on the engine( 50 Nm ) ,

- the catalytic pre-converter gearbox-sidedownstream stay mounting bolts on the cataly-tic pre-converter ( 50 Nm ) ,

- the catalytic pre-converter timing-end downs-tream stay mounting bolts on the engine ( 50Nm ) ,

- the catalytic pre-converter timing-end downs-tream stay mounting nuts on the catalytic pre-converter ( 30 Nm ) .

Tighten to torque:

- the catalytic pre-converter outlet exhaust flan-ge studs ( 7 Nm ) .

- the exhaust flange nuts ( 21 Nm ) ,




tighten to torque the battery cover mounting bolts( 4 Nm ) .

WARNING

Always replace:

- the catalytic converter seal,

- the connector clip between the turbochargerand the catalytic pre-converter.

Note:

Make sure there is no contact between the cata-lytic pre-converter and the turbocharger oil returnpipe.

WARNING


WARNING


19B-15

EXHAUSTCatalytic converter: Removal - Refitting


19B




Remove the downstream oxygen sensor.

Cut the exhaust pipe (see 19B, Exhausts, Generalinformation ).

Remove:

- the exhaust bracket mounting nuts (1) ,




Tightening torquesm

oxygen sensor 45 Nm

exhaust bracket studs 7 Nm

exhaust bracket nuts) 21 Nm


4 Nm

F4R, and 770 or 771 – K4J, and 730 or 732 – K4M,and 760 or 761

101793

11

19B-16



19BREFITTING

Refit the downstream oxygen sensor.

Tighten to torque the oxygen sensor ( 45 Nm )using the (Mot. 1495-01) .

Refit and tighten to torque if necessary the exhaustbracket studs ( 7 Nm ) .

Fit:

- the catalytic converter,

- the sleeve (see 19B, Exhausts, General informa-tion ).


Tighten to torque the exhaust bracket nuts) ( 21Nm )

Tighten the sleeve while easing the exhaust to ensu-re alignment.

Reconnect the oxygen sensor.






WARNING




WARNING

Always replace:

- the exhaust bracket seal.

- all the disconnected air inlet plastic pipes.

WARNING


19B-17


F9Q, and 800 or 808

19B



Remove:



Remove the nuts (1) from the exhaust bracket (atthe catalytic converter outlet).

Remove the mounting bolt (2) from the exhaust piperubber mounting bush on the body.

Tightening torquesm

nuts mounting the cata-lytic converter onto theturbocharger

30 Nm

catalytic converter staynut (timing end)

30 Nm

catalytic converter staymounting bolt (timingend)

44 Nm

catalytic converter staymounting nut (flywheelend)

21 Nm

exhaust bracket studs(at the catalytic conver-ter outlet)

7 Nm

exhaust bracket nuts (atthe catalytic converteroutlet)

21 Nm

exhaust pipe supportmounting bolt (on thebody)

21 Nm


4 Nm

wheel bolts 110 Nm

101118

Note:

Mark with a pen the position of the exhaust rub-ber mounting bush supports on the vehicle body.

102116

1

2

19B-18


F9Q, and 800 or 808

19B

Remove the (3) silencer rubber mounting bush bolt.


Remove the catalytic converter stay mounting bolts(4) (flywheel end).

Remove:

- the catalytic converter stay mounting bolts (5) (timi-ng end),

- the catalytic converter stay (timing end).

Remove the engine tie-bar (6) .

102117

102479

3

44

101120

102313

55

6

19B-19


F9Q, and 800 or 808

19B

Remove:

- the engine lifting bracket,

- the nuts (7) securing the catalytic converter to theturbocharger,

- the catalytic converter from underneath the vehicle.

REFITTING

The order for fitting catalytic converter stays must berespected.


- the catalytic converter stay mounting bolts (timingend),

- the stay mounting bolts (flywheel end),

- the catalytic converter nuts on the turbocharger,

Tighten to torque the nuts mounting the catalyticconverter onto the turbocharger ( 30 Nm ) .

Refitting the stay at the timing end


- the catalytic converter stay nut (timing end) ( 30Nm ) (8) ,

- the catalytic converter stay mounting bolt (timi-ng end) ( 44 Nm ) (9) .

101121

WARNINGDo not reuse an old sleeve.



WARNING

The gaskets must always be replaced.

777

101120

8 9

19B-20


F9Q, and 800 or 808

19BRefitting the stay at the timing end

Tighten to torque and in order the catalytic conver-ter stay mounting nut (flywheel end) ( 21 Nm )(10) .


Tighten to torque:

- the exhaust bracket studs (at the catalytic con-verter outlet) ( 7 Nm ) .

- the exhaust bracket nuts (at the catalytic con-verter outlet) ( 21 Nm ) ,

- the exhaust pipe support mounting bolt (on thebody) ( 21 Nm ) .





Tighten to torque:



102479

Note:

Make sure there is no contact between the cata-lytic conver ter and the turbocharger oil returnpipe.

WARNING


10

19B-21


K9K, and 722 or 728 or 729 or 732

19B




Remove:

- the exhaust pipe bracket mounting bolts (1) ,

- the catalytic converter stay mounting bolt (2) .

Loosen the other stay mountings on the gearbox.

Remove the stay (3) .

Tightening torquesm

turbocharger outletstuds

7 Nm

catalytic convertermounting nuts on theturbocharger

26 Nm

upstream stay moun-ting bolts on the engine

44 Nm

downstream staymounting bolts on thegearbox

21 Nm

upstream stay moun-ting bolt on the catalyticconverter

25 Nm

downstream staymounting bolt on thecatalytic converter

21 Nm

bolt securing theexhaust pipe bracketonto the body

21 Nm

catalytic converter out-let exhaust bracketstuds

7 Nm


ball joint bracket boltswith their springs

21 Nm


4 Nm

102076

3

2

1

19B-22


K9K, and 722 or 728 or 729 or 732

19B

Remove the mounting bolt (4) from the exhaust piperubber mounting bush on the body.

Remove the mounting bolt (5) from the silencer rub-ber mounting bush.


Remove:

- the catalytic converter upstream stay mountingbolts,


- the catalytic converter mounting nuts on the turbo-charger (7) ,


102116

Note:


102117

4

5

102077

19B-23


K9K, and 722 or 728 or 729 or 732

19BREFITTING

Tighten to torque the turbocharger outlet studs ( 7Nm ) .

Fit the catalytic converter.


- the upstream stay bolts on the engine,

- the upstream stay bolts on the catalytic converter,

- the downstream stay bolts on the gearbox,

- the downstream stay bolts on the catalytic conver-ter,

- the catalytic converter/turbocharger mounting nuts.

Tighten to torque and in order

- the catalytic converter mounting nuts on theturbocharger ( 26 Nm ) ,

- the upstream stay mounting bolts on the engine( 44 Nm ) ,

- the downstream stay mounting bolts on thegearbox ( 21 Nm ) ,

- the upstream stay mounting bolt on the cataly-tic converter ( 25 Nm ) ,

- the downstream stay mounting bolt on the cata-lytic converter ( 21 Nm ) ,

- the bolt securing the exhaust pipe bracket ontothe body ( 21 Nm ) ,

Tighten to torque:

- the catalytic converter outlet exhaust bracketstuds ( 7 Nm ) ,


Tighten to torque the ball joint bracket bolts withtheir springs ( 21 Nm ) .






WARNING

Always replace:

- the catalytic converter seal,

- the turbocharger - catalytic converter bracketstuds.

Note:

Make sure there is no contact between the cata-lytic conver ter and the turbocharger oil returnpipe.

K9K, and 722 or 728 or 729

K9K, and 732

WARNING


WARNING


19B-24


M9R, and 700

19BREMOVAL




Remove:



- the acoustic protection clips on the scuttle panelpartition,

- the acoustic protection.

Remove:

- the nuts (1) mounting the catalytic converter to theturbocharger,


Equipment required

roller-type stud removal tool

safety belt

Tightening torquesm

studs on the turbochar-ger

14.5 Nm

catalytic convertermounting clamp moun-ting bolts on the cylinderblock

21 Nm

catalytic convertermounting nuts on theturbocharger

21 Nm

catalytic converter half-clamp mounting bolts

21 Nm

stay mounting bolt onthe catalytic converter

8 Nm

stay mounting nuts onthe cylinder block

21 Nm

stay mounting nuts onthe catalytic converter

21 Nm

bolts of the ball-jointedbracket with springs

21 Nm

silencer rubber moun-ting bush mounting bolt

21 Nm

exhaust pipe rubbermounting bush moun-ting bolt

21 Nm

IMPORTANT

Wear protective gloves during all operations.

114986

19B-25


M9R, and 700

19B

Remove:

- the lower engine tie-bar (see 19D, Engine moun-ting, rear suspended engine mounting: Remo-val - Refitting ).

- the catalytic converter stay mounting bolt (2) ,

- the catalytic converter stay mounting nuts (3) ,

- the nuts (4) mounting the stay on the cylinderblock,

- the catalytic converter stay,

- the catalytic converter studs using a roller-typestud removal tool .

Remove the bolts from the ball-jointed bracket (5)with springs.

114771 114991

19B-26


M9R, and 700

19B

Remove:

- the exhaust pipe rubber mounting bush mountingbolt (6) ,

- The silencer rubber mounting bush mounting bolt(7) .

Detach the exhaust pipe.


Remove:

- the catalytic converter half-clamp mounting bolts(8) ,

- the catalytic converter half-clamps (9) .

Remove the catalytic converter, timing end.

Fit the catalytic converter using a safety belt to thelifting eye on the timing end.

102116

102117

Note:


114980

19B-27


M9R, and 700

19B

Remove:

- the catalytic converter mounting clamp mountingbolts (10) ,

- the catalytic converter mounting clamps.

Remove the safety belt .

Move the engine towards the front of the vehicle.

Remove the catalytic converter.

REFITTING


Remove the seal from the ball-jointed bracket.

Remove the turbocharger studs using a roller-typestud removal tool .


- on the exhaust pipe,

- on the catalytic converter in case of reuse,

- the turbocharger,

Refit the new studs onto the turbocharger using aroller-type stud removal tool .

Tighten to torque the studs on the turbocharger (14.5 Nm ) .

Fit the new catalytic converter mounting clamps ontothe cylinder block.

Finger tighten the catalytic converter mountingclamp mounting bolts on the cylinder block until con-tact is made.

Tighten to torque the catalytic converter mountingclamp mounting bolts on the cylinder block ( 21Nm ) .

114981

114843

19B-28


M9R, and 700


Move the engine towards the front of the vehicle.

Fit:

- the new seal between the turbocharger and the ca-talytic converter,


Refit the catalytic converter onto the turbocharger.

Fit:

- the new catalytic converter nuts onto the turbochar-ger,

- the new catalytic converter half-clamps.

Refit:

- the catalytic converter studs using a roller-typestud removal tool ,

- the catalytic converter half-clamp mounting bolts,

- the catalytic converter stay,

- the catalytic converter stay mounting bolt,

- the stay mounting nuts on the catalytic converter,

- the stay mounting nuts on the cylinder block.

Tighten to torque:

- the catalytic converter mounting nuts on theturbocharger ( 21 Nm ) ,

- the catalytic converter half-clamp mountingbolts ( 21 Nm ) ,

- the stay mounting bolt on the catalytic conver-ter ( 8 Nm ) ,

- the stay mounting nuts on the cylinder block (21 Nm ) ,

- the stay mounting nuts on the catalytic conver-ter ( 21 Nm ) .


Refit the lower engine tie-bar (see 19D, Enginemounting, Rear suspended engine mounting:Removal - Refitting ).

Tighten to torque the lower engine tie-bar (see 19D,Engine mounting, Rear suspended enginemounting: Tightening torque ).

Refit the new seal to the ball-jointed bracket.

Fit the exhaust pipe.

Refit:

- the exhaust pipe rubber mounting bush mountingbolt, aligning the marks,

- the silencer rubber mounting bush mounting bolt,aligning the marks,

- the ball-jointed bracket bolts with springs.

Tighten to torque:

- the bolts of the ball-jointed bracket with springs( 21 Nm ) ,

- the silencer rubber mounting bush mountingbolt ( 21 Nm ) ,

- the exhaust pipe rubber mounting bush moun-ting bolt ( 21 Nm ) .

Refit:


- the acoustic protection,

- the acoustic protection clips on the scuttle panelpartition,




114844

19B-29

EXHAUSTExpansion chamber: Removal - Refitting


19B

REMOVAL

Position the vehicle on a lift.


Cut the exhaust pipe (see 19B, Exhausts, GeneralVehicle Information ).

Remove:

- the bolts (1) securing the expansion chamber to therubber mounting bush support,

- the expansion chamber.

REFITTING

Fit:

- the expansion chamber,


Tighten to torque:

- the bolts securing the rubber mounting bushsupport on the expansion chamber ( 8 Nm ) ,

- the bolts securing the rubber mounting bushsupport on the body ( 21 Nm ) .

Tighten the sleeves, while easing the exhaust pipeto ensure the correct alignment of the pipe .



Tightening torquesm

bolts securing the rub-ber mounting bush sup-port on the expansionchamber

8 Nm

bolts securing the rub-ber mounting bush sup-port on the body

21 Nm

101818

Note:

If the rubber mounting bushes are damaged,mark the position of the support on thebodywork, then replace the « support / rubbermounting bush assembly » .

1

WARNINGCut the new expansion chamber pipe (see 19B,Exhaust, General Vehicle Information ).

WARNING


The « sleeve tightening nuts and bolts » assem-bly must be positioned so that it cannot comeinto contact with the underbody.


19B-30

EXHAUSTSilencer: Removal - Refitting 19B

REMOVAL


Cut the exhaust pipe (see 19B, Exhausts, Generalinformation ).

Remove:

- the silencer mounting bolts (1) on the rubber moun-ting bush support,

- the the silencer.

REFITTING

Fit:

- the silencer,


Tighten to torque:

- the bolts securing the rubber mounting bush onthe silencer ( 8 Nm ) ,

- the bolts securing the rubber mounting bushsupport on the body ( 21 Nm ) .

Tighten the sleeve, while easing in the exhaust pipeto ensure the correct alignment of the pipe.



Tightening torquesm

bolts securing the rub-ber mounting bush onthe silencer

8 Nm

bolts securing the rub-ber mounting bush sup-port on the body

21 Nm

101817

Note:

If the rubber mounting bushes are damaged:

- mark the position of the mounting on the vehiclebody,

- replace the « support / rubber mounting bushfitting assembly » .

1

WARNING


The « sleeve tightening nut and bolts assembly »must be positioned so that it cannot come intocontact with the underbody.


19B-31

EXHAUSTParticle filter: Function

F9Q, and 804

19B

I - SAFETY ADVICE

Due to the dangers of high temperatures, be sure to observe the following instructions:

- never open or separate the pressure tapping circuit,except at the level of the unions on the exhaust pipe(only the supplier can guarantee pressure tapping cir-cuit sealing),

- Position the pressure pipes correctly. If the pipes arenot positioned correctly, their flexible sections may betwisted which will create low points and this may re-sult in the pipes rupturing when fluid freezes and ex-pands.

II - OPERATING PRINCIPLE

The particle filter, placed underbody on the catalyticpre-convertor outlet, limits the pollutant emissions byaccumulating the unburnt particles from the exhaust fu-mes (loading or filtering phase), then these particlesare eliminated by combustion (regeneration phase).

Using sensors, the injection computer measures thetemperature as well as the pressure of the exhaust fu-mes upstream and downstream of the particle filter.

The injection computer continuously evaluates the le-vel of clogging of the particle filter using the pressuredifference upstream and downstream of the particle fil-ter. When it is clogged, the two temperature values in-form the injection computer that the temperatureconditions are high enough (approximately 600˚C ) totrigger regeneration.

This consists of burning the particles held in the parti-cle filter: to do this, the injection switches to « delayedinjection » mode and the fuel not burned in the com-bustion chambers burns the residues contained in theparticle filter cells.

The extent to which the particle filter is clogged de-pends on the user's driving style:

- during an average trip (combined cycle and motorwayof more than 15 minutes ), the particle filter automa-tically burns the particles without being noticed by thecustomer (apart from some white smoke): this is« spontaneous regeneration » ,

- if the operating temperature is not high enough to trig-ger spontaneous regeneration, clogging increasesuntil it exceeds 35 g ; an acceleration request to trig-ger spontaneous regeneration is then sent to the dri-ver via an instrument panel warning light; the samehappens if several attempts to regenerate have failed.

- if these conditions are still not met and clogging rea-ches 45 g (min) . « Static regeneration » , using dia-gnostic tool must be performed in the workshop (« SERVICE » warning light comes on and the« CHECK ANTIPOLLUTION » message appears:(see 19B, Exhaust, Particle filter: Cleaning ).

Equipment required

diagnostic tool

IMPORTANT

Do not park and run the engine in a place wherecombustible substances and materials such asgrass or leaves can come into contact with the hotexhaust system.

19B-32

EXHAUSTParticle filter: Removal - Refitting

F9Q, and 804

19B




Cut the exhaust pipe after the particle filter (see 19B,Exhaust : repair precautions ) and (see 19B, Ex-haust: General information ).

Remove the downstream pressure pipe (1) from itsadapter (2) bolted to the exhaust pipe.

Tightening torquesm

rubber mounting bushsupport mounting nut onthe particle filter

25 Nm

exhaust bracket nutsbetween the connectionhose and the catalyticpre-converter

21 Nm

rubber mounting bushnuts on the sub-frame

25 Nm

exhaust sleeve nut 25 Nm

downstream pressuremeasurement tappingon its adapter

21 Nm

connection clip boltbetween the silencerand the particle filter

25 Nm

exhaust flange nutsbetween the connectionhose and the catalyticpre-converter

21 Nm

nuts mounting the rub-ber mounting bush sup-port onto the sub-frame

25 Nm

106673

WARNING

When the pressure measurement tapping isremoved, the adapter must be held (2) with alock wrench.

WARNING

The pressure measurement circuit must never beopened except at the adapters on the exhaustpipe.

19B-33


F9Q, and 804

19B

Remove the heat shield (3) mounting clip then moveit aside slightly

Unpick the downstream pressure measurement tap-ping and also the downstream temperature sensorcabling from the heat shield.

Pass the downstream pressure measurement tap-ping into the engine compartment whilst leaving thepressure sensor complete.

Disconnect the particle filter pressure sensor con-nector (4) located in the engine compartment.

Remove the retaining clip (5) from the cabling on theparticle filter pressure sensor mounting.

Disconnect the upstream and downstream tempera-ture sensor offset connectors (6) .

Unpick the upstream and downstream temperaturesensor offset connectors (6) .

Remove:

- the bolt (7) securing the filter particle pressure sen-sor mounting located in the engine compartment.

- the particle filter pressure sensor assembly (8) andits mounting.

111881

111882

111885

111885

19B-34


F9Q, and 804

19B

Remove:

- the nuts (9) on the exhaust flange between the con-nection hose and the catalytic pre-converter,

- the sub-frame rubber mounting bush bolts (10) ,

- the particle filter.

Remove the particle filter assembly:

- the rubber mounting bush,

- the upstream and downstream temperature sen-sors from their adapters on the exhaust line (see19B, Exhaust, Particle filter temperature sen-sor: Removal - Refitting ).

- the upstream pressure measurement tapping at itsadapter on the exhaust pipe (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).

- the connection hose (see 19B, Exhaust, Connec-tion hose: Removal - Refitting ).

REFITTING

With particle filter removed, refit:

- the connection hose and its new seals (see 19B,Exhaust, Connection hose: Removal - Refitting).

107038

WARNING

Always replace:

- the seal between the hose and particle filter,

- the seal between the hose and the catalytic pre-converter,

- any adapter on the exhaust pipe that has beenloosened,

WARNING

Always clean the bearing surfaces of the connec-tion hose - par ticle filter flanges thoroughly.

19B-35


F9Q, and 804

19B- the upstream and downstream temperature sen-sors on their adapters on the exhaust pipe (see19B, Exhaust, Particle filter temperature sen-sors: Removal - Refitting ).

- the upstream pressure measurement tapping at itsadapter on the exhaust line (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).

- the rubber mounting bush on the particle filter.

Torque tighten the rubber mounting bush supportmounting nut on the particle filter ( 25 Nm ) .

Place the pressure sensor and its mounting in theengine compartment before fitting the particle filter.

Tighten to torque:

- the exhaust bracket nuts between the connec-tion hose and the catalytic pre-converter ( 21Nm ) .

- the rubber mounting bush nuts on the sub-fra-me ( 25 Nm ) .

Fit the exhaust sleeve (see 19B, Exhaust : GeneralVehicle Information ) by applying sealing mastic forthe exhaust.

Tighten to torque the exhaust sleeve nut ( 25 Nm )at the same time as making sure that the exhaustpipe is correctly aligned.

Coat the downstream pressure measurement tap-ping threads with ANTI-SEIZE high temperaturegrease.

WARNING

When fitting the particle filter, be sure to pass thedownstream pressure measurement tappingbehind the heat shield.

WARNING

Make sure that the grease does not flow beyondthe threading.

106673

WARNING

All the adapters on the exhaust pipe (12) must bereplaced.

19B-36


F9Q, and 804

19B

Fit the rigid part of the downstream pressure measu-rement tapping then position it so that it is parallel (±±±±3˚ ) to the exhaust pipe longitudinal axis.

Tighten to torque the downstream pressuremeasurement tapping on its adapter ( 21 Nm )bolted to the exhaust pipe.


Tighten to torque:

- the connection clip bolt between the silencerand the particle filter ( 25 Nm ) ,

- the exhaust flange nuts between the connec-tion hose and the catalytic pre-converter ( 21Nm ) ,

- the nuts mounting the rubber mounting bushsupport onto the sub-frame ( 25 Nm ) .


106672

WARNING

Make sure, after tightening the pressure measu-rement tappings, that this pressure measurementtapping has no low points (siphon) susceptible towater accumulation.

To do this:

- check that the rigid sections of the pressurepipes are correctly positioned in relation to theexhaust pipe longitudinal axis,

- at the retaining clips, manipulate the pressuremeasurement tappings on the heat shield (turnthe tapping in the clip so as to avoid the lowpoints).

WARNING


19B-37


F9Q, and 804

19B

Use the diagnostic tool to clear any faults which maybe stored by the injection computer before restartingthe engine.

REINITIALISING THE PARTICLE FILTER PARAMETERS

Command RZ008: ADAPTATIVES AFTER REPLACEMENT OF THE PARTICLE FILTER

Command SC030 enables the parameters to be re-set to 0 depending on the type of operation carried out.

- PR391 : distance travelled since the particle filterwas last replaced,

- PR415 : distance travelled since the last regenera-tion

- PR412 : time since the last regeneration,

- PR383 : mass of soot in the particle filter.

Once the command has finished, check that the pa-rameters are at 0, so that the computer establishesa new regeneration strategy when driving and cansignal the system faults.

After repairing: Repeat the conformity check fromthe start.

WARNING

Connect the battery, starting with the positive ter-minal. carry out the necessary programming (see80A, Battery: Removal - Refitting ).

WARNING

With the engine running, carry out a leak test andcheck, using a leak detector for 5 minutes , thatthere is no leak on the adapters on the exhaustpipe.

Note:

This command is only carried out after replacingthe particle filter.

19B-38

EXHAUSTParticle filter pressure sensor: Removal - Refitting

F9Q, and 804

19B

(A) Particle filter pressure sensor.

(B) Upstream pressure measurement tapping endpiece.

(C) Downstream pressure measurement tappingend piece.

REMOVAL

Remove the particle filter (see 19B, Exhaust, Parti-cle filter: Removal and Refitting ).

Tightening torquesm

upstream pressuremeasurement tappingon its union bolted ontothe exhaust pipe

21 Nm

107038

C

B

A

19B-39


F9Q, and 804

19B

Remove the upstream pressure pipe (1) from its in-termediary adapter (2) bolted to the exhaust pipe.

Remove:

- the mounting nut (3) from the particle filter pressuresensor mounting (4) ,

- the particle filter pressure sensor:

106670

WARNING

When removing the pressure measurement tap-ping (1) from its adapter it is essential to openthe adapter (2) with a lock wrench.

WARNING

The pressure measurement circuit must never beopened except at the level of the adapters on theexhaust pipe.

1

2

111885

WARNING

Never separate the pressure measurement tap-pings (5) from the particle filter pressure sensor(6) ; replace the « sensor - pipes - end pieces »assembly if necessary, this is supplied assem-bled by the Parts Department (see Particlefilter : repair precautions, Safety instructions).

3

6

5

4

6

19B-40


F9Q, and 804

19BREFITTING

Coat the upstream pressure measurement tappingthreads with ANTI-SEIZE high temperature grease.

106673

WARNING

Each exhaust pipe intermediary adapter (7) thatis removed must be replaced.

WARNING


7

19B-41


F9Q, and 804

19B

Fit the rigid part of the upstream pressure measure-ment tapping then position it so that it is parallel ( ±±±±3˚ ) with the exhaust pipe longitudinal axis.

Tighten to torque the upstream pressure measure-ment tapping on its union bolted onto the ex-haust pipe ( 21 Nm ) .

Refit the particle filter (see 19B, Exhaust, Particlefilter: Removal - Refitting ).

Use the diagnostic tool to clear any faults which may

be stored by the injection computer before restartingthe engine.

106672

WARNING

Make sure, after tightening the pressure measu-rement tappings, that this pressure measurementline assembly has no low points (siphon) suscep-tible to water accumulation.

To do this:

- check that the rigid sections of the pressurepipes are correctly positioned in relation to theexhaust pipe longitudinal axis,

- at the retaining clips, manipulate the pressuremeasurement tappings on the heat shield (turnthe tapping in the clip so as to avoid the lowpoints).

19B-42

EXHAUSTParticle filter temperature sensors: Removal - Refitting

F9Q, and 804

19B

(A) Upstream particle filter temperature sensor

(B) Downstream particle filter temperature sensor

I - (A) UPSTREAM PARTICLE FILTER TEMPERATURE SENSOR

1 - Removal

Remove the particle filter (see 19B, Exhaust, Parti-cle filter: Removal - Refitting ).

Equipment required

diagnostic tool

Tightening torquesm

adapter, if it has beenreplaced

44 Nm

upstream particle filtertemperature sensor.

30 Nm

adapter, if it has beenreplaced

44 Nm

downstream particle fil-ter temperature sensor

30 Nm

Tightening torquesm

107038

19B-43


F9Q, and 804

19B

Remove the upstream particle filter temperaturesensor (1) from its adapter (2) bolted onto the ex-haust pipe.

2 - Refitting

Tighten to torque the adapter, if it has been repla-ced ( 44 Nm ) .

Coat the threads on the upstream particle filter tem-perature sensor with ANTI-SEIZE high temperaturegrease.

Tighten to torque the upstream particle filter tem-perature sensor. ( 30 Nm ) .

Check that:

- that there is no contact with the wiring harness,

- the extent of wear on the wiring harness.

Replace the wiring harness if necessary.


II - (B) DOWNSTREAM PARTICLE FILTER TEMPERATURE SENSOR

1 - Removal




Disconnect the downstream particle filter temperatu-re sensor offset connector (3) .

106671

WARNING

When the upstream particle filter temperaturesensor (1) is removed, the adapter must be held(2) with a lock-wrench.

WARNING

Always replace any adapter (2) that has beenremoved from the exhaust pipe.

WARNING


111882

19B-44


F9Q, and 804

19B

Unpick the downstream particle filter temperaturesensor offset connector (3) from its mounting.

Remove the downstream particle filter temperaturesensor (4) from its adapter (5) bolted onto the ex-haust pipe.

2 - Refitting

Tighten to torque the adapter, if it has been repla-ced ( 44 Nm ) .

Coat the threads on the downstream particle filtertemperature sensor with ANTI-SEIZE high tempera-ture grease.

Tighten to torque the downstream particle filtertemperature sensor ( 30 Nm ) .

Check that:

- there is no contact with the wiring harness,

- the extent of wear on the wiring harness.

Replace the wiring harness if necessary.


Connect the battery, starting with the positive termi-nal

Before restarting the engine, use the diagnostictool to clear any faults stored by the injection com-puter.

111885

106671

WARNINGWhen the downstream particle filter temperaturesensor (4) is removed, the adapter must be held(5) with a lock wrench.

WARNINGAlways replace any adapter (3) that has beenremoved from the exhaust pipe.

WARNING


WARNING

Carry out the necessary programming (see sec-tion 80A, Battery: Removing - Refitting ).

19B-45

EXHAUSTConnecting hose: Removal - Refitting

F9Q, and 804

19B

REMOVAL

Remove:

- the particle filter (see 19B, Exhaust, Particle fil-ter: Removal - Refitting ).

- the upstream temperature sensor and its adapteron the exhaust pipe (see 19B, Exhaust, Particlefilter temperature sensor: Removal - Refitting ).


Remove:

- the nuts for the exhaust flange between the con-nection hose and the particle filter,

- the connection hose.

REFITTING

Refit:

- the connection hose with new seals,

- the upstream temperature sensor and its adapteron the exhaust pipe (see 19B, Exhaust, Particlefilter temperature sensor: Removal - Refitting ).


Tighten to torque the exhaust flange nuts ( 21 Nm) between the connection hose and the particle filter.


Tightening torquesm

exhaust flange nuts 21 Nm

WARNING

Always replace:

- the flange seal between the connection hoseand the catalytic pre-converter,

- the flange seal between the connection hoseand particle filter,

WARNING

Always clean the bearing surfaces thoroughly on:

- the hose connection flanges for the catalyticpre-converter connection,

- the flange between the connection hose andthe particle filter,

19B-46

EXHAUSTParticle filter: Cleaning

F9Q, and 804

19BPROCEDURE FOR FORCED REGENERATION OF THE PARTICLE FILTER USING THE CLIP DIAGNOSTIC TOOL

Command SC017: REGENERATION OF THE PARTICLE FILTER

To run this command, select the specific com-mands mode on the Clip tool, and select commandSC017 or VP040 .

Follow this procedure:

- run command SC017 or VP040 ,

- during regeneration, the engine speed will be heldat 1500 rpm , and the engine noise changes (de-layed injection),

- the exhaust fumes rise in temperature and burn thesoot retained in the particle filter,

- the command lasts for approximately 30 minutes ,

- when the engine speed returns to idle speed thecommand has terminated,

- check the quantity of soot contained in the particlefilter PR383 < 10 .

Once forced regeneration of the particle filter is com-plete:

- deal with the present faults,

- clear the stored faults.

Allow the engine to cool down.


Replace the oil filter.

Top up the oil.

Note:

Only run this command under the following con-ditions:

- fault DF308 Particle filter clogged , or DF312Number of regenerations exceeded , orDF383 Particle filter regeneration impossiblepresent,

- soot weight in the particle filter greater than45 g .

IMPORTANT

During the forced regeneration of the particle fil-ter, the temperature in the exhaust pipe risessignificantly.

Try to carry out this procedure outside the works-hop if possible or use an exhaust gas extractorapproved for high temperatures.

WARNING

Check the engine oil level before running thecommand to avoid any engine racing.

The level should be between « MIN » and« MAX » on the dipstick.

Note:

If necessary, regeneration can be stopped bypressing the engine start button twice in succes-sion.

Note:

Be prepared for strong odours and thick smokeduring particle filter regeneration.

Note:

The level should be between « MIN » and« MAX » on the dipstick.

19B-47


F9Q

19B

PROCEDURE FOR PARTICLE FILTER FORCED REGENERATION USING THE CLIP DIAGNOSTIC TOOL

Connect the diagnostic tool to the vehicle.

For the particle filter forced regeneration procedure,see MR 366 or MR 372 Fault finding, 13B, Dieselinjection, Fault finding, Interpretation of com-mands, Particle filter regeneration .

When particle filter forced regeneration is complete, using the diagnostic tool:

- deal with the present faults,

- clear the stored faults.


Remove the oil filter using the (Mot. 1329) .

Coat the new oil filter sealing ring with engine oil.

Tighten the oil filter until the seal makes contact withthe engine.

Tighten the new oil filter manually 3/4 of a turn.

Wipe away any excess oil.

Remove the engine oil filler cap.


Remove the sump drain plug using the (Mot. 1018)or an 8 mm square male drain pipe union .

Allow all the engine oil to flow into a drain tray.



Mot. 1018 Sump plug tool.

Equipment required

diagnostic tool

kit for particle filter

Tightening torquesm

engine drain plug 20 Nm

rubber mountingbushes on the body

21 Nm

rubber mounting bushon the connector pipe

8 Nm

rubber mounting bushon the rear silencer

8 Nm

IMPORTANT

During forced regeneration of the particle filter,the temperature in the exhaust pipe rises signifi-cantly.

Be sure either to carry out the operation outsidethe workshop, or to use the kit for particle filter, approved for high temperatures, on the exhaustgas extractors in the workshop.

WARNING

To prevent engine racing, check the engine oillevel using the dipstick before running the forcedregeneration command.

The engine oil level must be between the« MIN » and « MAX » marks on the dipstick.

Note:

If required, the forced regeneration proceduremay be stopped by pressing the engine Start but-ton twice in succession.

Note:

Be prepared for strong odours and thick smokeduring particle filter forced regeneration.

IMPORTANT

Allow the engine to cool before draining the oil.

19B-48


F9Q

19BRubber-lipped seal

Refit the drain plug with its new seal (no fitting direc-tion).

Tighten to torque the engine drain plug ( 20 Nm ) .

Clean any traces of the drained oil from the sump.


Refill the engine oil.

Refit the filler plug.

Wait for 10 minutes .

Check the oil level using the dipstick.

Top up if necessary.

After any particle filter forced regeneration opera-tion, always replace:

- the particle filter rubber mounting bush on the axlesub-frame (see MR 364 or MR 370, 19B, Exhaust,Particle filter: Removal - Refitting ),

- the particle filter pressure sensor with its upstreamand downstream pressure measurement tappings(see MR 364 or MR 370, 19B, Exhaust, Particlefilter pressure sensor : Removal - Refitting ),

- the exhaust connector pipe rubber mounting bushon the body,

- the rear silencer rubber mounting bush on the bo-dy.

For the connector pipe and rear silencer rubber mounting bushes, tighten to torque:

- the mounting bolt of the rubber mounting busheson the body ( 21 Nm ) ,

- the mounting bolts of the rubber mounting bushon the connector pipe ( 8 Nm ) ,

- the mounting bolts of the rubber mounting bushon the rear silencer ( 8 Nm ) ,

113765

Note:

The engine oil level must be between the« MIN » and « MAX » marks on the dipstick.

19C-1

RESERVOIRDraining the fuel tank


19CDRAINING THE FUEL TANK

Disconnect the fuel inlet union (1) .

Position and fit a (3) « T » (Mot. 1311-08) union.

Fit a pipe (2) long enough to carry the fuel into a con-tainer to the « T » -union outlet.


Mot. 1311-08 Union for measuringfuel pressure

WARNING

During this operation, it is essential to:

- refrain from smoking or bringing red hot objectsclose to the work area,

- guard against petrol splashes caused by the resi-dual pressure in the pipes,


WARNING

The ignition must be switched off during this opera-tion.

K4J, and 730 or 732 – F4R, and 770 or 771 or 776

101496

1

2

3

19C-2



19C

Disconnect the fuel inlet union (1) .

Position and fit a (3) « T » (Mot. 1311-08) union.

Fit a pipe (2) long enough to carry the fuel into a con-tainer to the « T » -union outlet.

Remove the protection and switching unit cover.

Place the electrical connector (4) to one side withoutdisconnecting it.

Disconnect the brown connector (6) from the Protec-tion and Switching Unit.

K4M, and 760 or 761

101803

3

2

1

102502

102503

4

6

19C-3



19C

Connect terminal (5) of the brown connector to a +battery supply to operate the fuel pump.

Let the petrol flow out until it comes intermittently.

Disconnect the + battery supply from terminal (5) .

102501

Note:

It is also possible to use the pneumatic siphoningPump tool for draining the fuel tank (see catalo-gue entitled Equipment) , to be adapted on theunion at « T » (Mot. 1311-08) .

1

5

12

19C-4


C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732

19C

DRAINING THE FUEL TANK


Lift up the cushion from the rear bench seat (seeWorkshop repair Manual 365 Bodywork, 76A,Rear seat mountings and runners, Completeseat base ).

Remove the carpet retaining clip.

Take out the carpet.

Remove:

- the closure panel mounting bolts (1) ,

- the closure panel,

- the inspection flap blanking cover (2) .

Equipment required

petrol or diesel tank drain pneumatic siphoningpump

IMPORTANT


- refrain from smoking or bringing red hot objectsclose to the work area,



99641

Note:

Since diesel vehicles are not fitted with an electri-cal fuel pump, the petrol or diesel tank drainpneumatic siphoning pump tool must be usedto drain the tank.

102460

102461

2

11

19C-5


C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732

19C

Disconnect:

- the fuel tank sender connector (3) ,

- the body height sensor connector (4) (if fitted),

- union (5) .

Make preparations for the fuel outflow.

Connect the rubber suction pipe of the petrol or die-sel tank drain pneumatic siphoning pump to thediesel fuel supply quick-release union, and the si-phoning pump's backflow pipe to the container (5) .

Run the petrol or diesel tank drain pneumatic si-phoning pump .

Let the fuel flow out until it comes intermittently.

Drain the tank.



102462

WARNING


5

4 3

19C-6

RESERVOIRFuel tank: Description

F4R or K4J or K4M

19C

102487

10

9

8

7

65

5

4

3

13

2

2

2

22

12

1

11

No. Description

1 Tank

2 Mounting holes

3 Filler neck

4 Neck mounting clips

5 Brake pipe retaining clips

6 Fuel supply pipe

7 Petrol vapour supply pipe

8 Petrol vapour absorber supply pipe (from the tank)

9 Fresh air vent

10 Petrol vapour absorber

11 Overfill prevention valve and leak prevention valve in case of vehicle roll-over

12 Anti-backflow pipe (degassing - filling)

13 Petrol suction assembly

19C-7


F4R or K4J or K4M

19C

13036

10

9

8

7

6

5

4

3

2

1

No. Description

1 Connection to petrol vapour absorber

2 Overfill prevention ball

19C-8


F4R or K4J or K4M

19C

ROLE OF THE FILLER NECK AND VALVES

1 - Overpressure/underpressure safety valves

If the petrol vapour recirculation circuit is blocked, thisvalve prevents the fuel tank being subjected to excesspressure (the tank expands) or underpressure (as fuelis used, the tank collapses).

2 - Restriction valve

This valve prevents diesel fuel or leaded petrol pumpnozzles from entering the tank.

3 - Overfill prevention valve and vehicle roll-over leak prevention valve

The ball acts as an overfill prevention valve.

When the vehicle is stationary, during filling, the ballrests on its seat, retaining a specific volume of air in thetank.

When the vehicle is moving, the ball leaves its seat,enabling a connection between the tank and the petrolvapour absorber.

When the tank is full, a sufficient volume of air to allowthe fuel contained within it to expand must remain inthe tank, but not so much as to make the tank burst.

The vehicle roll-over leak prevention valve preventsthe fuel tank from emptying via the pipe to the petrolvapour absorber.

4 - Filler neck

The filler neck for unleaded petrol has the following:

- a smaller diameter filling opening (restriction valve).Leaded petrol damages the toxic fume filter system:catalytic converter and oxygen sensor,

- a valve blocking the filling opening (to prevent petrolvapour release or backflow of petrol),

- a leak-tight cap.

3 Filling anti-backflow pipe

4 Restriction valve

5 Excess pressure/underpressure safety valve

6 Air outlet hole during filling

7 Volume of air allowing fuel expansion

8 Fuel inlet for filling

9 Usable fuel volume

10 Overfill prevention valve and vehicle roll-over leak prevention valve

No. Description

19C-9



19C

110881

3

2

2

222

1

10

8

9

7

65

4

No. Description

1 Tank

2 Mounting holes

3 Filler neck

4 Neck mounting clips

5 Brake pipe retaining clips

6 Fuel supply pipe

7 Fuel return pipe

8 Drying the reservoir and leak prevention valve in case of vehicle roll-over

9 Anti-backflow pipe (degassing - filling)

10 Diesel suction assembly

19C-10



19C

13036-1

3

2

1

8

7

6

5

4

No. Description

1 Fresh air vent

2 Overfill prevention ball

19C-11



19C

ROLE OF THE FILLER NECK AND VALVES

1 - Overfill prevention valve and vehicle roll-over leak prevention valve

The ball acts as an overfill prevention valve.

When the vehicle is stationary, during filling, the ballrests on its seat, retaining a specific volume of air in thetank.

When the vehicle is moving, the ball leaves its seat,thus allowing the reservoir to be open to the air.

When the tank is full, a sufficient volume of air to allowthe diesel fuel contained within it to expand must re-main in the tank, but not so much as to make the tankexplode.

The vehicle roll-over leak prevention valve preventsthe fuel tank from emptying via the air pipe.

2 - Filler neck

The filler neck for unleaded fuel has a leaktight cap.

3 Filling anti-backflow pipe

4 Air outlet hole during filling

5 Volume of air allowing fuel expansion

6 Fuel inlet for filling

7 Usable fuel volume

8 Drying the reservoir and leak prevention valve in case of vehicle roll-over

No. Description

19C-12

RESERVOIRFuel tank: Removal - Refitting 19C

REMOVAL

Drain the fuel tank (see 19C, Fuel tank, Drainingthe fuel tank ).

Remove the « pump-sender-filter » assembly (see19C, Fuel tank, Pump-sender-filter ) for petrol en-gines or the sender (see 19C, Fuel tank, Sender )for diesel engines.



Remove:


- the nuts mounting the exhaust clamp on the mani-fold,

- the bolt mounting the expansion chamber on thebody,

- the bolts connecting the silentbloc mounting to thesilencer,

- the exhaust pipe from the sub-frame and the rearaxle.

Disconnect the headlight height adjustment sensorwiring (depending on vehicle equipment level).

Unclip the headlight height adjustment sensor linka-ge (depending on vehicle equipment level).

Remove the petrol vapour absorber (see 14A, Anti-pollution, Petrol vapour absorber ).

Unclip the petrol vapour absorber pipes.

Disconnect the connectors on the « Pump-Sender-Filter » assembly (see 19C, Fuel tank, Pump-Sen-der-Filter ).

Remove:

- the mounting bolts (1) from the fuel tank and theheat shield,

- the heat shield mounting clips (2) ,

- the heat shield (3) .

Equipment required

component jack

Tightening torquesm

wheel bolt 110 Nm

fuel tank mounting 21 Nm


4 Nm

IMPORTANT


- refrain from smoking or bringing red-hot objectsnear the working area,

- watch out for fuel splashes when disconnectingthe union,


F4R or K4J or K4M

102465

3

2

1

19C-13


Remove mounting clips (4) from the brake and fuelpipes.

Unclip:

- the fuel pipe unions at the catalytic converter,

- the clips from the fuel pipes.

Remove fuel tank filler neck hose connection clips(5) .

Move the hoses to one side.

Position the component jack under the tank.

Remove the fuel tank mounting bolts (6) .

Lower the fuel tank.

Remove the tank by turning it around the exhaust pi-pe.

Take care not to damage the brake pipes or the par-king brake cable.

102467

102468

444

5

102466

102459

66

19C-14


REFITTING

Reshape the heat shield.

Take care not to bring the heat shield into contactwith the fuel tank.

The tank hose securing clips must always be repla-ced.


Tighten to torque:

- the wheel bolt ( 110 Nm ) ,

- the fuel tank mounting ( 21 Nm ) .

Check that the fuel pipe unions click into place.

Refit the « pump-sender-filter » assembly (see 19C,Fuel tank, Pump-sender-filter ) for petrol enginesor the sender (see 19C, Fuel tank, Sender ) for die-sel engines.



WARNING


19C-15

RESERVOIRFiller neck: Removal - Refitting 19C

REMOVAL

Drain the fuel tank (see 19C, Fuel tank, Drainingthe fuel tank ).



Remove:

- the rear right-hand wheel,

- the rear right-hand wheel arch liner.

Disconnect the anti-backflow pipe (1) .

Remove filler pipe clips (2) .

Remove the filler neck mounting bolts (3) .

Remove:

- the filler neck mounting bolts (4) ,

- the filler neck.

REFITTING

Always replace the clips with new ones.



Tightening torquesm


4 Nm

IMPORTANT


- refrain from smoking or bringing red hot objectsnear the working area,

- watch out for fuel splashes when disconnectingthe union,


102468

2 1

102469

104559

WARNING


3

4

19C-16

RESERVOIRFiller neck: Removal - Refitting 19C


19C-17

RESERVOIRSender unit: Removal - Refitting

F9Q or K9K or M9R

19C


Lift up the rear bench seat base (see MR 365 Bo-dywork, 76A, Rear seat runners and frames,Complete seat base ).


Move the carpet to one side.

Remove:



- the blanking cover (2) on the inspection flap.


Mot. 1397 Universal spanner forremoving fuel sendernut

Tightening torquesm


4 Nm

IMPORTANT





102461

19C-18


F9Q or K9K or M9R

19C

Disconnect:

- electrical connectors (3) ,

- quick-release union(s) (4) .

Prepare for fuel outflow.

Fit the correct blanking plugs into the unions (seeMR 364 Mégane, 13B, Injection: Cleanliness gui-delines ).

Remove the nut from the sender using tool (Mot.1397) (5) .

Remove the sender unit, being careful with the float.

104546 104547

WARNING

Refit the sender nut as soon as the sender hasbeen removed to prevent any deformation of thefuel tank.

19C-19


F9Q or K9K or M9R

19CREFITTING

Replace the O-ring seal.

Refit the sender unit by aligning mark (6) on the sen-der with mark (7) on the tank.

Position nut (9) .

Tighten the nut (9) until mark (8) on the nut is alignedwith mark (7) on the tank and mark (6) on the sen-der.


Connect the battery starting with the positive termi-nal (see MR 364 Mégane, 80A, Battery: Removal -Refitting ).


102470

19C-20

RESERVOIRPump-sender unit-filter: Removal - Refitting

K4M – F4R – K4J

19C


Lift up the rear bench seat base (see MR 365 Bo-dywork, 76A, Rear seat runners and frames,Complete seat base ).


Move the carpet to one side.

Remove:



- the blanking cover (2) on the inspection flap.

Disconnect:

- electrical connectors (3) ,

- quick-release union(s) (4) .

Prepare for fuel outflow.


Mot. 1397 Universal spanner forremoving fuel sendernut

Tightening torquesm


4 Nm

IMPORTANT





102461

104546

11

2

19C-21

RESERVOIRPump-sender unit-filter: Removal - Refitting

K4M – F4R – K4J

19C

Remove the nut from the pump/sender/filter assem-bly using tool (Mot. 1397) (5) .

Remove the pump/sender/filter assembly, being ca-reful not to damage the float.

REFITTING

Replace the O-ring seal.

Refit the pump/sender/filter assembly, aligning mark(6) on the pump/sender/filter assembly with mark (7)on the tank.

Position the nut (9) .

Tighten the nut (9) until the mark (8) on the nut is ali-gned with mark (7) on the tank and mark (6) on thepump/sender/filter assembly.


Connect the battery starting with the positive termi-nal (see MR 364 Mechanical systems, 80A, Batte-ry: Removal - Refitting ).


104547

WARNING

Refit the pump/sender/filter assembly nut assoon as the pump/sender/filter assembly hasbeen removed to prevent any deformation of thefuel tank.

102470

19C-22

RESERVOIRPetrol filter: General information


19C

The fuel filter is located in the fuel tank; it is built intothe « pump-sender-filter » assembly and cannot be re-moved.

The filter is intended to have a long service life.

Checking the fuel supply pressure and the pump deli-very rate is the equivalent of running fault finding on the« pump-sender-filter » assembly.

102299

WARNING

The « pump-sender-filter » assembly must be repla-ced if one of the components is faulty.

19C-23

RESERVOIRFuel level sensor: Checking 19C

Checking the sender unit

MEASURING HEIGHT H

Place the removed sender on a flat surface.

H is the height measured between the float pin andthe working plane.

Capacity Resistance value between terminals A1 and B2 (Ω) ±±±± 10 Ω

Height H (mm) ±±±± 6mm

Tank full 20 upper stop

Tank 3/4 full 95 150

Tank 1/2 full 170 111

Tank 1/4 full 245 72

Spare 290 40

Tank empty 320 lower stop

Note:

All these values are given as a guide.

19D-1

ENGINE MOUNTINGSuspended engine mounting

K4J, and 730 or 732 – K4M, and 760, and JR5

19D

Tightening torques (in Nm)

103235

6554

33

2

11

7

(1) 62

(2) 105

(3) 62

(4) 105

(5) 62

(6) 180

(7) 62

19D-2


K9K, and 722 or 728

19D


103236

2

1

1

10

7

7

8

9

66

44

333

5

(1) 62

(2) 105

(3) 62

(4) 105

(5) 62

(6) 62

(7) 21

(8) 62

(9) 180

(10) 62

19D-3


F9Q, and 800 or 804 or 808

19D


103237

10

99

888

7 6 12

555

44433

2

111

11

(1) 62

(2) 105

(3) 105

(4) 62

(5) 62

(6) 180

(7) 105

(8) 62

(9) 21 for M8 bolts

62 for M10bolts

(10) 62

(11) 180

(12) 62

19D-4


K4M, and 761

19D


103274

33

2

11

7

8

8

9

6

55

4

(1) 62

(2) 105

(3) 62

(4) 105

(5) 62

(6) 180

(7) 62

(8) 21 for M8 bolts

62 for M10bolts

(9) 62

19D-5


F4R, and 770 or 771 or 776

19D


103275

7

3

6

2

55

9

9

12

11

10

88

1

11

44

(1) 62

(2) 105

(3) 105

(4) 62

(5) 62

(6) 180

(7) 105

(8) 62

(9) 21

(10) 62

(11) 180

(12) 62

19D-6


F4R, and 770 or 771 or 776

19D


103244

11

1010

99

9

888

7 6

555

13

444

33

2

11

1

12

(1) 62

(2) 105

(3) 105

(4) 62

(5) 62

(6) 180

(7) 105

(8) 62

(9) 21

(10) 62

(11) 180

(12) 62

19D-7



19D


110743

9

77

77

11

1

666544

3333

2

8

(1) 62

(2) 105

(3) 62

(4) 105

(5) 62

(6) 62

(7) 62

(8) 62

(9) 62

19D-8


K9K, and 732

19D


113926

(1) 62

(2) 62

(3) 105

(4) 115

(5) 62

(6) 180

(7) 105

(8) 62

(9) 105

(10) 62

(11) 62

19D-9

ENGINE MOUNTINGSuspended engine mounting: Tightening torque

K9K, and 732

19D

113926

No. Description Tightening

torque

(Nm)

(1) Bolt mounting the lower engine tie-bar on the sub-frame 105

(2) Bolt mounting the lower engine tie-bar onto its support 180


(4) Bolt mounting the upper engine tie-bar onto the bodywork 105

(5) Bolt mounting the upper engine tie-bar onto the engine 115

(6) Bolt mounting the right-hand suspended mounting support on the body 62

(7) Bolt mounting the right-hand suspended mounting support on the engine 62

(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 62

(9) Bolt mounting the left-hand suspended mounting support on the body 62

(10) Left-hand rubber pad mounting nut on the gearbox mounting 62

(11) Left-hand rubber pad mounting bolts on the body mounting 105

19D-10


M9R, and 700

19D

114630

No. Description Tightening tor-que (Nm)

(1) Bolt mounting the lower engine tie-bar on the sub-frame 105


(3) Lower engine tie-bar support mounting bolt 62

(4) Bolt mounting the upper engine tie-bar onto the bodywork 105

(5) Bolt mounting the upper engine tie-bar onto the engine 115

(6) Bolt mounting the right-hand suspended mounting support on the body 62

(7) Bolt mounting the right-hand suspended mounting support on the engine 62

(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 105

(9) Bolt mounting the left-hand suspended mounting support on the body 62

(10) Left-hand rubber pad mounting nut on the gearbox mounting 62

(11) Left-hand rubber pad mounting bolts on the body mounting 62

19D-11



19D

106075

No. Tightening torque (Nm)

(1) 62

(2) 105

(3) 105

(4) 62

(5) 62

(6) 180

(7) 105

(8) 62

(9) 62

(10) 21

(11) 105

(12) 180

(13) 62

19D-12

ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting

K9K, and 732

19D

REMOVAL



Remove:


- the scuttle panel grille (see MR365 Bodywork,55A, Exterior protection, Scuttle panel grille ),

- the battery (see 80A, Battery: Removal - Refit-ting ).

Disconnect the engine management computer con-nectors (1) .

Unclip:

- the battery negative terminal wiring harness,

- the wiring harness from the battery tray.

Remove:


- the battery tray with the computer and its support.


Mark the position of the suspended mounting on thebody.



Tightening torquesm

left-hand suspendedmounting bolts on thegearbox

62 Nm

left-hand suspendedmounting bolts on thebody

62 Nm

left-hand rubber padmounting bolts on thebody mounting

105 Nm

left-hand rubber padmounting nut on thegearbox mounting

62 Nm

101822

102450

19D-13

ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting

K9K, and 732

19DII - OPERATION FOR REMOVAL OF PART CONCERNED

Remove:

- the left-hand rubber pad mounting nut (3) on thegearbox mounting,

- the left-hand rubber pad mounting bolts (4) on thebody mounting,

- the rubber pad,

- the bolts (5) mounting the left-hand suspendedmounting on the body,

- the left-hand suspended mounting on the body,

- the bolts (6) mounting the left-hand suspendedmounting on the gearbox.

- the gearbox left-hand suspended mounting.

REFITTING


Refit the gearbox left-hand suspended mounting.

Refit the bolts mounting the left-hand suspendedmounting on the gearbox.

Tighten to torque the left-hand suspended moun-ting bolts on the gearbox ( 62 Nm ) .

Refit the left-hand suspended mounting on the body.

Refit the bolts mounting the left-hand suspendedmounting on the body,

Tighten to torque the left-hand suspended moun-ting bolts on the body ( 62 Nm ) .

Refit the left-hand rubber pad.

Refit the left-hand rubber pad mounting nut onto thegearbox mounting and the left-hand rubber padmounting bolts onto the body mounting.

Tighten to torque:

- the left-hand rubber pad mounting bolts on thebody mounting ( 105 Nm ) ,

- the left-hand rubber pad mounting nut on thegearbox mounting ( 62 Nm ) .



Refit:

- the battery tray with the engine management com-puter and its support,

- the battery tray mounting bolts.

Clip:

- the battery negative terminal wiring harness,

- the wiring harness onto the battery tray.

Connect the engine management computer connec-tors.

Refit:

- the scuttle panel grille (see MR 365, 55A, Exteriorprotection, Scuttle panel grille ),



112655

19D-14

ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - Refitting

K9K, and 732

19D

REMOVAL




Remove the scuttle panel grille (see MR 365, Bo-dywork, 55A, Exterior protection, Scuttle panelgrille ).


Mark the position of the suspended mounting on thebody.


Remove:

- the upper engine tie-bar mounting bolt (2) on theengine,

- the upper engine tie-bar mounting bolt (1) on thebody,


- the bolts (3) mounting the suspended mounting onthe body,



Tightening torquesm

bolts mounting theright-hand suspendedmounting on the body

62 Nm

bolts mounting theright-hand suspendedmounting support on theengine

62 Nm

upper engine tie-barmounting bolt on theengine

115 Nm

upper engine tie-barmounting bolt on thebody

105 Nm

102450

113927

19D-15

ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - Refitting

K9K, and 732

19D- the bolts (4) mounting the suspended mounting onthe engine,

- the suspended mounting.

REFITTING


Refit:

- the right-hand suspended mounting support,

- the bolts mounting the right-hand suspendedmounting support on the body,

- the bolts mounting the right-hand suspendedmounting on the engine,


- the upper engine tie-bar mounting bolt onto the bo-dy,

- the upper engine tie-bar mounting bolt onto the en-gine,

Tighten to torque:

- the bolts mounting the right-hand suspendedmounting on the body ( 62 Nm )

- the bolts mounting the right-hand suspendedmounting support on the engine ( 62 Nm )

- the upper engine tie-bar mounting bolt on theengine ( 115 Nm )

- the upper engine tie-bar mounting bolt on thebody ( 105 Nm )


Remove the (Mot. 1453)

Refit the scuttle panel grille (see MR 365, Bo-dywork, 55A, Exterior protection, Scuttle panelgrille ).

Connect the battery (see 80A, Battery: Removal -Refitting).

19D-16

ENGINE MOUNTINGRear suspended engine mounting: Removal - Refitting

K9K, and 732

19D

REMOVAL




Remove the engine undertray


Remove:

- the bolt mounting the engine tie-bar on the sub-fra-me (1) ,

- the bolt mounting the engine tie-bar on its support(2) .

REFITTING


Refit:

- the bolt mounting the engine tie-bar on its support

- the bolt mounting the engine tie-bar on the sub-fra-me

Tighten to torque:

- the bolt mounting the engine tie-bar on its sup-port ( 180 Nm ) ,

- the bolt mounting the engine tie-bar on the sub-frame ( 105 Nm ) .




Tightening torquesm

bolt mounting theengine tie-bar on itssupport

180 Nm

bolt mounting theengine tie-bar on thesub-frame

105 Nm

112653

19D-17

ENGINE MOUNTINGRear suspended engine mounting: Removal - Refitting

M9R, and 700

19D

REMOVAL






Remove:

- the bolt mounting the engine tie-bar on the sub-fra-me,

- the bolt mounting the engine tie-bar on its support.

Remove the engine tie-bar.

- by pushing it back (1) to detach it from its support,

- by pivoting it (2) to the right.

REFITTING


Refit:

- the bolt mounting the engine tie-bar on its support

- the bolt mounting the engine tie-bar on the sub-fra-me

Tighten to torque:

- the bolt mounting the engine tie-bar on its sup-port ( 180 Nm ) ,

- the bolt mounting the engine tie-bar on the sub-frame ( 105 Nm ) .




Tightening torquesm

bolt mounting theengine tie-bar on itssupport

180 Nm

bolt mounting theengine tie-bar on thesub-frame

105 Nm

114650

114632

Date post:	23-Oct-2014
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MR364MEGANE1-1

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