Engine and peripherals 10A ENGINE AND CYLINDER BLOCK ASSEMBLY 11A TOP AND FRONT OF ENGINE 12A FUEL MIXTURE 12B TURBOCHARGING 13A FUEL SUPPLY 13B DIESEL INJECTION 13C PREHEATING 14A ANTIPOLLUTION 16A STARTING - CHARGING 17A IGNITION 17B PETROL INJECTION X79 NOVEMBER 2009 "The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared.
19A COOLING 19B EXHAUST 19C TANK 19D ENGINE MOUNTING X79 NOVEMBER 2009 "The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared. The procedures may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are constructed". EDITION ANGLAISE All rights reserved by Renault.
DUSTER - Chapitre 1 DUSTER - Chapitre 1ContentsPages Contents Pages 10A ENGINE AND CYLINDER BLOCK ASSEMBLY 11A TOP AND FRONT OF ENGINE Crankshaft seal on timing end: Removal - Refitting 10A-1 Pressure at end of compression: Check 11A-1 Crankshaft seal, gearbox end: Removal - Refitting 10A-5 Accessories belt: Removal Refitting 11A-2 Lower cover: Removal Refitting 10A-9 Crankshaft accessories pulley: Removal - Refitting 11A-10 Conrod bearing shell: Removal - Refitting 10A-24 Timing belt:
Contents 12A 12B 13A DIESEL INJECTION Throttle valve: Removal Refitting 12A-11 Crankshaft position sensor: Removal - Refitting 13B-8 Inlet distributor: Removal Refitting 12A-12 High pressure pump: Removal - Refitting 13B-9 Injector holder shim: Removal - Refitting 12A-14 Flow actuator: Removal Refitting 13B-14 Exhaust manifold: Removal Refitting Venturi: Removal - Refitting 13B-16 12A-16 High pressure pipe: Check 13B-18 High pressure pipe between pump and rail: Removal Refitting 13B-
Contents 14A ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal Refitting 14A-4 Exhaust gas cooler: Removal - Refitting 14A-7 Exhaust gas recirculation assembly: Removal Refitting Exhaust gas recirculation rigid pipe: Removal Refitting 16A 14A-12 Alternator: Removal Refitting 16A-1 Starter: Removal - Refitting 16A-8 16A-12 IGNITION Coils: Removal - Refitting 17B 14A-9 STARTING - CHARGING Alternator pulley: Removal Refitting 17A 19A 17A-1 COOLING Engine cooling system: Opera
Contents 19B 19C 19D EXHAUST Intermediate pipe: Removal Refitting 19B-18 Silencer: Removal - Refitting 19B-20 TANK Fuel tank: Draining 19C-1 Fuel tank: Removal Refitting 19C-3 Fuel level sensor module: Removal - Refitting 19C-8 ENGINE MOUNTING Suspended engine mounting: Tightening torque 19D-1 Left-hand suspended engine mounting: Removal Refitting 19D-2 Right-hand suspended engine mounting: Removal Refitting 19D-4 Lower engine tie-bar: Removal - Refitting 19D-8
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 10A K9K REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 10A K9K REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft seal on timing end. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 10A K9K 20772 20770 a Screw the threaded rod (10) of theinto the crankshaft. a Fit the protector with the new seal in place on the spacer, taking care not to touch the seal. 20771 20769 a On the crankshaft, fit the spacer (11) of the. a Fit the cover (12) and nut (13) (with the thread (14) of the nut towards the outside of the engine) of the.
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal on timing end: Removal - Refitting 10A K9K 20768 20766 a Remove the nut, the cup, the protector and the threaded rod. III - FINAL OPERATION a Refit: - the timing belt sprocket (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) , - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres).
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 10A K4M or K9K REMOVAL K9K I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 10A K4M or K9K II - REFITTING OPERATION K9K 22760 a Extract the crankshaft seal at the gearbox end by screwing the threaded rod (7) . 18687 a Note: REFITTING This type of seal is extremely fragile. I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft seal on gearbox end. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 10A K4M or K9K 20760 20762 a Mount theon the crankshaft, securing it using bolts (10) . a Fit the cover (11) and nut (12) (with the thread (13) of the nut towards the outside of the engine) of the. 20761 20763 a Fit the protector with its seal in place on the, taking care not to touch the seal. a Tighten the nut until the cover touches the cylinder block.
ENGINE AND CYLINDER BLOCK ASSEMBLY Crankshaft seal, gearbox end: Removal - Refitting 10A K4M or K9K K4M 20764 134544 a Refit the crankshaft seal at the gearbox end, using the tool (14) . III - FINAL OPERATION a Refit: - the flywheel (see 10A, Engine and cylinder block assembly, Flywheel: Removal - Refitting, page 10A-75) (20A, Clutch), - the clutch (see Pressure plate - Disc: Removal Refitting) (20A, Clutch), 20765 a Remove the nut, the cover, the protector and the base plate.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K a Remove: Special tooling required Tav. 1747 - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), Threaded rods for carrying out subframe operations. - the front wheel arch side liners, - the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, page 19D-8) . Tightening torquesm oil pump bolts 25 N.m sump bolts on the cylinder block 14 N.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K 24762 a Remove the power-assisted steering low pressure pipe bolt (2) on the front axle subframe. 144756 a Remove the front axle subframe tie-rod upper bolts (5) . 145789 a Remove the cooling pipe support bolt (3) on the sump. 135708 a Remove: - the right-hand driveshaft flange bolt (9) on the relay bearing, - the bolts (10) from the relay bearing, - the relay bearing.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K 144755 a Remove: - the bracket bolts (12) , - one by one, the front axle subframe bolts (11) and replace them in turn with the threaded rods of the (Tav. 1747). 108645 Note: Make sure the threaded rod of the (Tav. 1747) is sufficiently screwed into the threaded hole and that the nut of the tool is correctly resting on the front axle subframe.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K II - REMOVAL OPERATION STANDARD HEATING RECIRCULATION 107936 a Remove: - the engine-gearbox coupling bolts (14) , 24761 - the sump bolts, a Remove the power-assisted steering pump support bolt (13) on the sump. - the sump. Note: If the sump cannot be extracted because it is in contact with the oil pump strainer, do not force the removal of the sump as this may damage the oil splash plate.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K a Clean the cylinder block joint face using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting K9K II - REFITTING OPERATION 20170 a Note: When refitting the sump, ensure that: - the oil splash plate tabs (17) are positioned correctly in the slots (18) , - the coupling faces of the sump and cylinder block are correctly aligned, to prevent the clutch housing being deformed when fitting the gearbox. Refit the oil splash plate.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K9K Note: If the oil pump was loosened beforehand in order to extract the sump, position the sump in order to slide the oil pump strainer into the oil splash plate of the sump. Position a component jack to support the sump. Lean the sump towards the front of the vehicle in order to access the oil pump bolts. Torque tighten the oil pump bolts (25 N.m) using the small torque wrench 77 11 226 888.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting K9K a One by one, remove the threaded rods of the (Tav. 1747) and replace them in turn with new front axle subframe bolts. a Refit: - the relay bearing bolts, - the right-hand driveshaft flange bolt(s) on the relay bearing. a Tighten to torque and in order: - the relay bearing bolts (44 N.m), - the right-hand driveshaft flange bolt(s) on the relay bearing (21 N.m). a Refit the front axle subframe tie-rod upper bolts.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M a Remove: Special tooling required Tav. 1747 - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres), Threaded rods for carrying out subframe operations. - the front wheel arch side liners, - the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, page 19D-8) . Tightening torquesm sump bolts on the cylinder block 14 N.m sump bolts on the gearbox 44 N.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M 145789 a Remove the cooling pipe support bolt (2) on the sump. 135708 a Remove: - the right-hand driveshaft flange bolt (5) on the relay bearing, - the bolts (6) from the relay bearing, - the relay bearing. 144756 a Remove the front axle subframe tie-rod upper bolts (4) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M 144755 a Remove: - the bracket bolts (11) , - one by one, the front axle subframe bolts (10) and replace them in turn with the threaded rods of the (Tav. 1747). 108645 Note: Make sure the threaded rod of the (Tav. 1747) is sufficiently screwed into the threaded hole and that the nut of the tool is correctly resting on the front axle subframe.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M a Clean the cylinder block joint face using SUPER CLEANING AGENT FOR JOINT FACES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). II - REMOVAL OPERATION WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M II - REFITTING OPERATION 20166 20170 a Note: When removing the sump, ensure that: - the oil splash plate tabs (15) are positioned correctly in the slots (16) , - the coupling faces of the sump and cylinder block are correctly aligned, to prevent the clutch housing being deformed when fitting the gearbox. Refit the oil splash plate.
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting 10A K4M - the sump bolt on the multifunction support (25 N.m). III - FINAL OPERATION a Fit the front axle subframe. a Refit the brackets. a Torque tighten the bracket bolts (62 N.m). a One by one, remove the threaded rods of the (Tav. 1747) and replace them in turn with new front axle subframe bolts. K4M a Torque tighten the front axle subframe bolts (110 N.m).
ENGINE AND CYLINDER BLOCK ASSEMBLY Lower cover: Removal - Refitting K4M a Refit the front bumper (see Front bumper assembly: Exploded view) and (see Exterior body front trim assembly: Exploded view) (55A, Exterior protection). a Refit: - the engine undertray, - the front wheel arch side liners, - the front wheels (see Wheel: Removal - Refitting) (35A, Wheels and tyres). a Top up the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-32) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K a Strap the radiator to the vehicle using safety strap(s). Equipment required a Remove the front axle subframe (see Front axle subframe: Removal - Refitting) (31A, Front axle components). safety strap(s) component jack indelible pencil torque wrench Diagnostic tool Tightening torquesm con rod cap bolts 20 N.m + 45˚ ± 6˚ oil pump bolts 25 N.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K 112328 a Remove the catalytic converter upstream stay (3) . 140917 a Tilt the engine oil sump forwards in order to access the oil pump bolts. a Partially loosen the oil pump bolts 3 mm to 5 mm. a Detach the oil pump from its position in order to remove the engine oil sump. a Remove: - the engine oil sump, - the engine oil sump seal, - the oil pump.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K II - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2 139300 139306 a Remove: - the con rod bolts, a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean the big ends. - the con rod cap, - the lower con rod bearing shell. a Mark the position of the con rod cap in relation to the con rod body using a indelible pencil.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K 139310 a Fit the tie rod of the toolon the con rod body. 139315 a a Push the con rod upwards to release the con rod from the crankpin. WARNING Failure to observe the following procedure may damage the piston base cooling jets. a Turn the crankshaft 90˚ clockwise (timing end). Pull the con rod - piston assembly using the tie rod of the tool, taking care not to allow the piston to touch the piston base cooling jets.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K a Note: Always replace con rod bearing shells with a width of 20 mm by con rod bearing shells with a width of 18 mm. If the set of con rod bearing shells only includes con rod bearing shells which are 18mm wide, only use the head of the toolwith the marking " K9K SUP ". Fit the head of the toolwith the marking " K9K INF " on the threaded sleeve of the tool. a Position the lower con rod bearing shell on the tool.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K II - REMOVAL - REFITTING OPERATIONS FOR THE CON ROD BEARING SHELLS ON CYLINDERS NO.3, 1 AND 4 a Perform the same removal - refitting operations as for the con rod bearing shells on cylinder no. 2. Note: For removing and refitting the con rod bearing shells on cylinders no. 1 and no.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting 10A K9K 20166 140918 a Tilt the engine oil sump forwards in order to access the oil pump bolts. a Torque tighten the oil pump bolts (25 N.m) using the torque wrench PROSTEEL, part number 77 11 226 888 starting with the 13 mm bolt. a Note: Check that the engine oil sump seal is definitely in place before tightening the engine oil sump bolts. a Refit the engine oil sump bolts.
ENGINE AND CYLINDER BLOCK ASSEMBLY Conrod bearing shell: Removal - Refitting K9K 123824 a Disconnect the crankshaft position sensor (4) to prevent the engine from starting. a Refit the oil filter (see 10A, Engine and cylinder block assembly, Oil filter: Removal - Refitting, page 10A-34) a Fill up the engine oil (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-32) . a Start the engine using the starter until the engine oil warning light goes out.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling 10A K4M or K9K III - PARTS AND CONSUMABLES FOR REPAIR a parts always to be replaced: Drain plug seal on engine oil sump. Equipment required oil recovery tray a Consumable: oil change wrench - Engine oil (see Engine oil: Specifications) . torque wrench IV - OIL SERVICE oil change end piece with an 8 mm square drive a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine oil: Draining - Refilling 10A K4M or K9K V - FILLING a Fill the engine with oil, respecting the recommended quantity. a Wait at least 10 minutes. a Check the oil level using the dipstick. a Top up the engine oil level if necessary. a Refit: - the engine oil filler cap, - the dipstick. 144757 a Remove the drain plug (2) using theor a oil change wrench. a Let the engine oil flow out completely. a Remove the drain plug seal.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting 10A K9K REFITTING Special tooling required Mot. 1329 Oil filter removing tool (76 mm diameter) I - REFITTING PREPARATION OPERATION a parts always to be replaced: Oil filter. a Lubricate the new oil filter seal with new engine oil. WARNING II - REFITTING OPERATION FOR PART CONCERNED Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine).
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting 10A K4M II - REMOVAL OPERATION Special tooling required Mot. 1329 Oil filter removing tool (76 mm diameter) Equipment required oil recovery tray IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. 116556 WARNING a Remove the oil filter using the (Mot. 1329) (1) . Always check the oil level using the dipstick. Do not exceed the maximum level on the dipstick (could destroy the engine).
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil filter: Removal - Refitting K4M a Top up the engine oil level to the dipstick if necessary (see 10A, Engine and cylinder block assembly, Engine oil: Draining - Refilling, page 10A-32) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting 10A K9K, and 796 Tightening torquesm oil heat exchanger bolt 39 N.m oil filter support bolt 28 N.m 106794 - the engine undertray, (1) Oil filter holder mounting bolt (2) Oil filter (3) Oil filter holder (4) Coolant - oil heat exchanger mounting bolts (5) Coolant - oil heat exchanger (6) Oil pressure sensor - the closure panel component under the diesel filter.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting 10A K9K, and 796 24821 a Disconnect the air outlet duct (7) on the intercooler. 113894 a Disconnect the oil pressure sensor connector (9) . a Place a container under the engine on the oil filter side. a Remove the bolt (10) from the oil filter support. a Remove the oil filter support. 24811 a Move aside the air outlet duct. a Remove the air outlet duct support (8) from the fan assembly mounting.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting 10A K9K, and 796 113895 107306 a Remove the oil-water heat exchanger seals (13) . a Remove: - the bolt (12) from the oil-coolant heat exchanger, - the oil-water heat exchanger. a Using a clean cloth, clean up any oil and coolant runs on the cylinder block and on the oil filter support.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting 10A K9K, and 796 III - FINAL OPERATION 107306 a Refit new seals (14) and (15) on the oil-water heat exchanger. 133518 a Apply soapy water to the two seals (15) in contact with the coolant pump inlet pipe. II - REFITTING OPERATION FOR PART CONCERNED a Refit the oil-water heat exchanger. a Torque tighten the oil heat exchanger bolt (39 N.m).
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil-coolant heat exchanger: Removal - Refitting K9K, and 796 a Connect the air outlet duct to the intercooler. a Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Refit: - the closure panel component under the diesel filter, - the engine undertray, - the engine cover. a Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting K9K Tightening torquesm oil pressure sensor 33 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove the engine undertray. II - OPERATION FOR REMOVAL OF PART CONCERNED 113894 a Disconnect the oil pressure sensor connector. a Remove the oil pressure sensor (2) using the.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure sensor: Removal - Refitting 10A K4M II - FINAL OPERATION a Connect the oil pressure sensor connector. Tightening torquesm oil pressure sensor a Refit the engine undertray. 35 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Remove: - the engine undertray bolts, - the engine undertray.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting 10A K9K II - REFITTING OPERATION FOR PART CONCERNED Tightening torquesm oil pump bolts a Refit the oil pump. 25 N.m a Torque tighten the oil pump bolts (25 N.m). REMOVAL III - FINAL OPERATION I - REMOVAL PREPARATION OPERATION a Refit the sump (see 10A, Engine and cylinder block assembly, Lower cover: Removal - Refitting, page 10A-9) . a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pump: Removal - Refitting 10A K4M II - REFITTING OPERATION a Refit the oil pump. Tightening torquesm oil pump bolts a Torque tighten the oil pump bolts (25 N.m). 25 N.m III - FINAL OPERATION REMOVAL a Refit the sump (see 10A, Engine and cylinder block assembly, Lower cover: Removal - Refitting, page 10A-9) . I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check 10A K4M or K9K Oil pressure tables: II - CHECK Minimum oil pressure (bar) Maximum oil pressure (bar) Idling speed 3000 rpm 3000 rpm D4D, D4F 1.5 3.9 5.3 K7J, K7M 1.3 3.7 5.0 Engine Minimum oil pressure (bar) Maximum oil pressure (bar) Idling speed 4000 rpm 4000 rpm K4M 0.5 3.1 4.4 K9K 0.8 3.4 5.
ENGINE AND CYLINDER BLOCK ASSEMBLY Oil pressure: Check K4M or K9K a Top up the engine oil level if necessary (see Engine oil: Specifications) . a Start the vehicle and check that there are no oil leaks at the oil pressure sensor.
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting 10A K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Remove the air conditioning compressor bolts (without opening the circuit) (see Compressor: Removal - Refitting) (62A, Air conditioning). Tightening torquesm multifunction support bolts on the cylinder block 44 N.m lower bolt of the multifunction support on the sump 25 N.m a Attach the air conditioning compressor to the subframe.
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting 10A K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Refit (see Power-assisted steering pump: Removal - Refitting) (36B, Power-assisted steering): REFITTING - the power-assisted steering pump, I - REFITTING OPERATION - the bolt of the power-assisted steering high pressure pipe on the cylinder block.
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting 10A K4M, and STANDARD HEATING RECIRCULATION II - REMOVAL OPERATION Tightening torquesm multifunction support bolts on the cylinder block 44 N.m multifunction support bolt on the sump 25 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting 10A K4M, and STANDARD HEATING RECIRCULATION REFITTING - the high pressure pipe bolt on the cylinder block. I - REFITTING OPERATION a Refit: - the alternator (see 16A, Starting - Charging, Alternator: Removal - Refitting, page 16A-1) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting 10A K9K AIR CONDITIONING Tightening torquesm multifunction support bolts on the cylinder block 44 N.m multifunction support bolt on the sump 25 N.m a Disconnect the air conditioning compressor connector. a Remove the air conditioning compressor bolts (without opening the circuit) (see Compressor: Removal - Refitting) (62A, Air conditioning). a Attach the air conditioning compressor to the lower front cross member.
ENGINE AND CYLINDER BLOCK ASSEMBLY Multifunction support: Removal - Refitting K9K REFITTING REFITTING OPERATION 19704 a Refit the multifunction support. a Position bolts (1) to (7) without tightening them. a Pretighten the multifunction support bolts (1) and (2) on the cylinder block 5 N.m. a Loosen bolts (1) and (2) a half-turn. a Pretighten the multifunction support bolt (7) on the sump 5 N.m. a Pretighten the multifunction support bolts (1) and (2) on the cylinder block 5 N.m.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M REMOVAL Special tooling required Mot. 1448 Remote operation pliers for hose clips. Mot. 1390 Support for removal - refitting of engine - gearbox assembly I - REMOVAL PREPARATION OPERATION a IMPORTANT To prevent the vehicle from falling, lash it to the vehicle lift using a strap. Equipment required a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M 116654 a Disconnect the accelerator cable on the throttle valve at (1) . a Remove the accelerator cable from the inlet distributor at (2) . 145507 a Remove the fuse and relay box cover. a Remove the side protector (6) of the fuse and relay box. a Disconnect the engine harness - front wiring connector (7) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . 145509 145510 a Disconnect: - the fuel supply pipe (9) on the injector rail, - the petrol vapour rebreather pipe (10) . a Disconnect the connector (12) from the fuel vapour recirculation solenoid valve.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M STANDARD HEATING RECIRCULATION AIR CONDITIONING 145498 145497 a Remove: a Remove: - the power-assisted steering low pressure pipe (13) on the oil reservoir using the (Mot. 1448), - the power-assisted steering low pressure pipe (17) on the oil reservoir using the (Mot.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M AIR CONDITIONING a Remove (see Compressor: Removal - Refitting) (62A, Air conditioning): - the pipe retaining bracket bolt on the compressor, - the pipe union bolts on the compressor. Note: Plugs must be fitted on the hoses to prevent moisture from entering the system. a Disconnect the compressor pipes. 24762 a Remove the power-assisted steering low pressure pipe bolt (22) on the front axle subframe.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M a Remove (see ) (36A, Steering assembly): - the heat shield bolts on the steering box, - the steering box heat shield, - the steering box bolts on the front axle subframe. a Attach the steering rack to the body. 116637 a Move aside the clips (27) of the coolant hoses on the water chamber using the (Mot. 1448). a Disconnect the cooling hoses from the water chamber.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M 118882 24810 a WARNING Do not pull the clip. If it is incorrectly handled in any way, the pipe will need to be replaced. a Disconnect the clutch control pipe on the clutch slave cylinder by pressing the clip (32) . a Recover the brake fluid in a container. a Fit blanking plugs on the pipe openings. a Remove the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, page 19D-8) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M II - REMOVAL OPERATION 135949 a Remove: 136472 a Mark the positions of the suspended engine mountings on the body. - the bolts (33) from the exhaust flange, - the exhaust bracket ring. a Support the engine - gearbox assembly on the engine marks (34) using the (Mot. 1390). a Move aside the exhaust pipe.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K4M 107929 123542 a Remove the nut (35) on the rubber pad support of the left-hand suspended engine mounting. a Lift the vehicle to remove the engine - gearbox assembly. a Strike the gearbox stud with a copper hammer to separate the engine - gearbox assembly from the body. Note: Ensure that no component obstructs the movement of the body around the engine - gearbox assembly. a Remove the engine - gearbox assembly.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K4M a Remove the (Mot. 1390) from the engine - gearbox assembly. a Check that there are no leaks. III - FINAL OPERATION a Proceed in the reverse order to removal. a Torque tighten: - the exhaust flange bolts (21 N.m), - the front axle subframe tie-rod upper bolts (21 N.m), - the anti-roll bar tie rod upper bolts (37 N.m), - the earth strap bolt on the gearbox (21 N.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 REMOVAL Special tooling required Mot. 1448 Remote operation pliers for hose clips. Mot. 1390 Support for removal - refitting of engine - gearbox assembly I - REMOVAL PREPARATION OPERATION a IMPORTANT To prevent the vehicle from falling, lash it to the vehicle lift using a strap. Equipment required a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 145506 a Remove the engine wiring bolt (1) on the battery mounting. a Unclip the battery wiring at (2) . a Remove the earth strap bolt (3) on the battery mounting. a Disconnect the connector (4) from the pre-postheating unit. a Disconnect the non-return valve (5) at the vacuum pump. 145507 a Remove the fuse and relay box cover. a Remove the side protector (6) of the fuse and relay box.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 - the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . 145503 145502 a Disconnect: - the fuel supply pipe (11) , a Disconnect the connector (9) from the water detection sensor on the diesel filter. - the fuel return pipe (12) . a Unclip the water detection connector on the diesel filter mounting at (10) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 - the air duct nut (18) on the gearbox, - the intercooler air ducts. a Disconnect (see Power-assisted steering pump: Removal - Refitting) (36B, Power-assisted steering): - the power-assisted steering low pressure hose on the power-assisted steering pump using the (Mot.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 AIR CONDITIONING 145505 a Remove the earth strap bolt (25) on the body. 145499 a Remove the power-assisted steering high pressure pipe bolt on the cylinder block. a Disconnect the pump assembly connectors (26) . a Unclip the pump assembly wiring at (27) . a Disconnect the connectors (23) from the fan assembly. a Unclip the fan assembly wiring at (24) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 145559 145500 a Move aside the cooling hose clip (32) on the water chamber using the (Mot. 1448). a Remove: - the power-assisted steering high pressure pipe bolt (29) on the gearbox, a Disconnect the cooling hose on the water chamber. - the power-assisted steering high pressure pipe bolt (30) on the gearbox support, - the earth strap bolt (31) on the gearbox.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 - the steering box heat shield, - the steering box bolts on the front axle subframe. a Attach the steering rack to the body. 24817 144756 a Remove: - the front axle subframe tie-rod upper bolts (34) , - the anti-roll bar tie rod upper bolts (35) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 24810 135949 a Remove: a WARNING - the bolts (38) from the exhaust flange, Do not pull the clip. If it is incorrectly handled in any way, the pipe will need to be replaced. - the exhaust bracket ring. a Move aside the exhaust pipe. a Disconnect the clutch control pipe on the clutch slave cylinder by pressing the clip (37) . Note: a Recover the brake fluid in a container.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 II - REMOVAL OPERATION 112813 107929 a Remove the nut (40) on the rubber pad support of the left-hand suspended engine mounting. a Strike the gearbox stud with a copper hammer to separate the engine - gearbox assembly from the body. 112814 a Note: Ensure that the (Mot. 1390) is correctly positioned on the multifunction support at (39) . a Position the (Mot. 1390) under the engine - gearbox assembly.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting 10A K9K, and 796 a Remove the (Mot. 1390) from the engine - gearbox assembly. III - FINAL OPERATION a Proceed in the reverse order to removal. a Torque tighten: - the exhaust flange bolts (21 N.m), - the front axle subframe tie-rod upper bolts (21 N.m), - the anti-roll bar tie rod upper bolts (37 N.m), - the earth strap bolt on the gearbox (21 N.
ENGINE AND CYLINDER BLOCK ASSEMBLY Engine - gearbox assembly: Removal - Refitting K9K, and 796 a Check that there are no leaks.
ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting 10A K4M REFITTING Tightening torquesm flywheel bolts I - REFITTING PREPARATION OPERATION 25 N.m + 50˚ ± 6˚ a Check the condition of the flywheel. a On the crankshaft, clean the flywheel bolt threading.
ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting K4M 107913 a Screw in the new flywheel bolts without tightening them. a Lock the engine using the. a Torque tighten in order the flywheel bolts (25 N.m + 50˚ ± 6˚). a Remove the tool. III - FINAL OPERATION a Refit: - the clutch pressure plate (see Pressure plate Disc: Removal - Refitting) , - the gearbox (see Manual gearbox: Removal - Refitting) .
ENGINE AND CYLINDER BLOCK ASSEMBLY Flywheel: Removal - Refitting 10A K9K a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean and degrease: Tightening torquesm flywheel bolts 55 N.m - the crankshaft bearing face on the flywheel if reused, REMOVAL - the flywheel pressure face on the crankshaft, I - REMOVAL PREPARATION OPERATION - the flywheel threading.
TOP AND FRONT OF ENGINE Pressure at end of compression: Check 11A K4M a Fully depress the accelerator pedal in order to open the throttle valve during the compression measurements. Equipment required petrol compression gauge Note: Diagnostic tool It is necessary to wait for at least 10 seconds before starting the engine each time (the starter will not run due to its thermal protection).
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 11A K9K, and STANDARD HEATING RECIRCULATION II - OPERATION FOR REMOVAL OF PART CONCERNED Equipment required offset spanner Auto tensioner Tightening torquesm new accessories belt tensioning roller bolt 40 N.m WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and STANDARD HEATING RECIRCULATION REFITTING I - REFITTING PREPARATION OPERATION a WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a Use a brush to remove any deposits from the crankshaft accessories pulley V-grooves.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 11A K9K, and AIR CONDITIONING II - REMOVAL OPERATION Tightening torquesm tensioning roller bolt 40 N.m WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley. WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K9K, and AIR CONDITIONING II - REFITTING OPERATION FOR PART CONCERNED 101878 a Rotate the tensioning roller clockwise using a 16 mm offset wrench. a Refit a new accessories belt. a Turn the crankshaft two revolutions clockwise (timing end) to position the accessories belt correctly.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 11A K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING II - REMOVAL OPERATION Tightening torquesm the automatic tensioning roller mounting bolts 21 N.m the fixed roller mounting bolt 21 N.m a IMPORTANT Wear cut-resistant gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING a Torque tighten: - the automatic tensioning roller mounting bolts (21 N.m), - the fixed roller mounting bolt (21 N.m). a Turn the accessories belt auto tensioner clockwise using a 16 mm spanner. a Lock the auto tensioner using a 6 mm Allen key. a Refit a new accessories belt. a Unlock the auto tensioner.
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting 11A K4M, and STANDARD HEATING RECIRCULATION II - REMOVAL OPERATION Tightening torquesm auto tensioner bolts 40 N.m IMPORTANT Wear cut-resistant gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
TOP AND FRONT OF ENGINE Accessories belt: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION a Refit the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres).
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 11A K9K II - REMOVAL OPERATION Special tooling required Mot. 1489 TDC locating pin. Tightening torquesm accessories pulley bolt 120 N.m + 95˚ ±15˚ TDC pin plug 25 N.m IMPORTANT Wear cut-resistant gloves during the operation. WARNING Do not run the engine without the accessories belt to avoid damaging the crankshaft accessories pulley.
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 11A K9K REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Crankshaft accessories pulley bolts. WARNING Only use brushes with plastic or non-corrosive metal (brass) bristles. a If reusing the crankshaft accessories pulley, clean the crankshaft accessories pulley V-grooves with a brush to eliminate any deposits. 19650 a Remove the TDC setting pin plug (7) .
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting K9K 14489 a Turn the crankshaft clockwise (timing end) smoothly using the bolt of the crankshaft accessories pulley, until the crankshaft presses against the tool (Mot. 1489) (9) . a Torque and angle tighten (with the crankshaft in contact with the TDC setting pin) the accessories pulley bolt (120 N.m + 95˚ ±15˚). a Remove the TDC setting rod (Mot. 1489).
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 11A K4M Tightening torquesm new crankshaft accessories pulley bolt 40 N.m + 145˚ ± 15˚ TDC pin plug 25 N.m IMPORTANT Wear cut-resistant gloves during the operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). 14491 a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 11A K4M II - REMOVAL OPERATION 14489 a Turn the crankshaft in its operating direction (clockwise at timing end), until the crankshaft presses against the TDC setting pin. 14487 a Remove the crankshaft accessories pulley bolt (6) .
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting 11A K4M 145073 a Position the setting tool. a Secure theto the ends of the camshafts using an M6 bolt (7) . 130493 a If the crankshaft is not pressing against the TDC tool, bring the crankshaft back by turning the flywheel using a screwdriver (9) . II - REFITTING OPERATION a Refit the crankshaft accessories pulley. a Torque and angle tighten the new crankshaft accessories pulley bolt (40 N.m + 145˚ ± 15˚).
TOP AND FRONT OF ENGINE Crankshaft accessories pulley: Removal - Refitting K4M - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) , - the air inlet duct. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M Tightening torquesm timing fixed roller bolt 50 N.m new crankshaft accessories pulley bolt 40 N.m + 145˚ ± 15˚ timing tension wheel nut 27 N.m lower timing cover bolts 12 N.m nut of each camshaft sprocket 30 N.m + 84˚ ± 4˚ TDC pin plug 20 N.m upper timing cover bolts 46 N.m upper timing cover nuts 46 N.m flywheel end lifting eye bolts 10 N.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M II - REFITTING OPERATION FOR PART CONCERNED II - REMOVAL OPERATION a The first procedure applies to replacing any timing face component which has a crankshaft timing sprocket without a collet and which does not require one or more of the camshaft sprockets to be loosened.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 14487-5 a Position the RENAULT badge (7) engraved on the stem of each camshaft sprocket vertically and pointing upwards. 14487-3 a Refit: - the crankshaft timing sprocket (9) , - a new timing belt, - a new timing fixed roller (10) . 2 - Refitting 108879 14487-2 a Refit a new timing tensioning roller by positioning the lug of the timing tensioning roller in the groove (8) . a Torque tighten the timing fixed roller bolt (50 N.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M a - Lower timing cover with a timing flap 103263 a Position the adjustable index (11) opposite the mark (12) , by turning the eccentric (13) clockwise using a 6 mm Allen key. a Torque tighten the timing tensioning roller nut (7 N.m). a Refit the toolon the cylinder block. Note: 130497 a Refit the lower timing cover (14) . a Tighten to torque the lower timing cover bolts (12 N.m).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M c - Lower timing cover with a timing flap 130493 109052 a Remove the timing flap from the lower timing cover. d - continuation of the refitting procedure regardless of the type of lower timing cover a Remove: - the bolt of the tool, - the setting tool, - thefrom the cylinder block.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 103263 a Check that the adjustable index (17) is opposite the notch (18) , if this is not the case: - loosen the timing tensioning roller nut by up to one turn while holding the eccentric with a 6 mm Allen key, 14490 a Position (without forcing) the camshaft setting tool(the camshaft end grooves must be horizontal and offset towards the bottom).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M a - Lower timing cover with a timing flap II - REFITTING OPERATION a The second procedure is used when replacing any timing face component which has a crankshaft timing sprocket with or without a collet, that requires one or more of the camshaft sprockets to be loosened. 109052 a Refit the lower timing cover flap, checking that the locating pin (20) fits properly in the notch (21) .
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 1 - Adjusting the timing a Note: If the stud loosens with the nut (see 11A, Top and front of engine, Camshaft: Removal Refitting, page 11A-49) (11A, Top and front of engine).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 145073 130493 a Fit: - the (23) onto the ends of the camshafts, - an M6 bolt (24) to hold the. a Refit: - the crankshaft timing sprocket, - the camshaft sprockets, - every camshaft sprocket nut. 14489 a Refit the toolon the cylinder block.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 14487-3 135896 a Position the RENAULT badge (27) etched on the stem of each camshaft sprocket vertically and pointing upwards. a Refit a new timing belt starting with the sprocket of each camshaft (without moving the sprocket of each camshaft). 2 - Refitting a Fit the tool (29) on the camshaft sprockets (use the bolt and nut of the upper timing cover to fit the tool).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M a Torque tighten the timing tensioning roller nut (7 N.m). Note: There are two types of lower timing cover: - without a timing flap, - with a timing flap. a - Lower timing cover with a timing flap 14487-2 a Refit a new timing fixed roller. a Torque tighten the timing fixed roller bolt (50 N.m) using the tool. 3 - Timing belt tension 130497 a Refit the lower timing cover (33) . a Tighten to torque the lower timing cover bolts (12 N.m).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M c - Lower timing cover with a timing flap 109051 109052 a Remove the timing flap from the lower timing cover. d - continuation of the refitting procedure regardless of the type of lower timing cover a Remove: - the bolt of the tool, - the, - the toolfrom the cylinder block, - the.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K4M 5 - Checking the timing a - Lower timing cover with a timing flap a Ensure that the index and the notch on the timing tensioning roller are in the correct position before checking the timing. a Screw toolinto the cylinder block. a Move the crankshaft slowly and smoothly until it comes into contact with the tool. 109052 a Refit the lower timing cover flap, checking that the locating pin (37) fits properly in the notch (38) .
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K4M a Refit: - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) , - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) , - the air
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 REMOVAL Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. I - REMOVAL PREPARATION OPERATION Mot. 1489 TDC locating pin. Mot. 1430 Set of 5 crankshaft and camshaft pulley timing pins. a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 145429 136656 a Mark the position of the suspended engine mounting in relation to the body.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 136660 136658 a Remove: - the bolts (5) from the right-hand suspended engine mounting support on the cylinder head, - the right-hand pendulum suspension support. II - REMOVAL OPERATION 136662 a Unclip the three tabs (4) . a Remove the lower timing cover. 19650 a Remove the TDC pin plug (6) using a 14 female torx socket.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 19702 14489 a Turn the crankshaft to position the camshaft pulley hole (7) almost opposite the cylinder head hole (8) . a Turn the crankshaft clockwise (timing end) smoothly until the crankshaft is against the (Mot. 1489). 19650-1 19655 a Screw tool (Mot. 1489) (9) into the cylinder block. a Insert the (Mot. 1430) (10) in the holes of the camshaft pulley and cylinder head. a Remove: - the (Mot. 1430), - the (Mot. 1489).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 - the timing belt tensioning roller. REFITTING I - REFITTING PREPARATION OPERATION a WARNING The belt must be replaced with a new one if it has been removed. WARNING When replacing the belt, always replace the tension wheels and idler pulleys.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 III - REFITTING OPERATION 19656-2 a Refit: - the crankshaft timing sprocket, - a new timing belt tensioning roller. a Put the tensioning roller lug (13) in the cylinder head groove (14) . a Engage the (Mot. 1430) in the camshaft pulley hole and the cylinder head hole at (15) , turning the camshaft using an 18 mm offset wrench if necessary. a Check that high-pressure pump pulley marking (16) is opposite the bolt head (17) .
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 19657 19658 a Fit the new timing belt, starting with the crankshaft sprocket, aligning the marks on the belt with those on the camshaft and high pressure pump pulleys. a Position the timing belt tensioning roller adjustable index opposite the lug (19) by turning the eccentric cam anti-clockwise using a 6 mm Allen key.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 19702 a Rotate the crankshaft clockwise through two revolutions (timing end). 19655 a Set the camshaft pulley using the (Mot. 1430). a Before the camshaft pulley hole (20) is opposite the cylinder head hole (21) , screw the (Mot. 1489) into the cylinder block. Note: There should be 19 belt tooth grooves between the marks on the camshaft pulley (22) and the high pressure pump pulley (23) .
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 1 - First position 111083 111081 a Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mmAllen key. a Gradually align the adjustable index marker (24) in the middle of the timing window (25) , turning the key anti-clockwise.
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting 11A K9K, and 796 der block. 2 - Second position a Bring the crankshaft slowly and smoothly into contact with the tool (Mot. 1489). 111082 19655 a Set the camshaft pulley using the (Mot. 1430). a If the tool (Mot. 1430) does not engage, repeat the timing belt refitting operation. a Remove: - the (Mot. 1489), - the (Mot. 1430).
TOP AND FRONT OF ENGINE Timing belt: Removal - Refitting K9K, and 796 19659 a Refit the lower timing cover, positioning the tab (28) in the opening (29) on the inner cover. a Clip on the lower timing cover. a Refit: - the upper timing cover, - the upper timing cover bolt. a Clip on the upper timing cover.
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K4M Tightening torquesm rocker cover bolts 22, 23, 20 and 13 8 N.m rocker cover bolts 1 to 12, 14 to 19, 21 to 24 15 N.m rocker cover bolts 22, 23, 20 and 13 15 N.m flywheel end lifting eye bolts on the rocker cover 11 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 11A K4M II - REMOVAL OPERATION 14497 a Remove the rocker cover bolts. a Remove the rocker cover vertically by tapping the lugs (1) with a copper hammer. a Remove the rocker cover.
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 11A K4M a REFITTING WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) I - REFITTING PREPARATION OPERATION a IMPORTANT Wear cut-resistant gloves during the operation. Note: Do not put oil on the gasket face of the cylinder head cover. IMPORTANT Wear goggles with side protectors for this operation.
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K4M 126216 a Use a cloth to remove any RESIN GLUE in the bearing channels (2) on the rocker cover.
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 11A K4M II - REFITTING OPERATION 14497 a Refit the rocker cover. - the camshaft seals (see 11A, Top and front of engine, Camshaft seal, timing end: Removal - Refitting, page 11A-56) , a Tighten to torque and in order: - rocker cover bolts 22, 23, 20 and 13 (8 N.m), - the inlet distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-12) , - rocker cover bolts 1 to 12, 14 to 19, 21 to 24 (15 N.m).
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting 11A K9K II - REFITTING OPERATION Tightening torquesm rocker cover bolts 12 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . 19712-1 a WARNING Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.).
TOP AND FRONT OF ENGINE Rocker cover: Removal - Refitting K9K III - FINAL OPERATION a Connect the oil vapour rebreathing pipe. a Refit the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting K4M Equipment required roller-type stud removal tool Tightening torquesm the camshaft dowel 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K4M II - REMOVAL OPERATION 14498 a Remove: - the inlet camshaft (1) , - the exhaust camshaft (2) .
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K4M Replacing a camshaft dowel a Note: It is essential to replace the camshaft dowel if it comes loose at the same time as the nut. a - Removal a Place the camshaft in a vice with aluminium jaws. 14499 a Remove: - the valve rockers (3) ; - the hydraulic tappets (4) . Note: To prevent any risk of unpriming the hydraulic tappets make sure that they are vertical.
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K4M - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) , - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) , - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the acces
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K9K Tightening torquesm bolts of the camshaft bearings 10 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K9K REFITTING II - OPERATION FOR REMOVAL OF PART CONCERNED I - REFITTING PREPARATION OPERATION a parts always to be replaced: Camshaft seal on timing end. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
TOP AND FRONT OF ENGINE Camshaft: Removal - Refitting 11A K9K a Apply four beads (6) of RESIN ADHESIVE (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) 7 mm in diameter on the cylinder head.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K4M Tightening torquesm inlet camshaft hub nut 30 N.m + 84˚ ± 4˚ exhaust camshaft hub nut 30 N.m + 84˚ ± 4˚ REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K4M II - REMOVAL OPERATION 135237 105257 a a Push theuntil contact is made between the ends of the claws (7) and the camshaft seal. Note: The inlet and exhaust camshaft seals are removed using the. a Always remove the end piece (4) of the tool. a Loosen bolts (5) and (6) fully from the. 145806 a Separate the claws by turning the nut (8) clockwise using an open-jawed spanner.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K4M a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean and degrease: - the seal mating face of each camshaft, - the camshaft seal housings. Note: It is strictly forbidden to lubricate the outer diameter of the ring before fitting. II - REFITTING OPERATION Fitting the camshaft seal. 135232 a Remove the camshaft seal by turning the bolt (9) clockwise.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K4M 105531 135229 a Fit the cover (14) and the collar nut (15) of the. 135231 a Fit the protector fitted with a new seal (13) on the inlet and exhaust camshaft, taking care not to touch the seal. a Screw on the stud (12) of the toolon the inlet and exhaust camshafts. 135229 a Screw on the collar nut until the cover touches the cylinder head. a Remove: - the nut, - the cover, - the threaded rod (16) .
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting K4M III - FINAL OPERATION a Refit: - the inlet camshaft pulley with a new nut, - the exhaust camshaft pulley with a new nut. a Fit the locking toolon the camshaft pulleys. a Torque tighten: - the inlet camshaft hub nut (30 N.m + 84˚ ± 4˚), - the exhaust camshaft hub nut (30 N.m + 84˚ ± 4˚). a Remove the locking tool.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K II - REMOVAL OPERATION Special tooling required Mot. 1430 Set of 5 crankshaft and camshaft pulley timing pins. Tightening torquesm camshaft stud camshaft pulley nut 12 N.m 30 N.m + 86˚ ± 6˚. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the front engine cover. a Remove: 118982 - the front right-hand wheel (see Wheel: Removal Refitting) (35A, Wheels and tyres), a Increase the hole (1) of the (2) using an 8.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K - the camshaft pulley. 105270 123970 a Position the claws of theon the camshaft. 105257 a 105271 a Push the tooluntil contact is made between the ends (9) of the claws and the camshaft seal. Note: The camshaft seal is removed using the. a Remove the camshaft seal (5) making sure that the end piece (6) of the toolis always removed. a Loosen bolts (7) and (8) fully from the.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K REFITTING I - REFITTING PREPARATION OPERATION a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean and degrease: - the camshaft seal housing in the cylinder head, - the camshaft seal mating face on the camshaft. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K II - REFITTING OPERATION FOR PART CONCERNED Note: For camshaft seals delivered fitted to a protective sleeve: - do not remove the camshaft seal from its protective sleeve, - fit the sleeve fitted with the camshaft seal to the camshaft, - push the protective sleeve towards the cylinder head until the camshaft seal reaches its limit on the cylinder head, - fit the seal on the camshaft by following the recommendations below.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K 21687-3 a Screw on the collar nut until the cover touches the cylinder head. 123075 a Note: The spacer (17) is used to fit the seal (18) and is used in addition to the tool (19) . 2 - Second fitting of the camshaft seal 123076 a Depending on the case, the Parts Department delivers seals (15) equipped with a spacer (16) amongst other things.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting 11A K9K 3 - Continued for both methods a Remove: - the collar nut from the, - the cover from the, - the stud of the, - the protective sleeve and the spacer, if fitted then throw them away. a Torque tighten the camshaft stud (12 N.m) a Refit: - the camshaft pulley, - a new camshaft pulley nut. 123073 a Position the bell (20) fitted with the spacer on the camshaft seal side and then position the collared nut (21) of the tool.
TOP AND FRONT OF ENGINE Camshaft seal, timing end: Removal - Refitting K9K III - FINAL OPERATION 107269 a Set the camshaft pulley hub using the tool (Mot. 1430). Note: If the pin (Mot. 1430) does not engage, turn the camshaft pulley hub using an 18 mm offset wrench to facilitate the setting of the camshaft pulley hub. a Refit: - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) .
TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting 11A K4M - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , Tightening torquesm new oil separator bolts - the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-11) , 15 N.
TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting 11A K4M REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: oil decanter bolt WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. WARNING When cleaning parts, it is essential that the parts do not impact on each other, otherwise their mating faces may be damaged and therefore their adjustments may be altered, which could damage the engine.
TOP AND FRONT OF ENGINE Oil decanter: Removal - Refitting 11A K4M 14497-4 a Torque tighten in order the new oil separator bolts (15 N.m).
FUEL MIXTURE Air inlet: Description 12A K4M Diagram of the air inlet circuit 102071 (1) Air inlet trunking (2) Air resonator (3) Air filter unit (4) Air filter (5) Throttle valve (6) Inlet manifold (7) Injector holder shim (8) Air inlet 12A-1
FUEL MIXTURE Air resonator: Removal - Refitting K4M REMOVAL REMOVAL OPERATION FOR PART CONCERNED 116562 a Remove: - the elastic mounting (1) from the air resonator unit, - the air resonator unit (2) . REFITTING REFITTING OPERATION FOR PART CONCERNED a Refit: - the air resonator unit, - the air resonator elastic mounting.
FUEL MIXTURE Air filter: Removal - Refitting 12A K4M REMOVAL II - REFITTING OPERATION FOR PART CONCERNED a Refit: I - REMOVAL PREPARATION OPERATION - the air filter, a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . a Disconnect the brake servo vacuum pipe (1) from the inlet distributor. - the air filter cover, - the two air filter cover bolts. III - FINAL OPERATION a Reconnect the brake servo vacuum pipe to the inlet distributor.
FUEL MIXTURE Air filter: Removal - Refitting 12A K9K REMOVAL 2 - Second fitting of air filter unit I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . II - OPERATION FOR REMOVAL OF PART CONCERNED 1 - First fitting of air filter unit 132602 a Remove the 9 bolts (3) from the air filter unit. a Move aside the air filter unit cover (4) . 132602 a Remove the 4 bolts (1) from the air filter unit.
FUEL MIXTURE Air filter: Removal - Refitting K9K II - REFITTING OPERATION FOR PART CONCERNED a Refit the air filter in the air filter unit cover. WARNING If the air filter is fitted incorrectly in the air filter unit, unfiltered air may enter the engine and cause the engine to malfunction. a Fit the air filter unit cover. III - FINAL OPERATION a Refit the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
FUEL MIXTURE Air filter unit: Removal - Refitting 12A K9K REMOVAL II - REFITTING OPERATION FOR PART CONCERNED I - REMOVAL PREPARATION OPERATION a Fit the air filter unit sideways against the EGR valve mounting. a Remove the engine cover. a Slide the air filter unit to the right. a Refit: - the turbocharger pressure sensor on the air filter unit. - the bolt of the turbocharger pressure sensor, a Refit the air filter unit by lowering it vertically from the injection end.
FUEL MIXTURE Air filter unit: Removal - Refitting 12A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm air filter unit bolts 9 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
FUEL MIXTURE Air filter unit: Removal - Refitting 12A K4M 116571 a Unclip: 101488 a Remove the two bolts (10) from the air filter unit. - the coolant pipes at (6) , - the breather (7) . 15757 116564 a Remove the air filter unit. a Remove the coolant pipes mounting bracket (8) . a Unpick the electrical wiring (9) from the oxygen sensor.
FUEL MIXTURE Air filter unit: Removal - Refitting K4M - the plastic rivets and clips every time they are removed. II - REFITTING OPERATION a Refit: - the air filter unit, - the two air filter unit bolts. a Torque tighten the air filter unit bolts (9 N.m). a Attach the electrical wiring to the oxygen sensor. a Refit the coolant pipes mounting bracket. a Reclip: - the breather, - the coolant pipes. a Refit: - the filter element, - the two air filter cover bolts.
FUEL MIXTURE Air flowmeter: Removal - Refitting 12A K9K, and 796 REMOVAL - the air flowmeter seal. REFITTING I - REMOVAL PREPARATION OPERATION a Remove the engine cover. I - REFITTING PREPARATION OPERATION a Always replace the air flowmeter seal on the air filter unit. II - REFITTING OPERATION FOR PART CONCERNED a Refit: - a new air flowmeter seal on the air filter box, - the air flowmeter, - the air flowmeter bolts. III - FINAL OPERATION 24831 a Disconnect the air flowmeter connector (1) .
FUEL MIXTURE Throttle valve: Removal - Refitting 12A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm throttle valve bolts 13 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . 116635 a Remove: - the throttle valve bolts (2) , - the throttle valve.
FUEL MIXTURE Inlet distributor: Removal - Refitting 12A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm intake distributor mounting bolts 9 N.m REMOVAL I - REMOVAL PREPARATION OPERATION 116653 a Remove: - the inlet distributor bolts (7) , - the inlet distributor. a When replacing the inlet distributor, remove: - the air temperature sensor, - the inlet air pressure sensor. 116654 a Disconnect the accelerator cable on the throttle valve at (1) .
FUEL MIXTURE Inlet distributor: Removal - Refitting 12A K4M a III - FINAL OPERATION a Refit the throttle valve equipped with a new seal (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, page 12A-11) . WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks. a Clip the wiring onto the inlet distributor.
FUEL MIXTURE Injector holder shim: Removal - Refitting 12A K4M Tightening torquesm injector holder shim bolts (7) and (8) 25 N.m injector holder shim bolts 9 to 16 21 N.m upper timing cover bolt 41 N.m suspended mounting bolt 62N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
FUEL MIXTURE Injector holder shim: Removal - Refitting 12A K4M REFITTING - the injector rail (see 17B, Petrol injection, Injector rail - Injectors: Removal - Refitting, page 17B-10) , I - REFITTING PREPARATION OPERATION a The injector holder shim seal must always be replaced. - the inlet distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, page 12A-12) . a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
FUEL MIXTURE Exhaust manifold: Removal - Refitting 12A K9K REFITTING Tightening torquesm I - REFITTING PREPARATION OPERATION exhaust manifold stud 9 N.m exhaust manifold nuts 26 N.m a parts always to be replaced: exhaust manifold seal.
FUEL MIXTURE Exhaust manifold: Removal - Refitting K9K III - FINAL OPERATION a Refit: - the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting, page 12B-1) , - the exhaust gas recirculation assembly (see 14A, Antipollution, Exhaust gas recirculation assembly: Removal - Refitting, page 14A-9) , - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, page 19B10) , - the engine undertray, - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal
FUEL MIXTURE Exhaust manifold: Removal - Refitting 12A K4M Tightening torquesm exhaust manifold studs 8 N.m exhaust m a n i fold mounting nuts 23 N.m bolts (6) mounting the stay on the cylinder block 21 N.m nut (7) mounting the stay on the exhaust manifold 21 N.m exhaust manifold upper heat shield mounting bolts 12 N.m upstream oxygen sensor 45 N.m exhaust bracket mounting bolts 21 N.m 116557 a Remove the nuts (1) from the exhaust flange.
FUEL MIXTURE Exhaust manifold: Removal - Refitting 12A K4M 116640 a Remove the stay (4) between the exhaust manifold and the cylinder block. 116642 a Using the workbench, remove: - the bolts (5) from the exhaust manifold lower heat shield, II - REMOVAL OPERATION - the lower heat shield from the exhaust manifold. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: exhaust manifold seal. a parts always to be replaced: ring between exhaust manifold and catalytic converter.
FUEL MIXTURE Exhaust manifold: Removal - Refitting 12A K4M II - REFITTING OPERATION FOR PART CONCERNED 15101 a Refit the exhaust manifold. a Tighten to torque and in order the exhaust manifold mounting nuts (23 N.m).
FUEL MIXTURE Exhaust manifold: Removal - Refitting K4M III - FINAL OPERATION 116640 a Refit the stay between the exhaust manifold and the cylinder block. a Tighten to torque and in order: - the bolts (6) mounting the stay on the cylinder block (21 N.m), - the nut (7) mounting the stay on the exhaust manifold (21 N.m). a Refit the exhaust manifold upper heat shield. a Torque tighten the exhaust manifold upper heat shield mounting bolts (12 N.m). a Refit the upstream oxygen sensor using the.
TURBOCHARGING Turbocharger: Removal - Refitting 12B K9K Equipment required Diagnostic tool Tightening torquesm new turbocharger studs on the exhaust manifold 9 N.m new turbocharger stud on the turbocharger 9 N.m turbocharger nuts 28 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this operation.
TURBOCHARGING Turbocharger: Removal - Refitting 12B K9K a parts always to be replaced: exhaust manifold stud on the turbocharger (if loosened). II - REMOVAL OPERATION WARNING Ensure that no foreign bodies enter the turbine or compressor during the refitting operation. Check that the turbocharger oil return pipe is not partially or completely blocked by scale. Check that there are no leaks. If there are, replace the part.
TURBOCHARGING Turbocharger: Removal - Refitting K9K a Use an open wrench to fit the new turbocharger nuts without tightening them (the turbocharger must be in contact with the manifold and the wrench should no longer turn without effort). a Torque tighten the turbocharger nuts (28 N.m). III - FINAL OPERATION a Refit (see 12B, Turbocharging, Turbocharger oil pipe: Removal - Refitting, page 12B-4) : - the turbocharger oil return pipe, - the turbocharger oil supply pipe.
TURBOCHARGING Turbocharger oil pipe: Removal - Refitting 12B K9K Equipment required Note: self-contained starter This procedure deals with removing and refitting the turbocharger oil return pipe and the turbocharger oil supply pipe. Diagnostic tool Tightening torquesm new turbocharger oil supply pipe hollow bolt to the turbocharger Torx bolt 18 N.m or Hexagonal bolt 14 N.m turbocharger oil supply pipe nut on the cylinder head shouldered nut 35 N.m or non-shouldered nut 23 N.
TURBOCHARGING Turbocharger oil pipe: Removal - Refitting 12B K9K a Remove: - the turbocharger oil supply pipe hollow boltfrom the turbocharger, - the turbocharger oil supply pipe. a Wipe away any oil run-off.
TURBOCHARGING Turbocharger oil pipe: Removal - Refitting 12B K9K - the turbocharger oil supply pipe nut on the cylinder head (shouldered nut 35 N.m or nonshouldered nut 23 N.m) using toolor tool. a Remove: - the engine undertray bolts, - the engine undertray, III - FINAL OPERATION - the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, page 19B10) .
TURBOCHARGING Turbocharger oil pipe: Removal - Refitting K9K a Extract the turbocharger oil return pipe from the cylinder block. a Remove the turbocharger oil return pipe seals. REFITTING THE TURBOCHARGER OIL RETURN PIPE I - REFITTING PREPARATION OPERATION a parts always to be replaced: turbocharger oil pipe seal.
TURBOCHARGING Intercooler: Removal - Refitting 12B K9K REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the front bumper (see Front bumper assembly: Exploded view) (55A, Exterior protection). 144818 145079 a Remove: - the air deflector mounting pins (1) , - the air deflector.
TURBOCHARGING Intercooler: Removal - Refitting 12B K9K 145428 119000 a Push the « radiator - fan » assembly in the direction of the arrow (4) in order to remove the intercooler. a Remove the intercooler (7) in the direction of the arrows (8) then (9) . a Remove the clips (5) of the intercooler ducts. REFITTING a Disconnect the intercooler ducts. I - REFITTING PREPARATION OPERATION a Check that the intercooler is not full of oil.
FUEL SUPPLY Fuel circuit: Operating diagram 13A K4M Operating diagram of the fuel supply circuit ( « pump - sender - fuel filter » assembly) 19310 The fuel supply circuit does not have a return. The fuel pressure does not vary with engine load.
FUEL SUPPLY Fuel circuit: Operating diagram 13A K4M Operating diagram of the fuel supply circuit (external filter) 106938 The fuel supply circuit does not have a return. The fuel pressure does not vary with engine load.
FUEL SUPPLY Manual priming pump: Removal - Refitting 13A K9K Note: IMPORTANT The priming pump is incorporated in the fuel supply pipe. To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: - (see Diesel injection: Precautions for the repair) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction). To remove the priming pump, remove the fuel supply pipe assembly.
FUEL SUPPLY Manual priming pump: Removal - Refitting 13A K9K II - FINAL OPERATION II - OPERATION FOR REMOVAL OF PART CONCERNED a Prime the fuel circuit using the priming pump. WARNING Check that there are no leaks: - run the engine at idle speed for 2 minutes, - accelerate several times at no load, - switch off the ignition, - check that there is no fuel escaping. 146375 a Disconnect the fuel supply pipe at the fuel tank end at (3) . a Insert the blanking plugs.
FUEL SUPPLY Diesel filter: Removal - Refitting 13A K9K IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: - (see Diesel injection: Precautions for the repair) , - (see Vehicle: Precautions for the repair) (01D, Mechanical introduction). IMPORTANT Wear leaktight gloves (Nitrile type) for this operation.
FUEL SUPPLY Diesel filter: Removal - Refitting 13A K9K II - REMOVAL OPERATION DELPHI type filter MAHLE type filter 146378 24798 a Disconnect the water detection sensor connector (5) . a Remove: a Remove: - the diesel filter protection plate nuts (6) , - the diesel filter protection plate nuts (2) , - the diesel filter protection plate, - the diesel filter protection plate, - the diesel filter from its mounting, noting its original position. a Disconnect the water detection sensor connector (4) .
FUEL SUPPLY Diesel filter: Removal - Refitting 13A K9K II - DRAINING THE WATER INSIDE THE DIESEL FILTER a Note: - Certain vehicles have a sensor for detecting water in the diesel fuel, located in the diesel filter. If water is detected, the injection fault warning light comes on. a Periodically drain any water contained in the diesel filter. a For filters without a water presence sensor: - open the drain plug, - let the water flow out, - close the plug.
FUEL SUPPLY Diesel filter: Removal - Refitting K9K Priming the supply circuit 24732 a Prime the fuel system with the manual priming pump (11) (automatic degassing).
FUEL SUPPLY Fuel pressure: Check 13A K4M Special tooling required Mot. 1311-08 Union for taking fuel pressure measurements. Tightening torquesm fuel pipe protector nuts 7 N.m fuel pipe protector bolt 7 N.m IMPORTANT 145185 During this operation, be sure to: a Remove: - refrain from smoking or bringing red hot objects near the working area, - the nuts (1) and the bolt (2) from the fuel pipe protector, - beware of fuel splashes when disconnecting the union, - the fuel pipe protector.
FUEL SUPPLY Fuel pressure: Check K4M 109173 a Connect: - the « T » union (Mot. 1311-08) (6) to the fuel tank outlet pipe, - the pipe (5) fitted with a pressure gauge contained in the test kitonto the « T » union (6) , - the fuel supply pipe (7) to the « T » union (6) . a Start the vehicle to run the fuel pump. a Determine the pressure: - the pressure must be constant (approximately 3.5 bar ± 0.2 bar), - It may take a few seconds to obtain a correct pressure reading.
FUEL SUPPLY Fuel flow: Check 13A K4M Special tooling required Mot. 1311-08 Union for taking fuel pressure measurements. Tightening torquesm fuel pipe protector nuts 7 N.m fuel pipe protector bolt 7 N.m IMPORTANT 145185 During this operation, be sure to: a Remove: - refrain from smoking or bringing red hot objects near the working area, - the nuts (1) and the bolt (2) from the fuel pipe protector, - beware of fuel splashes when disconnecting the union, - the fuel pipe protector.
FUEL SUPPLY Fuel flow: Check 13A K4M 109173 116568 a Disconnect the connector (12) from the passenger compartment engine harness. a Connect: - the « T » union (Mot. 1311-08) (6) to the fuel tank outlet pipe, - the pipe (5) contained in the test kitonto the « T » union (6) , - the fuel supply pipe (7) to the « T » union (6) . 109174 a Insert the pipe (11) into a graduated measuring cylinder (2000 ml). a Remove the Protection and Switching Unit cover.
FUEL SUPPLY Fuel flow: Check K4M 109172 a Connect the connector terminal (13) to the + BATTERY to operate the fuel pump. a Note the time taken for the measuring cylinder to fill up. Note: The minimum flow rate from the fuel pump is 60 l/h. a Remove the terminal (13) of the + BATTERY connector. a Refit the Protection and Switching Unit cover. a Disconnect: - the pipe fitted with the pressure gauge contained in the test kitfrom the « T » union, - the « T » union (Mot.
DIESEL INJECTION Diesel injection: List and location of components 13B K9K, and 796 123977 No. Description 1 High pressure pump 2 Injection computer 3 Injector rail pressure sensor 4 Spherical injector rail 5 Diesel temperature sensor 6 Diesel fuel flow actuator 7 Accelerometer 8 Injector 9 Venturi 10 Exhaust gas recirculation solenoid valve 11 Turbocharging air pressure sensor 12 Air flowmeter with integrated temperature sensor 13B-1 No.
DIESEL INJECTION Diesel injection: List and location of components 13B K9K, and 796 102085 High-pressure pump (1) . 102084 Injector rail pressure sensor (3) , Spherical injector rail (4) , Diesel temperature sensor (5) , Diesel fuel flow actuator (6) , Accelerometer (7) , Injectors (8) , Venturi (9) . 24765 Injection computer (2) . 112327 Exhaust gas recirculation solenoid valve (10) , Turbocharger (11) .
DIESEL INJECTION Diesel injection: List and location of components 13B K9K, and 796 24831 Air flowmeter with integrated temperature sensor (12) , Turbocharging air pressure sensor (13) . 20796 Coolant temperature sensor (15) . 24749 Cylinder marking sensor (14) . 24817 Top Dead Centre sensor (16) .
DIESEL INJECTION Diesel injection: List and location of components K9K, and 796 24729 Pre-postheating unit (17) . 24750 Accelerator pedal potentiometer (19) .
DIESEL INJECTION Diesel injection computer: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm injection computer nuts 8 N.m injection computer protector bolts 8 N.m Note: When programming, reprogramming or replacing the computer, it is necessary to program the new computer with the C2I parameters (injector flow correction) and the engine adaptives using the Diagnostic tool.
DIESEL INJECTION Diesel injection computer: Removal - Refitting K9K REFITTING I - REFITTING OPERATION a Fit the injection computer on its mounting studs. a Torque tighten the injection computer nuts (8 N.m). a Connect the injection computer connectors. II - FINAL OPERATION a Refit the injection computer protector. a Tighten to torque the injection computer protector bolts (8 N.m). a Clip on the positive terminal wiring. a Refit the battery (see Battery: Removal - Refitting) (80A, Battery).
DIESEL INJECTION Camshaft position sensor: Removal - Refitting K9K REMOVAL OPERATION FOR REMOVAL OF PART CONCERNED 24749 a Disconnect the connector (1) from the camshaft position sensor. a Remove: - the bolt (2) from the camshaft position sensor, - the camshaft position sensor. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit: - the camshaft position sensor, - the camshaft position sensor bolt. II - FINAL OPERATION a Reconnect the camshaft position sensor connector.
DIESEL INJECTION Crankshaft position sensor: Removal - Refitting 13B K9K, and 796 a Torque tighten the crankshaft position and speed sensor bolt (8 N.m). Tightening torquesm crankshaft position and speed sensor bolt a Connect the crankshaft position sensor connector. 8 N.m II - FINAL OPERATION a Refit the engine undertray. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
DIESEL INJECTION High pressure pump: Removal - Refitting 13B K9K, and 796 Equipment required Note: Diagnostic tool Never run the engine in the opposite direction to that of normal operation. Tightening torquesm REMOVAL the high pressure pump bolts 23 N.m high pressure pump pulley nut 70 N.m a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). dipstick guide and filler neck nuts on the high pressure rail 21 N.
DIESEL INJECTION High pressure pump: Removal - Refitting 13B K9K, and 796 109466 102360 a Disconnect: - the fuel return pipe (7) connecting the injectors to the high-pressure pump, - the injector rail pressure sensor (8) , - the accelerometer (9) , - the camshaft position sensor (10) . 24752 a Disconnect: - the heater plugs (3) , - the injectors (4) , - the connectors from the high pressure pump (5) . a Clean the diesel supply and return pipes (see Diesel injection: Precautions for the repair) .
DIESEL INJECTION High pressure pump: Removal - Refitting 13B K9K, and 796 102083 23168 a Remove the high pressure pipe (13) between the injector rail and the high pressure pump (see 13B, Diesel injection, High pressure pipe between pump and rail: Removal - Refitting, page 13B-19) . a Fit the high pressure pump pulley retaining tool (14) . a Put blanking plugs in all the openings of the injection circuit.
DIESEL INJECTION High pressure pump: Removal - Refitting 13B K9K, and 796 II - REMOVAL OPERATION 23169 a Position the (16) fitted with the. 102085 a Remove: WARNING - the high pressure pump bolts (17) , Ensure that the tool pushrod is correctly oriented and is pressing against the high pressure pump shaft. - the bracket (18) from the engine cover. a Screw the pushrod of the tooluntil the high pressure pump becomes detached. a Remove: - the high pressure pump, - the.
DIESEL INJECTION High pressure pump: Removal - Refitting 13B K9K, and 796 - the right-hand suspended engine mounting (see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting, page 19D-4) , - the neck located on the injector rail. a Secure the engine wiring on the neck.
DIESEL INJECTION Flow actuator: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm flow actuator bolts dipstick guide and filler neck nuts on the high pressure rail 6 N.m 21 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) . 24733 a Remove the dipstick guide and filler neck nuts (1) .
DIESEL INJECTION Flow actuator: Removal - Refitting 13B K9K REFITTING I - REFITTING PREPARATION OPERATION a Only unpack the new component when you are ready to fit it. WARNING Do not remove the blanking plugs from each component until the last moment. WARNING Do not damage the seal when refitting. Note: Do not lubricate the seals with grease or old diesel fuel. Use the applicator provided in the kit for the new part.
DIESEL INJECTION Venturi: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm Venturi bolt 6 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) . 24733 IMPORTANT a Remove the dipstick guide and filler neck nuts (1) .
DIESEL INJECTION Venturi: Removal - Refitting 13B K9K III - FINAL OPERATION a Connect the return pipe connecting the injector to the high-pressure pump. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a Start the engine. a Check that there are no fuel leaks. a Refit the engine cover. 102316 a Disconnect the return pipe (4) connecting the injector to the high pressure pump. II - REMOVAL OPERATION a Remove: - the bolt (5) of the Venturi (6) , - the Venturi. a Plug the openings.
DIESEL INJECTION High pressure pipe: Check 13B K9K Equipment required Diagnostic tool a WARNING Check that there are no diesel leaks after each operation. Note: the Diagnostic tool can be used for testing the high pressure circuit with the engine running. This command can be used to run fault finding on a leak due to an incorrectly fitted or tightened union. This command only works if the engine coolant temperature is over 60˚C.
DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting 13B K9K REMOVAL Equipment required I - REMOVAL PREPARATION OPERATION Diagnostic tool a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the front engine cover. Tightening torquesm nut of the high pressure pipe between the pump and the injector rail on the high pressure pump 28 N.m nut of the high pressure pipe between the pump and the rail on the injector rail 28 N.
DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting 13B K9K REFITTING - the injectors. I - REFITTING PREPARATION OPERATION a parts always to be replaced: High pressure pipe between the pump and rail. 24752 a Disconnect: - the high pressure pump connectors (3) . - the injector rail pressure sensor. 20960 a Clean the diesel supply and return pipes (see Diesel injection: Precautions for the repair) . a WARNING a Disconnect the diesel supply and return pipes (4) .
DIESEL INJECTION High pressure pipe between pump and rail: Removal - Refitting K9K a Slightly pretighten the high pressure pipe nuts. a Torque tighten: - the nut of the high pressure pipe between the pump and the injector rail on the high pressure pump (28 N.m), - the nut of the high pressure pipe between the pump and the rail on the injector rail (28 N.m). III - FINAL OPERATION a Refit the neck on the injector rail.
DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting 13B K9K REMOVAL Equipment required I - REMOVAL PREPARATION OPERATION Diagnostic tool a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove: Tightening torquesm injector rail nuts 28 N.m - the engine cover, « pump - rail » high pressure pipe nuts 28 N.m - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting 13B K9K 109466 a Disconnect the following connectors (2) : - the heater plugs, - the injectors. 24752 a Disconnect the high pressure pump connectors (3) . a Remove the bolts mounting the neck onto the injector rail. a Move the wiring to one side with the neck on the side. a Remove the clips connecting the high pressure pipes.
DIESEL INJECTION High pressure pipe between rail and injector: Removal - Refitting 13B K9K a Slightly pretighten the high pressure pipe nuts. Note: The assembly order of the « rail-injector » high pressure pipes is not important. a Mount a new clip provided with the new high pressure pipe. a If replacing the four high pressure pipes, torque tighten the injector rail nuts (28 N.m). a Torque tighten in order the « pump - rail » high pressure pipe nuts (28 N.m) : - injectors end, - on the injector rail end.
DIESEL INJECTION Injector rail: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm injector rail nuts 28 N.m nuts of the neck and dipstick guide on the injector rail 21 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) . 24733 a Remove the nuts (1) from the dipstick guide and neck.
DIESEL INJECTION Injector rail: Removal - Refitting 13B K9K 109466 102360 a Disconnect: - the pressure sensor (7) from the injector rail, - the accelerometer (8) . 24752 a Disconnect: - the heater plugs (3) , - the injectors (4) , 24733 - the connectors on the high pressure pump (5) , a Unclamp the engine wiring (9) and place it to one side. - the diesel return pipe connecting the injectors to the high pressure injection pump.
DIESEL INJECTION Injector rail: Removal - Refitting 13B K9K - the high pressure pipe between the high pressure pump and the injector rail (see 13B, Diesel injection, High pressure pipe between pump and rail: Removal - Refitting, page 13B-19) . - the high pressure pipes between the injector rail and the injectors (see 13B, Diesel injection, High pressure pipe between rail and injector: Removal - Refitting, page 13B-22) . a Torque tighten the injector rail nuts (28 N.m).
DIESEL INJECTION Fuel temperature sensor: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm fuel temperature sensor 15 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) .
DIESEL INJECTION Fuel temperature sensor: Removal - Refitting K9K REFITTING I - REFITTING PREPARATION OPERATION a Lubricate the O-ring with lubricant from the applicator supplied with the new part. II - REFITTING OPERATION a Note: Do not damage the O-ring when refitting. a Remove the blanking plugs. a Fit the fuel temperature sensor. a Torque tighten the fuel temperature sensor (15 N.m). a Connect the connector (3) of the fuel temperature sensor.
DIESEL INJECTION Injector leak flow: Check 13B K9K Equipment required Diagnostic tool PARTS AND CONSUMABLES FOR THE REPAIR Consumables: - cleaning cloths (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). - set of K9K blanking plugs (DELPHI injection) (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products).
DIESEL INJECTION Injector leak flow: Check K9K 107637 a Connect four of the transparent pipes (3) of theonto the diesel injector return. a Insert these pipes in the four graduated measuring cylinders (4) of the. Note: If necessary, attach the graduated measuring cylinder rail of theto the bonnet. a Connect the Diagnostic tool to the vehicle. a Follow the instructions given in test 9: Injector sealing test (see Fault finding - Test) (13B, Diesel injection). a Disconnect the transparent pipes from the.
DIESEL INJECTION Diesel injector: Removal - Refitting 13B K9K a Remove: Equipment required - the engine cover, - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) . Diagnostic tool Tightening torquesm diesel injector clamp bolt 28 N.m injector rail nuts 28 N.m « rail-injector» high pressure pipe nuts 24 N.m nuts of the neck and dipstick guide on the injector rail 21 N.
DIESEL INJECTION Diesel injector: Removal - Refitting 13B K9K 109466 102360 a Disconnect: - the pressure sensor (7) from the injector rail, - the accelerometer (8) . 24752 a Disconnect: - the heater plugs (3) , - the injectors (4) , 24733 - the connectors (5) on the high pressure pump, a Unclamp the engine wiring (9) and place it to one side. - the diesel return pipe connecting the injectors to the high pressure injection pump. a Remove the neck (10) located on the injector rail.
DIESEL INJECTION Diesel injector: Removal - Refitting 13B K9K II - OPERATION FOR REMOVAL OF PART CONCERNED REMOVING THE INJECTORS USING TOOLS (MOT. 921-01) AND (EMB. 880) 109462 120509 a Loosen the injector clamp bolt (11) . Note: If reusing a diesel injector, always mark the removed diesel injector in relation to its cylinder. a Remove the diesel injector (12) . (A) Tool for extracting injector holders (Mot. 921-01). (B) Pin extractor (Emb. 880).
DIESEL INJECTION Diesel injector: Removal - Refitting 13B K9K a Torque tighten the diesel injector clamp bolt (28 N.m). REFITTING I - REFITTING PREPARATION OPERATION a Always replace the heat protection washer of the diesel injector concerned. Cleaning parts III - FINAL OPERATION a Fit the high pressure pipes (see 13B, Diesel injection, High pressure pipe between rail and injector: Removal - Refitting, page 13B-22) . a Torque tighten the injector rail nuts (28 N.m).
DIESEL INJECTION Diesel injector: Removal - Refitting K9K 19724 a Program the alphanumeric code (C2I) (13) for the replaced injector(s) using the Diagnostic tool (see Fault finding - Replacement of components) (13B, Diesel injection). a Start the engine. a Check that there are no fuel leaks.
DIESEL INJECTION Accelerometer: Removal - Refitting 13B K9K Equipment required Diagnostic tool Tightening torquesm accelerometer 20 N.m dipstick guide and filler neck nuts on the high pressure rail 21 N.m IMPORTANT To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair (see Diesel injection: Precautions for the repair) . 24733 a Remove the nuts (1) from the dipstick guide and neck.
DIESEL INJECTION Accelerometer: Removal - Refitting K9K II - OPERATION FOR REMOVAL OF PART CONCERNED a Remove the accelerometer using. REFITTING I - REFITTING OPERATION FOR PART CONCERNED a Refit the accelerometer. a Torque tighten the accelerometer (20 N.m) using the. II - FINAL OPERATION a Connect the accelerometer connector. a Refit: - the « pump-rail » high pressure pipe (see 13B, Diesel injection, High pressure pipe between pump and rail: Removal - Refitting, page 13B19) , - the dipstick guide.
PREHEATING Pre-postheating unit: Removal - Refitting 13C K9K II - FINAL OPERATION a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). Tightening torquesm pre-postheating unit bolt 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). II - REMOVAL OPERATION 24729 a Disconnect the pre-postheating unit connector (1) . a Remove: - the bolt (2) from the pre-postheating unit, - the pre/postheating unit (3) .
PREHEATING Heater plugs: Removal - Refitting 13C K9K II - REMOVAL OPERATION Equipment required compressed air nozzle hinged wrench for heater plug Tightening torquesm heater plugs 15 N.m REMOVAL I - REMOVAL PREPARATION STAGE a Remove the front engine cover. 109466 15762 a Disconnect the connector from each heater plug. IMPORTANT Wear goggles with side protectors for this operation.
PREHEATING Heater plugs: Removal - Refitting K9K a Unscrew the heater plugs using a 10 mm long socket connected to a universal joint or a hinged wrench for heater plug. a Use a hose to unscrew the heater plugs completely. a Remove the heater plugs. REFITTING I - REFITTING OPERATION a Without tightening, fit the heater plugs using the hose. a Torque tighten the heater plugs (15 N.m). a Connect the connector for each heater plug. II - FINAL OPERATION a Refit the engine cover.
ANTIPOLLUTION Exhaust gas recirculation: List and location of components K9K 112326 (1) Exhaust gas recirculation solenoid valve (2) Intercooler (3) Exhaust gas inlet pipe (4) Metal air inlet tube (5) Intercooler bracket on the flywheel end (6) Intercooler suppor t on the timing end 14A-1 14A
ANTIPOLLUTION Fuel vapour absorber: Removal - Refitting 14A K4M a Remove the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres). IMPORTANT a Move aside the front section of the front right-hand wheel arch liner. During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, II - REMOVAL OPERATION - be careful of fuel splashes when disconnecting the union. IMPORTANT Wear leaktight gloves (Nitrile type) for this operation.
ANTIPOLLUTION Fuel vapour absorber: Removal - Refitting K4M REFITTING I - REFITTING PREPARATION OPERATION a Remove the blanking plugs. II - REFITTING OPERATION a Refit: - the fuel vapour absorber, - the fuel vapour absorber nuts. a Clip on the breather pipe (2) a Connect: - the solenoid valve connector, - the fuel vapour absorber pipes (1) . III - FINAL OPERATION a Fit the front section of the front right-hand wheel arch liner.
ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting K9K, and 796 Tightening torquesm exhaust gas recirculation solenoid valve bolts 10 N.m Note: The exhaust gas recirculation solenoid valve is fitted into the exhaust gas recirculation unit. REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting 14A K9K, and 796 a Note: Use the toolto detach the exhaust gas recirculation solenoid valves jammed in their exhaust gas cooler mountings on the gearbox end. Remove: - the bracket bolt (3) from the air filter unit, - the air filter unit bracket. Position the lugs (4) of the toolin the bracket holes of the exhaust gas recirculation solenoid valve.
ANTIPOLLUTION Exhaust gas recirculation solenoid valve: Removal - Refitting K9K, and 796 a Torque tighten the exhaust gas recirculation solenoid valve bolts (10 N.m). a Connect the exhaust gas recirculation solenoid valve connector. III - FINAL OPERATION a Refit the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) .
ANTIPOLLUTION Exhaust gas cooler: Removal - Refitting 14A K9K, and 796 II - REMOVAL OPERATION Tightening torquesm exhaust gas cooler bolts 12 N.m exhaust gas recirculation rigid pipe bolts 12 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
ANTIPOLLUTION Exhaust gas cooler: Removal - Refitting 14A K9K, and 796 - the joint face of the exhaust gas cooler mounting on the gearbox end, - the joint face of the exhaust gas cooler mounting on the timing end. a Fit the exhaust gas recirculation assembly equipped with the exhaust gas recirculation rigid pipe on the cylinder head.
ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting 14A K9K, and 796 Special tooling required Ms. 583 Pipe clamps. Tightening torquesm bolts of the exhaust gas recirculation assembly 21 N.m bolts on the « timing end lifting eye - air inlet metal tube assembly » 10 N.m IMPORTANT Wear cut-resistant gloves during the operation. I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting 14A K9K, and 796 II - REMOVAL OPERATION 145641 a Remove: - the bolts (9) from the lifting eye at the timing end, 118974 - the lifting eye on the timing end (10) , a Position the (Ms. 583) or the hose clamps on the coolant inlet and outlet hoses of the exhaust gas cooler.
ANTIPOLLUTION Exhaust gas recirculation assembly: Removal - Refitting K9K, and 796 a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean the joint faces of the exhaust gas cooler mounting at the gearbox end. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting 14A K9K, and 796 - the timing end lifting eye (2) , Tightening torquesm II - REMOVAL OPERATION bolts of the exhaust gas recirculation rigid pipe bracket on the cylinder head 21 N.m bolts of the exhaust gas recirculation rigid pipe on the exhaust manifold 36 N.m bolts of the exhaust gas recirculation rigid pipe on the exhaust gas recirculation assembly 12 N.m lifting eye bolts 10 N.
ANTIPOLLUTION Exhaust gas recirculation rigid pipe: Removal - Refitting K9K, and 796 a Clean using ABRASIVE PADS : - the joint face of the exhaust gas recirculation assembly, - the exhaust manifold seal face. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). a Use SURFACE CLEANER (see ) (04B, Consumables - Products) and CLEAN CLOTHS to degrease: - the exhaust manifold joint face, - the joint face of the exhaust gas recirculation assembly.
STARTING - CHARGING Alternator: Removal - Refitting 16A K9K Tightening torquesm alternator bolts 21 N.m alternator lead nut 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) . II - REMOVAL OPERATION 123831 a Remove the alternator upper bolt (3) . a Loosen the alternator lower bolt (4) .
STARTING - CHARGING Alternator: Removal - Refitting K9K II - REFITTING OPERATION a Refit: - the alternator with its lower bolt, - the alternator upper bolt. a Torque tighten the alternator bolts (21 N.m). a Connect the connector to the alternator. a Refit the alternator lead. a Torque tighten the alternator lead nut (14 N.m). III - FINAL OPERATION a Refit the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) .
STARTING - CHARGING Alternator: Removal - Refitting 16A K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING Tightening torquesm alternator bolts 21 N.m alternator lead nut 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
STARTING - CHARGING Alternator: Removal - Refitting 16A K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING REFITTING II - REMOVAL OPERATION I - REFITTING PREPARATION OPERATION 116659 a Remove: - the alternator lead nut, 18987 a Push the rings (8) to make fitting easier. - the alternator lead (4) . a Disconnect the alternator connector (5) . II - REFITTING OPERATION a Refit the alternator. a Torque tighten the alternator bolts (21 N.m). a Connect the connector to the alternator.
STARTING - CHARGING Alternator: Removal - Refitting K4M, and POWER ASSISTED STEERING, and AIR CONDITIONING - the front bumper (see Front bumper: Removal Refitting) (55A, Exterior protection). a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
STARTING - CHARGING Alternator: Removal - Refitting 16A K4M, and STANDARD HEATING RECIRCULATION Tightening torquesm alternator bolts 21 N.m positive terminal nut on the alternator 14 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). 108273 a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Disconnect the alternator's electrical connections (4) .
STARTING - CHARGING Alternator: Removal - Refitting K4M, and STANDARD HEATING RECIRCULATION REFITTING I - REFITTING PREPARATION OPERATION 18987 a Push the rings (10) to make fitting easier. II - REFITTING OPERATION a Refit the alternator. a Torque tighten the alternator bolts (21 N.m). III - FINAL OPERATION a Connect the alternator electrical connections. a Torque tighten the positive terminal nut on the alternator (14 N.m). a Connect the fuel supply pipe union on the injector rail.
STARTING - CHARGING Starter: Removal - Refitting 16A K9K Tightening torquesm starter bolts 44 N.m nut on the starter solenoid lead 5 N.m starter lead nut 8 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). 24809 a Unclip the engine wiring at (2) . II - REMOVAL OPERATION a Remove: - the nut (3) on the starter solenoid lead, - the nut (4) on the starter lead, - the starter leads, - the starter bolts (5) , - the starter.
STARTING - CHARGING Starter: Removal - Refitting K9K III - FINAL OPERATION a Clip: - the engine wiring, - the intercooler duct on the fan assembly. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
STARTING - CHARGING Starter: Removal - Refitting 16A K4M JR5 Tightening torquesm starter bolts 44 N.m starter lead nut 8 N.m nut on the starter solenoid lead 5 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
STARTING - CHARGING Starter: Removal - Refitting 16A K4M III - FINAL OPERATION II - REMOVAL OPERATION JR5 a Clip: - the gearbox control cable sleeve stops on the gearbox, - the control cables onto the gearbox. a Refit the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . a Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
STARTING - CHARGING Alternator pulley: Removal - Refitting K4M Equipment required pneumatic or electric wrench torque wrench open-ended spanner for torque wrench Tightening torquesm alternator pulley 80 N.m I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) . a Disconnect the battery (see Battery: Removal - Refitting) .
STARTING - CHARGING Alternator pulley: Removal - Refitting 16A K4M Mot. 1732 110276 117672 a Position the hexagonal socket (1) or the splined socket (2) from the kitorin the alternator pulley (depending on the version).
STARTING - CHARGING Alternator pulley: Removal - Refitting 16A K4M - the alternator pulley.
STARTING - CHARGING Alternator pulley: Removal - Refitting 16A K4M IV - REFITTING OPERATION FOR THE ALTERNATOR PULLEY 110269 110266 110274 110271 a Position: - the hexagonal socket (3) or the splined socket (6) in the alternator pulley (depending on the version), a Tighten the new alternator pulley. - the end piece (4) in the recess of the alternator rotor, - the end piece holder (5) on the end piece.
STARTING - CHARGING Alternator pulley: Removal - Refitting K4M 119770 a Immobilise the alternator rotor using the spanner (7) . a Torque tighten the alternator pulley (80 N.m) using the torque wrench (8) equipped with a 15mm open-ended spanner for torque wrench. a Remove the tools. a Clip the new protector onto the alternator pulley (if equipped).
STARTING - CHARGING Alternator pulley: Removal - Refitting 16A K9K Tightening torquesm alternator pulley nut 80 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
STARTING - CHARGING Alternator pulley: Removal - Refitting K9K 114623 a Fit: - the splined socket (4) of thein the free wheel pulley (5) , - the end piece and holder assembly (6) of theon the alternator shaft. a Immobilise the splined socket (4) . a Torque tighten the alternator pulley nut (80 N.m). a Turn the pulley by hand to check that the rotor turns easily. a Clip on the alternator pulley protector (if equipped).
IGNITION Coils: Removal - Refitting K4M Tightening torquesm ignition coil bolts 14 N.m REMOVAL REMOVAL OPERATION 116655 a Disconnect the connectors (1) from the ignition coils. a Remove: - the ignition coil bolts (2) , - the ignition coils. REFITTING I - REFITTING PREPARATION OPERATION a Always replace the ignition coil bolts. a If necessary, replace the ignition coil O-rings.
IGNITION Coils: Removal - Refitting 17A K4M 106443 a When refitting the ignition harness, it is essential to apply a bead of FLUOSTAR 2L 2 mm in diameter around the inner edge of the high-tension caps on the side of the spark plugs and coil (see Vehicle: Parts and consumables for the repair) (04B, Consumables-Products). II - REFITTING OPERATION a Refit: - the ignition coils, - the new ignition coil bolts. a Torque tighten the ignition coil bolts (14 N.m). a Connect the ignition coil connectors.
PETROL INJECTION Petrol injection: List and location of components 17B K4M 116656 (1) Air pressure sensor (2) Idle speed stepper motor (3) Air temperature sensor (4) Throttle position potentiometer (5) Ignition coil (6) Throttle valve (7) Upstream oxygen sensor (8) Downstream oxygen sensor (9) Injection computer (10) Relay unit (11) Crankshaft position sensor (12) Coolant temperature sensor (13) Pinking sensor (14) Injectors (15) Injector rail (16) Fuel vapour recirculatio
PETROL INJECTION Petrol injection: List and location of components 17B K4M (4) Throttle position potentiometer (5) Ignition coil 145183 (9) Injection computer 116635 (6) Throttle valve (7) Upstream oxygen sensor 116570 (10) 108424 (8) Downstream oxygen sensor 17B-2 Relay unit
PETROL INJECTION Petrol injection: List and location of components 17B K4M 116648 (11) Crankshaft position sensor 101493 (14) Injectors (15) Injector rail 101498 (12) Coolant temperature sensor (13) Pinking sensor 108415 17B-3 (16) Fuel vapour recirculation solenoid valve (17) Petrol vapour absorber
PETROL INJECTION Oxygen sensors: Removal - Refitting 17B K4M II - REMOVAL OPERATION Tightening torquesm 1 - Upstream oxygen sensor upstream oxygen sensor 45 N.m dow n s t r e a m sensor 45 N.m oxygen WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxygen sensor connectors or on the bodies of the oxygen sensors.
PETROL INJECTION Oxygen sensors: Removal - Refitting 17B K4M a Clip on the downstream oxygen sensor wiring at (6) . 2 - Downstream oxygen sensor II - FINAL OPERATION Upstream oxygen sensor a Refit: - the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, page 12A-6) , - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . 145184 a Unclip the wiring from the downstream oxygen sensor at (6) .
PETROL INJECTION Throttle valve potentiometer: Removal -Refitting 17B K4M II - REMOVAL OPERATION Tightening torquesm throttle valve potentiometer bolts 2.4 N.m air filter unit bolts 9 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . 116566 a Remove: - the two bolts (5) from the throttle valve potentiometer, - the throttle valve potentiometer (6) .
PETROL INJECTION Petrol injection computer: Removal - Refitting 17B K4M Equipment required Diagnostic tool Tightening torquesm injection computer nuts 8 N.m WARNING Do not use any product designed to improve the electrical contact in the injection computer and oxygen sensor connectors or on the bodies of the oxygen sensors. Failure to respect this advice causes the oxygen sensor to malfunction and results in failure to comply with the emission control standard.
PETROL INJECTION Petrol injection computer: Removal - Refitting K4M REFITTING I - REFITTING OPERATION a Refit the injection computer. a Torque tighten the injection computer nuts (8 N.m). a Connect the two connectors of the injection computer. II - FINAL OPERATION a Refit the channel. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). III - WHEN REPLACING THE INJECTION COMPUTER a The computer supplied as a spare part is not operational (also known as "blank").
PETROL INJECTION Crankshaft position sensor: Removal - Refitting 17B K4M REFITTING Equipment required I - REFITTING OPERATION Diagnostic tool a Refit the crankshaft position sensor. a Refit the engine wiring harness mounting support. Tightening torquesm crankshaft position sensor bolts a Refit the two bolts of the crankshaft position sensor. 8 N.m a Torque tighten the crankshaft position sensor bolts (8 N.m).
PETROL INJECTION Injector rail - Injectors: Removal - Refitting 17B K4M Tightening torquesm injector rail bolts injector rail protector nuts 9 N.m 21 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. 101801 IMPORTANT a Remove: During this operation, be sure to: - the two nuts (1) from the injector rail protector, - refrain from smoking or bringing red hot objects close to the working area, - the injector rail protector (2) .
PETROL INJECTION Injector rail - Injectors: Removal - Refitting 17B K4M REFITTING II - REMOVAL OPERATION I - REFITTING PREPARATION OPERATION a parts always to be replaced: injector clip on injector rail. a parts always to be replaced: injector seal. a Refit: - new seals on each injector, - the injectors on the injector rail, - a new clip on each injector. II - REFITTING OPERATION a Remove the blanking plugs. a Fit the « injector rail-injector » assembly. a Torque tighten the injector rail bolts (9 N.
COOLING Engine cooling system: Operating diagram 19A K9K, and 796 133248 (1) Engine (2) Cooling radiator (3) Heater radiator (4) Expansion bottle (5) Water pump (6) Thermostat (7) Bleed screw (8) Oil-water heat exchanger (9) Temperature switch (10) EGR 19A-1
COOLING Engine cooling system: Specifications Vehicles in the current range have cooling systems with the following basic specifications: - hermetically-sealed pressurised circuit (expansion chamber valve), - circuit using a type "D" coolant, - passenger compartment heating system via a "heater matrix" type radiator under the dashboard. I - GRADE AND QUANTITY OF COOLANT Engine Quantity (litres) K4M Approximately 5.45 (version with AC) K9K Approximately 4.
COOLING Engine cooling system: Check 19A 1 - Checking the expansion bottle cap valve IMPORTANT When working in the engine compartment, take care as the radiator fan(s) may start up unexpectedly (risk of being cut). To avoid any risk of serious burns when the engine is hot: - do not open the expansion bottle cap, - do not drain the cooling system, - do not open the bleed screw(s).
COOLING Engine cooling system: Check 1 - Checking the expansion bottle cap valve 97871 a Fit onto the tester, the adapter (Ms. 554-06). a Fit the expansion bottle cap to the adapter (Ms. 55406). Note: The pressure should not drop; if it does, look for the leak. a Pump with the, the pressure should stabilise at the expansion bottle cap valve rating with a test tolerance of ± 0.1 bar. 2 - Checking the sealing of the cooling circuit a Replace the expansion bottle cap with the adapter (Ms. 554-01).
COOLING Engine cooling circuit: List and location of components 19A K4M I - LIST OF COMPONENTS (14) Expansion bottle The engine cooling system is composed of: (15) Bleed screw - an engine cooling fan assembly (see 19A, Cooling, Engine cooling fan assembly: Removal - Refitting, page 19A-27) , (16) Engine - a cooling radiator (see 19A, Cooling, Cooling radiator: Removal - Refitting, page 19A-9) , - a coolant pump (see 19A, Cooling, Coolant pump: Removal - Refitting, page 19A-13) , - a thermostat (s
COOLING Cooling system: Draining - Refilling a Use a compressed air nozzle to blow air into the system through the expansion bottle opening to remove as much coolant as possible. Special tooling required Mot. 1448 Remote operation pliers for hose clips. Car. 1363 Set of trim removal levers. 19A a Refit the cooling radiator bottom hose.
COOLING Cooling system: Draining - Refilling K4M 19A K9K 123103 123975 a Open the bleed screw (2) . 123104 a Open the bleed screws (4) and (5) . a Fill the cooling system with engine coolant recommended by the manufacturer (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) via the expansion bottle until it overflows. a Close all the bleed screws as soon as the coolant starts to flow in a continuous stream.
COOLING Cooling system: Draining - Refilling a Pressurise the system using the toolto check that there are no leaks (see 19A, Cooling, Engine cooling system: Check, page 19A-3) . a Refit the expansion bottle cap. a Clean any surfaces soiled by the coolant. IV - BLEEDING a WARNING Do not open the bleed screw whilst the engine is running; this would damage the engine. Start the engine.
COOLING Cooling radiator: Removal - Refitting 19A K4M - the injector rail protector (see 13B, Diesel injection, Injector rail: Removal - Refitting, page 13B25) , Special tooling required Mot. 1448 Car. 1363 Remote operation pliers for hose clips. - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) , Set of trim removal levers. - the fan assembly (see 19A, Cooling, Engine cooling fan assembly: Removal - Refitting, page 19A-27) .
COOLING Cooling radiator: Removal - Refitting 19A K4M II - REFITTING OPERATION a Proceed in the reverse order to removal. a Refill and bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). 145080 a Remove the condenser bolts (2) . 145560 a Remove the cooling radiator hose clips (3) using the tool (Mot. 1448). a Disconnect the cooling radiator hoses using the (Car. 1363).
COOLING Cooling radiator: Removal - Refitting 19A K9K - the engine cover, Special tooling required - the air intake sleeve, Mot. 1448 Remote operation pliers for hose clips. Car. 1363 Set of trim removal levers. - the intercooler (see 12B, Turbocharging, Intercooler: Removal - Refitting, page 12B-8) , - the fan assembly (see 19A, Cooling, Engine cooling fan assembly: Removal - Refitting, page 19A-27) .
COOLING Cooling radiator: Removal - Refitting 19A K9K II - REFITTING OPERATION a Proceed in the reverse order to removal. a Refill and bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). 145080 a Remove the condenser bolts (2) . 145560 a Remove the cooling radiator hose clips (3) using the tool (Mot. 1448). a Disconnect the cooling radiator hoses using the (Car. 1363).
COOLING Coolant pump: Removal - Refitting 19A K9K, and 796 - the engine undertray. a Remove the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). Tightening torquesm bolts of the coolant pump inner timing cover bolts alternator bolts 10 N.m a Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Remove: 9 N.m - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) , 21 N.
COOLING Coolant pump: Removal - Refitting 19A K9K, and 796 REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant pump seal. a Use SURFACE CLEANER (see ) (04B, Consumables - Products) to clean and degrease: - the coolant pump sealing face if it is to be reused, - the cylinder block gasket face. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
COOLING Coolant pump: Removal - Refitting 19A K9K, and 796 a Refit: II - REFITTING OPERATION - the engine undertray, - the engine undertray bolts, - the engine cover. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . 102262 a Refit: - the coolant pump fitted with a new seal, - the coolant pump bolts. a Torque tighten in order (1) (2) (3) (4) (5) the bolts of the coolant pump (10 N.
COOLING Coolant pump: Removal - Refitting 19A K4M - the accessories belt (see 11A, Top and front of engine, Accessories belt: Removal - Refitting, page 11A-2) , Tightening torquesm coolant pump M8 bolt 27 N.m - the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting, page 11A-17) . coolant pump M6 bolts 10 N.m a Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) .
COOLING Coolant pump: Removal - Refitting 19A K4M REFITTING I - REFITTING PREPARATION OPERATION a IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. IMPORTANT Wear goggles with side protectors for this operation. WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
COOLING Coolant pump: Removal - Refitting K4M II - REFITTING OPERATION 14505 a Apply one to two drops of FRENETANCHE (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to the coolant pump bolts (1) and (4) . a Refit the coolant pump. a Fit the coolant pump bolts in order until contact is made. a Torque tighten in order: - the coolant pump M8 bolt (27 N.m) (1) . - the coolant pump M6 bolts (10 N.m) (2) to (8) .
COOLING Thermostat: Removal - Refitting K9K a The thermostat is integral with the coolant outlet unit. The coolant outlet unit must be replaced to replace it (see 19A, Cooling, Water chamber: Removal - Refitting, page 19A-22) .
COOLING Thermostat: Removal - Refitting 19A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Special tooling required Mot. 1448 Remote operation pliers for hose clips. IMPORTANT When working in the engine compartment, take care as the radiator fan(s) may start up unexpectedly (risk of being cut). To avoid any risk of serious burns when the engine is hot: - do not open the expansion bottle cap, - do not drain the cooling system, - do not open the bleed screw(s).
COOLING Thermostat: Removal - Refitting 19A K4M III - FINAL OPERATION - the thermostat cover. a Fill and bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Refit: - the engine undertray, - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . 123733 a Remove: - the thermostat (4) , - the thermostat seal (5) .
COOLING Water chamber: Removal - Refitting 19A K9K, and 796 - the expansion bottle nuts. a Move aside the expansion bottle. Tightening torquesm water chamber bolts expansion bottle nuts 11 N.m 8 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
COOLING Water chamber: Removal - Refitting 19A K9K, and 796 II - REMOVAL OPERATION 146342 a Disconnect the EGR assembly outlet pipe at (6) . 20070 a Move the EGR assembly outlet pipe aside. a Remove: a Disconnect the coolant temperature sensor connector. - the water chamber bolts (8) , - the water chamber, - the water chamber seal. REFITTING I - REFITTING PREPARATION OPERATION a parts always to be replaced: Cylinder head coolant outlet unit seal.
COOLING Water chamber: Removal - Refitting K9K, and 796 II - REFITTING OPERATION a Refit: - a new water chamber seal in the water chamber housing, - the water chamber. a Torque tighten the water chamber bolts (11 N.m). a Connect: - the cooling hoses to the water chamber, - the coolant temperature sensor connector, - the EGR assembly outlet pipe, a Position the air duct between the intercooler and the EGR assembly. a Connect: - the air duct on the EGR assembly, - the union to the vacuum pump.
COOLING Water chamber: Removal - Refitting 19A K4M II - REMOVAL OPERATION Tightening torquesm coolant outlet unit bolts (initial torque) water chamber bolts 4 N.m 12 N.m REMOVAL I - OPERATION FOR REMOVAL OF PART CONCERNED a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
COOLING Water chamber: Removal - Refitting K4M 116636 a Screw on the water chamber bolts without tightening them. a Torque tighten in order: - the coolant outlet unit bolts (initial torque) (4 N.m), - the water chamber bolts (12 N.m). III - FINAL OPERATION a Connect: - the coolant temperature sensor, - the expansion bottle hose, - the passenger compartment heater hose, - the top hose to the water chamber. a Refit the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
COOLING Engine cooling fan assembly: Removal - Refitting 19A K4M REMOVAL II - REMOVAL OPERATION I - REMOVAL PREPARATION OPERATION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove: - the injector rail protector (see 13B, Diesel injection, Injector rail: Removal - Refitting, page 13B25) , - the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) .
COOLING Engine cooling fan assembly: Removal - Refitting 19A K4M STANDARD HEATING RECIRCULATION AIR CONDITIONING 145561 a Disconnect the cooling fan assembly connector (5) . 145563 a Disconnect: a Unclip the engine cooling fan assembly wiring. - the engine cooling fan assembly connector (7) , a Move aside the wiring of the engine cooling fan assembly. - the engine cooling fan assembly resistor connector (8) . a Remove the engine cooling radiator bolts (6) .
COOLING Engine cooling fan assembly: Removal - Refitting 19A K4M II - REFITTING OPERATION a Proceed in the reverse order to removal. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). III - CHECKING THE OPERATION OF THE FAN UNIT a Start the engine. a Disconnect the coolant temperature sensor connector. a Check the operation of the fan assembly. a Connect the coolant temperature sensor connector. 144817 a Switch off the engine.
COOLING Engine cooling fan assembly: Removal - Refitting 19A K9K REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove: - the engine cover, - the air intake sleeve, - the front bumper (see Front bumper assembly: Exploded view) (55A, Exterior protection).
COOLING Engine cooling fan assembly: Removal - Refitting 19A K9K II - REMOVAL OPERATION STANDARD HEATING RECIRCULATION 144817 145561 a Disconnect the cooling fan assembly connector (7) . a Unclip the engine cooling fan assembly wiring. a Move aside the wiring of the engine cooling fan assembly. a Remove the engine cooling radiator bolts (8) . 144819 a Unclip the following from the support (4) : - the intercooler duct on the fan assembly, - the engine coolant hose.
COOLING Engine cooling fan assembly: Removal - Refitting 19A K9K AIR CONDITIONING 144817 a Unclip the « condenser - expansion valve » connecting pipe at (11) . WARNING In order to avoid any refrigerant leaks, do not damage (deform, twist, etc.) the pipe. 145563 a Disconnect: - the engine cooling fan assembly connector (9) , a Pull the fan assembly according to the arrows (12) passing it under the « condenser - expansion valve » connecting pipe.
COOLING Engine cooling fan assembly: Removal - Refitting K9K REFITTING I - REFITTING PREPARATION OPERATION In the event of replacement a Refit on the fan assembly: - the power-assisted steering hose clips, - the wiring clip, - the support of the intercooler duct and coolant hose on the fan assembly. II - REFITTING OPERATION a Proceed in the reverse order to removal. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). III - CHECKING THE OPERATION OF THE FAN UNIT a Start the engine.
COOLING Coolant pump inlet pipe: Removal - Refitting 19A K9K, and 796 a Remove the front bumper (see Front bumper: Removal - Refitting) (55A, Exterior protection). Tightening torquesm coolant pump inlet pipe bolt 22 N.m accelerometer 20 N.m a Drain the engine cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Remove the oil-water heat exchanger (see 10A, Engine and cylinder block assembly, Oil-coolant heat exchanger: Removal - Refitting, page 10A37) .
COOLING Coolant pump inlet pipe: Removal - Refitting K9K, and 796 a Use SURFACE CLEANER (see ) (04B, Consumables - Products) to clean and degrease: - the coolant pump inlet pipe seal housing if it is being reused, - the seal housing in the cylinder block. WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks). WARNING Do not scrape the joint faces of the aluminium, any damage caused to the joint face will result in a risk of leaks.
COOLING Coolant pump inlet pipe: Removal - Refitting 19A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm coolant pump inlet pipe bolt 22 N.m REMOVAL I - REMOVAL PREPARATION OPERATION a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). a Remove the injector rail protector.
COOLING Coolant pump inlet pipe: Removal - Refitting K4M a Refit the injector rail protector. a Fill the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) . a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) .
COOLING Expansion bottle: Removal - Refitting 19A REMOVAL Special tooling required Ms. 583 Pipe clamps. Mot. 1448 Remote operation pliers for hose clips. REMOVAL OPERATION Tightening torquesm expansion bottle nuts 8 N.m IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot.
COOLING Expansion bottle: Removal - Refitting - the expansion bottle bottom hose. a Refit the following using the tool (Mot. 1448) or « CLIC » clip pliers: - the clamp of the top hose of the expansion bottle, - the clamp of the bottom hose of the expansion bottle. a Fill the expansion bottle with coolant. a Remove the hose clamps (Ms. 583). a Refit the expansion bottle. a Torque tighten the expansion bottle nuts (8 N.m). III - FINAL OPERATION a Top up the coolant level in the expansion bottle.
COOLING Coolant temperature sensor: Removal - Refitting 19A K9K Tightening torquesm expansion bottle nuts 8 N.m IMPORTANT Wear leaktight gloves (Nitrile type) for this operation. IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot. 24814 Take care when carrying out a repair under the bonnet, as the radiator fan(s) may start to operate without warning.
COOLING Coolant temperature sensor: Removal - Refitting 19A K9K REFITTING II - REMOVAL OPERATION I - REFITTING PREPARATION OPERATION a parts always to be replaced: coolant temperature sensor seal. a Use SURFACE CLEANER (see ) to clean and degrease: - the mating face of the coolant temperature sensor if it is to be reused, - the coolant outlet unit.
COOLING Coolant temperature sensor: Removal - Refitting K9K a Perform the following operations: - top up the cooling system, - bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) .
COOLING Coolant temperature sensor: Removal - Refitting 19A K4M II - OPERATION FOR REMOVAL OF PART CONCERNED Tightening torquesm coolant sensor temperature 30 N.m IMPORTANT The circuits are designed to be pressurised, so be careful at high temperatures (risk of serious burns). Do not remove the cap from the expansion bottle while the engine is hot. Take care when carrying out a repair under the bonnet, as the radiator fan(s) may start to operate without warning.
COOLING Coolant temperature sensor: Removal - Refitting K4M III - FINAL OPERATION a Refit the air resonator (see 12A, Fuel mixture, Air resonator: Removal - Refitting, page 12A-2) . a Perform the following operations: - top up the coolant level, - bleed the cooling system (see 19A, Cooling, Cooling system: Draining - Refilling, page 19A-6) .
EXHAUST Exhaust: List and location of components 19B-1 19B
EXHAUST Exhaust: List and location of components 19B K4M 144569 19B-2
EXHAUST Exhaust: List and location of components (A) Area to be cut A (B) Area to be cut B (1) Exhaust system sealing ring (2) Catalytic converter (3) Downstream oxygen sensor (4) Expansion chamber (5) Expansion chamber rubber pad (6) Silencer (7) Silencer rubber pad 19B-3 19B
EXHAUST Exhaust: List and location of components 19B K9K 144609 19B-4
EXHAUST Exhaust: List and location of components (A) Area to be cut A (B) Area to be cut B (1) Exhaust system sealing ring (2) Intermediate pipe (3) Intermediate pipe rubber pad (4) Silencer (5) Silencer rubber pad 19B-5 19B
EXHAUST Exhaust: Precautions for the repair To do this: Special tooling required Mot. 1199-01 19B - clean the bearing faces of the connection using GREY ABRASIVE PADS, Exhaust pipe cutter (diameter 35/50 mm and diameter 50/65mm). Complete kit in a case. - degrease the bearing faces of the connection using SURFACE CLEANER and clean cloths, Equipment required - always replace the seal or sealing ring on the connection.
EXHAUST Exhaust: Precautions for the repair 19B 102118 Fit the (Mot. 1199-01) (1) on the exhaust pipe. Tighten the two bolts on the tool until they touch the pipe in order to clamp the tool onto the pipe. 100649 Before cutting the exhaust system, draw a line (D) between the two marks (P1) and (P2) . Turn the cutting tool using the handle and pressing it against the pipe (as indicated in the diagram above). Tighten the two bolts on the tool whilst cutting, until the pipe is completely cut.
EXHAUST Exhaust: Precautions for the repair 19B Exhaust sleeve with 1 bolt Note: If necessary, use a component jack to lift and hold the heavy and bulky components of the exhaust system. Position the second exhaust pipe onto the lugs inside the exhaust sleeve. 95478 Exhaust sleeve with 2 bolts 99227 Check that the two cut marks (3) are aligned (if applicable). Position the sleeve so that there is no risk of contact between its bolt or bolts and the heat shields.
EXHAUST Exhaust: Precautions for the repair Note: If there are leaks from the EXHAUST SLEEVES WITH 1 BOLT, apply EXHAUST MASTIC to the sleeve (see part no. in Technical Note 5068, 04B, Consumables - Products). If the application of exhaust mastic does not fix the leak: - remove and replace the used exhaust sleeve, - check the condition of the exhaust pipes (condition of the pipe surface, deburring of the area cut, damage to the pipes). - fit the new sleeve in accordance with the instructions given before.
EXHAUST Catalytic converter: Removal - Refitting 19B K9K, and 796 REMOVAL Tightening torquesm I - REMOVAL PREPARATION OPERATION turbocharger studs output 9 N.m a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). catalytic converter nuts on the turbocharger 28 N.m a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). upstream strut bolts on the engine 44 N.
EXHAUST Catalytic converter: Removal - Refitting 19B K9K, and 796 144536 145311 a Remove the bolt from the downstream strut on the catalytic converter (2) . a Remove the catalytic converter nuts on the turbocharger (5) . a Loosen the downstream strut bolt and nut on the gearbox (3) . a Remove the downstream strut.
EXHAUST Catalytic converter: Removal - Refitting 19B K9K, and 796 REFITTING II - REFITTING OPERATION a I - REFITTING PREPARATION OPERATION Note: a If a stud loosens during this operation, coat it with HIGH STRENGTH THREAD LOCK (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products). WARNING To ensure proper sealing, the gasket surfaces must be clean, dry and not greasy (avoid any finger marks).
EXHAUST Catalytic converter: Removal - Refitting K9K, and 796 a Check that there are no leaks and deal with them if necessary.
EXHAUST Catalytic converter: Removal - Refitting 19B K4M, and 4X2 TRANSMISSION a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery). Special tooling required Mot. 1199-01 Exhaust pipe cutter (diameter 35/50 mm and diameter 50/65mm). Complete kit in a case. II - REMOVAL OPERATION Equipment required component jack Tightening torquesm bolt of the exhaust flange 21 N.m oxygen sensor 45 N.
EXHAUST Catalytic converter: Removal - Refitting 19B K4M, and 4X2 TRANSMISSION 109399 a parts always to be replaced: ring between exhaust manifold and catalytic converter II - REFITTING OPERATION 135949 a Remove: a Refit: - the downstream oxygen sensor (if replacing the catalytic converter), - the exhaust flange bolts (2) , - the catalytic converter.
EXHAUST Catalytic converter: Removal - Refitting K4M, and 4X2 TRANSMISSION a Check that there are no leaks and deal with them if necessary.
EXHAUST Expansion chamber: Removal - Refitting 19B K4M, and 4X2 TRANSMISSION a Remove the rubber pad from the expansion chamber using the tool (Mot. 1857). Special tooling required Mot. 1199-01 Exhaust pipe cutter (diameter 35/50 mm and diameter 50/65mm). Complete kit in a case. Mot. 1857 Note: If the rubber pad is damaged, replace the rubber pad. Pliers for removing exhaust pipe rubber mounting bushes a Remove the expansion chamber.
EXHAUST Intermediate pipe: Removal - Refitting 19B K9K II - REMOVAL OPERATION Special tooling required Mot. 1199-01 Exhaust pipe cutter (diameter 35/50 mm and diameter 50/65mm). Complete kit in a case. Mot. 1857 Pliers for removing exhaust pipe rubber mounting bushes Equipment required component jack Tightening torquesm exhaust sleeve bolts 146344 25 N.
EXHAUST Intermediate pipe: Removal - Refitting K9K REFITTING I - REFITTING OPERATION a Refit the intermediate pipe. a Refit the exhaust sleeves (see 19B, Exhaust, Exhaust: Precautions for the repair, page 19B-6) .
EXHAUST Silencer: Removal - Refitting 19B 4X2 TRANSMISSION a Remove the rubber pad from the silencer using the tool (Mot. 1857). Special tooling required Mot. 1199-01 Exhaust pipe cutter (diameter 35/50 mm and diameter 50/65mm). Complete kit in a case. Mot. 1857 Note: If the rubber pad is damaged, replace the rubber pad. Pliers for removing exhaust pipe rubber mounting bushes a Remove the silencer.
TANK Fuel tank: Draining II - DRAINING OPERATION Special tooling required Mot. 1311-08 19C Union for taking fuel pressure measurements. K4M a Disconnect the fuel supply union from the injector rail (1) . Equipment required pneumatic transfer pump for fuels IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union. 145570 IMPORTANT a Fit a T-union (Mot. 1311-08) at (2) .
TANK Fuel tank: Draining 19C a Drain the fuel tank. REFITTING a Proceed in the reverse order to removal. 144823 a Remove: - the front right-hand wheel arch liner bolts (4) , - the clip of the wheel arch liner (5) , - the diesel filter protector (see ) . a Disconnect the fuel outlet pipe from the fuel filter. 144827 a Connect a pneumatic transfer pump for fuels to the fuel filter. a Prepare for fuel outflow.
TANK Fuel tank: Removal - Refitting 19C 4X2 TRANSMISSION REMOVAL Tightening torquesm I - REMOVAL PREPARATION OPERATION fuel tank bolts 21 N.m exhaust pipe bolts on the catalytic converter 21 N.m catalytic converter bolts on the exhaust manifold 21 N.m earth cable nut on the body 8 N.m a Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment). a Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
TANK Fuel tank: Removal - Refitting 19C 4X2 TRANSMISSION K4M K4M 109185 a Remove the body earth cable at (2) . 108424 a Remove the oxygen sensor connector by sliding it from its support (in the direction of the arrow). a Disconnect the oxygen sensor connector. 109183 a Remove: - the heat shield pins (4) , - the fuel tank heat shield.
TANK Fuel tank: Removal - Refitting 19C 4X2 TRANSMISSION K9K K4M 116557 114121 a Remove the catalytic converter mountings (6) on the exhaust manifold. a Remove the exhaust pipe mountings (8) from the catalytic converter. a Detach the exhaust line assembly on the left-hand side. a Place the exhaust line assembly on the left-hand side. a Attach the front section of the exhaust line assembly to the front lower arm on the left-hand side.
TANK Fuel tank: Removal - Refitting 19C 4X2 TRANSMISSION II - OPERATION FOR REMOVAL OF PART CONCERNED 109181 a Note: This operation requires two people. a Remove the bolts (11) from the fuel tank. 118344 a Remove the bolts (9) from the filler neck. a Lower the tank slightly. a Remove the fuel tank. REFITTING I - REFITTING PREPARATION OPERATION 108650 a Disconnect the snap-on unions (10) from the tank outlet pipes.
TANK Fuel tank: Removal - Refitting 19C 4X2 TRANSMISSION a Refit the fuel tank. a Connect the battery (see Battery: Removal - Refitting) (80A, Battery). a Refit the fuel tank bolts. a Torque tighten the fuel tank bolts (21 N.m). a Refit the external fuel filter (if fitted to the vehicle) (see Fuel filter: Removal - Refitting) . a Reconnect the snap-on unions to the tank outlet fuel pipes. a Refit the filler neck bolts.
TANK Fuel level sensor module: Removal - Refitting 19C K4M or K9K Special tooling required K9K Car. 1363 Set of trim removal levers. Mot. 1397 Universal spanner for removing fuel gauge nuts. IMPORTANT During this operation, be sure to: - refrain from smoking or bringing red hot objects close to the working area, - be careful of fuel splashes when disconnecting the union. IMPORTANT Wear goggles with side protectors for this operation.
TANK Fuel level sensor module: Removal - Refitting 19C K4M or K9K K4M 109176 144825 a Disconnect: - the connector (3) , a Remove the nut from the fuel level sensor module using the tool (Mot. 1397) (5) , a Let the fuel drain from the fuel level sensor module. a Remove: - the fuel level sensor module, taking care not to damage the float, - union (4) . - the fuel level sensor module seal. WARNING To prevent the tank from deforming, refit the fuel sender unit nut to the tank well immediately.
TANK Fuel level sensor module: Removal - Refitting 19C K4M or K9K the mark (8) on the fuel level sensor module must be positioned opposite the mark on the fuel tank (10) . II - REFITTING OPERATION K4M a Press the fuel level sensor module by hand (to prevent the seal from moving) and finger tighten the nut on the fuel tank. a Then use the tool (Mot. 1397) to tighten the nut of the fuel level sensor module to the mark on the fuel tank.
ENGINE MOUNTING Suspended engine mounting: Tightening torque 19D K9K 103236 No. Description Tightening (N.m) (1) Right-hand suspended mounting support bolt on the body 62 (3) Right-hand suspended mounting support bolt on the engine 62 (5) Left-hand mounting bolt on the gearbox 62 (6) Left-hand rubber pad mounting bolt on the body 21 (7) Left-hand rubber pad bolt on the mounting 105 (8) Stud on the gearbox mounting 180 (9) Gearbox mounting nut on the rubber pad 62 No.
ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting 19D Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm bolts mounting the lefthand suspended mounting on the gearbox 62 N.m bolt of the powerassisted steering pipe on the left-hand suspended mounting 21 N.m stud on the gearbox support 180 N.m a Fit the engine support tool (Mot.
ENGINE MOUNTING Left-hand suspended engine mounting: Removal - Refitting - the bolts (3) from the left-hand rubber pad mounting on the body, - the left-hand rubber pad mounting, - the power-assisted steering pipe bolt on the suspended mounting (if fitted to the vehicle), - the left-hand suspended mounting bolts (4) on the gearbox, - the left-hand suspended mounting on the gearbox. REFITTING I - REFITTING PREPARATION OPERATION a Always replace the self-locking nuts.
ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 19D K9K Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm right-hand suspended engine mounting bolts on the engine 62 N.m right-hand suspended engine mounting bolts on the body 62 N.m REMOVAL 146339 I - REMOVAL PREPARATION OPERATION a Disconnect the fuel pipe at (1) , a Remove the front engine cover. a Insert the blanking plugs.
ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 19D K9K REFITTING II - REMOVAL OPERATION I - REFITTING OPERATION 145429 a Mark the position of the right-hand suspended engine mounting on the body.
ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting 19D K4M II - REMOVAL OPERATION Special tooling required Mot. 1453 Engine anchorage support with multiple adjustments and retaining straps. Tightening torquesm right-hand suspended engine mounting bolts on the engine 62 N.m right-hand suspended engine mounting bolts on the body 62 N.m 144815 a Detach at (2) : REMOVAL - the fuel supply pipe, - the petrol vapour recirculation pipe.
ENGINE MOUNTING Right-hand suspended engine mounting: Removal - Refitting K4M II - FINAL OPERATION a Remove the engine support tool (Mot. 1453). a Refit the engine cover.
ENGINE MOUNTING Lower engine tie-bar: Removal - Refitting 19D REFITTING Tightening torquesm I - REFITTING OPERATION rear suspended engine mounting bolt on the subframe 105 N.m rear suspended engine mounting bolts on the gearbox 105 N.m a Refit: - the rear suspended engine mounting, - the rear suspended engine mounting bolts. a Torque tighten: - the rear suspended engine mounting bolt on the subframe (105 N.m), REMOVAL - the rear suspended engine mounting bolts on the gearbox (105 N.m).
