MR448FLUENCE1.pdf

© Renault s.a.s 2007

"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault.

OCTOBER 2009 EDITION ANGLAISE

X38, and B32 or L38

1 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

19A COOLING

19B EXHAUST

© Renault s.a.s 2007

"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".

All rights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault.

OCTOBER 2009 EDITION ANGLAISE

X38, and B32 or L38

19C TANK

19D ENGINE MOUNTING

FLUENCE - MEGANE GENERATION -Section 1

Contents

Pages

FLUENCE - MEGANE GENERATION - Section 1 ContentsPages

10AENGINE AND CYLINDER BLOCK ASSEMBLY

Crankshaft seal on timing end: Removal - Refitting 10A-1

Crankshaft seal, gearbox end: Removal - Refitting 10A-6

Lower cover: Removal - Refitting 10A-10

Conrod bearing shell: Removal - Refitting 10A-15

Engine oil: Draining - Refilling 10A-23

Oil filter: Removal - Refitting 10A-25

Oil-coolant heat exchanger: Removal - Refitting 10A-27

Oil pressure sensor: Removal - Refitting 10A-32

Oil level sensor: Removal - Refitting 10A-33

Oil pump: Removal - Refitting 10A-34

Oil pressure: Check 10A-35

Multifunction support: Removal - Refitting 10A-37

Engine - gearbox assembly: Removal - Refitting 10A-39

Flywheel: Removal - Refitting 10A-70

Drive plate: Removal - Refitting 10A-72

11A TOP AND FRONT OF ENGINE

Pressure at end of compression: Check 11A-1

Accessories belt: Removal - Refitting 11A-4

Crankshaft accessories pulley: Removal - Refitting 11A-8

Timing belt: Removal - Refitting 11A-16

Rocker cover: Removal - Refitting 11A-41

Camshaft: Removal - Refitting 11A-54

Cylinder head: Removal - Refitting 11A-61

Camshaft dephaser: Removal - Refitting 11A-87

Camshaft dephaser solenoid valve: Removal - Refitting 11A-90

Camshaft seal, timing end: Removal - Refitting 11A-91

Oil decanter: Removal - Refitting 11A-102

12A FUEL MIXTURE

Air resonator: Removal - Refitting 12A-1

Air filter: Removal - Refitting 12A-3

Contents

Air filter unit: Removal - Refitting 12A-5

Air flowmeter: Removal - Refitting 12A-7

Damper valve: Removal - Refitting 12A-9

Throttle valve: Removal - Refitting 12A-12

Inlet distributor: Removal - Refitting 12A-14

Injector holder shim: Removal - Refitting 12A-18

Exhaust manifold: Removal - Refitting 12A-20

12B TURBOCHARGING

Turbocharger: Removal - Refitting 12B-1

Turbocharger oil pipe: Removal - Refitting 12B-4

Intercooler: Removal - Refitting 12B-10

Intercooler air inlet pipe: Removal - Refitting 12B-12

Intercooler air outlet pipe: Removal - Refitting 12B-17

13A FUEL SUPPLY

Manual priming pump: Removal - Refitting 13A-1

12A FUEL MIXTURE 13B DIESEL INJECTION

Diesel injection: List and location of components 13B-1

Diesel injection computer: Removal - Refitting 13B-6

Camshaft position sensor: Removal - Refitting 13B-8

Crankshaft position sensor: Removal - Refitting 13B-12

High pressure pump leak flow: Check 13B-13

High pressure pump: Removal - Refitting 13B-16

Flow actuator: Removal - Refitting 13B-28

Venturi: Removal - Refitting 13B-30

Diesel injector fuel return rail: Removal - Refitting 13B-32

High pressure pipe between pump and rail: Removal - Refitting 13B-37

High pressure pipe between rail and injector: Removal - Refitting 13B-46

Injector rail: Removal - Refitting 13B-57

Rail pressure sensor: Removal - Refitting 13B-61

Fuel temperature sensor: Removal - Refitting 13B-63

Injector leak flow: Check 13B-66

Diesel injector: Removal - Refitting 13B-72

Accelerometer: Removal - Refitting 13B-80

Contents

13C PREHEATING

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

Heater plugs: Removal - Refitting 13C-2

14A ANTIPOLLUTION

Exhaust gas recirculation solenoid valve: Removal - Refitting 14A-1

Exhaust gas cooler: Removal - Refitting 14A-3

Exhaust gas recirculation assembly: Removal - Refitting 14A-4

Exhaust gas recirculation rigid pipe: Removal - Refitting 14A-16

16A STARTING - CHARGING

Alternator: Removal - Refitting 16A-1

Starter: Removal - Refitting 16A-5

19A COOLING

Engine cooling system: Specifications 19A-1

Engine cooling circuit: List and location of components 19A-3

Cooling system: Draining - Refilling 19A-8

Cooling radiator: Removal - Refitting 19A-11

Coolant pump: Removal - Refitting 19A-15

Thermostat: Removal - Refitting 19A-18

Water chamber: Removal - Refitting 19A-19

Engine cooling fan assembly: Removal - Refitting 19A-22

Coolant pump inlet pipe: Removal - Refitting 19A-25

Coolant temperature sensor: Removal - Refitting 19A-28

19B EXHAUST

Exhaust: List and location of components 19B-1

Catalytic converter: Removal - Refitting 19B-6

Intermediate pipe: Removal - Refitting 19B-12

Silencer: Removal - Refitting 19B-15

19C TANK

Fuel tank: Draining 19C-1

Fuel tank: Removal - Refitting 19C-4

Filler neck: Removal - Refitting 19C-13

Fuel level sensor module: Removal - Refitting 19C-15

19D ENGINE MOUNTING

Left-hand suspended engine mounting: Removal - Refitting 19D-1

19A COOLING

Contents

Right-hand suspended engine mounting: Removal - Refitting 19D-5

Lower engine tie-bar: Removal - Refitting 19D-10

19D ENGINE MOUNTING

10A-1

ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting

K9K

10AREMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).

a Disconnect the battery (see Battery: Removal - Re-fitting) (80A, Battery).

a Remove:

- the engine cover,

- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the front section of the front right-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray,

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

- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-4) ,

- the crankshaft accessories pulley (see 11A, Topand front of engine, Crankshaft accessoriespulley: Removal - Refitting, page 11A-8) .

a Remove the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting, page 19D-10) .

a Remove the right-hand suspended engine mounting(see 19D , Engine mounting, Right-hand sus-pended engine mounting: Removal - Refitting,page 19D-5) .

a Remove the camshaft position sensor (see 13B,Diesel injection, Camshaft position sensor: Re-moval - Refitting, page 13B-8) .

a Remove the timing belt (see 11A, Top and front ofengine, Timing belt: Removal - Refitting, page11A-16) .

a Remove the crankshaft timing sprocket (1) .

II - OPERATION FOR REMOVAL OF PART CONCERNED

a Fit the end piece (2) onto the tool (3) .

K9K, and 830 or 838

K9K, and 830 or 838

109043

105257

10A-2


K9K

10A

a Position the jaws of the toolonto the crankshaft nose(4) .

a Push on the tooluntil contact is made between theends (5) of the jaws and the crankshaft seal.

a Separate the jaws by screwing the nutof the tool (6) .

a Screw down the threaded rod (7) of the.

a Remove the crankshaft seal using the tool.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Crankshaft seal ontiming end (10,03,03,04).

105260

105261

105262

105263

10A-3


K9K

10Aa Use SURFACE CLEANER (see Vehicle: Parts

and consumables for the repair) (04B, Consuma-bles - Products) to clean and degrease:

- the crankshaft seal mating face on the crankshaft,

- the crankshaft seal housing in the crankshaft clo-sure panel.

II - REFITTING OPERATION FOR PART CONCERNED

a Tighten the threaded rod (8) :

- of the toolin the crankshaft with an M12 thread,

- of the toolin the crankshaft with an M14 thread.

a Insert the spacer (9) of thein the crankshaft.

a Fit the protector equipped with the crankshaft sealonto the spacer, taking care not to touch the crank-shaft seal.

WARNING

To ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-ger marks).

20772

20771

20770

10A-4


K9K

10A

a Fit the cover (10) and the nut (11) (positioning thethread (12) of the nut towards the outside of the en-gine).

a Screw on the nut until the cover touches the spacer.

20769 20768

20767

10A-5


K9K

10A

a Remove:

- the nut,

- the cover,

- the guard,

- the spacer,

- the threaded rod.

III - FINAL OPERATION

a Refit:

- the crankshaft timing sprocket,

- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting, page 11A-16) .

a Refit the camshaft position sensor (see 13B, Dieselinjection, Camshaft position sensor: Removal -Refitting, page 13B-8) .

a Refit the right-hand suspended engine mounting(see 19D , Engine mounting, Right-hand sus-pended engine mounting: Removal - Refitting,page 19D-5) .

a Refit the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting, page 19D-10) .

a Refit:






- the engine cover.

a Connect the battery (see Battery: Removal - Refit-ting) (80A, Battery).

20766

K9K, and 830 or 838

K9K, and 830 or 838

10A-6

ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - Refitting

K9K

10AREMOVAL



a Remove:

- the engine cover,

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

- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery),

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting, page 12A-5) ,



- the crankshaft position sensor (see 13B, Diesel in-jection, Crankshaft position sensor: Removal -Refitting, page 13B-12) ,

- the starter (see 16A, Starting - Charging, Starter:Removal - Refitting, page 16A-5) ,

- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),

- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection).

a Drain the gearbox (see Manual gearbox oils:Draining - Filling) .

a Remove:

- the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A,Driveshaft),

- the front right-hand wheel driveshaft (see Frontright-hand driveshaft: Removal - Refitting)(29A, Driveshaft),

- the differential output seals (see Differential out-put seal: Removal - Refitting) (21A, Manual gear-box).

a Remove:


- the radiator mounting cross member (see Radiatormounting cross member: Removal - Refitting)(31A, Front axle components),

- the front axle subframe (see Front axle subframe:Removal - Refitting) (31A, Front axle compo-nents),

- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (85A, Wiping -Washing),

- the scuttle panel grille (see Scuttle panel grille:Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (56A, Exterior equipment),

- the left-hand suspended engine mounting (see19D, Engine mounting, Left-hand suspendedengine mounting: Removal - Refitting, page19D-1) ,

- the manual gearbox (see Manual gearbox: Re-moval - Refitting) (21A, Manual gearbox).

- the hydraulic clutch release bearing (see Clutchthrust bearing: Removal - Refitting) (20A,Clutch),

- the clutch disc and pressure plate (see Pressureplate - Disc: Removal - Refitting) (20A, Clutch),

- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-70) .


a Fit the end piece (1) of the (2) .

105259

10A-7


K9K

10A

a Position the jaws (3) of theon the crankshaft (4) .

a Push the tooluntil contact is made between the ends(5) of the jaws and the crankshaft seal.

a Move the jaws away by tightening the bolt (6) usingan open-jawed spanner.

a Screw down the threaded rod (7) of the.

105265

105266

105267

105268

10A-8


K9K

10A

a Remove the crankshaft seal using the tool.

REFITTING


a

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean and degrease:

- the crankshaft seal mating face on the crankshaft,

- the crankshaft seal housing in the cylinder block.

a parts always to be replaced: Differential outputseal (12,01,05,10).


a Refit the crankshaft seal on the gearbox side (seeCylinder block: Rebuilding) (Technical Note6006A, 10A, Engine and peripherals).


a Refit:

- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-70) ,



- the manual gearbox (see Manual gearbox: Re-moval - Refitting) (21A, Manual gearbox),







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

a Refit:

- the new differential output seals (see Differentialoutput seal: Removal - Refitting) (21A, Manualgearbox),

- the front right-hand wheel driveshaft (see Frontright-hand driveshaft: Removal - Refitting)(29A, Driveshafts),

- the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A,Driveshafts).

a Fill the manual gearbox (see Manual gearbox oils:Draining - Filling) (21A, Manual gearbox).

a Refit:

- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),

105269

WARNING


10A-9


K9K

10A- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),


- the crankshaft position sensor (see 13B, Diesel in-jection, Crankshaft position sensor: Removal -Refitting, page 13B-12) .

a Bleed the clutch control circuit (see Clutch circuit:Bleed) (37A, Mechanical component controls).

a Refit:





- the engine cover.

10A-10

ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting

K9K

10A

REMOVAL



a Remove:

- the engine cover,

- the dipstick,


- the engine undertray.

a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-23) .


a Remove:

- the bolts (1) from the front right-hand wheel drive-shaft relay bearing,

- the front right-hand wheel driveshaft relay bearing.

a Remove the lower bolt (2) from the multifunctionsupport.

Tightening torquesm

sump bolts on the gear-box

44 N.m

sump bolts 14 N.m

ca ta ly t i c converterupstream strut bolt onthe cylinder block

50 N.m

ca ta ly t i c converterupstream strut bolts onthe catalytic converter

26 N.m

multifunction supportlower bolt

25 N.m

front right-hand wheeldriveshaft relay bearingbolts

44 N.m

IMPORTANT

Wear leaktight gloves (Nitrile type) for this opera-tion.

K9K, and 832 or 842

123838

123832

10A-11


K9K

10A

a Undo the bolt (3) of the catalytic converter upstreamstrut from the sump.

a Remove:

- the bolt (4) of the catalytic converter upstream strutfrom the cylinder block,

- the bolt (5) of the catalytic converter upstream strutfrom the catalytic converter,

- the catalytic converter upstream strut.

a Unclip the drain pipe from the injector rail protector:

- the gearbox,

- the sump.

a Move the injector rail protector drain pipe away fromthe sump.

a Disconnect the connector (6) from the oil level sen-sor.

135486 123834

10A-12


K9K

10AII - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

- the bolts (7) of the sump starting with the mountingbolts on the gearbox,

- the sump,

- the sump seal.

REFITTING


a parts always to be replaced: engine oil sumpseal (10,03,01,09).

a Wipe the oil pump strainer with a CLEAN CLOTH.

a Clean the cylinder block gasket surface using SU-PER CLEANING AGENT FOR JOINT FACES andABRASIVE PADS (see Vehicle: Parts and con-sumables for the repair) (04B, Consumables -Products).

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to degrease:

- the cylinder block gasket face,

20171

134211

Note:

If the sump cannot be extracted because it is incontact with the oil pump strainer, do not forcethe removal of the sump as this may damage theoil splash plate.

Loosen the oil pump bolts by a few turns (the tipof your finger should pass between the bolt headand the oil pump casing) using 10 mm and 13mm open-jawed spanners and while tilting thesump towards the front of the vehicle.

IMPORTANT

Wear goggles with side protectors for this opera-tion.

WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.

WARNING


WARNING

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

10A-13


K9K

10A- the sump joint face if it is to be reused.

a Apply:

- four beads of SILICONE ADHESIVE SEALANT(6) (see Vehicle: Parts and consumables for therepair) (04B, Consumables - Products) with a di-ameter of 5 mm and a length of 12 mm,

- two drops of SILICONE ADHESIVE SEALANT (7)(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) with a diame-ter of 5 mm.

If replacing the sump

a Remove the oil level sensor from the sump.

a Refit the oil level sensor to the new sump.


a Fit:

- a new sump seal to the sump,

- the sump fitted with a new seal.

20166

20167

Note:

If the oil pump was loosened beforehand in orderto extract the sump, position the sump in order topass the oil pump strainer into the oil splashplate of the sump.

Position a component jack to support the sump.

Lean the sump towards the front of the vehicle inorder to access the oil pump bolts.

Torque tighten the oil pump bolts (25 N.m) usingthe small torque wrench 77 11 226 888.

Fit the sump and then follow the following instruc-tions.

Note:

Before pressing the sump on the cylinder block,check that the sump seal is still in place and thatit has not come out of the grooves on the sides.

10A-14


K9K

10A

a Refit:

- the bolts from the sump on the gearbox,

- the sump bolts on the cylinder block.

a Torque tighten:

- the sump bolts on the gearbox (44 N.m),

- and in order, the sump bolts (14 N.m).


a Connect the connector to the oil level sensor.

a Fit the injector rail protector drain pipe.

a Clip the injector rail protector drain pipe onto:

- the sump,

- the gearbox.

a Refit the catalytic converter upstream stay.

a Torque tighten:

- the catalytic converter upstream strut bolt onthe cylinder block (50 N.m),

- the catalytic converter upstream strut bolts onthe catalytic converter (26 N.m).

a Tighten the catalytic converter upstream strut bolt onthe sump.

a Torque tighten the multifunction support lowerbolt (25 N.m).

a Refit the relay bearing of the front right-hand wheeldriveshaft.

a Torque tighten the front right-hand wheel drive-shaft relay bearing bolts (44 N.m).


a Fill up the engine oil (see 10A, Engine and cylinderblock assembly , Engine oil: Draining - Refilling,page 10A-23) .

a Refit:


- the dipstick,

- the engine cover.

a Disconnect the Top Dead Centre sensor to preventthe engine from starting.

a Activate the starter in order to prime the oil in the oilpump.

a Connect the Top Dead Centre sensor.

a Make sure that there are no oil leaks.

20171

K9K, and 832 or 842

10A-15

ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting

K9K

10A

REMOVAL



a Remove the engine undertray.

a Drain the oil from the engine (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-23) .

a Remove the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-25) .


a Remove the relay bearing of the front right-handwheel driveshaft.

a Disconnect the oil level sensor connector (ifequipped) (2) .

Equipment required

component jack

indelible pencil

torque wrench

Diagnostic tool

Tightening torquesm

con rod cap bolts 20 N.m + 45˚ ±±±±6˚

oil pump bolts 25 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Vehicle: Precautions for the repair) .

IMPORTANT


123838

123834

10A-16


K9K

10A

a Remove the catalytic converter upstream stay (3) .

a

Undo the bolts of the engine oil sump.

a Fit a component jack to support the engine oilsump.

a Remove the bolts from the engine oil sump.

a Detach the engine oil sump, while supporting it withthe component jack.

a Tilt the engine oil sump forwards in order to accessthe 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 re-move the engine oil sump.

a Remove:

- the engine oil sump,

- the engine oil sump seal,

- the oil pump.

112328

140940

WARNING

Failure to observe the following procedure maydamage the oil pump strainer.

140917

10A-17


K9K

10AII - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2

a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) to clean the big ends.

a Mark the position of the con rod cap in relation to thecon rod body using a indelible pencil.

a Position the crankshaft at Top Dead Centre.

a Remove:

- the con rod bolts,

- the con rod cap,

- the lower con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - products) to clean the bearing mating face onthe con rod cap.

139306

139300

Note:

If reusing the con rod bearing shells, mark theposition of the lower con rod bearing shell in rela-tion to the con rod cap.

10A-18


K9K

10A

a Fit the tie rod of the toolon the con rod body.

a Push the con rod upwards to release the con rodfrom the crankpin.

a Turn the crankshaft 90˚ clockwise (timing end).

a

Pull the con rod - piston assembly using the tie rod ofthe tool, taking care not to allow the piston to touchthe piston base cooling jets.

a Remove the upper con rod bearing shell.

a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - products) to clean the bearing mating face onthe con rod body.

REFITTING

I - REFITTING OPERATION FOR THE CON ROD BEARING SHELLS ON CYLINDER NO.2

a parts always to be replaced: con rod cap bolts(10,03,02,10)

139310 139315

WARNING

Failure to observe the following procedure maydamage the piston base cooling jets.

Note:

If reusing the con rod bearing shells, mark theposition of the upper con rod bearing shell inrelation to the con rod body.

10A-19


K9K

10Aa

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.

a

Fit the lower con rod bearing shell on the con rodcap using the tool.

a Position the lower con rod bearing shell so that theends do not protrude beyond the con rod cap.

a Lubricate the surface of the con rod bearing shell(crankshaft end) using new engine oil.

Note:

Always replace con rod bearing shells with awidth of 20 mm by con rod bearing shells with awidth of 18 mm.

If the set of con rod bearing shells only includescon rod bearing shells which are 18mm wide,only use the head of the toolwith the marking "K9K SUP ".

133814

133815

Note:

The contact surface between the bearing shelland the con rod must be dry and free of grease.

10A-20


K9K

10A

a Remove the tool head with the marking " K9K INF "and fit the head with the marking " K9K SUP ".

a Position the upper con rod bearing shell on the tool.

a Fit the upper con rod bearing shell on the con rodbody using the tool.

a Position the upper con rod bearing shell so that theends do not protrude beyond the con rod body.

a Lubricate the surface of the con rod bearing shell(crankshaft end) using new engine oil.

a Push the con rod - piston assembly back up intoplace.

a Turn the crankshaft 90˚ anticlockwise.

a Lubricate the crankpin with new engine oil.

a Pull the con rod - piston assembly to position the conrod on the crankshaft.

a

Refit:

- the con rod cap according to the mark made duringremoval,

- the new con rod bolts.

a Torque and angle tighten the con rod cap bolts (20N.m + 45˚ ±±±± 6 )̊.

II - REMOVAL - REFITTING OPERATIONS FOR THE CON ROD BEARING SHELLS ON CYLINDERS NO.3, 1 AND 4

a Perform the same removal - refitting operations asfor the con rod bearing shells on cylinder no. 2.


a parts always to be replaced: engine oil sumpseal (10,03,01,09)

parts always to be replaced: Oil filter (10,05,05,03)

parts always to be replaced: Drain plug seal onengine oil sump (10,03,01,04)

a Use a wooden spatula or an ABRASIVE PAD toclean the joint face of the cylinder block and engineoil sump.

a Refit the oil pump.

a Fit without tightening the oil pump bolts, while keep-ing a clearance of 3 mm to 5 mm.

a Fit the engine oil sump seal.

139318

Note:

Before refitting the con rod cap, ensure that thereare no impurities (filings, cloth lint, etc.) on thecon rod body or cap surfaces.

Note:

For removing and refitting the con rod bearingshells on cylinders no. 1 and no. 4, position thepistons at Bottom Dead Centre before performingthe same removal and refitting operations as forthe con rod bearing shells on cylinder no. 2.

WARNING

Do not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.

WARNING


WARNING


10A-21


K9K

10A

a Apply SILICONE ADHESIVE SEALANT (see Vehi-cle: Parts and consumables for the repair) :

- four beads with a diameter of 5 mm at (A) ,

- two drops with a diameter of 5 mm at (B) .

a Fit the engine oil sump while supporting it using acomponent jack.

a Tilt the engine oil sump forwards in order to accessthe oil pump bolts.

a Torque tighten the oil pump bolts (25 N.m) usingthe torque wrench PROSTEEL, part number 77 11226 888 starting with the 13 mm bolt.

a

a Refit the engine oil sump bolts.

a Torque tighten in order the engine oil sump bolts(see 10A, Engine and cylinder block assembly,Lower cover: Removal - Refitting, page 10A-10) .

a Refit the catalytic converter upstream stay (see 19B,Exhaust, Catalytic converter: Removal - Refit-ting, page 19B-6) .


a Refit the relay bearing of the front right-hand wheeldriveshaft (see Front right-hand driveshaft: Re-moval - Refitting) .


20166

20167

140918

Note:

Check that the engine oil sump seal is definitelyin place before tightening the engine oil sumpbolts.

10A-22


K9K

10A

a Disconnect the crankshaft position sensor (4) to pre-vent the engine from starting.

a Refit the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-25)

a Fill up the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-23) .

a Start the engine using the starter until the engine oilwarning light goes out.

a Connect the crankshaft position sensor.

a Refit the engine undertray.

a Clear the present faults using the Diagnostic tool.

123824

10A-23

ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - Refilling

K9K

10AI - RECOMMENDATIONS FOR REPAIR

a There is no direction of fitting for a seal fitted with arubber lip.

II - PARTS AND CONSUMABLES FOR THE REPAIR

a parts always to be replaced: Drain plug seal onengine oil sump (10,03,01,04).

a Consumable:

- Engine oil (see Engine oil: Specifications) (Tech-nical Note 6013A, 04A, Lubricants).

Special tooling required

Mot. 1018 8 mm square engine drainplug spanner.

Equipment required

oil recovery tray

oil change wrench

torque wrench

oil change end piece with an 8 mm square drive

Tightening torquesm

the drain plug 20 N.m

Engine

Average oil capacity

(adjusting using dipstick) (l)

Oil change with-o u t fi l t e rreplacement

Oil change withfilter replace-ment

K9K 4.4 4.5

113765

IMPORTANT


WARNING

Always check the oil level using the dipstick.

Do not exceed the maximum level on the dipstick(could destroy the engine).

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

Note:

When topping up the engine oil, always leave atleast 10 minutes before checking the level with adipstick.

10A-24

ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - Refilling

K9K

10AIII - OIL SERVICE


a Remove:

- the engine oil filler cap (1) ,

- the dipstick (2) ,



a Place the oil recovery tray under the engine.

a Remove the drain plug (4) from the sump using the(Mot. 1018) or a oil change wrench.

a Let the engine oil flow out.

a Remove the drain plug seal from the drain plug.

a Refit a new drain plug seal on the drain plug.

a Screw the drain plug onto the engine oil sump.

a Torque tighten the drain plug (20 N.m) using atorque wrench and a oil change end piece withan 8 mm square drive.

a Use a cloth to wipe away any oil drips on the engineoil sump.

a Remove the oil recovery tray.


IV - FILLING

a Position the vehicle back on the ground.

a Fill with engine oil, observing the type of engine oilrecommended by the manufacturer (see Engine oil:Specifications) (Technical Note 6013A, 04A, Lubri-cants).

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.

a Refit the dipstick.

136735

135627

10A-25

ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting

K9K

10A

REMOVAL



a Remove:



a Place a oil recovery tray underneath the engine.


a Remove the oil filter (1) using the tool (Mot. 1329)(2)

REFITTING


a parts always to be replaced: Oil filter (10,05,05,03).

a Lubricate the new oil filter seal with new engine oil.


a Refit a new oil filter by hand until the oil filter sealcomes into contact with the oil filter support.

a Tighten the new oil filter 3/4 of a turn by hand or us-ing the (Mot. 1329).


a Wipe any oil run-off with a cloth.

a Top up the oil level in the engine using oil recom-mended by the manufacturer (see Engine oil:Specifications) (Technical Note 6013A, 04A, Lubri-cants).

a Start the engine and leave it running for approxi-mately 30 seconds.

a Check there are no leaks from the oil filter.

a Remove the oil recovery tray.

a Refit:


- the engine undertray bolts.



Mot. 1329 Oil filter removing tool (76mm diameter)

Equipment required

oil recovery tray

IMPORTANT


WARNING




Note:


97160

10A-26

ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting

K9K

10Aa Check the oil level using the dipstick.

a Adjust the engine oil level if necessary.

Note:

The engine oil level must be between the “mini-mum” and “maximum” marks on the dipstick.

10A-27

ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting

K9K

10AREMOVAL



a Remove:

- the engine cover,






a Drain:

- the cooling system (see 19A, Cooling, Coolingsystem: Draining - Refilling, page 19A-8) ,

- the refrigerant fluid circuit using the refrigerantcharging station (see Refrigerant circuit: Drain-ing - Filling) (62A, Air conditioning).

a Remove the bolt (1) for the "intermediate pipe - com-pressor" connecting pipe from the air conditioningcompressor.

a Disconnect the « intermediate pipe - compressor »connecting pipe from the air conditioning compres-sor.

Equipment required

refrigerant charging station

Tightening torquesm

oil-wa t e r h e a texchanger bolt

39 N.m

oil filter support bolt 28 N.m

IMPORTANT

To avoid any risk of damaging the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out therepair (see Air conditioning: Precautions for therepair) (62A, Air conditioning).

IMPORTANT


IMPORTANT

Wear heat protective gloves during the operation.

IMPORTANT

The circuits are designed to be pressurised, so becareful at high temperatures (risk of serious burns).

Do not remove the cap from the expansion bottlewhile the engine is hot.

Take care when carrying out a repair under the bon-net, as the radiator fan(s) may start to operate with-out warning.

Do not open the bleed screw(s) with the engine run-ning.

WARNING

Prepare for the flow of fluid, and protect the sur-rounding components.

135509

10A-28


K9K

10Aa Fit a suitable blanking plug to:

- the opening of the « intermediate pipe -compressor » connecting pipe,

- the compressor opening.

a Remove the « intermediate pipe - compressor »connecting pipe.


a Disconnect the oil pressure sensor connector (2) .

a Remove:

- the bolt (3) from the oil filter support,

- the oil filter holder.

a Remove:

- the bolt (4) from the oil-coolant heat exchanger,

- the oil-water heat exchanger.

123835

123965

123966

10A-29


K9K

10A

a Remove the seal (5) from the oil filter support.

a Remove:

- the oil filter support bolt (7) from the oil filter support(6) ,

- the seals (8) from the oil filter support bolt.

REFITTING


a parts always to be replaced: coolant-engine oilheat exchanger seal on the cylinder block (10,05,05,12).

a Always replace:

- the seals of the oil filter support bolt,

- the oil filter support seal.

a Clean off any drips of oil and coolant using a CLEAN CLOTH :

- on the cylinder block,

- on the oil filter support,

- on the coolant pump inlet pipe.


- the housing of each seal in the oil-water heat ex-changer if it is to be reused,

- the oil-water heat exchanger joint face if it is to bereused,

- the mating face of each seal on the coolant pumpinlet pipe,

- the joint face on the cylinder block,

- the housing of each oil filter support seal,

- the housing of each seal in the oil filter support.

133518

133609

10A-30


K9K

10A

a Refit new seals (9) and (10) on the oil-water heat ex-changer.

a Apply soapy water to the two seals (9) in contactwith the coolant pump inlet pipe.


a Apply two drops of HIGH STRENGTH THREADLOCK (see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) to theoil-coolant heat exchanger bolt.

a Refit the oil-water heat exchanger.

a Torque tighten the oil-water heat exchanger bolt(39 N.m).

a Refit:

- new seals (11) to the oil filter support bolt (12) ,

- the oil filter support bolt (12) to the oil filter support(13) .

107306 133609

10A-31


K9K

10A

a Refit:

- a new seal in the housing of the oil filter support,

- the oil filter support, positioning the lug (14) in thehole (15) of the oil-water heat exchanger.

a Torque tighten the oil filter support bolt (28 N.m).

a Connect the oil pressure sensor connector.


a

a Fit the « intermediate pipe - compressor » connect-ing pipe on the air conditioning compressor.

a Remove the blanking plug from:

- the opening of the « intermediate pipe -compressor » connecting pipe,

- the compressor opening.

a Connect the « intermediate pipe - compressor »connecting pipe to the air conditioning compressor.

a Refit:

- the bolt for the "intermediate pipe - compressor"connecting pipe onto the air conditioning compres-sor,





- the engine cover,

a Perform the following operations:

- fill and bleed the cooling circuit (see 19A, Cooling,Cooling system: Draining - Refilling, page 19A-8) ,

- fill the refrigerant circuit using the refrigerantcharging station (see Refrigerant circuit: Drain-ing - Filling) (62A, Air conditioning).

133518

107857

WARNING

To avoid any leaks, check that the seal and thepipe surface are in good condition. The seal andthe surface must be clean and scratch free.

10A-32

ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure sensor: Removal - Refitting

K9K

10A

REMOVAL



a Remove:




a Disconnect the oil pressure sensor connector (1) .

a Torque tighten the oil pressure sensor (35 Nm) us-ing the.

REFITTING




a Refit the oil pressure sensor using the.

a Connect the oil pressure sensor connector.



Tightening torquesm

oil pressure sensor 35 Nm

123835

10A-33

ENGINE AND CYLINDER BLOCK ASSEMBLYOil level sensor: Removal - Refitting

K9K

10AREMOVAL



a Remove:




a Disconnect the connector (1) from the oil level sen-sor.

a Remove the oil level sensor .

REFITTING




a Refit the oil level sensor.




123834

10A-34

ENGINE AND CYLINDER BLOCK ASSEMBLYOil pump: Removal - Refitting

K9K

10A

REMOVAL



a Remove:

- the engine cover,

- the dipstick,



a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-23) .

a Remove the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting, page 10A-10) .


a Remove:

- the oil pump bolts (1) ,

- the oil pump.

REFITTING


a Check for oil pump centering rings on the cylinderblock.


a Refit the oil pump.

a Torque tighten the oil pump bolts (25 N.m).


a Refit the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting, page 10A-10) .

a Fill up the engine oil (see 10A, Engine and cylinderblock assembly , Engine oil: Draining - Refilling,page 10A-23) .

a Refit:


- the dipstick,

- the engine cover.

Tightening torquesm

oil pump bolts 25 N.m

IMPORTANT


135004

10A-35

ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: Check 10A

Oil pressure tables:

End pieces to be used:

Engine Engine suffixMinimum oil pressure (bar) Maximum oil

pressure(bar)Idling speed at 2000 rpm at 3000 rpm at 4000 rpm

H4J 700 XX XX XX XX XX

K4M

846

0.5 XX XX 3.1 4.4848

858

866

K9K

830

0.8 XX XX 3.4 5.2

832

834

836

837

838

842

F9Q870

1 XX 4.5 XX 5.9872

F4R 870 0.5 XX XX 2.2 4

M4R711

0.8 4.5 - - 4.5713

M9R610

1.4 XX 4.7 XX 6.4615

Engine End pieces

H4J + (F)

K4M (E) + (C) + (F)

K9K (E) + (C) + (F)

F9Q (E) + (C) + (F)

F4R (E) + (C) + (F)

M4R + (F)

M9R (C) + (F)

10A-36

ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: Check 10A

I - PREPARATION OPERATION FOR CHECK

a

II - CHECKING


a Remove:



a Remove the oil pressure sensor (see 10A, Engineand cylinder block assembly, Oil pressure sen-sor: Removal - Refitting, page 10A-32) .

a Start the vehicle.

a Monitor the engine oil pressure as the oil tempera-ture rises (approximately 80˚C or the first time theengine cooling fan is activated); it should not be lessthan the pressure at idle speed.

a If the oil pressure is lower than the pressure at idle speed, check that:

- the oil filter is not clogged,

- dirt or swarf is not present in the engine oil,

- the oil pump is in good condition and being correct-ly driven.

a Check the oil pressure in comparison with the valuesgiven in the table above.

a Switch off the engine.

a Remove thewith the end pieces.

a Refit the oil pressure sensor (see 10A, Engine andcylinder block assembly, Oil pressure sensor:Removal - Refitting, page 10A-32) .



a Check the oil level using the dipstick.

a Top up the oil level if necessary (see Engine oil:Specifications) (04A, Lubricants).

a Start the vehicle and check that there are no oilleaks at the oil pressure sensor.

WARNING




Note:


87363

10A-37

ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting

K9K

10A

REMOVAL




a Drain the refrigerant fluid circuit using the refriger-ant charging station (see Refrigerant circuit:Draining - Filling) (62A, Air conditioning).

a Remove:

- the engine cover,







- the headlights (see Headlight: Removal - Refit-ting) (80B, Headlights).

a Remove the turbocharger outlet air pipe (see 12B,Turbocharging, Intercooler air inlet pipe: Re-moval - Refitting, page 12B-12) .

a Remove the front bumper supports (see Frontbumper mounting: Removal - Refitting) (42A,Front upper structure).

a Remove:

- the audible warning (see Audible warning: Re-moval - Refitting) (82B, Horn),

- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure),

- the bonnet catch (see Bonnet lock: Removal -Refitting) (52A, Non-side opening element mecha-nisms),

- the alternator (see 16A, Starting - Charging, Al-ternator: Removal - Refitting, page 16A-1) ,

- the air conditioning compressor (see Compressor:Removal - Refitting) (62A, Air conditioning).


a Remove:

- the multifunction support bolts (1) ,

- the multifunction support.

REFITTING

I - REFITTING OPERATION FOR PART CONCERNED

a Refit the multifunction support.

Equipment required


Tightening torquesm

bolts (1) to (6) of themultifunction support

44 N.m

bolt (7) of the multifunc-tion support

25 N.m

123832

10A-38

ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting

K9K

10A

a Tighten to torque and in order:

- the bolts (1) to (6) of the multifunction support(44 N.m),

- the bolt (7) of the multifunction support (25N.m).

II - FINAL OPERATION

a Refit:

- the air conditioning compressor (see Compressor:Removal - Refitting) (62A, Air conditioning),

- the alternator (see 16A, Starting - Charging, Al-ternator: Removal - Refitting, page 16A-1) ,



- the audible warning (see Audible warning: Re-moval - Refitting) (82B, Horn).

a Refit the front bumper supports (see Front bumpermounting: Removal - Refitting) (42A, Front upperstructure).

a Refit the turbocharger air outlet pipe (see 12B, Tur-bocharging, Intercooler air inlet pipe: Removal -Refitting, page 12B-12) .

a Refit:

- the headlights (see Headlight: Removal - Refit-ting) (80B, Headlights),






- the engine cover.


a Fill the refrigerant circuit using a refrigerant charg-ing station (see Refrigerant circuit: Draining -Filling) (62A, Air conditioning).

123832

10A-39

ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting

K4M

10A

REMOVAL



a Remove:



- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting, page 12A-5) .

a Remove the air outlet pipe from the air filter box (see12A, Fuel mixture, Throttle valve: Removal - Re-fitting, page 12A-12) .

a Disconnect the fuel vapour rebreathing pipe (1) fromthe throttle valve.

a Unclip the fuel vapour rebreathing pipe from thethrottle valve.

a Disconnect the vacuum pipe (2) from the throttlevalve.

Equipment required


Tightening torquesm

bolt on the rubber padsupport of the left-handsuspended enginemounting

62 N.m

earth nut(s) on the body 8 N.m

bracket bolt of the con-necting pipe betweenthe « compressor -expansion valve » onthe compressor

8 N.m

connecting pipe bolts onthe condenser

8 N.m

WARNING

In order to avoid any refrigerant leaks, do not dam-age (deform, twist, etc.) the pipe.

WARNING

To prevent moisture from entering the system,place plugs on the cold loop components which areopen to the air.

IMPORTANT

Wear protective gloves during the operation.

IMPORTANT

To prevent the vehicle from falling, lash it to thevehicle lift using a strap.

136460

10A-40


K4M

10A

a Disconnect the fuel supply pipe (3) from the injectorrail.

a Fit blanking plugs on the fuel supply pipe.

a Unclip:

- the gear control cables from the manual gearboxby pressing at (6) ,

- the control cables by pushing at (7) .

a Move the gear control cables away from the manualgearbox.

136450

WARNING

To avoid any corrosion or damage, protect theareas on which fuel is likely to run.

5-SPEED MANUAL GEARBOX

144195

144390

10A-41


K4M

10A

a Unclip the control cable from the automatic gearboxat (8) using unclipping pliers.

a Unclip the automatic gearbox control cable at (9) .

a Move aside the automatic gearbox control cable.

a Place the toolbetween the brake fluid reservoir andthe clutch master cylinder.

a Remove the hydraulic clutch pipe (see Clutch cir-cuit: Removal - Refitting) (37A, Mechanical com-ponent controls).

a Remove:

- the breather pipe onto the gearbox,






a Drain the cooling system (see 19A, Cooling, Cool-ing system: Draining - Refilling, page 19A-8) .

a Drain the manual gearbox (see Manual gearboxoils: Draining - Filling) (21A, Manual gearbox).

a Drain the automatic gearbox (see Automatic gear-box oil: Draining - Filling) (23A, Automatic gear-box).

a Drain:

- the refrigerant circuit using a refrigerant chargingstation (see Refrigerant circuit: Draining - Fill-ing) (62A, Air conditioning),

- the engine oil if necessary (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-23) .

a Disconnect the reverse gear switch connector.

4-SPEED AUTOMATIC GEARBOX

144263

136542




JH3

10A-42


K4M

10Aa Disconnect the downstream oxygen sensor connec-

tor.

a Remove:

- the bolts (10) from the exhaust flange,

- the exhaust flange ring,

- the lower engine tie-bar (see 19D, Engine mount-ing, Lower engine tie-bar: Removal - Refitting,page 19D-10) ,



a Unclip the deflectors at (11) and (12) .

a Remove:


- the front bumper mountings (see Front bumpermounting: Removal - Refitting) (42A, Front up-per structure).

a Remove:


135949

135961

136540

10A-43


K4M

10A- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure),


- the bonnet catch (see Bonnet lock: Removal -Refitting) (52A, Non-side opening element mecha-nisms).

a Remove the bolts (13) of the engine wiring channelfrom the cooling fan assembly.

a Disconnect from the cooling fan assembly:

- the connector (14) ,

- the resistor connector (15) ,

- the relay unit (16) of the front end panel.

a Unclip the cooling fan assembly wiring.

a Move aside the cooling fan assembly wiring.

135736

135482

10A-44


K4M

10A

a Remove using the:

- the top cooling hose clip (17) from the cooling radi-ator,

- the expansion bottle degassing hose clip (18) fromthe cooling radiator,

- the bottom cooling hose clip (19) from the coolingradiator.

a Disconnect:

- the top cooling hose from the cooling radiator,

- the expansion bottle degassing hose from the cool-ing radiator,

- the bottom cooling hose from the cooling radiator.

135954

135951

10A-45


K4M

10A

a Remove:

- the bolt (20) of the « condenser - expansion valve »connecting pipe bracket,

- the bolt (21) for the « compressor - condenser »connecting pipe bracket.

a Disconnect:

- the « condenser - expansion valve » connectingpipe from the condenser,

- the « compressor - condenser » connecting pipeon the condenser.

a Insert the blanking plugs.

a Disconnect the refrigerant pressure sensor connec-tor.

a Unclip the wiring of the right-hand headlight (23) onthe front end panel.

a Disconnect:

- the windscreen washer pump connector,

- the windscreen washer pump wiring.

135952

135955

144264

10A-46


K4M

10A

a Remove the bolt (2 4) between the windscreenwasher reservoir and the front end panel.

a Remove:

- the front end panel clips (25) ,

- the front end panel bolts (26) ,

- the front of the vehicle.

a Disconnect the connectors (28) from the battery dis-connection unit.

a Unclip the wiring of the battery disconnection unit.

a Move aside the battery cables.

a Unclip the battery wiring channel (29) from the left-hand suspended engine mounting.

HEADLIGHT WASHERS WITH BLADE

136535

135719

135508

135506

10A-47


K4M

10A

a Remove:

- the Protection and Switching Unit cover (30) ,

- the Protection and Switching Unit from its unit.

a Disconnect the connectors (31) from the Protectionand Switching Unit.

a Remove:

- the Protection and Switching Unit,

- the engine wiring.

a Remove the air resonator (see 12A, Fuel mixture,Air resonator: Removal - Refitting, page 12A-1) .

a Disconnect the automatic gearbox computer con-nector (see Automatic gearbox converter: Re-moval - Refitting) (23A, Automatic gearbox).

a Remove:

- the bolts (32) from the engine fuse box,

- the engine fuse box.

a Remove the bolt (33) from the « compressor - ex-pansion valve » connecting pipe bracket.

a Disconnect the « compressor - expansion valve »connecting pipe from the compressor.


135721

135722


135504

135724

10A-48


K4M

10A

a Remove the bolt of the « compressor - condenser »connecting pipe support at (34) .

a Move aside the « compressor - condenser » con-necting pipe.

a Remove:

- the earth nuts (37) on the body,

- the earth terminals on the body.

a Disconnect the earth wiring on the body at (38) .

a Disconnect the fuel vapour absorber connector (39).

a Unclip the fuel vapour absorber wiring:

- on the expansion bottle,

- on the body.

a Remove the fuel vapour absorber wiring.

135723

144262

136466

10A-49


K4M

10A

a Remove using the:

- the clip (40) of the hose between the heater matrixand the coolant pump inlet pipe,

- the clip (41) of the hose between the heater matrixand the coolant outlet unit,

- the clip (42) of the expansion bottle outlet hose.

a Disconnect:

- the hose between the heater matrix and the coolantpump inlet pipe,

- the hose between the heater matrix and the coolantoutlet unit,

- the expansion bottle outlet hose.


a Mark the positions of the suspended engine mount-ings on the body.

a Support the « engine - gearbox » assembly on theengine marks (43) with the.


135720

135501

136472

10A-50


K4M

10A

a Remove the bolt (44) on the rubber pad support ofthe left-hand suspended engine mounting.

a Raise the vehicle, moving the engine towards thefront.

a Remove the « engine and gearbox » assembly.

REFITTING


a For standard engine replacements (see Engine:Standard replacement) (Technical Note 6023A,10A, Engine and peripherals).

a parts always to be replaced: ring between ex-haust manifold and catalytic converter (10,08,02,20)


a Position the « engine-gearbox » assembly in the ve-hicle.

a Refit the bolt on the rubber pad support of the left-hand suspended engine mounting.

a Torque tighten the bolt on the rubber pad supportof the left-hand suspended engine mounting (62N.m).


a Remove thefrom the « engine - gearbox » assem-bly.


a Connect:

- the hose between the heater matrix and the coolantpump inlet pipe,

- the hose between the heater matrix and the coolantoutlet unit,

- the expansion bottle outlet hose.

a Using the, fit:

- the clip between the heater matrix and the coolantpump inlet pipe,

- the clip between the heater matrix and the coolantoutlet unit,

- the expansion bottle outlet hose clip.

a Fit the fuel vapour absorber wiring in place.

a Clip the fuel vapour absorber wiring:

- on the expansion bottle,

- on the body.

a Connect the connector to the fuel vapour absorber.

a Refit:

- the earth terminal(s) on the body,

- the earth nut(s) on the body.

a Torque tighten the earth nut(s) on the body (8N.m).

a

a Remove the blanking plugs.

a Fit a new seal on the « compressor - expansionvalve » connecting pipe.

a Couple the « compressor - expansion valve » con-necting pipe on the compressor.

a Refit the bolt of the « compressor - expansionvalve » connecting pipe bracket.

a Torque tighten the bracket bolt of the connectingpipe between the « compressor - expansionvalve » on the compressor (8 N.m).

134554

WARNING

Do not remove the blanking plugs from eachcomponent until the last moment.

Also, do not remove the components from theirpackaging until they are to be fitted to the vehi-cle.

10A-51


K4M

10Aa Refit the « compressor - condenser » connecting

pipe support.

a Refit:

- the engine fuse box,

- the air resonator (see 12A, Fuel mixture, Air res-onator: Removal - Refitting, page 12A-1) .

a Fit the engine wiring.

a Connect the Protection and Switching Unit connec-tors.

a Fit the protection and switching unit.

a Refit the Protection and Switching Unit cover.

a Clip on the battery wiring channel.

a Position the battery cables.

a Clip on the wiring of the battery disconnection unit.

a Connect the connectors on the battery disconnec-tion unit.

a Refit:

- the front panel,

- the front end panel bolts,

- the front end panel clips.

a Clip the wiring of the right-hand headlight on thefront end panel.

a Connect:

- the windscreen washer pump connector,

- the windscreen washer pump wiring.

a Refit the bolt between the windscreen washer reser-voir and the front end panel.

a Connect the refrigerant pressure sensor connectoron the condenser.


a Connect:

- the « condenser - expansion valve » connectingpipe on the condenser,


a Refit:

- the « condenser - expansion valve » connectingpipe bracket bolt,

- the « compressor - condenser » connecting pipebracket bolt.

a Torque tighten the connecting pipe bolts on thecondenser (8 N.m).

a Connect:

- the top cooling hose on the cooling radiator,

- the expansion bottle degassing hose to the coolingradiator,

- the bottom cooling hose on the cooling radiator.

a Using the, fit:

- the top cooling hose clip on the cooling radiator,

- the expansion bottle degassing hose clip on thecooling radiator,

- the bottom cooling hose clip on the cooling radia-tor.

a Fit the cooling fan assembly wiring.

a Clip the cooling fan assembly wiring.

a Connect:

- the cooling fan assembly connector,

- the cooling fan assembly resistor connector,

- the relay unit on the front end panel.

a Refit:

- the engine wiring channel on the cooling fan as-sembly,





K4M

HEADLIGHT WASHERS WITH BLADE

10A-52


K4M

10A

a Refit:

- the front bumper supports (see Front bumpermounting: Removal - Refitting) (42A, Front up-per structure),


a Refit:

- the air deflectors,

- the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A,Driveshafts),



- a new ring between the exhaust manifold and thecatalytic converter,

- the exhaust flange bolts.

a Connect the downstream oxygen sensor connector.

a Connect the reverse gear switch connector.

a Refit the hydraulic clutch pipe (see Clutch circuit:Removal - Refitting) (37A, Mechanical componentcontrols).

a Remove the toolbetween the brake fluid reservoirand the clutch master cylinder.

a Bleed the clutch (see Clutch circuit: Bleed) (37A,Mechanical component controls).

a Clip on the gearbox control cables.

a Adjust the mechanical gearbox control cables (seeMechanical gear control cable: Adjustment)(37A, Mechanical component controls).

a Remove the blanking plugs on the fuel supply pipe.

a Connect:

- the fuel supply pipe to the injector rail,

- the fuel vapour rebreathing pipe on the throttlevalve.

a Clip the fuel vapour rebreathing pipe onto the throttlevalve.

a Connect the vacuum pipe to the throttle valve.

a Refit:

- the air filter unit air outlet pipe (see 12A, Fuel mix-ture, Throttle valve: Removal - Refitting, page12A-12) ,

- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting, page 12A-5)


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

a Fill the cooling system (see 19A, Cooling, Coolingsystem: Draining - Refilling, page 19A-8) .


a Fill the automatic gearbox (see Automatic gearboxoil: Draining - Filling) (23A, Automatic gearbox).

a Refill:


K4M

K4M, and JH3


K4M, and 5-SPEED MANUAL GEARBOX



10A-53


K4M

10A- the engine oil if necessary (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-23) .

a Refit:





- the breather pipe from the gearbox.

10A-54


K9K

10A

REMOVAL



a Remove:

- the engine cover,


Mot. 1448 Remote operation pliers forhose clips.

Equipment required


safety strap(s)

Tightening torquesm

bolt of the left-hand sus-pended engine mount-ing support on thegearbox

62 N.m

bolts for the right-handsuspended enginemounting « rubber pad -cover » assembly on thecylinder head

62 N.m

bolts for the right-handsuspended enginemounting « rubber pad -cover » assembly on thebody

62 N.m

« dehydrator reservoir -compressor » connect-ing pipe bolt on thecompressor

8 N.m

earth cable nut on thebody

8 N.m

power cable nuts on thebattery disconnectionunit

8 N.m

connecting pipe bracketbolt for the « condenser- expansion valve »

8 N.m

connecting pipe bracketb o l t f o r t h e« c o m p r e s s o r -condenser »

8 N.m

air filter unit air outletpipe clip on the turbo-charger

5.5 N.m

IMPORTANT

To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and opera-tion recommendations before carrying out any repair:

- (see Diesel injection: Precautions for therepair) ,

- (see Vehicle: Precautions for the repair) (01D,Mechanical introduction).

IMPORTANT


WARNING

To prevent impurities from entering the circuit, placeprotective plugs on all fuel circuit componentsexposed to the open air.

WARNING


WARNING

Keep the pipe unions away from contaminatedareas.

WARNING

To prevent moisture from entering the system,place plugs on the cold loop components which areopen to the air.

10A-55


K9K

10A- the battery (see Battery: Removal - Refitting)(80A, Battery),






a

a Drain:


- the manual gearbox (see Manual gearbox oils:Draining - Filling) (21A, Manual gearbox).


- the engine oil (if necessary) (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-23) .

a Remove:




a Remove the exhaust bracket bolts (3) from the cata-lytic converter.

a Move the exhaust bracket away from the catalyticconverter.

a Disconnect the oil vapour rebreathing pipe unionfrom the air filter unit air outlet pipe.

a Disconnect the oil vapour rebreathing pipe from therocker cover.

a Remove the oil vapour rebreathing pipe.

IMPORTANT

To avoid any risk of damaging the systems, applythe safety and cleanliness instructions and oper-ation recommendations before carrying out therepair (see Air conditioning: Precautions forthe repair) (62A, Air conditioning).

136392

K9K, and 832 or 842

10A-56


K9K

10A

a Undo the air filter unit air outlet pipe clip (4) from theturbocharger.

a Disconnect the air filter unit air outlet pipe from theturbocharger.

a Remove:



- the air outlet pipe of the air filter unit,

- the turbocharger air outlet pipe (see 12B, Turbo-charging, Intercooler air inlet pipe: Removal -Refitting, page 12B-12) ,

- the intercooler air outlet pipe (see 12B, Turbo-charging, Intercooler air outlet pipe: Removal -Refitting, page 12B-17) ,



a Remove:

- the top air deflector of the cooling radiator,

- the side air deflectors of the cooling radiator,


- the front impact cross member (see Front impactcross member: Removal - Refitting) (41A, Frontlower structure).

a Disconnect the connector (7) from the refrigerant cir-cuit pressure sensor.

a Unclip:

- the refrigerant circuit pressure sensor wiring fromthe « condenser - evaporator » connecting pipe at(8) ,

- the refrigerant circuit pressure sensor wiring fromthe front end panel at (9) .

a Remove:

- the bolt (10) of the « compressor - condenser »connecting pipe bracket from the body,

- the bolt (11) of the « condenser - expansion valve »connecting pipe bracket,

- the bolt (12) for the « compressor - condenser »connecting pipe bracket.

a Disconnect the following from the condenser:

- the « condenser - expansion valve » connectingpipe,

- the « compressor - condenser » connecting pipe.


136639

135512

10A-57


K9K

10A

a Use the tool (Mot. 1448) to separate the cooling ra-diator bottom cooling hose clip (13) from the coolingradiator.

a Disconnect the cooling radiator bottom cooling hosefrom the cooling radiator.

a Separate from the cooling radiator:

- the expansion bottle top cooling hose clipusing thetool (14) ,

- the top cooling hose clip (15) using the tool (Mot.1448).

a Disconnect from the cooling radiator:

- the expansion bottle top cooling hose,

- the cooling radiator top cooling hose.

a Remove the bonnet catch (see Bonnet lock: Re-moval - Refitting) (52A, Non-side opening elementmechanisms).

a Unclip the bonnet catch cable (16) on the front endpanel.

a Move aside the bonnet catch cable.

a Unclip the front impact cross member wiring fromthe front end panel at (17) .

135951

135954

138486

135511

10A-58


K9K

10Aa Unclip the expansion bottle top cooling hose from

the front end panel.

a Remove the bolts (19) of the fan assembly wiringchannel from the front end panel.

a Remove from the front end panel:

- the clips (20) ,

- the upper bolts (21) .

a Remove the lower bolts (23) from the front end pan-el.

a Disconnect:

- the fan assembly connector (24) ,

- the fan assembly resistor connector (25) .

a Unclip:

- the fan assembly wiring from the fan assembly at(26) ,

- the relay unit (27) from the front end panel.

a Move the fan assembly wiring away from the frontend panel.

135882

135719

135881

135482

10A-59


K9K

10A

a Tilt the front end panel towards the vehicle front (A) .

a Remove the front end panel by pulling it upwards (B).

a Disconnect:

- the connector (28) from the turbocharging pressureregulation solenoid valve,

- the connectors (29) from the battery disconnectionunit.

a Unclip the battery disconnection unit wiring from thebattery disconnection unit.

a Remove the power cable nuts (30) from the batterydisconnection unit.

a Move aside the power cables.

a Unclip the power wiring channel (31) from the left-hand suspended engine mounting.

a Remove the air resonator (see 12A, Fuel mixture,Air resonator: Removal - Refitting, page 12A-1) .

135510

135508

135507

135506

10A-60


K9K

10A

a Remove the air resonator support nuts (32) .

a Move aside the air resonator support.

a Disconnect the pre-postheating unit connector (33) .

a Remove the earth cable nut (34) from the body.

a Move the earth cable away from the body.

a Remove the Protection and Switching Unit cover(35) .

a Disconnect the connectors (36) from the Protectionand Switching Unit.

K9K, and 830 or 838

136669

135505

135721

135722

10A-61


K9K

10A

a Remove:

- the bolt (37) from the engine fuse box,

- the nuts (38) from the engine fuse box.

a Move aside the engine fuse box.

a Disconnect the diesel fuel heater connector (39) .

a Unclip:

- the diesel heater wiring from the body at (40) ,

- the diesel heater wiring from the « condenser -evaporator » connecting pipe at (41) ,

- the diesel heater wiring from the radiator mountingcross member.

a Move aside the diesel heater wiring.

a Disconnect the brake servo pipe union (42) from thevacuum pump.

a Fit the tool (47) onto the clutch master cylinder sup-ply pipe.

a Disconnect the clutch pipe from the clutch mastercylinder by pulling on the clip (48) .

a Fit an appropriate blanking plug:

- on the opening of the clutch pipe,

135504

135503

134490

134486

10A-62


K9K

10A- on the opening of the clutch master cylinder.

a Remove the bolt (49) of the « dehydrator reservoir -compressor » connecting pipe from the air condi-tioning compressor.

a Disconnect the « dehydrator reservoir -compressor » connecting pipe from the air condi-tioning compressor.

a Fit an appropriate blanking plug.

a Separate the expansion bottle bottom cooling hoseclip (50) from the expansion bottle.

a Disconnect the expansion bottle bottom coolinghose from the expansion bottle.

a Unclip the expansion bottle bottom cooling hosefrom the high pressure pump protector.

a Separate the clip (51) of each heater matrix coolinghose on the heater matrix (52) .

a Disconnect the heater matrix cooling hoses (52)from the heater matrix.

135509

135501

K9K, and 832 or 842

135499

10A-63


K9K

10A

a Unclip the fuel supply pipe from the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.

a Disconnect the fuel supply pipe from the high pres-sure pump.


- on the fuel supply pipe union opening,

- on the high pressure pump opening.

a Unclip the diesel return pipe from the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.

a Disconnect the diesel fuel return pipe from the dieselinjector fuel return rail.


- on the opening of the diesel fuel return pipe union,

- on the opening of the fuel return rail.

K9K, and 832 or 842

134494

10A-64


K9K

10A

a Unclip the fuel return union (55) of the high pressurepump from the high pressure pump protector.

a Remove:

- the bolt (56) of the high pressure pump protector,

- the high pressure pump protector.

a Unclip the fuel supply pipe from the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.

a Disconnect the fuel supply pipe from the high pres-sure pump (57) .

a Fit suitable blanking plugs on:

- on the fuel supply pipe union opening,

- on the high pressure pump opening.

a Unclip the diesel return pipe from the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.

a Disconnect the diesel return pipe (55) from the fuelreturn pipe union of the high pressure pump.


- on the opening of the fuel return pipe union,

- on the opening of the diesel return pipe union of thehigh pressure pump.

a Remove the radiator mounting cross member (seeRadiator mounting cross member: Removal -Refitting) (31A, Front axle components).


a Strap the « engine - gearbox » assembly to the too-lusing a safety strap(s).

a Position theunder the « engine - gearbox » assem-bly.

K9K, and 830 or 838

135873

13587217765

10A-65


K9K

10A

a Remove:

- the upper engine tie-bar bolts (58) ,

- the upper engine tie-bar.

a Remove the bolts (59) for the right-hand suspendedengine mounting « rubber pad - cover » assemblyfrom the body.


a Raise the engine slightly using the toolequipped withthe tooluntil the right-hand suspended enginemounting « rubber pad - cover » assembly detachesfrom the body.

a Remove:

- the bolts (62) for the right-hand suspended enginemounting « rubber pad - cover » assembly from thecylinder head,

- the right-hand suspended engine mounting « cover- rubber pad » assembly.

a Remove the « engine - gearbox » assembly usingthe.

REFITTING


a parts always to be replaced: seal between cata-lytic converter and exhaust downpipe hose (10,08,02,21).

K9K, and 832 or 842

134221

134495

K9K, and 830 or 838

135411

10A-66


K9K

10Aa Use GREY ABRASIVE PADS (see Vehicle: Parts

and consumables for the repair) (04B, Consuma-bles - Products) to clean the joint face:

- the intermediate pipe,

- of the catalytic converter.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to degrease the joint face:


- of the catalytic converter.


a Position the « engine - gearbox » assembly in theengine compartment.

a Torque tighten the bolt of the left-hand suspendedengine mounting support on the gearbox (62N.m).

a Refit the right-hand suspended engine mounting« cover - rubber pad » assembly.

a Lower the engine using the toolfitted with the toolun-til the « rubber pad - cover » assembly of the right-hand suspended engine mounting touches the body.

a Refit the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly to thebody.

a Torque tighten:

- the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly onthe cylinder head (62 N.m),

- the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly onthe body (62 N.m).

a Remove:

- with the toolthe safety strap(s) of the « engine -gearbox » assembly,

- the toolbeneath the « engine-gearbox » assembly.


a Refit the radiator mounting cross member (see Ra-diator mounting cross member: Removal - Refit-ting) (31A, Front axle components).

a Remove the blanking plug:

- the diesel injector fuel return rail opening,

- from the opening of the diesel fuel return pipeunion.

a Connect the diesel fuel return pipe union to the die-sel injector fuel return rail.


- from the opening of the diesel return pipe union ofthe high pressure pump,

- from the opening of the fuel return pipe union.

a Connect the union of the diesel fuel return pipe tothe union of the high pressure pump fuel return pipe.

a Clip the diesel return pipe on the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.


- the opening of the high pressure pump,

- on the fuel supply pipe union opening.

a Connect the fuel supply pipe to the high pressurepump.

a Clip the fuel supply pipe on the « rubber pad -cover » assembly of the right-hand suspended en-gine mounting.

a Refit the high pressure pump protector.

a Clip the high pressure pump fuel return union ontothe high pressure pump protector.

a Connect the heater matrix cooling hoses on theheater matrix.

WARNING


K9K, and 832 or 842

K9K, and 830 or 838

K9K, and 830 or 838

10A-67


K9K

10Aa Fit the clip of each heater matrix cooling hose on the

heater matrix.

a Clip the expansion bottle bottom cooling hose on thehigh pressure pump protector.

a Connect the expansion bottle bottom cooling hoseon the expansion bottle.

a Fit the clip of the expansion bottle bottom coolinghose on the expansion bottle.

a Remove the blanking plug.

a Couple the « dehydrator reservoir - compressor »connecting pipe to the air conditioning compressor.

a Torque tighten the « dehydrator reservoir -compressor » connecting pipe bolt on the com-pressor (8 N.m).


- the opening of the clutch master cylinder,

- from the opening of the clutch pipe.

a Connect the hydraulic clutch pipe on the clutch mas-ter cylinder.

a Remove the toolfrom the clutch master cylinder sup-ply pipe.

a Bleed the hydraulic clutch circuit (see Clutch cir-cuit: Bleed) (37A, Mechanical component controls).

a Fit the manual gearbox control cables.

a Connect the brake servo pipe union to the vacuumpump.

a Position the diesel heater wiring.

a Clip:

- the diesel heater wiring on the radiator mountingcross member,

- the diesel heater wiring on the « condenser -evaporator » connecting pipe,

- the diesel heater wiring on the body.

a Connect the diesel fuel heater connector.

a Fit the engine fuse box.

a Refit:

- the engine fuse box nuts,

- the engine fuse box bolt.

a Connect the Protection and Switching Unit connec-tors.

a Refit the Protection and Switching Unit cover.

a Fit the earth cable on the vehicle body.

a Torque tighten the earth cable nut on the body (8N.m).

a Connect the pre-postheating unit connector.

a Fit the air resonator support.

a Refit the nuts of the air resonator support.

a Refit the air resonator (see 12A, Fuel mixture, Airresonator: Removal - Refitting, page 12A-1) .

a Clip the power wiring channel on the left-hand sus-pended engine mounting.

a Position the power cables.

a Refit the power cable nuts on the battery disconnec-tion unit.

a Torque tighten the power cable nuts on the bat-tery disconnection unit (8 N.m).

a Clip the battery disconnection unit wiring onto thebattery disconnection unit.

a Connect:

- the connectors of the battery disconnection unit,

- the turbocharging pressure regulation solenoidvalve connector.

a Refit the front end panel.

a Fit the fan assembly wiring.

a Clip:

- the relay unit on the front end panel,

- the fan assembly wiring on the fan assembly.

a Connect:

- the fan assembly connector,

- the fan assembly resistor connector.

a Refit:

- the lower bolts from the front end panel,

- the front end panel upper bolts,

- the front end panel clips,

- the bolts of the fan assembly wiring channel on thefront end panel.

a Clip the expansion bottle top cooling hose onto thefront end panel.

K9K, and 832 or 842

K9K, and 830 or 838

10A-68


K9K

10Aa Clip the wiring of the front impact cross member onto

the front end panel.

a Fit the bonnet catch cable.

a Clip the bonnet catch cable onto the front end panel.

a Refit the bonnet catch (see Bonnet lock: Removal- Refitting) (52A, Non-side opening element mecha-nisms).

a Connect:

- the cooling radiator top cooling hose on the coolingradiator,

- the expansion bottle top cooling hose to the coolingradiator.

a Fit the clip:

- of the cooling radiator top cooling hose on the cool-ing radiator using the tool (Mot. 1448),

- of the expansion bottle top cooling hose using thetool.

a Connect the cooling radiator bottom cooling hose tothe cooling radiator.

a Fit the clip of the cooling radiator bottom coolinghose on the cooling radiator using the tool (Mot.1448).


a Connect:

- the « condenser - expansion valve » connectingpipe on the condenser,


a Refit:

- the « condenser - expansion valve » connectingpipe bracket bolt,

- the « compressor - condenser » connecting pipebracket bolt.

a Torque tighten:

- the connecting pipe bracket bolt for the« condenser - expansion valve » (8 N.m),

- the connecting pipe bracket bolt for the« compressor - condenser » (8 N.m).

a Refit the bolt of the « compressor - condenser » con-necting pipe bracket on the body.

a Clip the refrigerant circuit pressure sensor wiring:

- on the front end panel,

- on the « condenser - evaporator » connecting pipe.

a Connect the connector of the refrigerant circuit pres-sure sensor.

a Refit:




- the cooling radiator top air deflector.


a Refit:




- the air outlet pipe of the air filter unit,


- the battery tray (see Battery tray: Removal - Re-fitting) (80A, Battery).

a Connect the air filter unit air outlet pipe to the turbo-charger.

a Torque tighten the air filter unit air outlet pipe clipon the turbocharger (5.5 N.m).

a Refit the oil vapour rebreathing pipe.

a Connect the oil vapour rebreathing pipe onto therocker cover.

a Connect the oil vapour rebreathing pipe union to theair filter unit air outlet pipe.

a Fit the exhaust bracket on the catalytic converter.

WARNING

Check that the surface of the pipe is in good con-dition to prevent leaks. The surface must beclean and scratch free.

K9K, and 832 or 842

10A-69


K9K

10Aa Refit the exhaust bracket bolts on the catalytic con-

verter.

a Refit:

- new differential output seals (see Differential out-put seal: Removal - Refitting) (21A, Manual gear-box),


- the front right-hand wheel driveshaft (see Frontright-hand driveshaft: Removal - Refitting)(29A, Driveshafts).

a Refill:

- the engine oil (if necessary) (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-23) ,

- and bleed the cooling system (see 19A, Cooling,Cooling system: Draining - Refilling, page 19A-8) ,

- the manual gearbox (see Manual gearbox oils:Draining - Filling) (21A, Manual gearbox),

- the refrigerant circuit using a refrigerant chargingstation (see Refrigerant circuit: Draining - Fill-ing) (62A, Air conditioning).

a Refit:






- the engine cover.

10A-70

ENGINE AND CYLINDER BLOCK ASSEMBLYFlywheel: Removal - Refitting

K9K

10A

REMOVAL



a Remove:

- the engine cover,



a Remove:




- the crankshaft position sensor (see 13B, Diesel in-jection, Crankshaft position sensor: Removal -Refitting, page 13B-12) ,




a Drain the gearbox (see Manual gearbox oils:Draining - Filling) .

a Remove:




a Remove:







- the clutch disc and pressure plate (see Pressureplate - Disc: Removal - Refitting) (20A, Clutch).


REFITTING


a parts always to be replaced: Flywheel bolts (10,03,03,14).


- the crankshaft bearing face on the flywheel if re-used,

- the flywheel pressure face on the crankshaft,

- the flywheel threading.


a Refit:

- the flywheel,

- new flywheel bolts,

- the.

IMPORTANT

Consult the safety and cleanliness advice and oper-ation recommendations before carrying out anyrepair operation (see Clutch: Precautions for therepair) (20A, Clutch).

10A-71

ENGINE AND CYLINDER BLOCK ASSEMBLYFlywheel: Removal - Refitting

K9K

10AIII - FINAL OPERATION

a Refit:








a Refit:

- new differential output seals (see Differential out-put seal: Removal - Refitting) (21A, Manual gear-box),




a Refit:




- the crankshaft position sensor (see 13B, Diesel in-jection, Crankshaft position sensor: Removal -Refitting, page 13B-12) .

a Bleed the clutch control circuit (see Clutch circuit:Bleed) (37A, Mechanical component controls).

a Refit:



a Refit:



- the engine cover.

10A-72

ENGINE AND CYLINDER BLOCK ASSEMBLYDrive plate: Removal - Refitting

K4M, and DP0

10A

REMOVAL



a Remove:








a Drain the automatic gearbox (see Automatic gear-box oil: Draining - Filling) (23A, Automatic gear-box).

a Remove:

- the front right-hand wheel driveshaft (see Frontright-hand driveshaft: Removal - Refitting)(29A, Driveshaft),

- the front left-hand wheel driveshaft (see Front left-hand driveshaft: Removal - Refitting) (29A,Driveshaft),




- the automatic gearbox (see Automatic gearbox:Removal - Refitting) (23A, Automatic gearbox).

II - REMOVAL OPERATION

a Position the (Mot. 582-01) (1) .

a Remove:

- the bolts (2) ,

- the drive plate (3) ,

- the (Mot. 582-01).

REFITTING


a Check that the drive plate is not damaged (run-outtolerance of 0.2 mm on the outer diameter).

II - REFITTING OPERATION

a Fit the drive plate, ensuring it is correctly positionedin relation to the centring pins.

a Apply HIGH RESISTANCE THREADLOCK (seeVehicle: Parts and consumables for the repair)(04B, Consumables - Products) to the bolt threads.


Mot. 582-01 Flywheel locking tool.

Equipment required

Diagnostic tool

Tightening torquesm

drive plate bolts 55 N.m + 50˚ ±±±±5˚

110226

10A-73

ENGINE AND CYLINDER BLOCK ASSEMBLYDrive plate: Removal - Refitting

K4M, and DP0

10Aa Tighten the bolts on the drive plate.

a Fit the tool (Mot. 582-01) to immobilise the starterdrive ring for tightening.

a Torque tighten in order and to angle the drive platebolts (55 N.m + 50˚ ±±±± 5˚).

a Remove the (Mot. 582-01).


a Proceed in the reverse order to removal.


- fill the automatic gearbox (see Automatic gearboxoil: Draining - Filling) (23A, Automatic gearbox),

- a conformity check using the Diagnostic tool.

110226

11A-1

TOP AND FRONT OF ENGINEPressure at end of compression: Check

K4M

11A

CHECK


a Remove:

- the engine cover,

- the ignition coils (see Coils: Removal - Refitting) ,

- the spark plugs (see Plugs: Removal - Refitting) .

a Disconnect the injector connectors.

a Connect a petrol compression gauge (1) .

a Run command with Diagnostic tool :

- RZ003 : "ADAPTATIFS MOTEUR",

- VP036 : "INHIBITION ALIMENTATION CAR-BURANT".

a Put the vehicle under starting conditions:

- gear lever in neutral position for manual gearbox,

- brake pedal depressed.

II - TEST OPERATION

a Press the vehicle start button to trigger the enginestarting phase.

a Measure the compression of cylinder no.1.

a Fully depress the accelerator pedal in order to openthe throttle valve during the compression measure-ments.

a Measure the compression of the other cylinders.


a Disconnect the petrol compression gauge.

a Connect the injector connectors.

a Refit:

- the spark plugs (see Plugs: Removal - Refitting) ,


- the engine cover.

a Remove the card from the reader to interrupt the +after ignition feed and wait for the loss of communi-cation message to appear on the Diagnostic tool.

a When the loss of communication message appearsor after waiting 9 minutes, force the vehicle's + afterignition feed.

Equipment required

petrol compression gauge

Diagnostic tool

136451

Note:

The engine will be driven by the starter for 20seconds, without being started.

Note:

Put the vehicle under forced + after ignition feedas soon as the starter has stopped (in order tomaintain the inhibition of the engine starting andto be able to measure the compression of theother cylinders).

Note:

It is necessary to wait for at least 10 secondsbefore starting the engine each time (the starterwill not run due to its thermal protection).

Note:

If the message does not appear, wait 9 minutes.

11A-2


K9K

11A

CHECK


a Remove the preheater plugs (see 13C, Preheating,Heater plugs: Removal - Refitting, page 13C-2) .

a Disconnect:

- the connector (1) for the fuel pressure regulationsolenoid valve,

- the connector (2) from the fuel flow regulating sole-noid valve.

a Disconnect the connector (5) from the fuel pressureregulation solenoid valve.

II - TEST OPERATION

a Use an open-jawed spanner to moderately tighten:

- the hose end piece,

Equipment required

diesel compression gauge

self-contained starter

Diagnostic tool

K9K, and 832 or 842

134706

K9K, and 830 or 838

135874

136734

11A-3


K9K

11A- the adapter of the diesel compression gauge onthe.

a Moderately tighten the unions of the diesel com-pression gauge using an open-jawed spanner.

a Connect the self-contained starter.

a Force the vehicle's + after ignition feed.

a Connect the Diagnostic tool.

a Run commands:

- RZ009 "Apprentissage fonctions véhicule",

- VP036 "Inhibition alimentation carburant.

a Operate the starter for 15 seconds until the needleof the diesel compression gauge stabilises to ob-tain the maximum value.

a Make progress with the diagram sheet.

a Carry out the same procedure for the other cylin-ders.

a Check that the cylinder compression values are allapproximately equal.

a Run the command VP037 "Arrêt inhibition alimen-tation carburant.

a Disconnect:

- the Diagnostic tool,

- the self-contained starter.

a Undo:

- the diesel compression gauge on the hose endpiece,

- the flexible end pieceusing an open-jawed span-ner.

a Remove the flexible end piecewhich was fitted inplace of one of the removed plugs.


a Connect the connector to the fuel pressure regula-tion solenoid valve.

a Connect the connector to the fuel flow regulation so-lenoid valve.

a Refit the heater plugs (see 13C, Preheating, Heaterplugs: Removal - Refitting, page 13C-2) .136733

Note:

The pressure value after compression must be atleast 18 bar.

K9K, and 832 or 842

11A-4

TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting

K4M

11A

REMOVAL



a Remove:


- the front section of the front right-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (55A, Exterior protection).

a Remove:

- the bolts (1) of the fairing support under the engine,

- the fairing support under the engine.


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

a Remove the accessories belt.

Tightening torquesm

tensioning roller bolt 40 N.m

bolts of the fairing sup-port under the engine

21 N.m

IMPORTANTWear protective gloves during the operation.

WARNING

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

143770

135891

11A-5


K4M

11Aa Remove:

- the tensioning roller bolt,

- the tensioning roller.

REFITTING


a parts always to be replaced: Accessories belt(10,10,01,03).

a parts always to be replaced: Accessories belttensioning roller (10,10,01,04).

a Use a brush to remove any deposits from the crank-shaft pulley V-grooves.


a Refit a new tensioning roller.

a Tighten to torque the tensioning roller bolt (40N.m).

a Turn the accessories belt tensioning roller clockwiseusing a 16 mm spanner.

a Refit a new accessories belt.

a Rotate the crankshaft clockwise twice to balance theaccessories belt tension on every pulley.

a Refit the fairing support under the engine.

a Torque tighten the bolts of the fairing support un-der the engine (21 N.m).


a Refit:


- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres).

11A-6


K9K

11A

REMOVAL



a Remove:






a Turn the accessories belt tensioning roller clockwiseat (1) using a 16 mm offset spanner.

a Remove the accessories belt.

a Remove:

- the accessories belt tensioning roller bolt (2) ,

- the accessories belt tensioning roller.

Equipment required

offset spanner

Tightening torquesm

new accessories belttensioning roller bolt

40 N.m

IMPORTANT


WARNING


135477

135490

11A-7


K9K

11AREFITTING


a

a Use a brush to remove any deposits from the crank-shaft accessories pulley V grooves.

a parts always to be replaced: Accessories belt(10,10,01,03).

a parts always to be replaced: Accessories belttensioning roller (10,10,01,04).

a parts always to be replaced: Accessories ten-sioning roller bolt (10,10,01,09).


a Refit a new accessories belt tensioning roller.

a Torque tighten the new accessories belt tension-ing roller bolt (40 N.m).

a Refit a new accessories belt.

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


a Refit:




WARNING

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

11A-8

TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - Refitting

K9K

11A

REMOVAL



a Remove:

- the engine cover,





- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-4) .


a Remove:

- the crankshaft accessories pulley bolt (3) ,

- the crankshaft accessories pulley (4) .

REFITTING


a parts always to be replaced: Crankshaft acces-sories pulley bolts (10,03,03,10).

a If reusing the crankshaft accessories pulley, cleanthe crankshaft accessories pulley V-grooves with abrush to eliminate any deposits.

Tightening torquesm

crankshaft accessoriespulley bolt

120 N.m + 95˚±±±± 15˚

TDC pin plug 23 N.m

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

IMPORTANT


135491

WARNING

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

11A-9


K9K

11A

a Refit the old crankshaft accessories pulley bolt (5)with a spacer (6) .

a Turn the crankshaft clockwise (timing end) using theold bolt of the crankshaft accessories pulley, untilthe collet of the crankshaft timing pinion (7) is almostvertical and facing upwards.

a Remove the TDC setting pin plug (8) .

a Screw toolinto the cylinder block.

a Remove the old bolt from the crankshaft accessoriespulley fitted with its spacer.


a Refit:

- the crankshaft accessories pulley,

- a new crankshaft accessories pulley bolt.

107272

135472

135471

11A-10


K9K

11A

a Turn the crankshaft clockwise (timing end) smoothlyusing the bolt of the crankshaft accessories pulley,until the crankshaft presses against the tool (9) .

a Torque tighten the crankshaft accessories pulleybolt (120 N.m + 95˚ ±±±± 15˚).


a Remove thefrom the cylinder block.

a Apply a drop of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) to the threadof the TDC pin plug.

a Tighten to torque the TDC pin plug (23 N.m).

a Refit:





- the engine cover.

14489

11A-11


K4M

11A

REMOVAL



a Remove:

- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting, page 12A-12) ,






a Remove:

- the nut (2) securing the engine wiring on the liftingeye,

- the dipstick guide bolt (3) from the lifting eye.

a Unclip the engine wiring connector (4) from the liftingeye.

a Move aside the engine wiring.

a Remove:

- the lifting eye bolts (5) ,

- the lifting eye.


Mot. 1489 TDC locating pin.

Tightening torquesm

new bolt of the crank-shaft accessories pulley

40 N.m + 145˚±±±± 15˚

lifting eye bolts 10 N.m

dipstick guide tube bolt 10 N.m

TDC pin plug 25 N.m

IMPORTANT


WARNING


136454

135260

11A-12


K4M

11A

a Pierce the centre of the plugs (6) at the camshaftends with a screwdriver.

a Remove:

- the plugs from the camshaft ends with a screwdriv-er,

- the TDC setting pin plug (7) .

a Position the camshaft grooves (8) almost horizontal-ly and offset towards the bottom turning the crank-shaft in the operating direction (clockwise at timingend).

a Screw in the TDC setting pin (Mot. 1489) (9) .

a Turn the crankshaft in its operating direction (clock-wise at timing end), until the crankshaft pressesagainst the TDC setting pin (Mot. 1489).

a The camshaft grooves (10) must be horizontal andoffset downwards.

a Remove the TDC setting pin (Mot. 1489).

14491

14491-1

14489

135905

11A-13


K4M

11A

a Lock the flywheel using a screwdriver.


a Remove:

- the crankshaft accessories pulley bolt (11) ,

- the crankshaft accessories pulley.

REFITTING



a parts always to be replaced: Inlet camshaft cap(10,02,02,11).

a parts always to be replaced: Exhaust camshaftcap (10,02,02,12).

a Fit:

- the timing tool (12) fitted with the (13) ,

- a lifting eye bolt (14) to secure the timing toolfittedwith the.

135257

135907

135240

11A-14


K4M

11A

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

a Check that the crankshaft is pressing against theTDC setting pin.

a The crankshaft groove must be upwards.

a If the crankshaft is not pressing against the TDC set-ting pin, bring the crankshaft back by turning the fly-wheel using a screwdriver.


a Refit the accessories crankshaft pulley with a newbolt.

a Torque tighten the new bolt of the crankshaft ac-cessories pulley (40 N.m + 145˚ ±±±± 15˚).


a Remove:

- the TDC setting pin (Mot. 1489),

- the lifting eye bolt from the timing toolfitted with the,

- the timing toolfitted with the.

a Refit:

- a new inlet camshaft plug using the,

- a new exhaust camshaft plug using the,

- the lifting eye.

a Torque tighten the lifting eye bolts (10 N.m).

a Fit the engine wiring on the lifting eye.

a Clip the engine wiring connector on the lifting eye.

a Refit:

- the engine wiring retaining bolt on the lifting eye,

- the dipstick guide on the lifting eye.

a Torque tighten the dipstick guide tube bolt (10N.m).

a Place a drop of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) on the threadof the TDC setting pin plug.

a Refit the TDC setting pin plug.

a Torque tighten the TDC pin plug (25 N.m).

a Refit:




14489-2

135257

K4M

11A-15


K4M

11A- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting, page 12A-12) .

11A-16

TOP AND FRONT OF ENGINETiming belt: Removal - Refitting

K9K

11A

REMOVAL




a Remove:

- the engine cover,









a Refit the old crankshaft accessories pulley bolt witha spacer (which does not cover the crankshaft timingsprocket mark) on the crankshaft.


Equipment required

offset spanner

Tightening torquesm

timing belt tensioningroller bolt

27 N.m

camshaft pulley hubbolts

14 N.m

new crankshaft acces-sories pulley bolt

120 N.m + 95 ±±±±15˚

TDC setting pin plug 25 N.m

K9K, and 830 or 838

107272

11A-17


K9K

11A

K9K, and 832 or 842

135495

135494

135493

135492

11A-18


K9K

11A

a Remove:

- the upper timing cover (1) by pressing on the clips(2) ,

- the bolt (3) from the intermediate timing cover (4) ,

- the intermediate timing cover (4) by pressing on theclips (5) ,

- the lower timing cover (6) by pressing on the clips(7) .

135475

135476

11A-19


K9K

11A

a Unclip the upper timing cover at (8) .

a Remove:

- the bolt (9) from the upper timing cover,

- the upper timing cover,

- the lower timing cover by pressing the clips (10) .

K9K, and 830 or 838

136654

136656

136660

136662

11A-20


K9K

11A

a Remove the bolts (11) from the right-hand suspend-ed engine mounting support on the cylinder head. a Remove the bolts (12) from the right-hand suspend-

ed engine mounting support on the cylinder head.

a Remove the right-hand suspended engine mountingsupport.

a Remove the TDC setting pin plug (13) .

K9K, and 832 or 842

135496

K9K, and 830 or 838

136658

135472

11A-21


K9K


a Turn the crankshaft clockwise (timing end) using theold crankshaft accessories pulley bolt and its spacerto position the hole (14) of the camshaft pulley hubalmost opposite the hole (15) in the cylinder head.

a Screw tool (16) into the cylinder block.

a Turn the crankshaft clockwise (timing end) smoothlyuntil the crankshaft comes in contact with the.

a Insert the tool (17) in the holes of the camshaft pul-ley hub and the hole of the cylinder head.

107270

135471

14489-1

109049

11A-22


K9K

11A

a Undo the timing belt tensioning roller bolt (18) .

a Loosen the timing belt tensioning roller by turningthe eccentric cam using a 6 mm Allen key.

a Remove:

- the timing belt,

- the timing belt tensioning roller bolt,

- the timing belt tensioning roller.

REFITTING


a parts always to be replaced: Timing belt (10,02,04,02).

a parts always to be replaced: Timing belt tension-ing roller (10,02,04,04).


a Always replace the timing belt tensioning roller bolt.


a Refit the new timing belt tensioning roller.

a Fit the timing belt tensioning roller lug (19) in the cyl-inder head groove (20) .

a Check that:

- the mark (21) on the high-pressure pump is offsetby one tooth to the right of the vertical axis (22) ,

109046

K9K, and 832 or 842

109042

109043

11A-23


K9K

11A- the crankshaft is resting on the tool(the cotter (23)of the crankshaft timing sprocket must be verticaland upwards).

a Refit the new timing belt tensioning roller.

a Fit the timing belt tensioning roller lug (29) in the cyl-inder head groove (30) .

a Check that:

- Check that the mark (31) on the high pressurepump is opposite the bolt head (32) .

K9K, and 830 or 838

136389

109043

11A-24


K9K

11A- the crankshaft is resting on the tool(the cotter (33)of the crankshaft timing sprocket upwards).

a Check that the crankshaft is resting on the toolwhileturning the crankshaft clockwise using the old crank-shaft accessories pulley bolt and its spacer.

a Remove the bolt (34) from the camshaft pulley hub.

a Loosen the other bolts of the camshaft pulley hub byone turn.

14489

109049

11A-25


K9K

11A

a Fit the new timing belt starting with the crankshaftsprocket.

a Align the timing belt marks with the marks:

- of the crankshaft timing sprocket,

- of the camshaft pulley,

- of the high pressure pump pulley.

a Bring the timing belt tensioning roller adjustable in-dex (35) opposite the lug (36) using a 6 mm Allenkey, turning it anti-clockwise.

a Tighten the timing belt tensioning roller bolt.

109044

Note:

There should be 19 timing belt tooth groovesbetween the marks on the camshaft pulley andthe high pressure pump pulley and 51 timing belttooth grooves between the marks on the crank-shaft timing sprocket and the high pressurepump pulley.

19658

11A-26


K9K

11A

a

109047

Note:

Check that the camshaft pulley hub bolts are notfully up against the camshaft pulley wheel.

11A-27


K9K

11A

a Refit the camshaft pulley hub lower bolt (37) .

a Tighten the camshaft pulley hub bolts.

a Remove:

- the,

- the.

109045

11A-28


K9K

11A

a Turn the crankshaft two turns clockwise (timing end) using the old crankshaft accessories pulley bolt and its spacer until the hole (38) of the camshaft pulley hub is opposite the hole (39) in the cylinder head:

- screw toolinto the cylinder block,

- turn the crankshaft clockwise (timing end) smoothlyusing the old crankshaft accessories pulley boltand its spacer, until the crankshaft comes into con-tact with the.

a Set the camshaft pulley hub using the tool (40) .

a

a Loosen the camshaft pulley hub bolts by one turn.

107270

109049

109048

Note:

If the tooldoes not engage correctly:

-loosen the camshaft pulley hub bolts by up toone turn,

-turn the camshaft pulley hub using an 18mmoffset spanner to set the camshaft pulley hub,

-do not retighten the camshaft pulley hub bolts.

Note:

After the two turns, the adjustable index of thetensioning roller may be in two different positions.

The rotation of the tension wheel eccentricdepends on the position.

11A-29


K9K

11AFirst position of the index of the timing belt tensioning roller

a Loosen the timing belt tensioning roller bolt by up toone turn while holding the adjustable index with a 6mm Allen key.

a Gradually align the adjustable index of the timingbelt tensioning roller in the middle of the timing win-dow by turning the key anticlockwise.

Second position of the adjustable index of the timing belt tensioning roller

a Loosen the timing belt tensioning roller bolt by up toone turn while holding the adjustable index with a 6mm Allen key.

a Gradually position the adjustable index of the timingbelt tensioning roller in the middle of the timing win-dow by turning the key clockwise.

a Torque tighten:

- the timing belt tensioning roller bolt (27 N.m),

- the camshaft pulley hub bolts (14 N.m).

111083

111081

111082

111081

11A-30


K9K

11Aa Remove:

- the,

- the.

a Turn the crankshaft two turns clockwise (timing end)using the old crankshaft accessories pulley bolt andits spacer until the hole of the camshaft pulley hub isopposite the hole in the cylinder head.

a Screw toolinto the cylinder block.

a Turn the crankshaft clockwise (timing end) smoothlyusing the old crankshaft accessories pulley bolt andits spacer, until the crankshaft comes into contactwith the tool.

a Set the camshaft pulley hub using the tool.

a If the tooldoes not engage, repeat the timing belt re-fitting operation.


a Refit the right-hand suspended mounting support.

a Refit the lower timing cover by positioning the lowertiming cover tab in the inner cover opening.

a Clip on the lower timing cover.

a Refit the intermediate timing cover.

a Clip on the intermediate timing cover.

a Refit:

- the intermediate timing cover bolt,

- the upper timing cover.

a Clip on the upper timing cover.

a Clip on the lower timing cover.

a Refit:


- the upper timing cover bolt.


109049

123839

K9K, and 832 or 842

K9K, and 830 or 838

11A-31


K9K

11A




a Remove the old crankshaft accessories pulley boltwith its spacer.

a Refit:

- the crankshaft accessories pulley,

- a new crankshaft accessories pulley bolt.

a Turn the crankshaft clockwise (timing end) smoothlyusing the bolt of the crankshaft accessories pulley,until the crankshaft presses against the tool.

a Torque tighten a new crankshaft accessories pul-ley bolt (120 N.m + 95 ±±±± 15˚).

a Remove the tool.

a Apply a drop of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) to the threadof the TDC setting pin plug.

a Torque tighten the TDC setting pin plug (25 N.m).

a Refit:






- the engine cover.


K9K, and 830 or 838

K9K, and 830 or 838

14489

11A-32


K4M, and 838 or 839

11A

REMOVAL




a Remove:








- the crankshaft accessories pulley (see 11A, Topand front of engine, Crankshaft accessoriespulley: Removal - Refitting, page 11A-8) ,

- the right-hand suspended engine mounting (see19D, Engine mounting, Right-hand suspendedengine mounting: Removal - Refitting, page19D-5) .

a Remove:

- the bolts (1) from the upper timing cover,

- the upper timing cover nuts (2) ,


- the lower timing cover bolts (3) ,

- the lower timing cover.


Mot. 1489 TDC locating pin.

Tightening torquesm

timing fixed roller bolt 50 N.m

nut of the timing ten-sioning roller (initialtorque)

7 N.m

lower timing cover bolts 12 N.m

exhaus t camshaf tsprocket nut

30 N.m + 84˚ ±±±±4

camshaft dephaser bolt 100 N.m

timing tension wheel nut 27 N.m

flywheel end lifting eyebolts

10 N.m

TDC pin plug 20 N.m

upper timing cover bolts 46 N.m

upper timing cover nuts 46 N.m

135906

11A-33


K4M, and 838 or 839


a Loosen the nut (4) of the timing tensioning roller.

a Remove:

- the bolt (5) of the timing fixed roller,

- the timing fixed roller,

- the timing belt,

- the timing tensioning roller nut,

- the timing tensioning roller,

- the crankshaft timing sprocket.

REFITTING


a parts always to be replaced: Timing belt (10,02,04,02).

a parts always to be replaced: Timing belt tension-ing roller (10,02,04,04).

a parts always to be replaced: Timing fixed roller(10,02,04,05).

a parts always to be replaced: Inlet camshaft cap(10,02,02,11).

a parts always to be replaced: Exhaust camshaftcap (10,02,02,12).


a parts always to be replaced: Camshaft dephasersprocket bolt (10,02,02,06).

a parts always to be replaced: Exhaust camshaftpulley nut (10,02,02,13).


a Remove the camshaft dephaser (see 11A, Top andfront of engine, Camshaft dephaser: Removal -Refitting, page 11A-87) .

1 - Adjusting the timing

a

103268

Note:

Do not drop the crankshaft timing sprocket whenremoving the timing belt.

Note:

If the stud is loosened with the nut (see 11A, Topand front of engine, Camshaft: Removal -Refitting, page 11A-54) .

WARNING

Always degrease:

- the end of the crankshaft (timing end),

- the timing sprocket pressure faces and bore ofthe crankshaft,

- the crankshaft accessories pulley bearingfaces,

- the camshaft ends (timing end),

- the camshaft sprocket bores and bearing faces.

This is to avoid timing slippage.

This slippage leads to engine damage.

11A-34


K4M, and 838 or 839

11A

a Position the camshaft grooves horizontally and be-low the centre line, by turning the camshafts withtheif necessary.

a Fit thewith the (6) .

a Fit:

- the (7) fitted with theon the end of the camshaft,

- a lifting eye bolt (8) to secure the toolequipped withthe tool.

a Refit:

- the camshaft dephaser (see 11A, Top and front ofengine, Camshaft dephaser: Removal - Refit-ting, page 11A-87) ,

- the crankshaft timing sprocket.

14490

103261

111337

111336

11A-35


K4M, and 838 or 839

11A

a Refit the tool (Mot. 1489) (9) on the cylinder block.

a Use a screwdriver to check that the flywheel doesnot turn (clockwise at the timing end), otherwisebring the crankshaft back into contact with the tool(Mot. 1489) (9) using the screwdriver; the crank-shaft groove (11) should be at the top.

14489 135257

132387

11A-36


K4M, and 838 or 839

11A

a Position:

- the RENAULT badge (12) etched on the stem ofthe exhaust camshaft sprocket vertically and point-ing upwards,

- the camshaft dephaser mark (13) vertically andpointing upwards.

a Make a mark (14) with a pencil between the cam-shaft dephaser gear and the rocker cover.

2 - Refitting

a Refit a new timing tensioning roller by positioning thelug of the timing tensioning roller in the groove (15) .

a Screw on the timing tensioning roller nut withouttightening it.

130492

108879

11A-37


K4M, and 838 or 839

11A

a Refit a new timing belt starting with the sprocket ofeach camshaft (without moving the sprocket of eachcamshaft).

a Fit the tool (16) on the camshaft sprockets (use thebolt and nut of the upper timing cover to fit the tool).

a Refit a new timing fixed roller (17) .

a Torque tighten the timing fixed roller bolt (50N.m).

3 - Timing belt tension

a Position the adjustable index (18) opposite the mark(19) , by turning the eccentric (20) clockwise usingan Allen key.

a Torque tighten the nut of the timing tensioningroller (initial torque) (7 N.m).

130495

Note:

Take care to properly tighten the timing beltbetween the two camshaft sprockets.

Note:

Take care to properly tighten the timing beltbetween the exhaust camshaft sprocket and thecrankshaft timing sprocket.

130497

103263

11A-38


K4M, and 838 or 839

11A

a Refit the lower timing cover (21) .

a Tighten to torque the lower timing cover bolts (12N.m).

a Refit the crankshaft accessories pulley (see 11A,Top and front of engine, Crankshaft accessoriespulley: Removal - Refitting, page 11A-8) .

a Torque tighten:

- and angle tighten the exhaust camshaft sprocketnut (30 N.m + 84˚ ±±±± 4),

- the camshaft dephaser bolt (100 N.m).

a Refit the camshaft dephaser plug.

a Remove:

- the timing flap from the lower timing cover,

- the lifting eye bolt from the,

- thefitted with the,

- the tool (Mot. 1489) from the cylinder block,

- the.

4 - Checking the tension

a Rotate the crankshaft twice clockwise at the timingend and before aligning the marks made previouslyby the operator (on the camshaft dephaser), screwthe tool (Mot. 1489) into the cylinder block.

a Move the crankshaft slowly and smoothly until itcomes into contact with the tool (Mot. 1489).

a Remove the tool (Mot. 1489).

130497 109052

11A-39


K4M, and 838 or 839

11A

a Check through the lower timing cover window that the adjustable index (22) is opposite the notch (23) , if this is not the case:

- loosen the timing tensioning roller nut by up to oneturn while holding the eccentric with an Allen key,

- gradually move the adjustable index marker (22)opposite the mark (23) turning the eccentric cam(24) clockwise.

a Torque tighten the timing tension wheel nut (27N.m).

5 - Checking the timing

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

a Screw tool (Mot. 1489) into the cylinder block.

a Move the crankshaft slowly and smoothly until itcomes into contact with the tool (Mot. 1489).

a Position (without forcing) the toolequipped with thetool(the camshaft end grooves must be horizontaland offset downwards).

a Remove:

- the timing toolfitted with the,

- the (Mot. 1489) from the cylinder block.

109051

103263

14490

Note:

If the toolequipped with the toolcannot beengaged, readjust the timing and the tension.

11A-40


K4M, and 838 or 839

11A

a Refit the lower timing cover flap, checking that thelocating pin (25) fits properly in the notch (26) .


a Refit:

- a new inlet camshaft plug using the,

- a new exhaust camshaft plug using the,

- the lifting eye on the flywheel end.

a Torque tighten the flywheel end lifting eye bolts(10 N.m).

a Fit the engine wiring.

a Refit the engine wiring nut.

a Clip the engine wiring connector onto the flywheelend lifting eye.

a Apply a drop of SILICONE ADHESIVE SEALANT(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) to the threadof the TDC pin plug.

a Tighten to torque the TDC pin plug (20 N.m).

a Refit the upper timing cover.

a Torque tighten:

- the upper timing cover bolts (46 N.m),

- the upper timing cover nuts (46 N.m).

a Refit:

- the right-hand suspended engine mounting (see19D, Engine mounting, Right-hand suspendedengine mounting: Removal - Refitting, page19D-5) ,








109052

11A-41

TOP AND FRONT OF ENGINERocker cover: Removal - Refitting

K9K

11A

REMOVAL


a Remove:

- the engine cover,









a Remove the upper timing cover (1) by pressing theclips (2) .



Tightening torquesm

rocker cover bolts 11 N.m

IMPORTANT


K9K, and 830 or 838

K9K, and 830 or 838

K9K, and 832 or 842

135494

135495

11A-42


K9K

11A

a Remove:


- the upper timing cover by pressing the clips (4) .


a Remove the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting, page 12A-9) .

K9K, and 830 or 838

136654

136656

K9K, and 832 or 842

11A-43


K9K

11A

a Disconnect the oil vapour rebreathing pipe unionfrom the air filter unit air outlet pipe at (9) .

a Remove the oil vapour rebreathing pipe clip (10)from the oil vapour rebreathing valve using the (Mot.1448).

a Disconnect the oil vapour rebreathing pipe from theoil vapour rebreathing valve.

a Remove the nut (11) from the gearbox breather pipesupport.

a Separate the gearbox breather pipe support.

a Remove:

K9K, and 830 or 838

135880

135879

135845

112325

11A-44


K9K

11A- the bolts (12) of the oil vapour rebreathing valvebracket,

- the oil vapour rebreathing valve bracket.

a Disconnect the brake servo pipe union from the vac-uum pump.

a Remove:

- the nuts (13) of the oil vapour rebreathing valve,

- the oil vapour rebreathing valve,

- the oil vapour rebreathing valve seal from the oilvapour rebreathing valve.

a Unclip the injector rail protector cover at (14) .

a Remove:

- the injector rail protector cover bolt (15) ,

- the injector rail protector cover nut (16) ,

- the injector rail protector cover,


a Remove:



K9K, and 832 or 842

134699

K9K, and 830 or 838

135878

11A-45


K9K

11A

a Remove:

- the injector rail protector cover mounting bolts (21),

- the injector rail protector cover mounting.

a Unclip the diesel injector wiring from the rocker cov-er at (22) .

a Unclip the fuel return rail from the rocker cover at(23) .

134702

K9K, and 832 or 842

134701

K9K, and 832 or 842

134700

11A-46


K9K

11A

a Unclip the fuel return rail from the rocker cover at(24) .



a Remove:

- the rocker cover bolts (31) ,

- the rocker cover,

- the rocker cover seal.

a Remove:


K9K, and 830 or 838

135860

K9K, and 832 or 842

K9K, and 832 or 842

135489

K9K, and 830 or 838

135876

11A-47


K9K

11A- the rocker cover,


REFITTING


a parts always to be replaced: rocker cover seal(10,02,01,12).

a Clean the gasket surface of the cylinder head usingGREY ABRASIVE PADS (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products).

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to degrease:

- the cylinder head joint face,

- the rocker cover seal housing in the rocker cover ifit is to be reused.

a

a Apply four beads (35) of SILICONE ADHESIVESEALANT (see Vehicle: Parts and consumablesfor the repair) (04B, Consumables - Products) 2mm in diameter and 10 mm long.

If replacing the rocker cover

a Remove:

- the bolt from the camshaft position sensor,

- the camshaft position sensor from the rocker cover.

a Refit:

- the camshaft position sensor onto the new rockercover,

- the camshaft position sensor bolt.

WARNING


WARNING


19712-1

WARNING


K9K, and 832 or 842

11A-48


K9K

11AII - REFITTING OPERATION FOR PART CONCERNED

a Refit the rocker cover, fitted with a new gasket.

a Tighten to torque and in order the rocker coverbolts (11 N.m).



a Clip on the rocker cover:

- the fuel return rail,

- the diesel injector wiring.

a Refit the injector rail protector cover mounting.

a Refit the injector rail protector cover.

a Clip the injector rail protector cover into place.

a Refit:

- a new seal on the oil vapour rebreathing valve,


- the oil vapour rebreathing valve nuts.


a Refit:

- the oil vapour rebreathing valve bracket,

- the oil vapour rebreathing valve bracket bolts.

a Fit the gearbox breather pipe mounting.

a Refit the nut of the gearbox breather pipe mounting.

a Connect the oil vapour rebreathing pipe to the oil va-pour rebreathing valve.

a Fit the oil vapour rebreathing pipe clip on the oil va-pour rebreathing valve using the tool (Mot. 1448).

a Connect the oil vapour rebreathing pipe to the air fil-ter box air outlet pipe.

a Refit the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting, page 12A-9) .


a Refit the upper timing cover.


a Refit the upper timing cover bolt.

135489

K9K, and 832 or 842

K9K, and 830 or 838

K9K, and 832 or 842

K9K, and 830 or 838

11A-49


K9K

11A




a Refit:





- the engine cover.

K9K, and 830 or 838

K9K, and 830 or 838

11A-50


K4M

11A

REMOVAL




a Remove:

- the engine cover,


a Remove:









- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting, page 11A-16) ,


- the inlet distributor (see 12A, Fuel mixture, Inletdistributor: Removal - Refitting, page 12A-14) ,

- the oil decanter (see 11A, Top and front of en-gine, Oil decanter: Removal - Refitting, page11A-102) .

a Remove:

- the camshaft dephaser solenoid valve (see 11A,Top and front of engine, Camshaft dephasersolenoid valve: Removal - Refitting, page 11A-90) ,

- the camshaft position sensor (see Camshaft posi-tion sensor: Removal - Refitting) .

a Position the toolon the camshaft pulleys.

a Remove (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refitting, page 11A-87) :

- the camshaft dephaser,

- the exhaust camshaft sprocket.

Tightening torquesm

rocker cover bolts 23,18, 19, and 24

14 N.m

rocker cover bolts 1 to17, 20, 21, and 22

12 N.m

K4M, and 838 or 839

K4M, and 838 or 839

11A-51


K4M


a Remove the rocker cover bolts.

a Remove the rocker cover vertically by tapping thelugs (3) with a copper hammer.

a Remove:

- the rocker cover,

- the exhaust camshaft,

- the exhaust camshaft seal,

- the inlet camshaft,

- the inlet camshaft seal.

REFITTING




a

a Clean the gasket face of the rocker cover and cylin-der head with SUPER CLEANING AGENT FORGASKET FACES (see Vehicle: Parts and con-sumables for the repair) (04B, Consumables -Products) to dissolve any pieces of seal that are stillattached.

a Apply the product to the part to be cleaned, wait ap-proximately 10 minutes, then remove the residuewith a wooden spatula.

a Lubricate the cylinder head camshaft bearings withengine oil.

136589

Note:

The rocker cover bolts are not the same length;mark their positions.

K4M, and 838 or 839

WARNING


WARNING

Do not allow this product to drip onto the paint-work.

Clean the cylinder head carefully to avoid anyforeign bodies entering the oil return and supplypipes.

Failure to follow this advice could lead to theblocking of the various oil inlet galleries, whichwould quickly result in engine damage.

WARNING


Note:

Do not put oil on the gasket face of the cylinderhead cover.

11A-52


K4M

11A

a Using a stipple roller, apply RESIN ADHESIVE (seeVehicle: Parts and consumables for the repair)(04B, Consumables - Products) to the joint face untilit is well coated.

a Use a cloth to remove any RESIN ADHESIVE in therocker cover bearings (4) .


a Refit the camshafts while positioning them correctly(see Camshaft: Check) (Technical Note 6023A,10A, Engine and peripherals).

a Refit the rocker cover.


- rocker cover bolts 23, 18, 19, and 24 (14 N.m),

- rocker cover bolts 1 to 17, 20, 21, and 22 (12N.m).


a Refit the timing end camshaft seals (see 11A, Topand front of engine, Camshaft seal, timing end:Removal - Refitting, page 11A-91) .

a Refit (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refitting, page 11A-87) :

- the camshaft dephaser with a new bolt,

- the exhaust camshaft sprocket with a new nut.

a Refit:

- the camshaft position sensor (see Camshaft posi-tion sensor: Removal - Refitting) ,

14517

126216

WARNING


136589

K4M, and 838 or 839

K4M, and 838 or 839

11A-53


K4M

11A- the camshaft dephaser solenoid valve (see 11A,Top and front of engine, Camshaft dephasersolenoid valve: Removal - Refitting, page 11A-90) .

a Refit:

- the oil decanter (see 11A, Top and front of en-gine, Oil decanter: Removal - Refitting, page11A-102) ,











a Refit:


- the engine cover.


11A-54

TOP AND FRONT OF ENGINECamshaft: Removal - Refitting

K4M

11A

REMOVAL




a Remove the throttle valve (see 12A, Fuel mixture,Throttle valve: Removal - Refitting, page 12A-12).

a Remove:













a Remove:




- the exhaust camshaft pulley.

a Remove:

- the rocker cover (see 11A, Top and front of en-gine, Rocker cover: Removal - Refitting, page11A-41) ,

- the timing end camshaft seals (see 11A, Top andfront of engine, Camshaft seal, timing end: Re-moval - Refitting, page 11A-91) .


a Remove:

- the inlet camshaft (1) ,

- the exhaust camshaft (2) .

Equipment required

roller-type stud removal tool

Tightening torquesm

the camshaft dowel 8 N.m

134576

11A-55


K4M

11A

a Remove:

- the valve rockers (3) ;

- the hydraulic tappets (4) .

REFITTING


a Refit the camshafts while positioning them correctly(see Top of engine: Specifications) (TechnicalNote 6023A, 10A, Engine and peripherals).

a

a To check if re-priming is necessary, press the top ofthe tappet with your thumb. If the tappet piston de-presses, immerse the tappets in a container full ofdiesel then reprime them.

Replacing a camshaft dowel

a

a - Removal

a Place the camshaft in a vice with aluminium jaws.

a Remove the dowel using a roller-type stud remov-al tool (5) .

b - Cleaning the camshaft

a

c - Refitting

a Place the camshaft in a vice with aluminium jaws.

14499

Note:

To prevent any risk of unpriming the hydraulictappets make sure that they are vertical.

Note:

It is essential to reprime the hydraulic tappets asthese may become drained if removed for a longtime.

Note:

It is essential to replace the camshaft dowel if itcomes loose at the same time as the nut.

109050

Note:

Clean the thread hole of the camshaft carefully toprevent foreign bodies from entering the latter.

11A-56


K4M

11A

a Refit the new camshaft dowel (precoated section (6)on the camshaft side).

a Torque tighten the camshaft dowel (8 N.m) using aroller-type stud removal tool (7) .


a Refit:

- the hydraulic tappets,

- the valve rockers,

- the inlet camshaft, by lubricating the inlet camshaftbearings,

- the exhaust camshaft, by lubricating the exhaustcamshaft bearings.


a Refit:



a Refit:




- the camshaft dephaser solenoid valve (see 11A,Top and front of engine, Camshaft dephasersolenoid valve: Removal - Refitting, page 11A-90) .

a Refit:












a Refit the throttle valve (see 12A, Fuel mixture,Throttle valve: Removal - Refitting, page 12A-12).


109050

11A-57


K9K

11A

REMOVAL




a Remove:

- the engine cover,











a Remove:


- the turbocharger air outlet pipe (see 12B, Turbo-charging, Intercooler air inlet pipe: Removal -Refitting, page 12B-12) .


a Remove:


- the vacuum pump (see Vacuum pump: Removal- Refitting) (37A, Mechanical component controls).

a Increase the hole (1) of the (2) using an 8.5 mm drillbit.

Tightening torquesm

bolts of the camshaftbearings

10 N.m

K9K, and 830 or 838

K9K, and 830 or 838

K9K, and 832 or 842

118982

11A-58


K9K

11A

a Undo the camshaft pulley hub bolts (3) .

a Fit theon the cylinder head to lock the camshaft pul-ley wheel.

a Tighten the camshaft pulley hub bolts (3) .

a Remove:

- the nut (4) from the camshaft pulley,

- the,

- the camshaft pulley.


a Mark the position of the camshaft bearings.

a Remove:

- the camshaft bearings bolts (5) ,

- the camshaft bearings,

- the camshaft,

- the timing end camshaft seal.

REFITTING


a parts always to be replaced: Camshaft seal ontiming end (10,02,02,02).

a Use GREY ABRASIVE PADS (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) to clean the bearing faces of thecamshaft bearings.

118983

113563

113565

11A-59


K9K



- the bearing faces of the camshaft bearings on thecylinder head,

- the bearing faces of the camshaft bearings on thecamshaft bearings.

a Apply four beads (6) of RESIN ADHESIVE (see Ve-hicle: Parts and consumables for the repair)(04B, Consumables - Products) 7 mm in diameteron the cylinder head.


a Position the camshaft by positioning the timing endcamshaft groove vertically.

a Refit the camshaft bearings.

a Refit the camshaft bearing bolts (1) , (3) , (4) and (2)in order.

a Tighten the camshaft bearing bolts (1) , (3) , (4) and(2) in order.

a Refit the camshaft bearing bolts in order.

a Tighten to torque and in order the bolts of the cam-shaft bearings (10 N.m).


a Refit:

- the camshaft seal (see 11A, Top and front of en-gine, Camshaft seal, timing end: Removal - Re-fitting, page 11A-91) ,

- the vacuum pump (see Vacuum pump: Removal- Refitting) (37A, Mechanical component controls),

- the rocker cover (see 11A, Top and front of en-gine, Rocker cover: Removal - Refitting, page11A-41) .


a Refit:



WARNING


WARNING


WARNING


20064-1

113563

K9K, and 832 or 842

11A-60


K9K

11A




a Refit:





- the front right-hand wheels (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the engine cover.


K9K, and 830 or 838

K9K, and 830 or 838

11A-61

TOP AND FRONT OF ENGINECylinder head: Removal - Refitting

K9K

11A

REMOVAL




a Remove:

- the engine cover,






a Remove:



- the scoop under the scuttle panel grille (see Scoopunder the scuttle panel grille: Removal - Refit-ting) (56A, Exterior equipment).

a Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting, page19B-6) .



Equipment required

cylinder head rule

set of feeler gauges

Tightening torquesm

new cylinder head bolts(initial torque)

20 N.m

new cylinder head bolts 25 N.m

new cylinder head bolts 270˚ ±±±± 10˚

alternator lower bolt 25 N.m

alternator upper bolt 25 N.m


5.5 N.m

rocker cover bolts 11 N.m

IMPORTANT




IMPORTANT


IMPORTANT

Use the diagnostic tool before any operation is car-ried out on the injection circuit to check:

- that the rail is not under pressure,

- that the fuel temperature is not too high.

Working on the circuit with the engine running isstrictly forbidden.

11A-62


K9K

11A

a Remove the bolts (1) from the exhaust bracket.

a Move the exhaust pipe to one side.

a Remove:

- the bolts (2) from the bracket of the exhaust gasesduct at the outlet of the turbocharger,

- the bracket from the exhaust gases duct at the out-let of the turbocharger.

a Remove:

- the turbocharger oil return pipe (see 12B, Turbo-charging, Turbocharger oil pipe: Removal - Re-fitting, page 12B-4) ,






a Remove:


- the intercooler air outlet pipe (see 12B, Turbo-charging, Intercooler air outlet pipe: Removal -Refitting, page 12B-17) .



139188

139205

K9K, and 830 or 838

K9K, and 830 or 838

K9K, and 832 or 842

11A-63


K9K

11A

a Disconnect the oil vapour rebreathing pipe unionfrom the air filter unit air outlet pipe at (6) .

a Remove the oil vapour rebreathing pipe clip (7) fromthe oil vapour rebreathing valve using the (Mot.1448).


a Remove the nut (8) from the gearbox breather pipesupport.

a Separate the gearbox breather pipe support.

a Remove:

K9K, and 830 or 838

135880

135879

135845

112325

11A-64


K9K

11A- the bolts (9) of the oil vapour rebreathing valvebracket,



a Remove:



- the seal of the oil vapour rebreathing valve.


a Remove:





a Remove:



K9K, and 832 or 842

134699

K9K, and 830 or 838

135878

11A-65


K9K

11A

a Remove:



a Unclip the diesel injector wiring from the rocker cov-er at (19) .

a Unclip the diesel injector fuel return rail from therocker cover at (20) .

a Remove the fuel return rail (see 13B, Diesel injec-tion, Diesel injector fuel return rail: Removal -Refitting, page 13B-32) .


134702

K9K, and 832 or 842

134701

K9K, and 832 or 842

134700

K9K, and 830 or 838

K9K, and 832 or 842

11A-66


K9K

11A

a Remove:


- the rocker cover,


a Remove:


- the rocker cover,


a Remove:

- the dipstick,

- the dipstick guide bolts (39) .

a Move aside the dipstick guide.

a Disconnect the vacuum pipe (40) from the vacuumpump.

K9K, and 832 or 842

135489

K9K, and 830 or 838

135876

134703

134704

11A-67


K9K

11Aa Unclip the hose of the turbocharging pressure regu-

lator solenoid valve from the cylinder head.

a Disconnect the hose (41) of the turbocharging pres-sure regulator solenoid valve from the turbocharger.

a Disconnect the hose (44) of the turbocharging pres-sure regulator solenoid valve from the turbocharger.

a Disconnect the connector (45) from the exhaust gasrecirculation solenoid valve.

K9K, and 832 or 842

135487

K9K, and 830 or 838

135875

134705

11A-68


K9K

11A

a Undo the air filter unit air outlet pipe clip (55) fromthe turbocharger.





K9K, and 832 or 842

135410

K9K, and 830 or 838

136639

11A-69


K9K

11A

a Unclip the heater matrix cooling hose from the waterchamber (57) .

a Separate the heater matrix cooling hose clip (58)from the exhaust cooler cover using the tool (Mot.1448).

a Disconnect the heater matrix cooling hose from theexhaust gas cooler cover (59) .

a Separate the clip (63) of the cooling radiator topcooling hose (64) from the water chamber using thetool (Mot. 1448).

a Disconnect the cooling radiator top cooling hosefrom the water chamber (64) .

a Separate the heater matrix cooling hose clip (65)from the water chamber cooling hose using the tool(Mot. 1448).

a Disconnect the heater matrix cooling hose from thewater chamber cooling hose (66) .

a Disconnect the coolant temperature sensor connec-tor.

135484

135485

139156

11A-70


K9K

11A

a Unclip:

- the expansion bottle bottom cooling hose from thehigh pressure pump protector (67) ,

- the alternator wiring from the injector rail protectorat (68) .

a Disconnect:

- the connector (69) from the injector rail pressuresensor,

- the fuel temperature sensor connector (70) ,


- the connector (72) for the fuel flow regulation sole-noid valve,

- all heater plug connectors,

- the connector for each diesel injector.

a Unclip the injection wiring clip (73) .

a Remove the nut from the injection wiring bracket.

a Disconnect:






a Unclip the injection wiring clips (88) .

a Move aside the injection wiring.

K9K, and 832 or 842

134706

134706

K9K, and 830 or 838

135874

11A-71


K9K

11A

a Disconnect the fuel supply pipe union (89) from thehigh pressure pump.

a Fit a suitable blanking plug to:

- the fuel supply pipe union opening,

- the high pressure pump opening.

K9K, and 832 or 842

134707

11A-72


K9K

11A

a Unclip the high pressure pump fuel return union fromthe high pressure pump protector at (94) .

a Remove:

- the bolt (95) of the high pressure pump protector,


a Disconnect the fuel supply pipe (96) from the highpressure pump.


- the fuel supply pipe union opening,


a Disconnect the fuel drain pipe from the injector railprotector (97) .

K9K, and 830 or 838

135873

135872

K9K, and 832 or 842

135468

11A-73


K9K

11A

a Remove the alternator upper bolt (99) .

a Loosen the alternator lower bolt (100) .

a Tilt the alternator slightly towards the front of the ve-hicle.

a Remove:

- the bolts (101) from the inner cover,

- the inner cover.




a Remove:


- the inner cover.


a

K9K, and 832 or 842

123969

K9K, and 830 or 838

136665

Note:

The operation to remove the cylinder headrequires two people.

11A-74


K9K

11A

a Remove the tool.

a Insert the toolin the holes of the camshaft pulley huband the hole of the cylinder head.

a Remove:

- the cylinder head bolts (108) ,

- the cylinder head from the cylinder block,

- the cylinder head gasket.

REFITTING


a

a parts always to be replaced: cylinder head bolts(10,02,01,14).

a parts always to be replaced: Cylinder head gas-ket (10,02,01,04).

a parts always to be replaced: rocker cover seal(10,02,01,12).

a Always replace the seal for the turbocharger air inletpipe.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to clean and degrease:

- the rocker cover seal housing,

- the cylinder head joint face.

K9K, and 832 or 842

Note:

Turn the camshaft slightly to facilitate the removalof the cylinder head bolt on the camshaft positionsensor target.

19712

IMPORTANT


IMPORTANT


WARNING


WARNING




WARNING


11A-75


K9K

11A

a Always replace the seal of the oil vapour rebreathingvalve.

1 - Cleaning the cylinder head joint face

a

a Clean the gasket surface using GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products):

- the cylinder head,

- the cylinder block.

a Use a SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to degrease the joint faces:


- of the cylinder block,

- of the exhaust gas cooler mounting on the gearboxside,

- of the oil vapour rebreathing valve.

2 - Checking the gasket face

a Check with a cylinder head rule and a set of feelergauges to determine if the joint face has been de-formed.

a The maximum deformation is 0.05 mm.

3 - Cleaning the joint face of the rocker cover

a

a Clean the gasket surface of the cylinder head usingGREY ABRASIVE PADS (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products).



- the rocker cover housing.

4 - Cleaning the joint face of the turbocharger air inlet pipe

a Clean the gasket surface of the turbocharger usingGREY ABRASIVE PADS (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products).


- the turbocharger joint face,

- the housing of the turbocharger air inlet pipe.

K9K, and 830 or 838

WARNING

Protect the oilway so that foreign bodies do notenter the oil pipes in the cylinder head.

Failure to follow this instruction could lead to theblocking of the oilways, resulting in a rapid deteri-oration of the camshaft.

WARNING

No regrinding of the cylinder head is permitted.

Note:

If the cylinder head is faulty:

-strip down the cylinder head (see Stripping thecylinder head) (Technical Note 6006A, 10A,Engine and cylinder block assembly),

-test the cylinder head for possible cracks usingthe cylinder head test kit,

-rebuild the cylinder head (see Reassemblingthe cylinder head) (Technical Note 6006A, 10A,Engine and cylinder block assembly).

WARNING


WARNING


11A-76


K9K


a Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.

a Fit:

- a new cylinder head gasket, centred by two dow-els,

- the cylinder head on the cylinder block.

a Refit in order the new cylinder head bolts.

a Pretighten to torque and in order the new cylinderhead bolts (initial torque) (20 N.m).

a Tighten to torque and in order the new cylinderhead bolts (25 N.m).

a Check that all of the new cylinder head mountingbolts are tightened to the correct torque (25 N.m).

a Angle tighten in order the new cylinder head bolts(270˚ ±±±± 10 )̊.


a Refit the inner cover.

a Fit the alternator in place.

a Refit the alternator upper bolt.

a Torque tighten:

- the alternator lower bolt (25 N.m),

- the alternator upper bolt (25 N.m).

a Connect the fuel drain pipe to the injector rail protec-tor.


- the opening of the high pressure pump,

- on the fuel supply pipe union opening.



a Clip the high pressure pump fuel return union ontothe high pressure pump protector.

a Fit the injection wiring.

Note:

The operation to refit the cylinder head requirestwo people.

Note:

The cylinder head gasket has a foolproofingdevice which must be positioned on the cylinderblock inlet side.

WARNING

In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.

WARNING

Do not oil the new bolts. Be sure to oil boltsbeing reused.

19712

K9K, and 832 or 842

K9K, and 830 or 838

11A-77


K9K

11A

a Refit the injection wiring bracket nut.

a Clip on the injection wiring clip.

a Connect:

- the connector for each diesel injector,


- the connector for the fuel flow regulation solenoidvalve,

- the connector for the fuel pressure regulation sole-noid valve,

- the fuel temperature sensor connector,

- the injector rail pressure sensor connector.

a Clip:

- the alternator wiring on the injector rail protector,

- the expansion bottle bottom cooling hose on thehigh pressure pump protector.

a Clip on the injection wiring clips.

a Connect:






a Connect:

- the coolant temperature sensor connector,

- the heater matrix cooling hose to the water cham-ber cooling hose.

a Fit the heater matrix cooling hose clip onto the waterchamber cooling hose using the tool (Mot. 1448).

a Connect the cooling radiator top cooling hose to thecoolant outlet unit.

a Fit the cooling radiator top cooling hose clip on thecoolant outlet unit using the tool (Mot. 1448).

a Connect the heater matrix cooling hose to the ex-haust gas cooler cover.

a Fit the heater matrix cooling hose clip on the exhaustgas cooler cover using the tool (Mot. 1448).

a Clip the heater matrix cooling hose onto the waterchamber.



a Connect:

- exhaust gas recirculation solenoid valve connector,

- the turbocharging pressure regulation solenoidvalve hose to the turbocharger.

a Clip on the turbocharging pressure regulation sole-noid valve hose.

a Connect the turbocharging pressure regulation sole-noid valve hose to the vacuum pump.

a Fit the dipstick guide tube.

a Refit:

- the dipstick guide bolts,

- the dipstick.

K9K, and 832 or 842

K9K, and 830 or 838

K9K

K9K

K9K

11A-78


K9K

11A

a

a Place beads (109) of SILICONE ADHESIVE SEAL-ANT (see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) 2 mm indiameter and 10 mm long.

a Refit the rocker cover, fitted with a new gasket.

a Torque tighten the rocker cover bolts (11 N.m).


a Refit the diesel injector fuel return rail (see 13B, Die-sel injection, Diesel injector fuel return rail: Re-moval - Refitting, page 13B-32) .

a Clip on the rocker cover:

- the diesel injector fuel return rail,

- the diesel injector wiring.

a Refit the injector rail protector cover mounting.


a Clip on the injector rail protector cover.

a Refit:

- the new oil vapour rebreathing valve seal on the oilvapour rebreathing valve,

- the oil vapour rebreathing valve.


a Refit the oil vapour rebreathing valve bracket.

a Fit the breather mounting on the gearbox.

a Refit the nut of the breather mounting on the gear-box.


a Fit the oil vapour rebreathing pipe clip on the oil va-pour rebreathing valve using the tool (Mot. 1448).




a Refit:



a Refit the camshaft position sensor (see 13B, Dieselinjection , Camshaft position sensor: Removal -Refitting, page 13B-8) .

19712-1

WARNING


K9K, and 832 or 842

K9K, and 830 or 838

K9K, and 832 or 842

K9K, and 830 or 838

K9K, and 832 or 842

K9K, and 830 or 838

11A-79


K9K

11A


a Refit:



- the turbocharger oil return pipe (see 12B, Turbo-charging, Turbocharger oil pipe: Removal - Re-fitting, page 12B-4) .

a Refit the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting, page19B-6) .

a Refit:



- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (85A, Wiping -Washing).

a Refit:





- the engine cover.


a Fill and bleed the cooling system (see 19A, Cool-ing, Cooling system: Draining - Refilling, page19A-8) .

K9K, and 830 or 838

11A-80


K4M

11A

REMOVAL




a Remove:

- the engine cover,


a Remove:






a Remove:





a Remove:


- the ring between the exhaust manifold and the cat-alytic converter.

a Remove:

- the exhaust manifold strut nut (2) from the exhaustmanifold,

Tightening torquesm

cylinder head bolts (ini-tial torque)

20 N.m

cylinder head bolts 240˚ ±±±± 6˚

lifting eye bolts 10 N.m

IMPORTANTWear protective gloves during the operation.

136392

136470

11A-81


K4M

11A- the exhaust manifold strut bolt (3) from the cylinderblock,

- the exhaust manifold stay,




- the spark plugs (see Plugs: Removal - Refitting) .

a Unclip the wiring from the lifting eye.

a Remove:

- the engine wiring retaining nut,

- the lifting eye bolts (4) ,

- the lifting eye.

a Remove:

- the dipstick guide bolt (5) ,

- the dipstick guide.

a Remove:



- the camshaft dephaser (see 11A, Top and front ofengine, Camshaft dephaser: Removal - Refit-ting, page 11A-87) .

a Remove:


135260

K4M, and 838 or 839

136454

K4M, and 838 or 839

11A-82


K4M

11A- the rocker cover (see 11A, Top and front of en-gine, Rocker cover: Removal - Refitting, page11A-41) ,

- the camshafts (see 11A, Top and front of engine,Camshaft: Removal - Refitting, page 11A-54) ,

- the timing end camshaft seals (see 11A, Top andfront of engine, Camshaft seal, timing end: Re-moval - Refitting, page 11A-91) ,

- the injector rail (see Injector rail - Injectors: Re-moval - Refitting) .

a Using theororremove:

- the top hose clip (7) from the coolant outlet unit,

- the heater matrix hose clip (8) .

a Disconnect:

- the top hose from the coolant outlet unit,

- the heater matrix hose,

- the coolant temperature sensor connector.

a Disconnect the upstream oxygen sensor connector(9) .

134583

136546

11A-83


K4M

11A

a

a Remove:

- the valve rockers (12) ,

- the hydraulic tappets (11) .


a Remove:

- the cylinder head bolts,

- the cylinder head.

a Mount the cylinder head on the cylinder head sup-port.

a Remove the cylinder head gasket from the cylinderblock.

REFITTING


a parts always to be replaced: cylinder head bolts(10,02,01,14).

a parts always to be replaced: Cylinder head gas-ket (10,02,01,04).

a parts always to be replaced: ring between ex-haust manifold and catalytic converter (10,08,02,20).

134573

134575

Note:

To prevent any risk of unpriming the hydraulictappets, make sure that they are vertical.

134578

11A-84


K4M

11A1 - Cleaning the cylinder head joint face

a

a Use SUPER CLEANING AGENT FOR JOINT FA-CES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean:

- the cylinder head gasket face if being reused,

- the cylinder block gasket face.


- the cylinder head gasket face if being reused,


2 - Checking the gasket face

a Check for gasket face deformation using a ruler anda set of shims.

a The maximum deformation is 0.05 mm.


a Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.

a Check that the centring dowel is present on the cyl-inder block.

IMPORTANT


IMPORTANT


WARNING


WARNING




WARNING


WARNING

Protect the oilway so that foreign bodies do notenter the oil pipes in the cylinder head.

Failure to follow this instruction could lead to theblocking of the oilways, resulting in a rapid deteri-oration of the camshaft.

WARNING

No regrinding of the cylinder head is permitted.

Note:

If the cylinder head is faulty:

- strip down the cylinder head (see Cylinderhead: Stripping - Rebuilding) (Technical Note6023A, 10A, Engine and peripherals),

- test the cylinder head in order to detect anypossible cracks using the cylinder head test kit(see Cylinder head test tank: Use) (TechnicalNote 6026A, 11A, Top and front of engine),

- rebuild the cylinder head (see Cylinder head:Stripping - Rebuilding) (Technical Note6023A, 10A, Engine and peripherals).

WARNING


11A-85


K4M

11Aa Fit:

- a new cylinder head gasket,

- the cylinder head equipped with new bolts on thecylinder block.

a Without tightening, fit the cylinder head bolts in or-der.

a Pretighten to torque and in order the cylinder headbolts (initial torque) (20 N.m).

a Check that all the cylinder head bolts are tightenedto the correct torque of 20 N.m.

a Angle tighten in order the cylinder head bolts (240˚±±±± 6˚).


a

a Reprime the hydraulic tappets (hydraulic tappetsmay empty after a long down time).

a To check if repriming is necessary, press the top ofthe tappet (13) with your thumb.

a If the tappet piston sinks, dip the tappet in a contain-er filled with diesel.

a Press on the top of the tappet to expel air bubbles.

a Refit:

- the hydraulic tappets,

- the valve rockers.

a Connect:

- the upstream oxygen sensor connector,


- the hose to the heater matrix,

- the top hose to the water chamber.

a Using theororfit:

- the clip on the heater matrix hose,

- the top hose clip on the water chamber.

WARNING

In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.

WARNING

Do not oil the new bolts. Be sure to oil boltsbeing reused.

134578

Note:

Do not retighten the cylinder head bolts afterapplying this procedure.

14499

Note:

Because this engine is equipped with hydraulictappets, there is no valve clearance adjustment.

11A-86


K4M

11Aa Refit:

- the injector rail (see Injector rail - Injectors: Re-moval - Refitting) ,

- the camshafts (see 11A, Top and front of engine,Camshaft: Removal - Refitting, page 11A-54) ,




a Refit:



- the camshaft position sensor (see Camshaft posi-tion sensor: Removal - Refitting) .

a Refit the dipstick guide.

a Torque tighten the dipstick guide tube bolt (10N.m).

a Refit the lifting eye.

a Torque tighten the lifting eye bolts (10 N.m).

a Fit the engine wiring on the lifting eye.

a Clip the wiring onto the lifting eye.

a Refit:

- the spark plugs (see Plugs: Removal - Refitting) ,




- the exhaust manifold stay,


- the exhaust bracket,








a Refit:


- the engine cover.



K4M, and 838 or 839

11A-87

TOP AND FRONT OF ENGINECamshaft dephaser: Removal - Refitting

K4M, and 838 or 839

11A

REMOVAL




a Remove:

- the engine cover,


a Remove:











a Position the tool (1) on the camshaft pulleys.

a Remove the camshaft dephaser blanking cover (2) .

a Undo:

- the camshaft dephaser bolt (3) ,

- the exhaust camshaft sprocket nut (4) .

a Remove the toolfrom the camshaft pulleys.

a Remove:

- the exhaust camshaft pulley nut,

Tightening torquesm

new nut on the exhaustcamshaft pulley

30 N.m + 84˚ ±±±±4˚

new bolt on the cam-shaft dephaser

100 N.m

136530

103264

11A-88


K4M, and 838 or 839

11A- the exhaust camshaft pulley.

- the camshaft dephaser bolt,

- the camshaft dephaser.

REFITTING




a If fitting a new camshaft dephaser, check that it islocked by following the procedure described below:

a Fit a stud to the camshaft dephaser hub and tightenit.

a Place the camshaft dephaser in a vice fitted withjaws.

a Mechanically lock the camshaft dephaser by rotatingit to the left or right using a tubular hexagon boxspanner.

a Check that the camshaft dephaser is correctlylocked (no rotation of the hub in relation to the wheelto the left or right).

a If there is a rotation of the hub in relation to thewheel, the camshaft dephaser is faulty and must bereplaced.

a Degrease the end of the camshaft (timing end) andclean the bores and bearing faces of the camshaftdephaser.


a Refit:


- the camshaft dephaser,

- a new nut on the exhaust camshaft pulley,

- a new bolt on the camshaft dephaser.

a Position the toolon the camshaft pulleys.

a Torque tighten:

- the new nut on the exhaust camshaft pulley (30N.m + 84˚ ±±±± 4˚),

- the new bolt on the camshaft dephaser (100N.m).

a Refit the blanking cover on the camshaft dephaser.

a Remove the toolfrom the camshaft pulleys.

WARNINGFailure to adhere to the following procedure maycause the timing belt to be incorrectly timed.

111339

111340

11A-89


K4M, and 838 or 839


a Refit:









a Refit:


- the engine cover.


11A-90

TOP AND FRONT OF ENGINECamshaft dephaser solenoid valve: Removal - Refitting

K4M, and 838 or 839

11A

REMOVAL

I - OPERATION FOR REMOVAL OF PART CONCERNED

a Disconnect the connector (1) from the camshaftdephaser solenoid valve.

a Remove:

- the bolt (2) from the camshaft dephaser solenoidvalve,

- the camshaft dephaser solenoid valve.

REFITTING


a Refit the camshaft dephaser solenoid valve.

a Torque tighten the camshaft dephaser solenoidvalve bolt (10 N.m).

a Connect the camshaft dephaser solenoid valve con-nector.

Tightening torquesm

camshaft dephasersolenoid valve bolt

10 N.m

136579

136578

11A-91

TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - Refitting

K4M

11AREMOVAL




a Remove:

- the engine cover,


a Remove:










a Remove (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refitting, page 11A-87) :

- the exhaust camshaft sprocket,

- the camshaft dephaser.


a

a Always remove the end piece (3) of the tool.

a Completely unscrew the nut (4) and the boltof the (5).

a Position the claws of theon the camshaft.

K4M, and 838 or 839

105257

Note:

The camshaft seal is removed from the timingend using the.

135237

11A-92


K4M

11A

a Push the tooluntil contact is made between the endsof the claws and the camshaft seal.

a Separate the claws by turning the bolt (6) clockwiseusing an open-jawed spanner.

a Remove the camshaft seal by turning the bolt (7)clockwise.

REFITTING





135237

135236

135232

K4M, and 838 or 839

11A-93


K4M


and consumables for the repair) (04B, Consuma-bles - Products) to degrease:

- the camshaft seal mating face on each camshaft,

- the camshaft seal housings.


a

a Fit the protector fitted with a new seal (11) on the in-let and exhaust camshaft, taking care not to touchthe seal.

a Screw on the stud (10) of the toolon the inlet and ex-haust camshafts.

WARNING


WARNING


18687

Note:

Always hold the camshaft seal with the protector(8) when handling, as this type of seal is veryFRAGILE. It is strictly forbidden to touch the seal(9) in order to prevent any oil leaks once thecamshaft seal is fitted to the engine.

105531

135231

11A-94


K4M

11A

a Fit the cover (12) and the collar nut (13) of the.

a Screw on the collar nut (14) until the cover touchesthe cylinder head.

a Remove:

- the collar nut from the,

- the cover of the tool,

- the stud of the tool.

a Refit (see 11A, Top and front of engine, Camshaft dephaser: Removal - Refitting, page 11A-87) :

- the camshaft dephaser with a new bolt,

- the exhaust camshaft sprocket with a new nut.


a Refit:





- the lower engine tie-bar (see 19D, Engine mount-ing, Lower engine tie-bar: Removal - Refitting,page 19D-10) .




a Refit:


- the engine cover.


135229

135229

K4M, and 838 or 839

11A-95


K9K

11A

REMOVAL




a Remove:

- the engine cover,






- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-4)






a Increase the hole (1) of the (2) using an 8.5 mm drillbit.

Equipment required

offset spanner

Tightening torquesm

camshaft pulley nut 30 N.m + 86˚ ±±±±6˚.

K9K, and 830 or 838

K9K, and 830 or 838

118982

11A-96


K9K

11A



a Tighten the camshaft pulley hub bolts (3) .

a Remove:

- the nut (4) from the camshaft pulley,

- the,

- the camshaft pulley.


a

a Loosen bolts (6) and (7) fully from the.

118983

123970

105257

Note:

The timing end camshaft seal (5) is removedusing the toolwhich is not equipped with the endpiece (A) to enable it to be fitted on the camshaftpulley stud.

11A-97


K9K

11A

a Position the claws of theon the camshaft.

a Push the tooluntil contact is made between the ends(8) of the claws and the camshaft seal.

a Separate the claws by turning the bolt (9) clockwiseusing an open-jawed spanner.

a Remove the camshaft seal by turning the bolt (10)clockwise.

REFITTING



105270

105271

105272

105273

11A-98


K9K

11Aa parts always to be replaced: camshaft timing

sprocket nut (10,02,02,18).

a Clean and degrease with SURFACE CLEANER (see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products) and a CLEAN CLOTH :

- the camshaft seal mating face on the camshaft,

- the camshaft seal housing in the cylinder head.


a Screw the stud (11) of theonto the camshaft.

a Fit a new camshaft seal on the camshaft.

105531

21687

21687-1

Note:

For camshaft seals delivered fitted to a protectivesleeve:

-do not remove the camshaft seal from its protec-tive sleeve,

-fit the sleeve fitted with the camshaft seal on thecamshaft,

-push the protective sleeve towards the cylinderhead until the camshaft seal is in full contact withthe cylinder head,

-fit the seal on the camshaft by following the rec-ommendations below.

11A-99


K9K

11A1 - First fitting of the camshaft seal

a Fit the cover (12) and the collar nut (13) of the.

a Screw on the collar nut until the cover touches thecylinder head.

a Remove:


- the cover from the,

- the stud of the,

- the protective sleeve.

2 - Second fitting of the camshaft seal

a Depending on the case, the Parts Department deliv-ers seals (14) equipped with a spacer (15) amongstother things.

a

21687-2

21687-3

123076

123075

Note:

The spacer (16) is used to fit the seal (17) . It isused with the tool (18) .

11A-100


K9K

11A

a Fit the cover (19) equipped with the spacer on thecamshaft seal end and the collar nut (20) of the tool.

a Screw on the collar nut until the spacer fitted on thecover touches the cylinder head.

a Remove:


- the cover from the,

- the stud of the,

- the protection sleeve.

3 - Continued for both methods

a Refit:

- the camshaft pulley,

- a new camshaft pulley nut.



a Tighten:

- the camshaft pulley hub bolts,

- to torque and angle the camshaft pulley nut (30N.m + 86˚ ±±±± 6˚.)

a Remove the tool.

21687-2

Note:

The spacer fits on the cover of the toolso that theedge of the spacer is on the side of the camshaftseal.

21687-3

116756

11A-101


K9K


a Set the camshaft pulley hub using the tool.

a Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting, page 11A-16) .



a Refit:





- the engine cover.


109049

Note:

If the tooldoes not fit, turn the camshaft pulleyhub using an 18 mm offset spanner to adjustthe camshaft pulley hub.

K9K, and 830 or 838

11A-102

TOP AND FRONT OF ENGINEOil decanter: Removal - Refitting

K4M

11A

REMOVAL



a Remove:

- the three ignition coils on the flywheel end (seeCoils: Removal - Refitting) ,

- the inlet distributor (see 12A, Fuel mixture, Inletdistributor: Removal - Refitting, page 12A-14) .


a Remove:

- the oil decanter bolts,

- the oil decanter.

REFITTING


a parts always to be replaced: oil decanter bolt(11,04,06,23).

a Use SUPER CLEANING AGENT FOR JOINT FA-CES (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) to clean:

- the joint face on the oil separator if it is to be re-used,

- the joint face on the rocker cover.


- the joint face on the oil separator if it is to be re-used,

- the joint face on the rocker cover.

Tightening torquesm

oil separator bolts 15 N.m

136587

WARNING

When cleaning par ts, it is essential that the partsdo not impact on each other, otherwise their mat-ing faces may be damaged and therefore theiradjustments may be altered, which could dam-age the engine.


WARNING


WARNING


11A-103

TOP AND FRONT OF ENGINEOil decanter: Removal - Refitting

K4M

11A

a Apply RESIN ADHESIVE (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products) using a stipple roller on the joint face ofthe oil separator until the joint face is completelycoated.


a Refit:

- the oil decanter,

- new bolts on the oil decanter.

a Torque tighten in order the oil separator bolts (15N.m).


a Refit:


- the three ignition coils on the flywheel end (seeCoils: Removal - Refitting) .


102738

136587

12A-1

FUEL MIXTUREAir resonator: Removal - Refitting 12A

REMOVAL



a Remove:




- the left-hand headlight (see Headlight: Removal -Refitting) (80B, Headlights).


a Disconnect the air outlet pipe from the air resonator(1) .

a Unclip the air resonator contacts (2) .

a Remove the air resonator .

K4M or K9K

K4M or K9K

138482

K4M

140279

12A-2

FUEL MIXTUREAir resonator: Removal - Refitting 12A

a Unclip the air resonator contacts (2) .

a Remove the air resonator .

REFITTING


a Refit the air resonator.

a Clip on the air resonator contacts.

a Connect the air outlet pipe to the air resonator.


a Refit:

- the left-hand headlight (see Headlight: Removal -Refitting) (80B, Headlights),



- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).

K9K

141347

K4M or K9K

K4M or K9K

12A-3

FUEL MIXTUREAir filter: Removal - Refitting 12A

REMOVAL


a Remove the battery cover.

a Move aside the wiring (1) .


a Undo the bolts (2) from the air filter unit slide valve.

a Pull the air filter unit slide valve upwards at (3) .

K9K

138705

134240

134239

12A-4

FUEL MIXTUREAir filter: Removal - Refitting 12A

a Remove the air filter (4) .

REFITTING


a Clean the air filter housing.


a

a Refit:

- the air filter,

- the air filter unit slide valve,

- the air filter unit slide valve bolts.


a Refit the battery cover.

134237

WARNING

If the air filter is fitted incorrectly in the air filterunit, unfiltered air may enter the engine.

12A-5

FUEL MIXTUREAir filter unit: Removal - Refitting 12A

REMOVAL


a Remove:




a Loosen the clip (1) of the air outlet pipe on the air fil-ter unit.

a Disconnect the air outlet pipe from the air filter unit.

a Move aside the air outlet pipeon the air filter unit.

a Disconnect the air flowmeter connector (2) .

a Loosen the clip (1) of the air outlet pipe on the air fil-ter unit.

a Move aside the air outlet pipe (4) on the air filter unit.

III - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:

- the air inlet sleeve bolt (5) ,

- the air inlet sleeve from the air filter unit (6) ,

Tightening torquesm

air filter unit bolt 8 N.m

air inlet sleeve bolt 8 N.m

K9K

134038

K4M

135707

K4M or K9K

134073

12A-6

FUEL MIXTUREAir filter unit: Removal - Refitting 12A

- the air filter unit bolt (7) ,

- the air filter unit.

If replacing the air filter unit

a Remove the air flowmeter (see 12A, Fuel mixture,Air flowmeter: Removal - Refitting, page 12A-7) .

REFITTING


a Refit the air flowmeter (see 12A, Fuel mixture, Airflowmeter: Removal - Refitting, page 12A-7) .


a Refit:

- the air filter unit,

- the air inlet sleeve on the air filter unit.

a Torque tighten:

- the air filter unit bolt (8 N.m),

- the air inlet sleeve bolt (8 N.m).

a Connect the air flowmeter connector.

a Connect the air outlet pipe of the air filter unit.

a Tighten the clip of the air outlet pipe on the air filterunit.


a Refit:



K9K

K9K

K9K

12A-7

FUEL MIXTUREAir flowmeter: Removal - Refitting

K9K

12A

REMOVAL


a Remove the front engine cover.

a Loosen the air filter unit air outlet pipe clip (1) on theair flowmeter.

a Disconnect the air filter unit air outlet pipe from theair flowmeter.

a Move the air filter unit air outlet pipe slightly awayfrom the air flowmeter.


a Disconnect the air flowmeter connector (6) .

a Remove:

- the bolts (7) from the air flowmeter,

- the air flowmeter (8) ,

- the air flowmeter seal.

Tightening torquesm

air filter box air outletpipe clip on the air flow-meter

5.5 N.m

138655

139953

134041

12A-8

FUEL MIXTUREAir flowmeter: Removal - Refitting

K9K

12AREFITTING


a parts always to be replaced: Air flowmeter seal(11,04,06,26).


a Refit:

- the air flowmeter, fitted with a new seal,

- the air flowmeter bolts.

a Connect the air flowmeter connector.


a Fit the air filter unit air outlet pipe.

a Connect the air filter box air outlet pipe to the airflowmeter.

a Torque tighten the air filter box air outlet pipe clipon the air flowmeter (5.5 N.m).

12A-9

FUEL MIXTUREDamper valve: Removal - Refitting

K9K, and 832 or 842

12A

REMOVAL



a Disconnect the turbocharger pressure sensor con-nector (1) .

a Unclip the turbocharger pressure sensor wiring (2)from the intercooler air outlet pipe.

a Loosen the clip (3) of the intercooler air outlet pipefrom the damper valve.

a Disconnect the intercooler air outlet pipe from thedamper valve.

a Disconnect:

- the damper valve connector (7) ,

- the connector (8) from the camshaft position sen-sor.

a Unclip the damper valve wiring from the injector railprotector cover.

a Remove the breather support nut (11) from the man-ual gearbox.

a Separate the manual gearbox breather with its sup-port.

Tightening torquesm

intercooler air outletpipe clip on the dampervalve

5.5 N.m

134215

121889

134488

12A-10


K9K, and 832 or 842

12A

a Disconnect the brake servo pipe union (14) from thevacuum pump.


a Remove:

- the damper valve bracket bolts (16) ,

- the damper valve bracket.

a Remove:

- the damper valve bolts (18) ,

- the damper valve,

- the damper valve seal.

REFITTING


a parts always to be replaced: Damper valve seal(11,01,10,04).

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean and degrease the joint fa-ces:

- of the exhaust gas recirculation support on the fly-wheel end,

- the damper valve if it is to be reused.


a Refit:

- a new damper valve seal,

- the damper valve,

- the damper valve bracket.

134490

134491

135464

12A-11


K9K, and 832 or 842



a Fit the manual gearbox breather to its support.

a Refit the gearbox breather mounting nut.

a Clip the damper valve wiring onto the injector railprotector cover.

a Connect:

- the camshaft position sensor connector,

- the connector to the damper valve.

a Connect the intercooler air outlet pipe on the dampervalve.

a Torque tighten the intercooler air outlet pipe clipon the damper valve (5.5 N.m).

a Clip the turbocharger pressure sensor wiring ontothe intercooler air outlet pipe.

a Connect the turbocharger pressure sensor connec-tor.

a Refit the engine cover.

12A-12

FUEL MIXTUREThrottle valve: Removal - Refitting

K4M

12A

REMOVAL



a Unclip the throttle valve wiring on the air pipe (6) .

a Undo:

- the clip (3) on the throttle valve air inlet pipe,

- the clip (4) on the air filter unit air outlet pipe.

a Disconnect the air filter unit air outlet pipe:

- from the air filter unit,

- from the throttle valve.

a Disconnect the oil vapour rebreathing pipe (5) fromthe air filter unit air outlet pipe (6) .

a Remove the air filter unit air outlet pipe (6) .


a Disconnect the union (7) of the fuel vapour absorberbleed solenoid valve pipe on the throttle valve.

a Disconnect the connector (8) from the throttle valve.

Tightening torquesm

throttle valve bolts 10 N.m

air pipe clip on the throt-tle valve

6 N.m

air pipe clip on the air fil-ter unit

6 N.m

136458

136460

135924

12A-13

FUEL MIXTUREThrottle valve: Removal - Refitting

K4M

12A

a Remove:

- the throttle valve bolts (9) ,

- the throttle valve,

- the throttle valve seal.

REFITTING


a parts always to be replaced: Throttle valve seal(11,04,06,25).


- the throttle valve joint face if it is to be re-used,

- the seal housing on the inlet distributor.


a Refit:

- a new seal on the inlet distributor,

- the throttle valve.

a In order, torque tighten the throttle valve bolts (10N.m).


a Connect to the throttle valve:

- the union of the fuel vapour absorber bleed sole-noid valve pipe on the throttle valve,

- the throttle valve connector.

a Fit the air filter unit air outlet pipe.

a Connect the air filter unit air outlet pipe:

- to air filter unit,

- to the throttle valve.

a Connect the oil vapour rebreathing pipe to the airpipe.

a Torque tighten:

- the air pipe clip on the throttle valve (6 N.m),

- the air pipe clip on the air filter unit (6 N.m).

a Clip the throttle valve wiring on the air pipe.


135923

WARNING



135923

12A-14

FUEL MIXTUREInlet distributor: Removal - Refitting

K4M

12A

REMOVAL




a Disconnect:

- all coil connectors (1) ,

- the air temperature sensor connector (2) .

a Unclip the wiring from the inlet distributor coils.

a Move the coil wiringto one side.

a Disconnect the following from the inlet distributor:

- the inlet distributor pressure sensor connector (3) ,

- the oil vapour rebreathing pipe (4) .

Tightening torquesm

bolts 1 to 5 of the inletmanifold

9 N.m

bolts 6 to 8 of the inletmanifold

12 N.m

IMPORTANT

During this operation, be sure to:

- refrain from smoking or bringing red hot objectsclose to the working area,

- be careful of fuel splashes when disconnecting theunion.

IMPORTANT


WARNING


WARNING


136482

136548

12A-15


K4M

12A

a Disconnect the brake servo pipe union (5) from theinlet distributor.

a Unclip the engine wiring (6) from the inlet distributor.

a Unclip the following from the inlet distributor:

- the oxygen sensor wiring at (7) ,

- the fuel vapour absorber bleed solenoid valve pipeat (8) .

a Disconnect the connector (9) from the camshaftdephaser solenoid valve.

a Unclip the camshaft dephaser solenoid valve wiringfrom the inlet distributor.

136460

136548

144469

136579

12A-16


K4M


a Remove:

- the inlet distributor bolts (10) ,

- the inlet distributor,

- the inlet distributor seals.

REFITTING


a parts always to be replaced: inlet distributor seal(10,07,01,07).

a

Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) to clean and degrease:

- the housing of each inlet distributor seal if reused,

- the joint face of the injector holder shim.

a Fit new seals to the inlet distributor.

a When replacing the inlet distributor, remove:

- the air temperature sensor,

- the inlet distributor pressure sensor.


a Refit the inlet distributor.


- bolts 1 to 5 of the inlet manifold (9 N.m),

- bolts 6 to 8 of the inlet manifold (12 N.m).


a Clip the camshaft dephaser solenoid valve wiringonto the inlet distributor.

a Connect the camshaft dephaser solenoid valve con-nector.

a Connect the following to the inlet distributor:

- the brake servo pipe union,

- the oil vapour rebreathing pipe,

- the inlet distributor pressure sensor connector.

a Clip the following onto the inlet distributor:

- the engine wiring,

- the fuel vapour absorber bleed solenoid valve pipe.

a Fit the coil wiring.

a Clip the coil wiring onto the inlet distributor.

136482

WARNING


WARNING


136482

12A-17


K4M

12Aa Connect:

- the connector of each coil,

- the air temperature sensor connector.



12A-18

FUEL MIXTUREInjector holder shim: Removal - Refitting

K4M

12A

REMOVAL




a Remove:

- the engine cover,



a Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting, page 11A-4) .

a Remove:



- the « injector rail - injector » assembly (see Injec-tor rail - Injectors: Removal - Refitting) .


a Remove:


- the right-hand pendulum suspension bolt (3) ,

- the injector holder shim bolts,

- the injector holder shim,

- the injector holder shim seal.

REFITTING


a parts always to be replaced: Inlet shim seal (11,04,04,09).

Tightening torquesm

bolts 1 and 2 on theinjector holder shim

30 N.m

bolts 3, 4, 5, 6, 7, 8, 9and 10 on the injectorholder shim

25 N.m

upper timing cover bolt 46 N.m

right-hand pendulumsuspension bolt

62 N.m

136491

135261

12A-19

FUEL MIXTUREInjector holder shim: Removal - Refitting

K4M




- the gasket face of the injector holder shim, in caseof reuse.


a Refit:

- a new seal on the injector holder shim,

- the injector holder shim.

a Fit without tightening the bolts on the injector holdershim.


- bolts 1 and 2 on the injector holder shim (30N.m),

- bolts 3, 4, 5, 6, 7, 8, 9 and 10 on the injectorholder shim (25 N.m).

a Torque tighten:

- the upper timing cover bolt (46 N.m),

- the right-hand pendulum suspension bolt (62N.m).


a Refit:

- the « injector rail - injector » assembly (see Injec-tor rail - Injectors: Removal - Refitting) ,



a Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt: Removal - Refitting,page 11A-4) .

a Refit:



- the engine cover.


WARNING


WARNING


135261

12A-20

FUEL MIXTUREExhaust manifold: Removal - Refitting

K4M

12A

REMOVAL





a Remove:





a Remove:




a Remove:


- the ring between the exhaust manifold and the cat-alytic converter.

a Remove:

- the nut (2) from the exhaust manifold stay,

- the bolt (3) from the exhaust manifold stay,

- the exhaust manifold strut.

Tightening torquesm

exhaust manifold studs 8 N.m

bolts of the lower heatshield12 N

.m

exhaust manifold nuts 26 N.m

bolts of the upper heatshield12 N.

m

exhaust manifold staybolt

44 N.m

exhaust manifold staynut44 N

.m

retaining bracket bolt ofthe heater matrixhoses10

N.m

135949

136514

12A-21


K4M

12A

a Disconnect the upstream oxygen sensor connector(4) .

a Unclip the heater matrix hoses from the retainingbracket (5) .

a Remove:

- the bolt of the heater matrix hose retaining bracket,

- the heater matrix hose retaining bracket.

a Remove:

- the bolts (6) from the upper heat shield,

- the upper heat shield.


a Remove:

- the exhaust manifold nuts,

- the exhaust manifold,

- the exhaust manifold gasket.

136546

135927

135255

135711

12A-22


K4M

12AWhen replacing the exhaust manifold

a Remove:

- the lower heat shield bolts (7) ,

- the lower heat shield,

- the upstream oxygen sensor using the.

REFITTING


a parts always to be replaced: exhaust manifoldseal (10,07,02,07).



- the exhaust manifold joint face if it is to be re-used,

- the cylinder head joint face.

a Tighten to torque the exhaust manifold studs (8N.m).

a Refit the upstream oxygen sensor using the tool.

a Refit the lower heat shield.

a Screw on the bolts (4) and (5) without tightening.

a Tighten in order and to torque the bolts of the lowerheat shield12 N (.m).

135911

109399

Note:

If a stud loosens during removal, coat it withHIGH RESISTANCE THREADLOCK (see Vehi-cle: Parts and consumables for the repair)(04B, Consumables - Products).

135911

12A-23


K4M


a Refit:

- a new exhaust manifold seal,

- the exhaust manifold.

a Torque tighten in order the exhaust manifold nuts(26 N.m).


a Refit the upper heat shield.

a Screw on the bolts (4) and (5) without tightening.

a Tighten in order and to torque the bolts of the up-per heat shield12 N. (m).

a Refit the exhaust manifold stay.

a Torque tighten:

- the exhaust manifold stay bolt (44 N.m),

- the exhaust manifold stay nut44 N (.m).

a Refit:


- the exhaust bracket bolts,

- the heater matrix hose retaining bracket.

a Torque tighten the retaining bracket bolt of theheater matrix hoses10 (N.m).

a Clip the hoses onto the retaining bracket of the heat-er matrix hoses.

a Connect the upstream oxygen sensor connector.

a Refit:


- the inlet distributor (see 12A, Fuel mixture, Inletdistributor: Removal - Refitting, page 12A-14) .


135711

135255

12A-24


K4M

12Aa Refit:



- the windscreen wiper arms (see Windscreen wip-er arm: Removal - Refitting) (85A, Wiping -Washing).



12A-25


K9K

12A

REMOVAL




a Remove:

- the engine cover,




a Remove:

- the catalytic converter (see 19B, Exhaust, Cata-lytic converter: Removal - Refitting, page 19B-6),



- the turbocharger oil supply pipe (see 12B, Turbo-charging, Turbocharger oil pipe: Removal - Re-fitting, page 12B-4) ,

- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting, page 12B-1) .

a Remove:

- the bolts (1) from the lifting eye at the timing end,

- the lifting eye on the timing end,

- the rigid exhaust gas recirculation pipe (see 14A,Antipollution, Exhaust gas recirculation rigidpipe: Removal - Refitting, page 14A-16) .


a Remove:

- the nuts (2) from the exhaust manifold,


a Mark the position of the exhaust manifold gasket.

a Remove the exhaust manifold gasket.

Tightening torquesm

exhaust manifold nuts 26 N.m

IMPORTANT


K9K, and 830 or 838

135463

113561

12A-26


K9K

12AREFITTING


a parts always to be replaced: exhaust manifoldseal (10,07,02,07).

a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean the joint face:


- of the exhaust manifold, if it is to be reused.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to clean and degrease the joint faces:


- of the exhaust manifold, if it is to be reused.


a Refit:

- a new exhaust manifold gasket in the positionmarked during removal,


a Torque tighten in order the exhaust manifold nuts(26 N.m).


a Refit:

- the exhaust gas recirculation rigid pipe (see 14A,Antipollution, Exhaust gas recirculation rigidpipe: Removal - Refitting, page 14A-16) ,


- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting, page 12B-1) .




- the catalytic converter (see 19B, Exhaust, Cata-lytic converter: Removal - Refitting, page 19B-6).


a Refit:


- the engine cover.


114532

K9K, and 830 or 838

12B-1

TURBOCHARGINGTurbocharger: Removal - Refitting

K9K

12B

REMOVAL





a Remove:




a Remove:




- the turbocharger oil supply pipe (see 12B, Turbo-charging, Turbocharger oil pipe: Removal - Re-fitting, page 12B-4) .


a Disconnect the turbocharging pressure regulationvalve control hose from the turbocharger.

a Remove:

- the turbocharger nuts (1) ,

- the turbocharger,

- the turbocharger seal.

Equipment required

torque wrench

Tightening torquesm

new turbocharger studson the exhaust manifold

9 N.m

new turbocharger studon the turbocharger

9 N.m

turbocharger nuts 28 N.m

IMPORTANT


K9K, and 830 or 838

K9K, and 832 or 842

113560

12B-2


K9K

12B

a Remove:

- the turbocharger nuts (1) ,

- the turbocharger,

- the turbocharger seal.

REFITTING


a

a parts always to be replaced: seal between ex-haust manifold and turbocharger (10,09,01,07).

a parts always to be replaced: Turbocharger nut(10,09,01,03).

a parts always to be replaced: exhaust manifoldstud on the turbocharger (if loosened) (10,09,01,11) (if loosened).

a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean the joint face:


- of the turbocharger if reused.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to clean and degrease the joint faces:


- of the turbocharger if reused.

a When replacing the turbocharger studs, torque tigh-ten:

- the new turbocharger studs on the exhaustmanifold (9 N.m),

- the new turbocharger stud on the turbocharger(9 N.m).


a Refit:

- a new seal between the exhaust manifold and theturbocharger on the exhaust manifold,

- the turbocharger.

a Bolt without tightening the turbocharger nuts usingan open-jawed spanner (the turbocharger must reston the manifold and the spanner must no longer turnwithout effort).

a Put a paint mark using a marker pen on the turbo-charger coinciding with a crest of the turbochargerlower nut.

a Tighten the lower nut of the turbocharger until thenext nut crest coincides with the paint mark made onthe turbocharger (the angle achieved corresponds to60˚).

a Torque tighten the other two turbocharger nuts (28N.m) using a torque wrench.

a Put some fresh oil in the internal oil circuit of the tur-bocharger using an oil can to facilitate the repriming.

K9K, and 830 or 838

136391

WARNING

Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notpartially or completely blocked by scale. Checkthat there are no leaks. If there are, replace thepart.

WARNING

Following a turbocharger fault, check that theintercooler and air circuit assembly are not full ofoil. If they are, remove them and clean them witha cleaning tray or station and dry them with acompressed air gun.

12B-3


K9K

12Ba Connect the turbocharger pressure regulating valve

control hose.


a Refit:









K9K, and 830 or 838

12B-4

TURBOCHARGINGTurbocharger oil pipe: Removal - Refitting

K9K

12B

REMOVING THE TURBOCHARGER OIL SUPPLY PIPE




a Disconnect:

- the oil vapour rebreathing pipe union from the airfilter unit air outlet pipe,

- the oil vapour rebreathing pipe from the rocker cov-er.


Equipment required


Diagnostic tool

Tightening torquesm

turbocharger oil supplypipe nut on the cylinderhead

35 N.m

turbocharger oil supplypipe hollow bolt

14 N.m


5.5 N.m

clip of the air filter unitair outlet pipe on the airfilter unit

5.5 N.m

turbocharger oil returnpipe bolts on the turbo-charger

12 N.m

Note:

This procedure deals with removing and refitting theturbocharger oil return pipe and the turbocharger oilsupply pipe.

IMPORTANT


IMPORTANT


WARNING

Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.

Check that the turbocharger oil return pipe is notpartially or completely blocked by scale. Check thatthere are no leaks. If there are, replace the part.

WARNING

Metal objects may enter the oil and air circuits as aresult of a broken turbocharger.

Failure to observe the following instructions will leadto the turbocharger breaking again.

K9K, and 832 or 842

12B-5


K9K

12B

a Disconnect the oil vapour rebreathing pipe unionfrom the air filter unit air outlet pipe (1) .

a Unclip the air flowmeter wiring from the air filter unitair outlet pipe at (2) .

a Loosen the clip (3) of the air filter unit air outlet pipefrom the air filter unit.

a Disconnect the air filter unit air outlet pipe from theair filter unit.

a Undo the air filter unit air outlet pipe clip (4) from theturbocharger.


a Remove the air outlet pipe from the air filter box.

K9K, and 830 or 838

135880

134038

136639

12B-6


K9K

12BII - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove the turbocharger oil supply pipe hollow bolt(5) .

a Loosen the nut (6) for the turbocharger oil supplypipe on the cylinder head, using the toolor the tool.

a Remove the nut (6) for the turbocharger oil supplypipe from the cylinder head.

a Remove the turbocharger oil supply pipe hollow bolt(7) .

a Loosen the nut (8) for the turbocharger oil supplypipe on the cylinder head, using the toolor the tool.

a Remove the nut (8) for the turbocharger oil supplypipe from the cylinder head.

a Remove the turbocharger oil supply pipe.

a Wipe away any oil run-off.

REFITTING THE TURBOCHARGER OIL SUPPLY PIPE


a parts always to be replaced: turbocharger oilsupply pipe (10,09,03,01).

a parts always to be replaced: Turbocharger oilsupply pipe bolt (10,09,03,04).


a Refit a new turbocharger oil supply pipe.

a Fit the turbocharger oil supply pipe nut on the cylin-der head, without tightening it.

K9K, and 832 or 842

135487

K9K, and 830 or 838

136643

12B-7


K9K

12Ba Refit a new hollow bolt for the turbocharger oil sup-

ply pipe on the turbocharger.

a Torque tighten:

- the turbocharger oil supply pipe nut on the cyl-inder head (35 N.m) using the toolor the tool,

- the turbocharger oil supply pipe hollow bolt (14N.m).


a Refit the air outlet pipe onto the air filter unit.



a Connect the air filter unit air outlet pipe to the air filterunit.

a Torque tighten the clip of the air filter unit air out-let pipe on the air filter unit (5.5 N.m).

a Clip the air flowmeter wiring onto the air filter unit airoutlet pipe.

a Refit the oil vapour rebreathing pipe.





a Disconnect the crankshaft (TDC) position sensorconnector to prevent the engine from starting-up.

a Connect a self-contained starter.

a Run the starter until the oil pressure warning lightgoes out on the instrument panel (wait for a few sec-onds).

a Switch off the ignition.

a Disconnect the self-contained starter.

a Connect the crankshaft (TDC) position sensor con-nector.

a Start the engine.

a Let the engine idle then depress the accelerator sev-eral times with no load.

a Switch off the ignition.

a Check:

- that the turbocharger is operating correctly,

- that there are no oil leaks from the turbocharger.

a Use the Diagnostic tool to check for an absence ofstored faults; deal with these and clear them as nec-essary.

REMOVING THE TURBOCHARGER OIL RETURN PIPE




a Remove:





K9K, and 832 or 842 K9K, and 830 or 838

12B-8


K9K


a Remove the turbocharger oil return pipe bolts (1) .

a Remove the turbocharger oil return pipe bolts (1) .

a Turn the turbocharger oil return pipe to facilitate itsremoval.

a Extract the turbocharger oil return pipe from the cyl-inder block.

a Remove the turbocharger oil return pipe seals.

K9K, and 832 or 842

135843

135488

K9K, and 830 or 838

135844

136641

12B-9


K9K

12BREFITTING THE TURBOCHARGER OIL RETURN PIPE


a parts always to be replaced: turbocharger oilpipe seal (10,09,03,05).


a Refit a new turbocharger oil return pipe fitted with anew seal.

a Lubricate the O-ring of the turbocharger oil returnpipe with fresh engine oil.

a Tighten to torque the turbocharger oil return pipebolts on the turbocharger (12 N.m).






K9K, and 830 or 838

12B-10

TURBOCHARGINGIntercooler: Removal - Refitting

K9K

12BREMOVAL



a Remove:






a Remove:

- the top air deflector,

- the side air deflectors.

a Press on the intercooler clip (7) .

a Unclip the intercooler in the direction of the arrow.

a Remove the intercooler.

REFITTING



a Refit the intercooler.

a Connect:

- the intercooler air outlet pipe,

- the intercooler air inlet pipe.

a Clip on the intercooler air pipe clips.

135705

135704

12B-11

TURBOCHARGINGIntercooler: Removal - Refitting

K9K

12B

a Always perform a "push-pull" test to ensure that theair pipes are correctly clipped (8) .

a Refit:

- the side air deflectors,

- the top air deflector.


a Refit:





135794

12B-12

TURBOCHARGINGIntercooler air inlet pipe: Removal - Refitting

K9K

12B

REMOVING THE TURBOCHARGER AIR OUTLET PIPE




a Pull the clip (1) for the turbocharger air outlet pipefrom the turbocharger.

a Pull the clip (1) for the turbocharger air outlet pipefrom the turbocharger.

a Pull the clip for the intercooler air inlet pipe (2) fromthe turbocharger air outlet pipe.

Equipment required

tweezers

Note:

This procedure describes removal and refittingoperations for the turbocharger air outlet pipe andthe intercooler air inlet pipe.

K9K, and 832 or 842

135409

K9K, and 830 or 838

136637

134496

12B-13


K9K

12B

a Remove:

- the bolt (3) from the turbocharger air outlet pipe,

- the turbocharger air outlet pipe,

- the seals from the turbocharger air outlet pipe.

REFITTING THE TURBOCHARGER AIR OUTLET PIPE


a Always replace the seals for the turbocharger airoutlet pipe.

a Remove the turbocharger air outlet pipe seals usinga tweezers.


a

137674 115068

115069

Note:

Ensure that the turbocharger air outlet pipe sealsare fitted in the correct direction.

12B-14


K9K

12Ba Refit:

- new turbocharger air outlet pipe seals in the turbo-charger air outlet pipe,

- the turbocharger air outlet pipe.

a Fit the clips onto the turbocharger air outlet pipe.

a Clip the turbocharger air outlet pipe onto:

- the intercooler air inlet pipe,

- the turbocharger.

a Refit the turbocharger air outlet pipe bolt.



REMOVING THE INTERCOOLER AIR INLET PIPE


a Remove:

- the engine cover,

- the turbocharger air outlet pipe,






a Remove:

- the right-hand headlight (see Headlight: Removal- Refitting) (80B, Headlights),

- the front right-hand bumper support (see Frontbumper mounting: Removal - Refitting) (42A,Front upper structure).


a Remove the intercooler air inlet pipe bolt (1) from thecooling radiator.

a Remove:

- the clip (3) from the intercooler air inlet pipe,

- the intercooler air inlet pipe,

- the intercooler air inlet pipe seal.

134492

134493

12B-15


K9K

12BREFITTING THE INTERCOOLER AIR INLET PIPE


a parts always to be replaced: turbocharger aircooler air inlet pipe seal (10,09,04,04).

a Remove the air inlet pipe seal of the intercooler us-ing a tweezers.


a

a Refit:

- a new seal on the intercooler air inlet pipe,

- the intercooler air inlet pipe.

a Fit the clip on the intercooler air inlet pipe.

a Clip the intercooler air inlet pipe onto the intercooler.

a Refit the bolt for the intercooler air inlet pipe onto thecooling radiator.


a Refit:

- the front right-hand bumper support (see Frontbumper mounting: Removal - Refitting) (42A,Front upper structure),

- the right-hand headlight (see Headlight: Removal- Refitting) (80B, Headlights).

a Refit:



115068

115069

Note:

Check that the seal of the intercooler air inletpipe is fitted the correct way round.

12B-16


K9K

12B- the front section of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),


- the intercooler air outlet pipe,

- the engine cover.

12B-17

TURBOCHARGINGIntercooler air outlet pipe: Removal - Refitting

K9K

12B

REMOVAL


a Remove:

- the engine cover,




a Remove the intercooler air outlet pipe clip (1) fromthe intercooler.

a Remove the nut (2) from the bracket of the intercool-er air outlet pipe.


a Unclip the turbocharger pressure sensor wiring (4)from the intercooler air outlet pipe.



a Remove the intercooler air outlet pipe.

Equipment required

tweezers

Tightening torquesm


5.5 N.m

135465

135406

134215

12B-18


K9K

12BREFITTING


a parts always to be replaced: turbocharger aircooler air outlet pipe seal (10,09,04,05).

a Remove the intercooler air outlet pipe seal at the in-tercooler end using a tweezers.


a

a Refit:

- a new seal for the intercooler air outlet pipe at theintercooler end,

- the intercooler air outlet pipe.





a Refit the nut for the bracket of the intercooler air out-let pipe.

a Fit the clip for the intercooler air outlet pipe.

a Clip the intercooler air outlet pipe onto the intercool-er.

115068

115069

Note:

Check that the intercooler air outlet pipe seal atthe intercooler end is fitted the correct wayround.

12B-19


K9K

12BIII - FINAL OPERATION

a Refit:


- the engine cover.

13A-1

FUEL SUPPLYManual priming pump: Removal - Refitting

K9K

13A

REMOVAL

OPERATION FOR REMOVAL OF PART CONCERNED

a Disconnect from the manual priming pump:

- the union (1) ,

- union (2) .


a Unclip the manual priming pump from the expansionbottle at (3) .

a Remove the manual priming pump.

REFITTING

REFITTING OPERATION FOR PART CONCERNED

a Clip the manual priming pump onto the expansionbottle.


a Connect the fuel pipes to the manual priming pump.

a Prime the fuel circuit using the manual primingpump.

a Start the engine, then let it run for a few minutes tocheck that it has started properly and that there areno leaks.

IMPORTANT




WARNING


WARNING


136606

136605

13B-1

DIESEL INJECTIONDiesel injection: List and location of components

K9K, and 832 or 842

13B

134042

134494

(1) Manual priming pump

134707

(2) High pressure pump

13B-2


K9K, and 832 or 842

13B

134705

(3) Exhaust gas recirculation sole-noid valve

135008

(4) Diesel injectors

121888

(5) Camshaft position sensor

134215

(6) Turbocharging air pressure sen-sor

13B-3


K9K, and 832 or 842

13B

134041

(7) Air flowmeter

135721

(8) Protection and switching unit

134212

(9) Injection computer

114213

(10) Coolant temperature sensor

13B-4


K9K, and 832 or 842

13B

135007

(11) Rail pressure sensor

134706

(12) Fuel temperature sensor

134043

(13) Air inlet valve

133985

(14) Fuel filter

13B-5


K9K, and 832 or 842

13B

134706

(15) Flow regulation solenoid valve

(16) Pressure regulation solenoidvalve

123824

(17) Crankshaft position sensor

135505

(18) Pre-postheating unit

13B-6

DIESEL INJECTIONDiesel injection computer: Removal - Refitting

K9K

13B

REMOVAL


a Apply the before repair procedure using the Dia-gnostic tool :

- connect the Diagnostic tool,

- select the « Diesel injection computer » ,

- go to repair mode,

- display the « before/after repair procedure » for thecomputer selected,

- carry out the operations described in the « Beforerepair procedure » section.



a Remove:

- the diesel injection computer mounting bolts (5) ,

- the diesel injection computer mounting with the die-sel injection computer.

a Disconnect the connectors (6) from the diesel injec-tion computer.

a Remove:

- the diesel injection computer nuts (7) ,

- the diesel injection computer.

Equipment required

Diagnostic tool

136462

136463

134213

13B-7

DIESEL INJECTIONDiesel injection computer: Removal - Refitting

K9K

13BREFITTING


a Refit the diesel injection computer on the diesel in-jection computer mounting.

a Connect the diesel injection computer connectors.

a Fit the diesel injection computer mounting with thediesel injection computer.

a Refit the diesel injection computer mounting bolts.


a Refit the diesel injection computer cover.


a Apply the after repair procedure using the Diagnos-tic tool :


- select the « Diesel injection computer » ,


- display the « before/after repair procedure » for thecomputer selected,

- carry out the operations described in the « After re-pair procedure » section.

13B-8

DIESEL INJECTIONCamshaft position sensor: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL





a Move the intercooler outlet air pipe slightly awayfrom the damper valve.


a Disconnect the connector (11) from the camshaftposition sensor.

a Remove:

- the bolt (13) from the camshaft position sensor,

- the camshaft position sensor,

- the camshaft position sensor seal.

Tightening torquesm


5.5 N.m

134043

121889

121888

13B-9


K9K, and 832 or 842

13BREFITTING


a parts always to be replaced: camshaft sensorseal (11,11,04,02).

a Lubricate the camshaft position sensor seal withnew engine oil.


- the camshaft position sensor seal housing in caseof reuse,

- the camshaft position sensor seal housing in therocker cover.


a Refit:

- the camshaft position sensor fitted with a new seal,

- the camshaft position sensor bolt.

a Connect the camshaft position sensor connector.


a Fit the intercooler air outlet pipe.




13B-10


K9K, and 830 or 838

13BREMOVAL



a Remove:

- the engine cover,









a Unclip the camshaft position sensor wiring from theupper timing cover (1)

a Disconnect the connector (2) from the camshaft po-sition sensor.

a Remove:

- the bolt (3) from the camshaft position sensor,

- the camshaft position sensor.

REFITTING


a parts always to be replaced: camshaft sensorseal (11,11,04,02).

a Lubricate the camshaft position sensor seal.


a Refit the camshaft position sensor fitted with a newseal.

a Connect the camshaft position sensor connector.

a Clip the wiring of the camshaft position sensor ontothe upper timing cover.

136652

13B-11


K9K, and 830 or 838


a Refit:








- the engine cover.

13B-12

DIESEL INJECTIONCrankshaft position sensor: Removal - Refitting

K9K

13BREMOVAL



a Remove:




a Disconnect the crankshaft position sensor connector(1) .

a Remove:

- the crankshaft position sensor bolt (2) ,

- the crankshaft position sensor.

REFITTING


a Refit:

- the crankshaft position sensor,

- the crankshaft position sensor bolt.

a Connect the crankshaft position sensor connector.



123824

13B-13

DIESEL INJECTIONHigh pressure pump leak flow: Check

K9K, and 832 or 842

13B

CHECK


a Remove:

- the engine cover,



a Disconnect the intercooler outlet air pipe from thedamper valve.


Equipment required

graduated measuring cylinder

Diagnostic tool

Tightening torquesm


5.5 N.m


5.5 N.m

IMPORTANT




134043

13B-14


K9K, and 832 or 842

13B

a Disconnect:

- the connector (2) from the camshaft position sen-sor,

- the damper valve connector (3) .

a Unclip the camshaft position sensor wiring and thedamper valve wiring (4) from the injector rail protec-tor cover.

a Move aside the camshaft position sensor wiring anddamper valve wiring.


a Remove:



- the injector rail protector cover.

a Disconnect the diesel injector fuel return rail from thehigh pressure pump (8) .

a Fit a blanking plug onto the opening of the diesel in-jector fuel return rail.

a Connect the 8 mm diameter offset union fitted withits hose contained in the toolto the high pressurepump union.

a Immerse this hose in the 500 ml graduated mea-suring cylinder.

a Connect:


- the damper valve connector,

- the intercooler air outlet pipe on the damper valve.



II - CHECKING OPERATION FOR PART CONCERNED



a Run commands:

- RZ009 Program vehicle functions,

- VP036 Inhibit fuel supply.

a Run the starter for 15 seconds.

121889

134699

135009

13B-15


K9K, and 832 or 842

13Ba Check that the minimum flow is 25 ml for 15 sec-

onds.

a Run command VP037 Stop fuel supply inhibition.

a Disconnect the Diagnostic tool.



a Loosen the clip of the intercooler air outlet pipe fromthe damper valve.

a Disconnect:

- the intercooler air outlet pipe on the damper valve,


- the camshaft position sensor connector.

a Disconnect the 8 mm diameter offset union fittedwith its hose contained in the toolon the high pres-sure pump union.

a Remove the blanking plug from the diesel injectorfuel return rail opening.

a Connect the diesel injector fuel return rail to the highpressure pump.

a Refit:


- the injector rail protector cover nut,

- the injector rail protector cover bolt.


a Fit the damper valve wiring.


a Connect:



- the intercooler air outlet pipe on the damper valve.


a Refit:


- the engine cover.

13B-16

DIESEL INJECTIONHigh pressure pump: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL




a Remove:

- the engine cover,







a Remove:






a Remove:


- the inner cover,


- the high pressure pipe between the high pressurepump and the injector rail (see 13B, Diesel injec-tion, High pressure pipe between pump andrail: Removal - Refitting, page 13B-37) .

Equipment required

offset spanner

Diagnostic tool

Tightening torquesm

high pressure pump pul-ley nut

70 N.m

high pressure pumpbolts

23 N.m



IMPORTANT




123969

13B-17


K9K, and 832 or 842

13B

a Disconnect the fuel supply pipe from the high pres-sure pump (4) .

a Fit a suitable blanking plug on the opening of:

- the fuel supply pipe,

- the high pressure pump.

a Remove:

- the high pressure pump protector nut (5) ,

- the bolt (6) from the high pressure pump protector,


a Disconnect the diesel injector fuel return rail union(7) from the high pressure pump.

134707 135000

WARNING


135001

13B-18


K9K, and 832 or 842

13Ba Fit a suitable blanking plug on the opening of:

- the diesel injector fuel return rail union,



a Remove:

- the high pressure pump bolts (8) ,


REFITTING


If replacing the high pressure pump

a - Remove the high pressure pump pulley

a

a Hold the high pressure pump in a vice with jaws, bythe lower mounting on the pulley side.

a Immobilise the high pressure pump pulley using aoffset spanner.

a Remove the nut from the high-pressure pump pul-ley.

135498

111743

Note:

If the high pressure pump is replaced, retain thehigh pressure pump pulley and refit it to the newhigh pressure pump.

13B-19


K9K, and 832 or 842

13B

a Fit tool (9) on the tool (10) .

a Remove the end piece (11) from the tool (10) .

a Fit theequipped with theto extract the high pressurepump pulley.

a Protect the contact zones between theandand thehigh pressure pump pulley.

a Extract the high pressure pump pulley.

a A damaged high pressure pump pulley must alwaysbe replaced.

b - Refitting the high pressure pump pulley

a Place the new high pressure pump in a vice withjaws, securing it at the lower mounting on the highpressure pump pulley side.

a Refit the high pressure pump pulley.

a Immobilise the high pressure pump pulley using a 32mm offset spanner.

a Torque tighten the high pressure pump pulley nut(70 N.m).


a Refit the high pressure pump.

a Torque tighten the high pressure pump bolts (23N.m).


a Remove the blanking plugs from the opening of:

- the high pressure pump,

- the diesel injector fuel return rail union.

a Connect the diesel injector fuel return rail union onthe high pressure pump.


a Remove the blanking plugs from:

- the fuel supply pipe,



a Refit:

- the high pressure pipe between the high pressurepump and the injector rail (see 13B, Diesel injec-tion, High pressure pipe between pump andrail: Removal - Refitting, page 13B-37) ,


- the inner cover.



a Torque tighten:



a Refit:




a Refit:



135002

Note:

Be sure not to mark the high pressure pump pul-ley when extracting it using theequipped with the.

13B-20


K9K, and 832 or 842

13B- the front section of the front right-hand wheel archliner (see Front wheel arch liner: Removal - Re-fitting) (55A, Exterior protection),




a Reprime the fuel circuit using the manual primingpump.

a Check that there are no diesel leaks.

a Apply the before - after repair procedure using the Diagnostic tool :


- select "Injection computer",


- display the "Before/after repair procedure" for thecomputer selected,

- select "High pressure pump" in the "List of compo-nents controlled by this computer" section,

- carry out the operations described in the "After re-pair procedure" section.

13B-21


K9K, and 830 or 838

13B

REMOVAL




a Remove:

- the engine cover,












- the camshaft position sensor (see 13B, Diesel in-jection, Camshaft position sensor: Removal -Refitting, page 13B-8) .


- the high pressure pipe between the high pressurepump and the injector rail (see 13B, Diesel injec-tion, High pressure pipe between pump andrail: Removal - Refitting, page 13B-37) .

Equipment required

Diagnostic tool

Tightening torquesm

the high pressure pumpbolts

23 N.m

high pressure pump pul-ley nut

70 N.m

right-hand suspendedengine mounting sup-port bolts

25 N.m

IMPORTANT


IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Diesel injection: Precautions for therepair) .

13B-22


K9K, and 830 or 838

13B

a Unclip the upper timing cover at (1) .

a Remove:


- the upper timing cover.

a Remove:

- the right-hand suspended engine mounting supportbolts (3) ,

- the right-hand pendulum suspension support.

a Remove:

- the bolt (4) from the high pressure pump protector,


a Clean the fuel supply unions on the high pressurepump (see Diesel injection: Precautions for therepair) .

136654

136656

136658

135873

13B-23


K9K, and 830 or 838

13Ba

a Disconnect the fuel supply pipe union from the highpressure pump (5) .


- the high pressure pump opening,

- the fuel supply pipe opening.

a Clean the fuel return unions on the high pressurepump (see Diesel injection: Precautions for therepair) .




- the opening of the diesel injector fuel return rail.

a Position the engine at Top Dead Centre. The cam-shaft pulley hole (7) should be opposite the cylinderhead hole (8) .

WARNING


135872

135872

107270

13B-24


K9K, and 830 or 838

13B

a Insert the tool (9) in the hole of the camshaft pulleyhub and the hole of the cylinder head.

a Remove the tool.


a Fit the (10) on the cylinder head.

a Remove the nut (11) from the high pressure pumppulley, immobilising the high pressure pump pulleyusing a 32 mm spanner in order not to constrain thetool.

19655

23168

Note:

If necessary, turn the engine slowly to adjust theposition of theon the high pressure pump pulleyteeth.

13B-25


K9K, and 830 or 838

13Ba

a Fit the tool (12) equipped with the tool adapted ac-cording to the type of high pressure pump pulley.

19655

136389

Note:

There are 2 possible fittings for the high pressure pump pulleys:

- the first type of pulley fitting (A) comprises 6spokes which are spaced equally apart,

- the second type of pulley fitting (B) comprises 4spokes which vary in width.

To extract the pulley (A) of the high pressurepump, use the toolin addition to tool.

To extract the pulley (B) of the high pressurepump, use the toolin addition to tool.

23169

Note:

Remove the spacer at the end of the pushrodfrom the toolto improve the positioning on thehigh pressure pump shaft.

Note:

Place the claws of the toolsoron the spokes ofthe high pressure pump pulley in order to ensurethat the claws are secure when removing the pul-ley and to avoid damaging the pulley spokes.

13B-26


K9K, and 830 or 838

13Ba Screw the pushrod of the tooluntil it makes contact

with the high pressure pump shaft.

a Remove the high pressure pump bolts (13) .

a Gradually screw the pushrod of theuntil the highpressure pump becomes detached.

a Remove the high pressure pump.

a Remove the toolfrom the high pressure pump pulley.

REFITTING


a Check for an index pin on the high pressure pumpshaft.


a Refit the high pressure pump on the cylinder headby inserting it into the high pressure pump pulley.

a Fit the high pressure pump bolts without tighteningthem.

a Torque tighten in order the high pressure pumpbolts (23 N.m).

a Torque tighten the high pressure pump pulley nut(70 N.m) while holding the high pressure pump pul-ley using a 32 mm spanner.

a Remove thefrom the cylinder head.

Note:

Check that the pushrod of the toolis correctly ori-ented and is pressing against the high pressurepump shaft. Adjust the toolif necessary.

136623

Note:

Guide and support the high pressure pump withone hand as it is being removed using the

Note:

If the high pressure pump is being reused, keepit in a sealed bag during the removal operation.

Note:

Check that the high pressure pump shaft is cor-rectly orientated in relation to the high pressurepump pulley.

136623

Note:

Check that the timing belt is correctly positionedand in good condition.

13B-27


K9K, and 830 or 838


a Refit the right-hand suspended mounting support.

a Torque tighten in order the right-hand suspendedengine mounting support bolts (25 N.m).

a Refit:


- the upper timing cover bolt.







- the fuel supply pipe opening,



a Refit:

- the high pressure pump protector,



- the camshaft position sensor (see 13B, Diesel in-jection, Camshaft position sensor: Removal -Refitting, page 13B-8) ,
















- select the "Injection computer",


- display the "After repair procedure" for the selectedcomputer,

- select "High pressure pump" in the "List of compo-nents stored by this computer",


136658

13B-28

DIESEL INJECTIONFlow actuator: Removal - Refitting

K9K, and 830 or 838

13B

REMOVAL


a Remove the engine cover.




a Remove:


- the injection rail protector cover,


a Disconnect the flow actuator connector (3) .

a Remove:

- the flow actuator bolts (4) ,

- the fuel flow actuator

IMPORTANT


Note:

Ensure that you have a new flow actuator beforeopening up the fuel circuit.

135878

135874

135865

13B-29

DIESEL INJECTIONFlow actuator: Removal - Refitting

K9K, and 830 or 838

13Ba Make sure that no impurities enter the high pressure

pump when the fuel flow actuator is removed.

REFITTING


a parts always to be replaced: Fuel flow regulatorseal on injection pump (11,05,10,20).


a Refit the flow actuator to the high pressure pump.

a Connect the flow actuator connector.


a Prime the fuel circuit using the manual primingpump.





a Start the engine.

a Check that there are no fuel leaks.


WARNING

Do not blast with compressed air once the fuelcircuit is open, otherwise impurities may enterthe system. Only use cleaning cloths.

WARNING



13B-30

DIESEL INJECTIONVenturi: Removal - Refitting

K9K, and 830 or 838

13B

REMOVAL


a Remove:

- the engine cover,



a Disconnect the diesel fuel return pipe union from theVenturi (1) .

a Fit blanking plugs on:

- the opening of the venturi,

- the diesel fuel return pipe opening.

a Disconnect the diesel fuel injector return rail from theVenturi (2) .


- the opening of the venturi,


Tightening torquesm

Venturi bolt 5.5 N.m

IMPORTANT


WARNINGTo avoid any corrosion or damage, protect theareas on which fuel is likely to run.

WARNING


Note:

Ensure that you have a new Venturi before openingup the fuel circuit.

135867

13B-31

DIESEL INJECTIONVenturi: Removal - Refitting

K9K, and 830 or 838

13B

a Remove:

- the Venturi bolt (3) ,

- the Venturi.

a Take care to ensure that no impurities get into thehigh pressure pump once the Venturi is removed.

REFITTING


a

a Refit the venturi to the high pressure pump.

a Torque tighten the Venturi bolt (5.5 N.m).



- the Venturi opening.

a Connect the fuel return rail to the Venturi.


- the opening of the diesel fuel return pipe union,

- the Venturi opening.

a Connect the diesel return pipe to the Venturi.



a Start the engine.



135866

WARNING


Note:

Do not lubricate the seals with grease or useddiesel fuel. Use the applicator provided in the kitfor the new part.

13B-32

DIESEL INJECTIONDiesel injector fuel return rail: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL





a Unclip the wiring for the turbocharging pressure sen-sor from the intercooler air outlet pipe at (2) .



a Separate the intercooler air outlet pipe from thedamper valve.

Tightening torquesm


5.5 N.m

IMPORTANT




IMPORTANT


WARNING


134215

13B-33


K9K, and 832 or 842

13B

a Disconnect:



a Unclip the damper valve wiring from the injector railprotector cover plate at (6) .



a Remove:




a Unclip the diesel fuel injector wiring from the rockercover.

121889

134699

13B-34


K9K, and 832 or 842


a Disconnect:


- the diesel fuel return pipe from the diesel injectorfuel return rail (11) .


- the diesel fuel return pipe opening,




- the opening of the diesel injector fuel return rail,


First step for removing the fuel return rail unions from the diesel injectors

a

a Using a fine, flat screwdriver, push the lower sec-tions of the diesel injector fuel return rail unions (13)towards the rocker cover to unlock them and posi-tion them fully up against the rocker cover.

134706

135009

111749

WARNING

Ensure that the clip is not completely removedfrom its housing, otherwise it may be damagedwhen the diesel return union is removed.

In the case where a clip has been completelyremoved from its housing, remove the injectorconcerned and replace the clip with a new clip(see 13B , Diesel injection, Diesel injector:Removal - Refitting, page 13B-72) .

13B-35


K9K, and 832 or 842

13BSecond step for removing the fuel return rail unions from the diesel injectors

a

a Use a thin, flat-blade screwdriver to push down (14)on the lower tabs of the clips previously in contactwith the rocker cover, without fully removing the clipsfrom their injectors.

a Manually remove the diesel injector fuel return railunions (15) , while pressing (14) on the lower tabs ofthe clips using a thin, flat-blade screwdriver.


- each diesel injector fuel return rail union,

- the opening of each diesel injector.

a Unclip the diesel injector fuel return rail from therocker cover at (16) .

a Remove the diesel injector fuel return rail.

REFITTING


a


a Push the diesel injector fuel return rail union clips to-wards the front of the vehicle to place them in theirinitial position.


- the opening of each diesel injector,

- each diesel injector fuel return rail union.

120940

Note:

With sufficient force applied to the clip whilepressing continuously with the screwdriver, thediesel injector fuel return rail unions will come outeffortlessly.

WARNING

Do not use the screwdriver as a lever on theinjector fuel return unions.

134700

Note:

If the fuel return rail is to be re-used, keep it in asealed plastic bag during the removal operation.

WARNING

Check the condition of the seals on the fuelreturn unions on the injectors. Check that theyare not cut or crushed, and have not come out oftheir grooves. Replace the diesel return pipeassembly if one of its components is damaged.

13B-36


K9K, and 832 or 842

13Ba Lubricate the unions of the diesel injector fuel return

rail using SILICONE-FREE LUBRICANT (see Ve-hicle: Parts and consumables for the repair)(04B, Consumables - Products) so that the seals arecompletely covered with product.

a Position the unions of the diesel injector fuel returnrail in front of the opening of each diesel injector,starting with injector number 4 (timing end).

a Clip the unions of the diesel injector fuel return railonto the opening of each diesel injector, starting withinjector number 4 (timing end).







- the diesel return pipe opening.

a Connect:

- the diesel fuel return pipe to the diesel injector fuelreturn rail,

- the fuel temperature sensor connector.


a Clip the diesel injector wiring onto the rocker cover.









a Clip the wiring for the damper valve onto the injectorrail protector cover plate.

a Connect:






Note:

Check that the fuel return rail unions are cor-rectly clipped in place.

13B-37

DIESEL INJECTIONHigh pressure pipe between pump and rail: Removal - Refitting

K9K, and 830 or 838

13B

REMOVAL





a Remove:

- the dipstick,




a Remove



Tightening torquesm

nuts for the high pres-sure pipe between thehigh pressure pump andthe injector rail

28 N.m

injector rail nuts 28 Nm

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Diesel injection: Precautions for therepair)

IMPORTANT


135877

135878

13B-38


K9K, and 830 or 838

13B

a Disconnect:







a Remove the nut (8) from the injection wiring bracket.


a Remove:

- the nuts (9) from the injector rail protector,

- the injector rail protector.


a Clean the unions of the high pressure pipes betweenthe high pressure pump and the injector rail (seeDiesel injection: Precautions for the repair)

135874 136625

WARNING


13B-39


K9K, and 830 or 838

13B

a

a Undo the injector rail nuts (10) .

a Remove the high pressure pipe (11) between thehigh pressure pump and the injector rail.

a Place a suitable blanking plug on:


- the injector rail opening.

REFITTING


a

a parts always to be replaced: High pressure pipebetween the pump and rail (11,05,03,02).


a Remove the blanking plug from:



135871

WARNING

Always hold the intermediate injector union inplace with a wrench when loosening the highpressure pipes.

Do not damage the injector return nozzle.

20960

WARNING

Before fitting a new high pressure pipe, lightlylubricate the nut threads with the oil from theapplicator provided in the new parts kit.

Be careful not to allow oil into the high pressurepipe.

Do not lubricate high pressure pipes suppliedwithout an applicator, as these high pressurepipes are self-lubricating.

WARNING



13B-40


K9K, and 830 or 838

13Ba Fit the new high pressure pipe between the injector

rail and the high pressure pump.

a Screw on the nuts for the high pressure pipe be-tween the high pressure pump and the injector railby hand without tightening, starting at the injector railend.

a Using the tool, torque tighten the nuts for the highpressure pipe between the high pressure pumpand the injector rail (28 N.m).

a Torque tighten the injector rail nuts (28 Nm).


a Refit the injector rail protector.




a Connect:






a Refit:


- the injection rail protector cover bolt.

a Clip on the injector rail protector cover plate.


a Refit:


- the dipstick.





a Check that there are no diesel leaks (see High pres-sure pipe: Check) .

13B-41


K9K, and 832 or 842

13B

REMOVAL









Tightening torquesm

nuts for the high pres-sure pipe between thehigh pressure pump andthe injector rail

28 N.m


5.5 N.m

IMPORTANT




IMPORTANT


134215

13B-42


K9K, and 832 or 842

13B

a Disconnect:






a Remove:




a Remove:

- the dipstick,



121889

134699

134703

13B-43


K9K, and 832 or 842

13B


a Disconnect:






- the connector (13) for the injector rail pressure sen-sor.


a Remove the nut (15) from the injection wiring brack-et.


a Unclip:

- the alternator wiring (21) from the injector rail pro-tector,

- the expansion bottle lower cooling hose from theinjection pump protector.


a Move the fuel drain pipe aside.

a Remove:


134999 134706

135468

13B-44


K9K, and 832 or 842

13B- the injector rail protector bolt (18) ,



a Clean the unions of the high pressure pipe betweenthe high pressure pump and the injector rail (seeDiesel injection: Precautions for the repair) .

a Remove the high pressure pipe between the highpressure pump and the injector rail (19) .

a Place a suitable blanking plug on:



REFITTING


a

a parts always to be replaced: High pressure pipebetween the pump and rail (11,05,03,02).





a Fit the new high pressure pipe between the injectorrail and the high pressure pump.

WARNING


135005

Note:

It is essential to use a spanner to hold the highpressure pump intermediate union when loosen-ing the high pressure pipe.

20960

WARNING




Note:

If the set of new pipes does not contain an appli-cator, do not lubricate the threads of the highpressure pipe (as they are self-lubricating pipes).

13B-45


K9K, and 832 or 842

13Ba Screw on by hand, without tightening, until contact is

made with the nuts of the high pressure pipe be-tween the high pressure pump and the injector rail,starting at the injector rail end.

a Using the toolor the tool, torque tighten the nuts forthe high pressure pipe between the high pres-sure pump and the injector rail (28 N.m).



a Fit the fuel drain pipe.





a Refit:

- injector rail pressure sensor connector,



- the connector for the fuel pressure regulation sole-noid valve,


- all heater plug connectors.



a Refit:


- the dipstick,










a Connect:






13B-46

DIESEL INJECTIONHigh pressure pipe between rail and injector: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL









Tightening torquesm

nuts for the high pres-sure pipe(s) betweenthe injector rail and thediesel injector(s)

28 N.m

injector rail nuts 28 N.m

nuts for the high pres-sure pipes between theinjector rail and the die-sel injectors

28 N.m

clip for the intercoolerair outlet pipe on thedamper valve

5.5 N.m

IMPORTANT




IMPORTANT


134215

13B-47


K9K, and 832 or 842

13B

a Disconnect:






a Remove:




- the dipstick,

- the dipstick guide tube bolts.


a Clean the high pressure pipe unions between the railand the injectors (see Diesel injection: Precau-tions for the repair) .


1 - Removing one, two or three high pressure pipes

a

a Loosen the nuts for the high pressure pipe betweenthe injector rail and the diesel fuel injector(s), usingthe tool.

a Remove:

- the nut(s) for the high pressure pipe(s) between theinjector rail and the diesel fuel injector(s) on the in-jector rail side,

121889

134699

1327

WARNING



WARNING


13B-48


K9K, and 832 or 842

13B- the nut(s) for the high pressure pipe(s) between theinjector rail and the diesel fuel injector(s) on the in-jector side,

- the high pressure pipe(s) between the injector railand the diesel fuel injector(s) concerned.


- the opening(s) on the injector rail,

- the opening of the diesel injector(s).

2 - Removing the four high pressure pipes


a Disconnect:






- the connector (13) for the injector rail pressure sen-sor.


a Remove the nut (15) from the injection wiring brack-et.


a Unclip:

- the alternator wiring from the injector rail protector,

- the coolant hose from the injection pump protector

a Unclip the expansion bottle lower cooling hose fromthe injection pump protector.


a Move the fuel drain pipe aside.

a Remove:


- the injector rail protector bolt (18) ,


134999

135468

13B-49


K9K, and 832 or 842

13B

a Undo the injector rail nuts (19) .a

a Loosen the nuts for the high pressure pipe betweenthe injector rail and the diesel fuel injectors, usingthe tool.

a Remove:

- the nut for the high pressure pipe between the in-jector rail and the diesel fuel injectors on the injec-tor rail side,

- the nut for the high pressure pipe between the in-jector rail and the diesel fuel injectors on the injec-tor side,

- the high pressure pipe between the injector rail andthe diesel fuel injectors.


- the injector rail openings,


135006 1327

WARNING



WARNING


13B-50


K9K, and 832 or 842

13BREFITTING


a

a parts always to be replaced: High pressure pipebetween the rail and injector (11,05,03,01).


1 - Refitting one, two or three high pressure pipes


- the injector rail opening(s),


a Screw on the nuts for the high pressure pipe(s) be-tween the injector rail and the diesel injector(s) byhand without tightening, starting on the injector railside.

a Using the toolor the tool, torque tighten the nuts forthe high pressure pipe(s) between the injectorrail and the diesel injector(s) (28 N.m).

2 - Refitting the four high pressure pipes





a Torque tighten:

- the injector rail nuts (28 N.m),

- using the toolor the toolthe nuts for the high pres-sure pipes between the injector rail and the die-sel injectors (28 N.m).


a Clip:

- the expansion bottle lower cooling hose onto the in-jection pump protector,

- the alternator wiring onto the injector rail protector.

a Fit the fuel drain pipe.





a Refit:

- injector rail pressure sensor connector,



20960

WARNING




WARNING



13B-51


K9K, and 832 or 842

13B- the connector for the fuel pressure regulation sole-noid valve,


- all heater plug connectors.




a Refit:


- the dipstick,






a Torque tighten the clip for the intercooler air out-let pipe on the damper valve (5.5 N.m).




a Connect:






13B-52


K9K, and 830 or 838

13B

REMOVAL



a Remove:

- the engine cover,


a Remove:

- the dipstick,




a Remove:



Tightening torquesm

nuts for the high pres-sure pipe(s) betweenthe injector rail and thediesel injector(s)

28 N.m

injector rail nuts 28 N.m

nuts for the high pres-sure pipes between theinjector rail and the die-sel injectors

28 N.m

IMPORTANT


IMPORTANT


135877

135878

13B-53


K9K, and 830 or 838

13Ba Clean the high pressure pipe unions between the rail

and the diesel fuel injectors (see Diesel injection:Precautions for the repair) .


1 - Removing one, two or three high pressure pipes

a

a Loosen the nuts for the high pressure pipe(s) be-tween the injector rail and the diesel fuel injector(s),using the tool.

a Remove:

- the nuts for the high pressure pipe(s) between theinjector rail and the diesel fuel injector(s) on the in-jector rail side,

- the nuts for the high pressure pipe(s) between theinjector rail and the diesel fuel injector(s) on the in-jector side,

- the high pressure pipes between the injector railand the diesel injectors concerned.


- the opening(s) on the injector rail,

- the opening of the diesel fuel injector(s).

2 - Removing the four high pressure pipes

a Disconnect:







a Remove the nut (8) from the injection wiring bracket.

a Separate the injection wiring.

1327

WARNING



WARNING


135874

13B-54


K9K, and 830 or 838

13B

a Remove:



a Undo the injector rail nuts (10) .

a

a Undo the high pressure pipe nuts between the railand the injector using the.

a Remove:

- the nut for the high pressure pipes between the in-jector rail and the diesel fuel injectors on the injec-tor rail side,

- the nut for the high pressure pipes between the in-jector rail and the diesel fuel injectors on the injec-tor side,

- the high pressure pipes between the injector railand the diesel fuel injectors concerned.




136625

135859

1327

WARNING



WARNING


13B-55


K9K, and 830 or 838

13BREFITTING


a

a parts always to be replaced: High pressure pipebetween the rail and injector (11,05,03,01).


1 - Refitting one, two or three high pressure pipes


- the injector rail opening(s),



a Using the toolor the tool, torque tighten the nuts forthe high pressure pipe(s) between the injectorrail and the diesel injector(s) (28 N.m).

2 - Refitting the four high pressure pipes





a Torque tighten:

- the injector rail nuts (28 N.m),

- using the toolor the toolthe nuts for the high pres-sure pipes between the injector rail and the die-sel injectors (28 N.m).





a Connect:



- the connector for the turbocharging fuel flow regu-lation solenoid valve,




a Refit:


- the injection rail protector cover bolt.

20960

WARNING




WARNING



13B-56


K9K, and 830 or 838

13Ba Clip on the injector rail protector cover plate.


a Refit:


- the dipstick.





a Check that there are no diesel leaks (see High pres-sure pipe: Check) .

13B-57

DIESEL INJECTIONInjector rail: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL



a Remove:

- the engine cover,



- the high pressure pipe between the injector rail andthe diesel injectors (see 13B, Diesel injection,High pressure pipe between rail and injector:Removal - Refitting, page 13B-46) .


a Remove:

- the nuts (1) from the injector rail,

- the injector rail.

REFITTING


a


a Refit the injector rail.


a Refit:

- the high pressure pipe between the injector rail andthe diesel injectors (see 13B, Diesel injection,High pressure pipe between rail and injector:Removal - Refitting, page 13B-46) ,

Equipment required

Diagnostic tool

IMPORTANT




IMPORTANT


135007

WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.


13B-58


K9K, and 832 or 842

13B- the high pressure pipe between the high pressurepump and the injector rail (see 13B, Diesel injec-tion, High pressure pipe between pump andrail: Removal - Refitting, page 13B-37) ,


- the engine cover.








- select "Injector rail pressure sensor" in the section"List of components connected to this computer",


13B-59


K9K, and 830 or 838

13B

REMOVAL



a Remove:

- the engine cover,



- the high pressure pipe between the injector rail andthe diesel injectors (see 13B, Diesel injection,High pressure pipe between rail and injector:Removal - Refitting, page 13B-46) .


a Remove:

- the nuts (1) from the injector rail,

- the injector rail.

REFITTING


a


a Refit the injector rail.

a Without tightening, fit the injector rail nuts.


a Refit:

- the high pressure pipes between the injector railand the diesel injectors (see 13B, Diesel injection,High pressure pipe between rail and injector:Removal - Refitting, page 13B-46) ,

Equipment required

Diagnostic tool

IMPORTANT


IMPORTANT


135869

WARNING



13B-60


K9K, and 830 or 838

13B- the high pressure pipe between the high pressurepump and the injector rail (see 13B, Diesel injec-tion, High pressure pipe between pump andrail: Removal - Refitting, page 13B-37) ,


- the engine cover.


a Check the high pressure circuit (see High pressurepipe: Check) .






- select "Injector rail pressure sensor" in the section"List of components connected to this computer",


13B-61

DIESEL INJECTIONRail pressure sensor: Removal - Refitting

K9K, and 832 or 842

13B

The injector rail pressure sensor (1) cannot be separat-ed from the injector rail.

In the event of a fault on the rail pressure sensor, re-place the “rail pressure sensor - injector rail and highpressure pipes” assembly (see 13B, Diesel injection,Injector rail: Removal - Refitting, page 13B-57) .

114076

13B-62

DIESEL INJECTIONRail pressure sensor: Removal - Refitting

K9K, and 830 or 838

13B

a The pressure sensor (1) cannot be removed fromthe spherical injector rail.

If the pressure sensor is faulty, replace the« pressure sensor - high pressure pipes and rail »assembly (see 13B, Diesel injection, Injector rail:Removal - Refitting, page 13B-57) .

102086

13B-63

DIESEL INJECTIONFuel temperature sensor: Removal - Refitting

K9K, and 832 or 842

13B

a The fuel temperature sensor (1) cannot be saparat-ed from the diesel injector fuel return rail.

a In the event of a fuel temperature sensor fault, re-place the « diesel injector fuel return rail - fuel tem-perature sensor » assembly (see 13B , Dieselinjection, Diesel injector fuel return rail: Remov-al - Refitting, page 13B-32) .

111747

13B-64


K9K, and 830 or 838

13B

REMOVAL






a Remove:




a Disconnect the fuel temperature sensor connector(3) .

a Remove the fuel temperature sensor.

Tightening torquesm

fuel temperature sensor 15 N.m

IMPORTANT


IMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.

WARNING


135878

135863

13B-65


K9K, and 830 or 838

13Ba Make sure that no impurities enter the high pressure

pump when the fuel temperature sensor is removed.

REFITTING


a Refit the fuel temperature sensor.

a Torque tighten the fuel temperature sensor (15N.m).

a Connect the fuel temperature sensor connector.






a Start the engine.



WARNING


13B-66

DIESEL INJECTIONInjector leak flow: Check

K9K, and 832 or 842

13B

CHECK




a Unclip the turbocharger pressure sensor wiring fromthe intercooler air outlet pipe at (2) .




Equipment required


Diagnostic tool

Tightening torquesm


5.5 N.m


5.5 N.m

IMPORTANT




IMPORTANT


134215

13B-67


K9K, and 832 or 842

13B

a Disconnect:



a Unclip the damper valve wiring (6) from the injectorrail protector cover.



a Remove:




a

a Using a thin, flat-blade screwdriver, push the lowertabs (10) of the diesel injector fuel return union clipstowards the rocker cover to unlock them and posi-tion them fully up against the rocker cover.

121889

134699

111749

WARNING

Ensure that the clip is not completely removedfrom its housing, otherwise it may be damagedwhen the diesel return union is removed.

In the case where a clip has been completelyremoved from its housing, remove the injectorconcerned and replace the clip with a new clip(see 13B , Diesel injection, Diesel injector:Removal - Refitting, page 13B-72) .

13B-68


K9K, and 832 or 842

13B

a

a Use a thin, flat-blade screwdriver to push down (11)on the lower tabs of the clips previously in contactwith the rocker cover, without fully removing the clipsfrom their injectors.

a Manually remove the diesel injector fuel return railunions (12) , while pressing (11) on the lower tabs ofthe clips using a thin, flat-blade screwdriver.

a Fit appropriate blanking plugs on each union of thediesel injector fuel return rail.

a Connect the four transparent hoses of the toolon thediesel injectors in place of each union of the dieselinjector fuel return rail.

a Insert these hoses in the four graduated measuringcylinders (13) of the tool.

a Connect:











a Run commands:

- RZ009 "Apprentissages fonctions véhicule",

- VP036 "Inhibition alimentation carburant".


a Check that the diesel injector return volume is great-er than or equal to 20 ml.

a Repeat the starting phase twice, allowing an intervalof 30 seconds between each starting phase.

a Run the command VP037 "Arrêt inhibition alimen-tation carburant".

120940

Note:

With sufficient force applied to the clip whilepressing continuously with the screwdriver, thediesel injector fuel return rail unions will come outeffortlessly.

WARNING

Do not use the screwdriver as a lever on theinjector fuel return unions.

107637

13B-69


K9K, and 832 or 842

13Ba Disconnect:





a Loosen the clip of the intercooler air outlet pipe fromthe damper valve.

a Disconnect:

- the intercooler air outlet pipe on the damper valve,



a Disconnect the four transparent pipes of the toolfromthe diesel injectors.

a Push the diesel injector fuel return union clips to-wards the front of the vehicle to place them into theiroriginal positions.

a Remove the blanking plug from each diesel injectorfuel return rail opening.

a Lubricate the diesel injector fuel return unions withSILICONE-FREE LUBRICANT (see Vehicle:Parts and consumables for the repair) (04B, Con-sumables - Products) until the seals are completelycovered.

a Place the diesel injector fuel return rail unions infront of the diesel injector openings starting with in-jector number 4 (timing end).

a Clip the diesel injector fuel return rail unions on thediesel injectors starting with injector number 4 (tim-ing end).

a Refit:


- the injector rail protector cover nut,



a Fit the damper valve wiring.


a Connect:








a Refit:


- the engine cover.

WARNING

Check the condition of the seals on the fuelreturn unions on the injectors. Check that theyare not cut or crushed, and have not come out oftheir grooves. Replace the entire diesel returnpipe if one of the components is damaged

Note:

Check that the unions of the fuel return rail arecorrectly clipped.

13B-70


K9K, and 830 or 838

13B

CHECK


a Remove:

- the engine cover,



a Remove:



a Disconnect the fuel return rail (3) from each dieselinjector.

Equipment required


Diagnostic tool

IMPORTANT


IMPORTANT


135878

135870

13B-71


K9K, and 830 or 838

13B

a Connect the four transparent hoses of the toolon thediesel injectors in place of each union of the dieselinjector fuel return rail.

a Insert these hoses in the four graduated measuringcylinders (6) of the tool.






a Run commands:

- RZ009 Vehicle function programming,

- VP036 Inhibit fuel supply.


a Check that the diesel injector return volume is great-er than or equal to 20 ml.

a Repeat the starting phase twice, allowing an intervalof 30 seconds between each starting phase.

a Run command VP037 Stop fuel supply inhibition.

a Disconnect:





a Disconnect the four transparent pipes of the toolfromthe diesel injectors.

a Connect the diesel injector fuel return rail unions tothe diesel injectors.

a Refit:




a Refit:


- the engine cover.

107637

Note:

The hose must be fitted with force on the dieselinjector fuel return nipple.

If a hose of the toolfits too easily onto the dieselinjector fuel nipple, due to hose deformation, cutoff the widened section of this hose in order toobtain a smaller diameter and to ensure that thehose is secure on the injector during the pres-surised test phase.

Note:

Check that the unions of the fuel return rail arecorrectly connected.

13B-72

DIESEL INJECTIONDiesel injector: Removal - Refitting

K9K, and 832 or 842

13B

REMOVAL




a Remove:

- the diesel injector fuel return rail (see 13B, Dieselinjection, Diesel injector fuel return rail: Re-moval - Refitting, page 13B-32) ,

- the high pressure pipe(s) between the injector railand the diesel injector(s) (see 13B, Diesel injec-tion, High pressure pipe between rail and injec-tor: Removal - Refitting, page 13B-46) .


a Remove:

- the bolt (1) from the bracket on the diesel injec-tor(s) concerned,

- the bracket of the diesel injector(s) concerned,

- the spacer of the diesel injector bracket concerned,

- the diesel injector(s) concerned,

- the compression washer located at the bottom ofthe diesel injector well concerned.

Equipment required

compressed air nozzle

Tightening torquesm

bolt of the diesel injec-tor(s)

30 N.m

IMPORTANT




IMPORTANT


135008

13B-73


K9K, and 832 or 842

13B

a

a Remove the diesel injector(s) from the well.

a Fit the appropriate blanking plug on the diesel injec-tor nose.

REFITTING


a

a parts always to be replaced: injector seal (11,11,02,02).

Cleaning the injector well and the injector

a

a Soak the diesel injector in INJECTOR CLEANINGPRODUCT (see Vehicle: Parts and consumablesfor the repair) (04B, Consumables - Products).

a Clean the nozzle of the diesel injector(s):

- either using CLEANING CLOTHS (see Vehicle:Parts and consumables for the repair) (04B,Consumables - Products) soaked in INJECTORCLEANING PRODUCT (see Vehicle: Parts andconsumables for the repair) (04B, Consumables- Products),

- or using a small brush with plastic bristles.

a Wipe using CLEANING RAGS (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products).

114010

Note:

If a diesel injector is stuck in its well and does notcome out, turn the diesel injector at the flat sur-face of the diesel injector clamp using a 13 mmopen-ended spanner.

Note:

If reusing the diesel injector(s) keep them in ahermetically sealed bag throughout the removaloperation.

WARNING



WARNING

It is strictly forbidden to clean the injectors with:

- a wire brush,

- an emery cloth,

- an ultrasonic cleaner.

IMPORTANT


WARNING


- a wire brush,

- an emery cloth,


IMPORTANT


13B-74


K9K, and 832 or 842

13B

a Fit an 11mm by 1/4" socket (2) (socket outer Ø =washer Ø) on an extension piece (3) .

a Wrap a CLEANING CLOTH (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) around the "socket - extensionpiece" assembly.

a Soak a CLEANING CLOTH in INJECTOR CLEAN-ING PRODUCT (see Vehicle: Parts and consum-ables for the repair) (04B, Consumables -Products).

a Insert the wipe-covered extension piece and endpiece down into the bottom of the well.

a Clean the injector well (pay particular attention to themating face of the washer).

a Remove the CLEANING CLOTH from the well.

a Insert a large diameter Phillips screwdriver (Ø > 8mm) into the well to block the opening to the com-bustion chamber.

a Blast out any scale residue in the well using a com-pressed air nozzle.

a Remove the screwdriver and repeat the cleaning op-eration for the injector well concerned twice in suc-cession.


a

a Remove the blanking plug from the diesel injectornose.

a Refit:

- the new compression washer,

- the diesel injector(s),

- the spacer of the diesel injector bracket,

- the bracket of the diesel injector(s),

- the bolt of the diesel injector bracket.

a Torque tighten the bolt of the diesel injector(s) (30N.m).

114994

Note:

Swivel the cloth-covered socket and extensionpiece around inside the well.

114926

WARNING



13B-75


K9K, and 832 or 842


a Refit:

- the high pressure pipe(s) between the injector railand the diesel injector(s) (see 13B, Diesel injec-tion, High pressure pipe between rail and injec-tor: Removal - Refitting, page 13B-46) ,

- the diesel injector fuel return rail (see 13B, Dieselinjection, Diesel injector fuel return rail: Re-moval - Refitting, page 13B-32) .




13B-76


K9K, and 830 or 838

13B

REMOVAL



a Remove:

- the engine cover,

- the high pressure pipe(s) between the injector railand the diesel injector(s) (see 13B, Diesel injec-tion, High pressure pipe between rail and injec-tor: Removal - Refitting, page 13B-46) .

a Clean the unions of the diesel injector return rail atthe diesel injectors (see Diesel injection: Precau-tions for the repair) .

a Disconnect the diesel injector fuel return rail from thediesel injectors (1) .

a Fit an appropriate blanking plug on each diesel in-jector.

Equipment required

open-ended spanner


Diagnostic tool

Tightening torquesm

bolts of the diesel injec-tor bracket

28 N.m

IMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Diesel injection: Precautions for therepair) .

IMPORTANT


135870

WARNING


Note:

It is essential to fit an appropriate blanking plugto the Venturi to avoid depriming the fuel returncircuit.

13B-77


K9K, and 830 or 838


a

a Remove:

- the bolt (2) from the bracket on the diesel injec-tor(s) concerned,

- the diesel injector bracket,

- the compression washer located at the bottom ofthe diesel injector well concerned.

a Fit the appropriate blanking plug on the diesel injec-tor nose.

REFITTING


a

a parts always to be replaced: injector seal (11,11,02,02).

Cleaning the diesel injector well

a

a Soak the diesel injector(s) in INJECTOR CLEAN-ING PRODUCT (see Vehicle: Parts and consum-ables for the repair) (04B, Consumables -Products).

a Clean the diesel injector nozzle:

- either using CLEANING CLOTHS (see Vehicle:Parts and consumables for the repair) (04B,Consumables - Products) soaked in INJECTORCLEANING PRODUCT (see Vehicle: Parts andconsumables for the repair) (04B, Consumables- Products),

- or using a small brush with plastic bristles.

135868

Note:

If reusing one or more diesel injectors, it isessential to mark the injector in relation to its cyl-inder before removing it. If reusing the dieselinjector(s) keep them in a hermetically sealedbag throughout the removal operation.

Note:

If the diesel injector is stuck in the well and doesnot come out, turn the diesel injector at the flatsurface of the diesel injector bracket using anopen-ended spanner.

WARNING



WARNING


- a wire brush,

- an emery cloth,


IMPORTANT


WARNING


- a wire brush,

- an emery cloth,


13B-78


K9K, and 830 or 838

13Ba Wipe using CLEANING RAGS (see Vehicle: Parts

and consumables for the repair) (04B, Consum-ables - Products).

a Fit an 11mm by 1/4" socket (3) (socket outer Ø =washer Ø) on an extension piece (4) .

a Wrap a CLEANING CLOTH (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) around the "socket - extensionpiece" assembly.

a Soak a CLEANING CLOTH in INJECTOR CLEAN-ING PRODUCT (see Vehicle: Parts and consum-ables for the repair) (04B, Consumables -Products).

a Insert the wipe-covered extension piece and endpiece down into the bottom of the well.

a Clean the diesel injector well (pay particular atten-tion to the mating face of the washer).

a Remove the CLEANING CLOTH from the well.

a Insert a large diameter Phillips screwdriver (Ø > 8mm) into the well to block the opening to the com-bustion chamber.

a Blast out any scale residue in the well using a com-pressed air nozzle.

a Remove the screwdriver and repeat the cleaning op-eration for the injector well(s) concerned twice insuccession.


a

a Refit:

- a new compression washer,

- the diesel injector(s),

- the diesel injector bracket,

- the bolt of the diesel injector bracket.

IMPORTANT


114994

Note:

Swivel the cloth covered socket and extensionpiece around inside the well.

114926

WARNING



13B-79


K9K, and 830 or 838

13B

a

a Torque tighten the bolts of the diesel injectorbracket (28 N.m).


a Remove the blanking plug of each diesel injector.

a Refit the high pressure pipe(s) between the injectorrail and the diesel injector(s) (see 13B, Diesel injec-tion, High pressure pipe between rail and injec-tor: Removal - Refitting, page 13B-46) .

a Connect the diesel injector fuel return rail to the die-sel injector.









- select "Injector" in the "List of components storedby this computer" section,


19724

Note:

If reusing a diesel injector, refit the injector in thecylinder marked beforehand. If reusing a dieselinjector, note the alphanumeric code (5) of theinjector and the cylinder on which it is fitted.

13B-80

DIESEL INJECTIONAccelerometer: Removal - Refitting

K9K, and 830 or 838

13B

REMOVAL





a

a Disconnect the accelerometer connector (1) .

a Remove the accelerometer using.

REFITTING


a Refit the accelerometer.

a Torque tighten the accelerometer (20 N.m) usingthe.

a Connect the accelerometer connector.




a Run command RZ004 Pressure regulation adaptive.

a Start the engine and leave it running for a few min-utes whilst depressing the accelerator slightly a fewtimes.

a Switch off the engine.

a Using Diagnostic tool, check that there are nostored faults; deal with them if necessary.







- select "Accelerometer" in the "List of componentsstored by this computer" section,


Equipment required

Diagnostic tool

Tightening torquesm

accelerometer 20 N.m

136390

Note:

Make sure that the metal tabs on the accelerom-eter connector are unlocked correctly to preventbreaking the connector.

13C-1

PREHEATINGPre-postheating unit: Removal - Refitting 13C

REMOVAL




a Remove:




- the air resonator (see 12A, Fuel mixture, Air res-onator: Removal - Refitting, page 12A-1) .

a Remove the air resonator support nuts (1) .

a Move aside the air resonator support.


REFITTING


a Refit the pre-postheating unit.

a Connect the pre-postheating unit connector.


a Fit the air resonator support.

a Refit:

- the air resonator support nuts,

- the air resonator (see 12A, Fuel mixture, Air res-onator: Removal - Refitting, page 12A-1) ,





136669

13C-2

PREHEATINGHeater plugs: Removal - Refitting

K9K, and 832 or 842

13C

REMOVAL


a Remove:

- the engine cover,





a Disconnect:



a Unclip the camshaft position sensor wiring and thedamper valve wiring (4) from the injector rail protec-tor cover.

a Move aside the camshaft position sensor wiring anddamper valve wiring.


a Remove:




Equipment required


heater plug removal tool

hinged wrench for heater plug

Tightening torquesm

heater plugs 15 N.m


5.5 N.m

134043

121889

134699

13C-3


K9K, and 832 or 842

13CII - OPERATION FOR REMOVAL OF PART CONCERNED

a Disconnect the connector (8) from each heater plug.

a Clean around the outside of the heater plugs with acompressed air nozzle to prevent any impuritiesfrom entering the cylinders.

a

a Unscrew the heater plugs (9) using a 10 mm long ra-dio socket connected to a universal joint or a hingedwrench for heater plug.

a Use a hose to unscrew the heater plugs completely(9) .

a Remove the heater plugs.

REFITTING


a Without tightening, fit the heater plugs using thehose.

a Torque tighten the heater plugs (15 N.m).

a Connect the connector for each heater plug.



a Clip:


- the wiring of the camshaft position sensor anddamper valve onto the injector rail protector cover.

134706

IMPORTANT


134707

Note:

If the heater plugs are seized, use the heaterplug removal tool (see Heater plug removaltool: Use) (Technical Note 5197A, 06A, Tooling).

13C-4


K9K, and 832 or 842

13Ca Connect:






a Refit:


- the engine cover.

13C-5


K9K, and 830 or 838

13C

REMOVAL


a Remove:

- the engine cover,



a Remove:




a Disconnect the connector (3) from each heater plug.

a Clean around the outside of the heater plugs with acompressed air nozzle to prevent any impuritiesfrom entering the cylinders.

Equipment required


heater plug removal tool

hinged wrench for heater plug

Tightening torquesm

heater plugs 15 N.m

135878

135861

IMPORTANT


13C-6


K9K, and 830 or 838

13C

a

a Unscrew the heater plugs (4) using a 10 mm long ra-dio socket connected to a universal joint or a hingedwrench for heater plug.

a Use a hose to unscrew the heater plugs completely(4) .

a Remove the heater plugs.

REFITTING


a Without tightening, fit the heater plugs using thehose.

a Torque tighten the heater plugs (15 N.m).

a Connect the connector for each heater plug.




a Refit:


- the engine cover.

135860

Note:

If the heater plugs are seized, use the heaterplug removal tool (see Heater plug removaltool: Use) (Technical Note 5197A, 06A, Tooling).

14A-1

ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting

K9K

14A

REMOVAL






a Remove:

- the bolts (9) from the exhaust gas recirculation so-lenoid valve,

- the exhaust gas recirculation solenoid valve,

- the exhaust gas recirculation solenoid valve seal.

Equipment required

Diagnostic tool

Tightening torquesm

exhaust gas recircula-tion solenoid valve bolts

10 N.m

IMPORTANT


IMPORTANT


K9K, and 832 or 842

135478

135461

14A-2

ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting

K9K

14AREFITTING


a parts always to be replaced: exhaust gas recir-culation solenoid valve seal (11,07,01,13).

a Always replace the clip on the cooling hose betweenthe exhaust gas cooler and the exhaust gas recircu-lation solenoid valve.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean and degrease the joint fa-ces:

- of the exhaust gas recirculation solenoid valve if itis being reused,

- of the exhaust gas recirculation mounting on thegearbox side.


a Refit:

- a new seal on the exhaust gas recirculation sole-noid valve,

- the exhaust gas recirculation solenoid valve.

a Torque tighten the exhaust gas recirculation sole-noid valve bolts (10 N.m).

a Connect the exhaust gas recirculation solenoidvalve connector.









- select "Exhaust gas recirculation solenoid valve" inthe "List of components controlled by this comput-er" section,


K9K, and 832 or 842

14A-3

ANTIPOLLUTIONExhaust gas cooler: Removal - Refitting

K9K, and 830 or 832

14AREMOVAL




a Remove:

- the engine cover,



a Remove:



a Remove:

- the exhaust gas recirculation rigid pipe (see 14A,Antipollution, Exhaust gas recirculation rigidpipe: Removal - Refitting, page 14A-16) ,

- the exhaust gas recirculation assembly (see 14A,Antipollution, Exhaust gas recirculation as-sembly: Removal - Refitting, page 14A-4) .


REFITTING


a parts always to be replaced: exhaust gas coolerseal (11,07,01,17).

a

a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean:

- the exhaust gas cooler joint faces, if they are beingreused,

- the joint face of the exhaust gas cooler mountingon the gearbox end.


- the exhaust gas cooler joint faces, if they are beingreused,

- the joint face of the exhaust gas cooler mountingon the gearbox end.



a Refit:


- the oil vapour rebreathing pipe .


a Refit:


- the engine cover.


a Bleed the cooling system (see 19A, Cooling, Cool-ing system: Draining - Refilling, page 19A-8) .


Note:

Take care not to damage the joint faces of theexhaust gas cooler on its mounting to preventany coolant leaks.

WARNING


14A-4

ANTIPOLLUTIONExhaust gas recirculation assembly: Removal - Refitting

K9K, and 830 or 832

14A

REMOVAL




a Remove:

- the engine cover,





a Remove:






Tightening torquesm


5.5 N.m


5.5 N.m

IMPORTANT


134702

134705

14A-5


K9K, and 830 or 832

14A

a Remove:



- the air inlet metal tube (14) ,

- the air inlet metal tube seals,

- the rigid exhaust gas recirculation pipe (see 14A,Antipollution, Exhaust gas recirculation rigidpipe: Removal - Refitting, page 14A-16) .






a Unclip the hose of the turbocharging pressure regu-lation solenoid valve from the exhaust gas coolercover.

135463 134038

14A-6


K9K, and 830 or 832

14A

a Fit the toolon each cooling hose (19) of the exhaustgas cooler cover.

a Separate the clip (20) of each cooling hose of the ex-haust gas cooler cover (19) on the exhaust gas cool-er cover using the tool (Mot. 1448).

a Disconnect the cooling hoses of the exhaust gascooler cover (20) from the exhaust gas cooler cover.


REFITTING


a Always replace the seals on the air inlet metal tube.

a Use GREY ABRASIVE PADS (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) to clean the joint faces of the ex-haust gas cooler mounting at the gearbox end.


- the housing of each air inlet metal tube seal,

- the housing of the air inlet metal tube in the cylinderhead,

- the housing of the air inlet metal tube in the ex-haust gas cooler mounting on the gearbox end.



a Connect the cooling hoses of the exhaust gas coolercover.

a Fit the clip on each cooling hose of the exhaust gascooler cover using the tool (Mot. 1448).

a Remove the toolon each cooling hose of the exhaustgas cooler cover.

a Clip the hose of the turbocharging pressure regula-tion solenoid valve onto the exhaust gas cooler cov-er.





a Torque tighten the clip of the air filter unit air out-let pipe on the air filter unit (5.5 N.m).


a Refit:

- the air inlet metal tube fitted with new seals,

- the lifting eye on the timing end.

135842

WARNING


WARNING


WARNING


14A-7


K9K, and 830 or 832

14Aa Connect the exhaust gas recirculation solenoid

valve connector.

a Refit:

- the injector rail protector cover mounting,



a Refit:




a Refit:


- the engine cover.



14A-8


K9K, and 838 or 842

14A

REMOVAL


a



a Remove:




a Disconnect:

- the oil vapour rebreathing pipe union from the airfilter unit air outlet pipe (1) ,

- the oil vapour rebreathing pipe from the rocker cov-er (2) .




Tightening torquesm

bolts of the exhaust gasrecirculation assemblyon the cylinder head

25 N.m

bolts of the exhaust gasrecirculation rigid pipeon the exhaust manifold

36 N.m


6 N.m


6 N.m

IMPORTANT


K9K, and 842

144364

14A-9


K9K, and 838 or 842

14A

a Disconnect the oil vapour rebreathing pipe unionfrom the air filter unit air outlet pipe (1) .

a Separate the clip (2) of the oil vapour rebreathingpipe away on the oil vapour rebreathing valve.





a Remove the nut (3) from the breather mounting onthe gearbox.

a Move the breather mounting away from the gearbox.

K9K, and 838

135880

K9K, and 842

K9K, and 838

135879

14A-10


K9K, and 838 or 842

14A

a Remove:

- the bolts (4) of the oil vapour rebreathing valvebracket,



a Remove:


- the oil vapour rebreathing valve.


a Remove:




135845

112325

K9K, and 842

134699

14A-11


K9K, and 838 or 842

14A


a Remove:



a Remove:




K9K, and 838

135878

134702

134705

14A-12


K9K, and 838 or 842

14A

a Remove:



- the air inlet metal tube (14) ,

- the air inlet metal tube seals,

a Remove the rigid exhaust gas recirculation pipe (see14A, Antipollution, Exhaust gas recirculation rig-id pipe: Removal - Refitting, page 14A-16) .





144367

134038

K9K, and 842

144363

14A-13


K9K, and 838 or 842

14A




a Unclip the hose of the turbocharging pressure regu-lation solenoid valve from the exhaust gas coolercover.

a Fit the toolon each cooling hose (19) of the exhaustgas cooler cover.

a Separate the clip (20) of each cooling hose of the ex-haust gas cooler cover (19) on the exhaust gas cool-er cover using the tool (Mot. 1448).

a Disconnect the cooling hoses of the exhaust gascooler cover (20) from the exhaust gas cooler cover.

K9K, and 838

136639

135842

WARNING


14A-14


K9K, and 838 or 842

14AII - REMOVAL OPERATION

a Remove:

- the bolts (21) from the exhaust gas recirculation as-sembly,

- the exhaust gas recirculation assembly.

REFITTING


a Always replace the seals on the air inlet metal tube.

a Use GREY ABRASIVE PADS (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) to clean the joint faces of the ex-haust gas cooler mounting at the gearbox end.


- the housing of each air inlet metal tube seal,

- the housing of the air inlet metal tube in the cylinderhead,

- the housing of the air inlet metal tube in the ex-haust gas cooler mounting on the gearbox end.

a parts always to be replaced: Exhaust gas recir-culation rigid pipe (11,07,01,08).

a parts always to be replaced: Exhaust gas recir-culation pipe seal (11,07,01,15).


a Fit a new exhaust gas recirculation rigid pipe with anew seal on the exhaust gas recirculation assembly.

a Refit the exhaust gas recirculation assemblyequipped with the exhaust gas recirculation rigidpipe on the cylinder head.

a Fit without tightening:

- the bolts of the exhaust gas recirculation assemblyon the cylinder head,

- the exhaust gas recirculation rigid pipe bolts on theexhaust manifold.

Fit and lock the snap-on clip of the exhaust gas recir-culation rigid pipe.

a Torque tighten:

- the bolts of the exhaust gas recirculation as-sembly on the cylinder head (25 N.m),

- the bolts of the exhaust gas recirculation rigidpipe on the exhaust manifold (36 N.m),


a Connect the cooling hoses of the exhaust gas coolercover.

a Fit the clip on each cooling hose of the exhaust gascooler cover using the tool (Mot. 1448).

a Remove the toolon each cooling hose of the exhaustgas cooler cover.

a Clip the hose of the turbocharging pressure regula-tion solenoid valve onto the exhaust gas cooler cov-er.



a Torque tighten the air filter unit air outlet pipe clipon the turbocharger (6 N.m).


144365

WARNING


WARNING


14A-15


K9K, and 838 or 842

14Aa Torque tighten the clip of the air filter unit air out-

let pipe on the air filter unit (6 N.m).


a Refit:

- the air inlet metal tube fitted with new seals,

- the lifting eye on the timing end.

a Connect the exhaust gas recirculation solenoidvalve connector.

a Refit:

- the injector rail protector cover mounting,




a Refit the oil vapour rebreathing valve.


a Refit the oil vapour rebreathing valve bracket.

a Fit the breather mounting on the gearbox.

a Refit the nut of the breather mounting on the gear-box.

a Refit:



a Connect the oil vapour rebreathing pipe:

- on the rocker cover,

- on the air filter box air outlet pipe.


a Fit the clip of the oil vapour rebreathing pipe on theoil vapour rebreathing valve.



a Refit the upper engine tie-bar (see 19D, Enginemounting, Right-hand suspended engine mount-ing: Removal - Refitting, page 19D-5) .

a Refit:


- the engine cover.



K9K, and 842

K9K, and 838

K9K, and 842

K9K, and 838

K9K, and 842

14A-16

ANTIPOLLUTIONExhaust gas recirculation rigid pipe: Removal - Refitting

K9K, and 830 or 832

14A

REMOVAL



a Remove the engine covers.


a Remove:





1 - First fitting

a Remove:

- the exhaust gas recirculation rigid pipe bolts (1) ,

- the snap-on clip (2) of the exhaust gas recirculationrigid pipe using the tool (Mot. 1567),

- the EGR rigid pipe.

2 - Second fitting

a Remove:

- the bolts (4) of the exhaust gas recirculation rigidpipe bracket from the cylinder head,


Mot. 1567 Remote pliers for exhaust gasrecirculation pipe clamps.

Tightening torquesm

EGR rigid pipe bolts 36 N.m

exhaust gas recircula-tion rigid pipe clip

5 N.m

bolts of the exhaust gasrecirculation rigid pipebracket on the cylinderhead

25 N.m

bolts of the exhaust gasrecirculation rigid pipeon the exhaust manifold

36 N.m

bolts of the exhaust gasrecirculation rigid pipeon the exhaust gasrecirculation assembly

12 N.m

113842

138793

14A-17


K9K, and 830 or 832

14A- the bolts (5) of the exhaust gas recirculation rigidpipe from the exhaust manifold,

- the bolts (6) of the exhaust gas recirculation rigidpipe from the exhaust gas recirculation assembly,

- the exhaust gas recirculation rigid pipe,

- the exhaust gas recirculation pipe rigid seal.

REFITTING


a

a Clean using ABRASIVE PADS :

- the joint face of the exhaust gas recirculation as-sembly,

- the exhaust manifold seal face.


- the exhaust manifold joint face,

- the joint face of the exhaust gas recirculation as-sembly.

a

1 - First fitting

a parts always to be replaced: Exhaust gas recir-culation rigid pipe (11,07,01,08)

a parts always to be replaced: Exhaust gas recir-culation pipe clip (11,07,01,14)

a parts always to be replaced: exhaust gas recir-culation pipe bolt (11,07,01,18)

2 - Second fitting


a parts always to be replaced: exhaust gas coolerseal (11,07,01,17)



1 - First fitting

a Refit the new exhaust gas recirculation rigid pipewith a new seal and a new clip.

a Torque tighten:

- the EGR rigid pipe bolts (36 N.m),

- the exhaust gas recirculation rigid pipe clip (5N.m).

2 - Second fitting

a Fit the new exhaust gas recirculation rigid pipe witha new seal.


- the bolts of the exhaust gas recirculation rigid pipeon the exhaust gas recirculation assembly,

- the bolts to the exhaust gas recirculation rigid pipeon the exhaust manifold,

- the bolts to the exhaust gas recirculation rigid pipebracket on the cylinder head.

a Torque tighten:

- the bolts of the exhaust gas recirculation rigidpipe bracket on the cylinder head (25 N.m),

- the bolts of the exhaust gas recirculation rigidpipe on the exhaust manifold (36 N.m),

- the bolts of the exhaust gas recirculation rigidpipe on the exhaust gas recirculation assembly(12 N.m).


a Refit:


- or the catalytic pre-converter (see Catalytic pre-converter: Removal - Refitting) (K9K*734),



a Refit the engine covers.

WARNING


WARNING


14A-18


K9K, and 838 or 842

14A

REMOVAL




a Remove:





a Remove:

- the bolts (1) from the EGR rigid pipe,

- the snap-fit clamp (2) using the (Mot. 1567),

- the rigid exhaust gas recirculation pipe (3) .

REFITTING




a parts always to be replaced: Exhaust gas recir-culation pipe clip (11,07,01,14)

a Use GREY ABRASIVE PADS (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) to clean the bearing face of:



a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to degrease the bearing face of:




a Refit the new rigid pipe, equipped with new bolts onthe manifold and a new seal on the manifold.

a Fit a new snap-fit clip.

a Tighten the bolts of the exhaust gas recirculation rig-id pipe on the manifold until they make contact.

a Adjust the exhaust gas recirculation rigid pipe in re-lation to the exhaust gas recirculation solenoidvalve.

a Lock the snap-fit clip of the rigid exhaust gas recircu-lation pipe using the (Mot. 1567).

a Torque tighten the bolts of the rigid pipe on theexhaust manifold (36 N.m)


a Refit:





Mot. 1567 Remote pliers for exhaust gasrecirculation pipe clamps.

Tightening torquesm

bolts of the rigid pipe onthe exhaust manifold

36 N.m

IMPORTANT


144366

16A-1

STARTING - CHARGINGAlternator: Removal - Refitting

K9K

16A

REMOVAL




a Remove:

- the engine cover,










a Remove:

- the top air deflector of the cooling radiator,





a Unclip the bonnet catch cable (3) on the front endpanel.

a Move aside the bonnet catch cable.

a Unclip the expansion bottle top hose (4) from thefront end panel.

Tightening torquesm

alternator bolts 25 N.m

alternator positive termi-nal nut

8 N.m

IMPORTANT


138486

135883

16A-2


K9K

16A

a Remove the engine wiring channel bolts (5) from thefront end panel.

a Remove:

- the front end panel clips (9) ,

- the front end panel upper bolts (10) .


a Tilt the front end panel towards the front of the vehi-cle.

a Unclip the expansion bottle bottom cooling hose (13)from the high pressure pump protector.

a Unclip the alternator wiring from the injector rail pro-tector.

135882

135719

135881

135884

16A-3


K9K


a Disconnect the alternator excitation connector (16) .

a Remove the nut (17) from the alternator positive ter-minal.

a Move aside the alternator wiring.

a Undo the alternator bolts (18) .

a Remove the alternator bolts (18) as far as possible.

a Move the alternator away from the multifunction sup-port using a screwdriver.

a Remove the alternator with its bolts.

REFITTING


a Compress the alternator rings (19) using pliers and avice to facilitate fitting.


a Refit the alternator equipped with its bolts.

a Torque tighten the alternator bolts (25 N.m).

a Position the alternator wiring.

a Torque tighten the alternator positive terminal nut(8 N.m).

a Connect the alternator excitation connector.


a Clip:

- the alternator wiring on the injector rail protector,

- the expansion bottle bottom cooling hose on thehigh pressure pump protector.

a Fit the front end panel.

a Refit:


- the front end panel upper bolts.

a Refit the front end panel clips.

a Refit the bolts of the engine wiring channel on thefront end panel.

135408

123831

18987

16A-4


K9K

16Aa Clip the expansion bottle top hose onto the front end

panel.

a Fit the bonnet catch cable.

a Clip the bonnet catch cable on the front end panel.

a Refit:








a Refit:







- the engine cover.


16A-5

STARTING - CHARGINGStarter: Removal - Refitting

K9K

16A

REMOVAL



a Remove:

- the engine cover,




a Remove the intercooler air outlet pipe (see 12B,Turbocharging, Intercooler air outlet pipe: Re-moval - Refitting, page 12B-17) .

a Disconnect:

- the connector (1) from the oil pressure sensor,

- the connector (2) from the oil level sensor.

a Loosen the nut on the starter solenoid (3) .

a Remove the nut of the starter supply terminal (4) .

a Move the starter wiring aside.


a Remove:

- the starter bolts (5) ,

- the starter.

Tightening torquesm

starter bolts 44 N.m

starter supply terminalnut

8 N.m

nut on the starter sole-noid

5 N.m

123835

135407

135480

16A-6

STARTING - CHARGINGStarter: Removal - Refitting

K9K

16AREFITTING


a When replacing the starter, remove the starter pro-tective shield.

a Refit the starter protective shield on a new starter.

a Check that the starter centring dowel is in place.


a Refit the starter.

a Torque tighten the starter bolts (44 N.m).


a Fit the starter wiring.

a Torque tighten:

- the starter supply terminal nut (8 N.m),

- the nut on the starter solenoid (5 N.m).

a Connect:

- the oil level sensor connector,

- the oil pressure sensor connector.

a Refit the intercooler air outlet pipe (see 12B, Turbo-charging, Intercooler air outlet pipe: Removal -Refitting, page 12B-17) .


a Refit:


- the engine cover.

19A-1

COOLINGEngine cooling system: Specifications 19A

Vehicles in the current range have cooling systems with the following basic specifications:

- hermetically-sealed pressurised circuit (expansionchamber valve),

- circuit using a “D” type coolant,

- passenger compartment heating systems equippedwith a "heater matrix" type radiator located under thedashboard which helps to cool the engine.

Volume of coolant

Special notes:

- protection down to -25˚C ±±±± 2 for cold and temperatecountries,

- protection down to -37˚C ±±±± 2 for very cold countries.

Thermostat

Engine Quantity(litres)

Grade

H4J 700 6.5

GLACEROL RX(type D)

Only use coolant

K4M 848 5.3

K4M 858 5.3

K4M 866 5.3

F4R 870 6.5

M4R 711 6.8

M4R 713 6.8

K9K 6.5

F9Q 870 6.3

F9Q 872 6.3

M9R 610 7.2

M9R 615 7.5

Engine Start of open-ing (˚C)

Fully open (˚C)

H4J 700 83 95

K4M 848 89 99 ±±±± 2

K4M 858 89 99 ±±±± 2

K4M 866 89 99 ±±±± 2

F4R 870 83 95

M4R 711

Cylinder head thermostat

93.5 96.5

Cylinder block thermostat

80.5 83.5

19A-2

COOLINGEngine cooling system: Specifications 19A

M4R 713

Cylinder head thermostat

93.5 96.5

Cylinder block thermostat

80.5 83.5

K9K 83 95

F9Q 870 83 95

F9Q 872 83 95

M9R 610 89 99 ±±±± 2

M9R 615 89 99 ±±±± 2

19A-3

COOLINGEngine cooling circuit: List and location of components

K9K

19A

K9K, and 830 or 832

Note:

The cooling systems of the K9K*838 and K9K*842engines are the same as those for the K9K*830 andK9K*832 engines but without an exhaust gas recir-culation assembly cooled by engine coolant.

135555

19A-4


K9K

19A

135558

19A-5


K9K

19A

135560

(1) Cooling radiator

(2) Expansion bottle

(3) Coolant-oil heat exchanger

(4) Water pump

(5) Engine

(6) Thermostat

(7) Water chamber

(8) Drain plug

(9) Bleed screws

19A-6


M4R

19A

135609

(1) Engine

(2) Cooling radiator

(3) Heater matrix

(4) Expansion bottle

(5) Water pump

(6) Thermostat

(7) Water chamber

(8) Coolant pump inlet pipe

(9) Throttle valve

(10) Coolant-oil heat exchanger

19A-7


M4R

19A

135610

(11) Bleed screw

(12) Drain plug

19A-8

COOLINGCooling system: Draining - Refilling

K9K

19A

DRAINING


a Remove:

- the engine cover,

- the expansion bottle cap,


- the front sections of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),




a Position the coolant recovery tray under the vehi-cle.

a Open the drain plug (1) for the radiator cooling sys-tem.

a Use a compressed air nozzle to blow air into thesystem through the expansion bottle opening to re-move as much coolant as possible.

CLEANING

a Fill the cooling system with water through the expan-sion bottle.

a Let the water run until the water collected by thecooling radiator bottom hose becomes clear.

a Use a compressed air nozzle to blow air into thecircuit through the expansion bottle opening to re-move as much water as possible.

a Close the drain plug of the radiator cooling system.

FILLING

a

Equipment required

coolant recovery tray


IMPORTANT

When working in the engine compartment, takecare as the radiator fan(s) may start up unexpect-edly (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).

WARNING

Before the operation, protect the electrical accesso-ries to prevent any risk of shor t circuiting and pro-tect the belts to avoid damaging them.

136540

Note:

There are two procedures for filling the cooling system:

- the procedure using the toolrecommended byRenault. It saves a considerable amount of timebecause it does not require the cooling systembleed screws to be opened,

- the procedure without a special tool.

19A-9


K9K

19A

1 - Filling procedure with the tool (Mot. 1700)

a Fill the cooling system with engine coolant recom-mended by the manufacturer (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables - Products) using the tool. Consult the user'smanual for this tool (see Cooling system fillingand diagnostic tool: Use) (Technical Note 3857A,19A, Cooling).

2 - Filling procedure without a special tool

a

Method to access the bleed screws on the heater matrix hose and on the coolant outlet unit

a Remove:

- the bleed screw (2) of the coolant outlet unit,

- the bleed screw (3) of the heater matrix hose.

a Fill the cooling system with engine coolant recom-mended by the manufacturer (see 19A, Cooling,Engine cooling system: Specifications, page

19A-1) and (see Vehicle: Parts and consumablesfor the repair) (04B, Consumables - Products) viathe expansion bottle until it overflows.

a Close all the bleed screws as soon as the coolantstarts to flow in a continuous stream.

a Pressurise the system using theto check that thereare no leaks (see Engine cooling system: Check) .

a Fill the expansion bottle until it overflows.

a Tighten the expansion bottle cap.

WARNING

It is essential to open all of the bleed screws toremove as much as air as possible in the coolingsystem. Failure to perform this procedure mayprevent the cooling system from filling properlyand may damage the engine.

K9K

135560

19A-10


K9K

19Aa Clean any surfaces soiled by the coolant.

BLEEDING

a

a Deactivate the air conditioning system so that thefan assembly is not operating from the start of theoperation.

a Start the engine.

a Maintain the engine speed at 1500 rpm, sharplyvarying the engine speed (up to the maximum) 2 to3 times approximately every 2 minutes until the fanassembly starts for the second time.

a Check that the heating is operating correctly.

a Allow the engine to cool until the coolant tempera-ture is less than 50˚C.

a Make sure the coolant fluid level is at the« Maximum » mark.

a Refit the expansion bottle cap.

FINAL OPERATIONa Remove the coolant recovery tray.

a Refit:


- the front sections of the front wheel arch liners (seeFront wheel arch liner: Removal - Refitting)(55A, Exterior protection),



- the engine cover.

WARNING

Do not open the bleed screw whilst the engine isrunning; this would damage the engine.

19A-11

COOLINGCooling radiator: Removal - Refitting

K9K

19A

REMOVAL



a Remove:

- the engine cover,









a Remove:

- the cooling radiator top air deflector,



- the intercooler air inlet pipe (see 12B , Turbo-charging, Intercooler air inlet pipe: Removal -Refitting, page 12B-12) ,


- the intercooler (see 12B, Turbocharging, Inter-cooler: Removal - Refitting, page 12B-10) ,


a Unclip the air conditioning condenser (2) from thecooling radiator by pulling upwards.

a Slightly separate the air conditioning condenser.



Equipment required

safety strap(s)

IMPORTANT






WARNING


135832

19A-12


K9K

19A

a Using a safety strap(s) (3) , attach the air condition-ing condenser to the front impact cross member.


a Use the tool (Mot. 1448) to separate the cooling ra-diator bottom cooling hose clip (4) from the coolingradiator.

a Disconnect the cooling radiator bottom cooling hosefrom the cooling radiator.

a Use the toolto separate the expansion bottle topcooling hose clip (5) from the cooling radiator.

a Disconnect the expansion bottle top cooling hosefrom the cooling radiator.

a Use the tool (Mot. 1448) to separate the cooling ra-diator top cooling hose clip (6) from the cooling radi-ator.

a Disconnect the cooling radiator top cooling hosefrom the cooling radiator.

135835

135836

135837

19A-13


K9K

19A

a Remove:

- the retaining bracket bolts (7) on the cooling radia-tor,

- the retaining brackets on the cooling radiator.

a Remove the cooling radiator from the front end pa-nel by:

- slightly pulling the cooling radiator towards the frontof the vehicle (8) ,

- pulling the cooling radiator upwards (9) .

REFITTING


a Refit the cooling radiator to the front end panel.

a Connect the cooling radiator top cooling hose to thecooling radiator.

a Fit the clip for the cooling radiator top cooling hoseon the cooling radiator using the tool (Mot. 1448).

a Connect the expansion bottle top cooling hose to thecooling radiator.

a Fit the clip for the expansion bottle top cooling hoseon the cooling radiator using the tool.

a Connect the cooling radiator bottom cooling hose tothe cooling radiator.

a Fit the clip for the cooling radiator bottom coolinghose on the cooling radiator using the tool (Mot.1448).


a Detach the air conditioning condenser from the frontimpact cross member.

135838

135839

135479

19A-14


K9K

19Aa Fit the air conditioning condenser.

a Clip the air conditioning condenser onto the coolingradiator.

a Refit:


- the intercooler (see 12B, Turbocharging, Inter-cooler: Removal - Refitting, page 12B-10) ,


- the intercooler air inlet pipe (see 12B , Turbo-charging, Intercooler air inlet pipe: Removal -Refitting, page 12B-12) ,





a Refit the headlights (see Headlight: Removal - Re-fitting) (80B, Headlights).

a Refit:





- the engine cover.


19A-15

COOLINGCoolant pump: Removal - Refitting

K9K

19A

REMOVAL




a Remove:

- the engine cover,













Tightening torquesm

coolant pump bolts 10 N.m



IMPORTANT


IMPORTANT


IMPORTANT





WARNING


K9K, and 830 or 838

K9K, and 830 or 838

19A-16


K9K

19A




a Remove:

- the inner timing cover bolts (5) ,

- the inner timing cover.


a Remove:

- the coolant pump bolts (9) ,

- the coolant pump,

- the coolant pump seal.

REFITTING


a parts always to be replaced: coolant pump seal(10,06,01,21).


- the coolant pump sealing face if it is to be reused,


123969

123968

WARNING


WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-ger marks).

19A-17


K9K


a Refit:

- a new coolant pump seal,

- the coolant pump,

- the bolts (2) and (5) of the coolant pump.

a Apply one or two drops of FRENETANCHE (seeVehicle: Parts and consumables for the repair)(04B, Consumables - Products) to the coolant pumpbolt (3) .

a Refit:

- the bolt (3) of the coolant pump,

- the bolts (1) and (4) of the coolant pump.

a Torque tighten in order the coolant pump bolts (10N.m).


a Refit the inner timing cover.



a Torque tighten:



a Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting, page 11A-16) .

a Refit the camshaft position sensor (see 13B, Dieselinjection , Camshaft position sensor: Removal -Refitting, page 13B-8) .



a Refit:






- the engine cover.



123968

K9K, and 830 or 838

K9K, and 830 or 838

19A-18

COOLINGThermostat: Removal - Refitting

K9K

19Aa The thermostat cannot be separated from the water

chamber.

Replace the « water chamber - thermostat » assem-bly if the thermostat is faulty (see 19A, Cooling, Wa-ter chamber: Removal - Refitting, page 19A-19) .

19A-19

COOLINGWater chamber: Removal - Refitting

K9K

19A

REMOVAL



a Remove:

- the engine cover,








a Unclip the expansion bottle bottom cooling hosefrom the coolant outlet unit at (1) .



Car. 1363 Set of tr im removal levers.

Tightening torquesm

coolant outlet unit bolts 11 N.m

IMPORTANT


IMPORTANT


IMPORTANT





WARNING


135484

19A-20


K9K

19A

a Remove the clip (2) of the cooling radiator top cool-ing hose (3) from the coolant outlet unit using thetool (Mot. 1448).

a Disconnect the cooling radiator top cooling hose (3)from the coolant outlet unit using the tool (Car.1363).

a Separate the clip (4) of the heater matrix coolinghose (5) from the coolant outlet unit using the tool(Mot. 1448).

a Disconnect:

- the heater matrix cooling hose (5) from the coolantoutlet unit using the tool (Car. 1363).

- the connector (6) from the coolant temperaturesensor.

a Remove:

- the water chamber bolts (5) ,

- the water chamber,

- the water chamber seal.

REFITTING


a parts always to be replaced: Cylinder head cool-ant outlet unit seal (10,06,01,19).



- the coolant outlet unit seal housing if it is to be re-used.

135485 135474

WARNING



19A-21


K9K


a Refit:

- a new coolant outlet unit seal in the coolant outletunit housing,

- the water chamber.

a Torque tighten the coolant outlet unit bolts (11N.m).

a Connect:


- the heater matrix cooling hose to the coolant outletunit.

a Fit the clip on the heater matrix cooling hose ontothe coolant outlet unit using the tool (Mot. 1448).

a Connect the cooling radiator top cooling hose to thecoolant outlet unit.

a Fit the clip of the cooling radiator top cooling hose onthe coolant outlet unit using the tool (Mot. 1448).

a Clip the expansion bottle bottom cooling hose on thecoolant outlet unit.


a Refit:





- the engine cover.


19A-22

COOLINGEngine cooling fan assembly: Removal - Refitting

K9K

19A

REMOVAL




a Remove:

- the engine cover,







a Remove the headlights (see Headlight: Removal -Refitting) (80B, Headlights).


a Remove:

- the top air deflector from the cooling radiator,

- the side air deflectors from the cooling radiator,




a Unclip the expansion bottle top cooling hose (6) fromthe front end panel.

IMPORTANT






WARNING

Before the operation, protect the electrical accesso-ries to prevent any risk of shor t circuiting and pro-tect the belts to avoid damaging them.

WARNING


135883

19A-23


K9K

19A

a Remove the bolts (7) of the engine cooling fan as-sembly wiring channel from the front end panel.

a Remove from the front end panel:

- the clips (8) ,

- the upper bolts (9) .


a Tilt the front end panel slightly towards the front ofthe vehicle.


a Disconnect:

- the fan assembly connector (12) ,

- the fan assembly resistor connector (13) .

a Unclip the fan assembly wiring from the fan assem-bly (14) .

135882

135719

135881

135482

19A-24


K9K

19A

a Remove:

- the bolts (15) from the fan assembly,

- the fan assembly.

REFITTING



a Refit the fan assembly on the front end panel.

a Clip the fan assembly wiring onto the fan assembly.

a Connect the following connectors:

- the fan assembly,

- the fan assembly resistor.


a Fit the front end panel.

a Refit:


- the front end panel upper bolts,

- the bolts of the engine cooling fan assembly wiringchannel on the front end panel.

a Refit the front end panel clips.

a Clip the expansion bottle top cooling hose onto thefront end panel.

a Refit:




- the side air deflectors on the cooling radiator,

- the top air deflector on the cooling radiator.

a Refit the front right-hand bumper supports (seeFront bumper mounting: Removal - Refitting)(42A, Front upper structure).

a Refit the headlights (see Headlight: Removal - Re-fitting) (80B, Headlights).


a Refit:





- the engine cover.


135466

19A-25

COOLINGCoolant pump inlet pipe: Removal - Refitting

K9K

19A

REMOVAL



a Remove:

- the engine cover,






a Drain:


- the refrigerant circuit using a refrigerant chargingstation (see Refrigerant circuit: Draining - Fill-ing) (62A, Air conditioning).

a Remove the oil-water heat exchanger (see 10A, En-gine and cylinder block assembly, Oil-coolantheat exchanger: Removal - Refitting, page 10A-27) .



Car. 1363 Set of tr im removal levers.

Equipment required


Tightening torquesm

coolant pump inlet pipebolt

25 N.m

IMPORTANT


IMPORTANT


IMPORTANT





WARNING


19A-26


K9K


a Remove the thermoplunger unit cooling hose clip (1)from the coolant pump inlet pipe using the tool (Mot.1448).

a Disconnect the thermoplunger unit cooling hose (2)from the coolant pump inlet pipe using the tool (Car.1363).

a Separate the cooling radiator bottom cooling hoseclip (3) from the coolant pump inlet pipe using thetool (Mot. 1448).

a Disconnect the cooling radiator bottom cooling hose(4) from the coolant pump inlet pipe using the tool(Car. 1363).

a Remove:

- the bolt (5) from the coolant pump inlet pipe,

- the coolant pump inlet pipe,

- the coolant pump inlet pipe seal.

REFITTING


a parts always to be replaced: seal between cool-ant pump inlet pipe and coolant pump (10,06,01,22).


- the coolant pump inlet pipe seal housing if it is be-ing reused,

- the seal housing in the cylinder block.

113896

135467

WARNING



19A-27


K9K


a Refit the coolant pump inlet pipe fitted with a newseal.

a Torque tighten the coolant pump inlet pipe bolt(25 N.m).

a Connect the cooling radiator bottom hose to thecoolant pump inlet pipe.

a Fit the cooling radiator bottom hose clip on the cool-ant pump inlet pipe using the tool (Mot. 1448).

a Connect the thermoplunger unit cooling hose to thecoolant pump inlet pipe.

a Fit the thermoplunger unit cooling hose clip to thecoolant pump inlet pipe using the tool (Mot. 1448).


a Refit:

- the coolant-oil heat exchanger (see 10A, Engineand cylinder block assembly, Oil-coolant heatexchanger: Removal - Refitting, page 10A-27) ,





- the engine cover.


- fill and bleed the cooling circuit (see 19A, Cooling,Cooling system: Draining - Refilling, page 19A-8) ,

- fill the refrigerant circuit using a refrigerant charg-ing station (see Refrigerant circuit: Draining -Filling) (62A, Air conditioning).

19A-28

COOLINGCoolant temperature sensor: Removal - Refitting

K9K

19A

REMOVAL



a Remove:

- the engine cover,







a Unclip the expansion bottle bottom cooling hose (1)from the coolant outlet unit.


a Disconnect the coolant temperature sensor connec-tor (2) .

a Remove:

- the clip (3) from the coolant temperature sensor,

- the coolant temperature sensor,

- the coolant temperature sensor seal.

IMPORTANT


IMPORTANT


IMPORTANT





WARNING


135484

114213

19A-29

COOLINGCoolant temperature sensor: Removal - Refitting

K9K

19AREFITTING


a parts always to be replaced: coolant tempera-ture sensor seal (10,06,01,18).


- the mating face of the coolant temperature sensorif it is to be reused,

- the coolant outlet unit.


a Refit:

- a new coolant temperature sensor seal on the cool-ant temperature sensor,

- the coolant temperature sensor,

- the coolant temperature sensor clip.

a Connect the coolant temperature sensor connector.


a Clip the expansion bottle bottom cooling hose on thecoolant outlet unit.

a Refit:





- the engine cover.


19B-1

EXHAUSTExhaust: List and location of components 19B

19B-2


K4M

138076

19B-3


(1) Catalytic converter

(2) Expansion chamber

(3) Silencer

(zc) Area to be cut

19B-4


K9K

138074

19B-5


(1) Intermediate pipe

(2) Silencer

(zc) Area to be cut

19B-6

EXHAUSTCatalytic converter: Removal - Refitting

K9K

19B

REMOVAL




a Remove:

- the engine cover,



a Remove:

- the bolts (1) from the lower engine tie-bar,

- the lower engine tie-bar.


Tightening torquesm

turbocharger studs 9 N.m

catalytic converter nutson the turbocharger

28 N.m

ca ta ly t i c converterupstream strut bolts onthe cylinder block

50 N.m

ca ta ly t i c converterupstream strut bolts onthe catalytic converter

26 N.m

lower engine tie-bar bolton the subframe

180 N.m

lower engine tie-bar bolton the lower engine tie-bar support

180 N.m

IMPORTANT

To avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tion recommendations before carrying out anyrepair (see Exhaust: Precautions for the repair) .

IMPORTANT


IMPORTANT


IMPORTANT

Catalytic converters contain ceramic fibres, theseare contained within a closed unit, and cannot dis-perse. Drilling or cutting catalytic converters is pro-hibited.

K9K, and 832 or 842

134223

K9K, and 830 or 838

19B-7


K9K

19BII - REMOVAL STAGE FOR THE PART CONCERNED.

a Remove the bolts from the exhaust flange (2) fittedwith their springs.

a Move the exhaust pipe to one side.

a Remove the catalytic converter downstream strutbolt (3) from the catalytic converter.

a Undo:

- the catalytic converter downstream strut bolt (4) onthe gearbox,

- the catalytic converter downstream strut nut (5) onthe gearbox,

a Remove the catalytic converter downstream strut bysliding it upwards.

136392

134216

19B-8


K9K

19B

a Undo the catalytic converter upstream strut bolt (6) .

a Remove:

- the catalytic converter upstream strut bolts (7) ,

- the catalytic converter upstream stay,

- the lifting bracket on the timing end,

- the catalytic converter nuts (8) ,

- the catalytic converter,

- the ring of the catalytic converter exhaust flange,

- the seal between the catalytic converter and theturbocharger.

REFITTING


a Always replace the ring of the catalytic converter ex-haust flange.

a parts always to be replaced: seal between turbo-charger and catalytic converter (10,09,01,08)

a Use ABRASIVE PADS to clean the joint face:


- on the catalytic converter in case of reuse,

- the turbocharger.

a Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (04B, Consuma-bles - Products) and CLEAN CLOTHS to degrease the joint face:


- on the catalytic converter in case of reuse,

- the turbocharger.

a If replacing the turbocharger studs, torque tightenthe turbocharger studs (9 N.m).

135486

109399

WARNING


19B-9


K9K

19BII - REFITTING OPERATION FOR PART CONCERNED

a Refit:

- a new seal between the catalytic converter and theturbocharger on the turbocharger,


- the catalytic converter upstream strut.


- the catalytic converter upstream strut bolt on thecylinder block,

- the upstream strut bolt on the sump.

a Refit the catalytic converter downstream strut.


- the catalytic converter downstream strut bolt on thegearbox,

- the catalytic converter downstream strut nut on thegearbox,

- the catalytic converter upstream strut bolts on thecatalytic converter,

- the catalytic converter downstream strut bolt on thecatalytic converter,

- the catalytic converter nuts on the turbocharger.

a Torque tighten:

- the catalytic converter nuts on the turbocharger(28 N.m),

- the catalytic converter upstream strut bolts onthe cylinder block (50 N.m).

a Tighten:

- the catalytic converter downstream strut bolt on themanual gearbox,

- the catalytic converter downstream strut nut on themanual gearbox.

a Torque tighten the catalytic converter upstreamstrut bolts on the catalytic converter (26 N.m).

a Tighten:

- the catalytic converter downstream strut bolt on thecatalytic converter,

- the catalytic converter upstream strut bolt on thesump.

a Refit a new ring on the catalytic converter exhaustflange.

a Fit the exhaust pipe on the catalytic converter.

a Refit the exhaust bracket bolts fitted with theirsprings.


a Refit the lower engine tie-bar.

a Torque tighten:

- the lower engine tie-bar bolt on the subframe(180 N.m),

- the lower engine tie-bar bolt on the lower en-gine tie-bar support (180 N.m).


a Refit:


- the lifting bracket,

- the engine cover.


Note:

Check that there is no contact between the cata-lytic conver ter and the turbocharger oil returnpipe during the entire catalytic converter tighten-ing operation.

K9K, and 832 or 842

K9K, and 830 or 838

19B-10


K4M

19B

REMOVAL




a Remove:

- the downstream oxygen sensor (see Oxygen sen-sors: Removal - Refitting) ,




a Cut the exhaust pipe (see Exhaust: Precautionsfor the repair) in the designated area to be cut (seeExhaust: Parts and consumables for the repair) .

a Remove:



- the exhaust bracket ring.

REFITTING


a Clean the bearing faces of the catalytic converter us-ing ABRASIVE PADS (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products).

Equipment required

component jack

IMPORTANT


IMPORTANT


IMPORTANT

Catalytic converters contain ceramic fibres, theseare contained within a closed unit, and cannot dis-perse. Drilling or cutting catalytic converters is pro-hibited.

WARNING

To prevent the surrounding components from over-heating, do not damage (tear, pierce, bend, etc.) aheat shield.

Any damaged heat shields must be replaced.

Note:

Put a component jack under the catalytic con-verter.

135949

IMPORTANT

Catalytic converters contain ceramic fibres, theseare contained within a closed unit, and cannotdisperse. Drilling or cutting catalytic converters isprohibited.

19B-11


K4M

19Ba Degrease the bearing faces of the catalytic convert-

er using SURFACE CLEANER and clean cloths(see Vehicle: Parts and consumables for the re-pair) (04B, Consumables - Products).


a Position a new after sales sleeve on the catalyticconverter (see Exhaust: Precautions for the re-pair) .


a Refit:



- the exhaust flange bolts.

a Tighten the sleeve bolts while guiding the exhaustpipe to ensure correct alignment.


a Refit:

- the downstream oxygen sensor (see Oxygen sen-sors: Removal - Refitting) ,



a Check:

- that all the exhaust pipe heat shields are in placeand properly attached,

- that there is no contact with the underbody.


a Check that there are no leaks and deal with them ifnecessary.

109399

IMPORTANT

Position the « nut and bolt securing the sleeve »assembly so that the assembly cannot come intocontact with the underbody.

19B-12

EXHAUSTIntermediate pipe: Removal - Refitting

K9K

19B

REMOVING THE INTERMEDIATE PIPE

I - PREPARATION OPERATION FOR REMOVAL OF THE INTERMEDIATE PIPE


a Cut the exhaust system (see Vehicle: Precautionsfor the repair) in the cutting zone provided for thispurpose on either side of the intermediate pipe (seeExhaust: Parts and consumables for the repair) .

II - INTERMEDIATE PIPE REMOVAL OPERATION

a

a Remove:

- the intermediate pipe bolts (1) ,

- the intermediate pipe balance weight (2) ,

- the intermediate pipe.

IMPORTANT


WARNINGTo prevent the surrounding components from over-heating, do not damage (tear, pierce, bend, etc.) aheat shield.


IMPORTANT


135629

Note:

If the rubber mounting bush is damaged, it mustalways be replaced.

19B-13


K9K

19BREFITTING THE INTERMEDIATE PIPE

a

a On the workbench, cut the new intermediate pipe (A) using the tool (see Exhaust: Precautions for the repair) to the following distances from the pipe edge:

- JZXX long chassis = 258 mm,

- JZXX standard chassis / KZXX = 327 mm,

- BZXX / DZXX = 387 mm,

- EZXX = 418 mm.

I - REFITTING OPERATION FOR INTERMEDIATE PIPE

a Refit the intermediate pipe equipped with the inter-mediate pipe balance weight.


a

a Fit new after-sales sleeves (see Exhaust: Precau-tions for the repair) .

a Check:

- that there is no contact with the underbody,

- the presence and correct positioning of all the ex-haust pipe heat shields.



REMOVING THE EXHAUST DOWNPIPE

I - PREPARATION OPERATION FOR REMOVAL OF THE EXHAUST DOWNPIPE


a Cut the exhaust system (see Vehicle: Precautionsfor the repair) in the cutting zone provided for thispurpose on either side of the intermediate pipe (seeExhaust: Parts and consumables for the repair) .

II - EXHAUST DOWNPIPE REMOVAL OPERATION

a Remove:

- the exhaust downpipe bolts (3) from the catalyticconverter,

- the sealing ring of the catalytic converter exhaustflange,

- the exhaust downpipe.

101960

Note:

The new intermediate pipe delivered by the PartsDepartment must be adapted before being fittedon the vehicle.

IMPORTANT


136392

19B-14


K9K

19BREFITTING THE EXHAUST DOWNPIPE

I - PREPARATION OPERATION FOR REFITTING THE EXHAUST DOWNPIPE

a Always replace the catalytic converter exhaustflange sealing ring.

a Clean the bearing face of the exhaust downpipe us-ing SURFACE CLEANER (see Vehicle: Parts andconsumables for the repair) (04B, Consumables -Products).

II - EXHAUST DOWNPIPE REFITTING OPERATION

a Refit:

- the new sealing ring of the catalytic converter ex-haust flange,

- the exhaust downpipe.

a Fit the exhaust downpipe bolts onto the catalyticconverter, without tightening.


a

a Fit a new After-Sales sleeve (see Exhaust: Precau-tions for the repair) .

a Tighten the exhaust downpipe bolts on the catalyticconverter.

a Check:


- the presence and correct positioning of all the ex-haust pipe heat shields.



109399

IMPORTANT


19B-15

EXHAUSTSilencer: Removal - Refitting

K9K

19B

REMOVAL



a Position a component jack under the exhaust si-lencer.


a Remove the silencer bolts (1) .

a Cut the exhaust pipe (see Exhaust: Precautionsfor the repair) in the designated area to be cut (seeExhaust: Parts and consumables for the repair) .

a Remove the exhaust silencer.

REFITTING


a Refit the exhaust silencer using a component jack.

a Fit a new After-Sales sleeve (see Exhaust: Precau-tions for the repair) .


a Check:


- that all the exhaust pipe heat shields are in place.


a Check that there are no leaks.

Equipment required

component jack

IMPORTANT


WARNING



IMPORTANT


135628

IMPORTANT


19C-1

TANKFuel tank: Draining 19C

DRAINING

I - DRAINING PREPARATION OPERATION


II - DRAINING OPERATION

a Unclip the manual fuel priming pump at (1) .

a Disconnect the fuel supply pipe union (2) from themanual fuel priming pump.

a Connect the pneumatic transfer pump for fuels onthe fuel supply pipe of the fuel priming pump.

Equipment required

pneumatic transfer pump for fuels

IMPORTANT




IMPORTANT


IMPORTANT


WARNING


WARNING


K9K

137737

137738

19C-2



a Disconnect the fuel supply pipe union from the injec-tor rail.

a Fit a « T » union at (1) .

a Connect a pneumatic transfer pump for fuels tothe « T » union outlet.

a Disconnect the fuel supply pipe union from the injec-tor rail.

a Fit a « T » union at (1) .

a Connect a pneumatic transfer pump for fuels tothe « T » union outlet.

a Drain the fuel tank.

REFITTING

a Disconnect the pneumatic transfer pump for fuelsfrom the fuel supply pipe of the manual fuel primingpump.

a Connect the fuel supply pipe on the manual fuelpriming pump.

a Refit the manual fuel priming pump.

a Disconnect the pneumatic transfer pump for fuelsfrom the « T » union outlet.

a Remove the « T » union.

a Connect the fuel supply union on the injector rail.


K4M

137771

M4R

115216

K9K

K4M or M4R

19C-3



19C-4

TANKFuel tank: Removal - Refitting 19C

REMOVAL




a Drain the fuel tank (see 19C, Tank, Fuel tank:Draining, page 19C-1) .

a Remove:

- the silencer (see 19B, Exhaust, Silencer: Remov-al - Refitting, page 19B-15) ,

- the connector pipe (see 19B, Exhaust, Intermedi-ate pipe: Removal - Refitting, page 19B-12) .

a Remove:

- the centre heat shield clips (1) ,

- the centre heat shield.

Equipment required

component support

Tightening torquesm

fuel tank bolts 21 N.m

rear heat shield bolts 21 N.m

IMPORTANT




IMPORTANT


IMPORTANT


WARNING


WARNING


WARNING



K9K

137741

19C-5


a Remove:

- the centre heat shield clips (1) ,

- the centre heat shield.

a Remove:

- the rear heat shield bolts (2) ,

- the rear heat shield.

K4M

136442

K9K

137733

19C-6


a Remove:

- the rear heat shield bolts (2) ,

- the rear heat shield.

a Remove the clip (3) from the « filler neck - fuel tank »connecting hose on the fuel tank side.

a Disconnect the anti-return pipe union (4) .

K4M

136447

K4M or K9K

136434

19C-7


a Unclip the rigid brake pipes (5) .

a Move the rigid brake pipes slightly to one side.

K9K

137732

19C-8


a Unclip the rigid brake pipes (5) .

a Move the rigid brake pipes slightly to one side.

a Unclip the fuel pipes (6) from the fuel tank.

a Move the fuel pipesto one side.

K4M

136425

136419

136430

K9K

137735

19C-9


a For vehicles equipped with a tank which has an off-set breather (tank with a breather pipe going fromthe tank to the wheel arch), disconnect the offsetbreather pipe (7) from the fuel tank.

a Unclip the fuel pipes (6) from the fuel tank.

a Move the fuel pipes to one side.

a Disconnect the union of the fuel vapour absorberoutlet pipe (7) .

a Move aside the fuel vapour absorber outlet pipe.

137977

K4M

136419

136432

19C-10



a Disconnect the filler neck hose at the fuel tank end.

a Fit a component support under the fuel tank.

a Undo the fuel tank bolts (8) .

a Gently lower the fuel tank.

a Disconnect:

- the fuel level sensor module connector,

- the fuel level sensor module pipe(s).

a Unclip:

- the fuel level sensor module connector from thetank,

- the fuel level sensor module pipe(s) from the tank.

a Remove:

- the fuel tank bolts (8) ,

- the fuel tank.

If the fuel tank is being replaced

a Remove the fuel level sensor module (see 19C,Tank, Fuel level sensor module: Removal - Refit-ting, page 19C-15) .

REFITTING


a parts always to be replaced: Fuel pipe clip be-tween the fuel tank filler neck and the fuel tank(11,08,01,05).

If the fuel tank is being replaced

a Refit the fuel level sensor module (see 19C, Tank,Fuel level sensor module: Removal - Refitting,page 19C-15) .

K4M or K9K

136423

136415

19C-11


a For vehicles equipped with a tank which does nothave an offset breather (tank without a breather pipegoing from the tank to the wheel arch), the new tankmust be adapted by cutting the breather pipe at (A)with the tool.


a Connect:

- the fuel level sensor module connector,

- the fuel level sensor module pipe(s).

a Clip:

- the fuel level sensor module connector on the tank,

- the fuel level sensor module pipe(s) on the tank.

a Refit the fuel tank.

a Torque tighten the fuel tank bolts (21 N.m).

a Connect the filler neck hose to the fuel tank.

a For vehicles equipped with a tank which has an off-set breather (tank with a breather pipe going fromthe tank to the wheel arch), connect the offsetbreather pipe of the fuel tank.


a Remove the component support.

a Fit the fuel vapour absorber outlet pipe.

a Connect the union of the fuel vapour absorber outletpipe.

a Position the fuel pipes.

K9K

138085

K9K

K4M

19C-12


a Clip the fuel supply pipes onto the fuel tank.

a Fit the rigid brake pipes.

a Clip on the rigid brake pipes.

a Connect the anti-return pipe union.

a Refit a new clip on the fuel tank end of the « fillerneck - fuel tank » connecting hose.

a Refit the rear heat shield.

a Torque tighten the rear heat shield bolts (21 N.m).

a Refit:

- the central heat shield,

- the centre heat shield clips,

- the connector pipe (see 19B, Exhaust, Intermedi-ate pipe: Removal - Refitting, page 19B-12) ,

- the silencer (see 19B, Exhaust, Silencer: Remov-al - Refitting, page 19B-15) .


19C-13

TANKFiller neck: Removal - Refitting 19C

REMOVAL




a Drain the fuel tank (see 19C, Tank, Fuel tank:Draining, page 19C-1) .

a Open the fuel tank flap.

a Remove:

- the bolts (1) from the filler neck on the fuel tankflap,

- the rear right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the rear right-hand wheel arch liner (see Rearwheel arch liner: Removal - Refitting) (55A, Ex-terior protection).

Tightening torquesm

filler neck earth bolts 21 N.m

IMPORTANT




IMPORTANT


IMPORTANT


WARNING


WARNING


WARNING


137736

19C-14

TANKFiller neck: Removal - Refitting 19C


a Remove the earth bolts (2) from the filler neck.

a Disconnect the anti-return pipe (3) .

a Remove the clip (4) from the « filler neck - fuel tank »connecting hose on the fuel tank side.

a Disconnect the filler neck hose from the fuel tank.

a Remove the filler neck.

REFITTING


a parts always to be replaced: Fuel pipe clip be-tween the fuel tank filler neck and the fuel tank(11,08,01,05).


a Refit the filler neck.

a Connect the filler neck hose to the fuel tank.

a Refit a new clip on the « filler neck - fuel tank » con-necting hose.

a Disconnect the anti-return pipe.

a Refit the earth bolts on the filler neck.

a Torque tighten the filler neck earth bolts (21 N.m).


a Refit:

- the rear right-hand wheel arch liner (see Rearwheel arch liner: Removal - Refitting) (55A, Ex-terior protection),

- the rear right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),

- the filler neck bolts on the fuel tank flap.


136440

136434

19C-15

TANKFuel level sensor module: Removal - Refitting 19C

REMOVAL




a Drain the fuel tank (see 19C, Tank , Fuel tank:Draining, page 19C-1) .

a Raise the rear bench seat.

a Remove:

- the subframe panel bolts (1) ,

- the subframe panel (2) ,

- the passenger compartment plastic blanking cover(3) from the fuel level sensor module.

IMPORTANT




IMPORTANT


IMPORTANT


WARNING


WARNING


138147

19C-16



a Disconnect:

- the fuel level sensor module connector (1) ,

- the fuel pipe unions (2) and (3) from the fuel levelsensor module.

a Disconnect:

- the fuel level sensor module connector (1) ,

- the fuel pipe union (2) from the fuel level sensormodule.

a Remove the fuel level sensor module nut (4) usingthe tool.

K9K

137742

K4M

143955

138143

19C-17


a Let the fuel drain from the fuel level sensor module.

a Remove:

- the fuel level sensor module, taking care not todamage the float,

- the fuel level sensor module seal.

REFITTING


a parts always to be replaced: Fuel level sensormodule nut (11,08,02,05).

a parts always to be replaced: Fuel level sensormodule seal (11,08,02,06).


a Position:

- the new seal (5) in the neck correctly,

- the fuel level sensor module (6) on the fuel tank. Alug on the fuel level sensor module and a recess inthe fuel tank ensure correct positioning in the fueltank.

a Use a hand to press the fuel level sensor module togrip the seal.

a Refit a new nut on the fuel tank.

a Tighten the fuel level sensor module nut using thetooluntil the nut mark (7) corresponds with the fueltank mark (8) .

a Connect:

- the fuel pipe unions on the fuel level sensor mod-ule,

- the fuel level sensor module connector.

a Connect:

- the fuel pipe union on the fuel level sensor module,

- the fuel level sensor module connector.


a Refit the passenger compartment plastic blankingcover on the fuel level sensor module.

a Refit the subframe panel of the fuel level sensormodule.

a Refit the rear bench seat.


WARNING

To prevent the tank from deforming, refit the fuelsender unit nut to the tank well immediately.

118996

137740

K9K

K4M

19D-1

ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting

K9K

19D

REMOVAL



a Remove:



a Remove:






a Remove:

- the bolt (1) for the lower engine tie-bar from thesubframe,

- the bolt (2) for the lower engine tie-bar from thelower engine tie-bar support,


Equipment required

indelible pencil

Tightening torquesm

support bolts for the left-hand suspended enginemounting on the gear-box

62 N.m

support bolts for the left-hand suspended enginemounting on the vehiclebody

62 N.m

support bolt for the left-hand suspended enginemount ing on thegearbox62

N.m

upper engine tie-bar bolton the engine

115 N.m

upper engine tie-bar bolton the body

105 N.m


180 N.m


180 N.m

K9K, and 832 or 842

134223

19D-2


K9K

19D

a Remove:



a Unclip the battery wiring channel from the left-handsuspended engine mounting (4) .

a Remove the battery wiring channel from the left-hand suspended engine mounting.

a Fit the tool (5) onto the clutch master cylinder supplyhose.

a Disconnect the hydraulic clutch pipe from the clutchmaster cylinder by pulling on the clip (6) .

K9K, and 832 or 842

134221

135506

134486

19D-3


K9K

19D

a Disconnect the hydraulic clutch pipe from the hy-draulic clutch release bearing by pulling on the clips(7) .


- the opening of the hydraulic clutch release bearing,

- the openings of the hydraulic clutch pipe,

- the opening of the clutch master cylinder.

a Remove the hydraulic clutch pipe.

a Fit the (10) fitted with the (11) .


a Remove the left-hand suspended engine mountingsupport bolt (12) on the gearbox.

a Detach the support on the gearbox from the left-hand suspended engine mounting.

a Mark the position of the left-hand suspended enginemounting support on the vehicle body using a indel-ible pencil.

a Remove:

- the bolts (13) from the left-hand suspended enginemounting support on the body,

135470

138818

134485

135500

19D-4


K9K

19D- the left-hand suspended engine mounting supporton the body.

REFITTING


a Refit the left-hand suspended engine mounting sup-port on the gearbox.

a Torque tighten the support bolts for the left-handsuspended engine mounting on the gearbox (62N.m).

a Fit the left-hand suspended engine mounting sup-port on the body.

a Position the left-hand suspended engine mountingsupport on the body according to the marks madeduring removal.

a Torque tighten:

- the support bolts for the left-hand suspendedengine mounting on the vehicle body (62 N.m),

- the support bolt for the left-hand suspended en-gine mounting on the gearbox62 (N.m).

a Remove thefitted with the.


a Refit the hydraulic clutch pipe.

a Clip the hydraulic clutch pipe onto the left suspend-ed engine mounting.


- the opening of the clutch master cylinder,

- the openings of the hydraulic clutch pipe,

- the opening of the hydraulic clutch release bearing.

a Connect the hydraulic clutch pipe to:

- the hydraulic clutch release bearing,

- the clutch master cylinder.

a Remove the toolfrom the clutch master cylinder sup-ply hose.

a Bleed the hydraulic clutch circuit (see Clutch cir-cuit: Bleed) (37A, Mechanical component controls).

a Fit the battery wiring channel.

a Clip the battery wiring channel onto the left-handsuspended engine mounting.

a Refit the upper engine tie-bar.

a Torque tighten:

- the upper engine tie-bar bolt on the engine (115N.m),

- the upper engine tie-bar bolt on the body (105N.m).

a Refit the lower engine tie-bar.

a Torque tighten:



a Refit:





a Refit:



K9K, and 832 or 842

K9K, and 832 or 842

19D-5

ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - Refitting

K9K

19D

REMOVAL



a Remove:






a Disconnect the fuel return pipe from the diesel injec-tor fuel return rail at (3) .




Tightening torquesm

bolts for the right-handsuspended enginemounting « rubber pad -cover » assembly on thecylinder head

62 N.m

bolts for the right-handsuspended enginemounting « rubber pad -cover » assembly on thebody

62 N.m

bolt for the upper enginetie-bar on the right-handsuspended enginemounting support

115 N.m

upper engine tie-bar bolton the body

105 N.m

IMPORTANT


IMPORTANT




K9K, and 832 or 842

134494

19D-6


K9K

19D

a Disconnect the diesel fuel return pipe from the highpressure pump union at (3) .

a Fit blanking plugs on:

- the opening of the high pressure pump union,


a Disconnect the fuel supply pipe (4) from the manualpriming pump.


- the fuel supply pipe opening,

- the opening of the manual priming pump.

a Unclip the fuel pipes from the right-hand suspendedengine mounting « rubber pad - cover » assembly at(5) .

a Move the fuel pipesto one side.

a Fit the (7) fitted with the (6) .

K9K, and 830 or 838

135412

138815

19D-7


K9K

19DII - OPERATION FOR REMOVAL OF PART CONCERNED

a Remove:





a Raise the engine slightly using the toolequipped withthe tooluntil the right-hand suspended enginemounting « rubber pad - cover » assembly detachesfrom the body.

K9K, and 832 or 842

134221

134495

K9K, and 830 or 838

135411

19D-8


K9K

19D

a Remove:



a Remove:



REFITTING


a Refit:

- the right-hand suspended engine mounting « cover- rubber pad » assembly,

- the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly to thecylinder head.

a Lower the engine using the toolfitted with the toolun-til the right-hand suspended engine mounting« rubber pad - cover » assembly touches the body.

a Refit the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly to thebody.

K9K, and 832 or 842

141500

K9K, and 830 or 838

141499

19D-9


K9K

19Da Torque tighten:

- the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly onthe cylinder head (62 N.m),

- the bolts for the right-hand suspended enginemounting « rubber pad - cover » assembly onthe body (62 N.m).

a Refit the upper engine tie-bar.

a Torque tighten:

- the bolt for the upper engine tie-bar on theright-hand suspended engine mounting sup-port (115 N.m),

- the upper engine tie-bar bolt on the body (105N.m).


a Remove thefitted with the.

a Position the fuel pipes.

a Clip the fuel pipes onto the « rubber pad - cover »assembly of the right-hand suspended enginemounting.


- the opening of the manual priming pump,

- the opening of the fuel supply pipe.

a Connect the fuel supply pipe union to the union ofthe manual priming pump.


- the diesel return pipe opening,

- the diesel injector fuel return rail opening.

a Connect the diesel return pipe to the diesel injectorfuel return rail.


- the diesel return pipe opening,

- the opening of the high pressure pump union.

a Connect the diesel fuel return pipe to the high pres-sure pump union.

a Refit:





K9K, and 832 or 842

K9K, and 832 or 842

K9K, and 830 or 838

19D-10

ENGINE MOUNTINGLower engine tie-bar: Removal - Refitting

K9K

19D

REMOVAL



a Remove:




a Remove:


- the bolt (2) for the lower engine tie-bar from thelower engine tie-bar support,

- the lower engine tie-bar,

- the lower engine tie-bar support bolts (3) ,

- the lower engine tie-bar support.

Tightening torquesm

lower engine tie-barmounting bolts

62 N.m


180 N.m


180 N.m

lower engine tie-bar tierod bolts on the gearbox

105 N.m


105 N.m

K9K, and 832 or 842

134487

19D-11

ENGINE MOUNTINGLower engine tie-bar: Removal - Refitting

K9K

19D

a Undo the bolt (4) for the lower engine tie-bar tie rodon the gearbox.

a Remove:

- the lower engine tie-bar tie rod bolt (5) ,

- the lower engine tie-bar tie rod (6) ,



REFITTING


a Refit the lower engine tie-bar support.

a Torque tighten the lower engine tie-bar mountingbolts (62 N.m).

a Refit the lower engine tie-bar on the subframe.

a Torque tighten:



a Refit:

- the lower engine tie-bar,

- the lower engine tie-bar tie rod.

a Torque tighten:

- the lower engine tie-bar tie rod bolts on thegearbox (105 N.m),

- the lower engine tie-bar bolt on the subframe(105 N.m).



K9K, and 830 or 838

135847

K9K, and 832 or 842

K9K, and 830 or 838

Documents

MR448FLUENCE1.pdf