01 Engine and Peripherals

1
Engine and peripherals

10A
ENGINE AND LOWER ENGINE ASSEMBLY
11A
TOP AND FRONT OF ENGINE
12A
FUEL MIXTURE
12B
TURBOCHARGING
13A
FUEL SUPPLY
13B
DIESEL INJECTION
13C
PREHEATING
14A
ANTIPOLLUTION
16A
STARTING - LOAD
17A
IGNITION
17B
PETROL INJECTION
X84, and J84
JANUARY 2006
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
Renault s.a.s. 2006
17C
LPG INJECTION
19A
COOLING SYSTEM
19B
EXHAUST
19C
RESERVOIR
19D
ENGINE MOUNTING
X84, and J84

JANUARY 2006
"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are
constructed."
Edition Anglaise
All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
Renault s.a.s. 2006
Scnic II - Section 1
Scnic II - Section 1 ContentsPage
Contents
Page
10A
FUEL MIXTURE
Engine identification
10A-1
Specifications
Oil consumption Check
10A-3
Air inlet
12A-12
Oil filter: Removal - Refitting
10A-4
Air resonator: Removal Refitting
12A-1
12A-22
Air filter: Replacement
12A-23
Air filter: Removal - Refitting
12A-24
Oil pressure sensor:

Removal - Refitting
10A-10
Oil level sensor: Removal Refitting
10A-14
General information
10A-15
Air filter unit: Removal Refitting
12A-26
Engine/gearbox assembly:
Removal - Refitting
10A-16
Air inlet duct: Removal Refitting
12A-40
Sump: Removal - Refitting
10A-99
Inlet manifold: Removal Refitting
12A-43
Injector holder shim:

Removal - Refitting
12A-55
Manifolds: Removal Refitting
12A-61
Exhaust manifold: Removal Refitting
12A-64
Throttle valve: Removal Refitting
12A-83
Air inlet flap: Removal Refitting
12A-88
Engine stop device
12A-89
Throttle valve: Cleaning
12A-90
Oil pump: Removal Refitting

Multifunction support:
Removal - Refitting
11A
12A
10A-118
10A-121

Accessories belt: Removal Refitting
Timing belt: Removal Refitting
11A-1
11A-11
Timing chain: Removal Refitting
11A-109
Tightening the cylinder head
11A-110
Cylinder head gasket :

Removal - Refitting
11A-115
Crankshaft seal at timing end

Removal - Refitting
11A-199
Cylinder head: Removal Refitting
11A-202
12B
TURBOCHARGING
Turbocharging pressure
regulation valve
12B-1
Pressure regulator: Checking
12B-5
Contents
12B
13A
TURBOCHARGING
Turbocharger: Removal Refitting
12B-10
Intercooler: Removal Refitting
12B-40
FUEL SUPPLY
Petrol supply circuit
13A-1
Diesel fuel supply circuit
13A-2
Petrol filter: General

information
13A-5
Diesel filter: Removal Refitting
13A-6
Injector rail - Injectors:

Removal - Refitting
13B
13B
13A-14
Fuel pressure
regulator:Checking
13A-20
Electric fuel: Checking
13A-22
DIESEL INJECTION
Specifications
13B-1
DIESEL INJECTION
High pressure pipe:
Checking
13B-66
Diesel injector: check
13B-69
Leak flow from injectors:

Check
13B-70
High pressure pump:

Removal - Refitting
13B-74
Diesel injector: Removal Refitting
13B-104
Diesel injector adjustment

value
13B-120
High-pressure pipe between

the pump and rail: Removal Refitting
13B-122
High-pressure pipe between

the rail and injector: Removal
- Refitting
13B-130
Injector rail: Removal Refitting
13B-141
Rail pressure sensor:

Removal - Refitting
13B-156
Fuel flow actuator: Removal Refitting
13B-163
Fuel pressure regulator:

Removal - Refitting
13B-169
Diesel temperature sensor:

Removal - Refitting
13B-173
Leak flow from injectors:

Check
13B-178
Accelerometer: Removal Refitting
13B-182
Venturi: Removal - Refitting
13B-183
Diesel injector fuel return rail:

Removal - Refitting
13B-185
Diesel injection: Precautions

for repair
13B-16
Location of components
13B-31
Flow regulation solenoid

valve: Removal - Refitting
13B-53
Pressure regulation solenoid

valve: Removal - Refitting
13B-54
Injection warning light
13B-55
Injection / air conditioning

programming
13B-57
Idling speed
13B-60
Injector rail protector:

Removal - Refitting
13B-189
Centralised coolant
temperature management
13B-62
Accelerator pedal sensor

general information
13B-190
Computer configuration
13B-64
Contents
13B
DIESEL INJECTION
14A
Accelerator pedal
potentiometer: Removal Refitting
13B-191
Diesel injection computer:

Removal - Refitting
13B-192
Engine speed and position

sensor: Removal - Refitting
PREHEATING
Pre/postheating unit:
Removal - Refitting
14A
Exhaust gas recirculation

mounting: Removal Refitting
14A-53

rigid pipe: Removal Refitting
14A-54
13B-196
16A
13C
ANTIPOLLUTION
13C-1
STARTING - LOAD
General alternator
information
16A-1
Alternator: Removal Refitting
16A-2
Heater plugs Removal Refitting
13C-2
Starter: Identification
16A-27
Pre-postheating control
13C-9
Starter: Removal - Refitting
16A-28
Alternator pulley: Removal Refitting
16A-46
ANTIPOLLUTION
Petrol vapour rebreathing:
Operation
14A-1
Fuel vapour recirculation

circuit: check
14A-3
Fuel vapour canister:

Removal - Refitting
14A-4
Fuel vapour
canister:Checking
14A-5
Oil vapour rebreathing
14A-6
Exhaust gas recirculation:

Description
Exhaust gas recirculation:
List and location of
components
unit: Removal - Refitting
solenoid valve: Removal Refitting
Intercooler: Removal Refitting
14A-16
14A-24
14A-25
17A
17B
IGNITION
Coils Removal - Refitting
17A-1
Spark plugs
17A-4
PETROL INJECTION
Fuel injection parts
description
17B-1
Oxygen sensors: Removal Refitting
17B-16
Accelerator pedal
potentiometer: Removal Refitting
17B-18
Position and speed sensor
17B-19
Petrol injection computer:

Removal - Refitting
17B-21
17B-23
Immobiliser function
17B-24
14A-37
14A-47
Contents
17B
17C
PETROL INJECTION
17C
LPG INJECTION
Throttle valve: Operating
17B-25
LPG injector: Check
17C-29
Special notes on the system

(when driving)
17B-26
LPG computer: Removal Refitting
17C-30
Conditions for carrying out

fault finding (when driving)
17B-28
Combustion misfire fault

finding
17B-29
19A
Catalytic converter fault

finding
17B-30
Oxygen sensor fault finding
17B-31
LPG INJECTION
COOLING SYSTEM
Engine cooling: Parts and
consumables for the repair
work
19A-1
Engine cooling
19A-2
Specifications
19A-3
Checking
19A-4
Diagram
19A-5
LPG injection: Precautions

for repair
17C-1
Cooling circuit: Draining Refilling
19A-13
LPG tank - pipe neck:

Removal - Refitting
17C-2
Engine cooling circuit:

Cleaning
19A-15
LPG tank: Removal Refitting
17C-4
Cooling circuit: Bleeding
19A-16
LPG tank: Draining
17C-8
Cooling radiator: Removal Refitting
19A-17
LPG level gauge: Removal Refitting
17C-14
Water pump: Removal Refitting
19A-20
LPG expansion valve:

Removal - Refitting
17C-15
Plenum chamber: Removal Refitting
19A-33
LPG pressure sensor:

Removal - Refitting
17C-18
Electric water pump:

Removal - Refitting
19A-36
LPG expansion valve

solenoid valve: Removal Refitting
17C-20
LPG expansion valve outlet

union: Removal - Refitting
Coolant circuit union:
Removal - Refitting
LPG injection rail: Removal Refitting
LPG injector: Removal Refitting
19B
EXHAUST
17C-22
General information
19B-1
17C-23
Pipe assembly
19B-4
17C-24
Catalytic pre-converter:
Removal - Refitting
19B-11
17C-28
Catalytic converter: Removal

- Refitting
19B-16
Expansion chamber:
Removal - Refitting
19B-33
Contents
19B
19C
19D
19D
EXHAUST
Silencer: Removal - Refitting
19B-34
Particle filter: Function
19B-35
Particle filter: Parts

description
19B-36
Particle filter: Removal Refitting
19B-37
Particle filter pressure

sensor: Removal - Refitting
19B-44
Particle filter temperature

sensors: Removal - Refitting
19B-48
Connecting hose: Removal Refitting
19B-51
Particle filter: Cleaning
19B-52
RESERVOIR
Draining the fuel tank
19C-1
Fuel tank: Removal Refitting
19C-6
Fuel tank: Description
19C-9
Filler neck: Removal Refitting
19C-15
Sender unit: Removal Refitting
19C-17
Petrol filter: General

information
19C-21
Pump-sender unit-filter:
Removal - Refitting
19C-22
Fuel level sensor: Checking
19C-26
ENGINE MOUNTING
Suspended engine
mounting: Tightening torque
19D-1
Suspended engine mounting
19D-2
ENGINE MOUNTING
Left-hand suspended engine
Rear suspended engine
19D-9
19D-14

10A
Vehicle type
Engine type
Engine suffix
Cubic
capacity
(cc) 3
Bore (mm)
Stroke
(mm)
Compression
ratio
JM0B
K4J
730
1390
79.5
42 (70)
10:1
JM0H
JM1A
JM0C
761
9.8:1
JM0J
JM1B
JM0Y
K4M
764
1598
79.5
80.5
782
JM0C
10:1
9.8:1
JM0J
JM1B
JM0B
770
JM0U
JM1N
771
JM0B
JM0U
JM1M
F4R
9.8:1
1998
82.7
93
JM1N
JM1U
JM0W
776
9.5:1
JM1T
18.25:1
JM0F
722
JM0T
17.9:1
17.6:1
JM1F
JM02
JM13
JM1E
K9K
724
1461
76
80.5
17.9:1
17.9:1
728
17.6:1
732
15.3:1
10A-1

Vehicle type
Engine type
JM1D
Engine suffix
Cubic
capacity
(cc) 3
Bore (mm)
Stroke
(mm)
804
10A
Compression
ratio
17:1
JM14
JM15
JM17
F9Q
1870
80
93
812
JM0G
18.4:1
JM1G
JM12
JM1K
M9R
700
1995
List of engine Workshop Repair Manuals to be consulted depending on the engine type:
- K4J and K4M engines Technical Note 3784A,
- K9K engine, Technical note 6006A,
- F9Q engine, Technical Note 3652A,
- F4R engine, Technical Note 6027 A,
- M9R engine, Technical Note 6017 A.
10A-2
84
90
15.7:1

Oil consumption Check
PROCEDURE FOR MEASURING OIL
CONSUMPTION
1 - Filling to the maximum level

Switch off the engine.
Note:
The operation should be carried out with the
engine warm after the fan unit has started operating.
Wait 2 minutes for all the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the MAXIMUM mark.
Make a paint mark on both the fuel filler cap and the
sump drain plug in order to be able to check later
that they have not been removed.
2 - Customer driving
Ask the customer to drive approximately 1200 miles
(2000 km) , without letting the oil level reach the
MINIMUM mark.
3 - Topping up
Switch off the engine.
Note:
The operation should be carried out with the
engine warm after the fan unit has started operating.
Wait 2 minutes for all the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the MAXIMUM mark.
Note the quantity of oil added and the mileage covered since the last top-up to maximum level.
4 - Measurement of the oil consumption

Oil consumption = Quantity of topping up oil (in litres)/number of kilometres (in thousands).
10A-3
10A

K4J, and 730 K4M, and 761 or 782
Special tooling required
Mot. 1329
Oil filter removing tool

(76 mm diameter).
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).
Remove the engine undertray.
110385
Position the (Mot. 1329) (1) on the oil filter.

Remove the oil filter.
REFITTING
Lubricate the oil filter seal with new engine oil.
Tighten the oil filter until it comes into contact with
the oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
Top up the engine oil.
Wipe any oil run-off with a cloth.
Refit the engine undertray.
10A-4
10A

K9K, and 722 or 728 or 732
III - FINAL OPERATION

Mot. 1329

(76 mm diameter).

REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift ).
111850

II - OPERATION FOR REMOVAL OF PART
CONCERNED
REFITTING
I - REFITTING PREPARATION OPERATION
II - REFITTING OPERATION FOR PART
CONCERNED
10A-5
10A

10A
F4R, and 770 or 771 or 776

Mot. 1329

(76 mm diameter).
Tightening torquesm
air conditioning compressor strut mounting
bolts
44 Nm
REMOVAL
111852

REFITTING
Refit the air conditioning compressor strut.

Tighten to torque the air conditioning compressor
strut mounting bolts (44 Nm) .
111851
Remove:
- the air conditioning compressor strut mounting
bolts (1) ,
- the air conditioning compressor strut.
10A-6

10A
M9R, and 700
Tightening torquesm
cover
25 Nm
REMOVAL
114779
Remove the cover - filter element assembly.

CONCERNED
114653
Gently loosen the cover (1) .

Allow the engine oil to run down the thread before
removing the cover - filter element assembly.
113320
Remove:
- the filter element (2) from the cover (3) ,
- the O-ring (4) from the cover (3) .
10A-7

10A
M9R, and 700
REFITTING

CONCERNED

Clean the cover.
114780
Refit:
- the new filter element (6) to the cover (7) ,
113869
- the cover - filter element assembly.
Correctly position the new O-ring (5) in its housing

on the cover.
Tighten to torque the cover (25 Nm) .
Lubricate the O-ring with new engine oil.

10A-8

10A
F9Q
REFITTING

Mot. 1329

(76 mm diameter).

Lubricate the new oil filter seal.
If the AC pipe is significantly deformed when the oil filter is removed, there may be a refrigerant leak.
To manage the risk of a leak in the MEGANE II and
SCENIC II equipped with F9Q engine, the ADVICE in
this Technical Note relating to the removal of the oil filter from the TOP OF THE ENGINE must be strictly followed.
II - REFITTING THE OIL FILTER

Tighten the oil filter until it makes contact.
Top up the engine oil (see 05A, Draining - Refilling
).
REMOVAL
Refit:
- the engine undertray,
Remove:
- the engine covers,
- the engine undertray.
Drain the engine oil (see 05A, Draining - Refilling ).
II - REMOVING THE OIL FILTER
115078
From the top of the engine, position the (Mot. 1329)

on the oil filter using an open-jawed spanner 27 mm
in width.
10A-9
- the engine covers.

Oil pressure sensor: Removal - Refitting
10A
M9R, and 700

Mot. 1495-01
22 mm socket for
removing/refitting oxygen sensors.
Tightening torquesm
oil pressure sensor
44 Nm
front end panel lower

mounting bolts
44 Nm
upper mounting bolts of

the front end panel
21 Nm
REMOVAL
112658
Remove:
Disconnect the battery (see 80A, Battery, Battery:

Removal - Refitting ).
- the engine component unit cover mounting bolts

(1) ,
Remove:
- the engine component unit cover.
- the engine protectors,

- the front bumper (see MR 371 Bodywork, 55A Exterior protection, Front bumper ).
115585
Disconnect the engine component unit connectors

(2) .
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Disconnect the screen washer tubes.
10A-10

10A
M9R, and 700

CONCERNED
114933
Unclip the air inlet scoop (6) .

114061
Disconnect the oil pressure sensor connector (8) .
102365
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
10A-11

10A
M9R, and 700
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
Refit the oil pressure sensor.
Tighten to torque the oil pressure sensor (44 Nm)
using the (Mot. 1495-01).
Connect the oil pressure sensor connector.
II - FINAL OPERATION
Refit:
- the front end panel,
115022
- the upper mounting bolts of the front end panel,

- the lower mounting bolts of the front end panel.
Tighten to torque:
- the front end panel lower mounting bolts (44
Nm) ,
- the upper mounting bolts of the front end panel
(21 Nm) .
Clip on the air inlet scoop.
Connect the screen washer tubes.
Fit the bonnet opening cable.
Connect the engine component unit connectors.
Refit:
115021
Remove the oil pressure sensor using the (Mot.

1495-01) (1) .
- the clips,
- the engine component unit cover,
- the engine component unit cover mounting bolts,
Note:
- the front bumper (see MR 371 Bodywork, 55A Exterior protection, Front bumper ),
Be careful not to damage the air conditioning

compressor connector.

- the engine protectors.
Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).
10A-12

10A
F9Q
Use the (Mot. 1495) and tighten to torque the oil
pressure sensor (32 Nm) .

Mot. 1495
22 mm oxygen sensor
removal/refitting socket - 1/2" square drive
and a 24 mm Allen
key.
Connect the oil pressure sensor.
Tightening torquesm
oil pressure sensor
32 Nm
REMOVAL
CONCERNED
115619
Disconnect the oil pressure sensor connector (1) .

Remove the oil pressure sensor (2) using the (Mot.
1495).
REFITTING
CONCERNED
Refit the oil pressure sensor.
10A-13

Oil level sensor: Removal - Refitting
10A
M9R, and 700

Connect the connector to the oil level sensor.
Tightening torquesm
oil level sensor

front right-hand wheel
25 Nm
Refit:
- the heat insulating material around the oil level
sensor,
130 Nm
- the front right-hand wheel.
REMOVAL
Tighten to torque the front right-hand wheel (130

Nm) .

Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
Remove the front right-hand wheel.
Move aside the heat insulating material around the
oil level sensor.
CONCERNED
114932
Disconnect the connector (1) from the oil level sensor.

Remove the oil level sensor.
REFITTING
CONCERNED
Refit the oil level sensor.
Tighten to torque the oil level sensor (25 Nm) .
10A-14

General information
Attach the (Mot. 836-05) fitted with suitable end pieces.

Mot. 836-05
10A
Oil pressure gauge kit.

Start the vehicle.
I - ENGINES AND THEIR MATCHING END PIECES
Carry out the check.

Engine
End pieces
K4J
E+C+F
K4M
E+C+F
F4R
B+F
K9K
E+C+F
F9Q
B+F
Check the values.
Min pressure (bar)

Engine
Engine
suffix
K4J
730
3000 rpm
1.2
3.5
1.2
3.5
1.2
3.5
0.9
760
K4M
M9R
Idling
speed
782
C+F
770
II - PRECAUTION FOR CHECK
F4R
The oil pressure check must be carried out with the engine warm (80C).
771
776
722
III - TEST PROCEDURE
K9K

728
732
804
Remove the oil pressure sensor (see 10A, Engine and

peripherals, Oil pressure sensor: Removal - Refitting ).
F9Q
812
M9R
700

Remove the (Mot. 836-05) with these end pieces.
Refit the oil pressure sensor (see 10A, Engine and peripherals, Oil pressure sensor: Removal - Refitting
).
87363
10A-15

Engine/gearbox assembly: Removal - Refitting
10A
F9Q, and 812

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

Mot. 1202-01
Pliers for large hose

clips.
Mot. 1202-02
Pliers for small hose

clips.
Mot. 1448
Long nose pliers for

hose clips.
Mot. 1390
Support for removing/

refitting the engine gearbox assembly.
Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle Panel
Grille ).
Equipment required
filling station
Tightening torquesm
104343
front end panel upper

mounting bolt
21 Nm

mounting bolt
44 Nm
half sub-frame front

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
wheel bolt
Remove:
- the air filter access panel mounting bolts (1) ,
- the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
130 Nm
REMOVAL
Remove:
104246
- the battery (see 80A, Battery, Battery: Removal Refitting ).
Remove:
- the scuttle panel partition mounting bolts (3) ,
- the scuttle panel partition.
- the front wheels,

- the right and left-hand wheel arch liners,
Drain:
- the gearbox (see 05A, Draining - Refilling, Gearbox ),
- the engine (see 05A, Draining - Refilling, Engine
),
10A-16

10A
F9Q, and 812
102504
Disconnect the connectors (6) .

Unclip the bonnet opening cable (7) .
Remove:
101212
- the clip (8) ,
Remove:
- the mounting bolt (9) .
- the half sub-frame side reinforcements (4) ,
- the front bumper (see MR 371, Bodywork, 55A,

Exterior protection, Front bumper ).
102365
Remove:
- the front end panel mounting bolts (10) ,
Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining - Refilling ).
112660
Remove the air sleeve (5) .
10A-17

10A
F9Q, and 812
106275
109537
Disconnect:
- the hoses from the expansion bottle on the cooling
radiator side (13) ,
- the pressostat connector on the condenser lower
air conditioning pipe (14)
Remove:
- the air conditioning pipes from the condenser (15) .
- the air conditioning pipe between the air conditioning compressor and the dehydration canister (16)
.
112661
WARNING
Plugs must be fitted to the hoses and the expansion valve to prevent moisture from entering the
system.
Disconnect:
- the intercooler hose (11) ,
- the fan unit resistor connector (12) ,
- the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448).
- the fan unit connector.
Unclip the wiring harness from the fan unit.
10A-18

10A
F9Q, and 812
102473
102500
Disconnect the duct (17) .
Remove the air filter outlet duct (21) .
Remove the cooling assembly.
Disconnect the flowmeter connector (22) .
104338
Remove:
- the fuel supply pipe (18) ,
- the fuel return pipe (19) .
101822
Disconnect the computer connectors.
WARNING
Remove:
Follow the cleanliness guidelines closely (see

13B, Diesel injection, Diesel injection: Precautions during repair ).
- the battery tray mounting bolts (23) ,

- the battery tray.
Watch out for diesel fuel splashes when disconnecting the supply union.
Fit plugs on the openings.
Disconnect the water sensor connector (20) .
10A-19

10A
F9Q, and 812
112657
106280
Remove the computer mounting (24) .
104553
Move the retaining tabs (25) slightly away from the

air filter unit upstream air duct.
Remove:
- the air filter unit upstream air duct,
- the air filter unit (26) .
10A-20

10A
F9Q, and 812
104245
104322
Remove the brake servo pipe (31) from the vacuum

pump.
Remove:
- the Protection and Switching Unit mounting bolt,
Disconnect the heating radiator hoses (32) from the

side of the scuttle panel using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
- the fuse box (27) ,

- the relay box (28) .
Disconnect the connectors from the Protection and
Switching Unit.
104085
Remove the gearbox controls, using a screwdriver.

104340
Remove:
- the pre-postheating unit connector (29) ,
- the earth strap (30) .
10A-21

10A
F9Q, and 812

- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (34) .
111879
101740
Pull out clip (33) .

Disconnect the hydraulic clutch supply pipes.
Note:
Plug the pipes to prevent fluid from escaping.
111880
Fit the (Mot. 1390).
102008
Remove:
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ),
10A-22

10A
F9Q, and 812
REFITTING
If carrying out a standard engine replacement operation (see Technical Note 3652A, Diesel engine High pressure Common Rail - 4 cylinders castiron, 10A, Engine and peripherals, Standard replacement ).
Position the engine - gearbox assembly in the
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ) in accordance
with the marks,
- the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ),
102742
- the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt (21
Nm) ,
- the front end panel lower mounting bolt (44 Nm)
,
- the half sub-frame front mounting bolt (105 Nm)
,
- the half sub-frame rear mounting bolt (21 Nm) ,
- the wheel bolt (130 Nm) .
Add the brake fluid to the brake fluid reservoir.
102419
Mark the suspended engine mounting in relation to

the body.
Remove:
IMPORTANT
Correctly attach the brake hose and ABS sensor
wiring.
Do not twist the brake hoses.
- the suspended engine mounting,

Perform the following operations:
- the suspended gearbox mounting,
Rotate the engine - gearbox assembly in order to
remove it.
- bleed the clutch system (see 37A, Mechanical

component controls, Bleeding the clutch system: ),
- top up the gearbox oil (see 05A, Draining - Refilling, Gearbox ),
Remove the engine - gearbox assembly.
10A-23

F9Q, and 812
- top up the engine oil (see 05A, Draining - Refilling, Engine ),
- top up the engine cooling system (see 19A, Cooling, Cooling system: Draining - Refilling ),
- bleed the engine cooling system (see 19A, Cooling, Bleeding the cooling system ).
Fill the coolant circuit using the filling station (see
62A, Air conditioning, Maintenance ).
Refit the battery (see 80A, Battery, Battery: Removal - Refitting ).
Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the system; (see 80C,
Xenon bulbs, Xenon headlights: Adjustment
).
Adjust the headlights (see 80B, Headlights,
Halogen headlights: Adjustment ).
10A-24
10A

10A
K4M, and 761 or 782

AIR CONDITIONING or CLIMATE CONTROL
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Mot. 1390
Drain the coolant circuit using the filling station

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

Equipment required
filling station
2
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
104343
Remove:
wheel bolt

130 Nm

REMOVAL
Remove:

- the front wheels,
Drain:
104246

).
10A-25
Remove:

10A
K4M, and 761 or 782
4
102504

Remove:
101212
- the clip (8) ,
Remove:
- the mounting (9) .

102365
Remove:
- front end panel mounting bolts (10) ,
112660
10A-26

10A
K4M, and 761 or 782
101795
Disconnect the fuel inlet pipe (11) from the injector

rail.
109537
Disconnect the hoses from the expansion bottle on

the cooling radiator side (13) .
Disconnect the pressostat connector from the lower
air conditioning pipe on the condenser (14) .
Remove:
.
WARNING
system.

112661
Disconnect:
10A-27

10A
K4M, and 761 or 782
101807
106280

Unclip the air resonators.
101822

Remove:
- the battery tray.
104553
Remove the air filter unit.
10A-28

10A
K4M, and 761 or 782
104245
Remove:
101812
Remove the brake servo hose (23) .

Switching Unit.
104240
Disconnect:
- hoses (24) and (25) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
- the downstream oxygen sensor connector.
111051
Disconnect the earth strap (22) .
10A-29

10A
K4M, and 761 or 782

- the multifunction switch cable (27) by loosening the
sleeve stop.
K4M, and 782
101743
Unclip the lever cables on the gearbox:

- grip the gearbox control at (A),
- pull the pin at (B),
- lift the gearbox control at (C).
101699
Remove the gearbox controls (28) .

K4M, and 761
103409
Remove:
- the multifunction switch cable ball joint (26) ,
10A-30

10A
K4M, and 761 or 782

- the half sub-frame cross member (30) .
K4M, and 761
101740
111616

Note:
111619
Fit (Mot. 1390).
102008
Remove:
10A-31

10A
K4M, and 761 or 782
K4M, and 782
111620
101866

the body.
Remove the suspended engine mounting.
K4M, and 761
111615
Fit (Mot. 1390).
103273
Remove the suspended engine mounting from the

gearbox.
10A-32

10A
K4M, and 761 or 782

- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ).
K4M, and 782

Tighten to torque:
Nm) ,
,
,
- the half sub-frame rear mounting bolt (21 Nm) .
IMPORTANT
102112
Remove the suspended engine mounting from the

gearbox.

wiring.

remove it.

- top up the engine cooling system (see 19A, Cooling, Cooling system: Draining - Filling ),
REFITTING
If carrying out a standard engine replacement operation (see Technical Note 3784A, Petrol engine - 4
cylinders - K4, 10A, Engine and peripherals,
Standard replacement ).
vehicle.
Refit:

Fill the refrigerant circuit using the filling station

with the marks,
10A-33
K4M, and 782

Bleed the clutch system (see 37A, Mechanical
component controls, Clutch system: Bleeding ).

K4M, and 761 or 782
Note:
).
10A-34
10A

10A
K9K, and 722 or 728
REMOVAL

Car. 1363
Trim removal lever.
Mot. 1202-01

clips.
Remove:
Mot. 1202-02

clips.
Mot. 1448


hose clips.
Mot. 1390
- the front wheels,



Drain:
Equipment required
filling station

).
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
wheel bolts

grille ).
130 Nm
WARNING
Procedure for removing the air inlet duct on the
intercooler (there is a danger of leakage and dislocation if this procedure is not complied with):
- separate the hose, using the (Car. 1363) tool,
- do not use a degreaser, brake cleaning product, or
any other product,
- clean the intercooler bearing face and the hose
using a dry, lint-free cloth,
104343
- refit the clip in the same recess if the hoses are

not replaced,
Remove:
- it is essential to replace the hoses and/or the intercooler if they are damaged.
If this procedure is not followed the pipes may leak

or come undone.

10A-35

10A
K9K, and 722 or 728
104246
Remove:
112660
102504

101212
Remove:
Remove:
- the clip (8) ,

10A-36

10A
K9K, and 722 or 728
102365
Remove:
102514
Remove:
- fuel inlet pipe (11) ,
- fuel return pipe (12) .
WARNING
- Follow the cleanliness guidelines closely (see
13B, Diesel injection, Diesel injection, Precautions during repair ).
- Watch out for diesel fuel splashes when disconnecting the supply union.
10A-37

10A
K9K, and 722 or 728
106275
109537

Remove:
.
112661
Note:
Disconnect:
system.

10A-38

10A
K9K, and 722 or 728
K9K, and 728

Move the turbocharger pressure solenoid valve to
one side.
102473

106280

Disconnect:
- the air duct between the air filter unit and the turbocharger.
- the flowmeter connector (if fitted to the vehicle).
101822

Remove:
- the battery tray.
10A-39

10A
K9K, and 722 or 728
112657
104245
Remove:
Switching Unit.
104553

Remove:
104340
Disconnect:
- the earth strap on the body (27) .
10A-40

10A
K9K, and 722 or 728
102263

pump.
104085
Remove the gearbox controls.
Disconnect the heating radiator hose from the scuttle panel (2 9) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448)
102264
Disconnect the heating radiator hose (30) using the

(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448).
101740

Disconnect the clutch hydraulic control.
10A-41

10A
K9K, and 722 or 728
110317
102008
Remove:
110318
Fit (Mot. 1390).
10A-42

10A
K9K, and 722 or 728
REFITTING
If carrying out a standard engine replacement operation (see Technical Note 6006A, Diesel engine High pressure Common Rail - 4 cylinders castiron, 10A, Engine and peripherals, Standradreplacement ).
vehicle.
Refit:
- the suspended engine mounting following the
marks (see 19D, Engine mounting, Suspended
mounting ),
102114
Tighten to torque:
Nm) ,
,
,
- the wheel bolts (130 Nm) .
IMPORTANT
102112

the body.

wiring.
Remove:

remove it.
- bleed the engine cooling system (see 19A, Cooling, Bleeding the cooling system ),
10A-43

K9K, and 722 or 728
component controls, Clutch system: Bleeding
).
Fill the refrigerant circuit using the filling station

Note:
).
10A-44
10A

10A
K4J, and 730

Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Mot. 1390

grille ).

Equipment required
filling station
2
Tightening torquesm

mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
104343
Remove:
wheel bolt

130 Nm

REMOVAL
Remove:

- the front wheels,
Drain:
104246

).
10A-45
Remove:

10A
K4J, and 730
4
102365
Remove:
101212
Remove:


10
8
101802
Disconnect the fuel supply union (10) .
102504

Remove:
- the clip (7) ,
10A-46

10A
K4J, and 730

Remove:
.
WARNING
system.
112661
Disconnect:
101103
Remove:
- the air resonator mounting (16) ,
- the air resonator.
109537

10A-47

10A
K4J, and 730
101822
104245
Remove:
Remove:
- the battery tray.

Switching Unit.
106280
Remove the computer mounting (18)

111051
10A-48

10A
K4J, and 730
A
C
A
101812
101743
Unclip the lever cables on the gearbox:

104240
Disconnect:
- hoses (23) and (24) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
101699
- the downstream oxygen sensor connector.
10A-49

10A
K4J, and 730
101740
102008
Remove:
Note:

Fit (Mot. 1390).
10A-50

10A
K4J, and 730
REFITTING
vehicle.
Refit:
with the marks,
101866
Tighten to torque:
Nm) ,
,
,
- the wheel bolt (130 Nm) ,
IMPORTANT
102112

the body.
Remove:

wiring.
- the suspended gearbox engine mounting,

remove it.
10A-51

K4J, and 730
).
Fill the coolant circuit using a filling station (see

Note:
).
10A-52
10A

10A
F4R, and 770 or 771 or 776
REMOVAL
Car. 1363
Trim removal lever.
Mot. 1202-01

clips.
Remove:
Mot. 1202-02

clips.
Mot. 1448

hose clips.
- the front wheels,

Mot. 1390
Drain:
Equipment required

),
filling station

Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
wheel bolt
grille ).
2
1
130 Nm
WARNING
Procedure for removing the air inlet duct on the F4R
776 intercooler (there is a danger of leakage and
dislocation if this procedure is not complied with):
Remove:
- detach the hose using the (Car. 1363) ,

any other product,
104343

not replaced,
- always replace the hose and/or the intercooler if
they have been damaged.
or come undone.
10A-53

10A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
104246
Remove:
112660
Remove the sleeve (5) .
101212
Remove:
102504

Unpick the bonnet opening cable (7) .
Remove:
- the clip (8) ,
- the attachment (9) .
10A-54

10A
F4R, and 770 or 771 or 776
F4R, and 776
102365
Remove:
106271
Disconnect the fuel supply pipe (12) from the injector

rail.

Disconnect:
F4R, and 770 or 771
- the fan unit connectors.
F4R, and 776
101795

rail.
101807
Remove the intercooler air duct (13) .
10A-55

10A
F4R, and 770 or 771 or 776
109536
109536
Disconnect:
Disconnect:
- the turbocharging pressure sensor connector (14) .
- the cooling radiator expansion bottle hoses (19) ,
- the air temperature sensor connector (15)

Remove:
Remove the air duct (17) .
.
WARNING
F4R, and 770 or 771
system.
101807
10A-56

F4R, and 770 or 771 or 776
101822

Remove:
- the battery tray.
10A-57
10A

10A
F4R, and 770 or 771 or 776
F4R, and 776
106280
106278
Remove the computer mounting (28)

Unclip the air resonators.
106632
Move the fuel vapour recirculation solenoid valve to

one side (24) .
104553

Undo bolt (25) .
Pull the mounting bracket away from the electric
coolant pump.
Move aside the electric coolant pump (26)
Remove the electric pump mounting (27) .
10A-58

10A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
104245
Remove:
101812


Disconnect the relay plate wiring harness connectors.
F4R, and 776
106787
111051
10A-59

10A
F4R, and 770 or 771 or 776
F4R, and 770
104240
Disconnect hoses (34) and (35) using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448).
101699
F4R, and 770 or 771

Disconnect the downstream oxygen sensor connector.
F4R, and 771
A
C
A
101743
Unpick the lever cables on the gearbox:

103409
Remove:
- the multifunction switch cable ball joint (37) ,
10A-60

10A
F4R, and 770 or 771 or 776

- the multifunction switch cable (38) by unlocking the
sleeve stop.
F4R, and 770 or 776
F4R, and 776
101740

Note:
104085
Remove the gearbox controls.
10A-61

10A
F4R, and 770 or 771 or 776
F4R, and 770 or 776
109534
102008
Remove:
- the front right-hand driveshaft (see 29A Driveshafts, Front right-hand driveshaft),
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft),
109533
10A-62

10A
F4R, and 770 or 771 or 776
F4R, and 771
111617
102742

the body.
F4R, and 770 or 776
111618
102112
Remove the suspended gearbox mounting.
10A-63

10A
F4R, and 770 or 771 or 776
REFITTING
F4R, and 771
vehicle.
Refit:
with the marks,
- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ).
- the front right-hand driveshaft (see 29A Driveshafts, Front right-hand driveshaft),
103273
Remove the suspended gearbox mounting.
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft),
Tighten to torque:
Nm) ,
,
,
- the wheel bolt (130 Nm) ,
IMPORTANT
wiring.
109535

remove it.

10A-64

F4R, and 770 or 771 or 776
- fill the coolant circuit using a filling station (see
F4R, and 770 or 776
component controls, Clutch system: Bleeding ).

Note:
).
10A-65
10A

10A
F9Q, and 804


Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Mot. 1390

Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle Panel
Grille ).
Equipment required
filling station
Tightening torquesm
104343

mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
wheel bolt
Remove:
130 Nm
REMOVAL
Remove:
104246
Remove:
- the front wheels,

Drain:
- the engine (see 05A, Draining - Refilling, Gearbox ),
10A-66

10A
F9Q, and 804
101212
112660
Disconnect the electric coolant pump.

Move the electric coolant pump to one side.
Remove:

112658
Remove:
- the air duct (5) ,
- the relay plate cover mounting bolts (6) .
10A-67

10A
F9Q, and 804
8
7
10
9
12
102504
106275

Remove:
- the clip (9) ,
13
11
112661
Disconnect:
102365
Remove:

10A-68


10A
F9Q, and 804
17
14
15
18
16
109537
102473
Disconnect:

radiator side (14) ,

Remove:
.
WARNING
21
system.
19
20
104338
Remove:
WARNING
Follow the cleanliness guidelines closely (see
Watch out for diesel fuel splashes when disconnecting the supply union.
Disconnect the water sensor connector (21) .
Insert plugs into the openings.
10A-69

10A
F9Q, and 804
23
26
22
24
112657
25
112659
Disconnect the computer connectors (22) .

Detach:
- the wiring harness from the battery negative terminal connector,
- the wiring harness (23) .
Remove:
27
- the battery tray,

- the mounting bolt (25) from the wiring harness.
Move the turbocharging pressure regulator solenoid
valve wiring harness to one side.
Disconnect the flowmeter connector.
Remove the air duct between the air filter unit and
the turbocharger.
104553

Remove:
10A-70

10A
F9Q, and 804
112459
Remove the brake assistance pipe from the vacuum

pump.
104245
Disconnect the heating radiator hoses (30) from the

side of the scuttle panel using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
Remove:
Switching Unit.
104085
Remove the gearbox controls, using a screwdriver.
104340
Remove:
- the pre-postheating unit connector (30) .
- the earth strap (31) ,
10A-71

10A
F9Q, and 804

111879
101740
Pull the clutch pipes clip (31) .

Note:
111880
102008
Remove:
10A-72

10A
F9Q, and 804
REFITTING
vehicle.
Refit:
with the marks,
102742
Tighten to torque:
Nm) ,
,
,
102419

the body.
Remove:
IMPORTANT
wiring.

remove it.

component controls, Bleeding the clutch system: ),
10A-73

F9Q, and 804
Note:
essential to initialise the system (see 80C,
Xenon bulbs, Xenon headlights: ). Adjustment ).
10A-74
10A

10A
K9K, and 732

WARNING
Car. 1363
Trim removal lever.
Mot. 1202-01

clips.

intercooler (there is a danger of leakage and dislocation if this procedure is not complied with):
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Mot. 1390

any other product,


not replaced,
- it is essential to replace the hoses and/or the intercooler if they are damaged.
Equipment required
filling station

or come undone.
Tightening torquesm
REMOVAL

mounting bolts
105 Nm
half sub-frame rear

mounting bolts
21 Nm
ball joint bracket bolts

with their springs
21 Nm
battery tray mounting

bolts
21 Nm

mounting bolt
44 Nm

mounting bolt
21 Nm
- the front wheels,
side reinforcement
mounting bolts
21 Nm

Remove:
wheel bolts

130 Nm
Drain:
),
grille ).
10A-75

10A
K9K, and 732
104343
Remove:
101212
Remove:
- the side reinforcement mounting bolts,
104246
Remove:
10A-76

10A
K9K, and 732
102504
Disconnect the connectors (7) from the Protection

and Switching Unit.
Unpick the bonnet opening cable (8) .
112660
Remove:
- the clips (9) ,
- the upper mounting bolts (10) .
102365
112658
Remove:
Remove:
- the air sleeve (5) ,
- the Protection and Switching Unit cover mounting

bolts (6) .

10A-77

10A
K9K, and 732
106275
109537

Remove:
.
Note:
112661
Disconnect:
10A-78
system.

10A
K9K, and 732
102473
112656
Disconnect the air duct from the intercooler (18) .
Remove:

WARNING
- Watch out for diesel fuel splashes when disconnecting the supply union.
10A-79

10A
K9K, and 732
112657
112659

Unclip:
- the wiring harness from the battery negative terminal,
- the wiring harness (22) from the computer connector.
Remove:
- the battery tray.
Move the turbocharger pressure solenoid valve to
one side.
104553
Disconnect the air flowmeter connector.

Remove the air duct between the air filter unit and
the turbocharger.
Move the retaining tabs (24) slightly away from air filter unit upstream air duct.
Remove:
10A-80

10A
K9K, and 732
104245
112946

pump.
Remove:
Disconnect:
- the heating radiator hose from the scuttle panel

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

Switching Unit.
104340
Disconnect:
- the earth strap on the body (29) .
10A-81
- the heating radiator hose (32) using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448).

10A
K9K, and 732
104085
101740

112947

102008
Remove:
- the ball joint bracket bolts with their springs,
- the half sub-frame mounting bolts,
10A-82

10A
K9K, and 732

CONCERNED
112814
112654
112813
Fit (Mot. 1390).
112655

the body.
Remove:
- the acoustic mass,
- the suspended gearbox mounting.
remove it.
10A-83

10A
K9K, and 732
REFITTING
Refit:


CONCERNED
IMPORTANT
wiring.
Connect the clutch hydraulic control.
Push in the clip.

vehicle.
Refit the gearbox controls.
Refit:
- the heater radiator hose using the (Mot. 1202-01)

or (Mot. 1202-02) or (Mot. 1448).
- the suspended engine mounting following the
marks (see 19D, Engine mounting, Suspended
mounting ),
Connect:
- the heater radiator hose from the scuttle panel

using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448).
Reconnect the brake assistance pipe to the vacuum
pump.
Connect:
- The acoustic mass (see 19D, Engine mounting,

Suspended mounting ).
- the pre-postheating unit connector,
- the earth strap on the body shell,
- the Protection and Switching Unit connectors.

Remove the (Mot. 1390).
Refit:
- the relay box,
- the fuse box,
Refit:
- the half sub-frame,
- the air filter unit,

- the air duct upstream of the air filter.
- the half sub-frame mounting bolts.
Refit the air duct between the air filter unit and the
turbocharger
Tighten to torque:
- the half sub-frame front mounting bolts (105
Nm) ,
Connect the air flowmeter connector.
- the half sub-frame rear mounting bolts (21 Nm) .
- the turbocharging pressure adjustment solenoid

valve,
Refit:
Refit:
- the battery tray,
- ball joint bracket bolts with their springs.
Tighten to torque the ball joint bracket bolts with
their springs (21 Nm) .
10A-84
- the battery tray mounting bolts.

Tighten to torque the battery tray mounting bolts
(21 Nm) .
Fit:
- the wiring harness for the computer connector,

10A
K9K, and 732

- the battery negative terminal connector wiring harness.
Connect the computer connectors.
Remove the blanking plugs.
- the air filter hose,

Exterior protection, Front bumper ),
- the half sub-frame side reinforcements,
Refit:
- the side reinforcement mounting bolts.
- the fuel return pipe,
Tighten to torque the side reinforcement mounting bolts (21 Nm) .
- the fuel supply pipe,

- the cooling system.
Refit:
Connect the air duct to the intercooler.

Refit:
- the scuttle panel partition,
- the air conditioning pipe between the air conditioning compressor and the dehydration canister.
- the scuttle panel partition mounting bolts,

- the air conditioning pipes to the condenser.

- the air filter access panel mounting bolts,
Connect:
air conditioning pipe,
- the scuttle panel grille (see MR 371 Bodywork,

55A, Exterior protection, Scuttle panel grille ).

radiator side,
Fit the fan unit wiring harness.

Connect:
- the fan unit connector,
- the fan unit resistor connector,
- the intercooler hose,

),
),
- top up the cooling circuit (see 19A, Cooling, Cooling circuit: Draining - Filling ),
Refit:
- bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ),

- the front end panel lower mounting bolts.
- fill the coolant circuit using the filling station (see

- the front end panel upper mounting bolts,

Tighten to torque:
,

Refit:

Nm) ,
Refit clips.
- the front wheels.
Tighten to torque the wheel bolts (130 Nm) .
Connect the Protection and Switching Unit connectors.
Refit:
Refit:
- the Protection and Switching Unit cover mounting

bolts,
10A-85

K9K, and 732
Note:
Xenon bulbs, Xenon headlight: Adjustment ).
10A-86
10A

10A
M9R, and 700
REMOVAL

Car. 1363
Trim removal lever.
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Remove:
Mot. 1448

hose clips.
Mot. 1390

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

- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting ),
- the right-hand and left-hand wheel arch liners,
Equipment required
filling station
Drain:
Tightening torquesm
half sub-frame mounting nuts
21 Nm
half sub-frame mounting bolts
105 Nm
side stiffener mounting

bolts
21 Nm

with their springs
21 Nm
engine accessories unit

mounting bolt
10 Nm
turbocharger outlet air

pipe on the intercooler
side
5.5 Nm
connecting hose mounting bolts
8 Nm
intercooler outlet air

pipe clip
5.5 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm

),
Remove the scuttle panel grille (see Workshop Repair Manual 371 Bodywork, 55A, Exterior protection, Scuttle panel grille ).
104343
Remove:
- the mounting bolts (1) from the air filter access panel,
- the mounting bolt (2) from the scuttle panel partition.
10A-87

10A
M9R, and 700
104246
Remove:
- the radiator tank partition mounting bolts (3) ,
112658
Remove:
- the engine accessories unit cover mounting bolts
(5) ,
114933
115585

Disconnect the connectors (6) from the engine accessories unit.
Remove:
- the clips (8) ,
- the front end panel upper mounting bolts (9) .
Disconnect the screen washer pipes.
10A-88

10A
M9R, and 700
102365
Remove:
- the front end panel lower mounting bolts (10) ,
Drain the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling ).
Clean the engine cooling system (see 19A, Cooling, Engine cooling system: Cleaning
Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting ).
115023
Remove the mounting bolt (11) from the intercooler

outlet air pipe.
Loosen the intercooler outlet air pipe clip (12) on the
intercooler side.
Disconnect:
- the hoses between the expansion bottle and the
cooling radiator (13) on the cooling radiator side,
- the evaporator-condenser connecting hose pressure sensor connector (14) .
Unclip the pressure sensor connector wiring harness on the fan unit.
Remove:
- the evaporator-condenser connecting hose mounting bolt (15) on the condensor side,
- the condensor-compressor connecting hose mounting bolt (16) on the condensor side,
- the compressor-dehydration canister connecting
hose mounting bolt (17) on the dehydration canister side.
10A-89

10A
M9R, and 700

Disconnect:
- the evaporator-condenser connecting hose on the
condensor side,
- the condensor-compressor connecting hose on the
condenser side,
hose on the dehydration canister side.
Note:
Plugs must be fitted on the pipes, the dehydration canister and the condenser to prevent moisture from entering the circuit.
112661
Disconnect:
115702
Undo the intercooler outlet air pipe clip (18) on the

damper valve side.
Disconnect the intercooler outlet air pipe on the intercooler side.
10A-90

10A
M9R, and 700
115703
115209
Detach the hose using the (Car. 1363).
Disconnect:
Undo the turbocharger outlet air pipe clip (20) on the

intercooler side.
Remove the clip (21) from the cooling radiator top

hose, using the (Mot. 1202-01) or the (Mot. 120202) or the (Mot. 1448).
Disconnect:
- the fuel return pipe (23) from the diesel filter,

- the fuel return pipe (24) on the fuel pipe,
WARNING
- the cooling radiator top hose.

- the turbocharger outlet air pipe on the intercooler
side.

- Watch out for diesel fuel splashing when disconnecting the supply union.
Fit blanking plugs in the fuel pipe openings.
115202
Remove the engine accessories unit mounting bolt

(25) .
10A-91

10A
M9R, and 700
115203
Remove the engine accessories unit support (26) .
115205
115204
Remove:
- the fuse holder (27) ,
104340
Disconnect the pre-postheating unit connector (30) .

Remove the earth strap mounting nut (31) on the body.
Disconnect the earth strap from the body.
10A-92

10A
M9R, and 700
115207
104085
Disconnect the brake servo pipe mounting connector (32) on the vacuum pump.
Remove the clip (33) from the plenum chamber heater radiator hose using the (Mot. 1202-01) or the
(Mot. 1202-02) or the (Mot. 1448).
Disconnect:
- the heater radiator hose from the plenum chamber,
- the plenum chamber heater radiator hose, by
squeezing the clip (34) .
Note:
Position the gear lever in fourth gear to remove
the gear levers.
115212
10A-93

10A
M9R, and 700
115003
101212
Pull the clip (36) .
Remove:
- the side stiffener mounting bolts,

- the side stiffeners (38) .
114992
Remove:
102008
- the ball joint bracket bolts (37) with their springs,
Remove:
- the rear suspended engine mounting (see 19D,

Engine mounting, Rear suspended engine
mounting: Removal - Refitting ),
- the half sub-frame mounting nuts (39) ,
10A-94
- the half sub-frame mounting bolts (40) ,

- the half sub-frame.

10A
M9R, and 700

CONCERNED
115000
115208
Remove the left-hand suspended engine mounting

nut (41) .
114999
Position the (Mot. 1390).
116055
Remove:
- the sound insulation mounting bolt (42) ,
- the sound insulation.
Unclip the manual priming pump from its support.
Mark the right-hand suspended engine mounting in
relation to the bodywork.
Remove:
- the manual priming pump support,
10A-95

10A
M9R, and 700

Clean the intercooler bearing face and the hoses
using a dry, lint-free cloth.
- the bolt (43) securing the right-hand suspended engine mounting on the engine stand,
- the bolts (44) securing the right-hand suspended
engine mounting on the body,
- the upper engine tie-bar mounting bolts,

CONCERNED
Position the engine and gearbox assembly in the
vehicle.
- the upper engine tie-bar (45) .
Refit the gearbox suspended engine mounting.

Fit without tightening the gearbox suspended engine
mounting bolts.
Tighten to torque the gearbox suspended engine
mounting bolts (see 19D, Engine mounting, Suspended engine mounting: Tightening torque ).
Fit without tightening the left-hand suspended engine mounting nut
Refit the upper engine tie-bar.
Screw without tightening:
- the right-hand suspended engine mounting bolts
on the body by aligning the marks,
- the bolts securing the right-hand suspended engine mounting on the engine stand.
Tighten to torque:
115321
Remove:
- the mounting bolts (46) from the gearbox suspended engine mounting,
- the gearbox suspended engine mounting.
Rotate the engine and gearbox assembly in order to remove it.
Remove the engine and gearbox assembly.
- the left-hand suspended engine mounting nut (see

19D, Engine mounting, Suspended engine
mounting: Tightening torque ),
- the upper engine tie-bar mounting bolts (see 19D,
Engine mounting, Suspended engine mounting: Tightening torque ),
- the bolts mounting the right-hand suspended engine mounting on the body (see 19D, Engine mounting, Suspended engine mounting: Tightening
torque ),
- the bolts securing the right-hand suspended engine mounting on the engine stand (see 19D, Engine
mounting, Suspended engine mounting: Tightening torque ).
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 6017A, Diesel engine - M9R,
10A, Engine and peripherals, Normal replacement ).
Refit the manual priming pump support.

Clip the manual priming pump on its support.
Refit:
- the sound insulation,
WARNING
- the sound insulation mounting bolt,
Do not use degreaser, brake cleaner or any other

product.
Tighten to torque the sound insulation mounting bolt

(see 19D, Engine mounting, Suspended engine
mounting: Tightening torque ).
It is essential to replace the hose and/or the

intercooler if they are damaged.
10A-96

10A
M9R, and 700

Apply HIGH RESISTANCE BOLT LOCKING
AGENT part no. 77 11 230 112 to the half sub-frame
mounting bolts.
Refit the half sub-frame.
Fit the clip to the plenum chamber heater radiator

hose using the (Mot. 1202-01) or the (Mot. 1202-02)
or the (Mot. 1448)
Connect:
- the brake servo pipe mounting connector on the
vacuum pump,
- the earth strap on the body.
Refit the earth strap nut on the body.
- the half sub-frame mounting nuts.
Connect:
Tighten to torque:
- the pre-postheating unit connector,
- the half sub-frame mounting nuts (21 Nm) ,
- the engine accessories unit connectors.
- the half sub-frame mounting bolts (105 Nm) .
Refit:
Refit:
- the relay box,
- the side stiffeners,
- the fuse holder,
- the side stiffener mounting bolts.

Tighten to torque the side stiffener mounting bolts
(21 Nm) .
Refit:
mounting: Removal - Refitting ).
Tighten to torque the rear suspension (see 19D, Engine mounting, Suspended engine mounting: Tightening torque ).
- the engine accessories unit mounting,

- the engine accessories unit mounting bolt.
Tighten to torque the engine accessories unit
mounting bolt (10 Nm) .
Remove the blanking plugs from the fuel pipes.
Connect:
- the fuel return pipe to the fuel pipe,
- the fuel return pipe to the diesel filter,
- the fuel supply pipe.
Refit the cooling assembly.
Connect:
- the cooling radiator bottom hose,
Refit the ball joint bracket balls with their springs.

Fill the gearbox with oil (see 05A, Draining-Filling,
Gearbox ).
Connect the clutch hydraulic control.
- the cooling radiator top hose.

Fit:
- the cooling radiator bottom hose clip, using the
(Mot. 1202-01) or the (Mot. 1202-02) or the (Mot.
1448) ,
- the cooling radiator top hose clip, using the (Mot.
1202-01) or the (Mot. 1202-02) or the (Mot. 1448).
Push in the clip.

component controls, Clutch circuit: Bleeding ).
Connect the turbocharger outlet air pipe on the intercooler side.
Note:
Tighten to torque the turbocharger outlet air pipe

on the intercooler side (5.5 Nm) .
Position the gear lever in fourth gear to refit the

gear levers.
Connect the fan unit connector.

Clip the fan unit wiring harness into place.
Refit the gearbox controls.
Connect the fan unit resistor connector.
Clip on the plenum chamber heater radiator hose.

Connect the plenum chamber heater radiator hose.
10A-97
Remove the blanking plugs from the air conditioning

pipes, condenser and dehydration canister.

10A
M9R, and 700

Connect:
hose on the dehydration canister side,
- the condensor-compressor connecting hose on the
condenser side,
- the evaporator-condenser connecting hose on the
condensor side.
Refit:
hose mounting bolt on the dehydration canister side,
- the condensor-compressor connecting hose mounting bolt on the condensor side,
- the evaporator-condenser connecting hose mounting bolt on the condensor side.
Tighten to torque the connecting hose mounting
bolts (8 Nm) .
- the front end panel upper mounting bolts (21

Nm) .
Refit the clips.
Refit:
- the engine accessories unit mounting bolts,
Exterior protection, Front bumper: Removal Refitting ),
Connect the evaporator-condenser connecting hose

pressure sensor connector.
Clip the pressure sensor connector wiring harness

on the fan unit.
- the front wheels (see 35A, Wheels and tyres,

Wheel: Removal - Refitting ),
Connect:
- the hoses between the expansion bottle and the

cooling radiator on the cooling radiator side,
- the intercooler outlet air pipe on the intercooler side.

Tighten to torque the intercooler outlet air pipe
clip (5.5 Nm) .
Refit the intercooler outlet air pipe mounting bolt on
the intercooler side.
Refit the air filter unit (see 12A, Fuel mixture, Air filter unit: Removal - Refitting ).

55A, Exterior protection, Scuttle panel grille:
Fill up the engine oil (see 05A, Draining-Filling, Engine ).
Refit:
- fill the coolant circuit using the filling station (see

62A, Air conditioning, Maintenance ),
- fill the cooling system (see 19A, Cooling, Cooling

system: Draining - Refilling ).

Refit the front end panel.
- bleed the cooling system (see 19A, Cooling, Cooling system: Bleeding ),

Tighten to torque:
- adjust the xenon headlights (if fitted to the vehicle),

(see 80C, Xenon bulbs, Xenon headlight: Adjustment ),

Nm) ,
- adjust the headlights (see 80B, Headlights,

10A-98

10A
K9K, and 722 or 728 or 732
Equipment required
safety belt
Tightening torquesm
sump mounting bolts
14 Nm
sump - gearbox mounting bolts
44 Nm
bolt mounting the sump

on the multifunction
support
21 Nm
catalytic converter upstream strut mounting

bolts
21 Nm
105 Nm
21 Nm
- the half sub-frame side reinforcement mounting

bolts,
half sub-frame side

reinforcement mounting
bolts
21 Nm
- the half sub-frame side reinforcements (1) .
wheel bolts
101212
Remove:
Fit the cooling assembly to the upper cross member

using a safety belt.
130 Nm
Note:
When fitting the safety belt , be careful:
REMOVAL
- not to crush the cooling hoses,

- not to strap up the half sub-frame.

Remove:
K9K, and 732

Move the diesel drain pipe away from the injector rail
protector.

- the dipstick.
Remove:
- the front wheels,
- the wheel arch liners,
Drain the engine oil (see 05A, Draining - Refilling,
Engine ).
10A-99

10A
K9K, and 722 or 728 or 732

Remove the mounting bolt from the sump on the
multifunction support.
Disconnect the oil level sensor.

CONCERNED
Remove:
- the sump mounting bolts,
- the sump.
REFITTING
102008
Remove:
K9K, and 732
- the half sub-frame mounting nuts,
Wipe the strainer with a cloth.

Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering.
K9K, and 732
Apply the product to the section to be cleaned: wait

approximately ten minutes, then remove the residue
using a wooden spatula.
Remove:
- the lower engine tie-bar mounting bolts,
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
- the engine tie-bar mounting lower bolt.

Loosen the lower engine tie-bar upper mounting
bolt.
WARNING
Excess sealant could be squeezed out when the
parts are tightened. A mixture of sealant and fluid
could cause damage to certain components
(engine, radiator, etc.).
Remove:
- the bolts mounting the right-hand driveshaft bracket on the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the relay bearing,
- the catalytic converter upstream stay mounting
bolts,
- the catalytic converter upstream stay.
10A-100

10A
K9K, and 722 or 728 or 732

CONCERNED
1 - FIRST FITTING
20167
20170
Refit the oil splash plate onto the cylinder block.

Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positioned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent damage to the clutch
housing.
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVE
SEAL with a diameter of 5 mm
- two points of SILICONE ADHESIVE SEAL at (5) ,
7 mm in diameter, at the connection between the
crankshaft closure panel and the cylinder block.
10A-101

10A
K9K, and 722 or 728 or 732

2 - SECOND FITTING
20171
108881
Refit the oil sump fitted with a new seal.

Fit:
- the sump mounting bolts without blocking them,
- the sump - gearbox mounting bolts without blocking them.
Tighten to torque and in order the sump mounting
bolts (14 Nm) .
Check that all the sump mounting bolts are tightened to torque (14 Nm) .
Tighten to torque the sump - gearbox mounting
bolts (44 Nm) .
20171
Refit the oil sump fitted with a new seal.

Fit:
bolts 14 Nm .
10A-102

10A
K9K, and 722 or 728 or 732

bolts 44 Nm .
- the half sub-frame mounting nuts (21 Nm) .

Connect the oil level sensor.
K9K, and 732

Fit the diesel drain pipe on the injector rail protector.

Refit the bolt mounting the sump on the multifunction
support.
Tighten to torque the bolt mounting the sump on
the multifunction support (21 Nm) .
Remove the safety belt.

Refit:
- the half sub-frame side reinforcements,
bolts.
Refit the catalytic converter upstream strut.

Tighten the catalytic converter upstream strut mounting bolts until contact is made.
Tighten to torque the catalytic converter upstream
strut mounting bolts (21 Nm) .
Refit:
Tighten to torque and in order the half sub-frame

side reinforcement mounting bolts (21 Nm) .
Refit:
- the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the front wheels.
- the bolts mounting the right-hand driveshaft bracket on the relay bearing,

K9K, and 732

Refit the lower bolt on the lower engine tie-bar
mounting (see 19A, Engine mounting, Suspended
mounting ).
Tighten the upper bolt on the lower engine tie-bar
mounting (see 19A, Engine mounting, Suspended
mounting ).
Refit the lower engine tie-bar (see 19A, Engine
mounting, Suspended mounting ).
Note:
Apply a drop of LOCTITE - FRENBLOC on the
half sub-frame mounting bolts.
Refit:
- the half sub-frame mounting nuts.
Tighten to torque:
- the half sub-frame mounting bolts (105 Nm) ,
10A-103
Top up the engine oil (see 05A, Draining - Refilling,

Engine ).
Refit:
- the dipstick,

10A
K4J, and 730 K4M, and 761 or 782
Equipment required
safety belt
Tightening torquesm
sump mounting bolts
14 Nm
sump - gearbox mounting bolts
44 Nm
bolt mounting the sump

on the multifunction
support
21 Nm
105 Nm
21 Nm
wheel bolts
101212
130 Nm
Remove:
bolts,
REMOVAL
Remove:

Note:
- the dipstick.

Engine ).
Remove:
- the front wheels,
10A-104


10A
K4J, and 730 K4M, and 761 or 782

WARNING
WARNING
102008
Remove:
Remove:
- the mounting bolts of the right-hand driveshaft
bracket on the relay bearing,
- the bolts mounting the relay bearing on the sump.

Remove the mounting bolt from the sump on the
multifunction support.
Remove:
- the sump.
REFITTING
10A-105

10A
K4J, and 730 K4M, and 761 or 782

I - FIRST FITTING
3
20167
20170
Refit the oil splash plate onto the cylinder block.

Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positioned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheel
end are aligned to prevent damage to the clutch
housing.
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHERESIVE SEAL 5 mm in diameter.
- two points of SILICONE ADHESIVE SEAL at (5) ,
7 mm in diameter, at the connection between the
crankshaft closure panel and the cylinder block.
10A-106

10A
K4J, and 730 K4M, and 761 or 782

II - SECOND FITTING
20171
108881
Refit the oil sump, fitted with a new seal.

Fit:
bolts (14 Nm) .
bolts (44 Nm) .
20171
Refit the oil sump with a new seal.

Fit:
bolts 14 Nm .
10A-107

K4J, and 730 K4M, and 761 or 782
bolts 44 Nm .
III - REFITTING (FOR FIRST AND SECOND
FITTINGS)
Refit the bolt mounting the sump on the multifunction
support.
Tighten to torque the bolt mounting the sump on
the multifunction support (21 Nm) .
Tighten to torque:
Engine ).
10A-108
10A

10A
F9Q, and 804 or 812
Equipment required
safety belt
Tightening torquesm
105 Nm
21 Nm
wheel bolts
130 Nm
REMOVAL
Remove:
101212
Remove:
- the dipstick.
- the half sub-frame side stiffeners mounting bolts,

- the half sub-frame side stiffeners (1) .

Engine ).

Remove:
Note:
- the front wheels,

10A-109

10A
F9Q, and 804 or 812

WARNING
WARNING
Note:
There are two fitting procedures for preparing the
cylinder block gasket face when refitting:
102008
- the first fitting procedure is used if the crankshaft closure panel has been sealed with SILICONE ADHESIVE SEAL ,
Remove:
- the mounting nuts from the half sub-frame,
- the second fitting procedure is used if the

crankshaft closure panel sealing is fitted with a
seal.

I - FIRST FITTING

- the sump.
REFITTING
15159
Apply a bead of SILICONE ADHESIVE SEAL :

- at (A) , on each side of bearing No. 1
- at (B) , the joint between the cylinder block and the
crankshaft closure panel.
10A-110

10A
F9Q, and 804 or 812

REFITTING (FOR FIRST AND SECOND FITTINGS)
II - SECOND FITTING
15195
Stage 1:
15159
Tighten to torque and in order, bolts (8) , (15) , (4)

, (19) , (11) , (12) to (18 Nm).
- Stage 2:
Note:
Do not cut the two crankshaft closure panel seal
tabs which sit higher than the cylinder block gasket face (B) .
Tighten to torque and in order, bolts (10) , (13) ,

(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18)
, (3) , (20) , (2) , (21) , (1) , (22) to (15 Nm).
Refit the lower engine tie-bar (see 19D, Engine
Apply a bead of SILICONE ADHESIVE SEAL silicone at (A) , on the connection between the crankshaft
closure panel and the cylinder block.
Tighten to torque:

Engine ).
10A-111

10A
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm
105 Nm
21 Nm
wheel mounting bolts
130 Nm
REMOVAL
Remove:
101212
Remove:
- the dipstick.

bolts,

Engine ).

Remove:
Note:
- the front wheels,

10A-112

10A
F4R, and 770 or 771 or 776
B
2
102008
15159
Remove:
Note:
Do not cut the two crankshaft closure panel seal

tabs which sit higher than the cylinder block gasket face (B) .

- the half sub-frame (2) ,
Apply a bead of SILICONE ADHESIVE SEAL at (A)

, on the connection between the crankshaft closure
panel and the cylinder block.
Refit the sump with a new gasket.
- the sump.
REFITTING
WARNING
WARNING
10A-113

F4R, and 770 or 771 or 776
10
11
22
12
21
20 19 18 17
13
16
15
14
15195
Stage 1:
Tighten to torque and in order, bolts (8) , (15) , (4)
, (19) , (11) , (12) to (18 Nm).
- Stage 2:
Tighten to torque and in order, bolts (10) , (13) ,
(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18)
, (3) , (20) , (2) , (21) , (1) , (22) to (15 Nm).
Tighten to torque:
- the wheel mounting bolts (130 Nm) .
Engine ).
10A-114
10A

10A
M9R, and 700

Mot. 1716
Removes housing with

silicone seals.
Equipment required
safety belt
Tightening torquesm
sump mounting bolts
16 Nm

mounting bolts
105 Nm
21 Nm
side stiffener lower

mounting bolts
21 Nm
102008
Attach the cooling assembly to the upper cross

member using a safety belt.
REMOVAL
Note:

Position the vehicle on a lift (see 02A, Lifting equipment, Underbody lift ).
When fitting the safety belt , be careful not to:

- pinch the cooling hoses,
- deform the air conditioning pipes,
- strap the half sub-frame.
Remove:
Remove:

- the dipstick,
- the lower mounting bolts (1) from the side stiffeners,
- the front wheels,
- the half sub-frame mounting nuts (2) ,
- the front wheel arch liners,
- the half sub-frame mounting bolts (3) ,

Drain the engine oil (see 10A, Engine and peripherals, Engine oil: Draining-refilling ).
10A-115

10A
M9R, and 700

CONCERNED
114264
Gradually detach the sump.

114997
Remove the sump mounting bolts.
Note:
To prevent deformation, use a series of small
movements.
Remove the sump.
REFITTING
Check that the sump is not:
- scratched,
- deformed.
If this is the case, replace the sump.
114263
Cut the sump's silicone seal (except at the coupling

face side and the lower engine tie-bar support side)
using the (Mot. 1716).
10A-116

10A
M9R, and 700

Check that the baseplate is not scratched.

Apply HIGH RESISTANCE BOLT LOCKING
AGENT part no. 77 11 230 112 to the half sub-frame
mounting bolts.
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
Refit:
- Wear goggles.
- Wear gloves during the operation.

WARNING
- the side stiffener lower mounting bolts.
Applying excess sealant could cause it to be

squeezed out when parts are tightened. The product mix may damage some components
(engine, radiator, etc).
Tighten to torque:
- the half sub-frame front mounting bolts (105
Nm) ,
WARNING
- the side stiffener lower mounting bolts (21 Nm) .
The sealing surfaces must be clean, dry and free


Refit:

CONCERNED

- the front wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery, B attery:
Fill up the engine oil (see 10A, Engine and peripherals, Engine oil: Draining-refilling ).
Refit:
- the dipstick,
114410
Apply a bead of SILICONE ADHESIVE SEAL (77

11 227 484) 5 mm 2 in diameter to the sump to
seal it.
Fit the sump.
Finger tighten the sump mounting bolts.
bolts (16 Nm) .
10A-117

Oil pump: Removal - Refitting
10A
F4R or F9Q or K4J or K4M or K9K

Connect the battery, starting with the positive terminal.
Tightening torquesm
oil pump mounting bolts
25 Nm
battery cover mounting

bolts
4 Nm
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal / Refitting ).
Tighten to torque the battery cover mounting bolts
(4 Nm) .
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Drain the engine oil.
Remove the sump (see 10A, Engine and peripherals, Sump ).
Example for F9Q engine
23224
Remove:
- the bolt (1) and the oil splash plate,
- the (2) oil pump bolts,
- the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts (25
Nm) .
Refit the sump (see 10A, Engine and peripherals,
Sump ).
Refill the engine oil.
10A-118

10A
M9R, and 700

CONCERNED
Tightening torquesm
bolts mounting the oil
pump on the cylinder
block
25 Nm

pump on the anti-splash
plate
10 Nm
strainer mounting bolts
10 Nm
REMOVAL
Remove the engine protectors.
113157

Remove the oil pump mounting bolt from the antisplash plate.
Remove:
Note:
Be careful not to damage the oil level sensor.

Remove:
Drain the engine oil (see 10A, Engine and peripherals, Engine oil: Draining-refilling ).
- the oil pump mounting bolts (2) on the cylinder

block,
Remove the sump (see 10A, Engine and peripherals, Sump: Removal - Refitting ).
- the oil pump.
REFITTING
If necessary, use a locally-produced hook to fit the
oil pump chain to the oil pump sprocket.
113156
Remove:
- the strainer mounting bolts (1) ,
- the strainer.
10A-119

M9R, and 700
CONCERNED
Refit the oil pump.
Finger tighten:
- the oil pump mounting bolts on the anti-splash plate,
- the oil pump mounting bolts on the cylinder block.
Tighten to torque the bolts mounting the oil pump
on the cylinder block (5 Nm) .
Tighten to torque:
- the bolts mounting the oil pump on the cylinder
block (25 Nm) ,
- the bolts mounting the oil pump on the antisplash plate (10 Nm) ,
Replace the oil strainer O-ring.
Refit the oil pump strainer.
Finger tighten the oil strainer mounting bolts.
Tighten the strainer mounting bolts (10 Nm) .
Refit:
- the sump (see 10A, Engine and peripherals,
Sump: Removal - Refitting .
Fill up the engine oil (see 10A, Engine and peripherals, Engine oil: Draining-refilling ).
Start the engine and wait until the engine oil warning
light goes out.
Check the engine oil level.
Refit the engine protectors.
10A-120
10A

Multifunction support: Removal - Refitting
10A
K4J, and 730 K4M, and 761 or 782
Tightening torquesm
multifunction support
mounting bolts
44 Nm
mounting bolt on the
sump
21 Nm
REMOVAL
Remove:
- the front wheels,
102265

- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ),
- the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ).
10A-121
Remove:
- the multifunction support mounting bolts (1) ,
- the bolts (2) mounting the multifunction support on
the sump,
- the multifunction support.

10A
K4J, and 730 K4M, and 761 or 782
REFITTING
BASIC HEATING
111057
102265
Remove:
Refit:
- the multifunction support,

- the multifunction support mounting bolts.
Tighten to torque and in order:
- the multifunction support mounting bolts (44
Nm) ,
- the multifunction support mounting bolt on the
sump (21 Nm) .
10A-122

K4J, and 730 K4M, and 761 or 782
BASIC HEATING
111057
Refit:
Tighten to torque and in order the multifunction
support mounting bolts (44 Nm) .
Refit:
- the front wheels.
10A-123
10A

10A
K9K, and 722 or 724 or 728 or 732

CONCERNED
Tightening torquesm
mounting bolts
44 Nm
sump
21 Nm
REMOVAL
Remove:
- the front wheels,
102265
Remove:

10A-124

- the bolts (2) mounting the multifunction support on
the sump,

10A
K9K, and 722 or 724 or 728 or 732
REFITTING
BASIC HEATING
CONCERNED
111057
Remove:
102265
Refit:
- the multifunction support mounting bolts (44
Nm) ,
- the multifunction support mounting bolt on the
sump (21 Nm) .
10A-125

K9K, and 722 or 724 or 728 or 732
BASIC HEATING
111057
Refit:
Refit:
- the front wheels.
10A-126
10A

10A
F4R, and 770 or 771 or 776
REFITTING
Refit:
Tightening torquesm
mounting bolts
44 Nm

Tighten to torque the multifunction support mounting bolts (44 Nm) .
REMOVAL
Refit:
- the alternator (see 16A, Starting-charging, Alternator ),

engine, Accessories belt: Removal - Refitting ).


Exterior protection, Front bumper: Removal Refitting ).
Remove:
- the front wheels,

- the front wheels.

- the alternator (see 16A, Starting - Charging, Alternator ).
104337
Remove:
10A-127

10A
F9Q, and 804 or 812
REFITTING
Refit:
Tightening torquesm
mounting bolts
44 Nm

Tighten to torque the multifunction support mounting bolts (44 Nm) .
REMOVAL
Refit:
- the alternator (see 16A, Starting-charging, Alternator ),



Remove:
- the front wheels,

- the front wheels.

- the alternator (see 16A, Starting - Charging, Alternator ).
104337
Remove:
10A-128

10A
M9R, and 700

Fit the air conditioning compressor on the half subframe.
Tightening torquesm
Unclip the fuel pipes from the fuel circuit support.
the fuel circuit support

mounting bolts
10 Nm
mounting bolts
44 Nm
air conditioning compressor mounting bolts
25 Nm

CONCERNED
REMOVAL
Remove:
114862
Remove:
114861
Disconnect the connector (1) from the air conditioning compressor.

Remove the air conditioning compressor mounting
bolts (2) .
Move the air conditioning compressor aside.
10A-129

10A
M9R, and 700
REFITTING

CONCERNED

If replacing the multifunction support
114862
Position the multifunction support.
114862
Remove the mounting bolts (4) from the fuel circuit

support.
Refit:
- the fuel circuit support on the new multifunction
support,
- the fuel circuit support mounting bolts.
Tighten to torque the fuel circuit support mounting bolts (10 Nm) .
10A-130
Finger tighten in order the multifunction support

mounting bolts.

M9R, and 700
Clip the fuel pipes onto the fuel circuit support.
Fit the air conditioning compressor.
Refit the air conditioning compressor mounting
bolts.
mounting bolts (25 Nm)
Connect the connector to the air conditioning compressor.
Refit:
10A-131
10A

Accessories belt: Removal - Refitting
11A
K4J, and 730 K4M, and 761 or 782 K9K, and 722 or 728 or 732 AIR CONDITIONING or CLIMATE
CONTROL
Tightening torquesm
tensioning roller mounting bolt
wheel bolts
bolts
40 Nm
130 Nm
4 Nm
IMPORTANT
Wear protective gloves throughout the operation.
WARNING
Never turn the engine in the opposite direction to its
normal operation.
101212
Remove the right-hand side stiffener (1) .

WARNING
It is essential to replace the accessories belt and
the tensioning roller.
WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft and the accessories pulley.
REMOVAL
Remove:
101878
Turn the accessories belt auto tensioner clockwise

using a 16 mm spanner.
- the front right-hand wheel,

- the front right-hand wheel arch liner.
Remove:
- the accessories belt,
- the tensioning roller.
11A-1

11A
K4J, and 730 K4M, and 761 or 782 K9K, and 722 or 728 or 732 AIR CONDITIONING or CLIMATE
CONTROL
REFITTING
Use a brush to remove any deposits from the
crankshaft pulley V-grooves.
Refit the tensioning roller.
Tighten to torque the tensioning roller mounting
bolt (40 Nm) .
106000
WARNING
The accessories belt has five teeth, but the air
conditioning compressor pulley has six grooves.
When fitting the accessories belt, it is essential to
check that the tooth (2) remains free.
Refit the accessories belt.
Rotate the crankshaft twice to correctly position the
accessories belt.
Tighten to torque:
- the wheel bolts (130 Nm) ,
- the battery cover mounting bolts (4 Nm) .
11A-2

11A
K4J, and 730 K4M, and 761 or 782 K9K, and 722 or 728 BASIC HEATING
REMOVAL

Mot. 1638
Accessories belt tension tool. For engines

fitted with a mechanical tensioning roller.
Mot. 1505

Remove:
Belt tension setting

tool (frequency meter)
Mot. 1715

Belt tension checking

tool (frequency indicator).
Tightening torquesm
tensioning roller mounting bolts
wheel bolt
bolts
35 Nm
130 Nm
4 Nm
IMPORTANT
WARNING
normal operation.
101212
Remove the side stiffeners (1) .

Loosen the tensioning roller bracket mounting bolts.
WARNING
Remove:


WARNING
REFITTING


WARNING
The two Torx mounting bolts of the tensioning roller must be replaced by M8 x 20 bolts (part number 77 03 002 059 ).
Refit:
- the tensioning roller with its new bolts,
- the accessories belt.
11A-3

11A
K4J, and 730 K4M, and 761 or 782 K9K, and 722 or 728 BASIC HEATING
2
20845
WARNING
The accessories belt has five teeth, while the
free pulley has six. When fitting the accessories
belt, it is essential to check that the tooth (2)
remains free.
107503
Tension the accessories belt using the (Mot. 1638) ,

tightening the nut (3) (with the two tensioning roller
mounting bolts loosened).
Check at (4) using the (Mot. 1505) or the (Mot.
1715) , that the accessories belt tension is between
223 and 245 Hz .
It is essential to turn the engine through two revolutions to position the accessories belt correctly.
Check that the accessories belt tension is between
223 and 245 Hz at the measuring point (4) , otherwise readjust the tension.
bolts (35 Nm) .
Tighten to torque:
- the battery cover mounting bolts (4 Nm)
11A-4

11A
F4R, and 770 or 771 or 776 F9Q, and 804 or 812 AIR CONDITIONING or CLIMATE CONTROL
Tightening torquesm
wheel bolts
bolts
50 Nm
130 Nm
4 Nm
IMPORTANT
WARNING
normal operation.
101212
Remove the right-hand side stiffener (1) .

WARNING
WARNING
REMOVAL
Remove:
104339
Turn the accessories belt auto tensioner anti-clockwise using a 16 mm spanner.

Remove:
11A-5

11A
F4R, and 770 or 771 or 776 F9Q, and 804 or 812 AIR CONDITIONING or CLIMATE CONTROL
REFITTING
Refit:
- the tensioning roller,
- the accessories belt.
bolt (50 Nm) .
Rotate the crankshaft twice to position the accessories belt correctly.
Tighten to torque:
11A-6

11A
M9R, and 700

Mot. 1770
Crankshaft pulley locking tool.
Tightening torquesm
fixed roller mounting
bolt
44 Nm
25 Nm
crankshaft accessories
pulley mounting bolt
50 Nm + 85
6
IMPORTANT
Wear protective gloves during all operations.
101212
Remove:
- the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting ),
REMOVAL
- the front right-hand wheel arch liner,

11A-7
- the bolts mounting the right-hand side stiffener on

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

11A
M9R, and 700

CONCERNED
114854
114854
Fit the (2) 3 mm Allen key into the tensioning roller

hole.
Turn the accessories belt tensioning roller clockwise
until the Allen key is fully inserted.
Remove the accessories belt.
Slightly pivot the accessories belt tensioning roller

clockwise.
Remove the (3) 3 mm Allen key.
Pivot the accessories belt tensioning roller anti-clockwise as much as possible.
116142
Remove:
- the tensioning roller mounting bolts (4) ,
11A-8

11A
M9R, and 700
114857
114849
Remove:
Remove:
- the protector (5) from the fixed roller,
- the crankshaft accessories pulley mounting bolt

using the (Mot. 1770) (1) ,
- the fixed roller mounting bolts (6) ,

- the fixed roller (7) .
- the washer,
- the crankshaft accessories pulley.
WARNING
When replacing the accessories belt recommended by the manufacturer, always replace:
REFITTING

- the tensioning roller and fixed roller,

- the crankshaft accessories pulley bolt,

WARNING
Only use brushes with plastic or non-corrosive
metal (brass) bristles.
WARNING
Do not run the engine without the accessories
belt so as not to damage the crankshaft accessories pulley.
Fit the new fixed roller.
Fit the fixed roller mounting bolt without tightening it.
Tighten to torque the fixed roller mounting bolt (44
Nm) .
11A-9

11A
M9R, and 700

Refit the fixed roller protector.

Refit:
- the right-hand side stiffener from the half sub-frame
cross member,
Note:
The Parts Department supplies the tensioning
roller pin.
- the right-hand side stiffener mounting bolts on the

half sub-frame cross member,
Fit the new tensioning roller.
Fit the tensioning roller mounting bolts without tightening them.

WARNING
When replacing the accessories belt recommended by the manufacturer, always replace:
- the tensioning roller and fixed roller,
- the crankshaft accessories pulley bolt,
bolt (25 Nm) .
Refit the new crankshaft accessories pulley by inserting it onto the two crankshaft flat surfaces.
Refit the washer inside the crankshaft accessories
pulley by inserting it onto the two crankshaft flat surfaces.
WARNING
Check that the washer fits properly on the
crankshaft flat surfaces.
Fit the new crankshaft accessories pulley mounting
bolt without tightening it.
Tighten to torque and angle the crankshaft accessories pulley mounting bolt (50 Nm + 85 6)
CONCERNED
Refit the new accessories belt.
Remove the tensioning roller pin.
Turn the crankshaft twice.
Check that the accessories belt V-blocks are well
positioned in the V-grooves of all the pulleys.
11A-10

Timing belt: Removal - Refitting
11A
K9K, and 722 or 728

- the right-hand wheel arch liner,

Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps.
Mot. 1453-01
Additional winder nut

on engine lift support
Mot. 1453.
Mot. 1489
TDC locating pin.
Mot. 1430
Set of 5 crankshaft
and camshaft pulley
timing pins.
1
2
Tightening torquesm
tensioning roller bolt
104343
25 Nm
accessories pulley
mounting bolt (M12
bolt):
60 Nm + 100
10
accessories pulley
mounting bolt (M14
bolt):
120 Nm + 95
15
tensioning roller mounting bolts
25 Nm
TDC pin plug
20 Nm
cylinder head suspended mounting bolts
21 Nm
wheel bolts
bolts
Remove:
55A, Exterior protection, Scuttle panel grille ),
- the scuttle panel mounting bolt (2) .
130 Nm
4 Nm
WARNING
104246
Remove:

normal operation.

REMOVAL
Remove:
11A-11


11A
K9K, and 722 or 728
102450
4
102115
Remove the lower engine tie-bar bolts (4) .

Remove the lower engine tie-bar.
102451
Install the (Mot. 1453) and the (Mot. 1453-01) with

the retaining straps.
102114
Mark the position of the suspended mounting in relation to the body.

Loosen the bolt (5)
WARNING
Do not damage the air conditioning pipe.
11A-12

11A
K9K, and 722 or 728
19654
Remove the upper timing cover by unclipping tabs

(6) .
11A-13

11A
K9K, and 722 or 728
19654-1
Remove:
- the high pressure pump camshaft sensor (7) ,
- the plastic bolt (8) .
Unclip the tabs (9) .
Remove the lower timing cover.
11A-14

11A
K9K, and 722 or 728
19654-2
Remove the cylinder head suspended mounting.
Positioning the timing at the setting point
12
11
10
19702
19650
Remove the TDC setting pin plug (10) .
11A-15
Rotate the crankshaft in a clockwise direction (timing

end) to position the hole (11) in the camshaft pulley
almost in line with the hole (12) in the cylinder head.

11A
K9K, and 722 or 728
2
1
19650-1
Screw in the TDC setting pin (1) (Mot. 1489).
19655
Insert the pin (2) (Mot. 1430) in the camshaft pulley

and cylinder head holes.
Remove:
- the pin (Mot. 1430) ,
- the TDC setting pin (Mot. 1489).
14489-1
Turn the crankshaft clockwise (timing end) smoothly

until the crankshaft comes in contact with the TDC
setting pin (Mot. 1489).
11A-16

11A
K9K, and 722 or 728
19656
Remove the crankshaft accessories pulley, locking

the flywheel with a screwdriver.
11A-17

11A
K9K, and 722 or 728
13
19656-1
Undo the tensioning roller bolt (13) to slacken the timing belt.
REFITTING
Remove:
WARNING
- the timing belt,
Replace the timing belt, the tensioning roller, the

crankshaft accessories pulley and bolt.
- be careful not to drop the crankshaft sprocket,

- the timing sprocket,
WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft accessories pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
11A-18

K9K, and 722 or 728
19710
Refit the timing sprocket.
11A-19
11A

11A
K9K, and 722 or 728

I - ADJUSTING THE TIMING
17
16
15
14
18
19656-2
Note:
Check that the tensioning roller lug (14) is correctly positioned in the groove (15) .
Refit the tensioning roller.
Insert the pin (2) (Mot. 1430) in the camshaft pulley
and cylinder head holes.
Screw the TDC setting pin into the cylinder block.
Check that the high pressure pump pulley mark (16)
is in line with the bolt head (17) .
14489
Check that the crankshaft is in contact with the TDC

setting pin (Mot. 1489) (crankshaft groove (18)
upwards).
11A-20

11A
K9K, and 722 or 728
19
19657
19658
Fit the new timing belt, aligning the marks on the belt
with those on the camshaft sprockets and the high
pressure pump.
Position the tensioning roller adjustable index marker (19) opposite the lug using a 6 mm Allen key,
turning it anti-clockwise.
Tighten to torque the tensioning roller bolt (25
Nm) .
Note:
Refit the crankshaft accessories pulley.
19 belt tooth spaces between the camshaft

sprocket and pump marks.
Torque and angle-tighten (crankshaft in contact with

the TDC setting pin):
- the accessories pulley mounting bolt (M12
bolt): (60 Nm + 100 10) ,
- the accessories pulley mounting bolt (M14
bolt): (120 Nm + 95 15) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430).
11A-21

11A
K9K, and 722 or 728
22
21
23
20
19702
Rotate the crankshaft clockwise through two revolutions (timing end).

Before the camshaft pulley hole (20) comes in line
with the cylinder head hole (21) , screw the TDC setting pin (Mot. 1489) into the cylinder block.
Bring the crankshaft slowly and smoothly into contact with the pin.
19655
Check:
- the timing pin (Mot. 1430) is correctly inserted in
the camshaft and cylinder head holes,
- that there are 19 belt tooth spaces between the
camshaft sprocket mark (22) and the high pressure
pump sprocket mark (23) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430).
Note:
After two turns, the tensioning roller index markers may be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-22

11A
K9K, and 722 or 728

First position
Second position
24
26
111083
111082
24
26
25
27
111081
111081
Loosen the tensioning roller bolt by no more than

one turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index marker (24) in

the middle of the timing window (25) , by turning the
key anti-clockwise.

key clockwise.
II - REFITTING
bolts (25 Nm) .
Refit the TDC pin plug, applying a drop of SILICONE
ADHESIVE SEAL to the thread hole.
11A-23

11A
K9K, and 722 or 728

Torque tighten the TDC pin plug (20 Nm) .
Torque tighten the cylinder head suspended

mounting bolts (21 Nm) .
19654-2
Refit the cylinder head suspended mounting.
11A-24

11A
K9K, and 722 or 728
19654-1
28
29
19659
Refit the lower timing cover, positioning the tab (28)

in the lower timing cover hole (29) .
11A-25

11A
K9K, and 722 or 728
19654
Refit:
- the upper timing cover,
mounting, Suspended engine mounting ) in accordance with the marks,
Tighten to torque:
11A-26

11A
K4M, and 761 or 782

Tightening torquesm

Multiple-adjusting
straps.
upper timing cover bolts

and nuts
Mot. 1453-01

Mot. 1453.

bolts
Mot. 1489
TDC locating pin.
WARNING
Mot. 1368
Tool for tightening tensioner bolt. 8 mm Torx

wrench, 12.7 mm
square
Mot. 799-01
Timing gear wheel

immobiliser.
Mot. 1496
Tool for setting camshaft.

Mot. 1490-01
Locking and adjusting

camshaft pulleys.
grille ).
Mot. 1487
Tool for removing the

camshaft covers (57
mm diameter).
Mot. 1488

camshaft covers (43
mm diameter).
Mot. 1453
wheel bolts
130 Nm
4 Nm

normal operation.
REMOVAL
2
1
Tightening torquesm
bolt
45 Nm
pulley bolt
40 Nm + 115
15
tensioning roller mounting nut
27 Nm
inlet camshaft pulley

dephaser bolt
75 Nm
inlet camshaft dephaser blanking cover
15 Nm
exhaust camshaft pulley nut
30 Nm + 84
4
TDC pin plug
41 Nm
104343
Remove:
20 Nm
11A-27

11A
K4M, and 761 or 782
104246
102450
Remove:
Remove:
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) with retaining straps.
11A-28

11A
K4M, and 761 or 782
101866
14491

the body.
Pierce the middle of the plugs on the end of the

camshaft using a screwdriver.
Remove:
Remove:
- the engine - suspended engine mounting assembly,
- the sealing plugs at the camshaft end with a

screwdriver,
- the lower engine tie-bar.
- the TDC setting pin plug (6) .
WARNING
5
4
101807
Remove:
- the air filter outlet duct (4) ,
- the throttle valve (5) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
11A-29

11A
K4M, and 761 or 782

ADJUSTING THE TIMING
14490
14491-1
Position the camshaft grooves (7) almost horizontally and offset towards the bottom turning the crankshaft in the direction of operation (clockwise timing
end).
Check that the camshaft grooves are horizontal and

offset downwards.
10
11
14487
Remove:
- the crankshaft accessories pulley (9) , locking the
flywheel with a screwdriver,
14489
Turn the crankshaft in its operating direction (timing

end clockwise), until the crankshaft comes into contact with TDC setting pin.
11A-30
- the upper timing cover (10) ,

- the lower timing cover (11) .

11A
K4M, and 761 or 782
REFITTING - PROCEDURE 1
The first procedure is used when replacing any timing component that does not require one or more
camshaft pulleys to be loosened.
WARNING
Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the fixed
roller.
13
12
WARNING
Always degrease:
the end of the crankshaft (timing end),
the timing sprocket bore and contact surfaces,
101872
the accessories pulley contact surfaces,
the camshaft ends (timing end),
Remove:
the camshaft sprocket bores and contact surfaces.
- the fixed roller (13) using the (Mot. 1368) ,
- This is to avoid slippage between:
- the timing belt, taking care not to drop the crankshaft sprocket.
the timing,
the crankshaft,
the camshaft sprockets.

- This slippage causes engine damage.
11A-31

11A
K4M, and 761 or 782
14490
103260
Position the camshaft grooves horizontally and offset towards the bottom by turning the camshafts with
the (Mot. 799-01) if necessary.
Mount the (Mot. 1496) on the ends of the camshafts.
27
75
36
31
17
16
19
10
13
d9
10
21
103308
Use a locally-produced mounting bracket to hold the

(Mot. 1496) in place.
11A-32

11A
K4M, and 761 or 782
15
14
17
103269
Check that mark (14) on the dephaser is vertical and

pointing upwards.
16
Make a mark (15) with a pencil between the dephaser belt and the rocker cover.
14489
Check that:
- the crankshaft is correctly in contact with the TDC
setting pin (Mot. 1489) (16) with the crankshaft
groove (17) upwards,
11A-33

11A
K4M, and 761 or 782

- the inlet camshaft dephaser wheel is correctly locked (wheel does not rotate right or left).
II - REFITTING
21
19
18
20
14487-3
Refit:
- the tensioning roller (19) ,
14505
- the timing sprocket (20) ,

- the timing belt,
Note:
When refitting the tensioning roller, make sure
that the lug of the tensioning roller is correctly
positioned in the groove (18) .
14487-2

Nm) using the (Mot. 1368).
11A-34

11A
K4M, and 761 or 782

III - BELT TENSION
26
23
25
22
27
24
103263
103263
Using a 6 mm Allen key, bring the adjustable index

marker (22) opposite the notch (23) , by turning the
eccentric (24) clockwise.
Torque tighten the tensioning roller mounting nut
(7 Nm) .
Tighten to torque and angle the crankshaft accessories pulley bolt (40 Nm + 115 15) (crankshaft
in contact with the TDC setting pin).
Remove:
- the camshaft setting tool (Mot. 1496) ,
Rotate the crankshaft through two clockwise revolutions (timing end) before aligning the marks (on
camshaft dephaser):
- screw the TDC pin (Mot. 1489) into the cylinder
block.
- move the crankshaft slowly and smoothly to rest on
the TDC setting pin.
Remove the TDC setting pin (Mot. 1489).
11A-35
Check that the adjustable index marker (25) coincides with slot (26) , or:
- loosen the tensioning roller nut by up to one turn,
holding the adjustable index marker with a 6 mm
Allen key,
- gradually move the adjustable index marker (25)
opposite the notch (26) turning the eccentric (27) in
a clockwise direction.

11A
K4M, and 761 or 782
30
29
28
103267

nut (27 Nm) (28) .
2 - Checking the timing
Check that the dephaser mark (29) is aligned with

mark (30) .
IV - CHECKING THE TIMING AND TENSION
Check that the tensioning roller indexes are correctly

positioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylinder block.
Move the crankshaft slowly and smoothly until it is
resting against the pin.
1 - Checking the tension

Rotate the crankshaft through two clockwise revolutions (timing end) before aligning the marks (on
camshaft dephaser):
- screw in the TDC setting pin (Mot. 1489) ,
the TDC setting pin (Mot. 1489).
Remove the TDC setting pin.
WARNING
Check that the tensioning roller index markers
are aligned. If not, repeat the tensioning procedure.
11A-36

11A
K4M, and 761 or 782
REFITTING -PROCEDURE 2
The second procedure is used for replacing all components requiring one or more of the camshaft pulleys to be slackened.
WARNING
If the stud is loosened with the nut (see Technical Note 3887A, Replacing K9 - K4 camshaft
pulley studs, 11A, Top and front of engine,
Camshaft ).
WARNING
roller.
14490
Fit the camshaft setting tool (Mot. 1496) without forcing (the camshaft grooves must be horizontal and
offset downwards).
WARNING
Always degrease:
WARNING
If the tool cannot be engaged, readjust the timing

and the tension.

the timing,
the crankshaft,
Refit the camshaft pulleys and the old nuts, tightening them to a torque of 15 Nm .
11A-37

11A
K4M, and 761 or 782
27
75
36
31
17
16
19
10
13
d9
10
21
14490
103308
Use a locally produced mounting bracket to hold the

103261
(Mot. 1496) if necessary.
11A-38
103260

11A
K4M, and 761 or 782
31
14489
33
35
34
32
103269

setting pin (Mot. 1489) (31) (crankshaft groove (32)
should be at the top).
Refit:
11A-39
- the exhaust camshaft pulley with a new nut,

- the inlet camshaft dephaser with a new bolt, checking that the inlet camshaft dephaser wheel is correctly locked (wheel does not rotate right or left).

11A
K4M, and 761 or 782

Position:
- the RENAULT logo (33) etched on the camshaft
pulley spokes vertically and towards the top,
- the dephaser marking (34) vertically and pointing
upwards.
Make a mark (35) with a pencil between the dephaser belt and the rocker cover.
II - REFITTING
37
38
36
14487-3
Refit:
- the timing belt on the camshaft pulleys (without moving the camshaft pulleys).
14505
39
Note:
103265
Fit the camshaft pulley locking tool (Mot. 1490-01)

(39) (use the timing cover mountings to fix the tool).
11A-40

11A
K4M, and 761 or 782

(7 Nm) .
Remove camshaft pulley immobilising tool (Mot.
1490-01).
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pulleys. In addition, from time to time, press the
camshaft pulleys against the camshafts.
40
Rotate the timing system through six revolutions

with the exhaust camshaft sprocket, using the (Mot.
799-01).
45
44
14487-3
Refit the fixed roller (40) .

46
Refit the crankshaft accessories pulley (without tightening the bolt, with 2 to 3 mm play between bolt
and pulley).
III - BELT TENSION
42
41
103263
Check that the adjustable index marker (44) coincides with slot (45) , or:
- Loosen the tensioning roller nut by up to one turn,
Allen key,
43

103263

11A-41

11A
K4M, and 761 or 782
49
47
48
103268

(27 Nm) .
Check that:
- the RENAULT badge (47) etched on the exhaust
camshaft pulley stem vertically and pointing
upwards,
- the dephaser marking (48) is aligned with the marking (49) already made by the operator.
103265
Fit the camshaft pulley immobilising tool (Mot. 149001).
11A-42

11A
K4M, and 761 or 782
50
51
14489
103265
Tighten to torque the inlet camshaft pulley dephaser bolt (75 Nm) .
WARNING
Refit the new inlet camshaft dephaser blanking cover (51) .
Check that the crankshaft is pressing against the

TDC setting pin (Mot. 1489) (50) .
Tighten to torque the inlet camshaft dephaser

blanking cover (15 Nm) .
in contact with the TDC setting pin),
Tighten to torque and angle the exhaust camshaft

pulley nut (30 Nm + 84 4) .
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool,
Rotate the crankshaft clockwise (timing end) through two revolutions and before completing the second revolution:
- screw the TDC setting pin (Mot. 1489) into the cylinder block,
- Slowly and smoothly position the crankshaft in contact with the TDC setting pin (Mot. 1489).
WARNING
Check that the fixed roller indexes are aligned. If
not, repeat the tensioning process.
11A-43

11A
K4M, and 761 or 782

Move the crankshaft slowly and smoothly into position against the pin.
15103-1
Refit:
mounting, Suspended engine mounting ),
- the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting ),
14490
- new inlet camshaft sealing plugs (Mot. 1487) ,

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

Tighten to torque:
WARNING

and the tension.
REFITTING
Refit the TDC setting pin cap, applying a drop of
RHODORSEAL 5661 onto the thread.
Refit the lower cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover bolts and
nuts (41 Nm) .
11A-44

11A
F4R, and 770 or 771 or 776

Tightening torquesm

Mot. 1672
Lower engine support.
Mot. 1054
TDC setting pin.
Mot. 1509
Camshaft sprocket
locking tool.
upper timing cover M10

bolts
wheel bolts
Mot. 1509-01
Adapter kit for tool

Mot.1509.
Mot. 799-01
Timing gear wheel

immobiliser.
Mot. 1496
Mot. 1487

camshaft covers (57
mm diameter).
Mot. 1488

bolts
38 Nm
130 Nm
4 Nm
Note:
The timing belt procedure is the same for engines
with or without camshaft dephasers.
WARNING
normal operation.

camshaft covers (43
mm diameter).
WARNING
so as not to damage the crankshaft accessories
pulley.
Tightening torquesm
bolt
50 Nm
tensioning roller nut
28 Nm
inlet camshaft pulley

dephaser bolt
100 Nm
exhaust camshaft pulley nut
30 Nm + 86
6
inlet camshaft dephaser blanking cover
25 Nm
inlet and exhaust camshaft pulley nut
30 Nm + 86
6
pulley mounting bolt
40 Nm + 110
+/- 10
lower timing cover M6

bolts
80 Nm
lower timing cover M8

bolts
20 Nm
upper timing cover M8

bolts
18 Nm
WARNING
On the F4R engine, it is essential to fit the crankshaft sprocket with the integrated cotter.
WARNING
Replace the following parts when they are removed:
- the camshaft pulley nuts,
- the crankshaft accessories pulley,
- the crankshaft accessories pulley bolt.
WARNING
When replacing the belt, always replace the tensioning rollers and fixed rollers.
11A-45

11A
F4R, and 770 or 771 or 776
REMOVAL
- the front right-hand wheel arch,
Remove the battery (see 80A, Battery, Battery: Removal - Refitting ).

F4R, and 776
grille ).
5
4
2
7
6
1
102504

104343
Remove:
Remove:
- the clip (6) ,
3
8
102365
104246
Remove:
Remove:
- the front end panel mountings (8) ,

11A-46

11A
F4R, and 770 or 771 or 776
105432
Position the (Mot. 1672) with their retaining straps.
101212
Remove:
- the radiator cross member right-hand side stiffener
(9) ,
Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Refitting ).
F4R, and 770 or 771
11
102742

the body.
Remove the suspended engine mounting assembly.
10
Note:
Be careful not to bend the air conditioning pipe.
101807
Remove:
- the throttle valve (11) ,
- the connector on the lifting bracket.
11A-47

11A
F4R, and 770 or 771 or 776
F4R, and 776
13
14
106632
12
Loosen nut (13) .
106278
Remove fuel vapour recirculation solenoid valve

(12) .
Pull the mounting bracket away from the electric

coolant pump.
Move aside the electric water pump (14) .
Remove the wiring harness mounting bracket.
15
15102
Remove the TDC setting pin cap (15) .
11A-48

11A
F4R, and 770 or 771 or 776
15105
15163-2
Gently turn the engine in the same direction, inserting the TDC setting pin (Mot. 1054) as far as the
setting point.
Remove the camshaft sealing plugs.

15106
Rotate the engine clockwise (timing end) so that the

camshaft grooves are offset below the centre line
and almost horizontal, as shown in the drawing.
Insert TDC setting pin (Mot. 1054) so that it is
between the balancing hole and the crankshaft setting groove.
11A-49
15106-1
At the setting point, the camshaft grooves must be

horizontal and offset below the centre line, as shown
in the drawing.

11A
F4R, and 770 or 771 or 776

Correct position
106519
15163-1
Incorrect position
15303
15163
Remove:
- the flywheel guard,
- the crankshaft pulley, locking the flywheel with a

screwdriver.
Reposition the TDC setting pin (Mot. 1054).
11A-50

11A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
16
17
18433
Remove:
11A-51

11A
F4R, and 770 or 771 or 776
F4R, and 776
18
106338
19
20
104719
Remove:
- the heat shield (18) ,
11A-52

11A
F4R, and 770 or 771 or 776

21
22
18433-2
Relax the timing belt by loosening the tensioning roller nut (21) .
Remove:
WARNING
Never turn the engine in the opposite direction to
its normal operation.
- the fixed roller (22) ,

- the timing belt,
- the crankshaft timing sprocket.
WARNING
When replacing the timing belt, always replace
the tensioning roller and fixed roller.
WARNING
The belt must be replaced with a new one if it
has been removed.
11A-53

F4R, and 770 or 771 or 776
II - ADJUSTING THE TIMING
104703
WARNING
Always degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and bearing faces (23)
,
- the crankshaft accessories pulley bearing
faces,
to prevent slippage between the timing gear and
the crankshaft.
This slippage causes engine damage.
WARNING
WARNING
In this case, the old camshaft pulley nuts must be
removed in order to correctly set the belt tension.
11A-54
11A

11A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
15815-3
Check that the camshaft dephaser wheel is correctly

locked (no rotation of the wheel to the left or to the
right).
11A-55

11A
F4R, and 770 or 771 or 776
16019
16019-3
Fit the (Mot. 1509) with the sprocket (Mot. 1509-01).
Tighten the bolt and collar nut (28) .
Fit the spacer (24) from the (Mot. 1509-01) on stud

(25) .
Bring the toothed sprocket of the (Mot. 1509) into

contact with the camshaft pulleys.
Tighten the toothed sprocket nuts (80 Nm) (29) .
Remove:
- the inlet camshaft dephaser blanking cover (30) ,
- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
- the camshaft pulleys.
WARNING
If the stud is loosened with the nut (see Technical Note 3884A, Replacing F4 camshaft pulley
studs, Top and front of engine, Camshaft ).
16019-1
Fit the upper bolt (26) while positioning the spacer

(27) (Mot. 1509-01) between the tool and the cylinder head cover (do not tighten the bolt).
11A-56

11A
F4R, and 770 or 771 or 776

Torque tighten the old mountings (15 Nm max.)
using the (Mot. 799-01).
F4R, and 776
WARNING
When replacing the timing belt, it is essential to
replace:
- the crankshaft accessories pulley,
- the tensioner pulley and fixed roller,
- the accessories and timing belts.
104711
Install the (Mot. 1509) with its toothed sprocket

(Mot. 1509-01).
Bring the toothed sprockets into contact with the
camshaft pulleys.
Tighten the toothed sprocket nuts (80 Nm) (32)
Remove:
15106-1
- the camshaft pulley nuts,
Position the grooves offset horizontally below the

centre-line as shown above by turning the camshafts using the (Mot. 799-01).
- the (Mot. 1509) ,

WARNING
If the stud is loosened with the nut (see Technical Note 3884A, Replacing F4 camshaft pulley
studs, Top and front of engine, Camshaft ).
Refit the degreased camshaft pulleys with the old

mountings.
11A-57

11A
F4R, and 770 or 771 or 776
15104
Position the (Mot. 1496) , attaching it to the end of

the camshafts.
15114
Correct position
F4R, and 770 or 771

Loosen:
- the inlet camshaft dephaser pulley bolt,
F4R, and 776

Loosen the camshaft pulley nuts.
15163-1
WARNING
Check that the crankshaft is correctly centred.
The crankshaft groove (33) must be between the
two ribs (34) .
11A-58

11A
F4R, and 770 or 771 or 776
15201
Refit the tensioning roller, correctly positioning (35)

the tensioning roller in the groove (36) .
15815-1
Refit:
- the timing belt,
Nm) .
11A-59

11A
F4R, and 770 or 771 or 776

III - BELT TENSION
F4R, and 770 or 771
15256
104728
Fit the (Mot. 1509) with the toothed sprockets (Mot.

1509-01) for locking the camshaft pulleys.
Note:
Do not rotate the tensioning roller anti-clockwise.

Align the tensioning roller marks (38) and (39) using
a 6 mm Allen key at (40) .
Torque tighten the tensioning roller nut to 7 Nm .
Offer up the toothed sprocket nuts against the camshaft pulleys.

Tighten:
- the toothed sprocket nuts (80 Nm) (40) ,
- the old inlet camshaft dephaser mounting bolt
(30 Nm) ,
- the old exhaust camshaft pulley nut (30 Nm) .
Remove the (Mot. 1509) fitted with the (Mot. 150901).
11A-60

11A
F4R, and 770 or 771 or 776
F4R, and 776
21877
104711
Make a pencil mark (43) between the camshaft pulleys and the camshaft bearing cap.
Fit camshaft pulley locking tool (Mot. 1509).
Remove the following tools:
- TDC setting pin (Mot. 1054) ,
- Camshaft setting tool (Mot. 1496).
Tighten to torque:
- the toothed sprocket nuts (80 Nm) (41) ,
- the old inlet and exhaust camshaft pulley nuts
(30 Nm) (42) .
11A-61

11A
F4R, and 770 or 771 or 776

15104
Fit the camshaft setting tool (Mot. 1496).

15163-2
Before completing two turns (i.e. half a tooth before

alignment of the marks made previously by the operator), insert the crankshaft TDC setting pin ( (Mot.
1054) (so that it is between the balancing hole and
the timing hole).
15163-1
Bring the timing to its setting point.
11A-62

11A
F4R, and 770 or 771 or 776
F4R, and 776
F4R, and 770 or 771
15104
104711
Position the (Mot. 1509) with the toothed sprockets

(Mot. 1509-01) for locking the camshaft pulleys.
Fit the (Mot. 1509) for locking the camshaft pulleys.
Tighten the bolt and the collar nut (44) .

Loosen:

Loosen:
- the old inlet camshaft pulley nut,
- the old inlet camshaft dephaser pulley mounting

bolt,
- the old exhaust camshaft pulley nut.

Remove the camshaft pulley locking tool (Mot.
1509).
Remove the (Mot. 1509) with the toothed sprockets
(Mot. 1509-01) for locking the camshaft pulleys.
11A-63

F4R, and 770 or 771 or 776
15256
Align marks (48) with mark (49) by loosening the

tensioning roller nut a maximum of one turn, holding
it with a 6 mm Allen key (50) .
Tighten fully the tensioning roller nut (28 Nm) .
11A-64
11A

11A
F4R, and 770 or 771 or 776

F4R, and 770 or 771
F4R, and 776
104728
Position the (Mot. 1509) with the toothed sprocket

for locking the camshaft pulleys.
104711
Bring the toothed sprocket nuts into contact with the

camshaft pulleys.
Fit the camshaft pulley locking tool (Mot. 1509).
Remove:
Bring the toothed sprocket nuts into contact with the

camshaft pulleys.
- the old inlet camshaft dephaser pulley mounting

bolt,
Remove:
Refit:
- the old inlet camshaft pulley nut,
- a new bolt on the inlet camshaft dephaser pulley,
- a new nut on the exhaust camshaft pulley.
Refit a new nut onto the inlet and exhaust camshaft

pulley.
Tighten to torque the inlet camshaft pulley dephaser bolt (100 Nm) .
Tighten to torque and angle the exhaust camshaft
pulley nut (30 Nm + 86 6)
Tighten to torque and angle the inlet and exhaust

camshaft pulley nut (30 Nm + 86 6) .
Remove the camshaft setting tool (Mot. 1496).
Remove the camshaft setting tool (Mot. 1496).
Tighten to torque the inlet camshaft dephaser

blanking cover (25 Nm)

- Camshaft pulley locking tool (Mot. 1509) with toothed sprocket (Mot. 1509-01).
11A-65
- Tool for locking camshaft pulleys (Mot. 1509).

11A
F4R, and 770 or 771 or 776

15104
Fit the camshaft setting tool (Mot. 1496) without forcing it.
15649
Before completing two turns (i.e. half a tooth before

alignment of the marks made previously by the operator), insert the crankshaft TDC setting pin ( (Mot.
1054) (so that it is between the balancing hole and
the timing hole).
If the tool does not engage, repeat the timing and

tensioning procedure.
REFITTING
Check that mark (55) is aligned with mark (56) on

the tensioning roller before checking the timing adjustment.
Refit:
- the lower timing cover,
- the upper timing cover.
WARNING
The crankshaft accessories pulley and bolt must
be replaced.
15106-1
The offset grooves (57) should be facing horizontally

downwards.
11A-66

11A
F4R, and 770 or 771 or 776
15303
15103-1
Block the flywheel using a large screwdriver.
Refit:
Tighten to torque and angle the crankshaft accessories pulley mounting bolt (40 Nm + 110 +/- 10)
.
- the new sealing plugs:

on the inlet camshaft (Mot. 1487) ,
to the exhaust camshaft (Mot. 1488) ,
- the right-hand suspended engine mounting (see
mounting ) in accordance with the marks.
WARNING
To avoid damaging the crankshaft accessories
pulley, do not start the engine without the accessories belt.
Refit:
Tighten to torque:
- the crankshaft accessories belt (see 11A, Top and

front of engine, Accessories belt: Removal Refitting ).
- the lower timing cover M6 bolts (80 Nm) ,
- the TDC pin plug, applying a drop of SILICONE

ADHESIVE SEAL to the thread hole.
- the lower timing cover M8 bolts (20 Nm) ,

- the upper timing cover M8 bolts (18 Nm) ,
- the upper timing cover M10 bolts (38 Nm) ,
11A-67

11A
F9Q, and 804 or 812

Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01

Mot. 1453.
Mot. 1054
TDC setting pin.
Mot. 1543
Tool for pretensioning

timing belt.
Mot. 1705
Adapter for the timing

belt pretensioning tool.
To be used with
Mot.1543.
104343
Mot. 1505
Belt tension setting

tool (frequency meter)
Mot. 1715
Belt tension checking

tool (frequency indicator).
Remove:
Tightening torquesm
45 Nm
new crankshaft accessories pulley mounting

bolt
4 Nm + 110 +/
- 10
wheel bolts
bolts
104246
130 Nm
Remove:
4 Nm

WARNING

engine, Accessories belt ).

normal operation.
REMOVAL
terminal.
grille ).
11A-68

11A
F9Q, and 804 or 812
102450
102420
Remove:
Mark the position of the suspended engine mounting
in relation to the body.
Slacken the bolt (4)
WARNING
Do not damage the air conditioning pipes (if fitted
to the vehicle).
102451
11A-69

11A
F9Q, and 804 or 812

15102
104329
Remove:
Rotate the crankshaft clockwise (timing end); bring

the camshaft pulley mark to half a tooth before the
mark on the guard.
- the TDC setting pin cap.

- the engine flywheel guard flap,
104330
104739
Remove:
- the crankshaft accessories pulley, locking the
- the timing cover mounting bolts (5) ,
- the timing cover.
11A-70
When the mark on the camshaft pulley is half a tooth

before the mark on the guard, press in the TDC setting pin (Mot. 1054) until the crankshaft is timed.

11A
F9Q, and 804 or 812
104326
104336
Loosen the tensioning roller mounting nut (6) to relax the tensioning roller.
Refit the tensioning roller, taking care to position it

correctly on the pin (7) .
Remove the timing belt.
REFITTING
9
9
WARNING
Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the
crankshaft accessories pulley.
8
10
16187
Check that the TDC setting pin (Mot. 1054) is in place.
Note:
The crankshaft groove (8) should be in the middle of the two crankshaft closure cover ribs (9) .
The crankshaft timing sprocket mark (10) should
be offset one tooth to the left of the vertical axis
of the engine.
11A-71

11A
F9Q, and 804 or 812
11
104327
16563
Fit the new timing belt, aligning the marks on the belt
with those on the crankshaft, camshaft and high
pressure pump sprockets (there should be 28 belt
tooth gaps between the mark on the camshaft sprocket and the mark on the high pressure pump sprocket).
Press the tensioning roller against the belt by tightening the bolt (11) on the tensioning roller support.
Note:
The bolt (11) is manufactured locally.
Fit the old crankshaft accessories pulley bolt.
12
104331
Mount the timing belt pretensioning tool (Mot. 1543)

fitted with the cover (Mot. 1705) (12) on the crankshaft accessories pulley bolt.
11A-72

11A
F9Q, and 804 or 812

(10 Nm) .
Turn the crankshaft through four revolutions.
Reposition the TDC setting pin (Mot. 1054).
Position the timing at its setting point (start pressing
on the rod half a tooth before the camshaft pulley
mark and the protection plate mark are aligned, to
prevent it falling into a crankshaft balancing hole).
Apply a pretensioning torque between the crankshaft timing sprocket and the tensioning roller using
the (Mot. 1543) and a torque wrench set to a torque
of (11 Nm) .
Place the sensor of the (Mot. 1505) between the
crankshaft sprocket and the tensioning roller.
Check that the tension value is 80 5 Hz ; if not, readjust.
104332
Pretension the timing belt between the crankshaft timing sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of
(11 Nm) .
13
104333
Position the sensor of the (Mot. 1505) or the (Mot.

1715) between the crankshaft sprocket and the tensioning roller.
Tension the belt to obtain the recommended value
90 3 Hz by turning the bolt (13) .
11A-73

nut (45 Nm) .

F9Q, and 804 or 812
105435
Remove the old crankshaft accessories pulley bolt.

Refit the crankshaft accessories pulley, without separating its two component parts.
Tighten to torque and angle the new crankshaft accessories pulley mounting bolt (4 Nm + 110 +/10) .
Refit:
WARNING
Battery: Removal - Refitting ).
Tighten to torque:
- the battery cover mounting bolts (4 Nm) ,
11A-74
11A

11A
K4J, and 730

Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01

Mot. 1453.
WARNING
normal operation.
Note:
The timing belt procedures the same for engines
with and without camshaft dephaser.
Mot. 1489
TDC locating pin.
Mot. 1368
Tool for tightening tensioner bolt. 8 mm Torx

wrench, 12.7 mm
square
REMOVAL
Mot. 799-01
Timing gear wheel

immobiliser.

Mot. 1496
grille ).
Mot. 1490-01

camshaft pulleys.
Mot. 1487

camshaft covers (57
mm diameter).
Mot. 1488

camshaft covers (43
mm diameter).
2
1
Tightening torquesm
bolt
45 Nm
pulley bolt
40 Nm + 115
15
27 Nm
new camshaft pulley

nuts
30 Nm + 84
4
104343
20 Nm
upper timing cover bolts

and nuts
41 Nm

bolts

TDC setting pin cap
wheel bolts
Remove:
130 Nm
4 Nm
11A-75

11A
K4J, and 730
104246
102450
Remove:
Remove:
102451
11A-76

11A
K4J, and 730
101866

the body.
101103
Remove:
- the air cleaner mounting,
Remove:
- the engine - suspended engine mounting assembly,

WARNING
14491
Pierce the middle of the plugs on the end of the

camshaft using a screwdriver.
Remove:
- the sealing plugs at the camshaft end with a
screwdriver (4) ,
- the TDC setting pin plug.
11A-77

11A
K4J, and 730

14490
14491-1
Position the camshaft grooves (5) almost horizontally and offset towards the bottom turning the crankshaft in the direction of operation (clockwise timing
end).
Check that the camshaft grooves are horizontal and

offset downwards.
14487
Remove:
- the crankshaft accessories pulley (7) , locking the
14489
Turn the crankshaft in its operating direction (timing

end clockwise), until the crankshaft comes into contact with TDC setting pin.
11A-78


11A
K4J, and 730
REFITTING - PROCEDURE 1
The first procedure is used when replacing any timing component that does not require one or more
camshaft pulleys to be loosened.
WARNING
roller.
11
10
WARNING
Always degrease:
101872
Remove:
- the fixed roller (11) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the timing

sprocket.
the timing,
the crankshaft,

11A-79

11A
K4J, and 730
14490
103261
Set the camshaft grooves horizontally and offset

downwards, by turning the camshafts with the (Mot.
799-01) if necessary.
27
75
36
31
17
16
19
10
13
d9
10
21
103308
Use a locally produced mounting bracket to hold

11A-80

11A
K4J, and 730
12
103260
14489
13
14487-1

11A-81

11A
K4J, and 730

II - REFITTING
14
14487-2
14505

Note:
III - BELT TENSION

There are two tensioning roller versions.
17
15
16
14487-3
Refit:
- the timing belt,
11A-82

11A
K4J, and 730

1 - Type one
19
2 - Second type
23
18
22
21
24
20
14505-1
103263
Move the adjustable index marker (18) on the tensioning roller 7 to 8 mm past the fixed index (19) ,
using a 6 mm Allen key i at (20) .

(7 Nm) .
Note:
Position (21) is the rest position of the adjustable

indexing mark.
in contact with the TDC setting pin).
Remove:
- the camshaft setting tool (Mot. 1496) ,
- screw the Top Dead Centre pin (Mot. 1489) into
the cylinder block.
the TDC setting pin.
For the first tensioning roller version, check that the
adjustable index marker (18) is aligned with the fixed
index (19) , otherwise:
Allen key.
- align the adjustable index marker (18) with the
fixed index marker (19) .
11A-83

11A
K4J, and 730

26
25
Move the crankshaft slowly and smoothly until it is

resting against the pin.
27
103263
For the second tensioning roller version, check that

the adjustable index marker (25) is opposite notch
(26) , otherwise:
Allen key,
nut (27 Nm) .
14490
offset downwards).
WARNING
and the tension.

- screw in the TDC setting pin (Mot. 1489) ,
the TDC setting pin (Mot. 1489).
WARNING
Check that the tensioning roller index markers
are aligned. If not, repeat the tensioning procedure.
11A-84

11A
K4J, and 730
REFITTING -PROCEDURE 2
The second procedure is used for replacing all components requiring one or more of the camshaft pulleys to be slackened.
WARNING
Camshaft ).
WARNING
roller.
14490
WARNING
Always degrease:
the timing,
the crankshaft,
Refit the camshaft pulleys and the old nuts, tightening to a torque of (15 Nm) .
103261
the (Mot. 1496) if necessary.
11A-85

11A
K4J, and 730
28
27
75
36
31
17
16
19
10
13
d9
10
21
103308
14489
Use a locally produced mounting bracket to hold the

30
29
14487-1
103260

Remove the old nuts from the camshaft pulleys and
replace them with new nuts (without locking the
nuts, clearance of 0.5 to 1 mm between the nuts
and the pulleys).
11A-86

Position the RENAULT badge (30) etched on the
camshaft pulley stems vertically and pointing
upwards.

11A
K4J, and 730

II - REFITTING
- the timing belt on the camshaft pulleys (without moving the camshaft pulleys).
31
34
14505
101876
Fit the camshaft pulley locking tool (Mot. 1490-01)

(34) (use the timing cover mountings to fix the tool).
Note:
35
32
33
14487-3
Refit the fixed roller (35) .

14487-3
Refit:

Refit the crankshaft accessories pulley (without tightening the bolt, with 2 to 3 mm play between bolt
and pulley).

11A-87

11A
K4J, and 730

III - BELT TENSION
2 - Second type
There are two tensioning roller versions.
41
1 - Type one
37
40
36
42
39
38
103263
14505-1
Move the adjustable index marker (36) on the tensioning roller 7 to 8 mm past the fixed index (37) ,
using a 6 mm Allen key at (38) .

nut (7 Nm) .
Remove camshaft pulley immobilising tool (Mot.
1490-01).
Note:
Position (39) is the rest position of the adjustable
indexing mark.
Note:
Check that the camshaft pulley nuts and bolt do
not come into contact with their respective pulleys. In addition, from time to time, press the
camshaft pulleys against the camshafts.
Rotate the timing system through six revolutions
with the exhaust camshaft sprocket, using the (Mot.
799-01).
For the first tensioning roller version, check that the
adjustable index marker (36) is aligned with the fixed
index (37) otherwise:
Allen key.
- align the adjustable index marker (36) with the
fixed index marker (37) .
11A-88

11A
K4J, and 730
44
43
45
103263
For the second tensioning roller version, check that

the adjustable index marker (43) is opposite notch
(44) otherwise:
14839
Fit the camshaft pulley immobilising tool (Mot. 149001).

Allen key.
opposite notch (44) turning the eccentric (45) in a
clockwise direction.
nut (27 Nm) .
14489
WARNING
Check that the crankshaft is in contact with the
TDC setting pin (Mot. 1489).
Tighten to torque and angle:
- the crankshaft accessories pulley bolt (40 Nm +
115 15) (crankshaft in contact with the TDC setting pin),
11A-89

11A
K4J, and 730

- the new camshaft pulley nuts (30 Nm + 84 4)
starting with the exhaust pulley.
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool,
Rotate the crankshaft clockwise through two revolutions (timing end); before two complete revolutions:
- screw the TDC setting pin (Mot. 1489) into the cylinder block,
- slowly and smoothly position the crankshaft in contact with the TDC setting pin (Mot. 1489).
14490
offset downwards).
WARNING
Check that the fixed roller indexes are aligned. If
not, repeat the tensioning process.
WARNING
and the tension.

REFITTING
Bring the crankshaft slowly and smoothly into contact with the pin.
Refit the TDC setting pin cap, applying a drop of

RHODORSEAL 5661 onto the thread.
Tighten to torque the TDC setting pin cap (20 Nm) .
Refit the lower timing cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover bolts and
nuts (41 Nm) .
11A-90

K4J, and 730
15103-1
Refit:
- the lower engine tie-bar (see 19D, Engine mounting, suspended engine mounting ),
- new inlet camshaft sealing plugs (Mot. 1487) ,
- new exhaust camshaft sealing plugs (Mot. 1488).
Tighten to torque:
11A-91
11A

11A
K9K, and 732

I - PRECAUTIONS DURING REPAIR

Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01

Mot. 1453.
WARNING
Mot. 1489
TDC locating pin.
Mot. 1430
Set of 5 crankshaft
and camshaft pulley
timing pins.

IMPORTANT
Wear protective gloves when handling.
The belt must be replaced with a new one if it

has been removed.
Do not run the engine without the accessories

belt so as not to damage the crankshaft accessories pulley.
When replacing the belt, always replace the tensioning rollers and fixed rollers.
Tightening torquesm
the camshaft pulley
wheel bolts
14 Nm
tensioning roller bolt
27 Nm
camshaft pulley wheel

bolts
14 Nm
the crankshaft accessories pulley M14 bolt
120 Nm + 95
15
II - PARTS AND CONSUMABLES FOR THE REPAIR

Parts always to be replaced:
- Timing belt,
TDC pin plug
20 Nm
cylinder head suspended mounting bolts
21 Nm
ball joint bracket mounting bolts with their

springs
21 Nm
- Timing belt tensioning roller,

- Crankshaft accessories pulley bolt.
Consumables:
- Silicone adhesive seal part no. 77 11 227 484
III - EQUIPMENT REQUIRED
Equipment:
- Protective gloves,
- Large screwdriver,
- Female torx socket (14),
- Allen key (6 mm),
- Offset spanner (18 mm),
- Bolt tightening gauge,
- Torque wrench.
11A-92

11A
K9K, and 732

IV - REMOVAL
1 - REMOVAL PREPARATION OPERATION
Remove:
104246
Remove:
104343
Remove:
11A-93

11A
K9K, and 732
102450
112654
Remove the acoustic mass (4) .

Detach the manual priming pump.
Remove:
- the engine suspended mounting.
WARNING
piping.
102451
Position the (Mot. 1453) fitted with the (Mot. 145301) with the retaining strap.
Remove:
- the exhaust ball joint bracket mounting bolts,
- the lower engine tie-bar mounting bolts.
11A-94

11A
K9K, and 732
112998
112990

Remove:
- the upper timing cover,
112989
Turn the timing belt gently.

Remove the cylinder head suspended mounting (8) .
11A-95

11A
K9K, and 732
19650
19650-1
Remove the TDC setting pin cap (9) .

2 - OPERATION FOR REMOVAL OF PART
CONCERNED
14489
107270
Turn the crankshaft to position the hole (10) of the

camshaft pulley almost opposite the hole (11) in the
cylinder head.
11A-96
Turn the crankshaft clockwise (timing end) smoothly

until the crankshaft comes in contact with the TDC
setting pin.

11A
K9K, and 732
109049
109046
Insert the pin (13) (Mot. 1430) in the camshaft pulley and cylinder head holes.
Remove:
Remove:
- the camshaft pulley timing pin (Mot. 1430) ,
- the timing belt,
- the timing tensioning roller.
107260
Remove the crankshaft accessories pulley, locking

the flywheel with a screwdriver.
11A-97

11A
K9K, and 732

V - REFITTING
- the mark on the high pressure pump (18) is offset

by one tooth to the right of the vertical axis (19) ,
1 - REFITTING OPERATION FOR PART

CONCERNED
- the crankshaft is in contact with the TDC setting pin

(Mot. 1489) (crankshaft timing sprocket cotter (20)
at the top).
109042
14489
109043
109042
Refit the timing tensioning roller.
Remove one bolt from the camshaft pulley wheel.
Place the tensioning roller lug (15) in the cylinder

head groove (16) .
Loosen the two other camshaft pulley wheel bolts

(22) by one turn.
Engage the pin (17) (Mot. 1430) in the camshaft

pulley and cylinder head holes using an 18 mm offset spanner if necessary.
Check that:
11A-98

11A
K9K, and 732
109044
Fit the timing belt, starting with the crankshaft sprocket, aligning the marks on the belt with those on the
crankshaft sprockets, the camshaft and the high
pressure pump. There should be 19 tooth spaces
between the camshaft sprocket marks and the high
pressure pump, and 51 tooth spaces between the
crankshaft sprockets and the high pressure pump.
11A-99

K9K, and 732
19658
Position the tensioning roller adjustable index marker (23) opposite the lug (24) using a 6 mm Allen
key, turning it anti-clockwise.
Tighten to torque the tensioning roller bolt (27
Nm) .
109047
Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.
11A-100
11A

11A
K9K, and 732
109045
Refit the bolt to the camshaft pulley wheel.

Tighten to torque the camshaft pulley wheel bolts
(14 Nm) .
Remove:
- the TDC setting pin,
- the camshaft pulley timing pin.
107272
Tighten the old crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing
sprocket mark) (25) onto the crankshaft.
11A-101

11A
K9K, and 732
107270
Rotate the crankshaft clockwise through two revolutions (timing end). Before the camshaft pulley hole
(26) is opposite the cylinder head hole (27) .
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
109049
Set the camshaft pulley using (Mot. 1430).
11A-102
109048
If the pin (Mot. 1430) does not engage:

- loosen the camshaft pulley wheel bolts by one turn
only,
- turn the camshaft pulley hub using an offset spanner to facilitate the setting of the camshaft pulley
hub,
- do not retighten the camshaft pulley wheel bolts.

11A
K9K, and 732
109045
Check that the crankshaft timing sprocket cotter (28)

is positioned vertically at the top.
After two turns, the tensioning roller index markers may be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-103

K9K, and 732
111083
111081

key anti-clockwise.
11A-104
11A

11A
K9K, and 732

- camshaft pulley timing pin (Mot. 1430).
Rotate the crankshaft clockwise through two revolutions (timing end). Before the camshaft pulley hole is
opposite the cylinder head hole.
Bring the crankshaft slowly and smoothly into contact with the TDC setting pin.
111082
109049
Set the camshaft pulley using the (Mot. 1430).

If this is not possible, repeat the timing belt refitting
operation.
111081

key clockwise.
Tighten to torque:
- the tensioning roller bolt (27 Nm) ,
- the camshaft pulley wheel bolts (14 Nm) .
Remove the tools:
11A-105

11A
K9K, and 732
107260
Refit the accessories crankshaft pulley with a new

bolt.
Tighten to torque and angle (crankshaft in contact
with the TDC setting pin) the crankshaft accessories pulley M14 bolt (120 Nm + 95 15)
Remove the tools:
- camshaft pulley timing pin (Mot. 1430).
2 - FINAL OPERATION
Refit the TDC setting pin cap, coating the thread with
SILICONE ADHESIVE SEAL .
11A-106
112989
Refit the cylinder head suspended mounting (33) .

Tighten to torque the cylinder head suspended

11A
K9K, and 732
112990
112990
Refit the upper timing cover (38)
19659
Refit:
112654
- the lower timing cover (34) , positioning the tab (35)

in the hole (36) in the inner timing cover,
- the timing cover plastic bolt (37) .
Refit:
- the upper engine tie-bar (see 19D, Engine mounting, Suspended engine mounting ).
Replace the manual priming pump.
Refit the acoustic mass (39) (see 19D, Engine
mounting, Suspended engine mounting ).
Remove the retaining strap of the (Mot. 1453) fitted
with the (Mot. 1453-01).
11A-107

K9K, and 732
Refit:
- the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting ),
- the exhaust ball joint bracket mounting bolts
Tighten to torque the ball joint bracket mounting
bolts with their springs (21 Nm) .
Refit:
engine, Accessories belt ),
- the scuttle panel mounting bolt,
11A-108
11A

Timing chain: Removal - Refitting
M9R, and 700
REMOVAL
Removal of the timing chain requires removal of the
engine - gearbox assembly (see 10A, Engine and
peripherals, Engine - gearbox assembly: Removal - Refitting ).
For removal of the timing chain (see Technical Note
6017A, M9R engine ).
REFITTING
For refitting the timing chain (see Technical Note
Refit the engine - gearbox assembly (see 10A, Engine and peripherals, Engine - gearbox assembly: Removal - Refitting ).
11A-109
11A

11A
K4J, and 730 K4M, and 761 or 782

CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
cylinder head mounting bolts
20 Nm
240 +/- 6
14500
Tighten to torque and in order the cylinder head

WARNING
Reuse the bolts if the length under the head
does not exceed 117.7 mm (otherwise replace
all the bolts).
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
Do not oil the new bolts. The bolts must be oiled
if reused.
Note:
11A-110
Check that all of the cylinder head mounting bolts

are tightened to the correct torque (20 Nm).
Angle-tighten in order the cylinder head mounting
bolts (240 +/- 6) .
WARNING
Do not re-tighten the cylinder head bolts after
applying this procedure.

K9K, and 722 or 728 or 732
Tightening torquesm
25 Nm
255 10
10
19712
WARNING
Always replace all of the cylinder head bolts with
new ones after removal.
To ensure that the bolts are correctly tightened,
use a syringe to draw off any oil that may be in
the cylinder head mounting holes.
Do not oil the new bolts.
Note:
bolts (255 10) .
WARNING
11A-111
11A

11A
F9Q, and 804 or 812

Tightening torquesm
30 Nm
230 +/- 6

bolts (230 +/- 6) .
WARNING
10

16189
WARNING
Systematically replace all cylinder head bolts
after removal.
To ensure correct tightening, use a syringe to
remove any oil that may be in the cylinder head
mounting holes.
Note:
the gasket faces must be clean, dry and free
11A-112

11A
F4R, and 770 or 771 or 776

Tightening torquesm
20 Nm
100 +/- 6
100 +/- 6
9
5
10
1
6
4
8
2
3
7
15153
WARNING
Note:
Systematically replace all cylinder head bolts

after removal.

In order to ensure that the bolts are correctly

tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.


Step 1
- angle-tighten in order the cylinder head mounting
bolts (100 +/- 6) .
11A-113

F4R, and 770 or 771 or 776
Step 2
- Angle-tighten in order the cylinder head mounting bolts (100 +/- 6) .
WARNING
11A-114
11A

Cylinder head gasket : Removal - Refitting
11A
K9K, and 722 or 728

WARNING
Car. 1363
Trim removal lever.
Mot. 1672
Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01
Procedure for removing the air inlet duct (K9K 728):

Mot. 1453.
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
- draw a marking on the inlet duct between the

stainless steel pipe and the hose,
- do not use degreasing agent, brake cleaning product or any other product,
- clean the stainless steel pipe and the hose with a
dry, lint-free cloth,
- if the hose is not being replaced, replace the clip
on the same marking,
- turn on clip on its pivot to facilitate its torque tightening,
- the hose and/or stainless steel pipe must be replaced if they are damaged.
- It is essential to replace the clip.
There is a risk of leaks and unseating if this procedure is not followed.
Equipment required
diagnostic tool
REMOVAL
cylinder head testing tool
angular tightening wrench
Remove:
Tightening torquesm
- the front engine covers,
rocker cover mounting

bolts
10 Nm
turbocharger oil return

pipe
9 Nm
intercooler hose clip

Remove:
5.5 Nm

bolts
4 Nm

IMPORTANT
Before any operation:
- connect the diagnostic tool ,
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
- be aware of the fuel temperature,
- order the special high pressure injection circuit
plug kit.
11A-115

11A
K9K, and 722 or 728
1
2
104343
19626
Fit the engine stand (Mot. 1672).
Remove:
Remove the (Mot. 1453) and the (Mot. 1453-01).

- the scuttle panel partition mounting bolts (2) .
104246
Remove:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
Cooling circuit: Oil change ).
11A-116

11A
K9K, and 722 or 728
K9K, and 722
K9K, and 728
9
12
8
5
11
10
102081
110326
Disconnect:
Disconnect:
- the air temperature and pressure sensor connector

(4) ,
- the air temperature and pressure sensor connector

(9) ,
- the exhaust gas recirculation valve control connector (5) ,
- the exhaust gas recirculation valve control connector (10) ,
- the air hoses (6) ,
- the engine speed and position sensor connector

(11) ,
- the air hose (7) ,

- the turbocharging pressure regulation valve rubber
pipe,
- the air sleeve from the air filter unit,
- the oil vapour rebreathing pipe from the rocker cover.
Remove the resonator unit mounting strut (8) .
11A-117
- the air hose (12) ,

- the rubber hose from the turbocharging pressure
regulator valve.

11A
K9K, and 722 or 728
16
17
18
110325
Pull the clip.
102086
Disconnect:
- the injector connectors,
- the heater plug connectors,
- the rail pressure sensor connector,
15
13
- the diesel fuel supply pipe from the pump,

- the diesel return pipe from the pump,
14
- the diesel temperature sensor (16) ,

- the fuel flow actuator connector (17) .
Remove the wiring and diesel return pipe support
(18) .
110322
Make a mark on the intake pipe between the stainless steel pipe and the hose (13) .
Undo bolt (14) .
Remove air duct (15) .
11A-118

11A
K9K, and 722 or 728
21 20
19
22
102263
Disconnect:
104175
Disconnect the turbocharger oil return pipe (22) .
- the scuttle panel hoses (19) using tool (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (20) on the vacuum
pump side,
- the coolant temperature sensor connector from the
scuttle panel.
- the radiator top hose from the cylinder head water
outlet using the (Mot. 1202-01) or (Mot. 1202-02)
or (Mot. 1448).
23
Unclip the heater radiator hose (21) .

Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
19710
Remove the inner timing cover (23) .
11A-119

11A
K9K, and 722 or 728

I - CLEANING
Clean the cylinder head.
IMPORTANT
Do not scratch the aluminium sealing surfaces.
During the operation, wear:
- goggles,
24
- gloves.
Clean the gasket faces with the product DCAPJOINT to dissolve the section of the gasket
which is still attached.
Apply the product to the section to be cleaned; wait
WARNING
19711
To prevent any foreign bodies from entering the

oil galleries (pipes in both the cylinder block and
cylinder head).
Remove:
- the rocker cover mounting bolts (24) ,
- the rocker cover.
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oilways.
25
Failure to follow this advice could block the pipe,

causing rapid camshaft damage.
II - CHECKING THE GASKET FACE
Check for gasket face deformation using a ruler and
a set of shims.
The maximum deformation is 0.05 mm .
25
WARNING
No regrinding of the cylinder head is permitted.
19712
Test the cylinder head to detect any possible cracks

using cylinder head testing tool.
Remove:
- the cylinder head mounting bolts (25) ,
For the cylinder head stripping procedure (See

Technical Note 6006A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder
head ).
- the cylinder head.
REFITTING
Fit the new cylinder head gasket, centred by two
dowels.
11A-120

11A
K9K, and 722 or 728

Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head.
1
3
WARNING

Refit the cylinder head.
7
4
Tighten the cylinder head (see 11A, Top and front

of engine, Tightening the cylinder head ) using
the angular tightening wrench.
WARNING
The seal faces must be clean, dry and free from
grease (avoid finger marks).
WARNING
19711

squeezed out when parts are tightened. The mixture of the product and coolant can cause some
components (engine, radiator) to deteriorate.
Refit the rocker cover.

Tighten to torque and in order the rocker cover
Reconnect the turbocharger oil return pipe, fitted
with new seals.
26
Tighten to torque the turbocharger oil return pipe

(9 Nm) .
26
26
19712-1
Fit the new rocker cover gasket.

Apply beads (26) of SILICONE ADHESIVE SEAL 2
mm in diameter.
19709
Reconnect:
- the oil vapour rebreathing pipe,
- the new turbocharger air sleeves.
K9K, and 728
Reconnect the air pipe by aligning the marks.
11A-121

K9K, and 722 or 728
Tighten to torque the intercooler hose clip (5.5
Nm) .
Refit:
- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ),
Timing belt: Removal - Refitting ),
Fill the cooling system (see 19A, Cooling, Cooling
system: Oil change ).
Reprime the diesel circuit (see 13B, Fuel supply,
Diesel fuel supply circuit ).
Bleed the cooling system (see 19A, Cooling, Cooling system: Bleeding ).
(4 Nm) .
11A-122
11A

11A
K4M, and 761 or 782

Tightening torquesm
Mot. 1672
Mot. 1453
Multiple-adjusting
straps.
Mot. 1669
Fitting cam follower

tappet.
Mot. 1453-01

Mot. 1453.
camshaft dephaser
solenoid valve bolt
spark plugs
12 Nm
coil mounting bolts (if

holes not threaded)
15 Nm
camshaft position sensor mounting bolt
10 Nm
inlet manifold mounting

bolts
9 Nm

bolts
4 Nm

camshaft pulleys.
Mot. 1573
Cylinder head support
Mot. 104
Cylinder head
gning tool
Mot. 1513
Tool for refitting camshaft dephaser solenoid

valve lip seal.
REMOVAL
Spark plug spanner

toolkit 16 & 21 mm torque 1.75 & 28 Nm +
square adapter 9-9.52
for spanner Ele. 1086
Remove:
Ele. 1382
Mot. 1632
Tool for fitting PTFE

camshaft seal
Mot. 1487

camshaft covers (57
mm diameter).
Mot. 1488

camshaft covers (43
mm diameter).
Equipment required
Tightening torquesm
mounting bolts no. 22,
23, 20 and 13 of the
cylinder head cover
12 Nm
oil decanter mounting

bolts
15 Nm
25 to 30 Nm

the holes are already
threaded)
Mot. 1490-01
ali-
10 Nm
11A-123

Remove:

11A
K4M, and 761 or 782
2
1
104343
19626
Remove:
Set up the engine stand (1) (Mot. 1672).
Remove the (Mot. 1453) and (Mot. 1669).
104246
Remove:
103265
Remove the camshaft pulleys using the (2) Mot.

1669 (Mot. 1669) camshaft pulley locking tool.

IMPORTANT
Be careful of petrol splashing out when disconnecting the fuel supply union.

11A-124
WARNING
Camshaft ).

11A
K4M, and 761 or 782

Remove:
- the injector rail protector,
- the fuel supply pipe from the injection rail.
Move the fuel supply pipe aside.
14889
18699
Remove the bracket mounting bolt (4) .

Move the bracket to one side.
102735
Remove the wiring harness bracket mounting bolts

(5) .
Disconnect:
- connector (6) from the coolant temperature sensor,
- the water unit hoses using the (Mot. 1453) or (Mot.
1453-01) or (Mot. 1490-01) ,
- the brake servo vacuum pipe (7) on the inlet manifold side.
Move the bracket/wiring harness assembly aside.
11A-125

11A
K4M, and 761 or 782

- the catalytic converter upstream oxygen sensor
connector.
8
9
14
12
15
11 10
18666
Disconnect:
104240
- the ignition coil connectors (8) ,
Disconnect the injector connector (14) .
- the air temperature sensor connector (9) ,
Unfasten clip (15) .
- the camshaft dephaser solenoid valve connector

(10) ,
Move the wiring harness to one side.
- the inlet manifold pressure sensor connector (11) ,

- the fuel vapour recirculation solenoid valve pipe
(12) ,
Remove:
- the ignition coils,
- the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
13
101809
Disconnect:
- the camshaft position sensor connector (13) ,
11A-126

11A
K4M, and 761 or 782

Remove the camshaft pulleys using the (Mot. 149001).
16
20
17
21
103272
Remove:
103255
- the lifting bracket (16) ,

- the inlet manifold mounting bolts (17) ,
WARNING
- the inlet manifold.
Do not remove the bolt (20) as it acts as a stop

for the squared cam tappet.
Remove:
- the oil decanter mounting bolts (21) ,
18
- the oil decanter.
19
101793
Remove:
- the catalytic converter-gearbox stay mounting bolts
(18) ,
- the catalytic converter/gearbox stay,
- the exhaust pipe mounting nuts (19) .
Move the exhaust pipe to one side.
11A-127

11A
K4M, and 761 or 782
23
24
22
22
103256
14499
Remove:
Remove:
- the rocker cover mounting bolts,
- the valve rockers (23) ,
- detach the rocker cover vertically, tapping the lugs

(22) with a copper hammer.
- the hydraulic tappets (24) .
WARNING
Note:
Do not damage the aluminium surfaces.
To prevent any risk of unpriming the hydraulic

tappets make sure that they are vertical.
Remove:
- the cylinder head mounting bolts,
Mount the cylinder head on the cylinder head mounting (Mot. 1573).
Remove the cylinder head gasket from the cylinder
block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
103258
Remove the inlet and exhaust camshafts.
- goggles,
- gloves.
Clean the gasket faces with DCAPJOINT to dissolve off the parts of the seal still attached.
11A-128

11A
K4M, and 761 or 782

26
WARNING
25
Do not allow this product to drip onto the paintwork.

Clean the cylinder head carefully to prevent
foreign bodies from entering the oil supply and
return galleries.
Failure to follow this guideline could lead to the
blocking of the oilways, resulting in rapid and
serious damage to the engine.
Use a ruler and set of shims to check that there is no
gasket face bow.
Maximum distortion: 0.05 mm
14689
WARNING
Check that the centring dowel is present (25) on the

cylinder block.
Set up tool (Mot. 104) (26) on the cylinder block.

using the cylinder head testing tool.
REFITTING
For the cylinder head stripping procedure (see NT

3784A, 4 cylinder - K4 petrol engine, 10A, Engine
and peripherals, Rebuilding the cylinder head ).
Position the pistons at mid-stroke to prevent any
contact with the valves when refitting the camshafts.
Always degrease:
Fit the new cylinder head gasket.

Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Tightening the cylinder
head ).
of engine, Tightening the cylinder head ).
- the combustion face of the cylinder head,

- the combustion face of the cylinder block.
11A-129

11A
K4M, and 761 or 782

I - CAMSHAFT MARKINGS
Inlet camshaft
27
28
14499
Reprime the hydraulic tappets (hydraulic tappets

may be empty after a long down time).
102507
To check if repriming is necessary, press the top of

the tappet (27) with your thumb.
(28)
The inlet camshaft is fitted with

the camshaft sensor target.
If the tappet piston depresses:

- immerse the tappets in a container full of diesel
fuel,
Exhaust camshaft
- refit the hydraulic tappets.

Refit:
- the valve rockers,
29
- the camshafts, oiling the bearings.
102506
(29)
11A-130
The exhaust camshaft is fitted

with the square cam.

11A
K4M, and 761 or 782
30
31
36
32
35
33
103685
103687
Position the pin (30) of tool (Mot. 1669) against the

bottom of the groove by turning the bolt (31) .
Tighten the bolt (35) until the pin (36) is hard up

against the bottom of the groove.
Mount the tool (Mot. 1669) on the rocker cover, correctly positioning the pin (32) in the rocker cover
hole (33) .
34
37
103688
103684
Fit rocker cover tool (Mot. 1669) using the bolts (34)
.
11A-131
Position the bolt of tool (Mot. 1669) in place of the

original bolt at (37) to hold the tappet in the compressed position.

11A
K4M, and 761 or 782
39
38
103686
15106-1
Turn the bolt (38) until the pin (39) is hard up against
the bottom of the groove.
Position the camshaft grooves horizontally and offset downwards.
Remove the (Mot. 1669) from the rocker cover.

Note:
The gasket faces on the cylinder head cover
must be clean, dry and free from grease (remove
any finger marks).
Note:
could damage certain components (engine,
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-132

K4M, and 761 or 782
40
14517
Using a stipple roller, apply LOCTITE 518 to the

camshaft rocker cover gasket face until it turns reddish.
Using a cloth, remove the LOCTITE 518 from (40)
on the six camshaft rocker cover bearings.
11A-133
11A

11A
K4M, and 761 or 782

II - TIGHTENING PROCEDURE
14497

- cylinder head cover mounting bolts 22, 23, 20
and 13 (8 Nm) ,
- cylinder head cover mounting bolts 1 to 12, 14
to 19 and 21 to 24 (12 Nm) .
Loosen in order mounting bolts 22, 23, 20 and 13.
Tighten to torque and in order mounting bolts no.
22, 23, 20 and 13 of the cylinder head cover (12
Nm) .
11A-134

11A
K4M, and 761 or 782
10
1
9
4
8
7
3
2
101820
Refit the oil decanter.

Tighten to torque and in order the oil decanter
102073
WARNING
of grease.
Remove bolt (10) of tool (Mot. 1669) to release the

tappet.
Refit the original bolt, applying a drop of LOCTITE
FRENETANCH .
41
WARNING
radiator).
Using a stipple roller, apply LOCTITE 518 on the
gasket face until it is reddish.
16016
Refit:
- the camshaft dephaser solenoid valve seal using
(Mot. 1513) (41) ,
- the camshaft dephaser solenoid valve.
Tighten to torque the camshaft dephaser solenoid
valve bolt (10 Nm) .
11A-135

11A
K4M, and 761 or 782
42
106443
On the ignition coils, apply a bead (42) of FLUORINATED GREASE 82 00 168 855 2 mm in diameter
to the inner circumference of the high tension cap.
11A-136

11A
K4M, and 761 or 782
4
3
1
2
5
43
6
103257
103272
Refit the plugs.
Tighten to torque and in order the inlet manifold

Torque tighten the spark plugs (25 to 30 Nm) using

the spark plug spanner set (Ele. 1382).
III - REPLACING THE CAMSHAFT SEALS
Refit the coils.

Tighten to torque:
- the coil mounting bolts (if the holes are already
threaded) (12 Nm) ,
- the coil mounting bolts (if holes not threaded)
(15 Nm) .
Refit the camshaft position sensor (43) with a new
seal.
Torque tighten the camshaft position sensor
mounting bolt (10 Nm)
Always replace all the inlet manifold seals.
44
45
20257
The elastomer seal is for this engines fitted with a

flat lip (44) and a protector (45) (which also assists in
fitting the seal to the engine).
11A-137

11A
K4M, and 761 or 782

1 - Fitting the exhaust camshaft seal
48
46
47
105531
18687
WARNING
It is very important to hold the protector (4 6)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (47) in order to prevent any oil
leaks once the seal is fitted to the engine.
48
21687
Screw the stud of (48) tool (Mot. 1632) onto the

camshaft.
11A-138

11A
K4M, and 761 or 782
21687-1
21687-3
Fit the protector, with a seal, to the camshaft.
Screw on the collar nut until the cover touches the

cylinder head.
Remove the nut, cover, protector and threaded rod.
2 - Fitting the inlet camshaft seal
49
50
WARNING
It is very important to hold the protector when
handling the seal, as this type of seal is very fragile. In order to prevent any oil leaks once the
seal is fitted to the engine, it is strictly forbidden
to touch the elastomer seal.
21687-2
Fit the housing (49) and the collar nut ring bolt (50)
of tool (Mot. 1632).
11A-139

11A
K4M, and 761 or 782
51
52
105531
105532
Fit the protector (51) , with a seal, to the camshaft.

Push the middle of the protector so that the seal
squeezes into the housing.
52
105534

camshaft.
105533
Remove the seal protector, taking care not to drop

the seal.
11A-140

11A
K4M, and 761 or 782
53
54
105535
Fit the housing (53) and the collar nut ring bolt (54)
of (Mot. 1632).
cylinder head.
15103-1
Refit:
- new inlet camshaft sealing plugs using the (Mot.
1487) ,
- new exhaust camshaft sealing plugs using tool
(Mot. 1488) ,
IV - REFITTING
Refit the timing belt (see 11A, Top and front of engine, Timing belt ).
WARNING

system: Oil change ).
Follow the second timing belt refitting procedure.

Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting
).
11A-141

(4 Nm) .

11A
F4R, and 770 or 771

Tightening torquesm
Mot. 1672
spark plugs
25 to 30 Nm
Mot. 1509
Camshaft sprocket
locking tool.

holes threaded)
12 Nm
Mot. 1509-01
Adapter kit for tool

Mot.1509.

non-threaded holes)
15 Nm
Mot. 1202-01

clips.

bolts
11 Nm
Mot. 1202-02

clips.

bolts
4 Nm
Mot. 1448

hose clips.
REMOVAL
Mot. 1573
Mot. 1517
Camshaft seal fitting

tool.
Remove:
Mot. 1512
Camshaft oil seal fitting tool (28 x 47).
Mot. 1487

camshaft covers (57
mm diameter).

Mot. 1488

camshaft covers (43
mm diameter).
Remove:
Equipment required
Tightening torquesm
mounting bolts 22, 23,

20 and 13 on the rocker
cover
8 Nm

bolts 1 to 12, 14 to 19
and 21 to 24
12 Nm
new or original oil

decanter mounting bolts
(in tapped holes)
10 Nm
new oil decanter mounting bolts (in non-tapped holes)
15 Nm
104343
Remove:
11A-142

11A
F4R, and 770 or 771
5
6
104246
Remove:
16019-4
Fit the (Mot. 1509) with the sprocket (Mot. 1509-01).

Tighten the collar nut (4) and the bolt (5) , then bring
the sprockets of the (Mot. 1509) into contact with the
camshaft pulleys while torque tightening the nuts
(80 Nm) (6) .
Remove the inlet camshaft dephaser blanking cover
using a 14 mm Allen key.
19626
Leave the engine mountings (Mot. 1672) in place.
11A-143

11A
F4R, and 770 or 771
16019-4
18699
Remove:
- inlet camshaft dephaser bolt,

WARNING
Camshaft ).
11A-144

11A
F4R, and 770 or 771
11
12
9
11
15
14 13
8
14889
18666
Disconnect:
10
- the camshaft dephaser connector (13) ,

(15) ,
- the injector connectors,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Remove:
- the plugs,
102735

(8) .
Disconnect:
- the connector (9) from the coolant temperature
sensor,
- the scuttle panel hoses using (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448).
11A-145
- the dephaser solenoid valve.

11A
F4R, and 770 or 771
20
16
21
17
102939
102940
Remove:
Remove:
- the engine lifting bracket (16) on the timing end,
- the oil decanter mounting bolts.

- the oil decanter (20) ,
- the lifting bracket on the flywheel end (21) .
18
19
101793
Remove:
- the catalytic converter-gearbox stay mounting bolts
(18) ,
11A-146

F4R, and 770 or 771
22
22
102941
Remove the rocker cover bolts.

Remove the rocker cover vertically, tapping the lugs
(22) with a copper hammer.
WARNING
Remove the camshaft seals.
11A-147
11A

11A
F4R, and 770 or 771
15151
11A-148

F4R, and 770 or 771
14499
Remove:
Note:
11A-149
11A

11A
F4R, and 770 or 771
15153

Remove:
- the cylinder head bolts,
WARNING
- Do not allow this product to drip on to the paintwork.

block.
- Clean the cylinder head carefully to prevent

foreign matter entering the oilways.
- Failure to follow this advice could lead to blocking of the various oil channels, resulting in rapid
destruction of the engine.
I - CLEANING
IMPORTANT
Use a cylinder head adjuster and set of shims to

check the gasket face bow.
- goggles,
- gloves.
11A-150
WARNING

11A
F4R, and 770 or 771

6027A, 4 cylinder - F4 petrol engine, 10A, Engine
25

contact with the valves when the camshafts are
being refitted.
Always degrease:
REFITTING
Check the bolts (see 11A, Top and front of engine,
Tightening the cylinder head ).
of engine, Tightening the cylinder head ) using a
angular tightening wrench.
14499
Re-prime the hydraulic tappets (hydraulic tappets

may empty if they have been removed for some time).
To check if re-priming is necessary, press the top of
the tappet at (25) with your thumb.
- immerse the thrust bearings in a container full of
diesel fuel,
Refit:
- the camshafts, oiling the bearings.
11A-151

11A
F4R, and 770 or 771
26
27
15152
15106-1
The camshafts are identified by the pulley mountings.
Position the camshaft grooves as shown in the diagram.
Detailed view of the pulley mountings:

- (26) : exhaust camshaft,
WARNING
- (27) : inlet camshaft.

Refit the camshafts, positioning them correctly (see

10A, Engine and peripherals, Engine peripherals: Specifications for camshaft identification ).
WARNING
squeezed out when parts are tightened. The sealing compound/fluid mixture can cause damage
to certain components (engine, radiator, etc.).
WARNING
Do not apply oil on the sealing surface of the
camshaft bearing cap cover.
11A-152

F4R, and 770 or 771
28
14517

crankshaft cylinder head joint face until the joint face
is reddish in colour.
Note:
Using a cloth, remove the LOCTITE 518 from
(28) on the camshaft rocker cover bearings.
11A-153
11A

11A
F4R, and 770 or 771
14497

- mounting bolts 22, 23, 20 and 13 on the rocker
cover (8 Nm) .
- the rocker cover mounting bolts 1 to 12, 14 to 19
and 21 to 24 (12 Nm) .
Slacken bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order mounting bolts 22,
23, 20, 13 (12 Nm) .
11A-154

11A
F4R, and 770 or 771
2
5
6
4
1
8
7
102738
102729

WARNING

- the new or original oil decanter mounting bolts

(in tapped holes) (10 Nm) ,
- the new oil decanter mounting bolts (in nontapped holes) (15 Nm) .
WARNING
squeezed out when parts are tightened. The sealing compound/fluid mixture can cause damage
to certain components (engine, radiator, etc.).
gasket face until it turns reddish.
11A-155

11A
F4R, and 770 or 771
29
106443
Apply to the four ignition coils a bead (29) of FLUORINE GREASE 82 00 169 855 , 2 mm in diameter
around the inner edge of the high voltage cap to improve sealing.
11A-156

11A
F4R, and 770 or 771
2
3
6
5
102939
15103-1
Refit:
Refit the plugs.
- the new sealing plugs:

Tighten to torque the spark plugs (25 to 30 Nm) .
on the inlet camshaft (Mot. 1487) ,
Refit the coils.
to the exhaust camshaft (Mot. 1488) ,
Tighten to torque:
- the coil mounting bolts (if holes threaded) (12
Nm) ,
- the right-hand suspended engine mounting (see

mounting ).
- the coil mounting bolts (if non-threaded holes)

(15 Nm) .

Refit the inlet manifold with its new seal.

Refit the camshaft dephaser solenoid valve, with a

new seal.
Replacing the camshaft seals:
- use the (Mot. 1517) for the inlet camshaft seal.
- use the (Mot. 1512) for the exhaust camshaft seal.
Refit:
- the timing belt (it is essential to follow the procedure (see 11A, Top and front of engine, Timing
belt: Removal - Refitting ),
11A-157

(4 Nm) .

11A
F9Q, and 812

WARNING
Mot. 1672
Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01
Fit plugs into the openings.

Mot. 1453.
Be sure to follow the safety instructions.

Refer to (see 13B, Diesel injection, Cleanliness
guidelines ).
REMOVAL
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Remove:
Mot. 1448

hose clips.

Equipment required
diagnostic tool
Remove:
- the battery tray,
Tightening torquesm
oil supply pipe bolt on
the turbocharger
22.5 Nm
oil supply pipe bolt on

the cylinder block
22.5 Nm
oil return pipe bolts

12 Nm

bolts
4 Nm
1
2
IMPORTANT
- connect the diagnostic tool ,
104343
Remove:

plug kit.
- the air filter access panel (1) mounting bolts,

- the scuttle panel partition mounting bolts (2) .
11A-158

11A
F9Q, and 812
6
7
5
104246
Remove:

105511
Disconnect:
- the air duct (5) to the turbocharger,
- the oil vapour rebreathing pipe (6) ,
- the engine - damping device valve pipe (7) .
Remove:
- the air duct (8) from the inlet manifold,
- the oil decanter (9) .
105432

11A-159

11A
F9Q, and 812
10
12
13
14
14
15
11
16
19
18983
15
17
Remove the vacuum tank mounting bolts (10) .
18
20
Disconnect:
- the turbocharger pressure regulation solenoid valve pipes,
105512
- the engine damping device solenoid valve connector (11) ,
Disconnect:
- the camshaft sensor connector (12) .
- the exhaust gas recirculation solenoid valve connector (13) ,
Remove the vacuum tank.
- the injector connectors (14) ,

- the heater plug connectors (15) ,
- the rail pressure sensor connector (16) ,
- the high-pressure pump pressure regulator connector (17) ,
- the diesel return temperature sensor connector
(18) ,
- the diesel filter connector,
- the diesel supply pipe (19) ,
- the diesel return pipe (20) .
Fit the blanking plugs.
11A-160

11A
F9Q, and 812
21
23
24
104323
18997
Disconnect:
Remove:
- the cylinder head outlet water unit hoses using the

(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the connector (21) from the coolant temperature

sensor.
- the oil supply pipe (23) ,
22
102348
Remove bolts (22) securing the high pressure pump.
11A-161
- the oil return pipe mountings (24) from the turbocharger.

11A
F9Q, and 812

WARNING
oil pipes (pipes in both the cylinder block and
cylinder head).
WARNING
25

from entering the cylinder head oil supply galleries.
Failure to follow this advice could block the oil
supply pipes, causing rapid camshaft damage.
16189
Check for gasket face bow using a ruler and a set of

shims.
Remove the cylinder head mounting bolts (25) .

WARNING
When removing the cylinder head, take care not
to cause any damage to its gasket face as it passes the turbocharger above it.
WARNING
Remove the cylinder head. This operation requires

two people.
For the cylinder head stripping procedure (see

Technical Note 3652A, 4-cylinder Cast Iron High
Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder
head ).
I - CLEANING
IMPORTANT
Do not scratch the aluminium joint surfaces.
REFITTING
- goggles,

the cylinder head.
- gloves.
Clean the gasket faces with DCAPJOINT to dissolve off the parts of the seal still attached to the sump
and the cylinder block.

of engine, Tightening the cylinder head ) using a
Tighten to torque:
- the oil supply pipe bolt on the turbocharger
(22.5 Nm) ,
- the oil supply pipe bolt on the cylinder block
(22.5 Nm) ,
11A-162

F9Q, and 812
- the oil return pipe bolts (12 Nm) .
Refit:
(4 Nm) .
11A-163
11A

F4R, and 776
WARNING
When removing and refitting the turbocharger the
repair procedures must be carefully applied to
ensure the system is sealed: FAILURE TO FOLLOW THESE INSTRUCTIONS COULD HAVE
SERIOUS SAFETY CONSEQUENCES FOR THE
DRIVER .
Removing the cylinder head gasket requires the engine and transmission assembly to be removed (see
10A, Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ).
For the cylinder head gasket stripping procedure
(see Technical Note 6027A, F4 4-cylinder petrol
engine, 10A, Engine and peripherals, Rebuilding
the cylinder head ).
11A-164
11A

11A
K4J, and 730

Tightening torquesm
Mot. 1448

hose clips.
Mot. 1453
Multiple-adjusting
straps.
(new or original) oil

decanter mounting bolts
in the pre-threaded housings
spark plugs
10 Nm .
25 to 30 Nm

the holes are already
threaded)
12 Nm

holes not threaded)
15 Nm
Mot. 1490-01

camshaft pulleys.

bolts
9 Nm
Mot. 1202-01

clips.

bolts
4 Nm
Mot. 1202-02

clips.
Mot. 1453-01

Mot. 1453.
Mot. 1672
REMOVAL
Mot. 1573
Mot. 104
Cylinder head
gning tool
Remove:
Ele. 1382
Spark plug spanner

ali-

Remove:
Mot. 1491
Camshaft oil seal fitting tool.
Mot. 1632
Tool for fitting PTFE

camshaft seal

Mot. 1669
Fitting cam follower

tappet.
Equipment required
Tightening torquesm
mounting bolts nos. 22,
23, 20 and 13 of the
cylinder head cover
12 Nm
oil decanter mounting

bolts (new) in the nonthreaded housings
15 Nm
11A-165

11A
K4J, and 730
2
1
104343
19626
Set up the engine stand (1) Mot. 1448 .
Remove:
Remove (Mot. 1453) ; and (Mot. 1453-01).

104246
Remove:
101876
Remove the camshaft pulleys using the camshaft

pulley locking tool (2) Mot. 1672 (Mot. 1490-01).

IMPORTANT

11A-166
Be careful of petrol splashing out when disconnecting the fuel supply union.
If the stud is loosened with the nut (see Technical
Note 3887A, Replacing K9 - K4 camshaft pulley
studs, 11A, Top and front of engine, Camshaft ).
Remove:
- the injector rail protector,
- the fuel supply pipe from the injection rail.
Move the fuel supply pipe aside.

11A
K4J, and 730

9
8
11
10
18699
18666
Disconnect:
(11) ,
- the catalytic converter upstream oxygen sensor

connector.
5
14889

(5) .
Disconnect:
- connector (7) from the coolant temperature sensor,
- the water unit hoses using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
11A-167

11A
K4J, and 730
12
15
13
14
104240
18706
Remove:
Unfasten clip (13) .
- the lifting bracket (14) ,
Remove:

- the plugs,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting ),
16
- the throttle valve (see 12A, Fuel mixture, Throttle

valve: Removal - Refitting ).
17
101793
Remove:
- the catalytic converter/gearbox strut mounting bolts
(16) ,
Move the exhaust pipe to one side.
11A-168

K4J, and 730
18
18431
Remove:
- the oil decanter mounting bolts (18) ,
- the oil decanter.
19
19
103256
Remove:
- the rocker cover mounting bolts,
- detach the cylinder head cover vertically, tapping
the lugs (19) with a copper hammer.
WARNING
11A-169
11A

11A
K4J, and 730
14498
11A-170

11A
K4J, and 730

20
WARNING
Do not allow this product to drip onto the paintwork.
21
Clean the cylinder head carefully to prevent

foreign bodies from entering the oilways.
Failure to follow this guideline could lead to the
blocking of the oilways, resulting in rapid and
serious damage to the engine.

Use a ruler and set of shims to check that there is no
gasket face bow.
14499
Remove:
WARNING

Note:
Remove:

3784A, 4 cylinder - K4 petrol engine, 10A, Engine
contact with the valves when refitting the camshafts.
Always degrease:
- the cylinder head mounting bolts,
block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
- goggles,
- gloves.
11A-171

11A
K4J, and 730
23
24
22
14689
14499
Check that the centring dowel is present (22) on the

cylinder block.
Reprime the hydraulic tappets (hydraulic tappets

may be empty after a long down time).
Set up tool (Mot. 104) (23) on the cylinder block.
To check if repriming is necessary, press the top of

the tappet (24) with your thumb.
REFITTING
- immerse the thrust bearings in a container full of

diesel fuel,

Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Tightening the cylinder
head ).
of engine, Tightening the cylinder head ).
11A-172

Refit:
- the camshafts, lubricating the bearings.

11A
K4J, and 730

I - CAMSHAFT MARKINGS
Inlet camshaft
101880
Position the groove (25) horizontally on the end of

the camshaft (groove below the centre line of the
camshaft).
The cams (26) for cylinder 1 must be located to the
right of the vertical axis (27) , flywheel end view.
11A-173

11A
K4J, and 730

Exhaust camshaft
101881
Position the groove (28) horizontally on the end of

the camshaft (groove below the centre line of the
camshaft).
The cams (29) for cylinder 1 must be located to the
left of the vertical axis (30) , flywheel end view.
11A-174

11A
K4J, and 730
31
15106-1
14517
Position the camshaft grooves horizontally and offset downwards.

camshaft rocker cover gasket face until it turns reddish.
WARNING
The gasket faces on the cylinder head cover
must be clean, dry and free from grease (remove
any finger marks).
WARNING
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-175
Using a cloth, remove the LOCTITE 518 at (31) from

the six cylinder head cover bearings.

11A
K4J, and 730

II - TIGHTENING PROCEDURE
14497

- cylinder head cover mounting bolts 22, 23, 20
and 13 (8 Nm) ,
- cylinder head cover mounting bolts 1 to 12, 14
to 19 and 21 to 24 (12 Nm) .
Loosen in order mounting bolts 22, 23, 20 and 13.
Tighten to torque and in order mounting bolts nos.
22, 23, 20 and 13 of the cylinder head cover (12
Nm) .
11A-176

11A
K4J, and 730
3
2
4
5
1
7
101869
18431

WARNING

of grease.
- the oil decanter mounting bolts (new) in the

non-threaded housings (15 Nm)
- the (new or original) oil decanter mounting
bolts in the pre-threaded housings (10 Nm .)
WARNING
radiator).
Using a stipple roller, apply LOCTITE 518 on the
gasket face until it is reddish.
11A-177

11A
K4J, and 730
32
106443
On the ignition coils, apply a bead (32) of FLUORINATED GREASE 82 00 168 855 , 2 mm in diameter
to the inner edge of the high-tension cap.
Refit the plugs.
Torque tighten the spark plugs (25 to 30 Nm) using
the spark plug spanner set (Ele. 1382).
Refit the coils.
Tighten to torque:
- the coil mounting bolts (if the holes are already
threaded) (12 Nm) ,
- the coil mounting bolts (if holes not threaded)
(15 Nm) .
Always replace all the inlet manifold seals.
11A-178

11A
K4J, and 730
5
2
1
6
14497-1

Refit:
valve: Removal - Refitting ),
33
unit: Removal - Refitting ).
III - REPLACING THE CAMSHAFT SEALS
There are two types of elastomer camshaft seal
which are easy to identify.
34
20256
The first type of elastomer seal is fitted with a spring

(33) and a lip seal (34) in a V shape.
11A-179

11A
K4J, and 730

1 - Fitting first version camshaft seals
37
35
36
38
20257
The second type of elastomer seal is fitted with a flat

lip seal (35) and a protector (36) (which also assists
in fitting the seal to the engine).
Note:
Both versions can be fitted on the same engine.
They are not interchangeable. It is essential to
use the same version when replacing an old
seal, except when one or more camshafts are
replaced.
11A-180
14892
Fit the seals using tool (Mot. 1491) (37) and the old
nuts (38) .

11A
K4J, and 730

2 - Fitting the second type of seal to the camshaft
41
39
40
105531
18687
WARNING
It is very important to hold the protector (3 9)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (40) in order to prevent any oil
leaks once the seal is fitted to the engine.
41
21687

camshaft.
11A-181

11A
K4J, and 730
21687-1
21687-3
Fit the protector, with a seal, to the camshaft.

cylinder head.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of engine, Timing belt ).
42
43
WARNING
Follow the second timing belt refitting procedure.
).
21687-2
Fit the housing (42) and the collar nut (43) of tool
(Mot. 1632).
11A-182

K4J, and 730
15103-1
Refit:
- the new inlet camshaft sealing plugs using tool
(Mot. 1669) ,
- the new exhaust camshaft sealing plugs using tool
(Mot. 1669).
(4 Nm) .
11A-183
11A

11A
F9Q, and 804

Always respect the repair precautions (see 13B,
Diesel injection, Diesel injection: Repair precautions ).

Mot. 1672
Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01

Mot. 1453.
Equipment required
Remove:
- the battery tray,
- the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ).
cylinder head testing equipment
Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ).
Remove:
engine, Accessories belt: Removal - Refitting) ,
Tightening torquesm
bolts
4 Nm

Timing belt: Removal - Refitting).
IMPORTANT
- connect the diagnostic tool (After-Sales),
plug kit.
105432
Fit the engine stand using the (Mot. 1672).
REMOVING - REFITTING
Remove:
Cooling system: Draining - Refilling ).
WARNING
11A-184

11A
F9Q, and 804
13
6
11
15
12
3
14
5
111887
111886
Disconnect:
- the vacuum pipe from the vacuum pump (11) ,
- the EGR connector (13) ,
10
- the coolant temperature sensor (14) ,

- the turbocharger vacuum pipes (15) .
111888
16
Disconnect:
17
17
- the air inlet duct (see 12A, Fuel mixture, Air inlet:
Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the throttle valve connector (5) ,
- the turbocharging pressure solenoid valve connector (6) ,
111965
- the air flow sensor connector (7) ,
Disconnect:
- the rail pressure sensor connector (8) ,
- the camshaft sensor connector (16) ,
- the diesel pressure regulator connector (9) .
Remove:
Fit the blanking plugs.
- the injection rail protector (10) (see 13B, Diesel injection, Injection rail protector ).
11A-185

11A
F9Q, and 804
18
18
19
20
111889
Disconnect:
- the diesel return temperature sensor connector,
- the high pressure pump pressure regulator connector,
102348
Remove:
- the diesel return pipe (19) ,
- the high pressure pump rear mounting bolts (20) ,
- the diesel fuel supply pipe.
- the windscreen wiper mounting,
Remove:
- the bonnet,
- the starter motor (see 16A, Starting-charging,

Starter motor: Removal - Refitting ),
- the cylinder head mounting bolts.
- the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ).

- the water hoses.
Disconnect the cylinder head outlet water unit hoses.
11A-186
WARNING
When removing the cylinder head, take care not
to cause any damage to its gasket face as it passes the turbocharger above it.

11A
F9Q, and 804

I - CLEANING
IMPORTANT
21

- goggles,
- gloves.
Clean the gasket faces with DECAPJOINT to dissolve any part of the gasket which is attached to the
sump and cylinder block.
111861

approximately 10 minutes, then remove residue
WARNING
oil galleries (galleries in both the cylinder block
and cylinder head).
21
WARNING
Protect the oil outlet duct to prevent any foreign
bodies from entering the cylinder head oilways.
Failure to follow this instruction could lead to the
pipes becoming blocked, causing rapid camshaft
damage.
111863
Remove the mounting bolts (21) from the exhaust

gas recirculation pipe.
Remove the mounting clip from the exhaust gas recirculation pipe.

a set of shims.
Remove the cylinder head mounting bolts.
Remove the cylinder head.

WARNING
Regrinding is not permitted.
using a cylinder head testing equipment.
(see Technical Note 3652A, 4-cylinder Cast Iron
High Pressure Common Rail Diesel Engine, 10A,
Engine and peripherals, Rebuilding the cylinder
head) for the procedure for stripping down the cylinder head.
11A-187

F9Q, and 804
REFITTING
the cylinder head.
Degrease the gasket faces.
Refit the cylinder head with a new cylinder head gasket.
Refit new cylinder head bolts.
of engine, Tightening the cylinder head) using a
Refit the catalytic pre-converter (see 19B, Exhaust,
Catalytic Pre-converter: Removal - Refitting ).
Refit the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).
).
(4 Nm) .
11A-188
11A

11A
K9K, and 732

IMPORTANT
Car. 1363
Trim removal lever.
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Mot. 1672
Mot. 1453
Multiple-adjusting
straps.
Mot. 1453-01

Mot. 1453.
Before carrying out any work on the injection system, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to follow the safety and cleanliness
advice specified in this document whenever work is
carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).
WARNING
Procedure for removing the air inlet duct (risk of
leaking and slipping if this procedure is not observed):
- do not use degreaser, brake cleaning agents, or
any other products,
Equipment required
diagnostic tool
- clean the bearing face on the intercooler and on

the hose with a dry, lint-free cloth,
hydraulic crane
- Always replace the clip with a new one,
load positioner
- place the clip in the same position if the hose is

not replaced,
- it is essential to replace the hose and/or the intercooler if they are damaged,
REMOVAL
Tightening torquesm
bolts
10 Nm
alternator mounting
bolts
21 Nm
air inlet duct clip
5.5 Nm

Remove
- the bonnet (see MR 371, Bodywork, 48A, Nonside opening element, Bonnet ).
WARNING
Before starting work on the vehicle, obtain:

- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,

- cleaning product (part no. 77 11 224 188) .
11A-189

11A
K9K, and 732
104343
Remove:
104175
Disconnect the turbocharger oil return pipe (4) .
Drain the cooling system via the radiator bottom hose, using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
104246
Remove:
Timing belt ).
- the catalytic converter (see 19B, Exhaust, Catalytic converter ).
11A-190
19710
Remove:
- the inner timing cover (5) mounting bolts,
- the inner timing cover.

11A
K9K, and 732
19626
112815

102473
Disconnect the air inlet pressure sensor connector

(6) .
Loosen clip (7) and (8) .
Remove the air inlet duct (9) .
11A-191

11A
K9K, and 732
112811
112992
Unclip injector rail protector cover (13) .
Pull the clip.
Remove:
- the mounting nut and bolt (14) from the injector rail
protector cover,
- the injection rail protector cover,
- the dipstick,
- the dipstick tube mounting bolts (15) .
Move the dipstick tube to one side.
112991
Make a mark (10) on the air inlet duct between the

stainless steel pipe and the hose.
Detach the hose from the stainless steel pipe.
Remove:
- the mounting bolt (11) from the stainless steel pipe,
- the stainless steel pipe (12) .
112993
Disconnect:
- the injector connector (16) ,
11A-192

11A
K9K, and 732

- the heater plugs connector (17) .
102267
112994
Disconnect:
Remove the upper mounting bolt (25) from the alternator.
- the connector (18) from the damper valve,
Loosen lower alternator mounting bolt (26) .
- the cylinder marking sensor connector (19) ,
Tilt the alternator forward.
- the pressure regulation solenoid valve connector

(20) ,
- the flow regulation solenoid valve connector (21) ,
- the diesel temperature sensor connector (22) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (23) .
Remove the wiring harness clip mounting nut (24) .
11A-193

11A
K9K, and 732
112656
113475
Remove:
Pour cleaning product into a container.
- the mounting bolts (29) from the injector rail protector cover mounting bracket,
IMPORTANT
Wear protective gloves when using cleaning product.
- the injector rail protector cover retaining bracket.
Soak the brush with cleaning product and clean the

fuel supply and return pipe unions.
Blast the cleaned areas with compressed air then
dry using new cloths.
IMPORTANT
Wear protective glasses.
WARNING
Do not blow compressed air once the fuel circuit
is open, otherwise impurities may enter the system. Use wipes if necessary.
111748
Unclip the diesel evacuation pipe.

Remove:
Disconnect:
- the injector rail protector support bolt and mounting

nuts (30) ,
- the injector rail protector support,
- the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting ).
Note:
Make preparations for fuel outflow. Clean with
new cloths.
Fit the correct blanking plugs.
11A-194

11A
K9K, and 732
112996
Disconnect the oil vapour rebreathing pipe (31) on

the rocker cover side.
Remove the air inlet duct (32) .
113476
Remove:
- the rocker cover mounting bolts (36) ,
- the rocker cover.
CONCERNED
112997
Disconnect:
- the exhaust gas recirculation solenoid valve connector ,
- the scuttle panel hoses (33) using tool (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (34) on the vacuum
pump side,
19712
Remove:
scuttle panel.
- the radiator top hose from cylinder head coolant
outlet housing (35) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
valve hose on the vacuum pump side,
valve hose on the pressure regulation valve side.
11A-195
- the cylinder head mounting bolts (37) ,

- the cylinder head using a hydraulic crane fitted
with a load positioner.

11A
K9K, and 732
REFITTING
II - OPERATION FOR REFITTING PART

CONCERNED
Fit the new cylinder head gasket, centred by two

dowels.
1 - CLEANING

the cylinder head.
IMPORTANT
Note:

Wear goggles.
Wear gloves during the operation.
Refit the cylinder head using a hydraulic crane fitted with a load positioner.
Clean the gasket faces with the product

DCAPJOINT to dissolve the section of the gasket which is still attached.

of engine, Tightening the cylinder head ) using
the angular tightening wrench.
Apply the product to the section to be cleaned;

wait approximately ten minutes, then remove the
residue using a wooden spatula.
Note:
WARNING
oil pipes (pipes in both the cylinder block and
cylinder head).

Fit the new rocker cover gasket.
WARNING
from entering the cylinder head oil supply galleries.
Failure to follow this advice could block the pipe,
causing rapid camshaft damage.
2 - CHECKING THE GASKET FACE

a set of shims.
19712-1
WARNING
Apply beads of (38) de RHODORSEAL 5661 2 mm

in diameter.

using cylinder head testing tool.
Note:
For the cylinder head stripping procedure (See
Technical Note 6006A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder
head ).
11A-196

squeezed out when parts are tightened. The mixture of the product and coolant can cause some
components (engine, radiator) to deteriorate.

11A
K9K, and 732

Refit:
- the injector rail protector cover retaining bracket,
- the injector rail protector cover retaining bracket
mounting bolts.
Connect:
- the fuel return pipe.
Refit the upper alternator mounting bolt.
Torque tighten the alternator mounting bolts (21
Nm) .
Fit the wiring harness.
Refit the wiring harness clip mounting nut.
Clip on the wiring harness retaining clip.
113476
Connect:
Tighten to torque and in order the rocker cover

- the diesel temperature sensor connector,
Connect:
- the connector of the pressure regulation solenoid

valve,

valve hose on the pressure regulation valve side.
valve hose on the vacuum pump side,
- the radiator top hose from the cylinder head coolant outlet housing using (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) ,
scuttle panel.
- the connector of the flow regulation solenoid valve,
- the cylinder marking sensor connector,

- the connector on the damper valve,
- the heater plug connector.
- the injectors' connector.
Refit:
- the dipstick tube,
- the brake servo vacuum pipe on the vacuum pump

side,
- the dipstick tube mounting bolts.
- the scuttle panel hoses using (Mot. 1202-01) or

(Mot. 1202-02) or (Mot. 1448) ,
Refit the air inlet duct between the air filter unit outlet
and the turbocharger inlet.
Connect the oil vapour rebreathing pipe on the rocker cover side.
- the dipstick,
- the injector rail protector cover mounting nut and

bolt,
Clip the injector rail protector cover.
Refit:
Refit:
- the clip on the stainless steel pipe if necessary,
- the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting ),
- the stainless steel pipe on the hose, aligning the

marking,
- the air inlet duct clip between the turbocharger and

the intercooler.
- the mounting nuts and bolt of the injector rail protector support.
Tighten to torque the air inlet duct clip (5.5 Nm) .

Clip the stainless steel pipe to the turbocharger.
Clip the diesel evacuation pipe.
11A-197

K9K, and 732
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct between the air inlet flap and the
intercooler.
Tighten the clips.
Connect the air inlet pressure sensor connector.
Fit the (Mot. 1453) fitted with the (Mot. 1453-01).
Remove the engine stand (Mot. 1672).
Refit:
- the inner timing cover,
- the inner timing cover mounting bolts.
Connect the turbocharger oil return pipe.
Refit:
- the catalytic converter (see 19B, Exhaust, Catalytic converter ),
Timing belt ).
- the scuttle panel mounting bolts.
Refit:
- the bonnet (see MR 371, Bodywork, 48A, Nonside opening element, Bonnet ),
11A-198
11A

Crankshaft seal at timing end Removal - Refitting
11A
M9R, and 700

CONCERNED
Tightening torquesm
crankshaft sealing ring
timing end
47 Nm
right-hand side stiffener mounting bolts
21 Nm
REMOVAL
Remove:
tyres, Wheel: Removal - Refitting .
101212
Remove:
- the right-hand side stiffener mounting bolts,
- the right-hand side stiffener (1) ,
11A-199
114853
Remove the crankshaft sealing ring using tool (2)

supplied in the spare parts kit for the new gasket.

11A
M9R, and 700
REFITTING

CONCERNED
114850
113656
Position the notches on the new sealing (3) opposite

the notches on the timing cover (4) .
Note:
114851
Engage the sealing ring notches in the timing cover

notches.
Tighten the sealing ring by hand using the tool supplied in the new gasket spare parts kit.
11A-200

M9R, and 700
114852
Using the tool supplied in the new gasket spare

parts kit tighten to torque the crankshaft sealing
ring timing end (47 Nm) .
Refit:
- the right-hand side stiffener,
- the right-hand side stiffener mounting bolts.
Tighten to torque the right-hand side stiffener
Refit:
tyres, Wheel: Removal - Refitting ).
11A-201
11A

Cylinder head: Removal - Refitting
M9R, and 700
REMOVAL
Removal of the cylinder head requires removal of
the engine - gearbox assembly (see 10A, Engine
and peripherals, Engine - gearbox assembly: Removal - Refitting ).
For removal of the cylinder head (see Technical
Note 6017A, M9R engine ).
REFITTING
For refitting the cylinder head (see Technical Note
Refit the engine - gearbox assembly (see 10A, Engine and peripherals, Engine - gearbox assembly: Removal - Refitting ).
11A-202
11A
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Engine
Gear-
Vehicle
Type
Suffix
box
Bore
Stroke
(mm)
(mm)
Compression
Cubic
capacity
ratio
(cm 3)
JM0U
JM1N
ND0
770
JM05
JM0U
9.8/1
F4R
82.7
93
1998
JM1M
DD0
771
ND0
776
JM1N
JM05
JM0W
9.5 0.3
Test carried out at idle speed(1)
Fuel (2)
Engine
emissions(3)
Pollutant
Type
Suffix
Idling
speed
CO2 (%)
CO (%)(4)
HC (ppm)
(minimum
Lambda ()
octane
rating)
(rpm)
F4R
770
771
776
/
/
750 50
0.5
14.5
100
maximum
maximum
maximum
(1)for
(3)for
a coolant temperature above 80C and after the

engine speed has stabilised at 2500 rpm for approximately 30 seconds .
(2)octane
(4)at
0.97<<1.03
Super
unleaded
(octane
rating 95)
the legal values, see specifications by country
2000 rpm CO should be 0.3 % (maximum)
rating 91 unleaded compatible
Temperature in C 1
-10
25
50
80
110
120
Negative temperature coefficient air temperature sensor (resistance in )
10454
to 8623
2174 to
1928
857 to
763
326 to
292
143 to
127
112 to
98
Negative temperature coefficient coolant

temperature sensor (resistance in )
13588
to 11332
2364 to
2140
850 to
772
290 to
275
117 to
111
90 to 86
12A-1
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776
Description
Brand - Type
Special notes
Injection computer
SAGEM 3000
Ignition and sequential multipoint injection computer

128 - track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump
It is part of a pump - sender - filter assembly

incorporating the pressure regulator
Pressure: 3.5 bar 0.06
Minimum flow: 80 to 120 l/h
SAGEM
Four coils
Primary resistance: tracks 1 and 2 approximately 0.5
Secondary resistance: track 1 and high voltage output: 10.5 k 1.5

2-track connector:
- 1: + 12 V supply
- 2: earth control
Ignition coils
BERU (F4R776 only)
Four coils
Primary resistance: track 1 and 2 approximately 0.5

2-track connector:
- 1: + 12 V supply
- 2: earth control
SIEMENS - DEKA 4
Bi-jet solenoid injector

Resistance: 14.5 0.7 at 20C
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors
SIEMENS - DEKA 7
(F4R776 only)
Resistance: 12 0.5 at 20C

2-track connector:
- 1: + 12 V supply
- 2: earth control
12A-2
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776

Description
Brand - Type
Special notes
SIEMENS - MAP03
Piezoelectric type sensor

Replace the seal with a new one whenever it is removed.
3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Manifold pressure sensor

BOSCH
(F4R776 only)

3-track connector:
- 1: + 5 V supply
- 2: earth
- 3: signal
Firing order
1-3-4-2
no. 1 at flywheel end
Accelerator pedal potentiometer
CTS
Dual gang potentiometer

Resistance values:
- gang 1: tracks 3 and 5: 1700 900
- gang 2: tracks 2 and 6: 2850 2050
6-track connector:
- 1: gang 2 signal
- 2: 5 V supply, gang 2
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Pinking sensor
SAGEM

Tightening torque: 20 Nm

sensor
SIEMENS
Variable reluctance type sensor

Resistance: 200 to 270 at 23C
12A-3
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776

Description
Brand - Type
Special notes
Upstream and downstream

oxygen sensors
BOSCH - LSF 4.2
The sensor heating is interrupted when the exhaust

gas temperature rises above 850 C .
Heating resistor: 9 at 20C
4-track connector:
- A: + heating resistor
- B: - heating resistor
- C: + signal
- D: - signal
Warm engine:
- Rich mixture > 800 mV
- Lean mixture < 50 mV
Fuel vapour absorber solenoid valve
Resistance: 26 4 at 23C
SAGEM
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature sensor
JAEGER
Negative temperature coefficient thermistor (see previous table)
Coolant temperature sensor
JAEGER ELTH
or SILEA
Refrigerant sensor
TEXAS INSTRUMENTS
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
Fault finding
diagnostic tool
CLIP only
12A-4
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776

Description
Brand - Type
Special notes
VDO Egas 5
Direct current geared electronic motor
60 mm diameter
6-track connector:
(F4R, and 770 or 771)
- 1: potentiometer gang no. 1 signal

- 2: 5 V potentiometer supply
- 3: + motor
- 5: - motor
- 6: common earth
Motor resistance: approximately 2.3 at 23C
Potentiometer resistance:
tracks 2 and 6: 1000 250
Throttle valve
VDO EgasT
Diameter 40 mm
6-track connector:
(F4R776 only)
- 1: earth
- 2: Potentiometer signal 1
- 3: - motor
- 4: + motor
- 5: + 5 V potentiometer supply
- 6: Potentiometer signal 2
tracks 1 and 5: 1000 250
Camshaft dephaser solenoid

valve
AISIN
It is controlled as all or nothing.
(F4R, and 770 or 771)

2-track connector:
- 1: +12 V supply
- 2: earth
CHAMPION
YCL
RC 87
Single electrode spark plugs

Gap: 0.90 mm 0.05
(F4R, and 770 or 771)
Torque: 25 to 30 Nm
Ignition spark plug

NGK PFR6G-9
(F4R776 only)
Gap: 0.90 mm 0.01

Torque: 25 to 30 Nm
Catalytic converter
EBERSPCHER
C175
(F4R, and 770 or 771 or 776)
12A-5
FUEL MIXTURE
Specifications
12A
K4M, and 761 or 782 K4J, and 730
Equipment required
diagnostic tool
Engine
Gear-
Vehicle
Type
Suffix
box
Bore
Stroke
(mm)
(mm)
Compression
Cubic
capacity
ratio
(cm 3)
JM0B
JM0H
JH3
K4J
730
42 (70)
1390
10 : 1
80.5
1598
9.8 : 1
JM1A
JM0C
JM0J
DP0
761
79.5
JM1B
K4M
JM0C
JM0J
JR5
782
JM1B
Test carried out at idle speed(1)

Fuel (2)
Engine
emissions(3)
Pollutant
Type
Suffix
Idling
speed
CO2 (%)
CO (%)(4)
HC (ppm)
(minimum
Lambda ()
octane
rating)
(rpm)
K4J
730
K4M
761
782
750 50
/
700 40
0.5
14.5
100
maximum
maximum
maximum
(1)for
(3)for
a coolant temperature above 80C and after the

engine speed has stabilised at 2500 rpm for approximately 30 seconds .
(2)octane
(4)at
0.97<<1.03
Super
unleaded
(octane
rating 95)
the legal values, see specifications by country
2000 rpm CO should be 0.3 % (maximum)
rating 91 unleaded compatible
Temperature in C 1
-10
25
50
80
110
120
Negative temperature coefficient air temperature sensor (resistance in )
10454
to 8623
2174 to
1928
857 to
763
326 to
292
143 to
127
112 to
98
Negative temperature coefficient coolant

temperature sensor (resistance in )
13588
to 11332
2364 to
2140
850 to
772
290 to
275
117 to
111
90 to 86
12A-6
FUEL MIXTURE
Specifications
12A
K4M, and 761 or 782 K4J, and 730
Description
Brand - Type
Special notes
Injection computer
SAGEM 3000
Ignition and sequential multipoint injection computer

128 - track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump
It is part of a pump - sender - filter assembly

incorporating the pressure regulator
Pressure: 3.5 bar 0.06
Minimum flow: 80 to 120 l/h
Ignition coils
SAGEM
Four coils
Primary resistance: tracks 1 and 2 approximately 0.5

2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors
SIEMENS - DEKA 4

2-track connector:
- 1: + 12 V supply
- 2: earth control
SIEMENS - MAP03

3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Firing order
1-3-4-2
no. 1 at flywheel end
12A-7
FUEL MIXTURE
Specifications
12A
K4M, and 761 or 782 K4J, and 730

Description
Brand - Type
Special notes
CTS

Resistance values:
- gang 1: tracks 3 and 5: 1700 900
- gang 2: tracks 2 and 6: 2850 2050
6-track connector:
- 1: gang 2 signal
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Pinking sensor
SAGEM


sensor
SIEMENS
Variable reluctance type sensor

K4J
Description
Brand - Type
Special notes
Upstream and
downstream oxygen sensors
DELPHIOSP+

4-track connector:
- C: + signal
- D: - signal
Warm engine:
12A-8
FUEL MIXTURE
Specifications
12A
K4M, and 761 or 782 K4J, and 730
K4M
Description
Brand - Type
Special notes
Upstream and
downstream oxygen sensors
BOSCH - LSF 4.2
The sensor heating is interrupted when the exhaust gas temperature

rises above 850 C .
4-track connector:
- C: + signal
- D: - signal
Warm engine:
Description
Brand - Type
Special notes
Fuel vapour absorber solenoid valve
SAGEM
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature
sensor
JAEGER
JAEGER ELTH
Refrigerant sensor
or SILEA
TEXAS INSTRUMENTS
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
Fault finding
diagnostic tool
CLIP only
12A-9
FUEL MIXTURE
Specifications
12A
K4M, and 761 or 782 K4J, and 730
K4J
Description
Brand - Type
Special notes
Throttle valve
VDO EI
60 mm diameter
6-track connector:
- 1: common earth
- 3: - motor
- 4: + motor
tracks 1 and 5: 1000 250
K4M
Description
Brand - Type
Special notes
Throttle valve
VDO Egas 5
57 mm diameter
6-track connector:
- 3: + motor
- 5: - motor
- 6: common earth
tracks 2 and 6: 1000 250
Camshaft dephaser solenoid valve
DELPHI
It is actuated by an opening cyclic ratio.

2-track connector:
- 1: +12 V supply
- 2: earth
12A-10
FUEL MIXTURE
Specifications
K4M, and 761 or 782 K4J, and 730
Description
Brand - Type
Special notes
Ignition spark plug
EYQUEMR FN 58
LZ o r CHAMPION
RC 87 YCL

Gap: 0.95 mm 0.05
Torque: 25 to 30 Nm
Catalytic converter
EBERSPCHER
C150
12A-11
12A
FUEL MIXTURE
Air inlet
12A
F4R, and 770 or 771

DIAGRAM OF THE AIR INTAKE CIRCUIT
4
5
2
102744
(1)
Air intake sleeve
(2)
Air resonator
(3)
Air filter unit
(4)
Throttle valve
(5)
Intake manifold
(6)
Injector holder shim
(7)
Air intake
12A-12
FUEL MIXTURE
Air inlet
12A
K4J, and 730

Diagram of the air inlet circuit
4
3
5
2
6
8
102071
(1)
Air intake trunking
(2)
Air resonator
(3)
Air filter box
(4)
Air unit
(5)
Throttle valve
(6)
Intake manifold
(7)
(8)
Air intake
12A-13
FUEL MIXTURE
Air inlet
12A
K4M, and 761 or 782

4
5
2
6
7
1
2
101190
(1)
Air intake sleeve
(2)
Air resonator
(3)
Air filter box
(4)
Throttle valve
(5)
Intake manifold
(6)
(7)
Air intake
12A-14
FUEL MIXTURE
Air inlet
12A
F9Q, and 812

114617
(1)
Air inlet
(2)
Air filter
(3)
Flowmeter
(4)
Turbocharger
(5)
Inlet manifold
(6)
Engine stop flap
(7)
Intercooler
12A-15
FUEL MIXTURE
Air inlet
12A
K9K, and 722

Air intake circuit diagram
3
7
8
1
6
102070
(1)
Air intake trunking
(2)
Air filter unit
(3)
Exhaust gas recirculation unit
(4)
Air resonator
(5)
Metal air intake tube
(6)
Air-to-air intercooler
(7)
Turbocharger
(8)
Air intake
12A-16
FUEL MIXTURE
Air inlet
12A
F4R, and 776
4
6
1
107841
(1)
Air intake
(2)
Air resonator
(3)
Air filter unit
(4)
Turbocharger
(5)
Intercooler
(6)
Intake distributor input
12A-17
FUEL MIXTURE
Air inlet
12A
K9K, and 728
4
3
5
8
1
110316
(1)
Air inlet sleeve
(2)
Air filter unit
(3)
(4)
Air resonator
(5)
Metal air inlet tube
(6)
Intercooler
(7)
Turbocharger
(8)
Air inlet
12A-18
FUEL MIXTURE
Air inlet
12A
F9Q, and 804

112269
(1)
Air inlet
(2)
Air filter unit
(3)
Flowmeter
(4)
Turbocharger
(5)
Inlet manifold
(6)
Damper flap
(7)
Intercooler
(8)
Air filter
(9)
EGR solenoid valve
12A-19
FUEL MIXTURE
Air inlet
12A
K9K, and 732
3
6
4
1
112302
(1)
Air inlet
(2)
Air filter unit
(3)
Flowmeter
(4)
Turbocharger
(5)
Damper flap
(6)
Air filter
(7)
Intercooler
(8)
Air resonator
12A-20
FUEL MIXTURE
Air inlet
12A
M9R, and 700

114472
(1)
Air inlet scoop
(2)
Noise-reducing air duct
(3)
Air resonator
(4)
Air filter unit
(5)
Air filter
(6)
Air flowmeter
(7)
Turbocharger
(8)
Intercooler
(9)
Damper flap
(10)
EGR solenoid valve
12A-21
FUEL MIXTURE
Air resonator: Removal - Refitting
12A
M9R, and 700
REMOVAL
REFITTING

CONCERNED
Remove the front bumper (see MR 371, Bodywork,

55A, Exterior protection, Front bumper ).
CONCERNED
115171
Position the air resonator.

Clip on the air resonator (4) then at (5) .
115171
Unclip:
Refit the front bumper (see MR 371, Bodywork,

55A, Exterior protection, Front bumper ).
- the air resonator (1) ,

- the retaining tab from the air resonator, then the air
resonator (2) .
Remove the air resonator (3) .
12A-22
FUEL MIXTURE
Air filter: Replacement
12A
K4J, and 730

I - REPLACING THE FILTER ELEMENT
Remove the engine covers.
104548
Disconnect brake servo vacuum pipe (2) from the inlet manifold.
101103
Remove:
WARNING
- the air resonator mounting bolt (1) ,
Do not damage the vacuum outlet on the inlet

manifold. If it is damaged, the inlet manifold will
need to be replaced.
- the air resonator housing.
Remove:
- air filter cover mounting bolts (3) ,
- the filter element.
II - REFITTING
12A-23
FUEL MIXTURE
12A
K4M F4R K9K F9Q M9R

Mot. 1608
Torque screwdriver.
Tightening torquesm
bolts
4 Nm
I - REMOVAL PRE PARATION OPERATION
104551
Cut out air filter access (3) .

Remove:
- the air filter access panel.
K4M, and 761 or 782 F4R, and 770 or 771 or 776

K9K, and 722 or 728 F9Q, and 812
103629
Remove the lip seal (1) .
103630
Remove:
104549
- the mounting nuts (2) from the scuttle panel grille,
Remove:
- the scuttle panel grille.
- the mounting bolts (5) from the battery cover,
12A-24
FUEL MIXTURE
12A
K4M F4R K9K F9Q M9R

III - REFITTING PREPARATION OPERATION
- the battery cover.
Note:
Clean the inside of the air filter unit.

CONCERNED
IV - REFITTING OPERATION FOR PART

CONCERNED
Refit the filter element into its cover.
WARNING
Correctly replace:
- the filter element in its cover,
- the cover - filter element assembly in the air
filter unit.
Non-filtered air may be directed to the engine if
this is incorrectly positioned.
101806
Remove the mounting bolts (6) from the cover.

Refit:
- the cover - filter element assembly,
- the cover mounting bolts.
V - FINAL OPERATION
K4M, and 761 or 782 F4R, and 770 or 771 or 776

K9K, and 722 or 728 F9Q, and 812
Refit:
- the battery cover,
- the mounting bolts to the battery cover.
(4 Nm) using the (Mot. 1608).
104550
Remove:
- the cover - filter element assembly,
Refit:
- the filter element from its cover.

- the scuttle panel grille,
- the scuttle panel grille mounting nuts,
- the lip seal.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting
12A
K4J, and 730
Tightening torquesm
air filter unit mounting
bolt
9 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:

104343
Removal
- the scuttle panel grilles (see Workshop Repair
Manual 371 Bodywork, 55A, Exterior protection, Scuttle panel grille ),
- the air filter access flap mounting bolts (1) ,

101103
Remove:
- the air resonator mounting bolt (4) ,
12A-26
FUEL MIXTURE
12A
K4J, and 730
5
8
104548
Disconnect brake servo vacuum pipe (5) from the inlet manifold.
101494
Remove:
- the oxygen sensor connector (7) ,
- the retaining bracket (8) .
WARNING
Remove:
- air filter cover mounting bolts (6) ,
- the filter element.
101488
Remove air unit mounting bolts (9) .

Withdraw the air filter unit.
12A-27
FUEL MIXTURE
K4J, and 730
REFITTING
Replace:
- the throttle body seal each time it is removed using
grease to make fitting easier,
- the plastic rivets and clips every time they are removed.
Tighten to torque the air filter unit mounting bolt (9
Nm) .
WARNING
Battery: Removal - refitting ).
(4 Nm)
12A-28
12A
FUEL MIXTURE
12A
F9Q, and 812 K9K, and 722 or 728

Tightening torquesm
bolts
21 Nm

bolts
4 Nm
- the battery.
REMOVAL
terminal.
1
2
104556
Disconnect the injection computer connectors (4) .
104343
F9Q, and 812 K9K, and 728

Remove:
- the scuttle panel grilles (see MR 371 Bodywork,
Remove:
- the wiring harness strap (6) .

Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
104246
Remove:
12A-29
FUEL MIXTURE
12A
F9Q, and 812 K9K, and 722 or 728
101811
Remove the injection computer and its support (7) .
104554
Remove:
- the air inlet sleeve (9) ,
F9Q, and 812 K9K, and 728
- the air ducts (10) .
104555
Remove the pipes (8) from the turbocharger regulation solenoid valve.
Move the solenoid valve to one side.
12A-30
104553
FUEL MIXTURE
F9Q, and 812 K9K, and 722 or 728
REFITTING
(21 Nm) .
WARNING
(4 Nm) .
12A-31
12A
FUEL MIXTURE
12A
F4R, and 770 or 771 or 776 K4M, and 761 or 782
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove the battery.
104246
Remove:
2
5
4
104343
Remove:
- The scuttle panel grilles (see MR 371 Bodywork,

101822

Remove:
12A-32
FUEL MIXTURE
12A
101811
101808
Remove the injection computer and its support (7) .
Remove:
- the air ducts (10) ,

REFITTING
(21 Nm) .
WARNING
104241
Unfasten clips (8) .

Remove the air duct.
12A-33

(4 Nm) .
FUEL MIXTURE
12A
K9K, and 732 F9Q, and 804

Tightening torquesm
bolts
21 Nm

bolts
4 Nm
- the battery.
REMOVAL
terminal.
4
1
2
112659

Unclip:
104343
Remove:
- the wiring harness for the computer connector,

- the wiring harness from the turbocharger regulation
solenoid valve,
Remove:
- the computer support upper mounting bolt,
- the mounting bolts (6) from the computer support,

- the injection computer with its support,
- the mounting bolts (7) from the battery tray,
- the wiring harness mounting bolt (8) .
104246
Remove:
12A-34
FUEL MIXTURE
12A
K9K, and 732 F9Q, and 804
104555
104553
Move the turbocharger regulation solenoid valve (9)

to one side.
REFITTING
11

(21 Nm) .
10
WARNING
11

(4 Nm) .
104554
Remove:
- the air ducts (11) .
12A-35
FUEL MIXTURE
12A
M9R, and 700
Tightening torquesm
air filter unit air outlet
pipe clip on the air flowmeter side
5.5 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm

bolts
21 Nm
REMOVAL
112659
Disconnect:
Remove
- the injection computer connectors (1) ,

- the air flowmeter connector,

- the turbocharger regulation solenoid valve connector.
Unclip:
- the wiring harness (2) from the injection computer
connector,
solenoid valve and air flowmeter,
- the turbocharger regulation solenoid valve on the
air filter unit,
- the wiring harness from the injection computer connectors, turbocharger regulation solenoid valve
and air flowmeter.
Remove:
- the mounting nut (4) from the wiring harness.
Remove the battery tray with the injection computer
support.
12A-36
FUEL MIXTURE
12A
M9R, and 700

112658
114933
Remove:
(5) ,
- the engine accessories unit cover,

102365
Remove:
115585

Remove:
- the clips (8) ,
12A-37
FUEL MIXTURE
12A
M9R, and 700
114847
115019
Undo the air filter unit air outlet pipe clip (12) on the
air flowmeter side.
Remove the air inlet scoop - anti-noise air pipe - air

filter unit inlet air pipe assembly (14) .
Disconnect the air filter unit air outlet pipe on the air
flowmeter side.

CONCERNED
115171
115020
Remove the air resonator (13) .

Remove air filter unit (15) .
12A-38
FUEL MIXTURE
12A
M9R, and 700
REFITTING

Refit:
- the wiring harness mounting nut,

Note:

(21 Nm) .
Check that the air filter unit rubber contact studs

are all in position.
Clip:
- the wiring harness for the injection computer connectors, turbocharger regulation solenoid valve
and air flowmeter,

CONCERNED
Refit the air filter unit.
- the turbocharger regulation solenoid valve on the

air filter unit,

solenoid valve and air flowmeter,
Connect the air filter unit air outlet pipe on the air
flowmeter side.
Tighten to torque the air filter unit air outlet pipe
clip on the air flowmeter side (5.5 Nm) .

- the wiring harness to the injection computer connector.
Refit:
Connect:
- the air inlet scoop - anti-noise air pipe - air filter

unit inlet air pipe assembly,
- the turbocharger regulation solenoid valve connector,
- the air resonator,
- the injection computer connectors.
Refit:
Tighten to torque:
Nm) ,

Nm) .
- Adjust the xenon headlights (if fitted to the vehicle),

- Adjust the headlights (see 80B, Headlights,

Connect the screen washer pipes.

Refit the clips.
Connect the engine accessories unit connectors.
Refit:
- the battery tray with the injection computer support.
12A-39
FUEL MIXTURE
Air inlet duct: Removal - Refitting
12A
F9Q, and 812
Tightening torquesm
inlet duct mounting
bolts
inlet duct nut
8 Nm
21 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:
104343
Remove:
- the scuttle panel grilles (see Workshop Repair
Manual 371 Bodywork, 55A, Exterior protection, Scuttle panel grille ),
- the air filter access panel securing bolts (1) ,

101893
Disconnect the turbocharging pressure sensor (4) .
12A-40
FUEL MIXTURE
12A
F9Q, and 812
REFITTING
1
6
5
2
3
101892
101884
Loosen the clip (5) .

Replace the seal.
Disconnect the air inlet hose.
Replace the inlet duct.

Move aside the air inlet hose.
Tighten to torque in order:
Disconnect the vacuum hose from the (6 )

diaphragm.
- the inlet duct mounting bolts (8 Nm) ,

- the inlet duct nut (21 Nm) .
WARNING

(4 Nm) .
101884
Remove:
- inlet duct mounting bolts (7) ,
- the air inlet duct (8) mounting nut,
- the air inlet duct.
12A-41
FUEL MIXTURE
12A
F9Q, and 804
REFITTING
Replace the seals.
Tightening torquesm
inlet duct mounting
bolts
25 Nm
inlet duct nut
21 Nm

bolts
Refit the inlet duct.

- the inlet duct mounting bolts (25 Nm) ,
- the inlet duct nut (21 Nm) .
4 Nm
To refit, proceed in the reverse order to removal.

REMOVAL
WARNING

terminal.

(4 Nm) .
111887
Disconnect:
- the oil vapour rebreather pipe,
- the pressure sensor connector (2) ,
- the inlet duct air duct (3) (4) ,
- the oil vapour rebreather pipe (5) :
on the oil separator,
on the turbocharger upstream air duct.
Remove:
- the inlet duct mounting bolts (6) ,
12A-42
FUEL MIXTURE
Inlet manifold: Removal - Refitting
12A
K4J, and 730
Tightening torquesm
inlet manifold bolts
9 Nm
throttle valve bolts
13 Nm
air unit bolts
9 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove:
unit ),
101794
Remove:

valve ).
- the inlet manifold bolts,

- the manifold.
REFITTING
Always replace all of the seals with new ones.
2
1
3
101100
Disconnect:
- the manifold pressure sensor (1) ,
- the ignition coils (2) ,
- the air temperature sensor (3) .
12A-43
FUEL MIXTURE
K4J, and 730
5
1
2
3
101794

bolts (9 Nm) .
Torque tighten:
- the throttle valve bolts (13 Nm) ,
- the air unit bolts (9 Nm) .
WARNING
Torque tighten the battery cover mounting bolts
(4 Nm) .
12A-44
12A
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 761 or 782
Tightening torquesm
inlet manifold bolts
9 Nm
motorised throttle valve

bolts
13 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:
1
2
104343
Remove:
Exterior protection, Scuttle panel grille ),
101807
Remove:
- the air duct (4) .
12A-45
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 761 or 782
10
7
9
8
102735
8
101795
Disconnect:
Disconnect the wiring harness (8) .
- the brake servo vacuum pipe (6) on the inlet manifold.
Disconnect the fuel inlet pipe (9) from the injector

rail.
WARNING
IMPORTANT

During this operation, it is essential to:
Disconnect the fuel vapour recirculation pipe (7) on

the throttle valve.
- refrain from smoking or bringing red hot objects

close to the working area,
- beware of fuel splashes when disconnecting the
supply union,
- protect sensitive areas from fuel outflow.
IMPORTANT
Unclip fuel vapour recirculation pipe (10) from the inlet manifold.
12A-46
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 761 or 782
7
6
8
1
4
102726
Remove the inlet manifold bolts.
102726

bolts (9 Nm) .
ON THE WORKBENCH
Torque tighten the motorised throttle valve bolts

(13 Nm) tightening the bolts evenly.
Remove the throttle valve.
REFITTING
Always replace all of the seals with new ones.
WARNING

(4 Nm) .
12A-47
FUEL MIXTURE
12A
F4R, and 776
Tightening torquesm
bolts
21 Nm

mounting bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
106633
Remove:
- the motorised throttle valve mounting bolts (4) ,

- the motorised throttle valve.
7
5
1
106270
Move aside the air duct (1) .

Remove the petrol vapour rebreather pipe (2) .
Disconnect the motorised throttle valve connector.
106787
Disconnect:
- the turbocharging pressure sensor connector (5) ,
- the vacuum pipe (6) from the brake servo,
- (7) the oil vapour recirculation pipe.
3
106272
Remove the air pipe (3) between the turbocharger

and the intercooler.
12A-48
FUEL MIXTURE
12A
F4R, and 776
REFITTING
Be sure to replace all the seals with new ones when
they are removed.
Proceed in the reverse order to removal
13
10
106271
Disconnect:
11
- the injector rail petrol supply pipe (8) ,
14
12
106337
- the injector connectors.

IMPORTANT
Torque tighten the motorised throttle valve mounting bolts (21 Nm) .

supply union,
WARNING

(4 Nm) .
IMPORTANT
Pull the electric wiring harness to one side.
106337
Remove the inlet manifold bolts.
12A-49
FUEL MIXTURE
12A
M9R, and 700

Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Tightening torquesm
inlet manifold studs
9 Nm
104343

bolts and nuts
25 Nm
Remove:
bolt mounting the dipstick guide on the inlet

manifold
10 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm

REFITTING
grille ).
104246
Remove:
12A-50
FUEL MIXTURE
12A
M9R, and 700
115585

114933
Remove:
- the clips (8) ,

102365
Remove:
112658

Remove:
(5) ,
12A-51
FUEL MIXTURE
12A
M9R, and 700
115723
115716
Remove:
Fit a hose clamp on the coolant outlet hose (13) from

the EGR cooler.
Remove the clip (14) from the EGR cooler coolant

outlet hose using the (Mot. 1202-01) , (Mot. 120202) or (Mot. 1448).
- the rigid EGR pipe between the EGR solenoid valve and EGR cooler (see 14A, Emission control,
Rigid EGR pipe: Removal - Refitting ),
- the EGR solenoid valve (see 14A, Emission control, Exhaust gas recirculation solenoid valve:
Removal - Refitting ),
- the oil filler cap - dipstick assembly (11) ,
Disconnect the coolant outlet hose from the EGR

cooler.
CONCERNED
- the dipstick guide tube mounting bolt (12) ,

- the dipstick guide tube.
Plug the opening of the dipstick guide tube on the
cylinder block.
115724
Unpick the wiring harness on the inlet manifold.

Remove:
- the inlet manifold mounting nuts (15) ,
- the inlet manifold mounting studs,
12A-52
FUEL MIXTURE
12A
M9R, and 700

- the inlet manifold,
- the inlet manifold seal.

CONCERNED
REFITTING
Clean the mating faces of:
- the inlet manifold in case of reuse,
WARNING
115724
Refit:
- the new inlet manifold seal,
Finger tighten the new studs until they make contact
with the inlet manifold.
Tighten to torque the inlet manifold studs (9 Nm) .
Tighten by hand until secure:
- the inlet manifold mounting nuts,
- the inlet manifold mounting bolts.
- the inlet manifold mounting nuts and bolts (15
Nm) ,
- the inlet manifold mounting bolts and nuts (25
Nm) .
Note:
the torque for mounting bolt 7 is given as an
example.
12A-53
FUEL MIXTURE
12A
M9R, and 700


Clip the wiring harness onto the inlet manifold.
Connect the coolant outlet hose to the EGR cooler.
Fit the clip to the EGR cooler coolant outlet hose

using the (Mot. 1202-01) , (Mot. 1202-02) or (Mot.
1448).
Remove the hose clamp on the EGR cooler coolant

outlet hose.

Remove the plug from the dipstick guide tube opening on the cylinder block.

Lubricate the new dipstick guide tube seal with engine oil.
Refit the dipstick guide tube into the cylinder block.
Finger tighten the mounting bolts until they are in

contact with the dipstick guide.
Tighten to torque the bolt mounting the dipstick

guide on the inlet manifold (10 Nm) .
Refit:
- the oil filler cap - dipstick assembly,
- the EGR solenoid valve (see 14A, Emission control, Exhaust gas recirculation solenoid valve:
- the rigid EGR pipe between the EGR solenoid valve and EGR cooler (see 14A, Emission control,
Rigid EGR pipe: Removal - Refitting ),
Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Refit:
12A-54
- Fill the cooling system (see 19A, Cooling, Cooling

system: Draining - Refilling ),
- Bleed the cooling system (see 19A, Cooling, Cooling system: Bleeding ),
(see 80C, Xenon headlights, Xenon headlight:
Adjustment ),
FUEL MIXTURE
Injector holder shim: Removal - Refitting
12A
K4J, and 730
Tightening torquesm
injector holder shim
mounting bolts 11 and
12
25 Nm

mounting bolts 13 and
20
21 Nm
timing upper cover bolt
44 Nm
suspended mounting
bolt
44 Nm

bolts
4 Nm
1
101801
Remove nuts (1) securing the injector rail guard.

REMOVAL
terminal.
Remove the inlet manifold (see 12A, Fuel mixture,
Inlet manifold ).
IMPORTANT

- expect fuel splashes when disconnecting the
supply union,
101802
Disconnect:
- the fuel supply union (2) ,

- the injectors (3) ,
IMPORTANT
- the pinking sensor (4) .
12A-55
FUEL MIXTURE
12A
K4J, and 730
REFITTING
7
19
10
15
11
12 16
8
20
18 14
13
17
101792
The injector holder shim seal must always be replaced.
6
101493
Remove bolts (5) securing the injector rail.

Pull the injection rail gently towards yourself to remove it.
Remove:
Insert all the mounting bolts.

Lie the injector holder shim flat against the upper timing cover and tighten bolt (8) finger-tight.
Lie the injector holder shim flat against the suspended engine mounting and tighten bolt (9) finger-tight.
- the nut (6) securing the wiring harness,
Position the injector holder shim against the (10)

shims on the rocker cover.
- the dipstick guide tube mounting (7) .

- injector holder shim mounting bolts 11 and 12
(25 Nm) ,
- injector holder shim mounting bolts 13 and 20
(21 Nm) .
Tighten to torque:
- the timing upper cover bolt (44 Nm) .
- the suspended mounting bolt (44 Nm) .
101792
Remove:
- the mounting bolt (9) from the suspended engine
mounting cover,
WARNING
- the mounting bolt (8) ,

(4 Nm) .
- the injector holder shim mounting bolts.
12A-56
FUEL MIXTURE
12A
K4M, and 761 or 782
Tightening torquesm
bolts 5 and 6 of the
25 Nm
bolts 7 to 14 of the injector holder shim
21 Nm
suspended mounting
bolt
44 Nm
upper timing cover bolt
44 Nm

bolts
4 Nm
REMOVAL
terminal.
Inlet manifold ).
101810
Disconnect the injectors (1) .

Remove:
IMPORTANT
- the bolts (2) securing the injector rail,

- the injector rail, pulling it carefully towards you.

supply union,
IMPORTANT
102303
Remove:
mounting cover,
12A-57
FUEL MIXTURE
K4M, and 761 or 782
REFITTING
13
10
14
12
11
102303

Fit all the mounting bolts.
Lie the injector holder shim flat against the upper timing cover and tighten the bolt (3) finger-tight.
Lie the injector holder shim flat against the suspended engine mounting and tighten the bolt (4) fingertight.
- bolts 5 and 6 of the injector holder shim (25 Nm)
,
- bolts 7 to 14 of the injector holder shim (21 Nm)
.
Tighten to torque:
- the suspended mounting bolt (44 Nm) ,
- the upper timing cover bolt (44 Nm) .
WARNING
(4 Nm) .
12A-58
12A
FUEL MIXTURE
12A
F4R, and 770 or 771
Tightening torquesm
bolts 7 and 8 of the
25 Nm
bolts 9 to 16 of the injector holder shim
21 Nm
bolt 6 from the suspended mounting
44 Nm
upper timing cover bolt

5
44 Nm

bolts
4 Nm
101801
Remove nuts (1) securing the injector rail guard.

REMOVAL
terminal.

Inlet manifold ).
IMPORTANT

supply union,
102728
Disconnect:
- the fuel supply union (2) ,
- the injection (3) wiring harness.
IMPORTANT
12A-59
FUEL MIXTURE
12A
F4R, and 770 or 771
REFITTING
6
4
15
11
16
5
14
10
12
13
101792

Fit all the mounting bolts.
102730
Remove:
Lie the injector holder shim flat against the upper timing cover and tighten the bolt (5) finger-tight.
Lie the injector holder shim flat against the suspended mounting and tighten the bolt (6) finger-tight.

- bolts 7 and 8 of the injector holder shim (25 Nm)
,
- bolts 9 to 16 of the injector holder shim (21 Nm)
.
Tighten to torque:
- bolt 6 from the suspended mounting (44 Nm) ,
- upper timing cover bolt 5 (44 Nm) .
101792
Remove:
WARNING

mounting cover,


(4 Nm) .
12A-60
FUEL MIXTURE
Manifolds: Removal - Refitting
12A
F9Q, and 812
REFITTING
Be sure to replace the manifold gaskets.
Tightening torquesm
manifold
studs
mounting
For studs removed when removing the manifolds:
8 Nm
- apply LOCTITE FRENBLOC to the cylinder head

thread holes inlet,
manifold mounting nuts
28 Nm

bolts
4 Nm
- wipe any run-off after refitting the studs,

- Tighten to torque the manifold mounting studs (8
Nm) .
Refit the manifolds.
REMOVAL
terminal.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
Tighten to torque the manifold mounting nuts (28

Nm) .
- the exhaust gas recirculation unit (see 14A, Emission control, Exhaust gas recirculation unit ),
WARNING
- the turbocharger (see 12B, Turbocharging, Turbocharger ).

(4 Nm) .
104423
Remove:
- the engine lifting bracket (1) ,
- the manifold mounting nuts,
- the manifolds.
12A-61
FUEL MIXTURE
12A
F9Q, and 804
Tightening torquesm
manifold
studs
mounting
8 Nm
manifold mounting nuts
28 Nm

bolts
4 Nm
REMOVAL
terminal.
Put the vehicle on a lift.
Remove:
- the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting
),
111872
- the exhaust gas recirculation unit (see 14A, Emission control, Exhaust gas recirculation unit ),
- the exhaust gas recirculation pipe,
- the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting ),
Starter motor: Removal - Refitting ),
111873
Remove:
- the Front Turbocharger Exhaust gas temperature
sensor,
- the manifold mounting nuts,
- the exhaust manifold (1) ,
- the inlet manifold (2) .
12A-62
FUEL MIXTURE
F9Q, and 804
REFITTING
Be sure to replace the manifold gaskets.
For studs removed when removing the manifolds:
- apply LOCTITE FRENBLOC to the cylinder head
thread holes inlet,
- wipe any run-off after refitting the studs,
- Tighten to torque the manifold mounting studs (8
Nm) .
Refit the manifolds.
Tighten to torque the manifold mounting nuts (28
Nm) .
WARNING
Refit the engine lifting bracket.
Refit:
- the exhaust gas recirculation solenoid valve (see
14A, Emission control, Exhaust gas recirculation unit ),
(4 Nm) .
12A-63
12A
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
12A
K9K, and 722 or 728

Mot. 1567

EGR duct clips.
Tightening torquesm
exhaust manifold studs
9 Nm
exhaust manifold
mounting nuts
26 Nm
exhaust gas recirculation unit mounting bolts
21 Nm
metal air inlet tube

mounting bolts
21 Nm
lifting eye
21 Nm
104246

bolts
Remove:
- the mounting bolts (3) from the scuttle panel partition,
4 Nm
REMOVAL
Place the vehicle on a two-post lift.

terminal.
6
8
102074
1
Remove:
- the lifting eye (5) ,
- the metal air inlet tube (6) ,
104343
Remove:
- the turbocharger (see 12B, Turbocharging, Turbocharger ),

- the metal exhaust gas recirculation tube (4) ,

- the exhaust gas recirculation unit mounting bolts

(7) ,

- the exhaust gas recirculation unit,
- the air filter access panel
- the manifold mounting nuts (8) ,
- the mounting bolt (2) from the scuttle panel mounting.
12A-64
- the manifold.
FUEL MIXTURE
12A
K9K, and 722 or 728
REFITTING
8
6
5
4
3
20848-1
Tighten to torque the exhaust manifold studs (9

Nm) .
Replace the manifold gasket.

WARNING
Refit the manifold.

Tighten to torque and in order the exhaust manifold
mounting nuts (26 Nm) .

(4 Nm) .
Fit:
- the exhaust gas recirculation unit,
- the new exhaust gas recirculation unit tube,
- the new clips on the new tube of the unit.
Tighten the new clips using the (Mot. 1567).
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolts (21 Nm) ,
- the metal air inlet tube mounting bolts (21 Nm) ,
- the lifting eye (21 Nm) .
Refit the turbocharger (see 12B, Turbocharging,
Turbocharger ).
12A-65
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 761 or 782 K4J, and 730
Mot. 1495-01
22 mm socket for
1
2
Tightening torquesm
manifold nuts (K4J and
K4M engines)
23 3 Nm
manifold nuts (F4R

engine)
18 Nm
heat shield bolt
10 Nm
oxygen sensors
45 Nm
bolts mounting the

exhaust pipe supports
onto the body
21 Nm
stay bolt on the exhaust

manifold
8 Nm
nut for the exhaust

manifold stay on the
gearbox
21 Nm
exhaust bracket nuts
20 Nm

bolts
104343
Remove:
4 Nm
REMOVAL
Position the vehicle on a two-post lift.
terminal.
104246
Remove:
- the mounting bolts (3) from the scuttle panel partition,
K4J
Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit ).
12A-66
FUEL MIXTURE
12A
F4R or K4M
Inlet manifold ).
4
101793
Remove exhaust bracket mountings (6) .

Remove the exhaust manifold stay (5) .
Note:
101501
Mark with a pen the position of the exhaust rubber mounting bush supports on the body.
Disconnect the downstream oxygen sensor (4) .
102116
Remove mounting bolt (7) from the exhaust pipe rubber mounting supports on the body.
12A-67
FUEL MIXTURE
12A
102117
101797
Remove:
Remove mounting bolt (8) from the silencer rubber

mounting bush on the body.
- the exhaust manifold mounting nuts,
Withdraw the exhaust pipe towards the rear of the

vehicle.
- the exhaust manifold.

ON THE WORKBENCH
10
101798
Remove oxygen sensor (9) using the (Mot. 149501).
101502
Remove the lower heat shield.
Remove the upper heat shield (10) from the exhaust

manifold.
REFITTING
Always replace:
- the manifold gaskets,
12A-68
FUEL MIXTURE
- the exhaust bracket gaskets,
- the manifold nuts.
101797

- the manifold nuts (K4J and K4M engines) (23
3 Nm) ,
- the manifold nuts (F4R engine) (18 Nm) ,
- the heat shield bolt (10 Nm) ,
- the oxygen sensors (45 Nm) ,
- the bolts mounting the exhaust pipe supports
onto the body (21 Nm) ,
- the stay bolt on the exhaust manifold (8 Nm) ,
- the nut for the exhaust manifold stay on the
gearbox (21 Nm) (for F4R engines only),
- the exhaust bracket nuts (20 Nm) .
WARNING
(4 Nm) .
12A-69
12A
FUEL MIXTURE
12A
F4R, and 776
REFITTING
Tightening torquesm
exhaust manifold
mounting nuts
20 Nm
the battery cover mounting bolts
4 Nm
WARNING
Always replace:
- the exhaust manifold seal,
- the exhaust manifold mounting nuts.
REMOVAL
terminal.
Remove:
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
21936
Remove:
12A-70
FUEL MIXTURE
F4R, and 776
6
5
1
7
8
4
21936

Refit:
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ).
WARNING
Tighten to torque the battery cover mounting
bolts (4 Nm) .
WARNING
Removal and refitting of the turbocharger requires careful application of the repair procedures to
ensure that the system is sealed correctly.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY HAVE SERIOUS SAFETY-RELATED CONSEQUENCES FOR THE DRIVER.
12A-71
12A
FUEL MIXTURE
12A
K9K, and 732

Mot. 1567

EGR duct clips.
Tightening torquesm
exhaust manifold
mounting studs
9 Nm
exhaust manifold
mounting bolts
26 Nm
25 Nm
mounting bolts of the

rigid exhaust gas recirculation pipe
35 Nm
104246
Remove:
REMOVAL
112815
Disconnect the (4) connector from the air inlet pressure sensor.
Loosen the clip (5) and move the air inlet duct (6) to
one side.
104343
Remove:
- the scuttle panel grille (see 371 Bodywork, 55A,
Exterior protection, Scuttle panel grille ).
12A-72
FUEL MIXTURE
12A
K9K, and 732
112810
113842
Remove:
Disconnect the damper flap connector (7) .
- the clip (10) from the rigid exhaust gas recirculation

pipe using the (Mot. 1567) ,
Remove:
- the mounting bolt (8) from the damper flap mounting bracket,
- the mounting bolts (11) from the rigid exhaust gas

recirculation pipe,
- the rigid exhaust gas recirculation pipe (12) .

- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).
- the bolts securing the timing end lifting eye.
113558
Loosen the mounting bolts (13) on the exhaust gas

recirculation unit.
Move the exhaust gas recirculation unit to one side.
113475
Remove the mounting bolts (9) from the injection rail

protector cover mounting bracket.
12A-73
FUEL MIXTURE
K9K, and 732
CONCERNED
113561
Remove:
REFITTING
It is essential to clean the joint faces carefully.
12A-74
12A
FUEL MIXTURE
12A
K9K, and 732

CONCERNED
20848-1
Tighten to torque the exhaust manifold mounting

studs (9 Nm) .
Fit the new snap-fit clamp.
Fit the new exhaust manifold gasket.
WARNING
Refit:
Ensure that you do not constrain the rigid

exhaust gas recirculation pipe before fitting the
snap-fit clamp.
- the exhaust manifold,

- the exhaust manifold mounting nuts.
Tighten to torque the exhaust manifold mounting
bolts (26 Nm) .
Tighten the mounting bolts of the rigid exhaust gas

recirculation pipe on the manifold until they make
contact.
Adjust the rigid exhaust gas recirculation pipe in relation to the cooler support.

Fit the exhaust gas recirculation unit.
Torque tighten the exhaust gas recirculation unit
Refit:
- the new rigid exhaust gas recirculation pipe with a
new seal,
- the new exhaust gas recirculation pipe mounting
bolts,
12A-75
Lock the snap-fit clamp of the rigid exhaust gas recirculation pipe using the (Mot. 1567).
Tighten to torque the mounting bolts of the rigid
exhaust gas recirculation pipe (35 Nm) .
Refit:
mounting bolts,
- the bolts securing the timing end lifting eye,
FUEL MIXTURE
K9K, and 732
- the damper flap mounting bracket mounting bolt.
Connect the damper flap connector.
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Remove:
Refit the engine covers.
12A-76
12A
FUEL MIXTURE
12A
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool
Tightening torquesm
Remove:
exhaust manifold studs
9 Nm
exhaust manifold
mounting nuts
initial torque:
18 Nm
exhaust manifold
mounting nuts
30 Nm
bolts mounting the rigid

EGR pipe on the EGR
cooler
35 Nm
bolts mounting the rigid

EGR pipe on the
exhaust manifold
35 Nm
bolt mounting the rigid

EGR pipe on the cylinder head
10 Nm

EGR pipe heat shield on
the cylinder head
10 Nm

EGR pipe heat shield on
the exhaust manifold
10 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
air filter unit air outlet

pipe clip on the air flowmeter side
5.5 Nm

bolts
21 Nm

104343
Remove:
IMPORTANT
104246
Remove:
12A-77
FUEL MIXTURE
12A
M9R, and 700

114847
Undo the air filter unit air outlet pipe clip (8) on the air
flowmeter side.
112659
Disconnect the air filter unit air outlet pipe on the air
flowmeter side.
Remove the front bumper (see MR 371 Bodywork,
55A, Exterior protection, Front bumper: Removal
- Refitting ).
Disconnect:
Unclip:
- the wiring harness (5) from the negative battery terminal,
- the wiring harness from the injection computer connector,
solenoid valve.
Remove:
114933
Unpick the wiring harness from the injection computer connectors.

support.
12A-78
FUEL MIXTURE
12A
M9R, and 700
102365
Remove:
112658
Remove:
(10) ,
- the engine accessories unit cover.
113280
115585

Remove:
113295
- the clips (13) ,

Remove:
- the mounting bolt (16) from the rigid EGR pipe heat
shield on the exhaust manifold,
12A-79
FUEL MIXTURE
12A
M9R, and 700

- the bolt (17) mounting the rigid EGR pipe heat
shield on the cylinder head,

CONCERNED
- the bolt (18) mounting the rigid EGR pipe on the cylinder head.
Remove the heat shield from the rigid EGR pipe.
113279
Remove:
- the exhaust manifold spacers,
- the exhaust manifold gasket.
113311
Remove the bolts (19) mounting the rigid EGR pipe

on the EGR cooler side.
REFITTING
Clean and degrease the mating faces of:
- the exhaust manifold if it is to be reused,
- the cylinder head face,
- of the rigid EGR pipe.
Check that the exhaust manifold studs are correctly
torque tightened (9 Nm) ; if not, replace any loose
exhaust manifold studs.
Tighten to torque the exhaust manifold studs (9
Nm) using a roller-type stud removal tool.
113281
Remove the bolts (20) mounting the rigid EGR pipe

on the exhaust manifold.
Remove the rigid EGR pipe.
Remove:
- the seal between the EGR cooler and the rigid
EGR pipe,
- the seal between the rigid EGR pipe and the exhaust manifold.
12A-80
FUEL MIXTURE
12A
M9R, and 700

Refit:
- the new seal on the rigid EGR pipe, on the exhaust
manifold side,
- the new seal on the rigid EGR pipe, on the EGR
cooler side.
Fit the rigid EGR pipe.
- the bolts mounting the rigid EGR pipe on the exhaust manifold,
113279
- the bolts mounting the rigid EGR pipe on the EGR

cooler,
- the bolt mounting the rigid EGR pipe on the cylinder head.
Note:
Tighten to torque:
Check that the manifold gasket is positioned correctly.
- the bolts mounting the rigid EGR pipe on the

EGR cooler (35 Nm) ,
Position the tab at (21) .

Refit the new gasket on the exhaust manifold, as indicated above.
CONCERNED
- the bolts mounting the rigid EGR pipe on the

exhaust manifold (35 Nm) ,
- the bolt mounting the rigid EGR pipe on the cylinder head (10 Nm) .
Fit the heat shield.
Refit:
Refit:
- the bolt mounting the rigid EGR pipe heat shield on

the cylinder head,

- the spacers.
Fit the new exhaust manifold mounting nuts without
tightening them.
- the bolt mounting the rigid EGR pipe heat shield on

the exhaust manifold.
Tighten to torque:
- the bolt mounting the rigid EGR pipe heat
shield on the cylinder head (10 Nm) ,
- the bolt mounting the rigid EGR pipe heat
shield on the exhaust manifold (10 Nm) .
Refit:
Tighten to torque:
Nm) ,
113279
Pretighten in order and to torque the exhaust manifold mounting nuts (initial torque: 18 Nm) .
12A-81

Nm) .
FUEL MIXTURE
12A
M9R, and 700

Refit the clips.


Refit:

(see 80C, Xenon bulbs, Xenon headlights: Adjustment ),
- the front bumper (see MR 371 Bodywork, 55A,

Connect the air filter unit air outlet pipe on the air
flowmeter side.
Tighten to torque the air filter unit air outlet pipe
clip on the air flowmeter side (5.5 Nm) .
Refit the battery tray with the injection computer support.
Position the injection computer connectors wiring
harness.
Refit:
(21 Nm) .
Fit:
- the turbocharger regulation solenoid valve wiring
harness,
Connect:
Refit:
- the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ),
12A-82

FUEL MIXTURE
Throttle valve: Removal - Refitting
12A
K4J, and 730
Tightening torquesm
throttle valve bolt
13 Nm
air filter unit bolts
9 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:
2
4
104343
Remove:
- the air filter access flap,
101489
Remove the air filter unit (4) (see 12A, Fuel mixture, Air filter unit ).
Disconnect:
- the fuel vapour recirculation pipe (6) on the control
solenoid valve.
12A-83
FUEL MIXTURE
K4J, and 730
7
101800
Remove:
- the mounting bolts (7) ,
- the throttle valve.
REFITTING
Replace the throttle valve seal each time it is removed (use lubricant to make it easier to fit).
Tighten to torque:
- the throttle valve bolt (13 Nm) ,
- the air filter unit bolts (9 Nm) .
WARNING
(4 Nm) .
Reinitialise the programming of the stops (see MR
Fault finding, 17B, Petrol injection, Fault finding
-configurations and programming ).
12A-84
12A
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 761 or 782
Tightening torquesm
throttle valve mounting
bolts
13 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:
104343
Remove:
104241
12A-85
FUEL MIXTURE
F4R, and 770 or 771 K4M, and 761 or 782
102735
Disconnect:
- the fuel vapour recirculation pipe (6) on the control
solenoid valve.
Remove:
- bolts (7) securing the throttle valve,
- the throttle valve.
REFITTING
Replace the throttle valve seal with a new one each
time it is removed.
Torque tighten the throttle valve mounting bolts
(13 Nm) distributing the tightening evenly.
WARNING
(4 Nm) .
12A-86
12A
FUEL MIXTURE
12A
F4R, and 776

- the motorised throttle valve.
Tightening torquesm
mounting bolts
REFITTING
10 Nm
Be sure to replace all the sealing joints with new

ones when they are removed.
REMOVAL
terminal.
Tighten to torque the motorised throttle valve

WARNING

1
106270
Disconnect:
- the air duct (1) and remove it,
- the fuel vapour rebreathing pipe (2) .
106633
Remove:
- motorised throttle valve mounting bolts (3) ,
12A-87
FUEL MIXTURE
Air inlet flap: Removal - Refitting
12A
K9K, and 732

Tighten to the inlet flap bolts by hand until contact is
made.
Tightening torquesm
inlet flap mounting bolts
Tighten to torque the inlet flap mounting bolts (12

Nm) .
12 Nm
Reconnect:
REMOVAL
- the vacuum pipe to the brake servo,

terminal.
- the connector to the inlet flap

Refit the inlet duct.
WARNING
carry out the necessary programming (see 80A,
Battery: Removal-Refitting ).
112815
Loosen the air duct clip (1) .
112810
Disconnect:
- the connector (2) from the air inlet flap,
- the vacuum pipe from the brake servo.
Move the inlet duct to one side.
Remove:
- the inlet flap mounting bolts (3) ,
- the inlet flap.
REFITTING
Refit the inlet flap.
12A-88
FUEL MIXTURE
Engine stop device
12A
F9Q, and 812

I - OBJECTIVE
The system is intended to stop the engine quickly after
the ignition is switched off.
II - DESCRIPTION
104953
- a solenoid valve (3) ,
1
101892
2
4
104421
- a vacuum (4) .
101894
The system consists of:

- a diaphragm (1) acting on the throttle,
- a throttle (2) ,
III - OPERATING PRINCIPLE

When the ignition is switched off, the solenoid valve
connects the vacuum and the diaphragm.
The diaphragm is submitted to the vacuum; this closes
the air inlet flap.
The engine can no longer take in air and stops running
immediately.
12A-89
FUEL MIXTURE
12A
F4R, and 770 or 771 or 776 K4J, and 730 K4M, and 761 or 782
IMPORTANT
Wear goggles with side protectors for this operation.
IMPORTANT
Note:
Wear protective goggles and gloves during the operation. Be sure to work in a clean environment so
as not to allow any contamination of the throttle
valve.
Remove the throttle valve (see 12A, Fuel mixture,
Throttle valve ).
106901
Hold the throttle valve flap open manually.

Spray the cleaning product, Part No. 77 11 171 437
on the inside of the cylinder until the dirt has been
cleared.
WARNING
Do not spray any cleaning product onto the outside of the cylinder, inside the spring housing or
onto the connector.
106899
Remove the external O-ring seals from the throttle

valve.
Note:
The Renault carburettor cleaning product, Part
No. 77 11 171 437 damages seals.
106900
Remove the cleaning product residue and the residue of the dirt using a cloth, Part No. 77 11 211 707 .
12A-90
FUEL MIXTURE
106902
Use a hot air gun along the edge of the throttle valve
and then on the outside of the cylinder.
Note:
If the throttle valve is dropped or receives any
other impact, it will need to be replaced.
It is essential to replace the throttle valve O-rings.
Refit the throttle valve (see 12A, Fuel mixture,
Throttle valve ).
WARNING
Fault finding, 17B, Petrol injection, Replacement
of components ).
12A-91
12A
TURBOCHARGING
Turbocharging pressure regulation valve
12B
F9Q, and 812
WARNING
It is essential to mark the supply and return pipes
on the turbocharging solenoid valve if the turbocharging solenoid valve is to be removed.
102480
103128
101889
The turbocharging pressure regulation valve

diaphragm (1) is controlled by a solenoid valve (2)
which is in turn controlled by the injection computer.
This solenoid valve varies the vacuum as a function of
the engine operating ranges, which allows the turbocharging pressure to be regulated.
The turbocharging pressure regulation valve is normally open. The engine operates as naturally aspirated.
The solenoid valve, normally closed, is supplied after
the engine is started following a delay which varies according to the coolant temperature.
12B-1
Axis
Description
Time in seconds
Coolant temperature in C
TURBOCHARGING
12B
F4R, and 776
2
21927
Pressure regulation valve diaphragm (1) is controlled

by solenoid valve (2) , which is in turn controlled by the
injection computer.
The pressure adjustment valve is closed in the rest position.
107010
The solenoid valve (2) is open in the rest position.

In the open position, the solenoid valve (2) compares
the turbocharger outlet (turbocharging pressure) and
diaphragm (1) .
Axis
Description
Time in seconds
Because of this, the turbocharging pressure acts directly on the diaphragm and the pressure adjustment
valve opens.
When the solenoid valve (2) is controlled, the turbocharging pressure signal (taken at the turbocharger
outlet) is diverted to the turbocharger inlet. Consequently, the diaphragm is not submitted to turbocharging pressure, the pressure adjustment valve closes.
The solenoid valve is open in the rest position and is
supplied when the engine is started. However, during a
timed delay which depends on coolant temperature,
the turbocharging pressure is limited and the engine
speed cannot exceed 2500 rpm.
This ensures that the oil has sufficient time to reach the
turbocharger bearings.
12B-2
TURBOCHARGING
12B
K9K, and 728

The turbocharging pressure regulator solenoid valve is
closed in the rest position; it is powered once the engine is started and after a delay which is dependent on
the coolant temperature.
WARNING
When removing the turbocharging pressure regulation solenoid valve, it is essential to mark the supply
and return pipes on the solenoid valve.
1
106553
101889
Turbocharging pressure regulation valve diaphragm

(1) is controlled by a turbocharging pressure regulator
solenoid valve (2) located on the computer mounting.
This solenoid valve is controlled by the injection computer.
This solenoid valve may, according to engine operating
ranges, vary the underpressure used to regulate the
turbocharging pressure delivered by a variable geometry turbocharger.
The pressure regulation valve is open in the rest position, the engine is therefore naturally aspirated.
12B-3
TURBOCHARGING
12B
K9K, and 732

The turbocharging pressure regulation solenoid valve
is closed in the rest position; it is powered once the engine is started and after a delay which is dependent on
the coolant temperature.
WARNING
When removing the turbocharging pressure regulation solenoid valve, it is essential to mark the supply
and return pipes on the solenoid valve.
114184
114185
The turbocharging pressure regulation valve

diaphragm (1) is controlled by a turbocharging pressure regulator solenoid valve (2) attached to a bracket
fixed onto the air filter unit. This solenoid valve is controlled by the injection computer.
This solenoid valve may, according to engine operating
ranges, vary the underpressure used to regulate the
turbocharging pressure delivered by a variable geometry turbocharger.
The pressure regulation valve is open in the rest position, the engine is therefore naturally aspirated.
12B-4
TURBOCHARGING
F9Q, and 812
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.
TURBOCHARGING PRESSURE REGULATION

VALVE
1 - Check
21869
Remove the turbocharger (see 12B, Turbocharging, Turbocharger ).
Note:
The check cannot be carried out with the turbocharger in place.
Use a magnetic holder fitted with a dial gauge placed on the end of the control valve stem (as far as
possible in the axis of the stem).
Gradually apply an underpressure to the control valve using the pressure and vacuum pump.
2 - Value
- For an underpressure value of 265 mbar , the rod

movement must be between 0.5 and 3.5 mm .
- For a pressure value greater than 600 mbar , the
rod is at the stop.
12B-5
12B
TURBOCHARGING
12B
K9K, and 722 or 724 or 728 or 732
K9K, and 724
WARNING
3 - Check

VALVE
K9K, and 722
1 - Check
21869

Note:
21869
Gradually apply pressure to the regulation valve

using a vacuum/pressure pump.
Note:
4 - Value
Gradually apply pressure to the regulation valve
using a vacuum/pressure pump.
2 - Value
For a pressure value of 1.4 bar , the rod movement
must be 4.3 mm
12B-6
For an underpressure value of 0.6 bar , the rod movement must be 7 mm 0.5
TURBOCHARGING
K9K, and 722 or 724 or 728 or 732
K9K, and 728 or 732

5 - Check
110748

Note:
Use a set of shims between the regulation valve rod
and the tappet (as far as possible into the rod shaft).
6 - Value
For an underpressure value of 0.5 bar , the rod gap
must be 1.7 mm
12B-7
12B
TURBOCHARGING
F4R, and 776
WARNING
TURBOCHARGING PRESSURE CONTROL VALVE

1 - Check
22807
Note:
Gradually apply increasing pressure to the control
valve using the pressure and vacuum pump.
2 - Value
- For a pressure value of 331 mbar , the rod movement must be 1 mm.
- For a pressure value of 544 mbar , the rod movement must be 5 mm.
12B-8
12B
TURBOCHARGING
F9Q, and 804
WARNING

VALVE
1 - Check
21869

Note:
2 - Value
- For an underpressure value of 200 mbar , the rod

movement must be between 2 and 4 mm .
- For an underpressure value of above 550 mbar ,
the rod movement must be between 8.6 and 11
mm .
12B-9
12B
TURBOCHARGING
Turbocharger: Removal - Refitting
12B
K9K, and 722 or 728
Equipment required
diagnostic tool
Tightening torquesm
turbocharger mounting
studs on the turbocharger
7 Nm
studs on the exhaust
manifold
7 Nm
nuts on the exhaust
manifold
26 Nm
turbocharger oil inlet

pipe union on the cylinder head
22.5 Nm
hollow bolt securing the

turbocharger oil inlet
duct on the turbocharger
22.5 Nm
bolts mounting the turbocharger oil return pipe

on the turbocharger
12 Nm
exhaust gas recirculation solenoid valve heat

shield mounting bolts
12 Nm

bolts
4 Nm
104343
Remove:
104246
REMOVAL
Remove:

terminal.
12B-10
TURBOCHARGING
12B
K9K, and 722 or 728
K9K, and 722
K9K, and 728
5
7
102081
110325
Pull out the clip.
Disconnect air duct (4) .

Remove the air duct (5) from the turbocharger.
Disconnect:
- the turbocharging pressure sensor (6) ,
11
1
- the exhaust gas recirculation solenoid valve (7) ,

- the turbocharging pipe (8) on the turbocharger,
10
- the pipe (9) between the turbocharging pressure

regulation valve and the air duct.
110323
Undo bolt (10) .

12B-11
TURBOCHARGING
12B
K9K, and 722 or 728
12
13
15
16
14
110326
102076
Disconnect:
Remove:
- the exhaust bracket mountings (15) ,
- the exhaust gas recirculation solenoid valve connector (13) ,
- the strut mounting on the catalytic converter,
- the turbocharging pipe (14) on the turbocharger,
- the strut mountings on the gearbox,

- the strut (16) .
- the pipe between the turbocharging pressure regulation valve and the turbocharging pressure regulation solenoid valve.
Note:
Mark with a pen the position of the exhaust rubber mounting bush supports on the vehicle body.
12B-12
TURBOCHARGING
12B
K9K, and 722 or 728
17
20
19
102116
Remove mounting bolt (17) from the exhaust pipe silentbloc supports on the body.
102077
Remove:
- the catalytic converter strut (19) ,
- the nuts (20) securing the catalytic converter to the
turbocharger,
- the catalytic converter.
18
21
22
102119
102117
Remove mounting bolt (18) from the silencer silentbloc bracket on the body.
vehicle.
12B-13
Remove:
- the bracket (21) ,
- the exhaust gas recirculation solenoid valve heat
shield (22) .
TURBOCHARGING
K9K, and 722 or 728
23
25
24
102079
Remove:
- the oil inlet pipe (23) ,
- the oil return pipe (24) ,
- the turbocharger upper mounting nuts (25) ,
- the turbocharger lower mounting nut from underneath,
- the turbocharger.
12B-14
12B
TURBOCHARGING
12B
K9K, and 722 or 728
REFITTING
Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).
WARNING
Ensure that no impurities enter the turbine or
compressor during the refitting operation.
Tighten to torque the exhaust gas recirculation

solenoid valve heat shield mounting bolts (12
Nm) .
Check that the turbocharger oil return pipe is not

completely or partially blocked by scale. Also
check that the sealing is perfect; if not, replace it.
WARNING
Check that the intercooler is not full of oil. If this
is the case, remove it, rinse with a cleaning agent
and then let it dry.
Run the starter motor until the oil pressure warning

light goes out (wait for a few seconds).
Before starting, disconnect the 4 injectors (starting

the engine is prohibited).
Switch off the ignition.

Reconnect the 4 injector connectors.
Start the engine.
WARNING
Let the engine idle then depress the accelerator several times under no load.
Always replace:
- all the O-rings and both copper seals on the turbocharger oil inlet duct,
- the exhaust bracket seal.
Connect the diagnostic tool and clear the stored

faults.
Make sure that there are no oil leaks.
- any damaged heat shield.

Tighten to torque:
Make sure that all the exhaust pipe heat shields are
in place and properly secured.
- the turbocharger mounting studs on the turbocharger (7 Nm) ,
Make sure that there is no contact with the underbody.
- the turbocharger mounting studs on the exhaust manifold (7 Nm) .

(4 Nm) .
Position the turbocharger on the exhaust manifold.

Tighten to torque the turbocharger mounting nuts
on the exhaust manifold (26 Nm) .
Apply LOCTITE FRENTANCH to the threads of the
turbocharger oil inlet pipe union on the cylinder
head.
Position the oil supply pipe on the turbocharger and
on the cylinder head, fitted with new seals.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cylinder head (22.5 Nm) ,
- the hollow bolt securing the turbocharger oil inlet duct on the turbocharger (22.5 Nm) .
Position the turbocharger oil return pipe on the turbocharger and on the cylinder block, applying new
seals in the process.
Tighten to torque the bolts mounting the turbocharger oil return pipe on the turbocharger (12
Nm) .
12B-15
TURBOCHARGING
12B
F9Q, and 812

terminal.

Mot. 1566
Spanner for removing

high pressure pipes.
Tightening torquesm
studs
8 Nm
nuts
26 Nm
hollow bolt mounting

the turbocharger supply
pipe
22.5 Nm
nut mounting the oil

supply pipe on the cylinder block
22.5 Nm
bolt mounting the oil

supply pipe on the cylinder block
25 Nm

pipe mounting bolt
12 Nm
studs
8 Nm
turbocharger union end

piece
26 Nm
nuts
26 Nm
oil supply pipe mounting nut, turbocharger

side
22.5 Nm
oil supply pipe mounting nut, cylinder block

side
22.5 Nm

pipe mounting bolts
12 Nm

bolts
4 Nm
104343
Remove:
104246
Remove:
REMOVAL
12B-16
TURBOCHARGING
12B
F9Q, and 812
104424
Disconnect:
104421
Disconnect the turbocharger air inlet and outlet pipes (6) .

- the turbocharger pressure regulation valve pipe (5)
.

Note:
During factory fitting, 2 types of oil supply pipe
may be fitted to this turbocharger.
The removal procedure for the turbocharger
depends on the type of pipe fitted.
12B-17
TURBOCHARGING
12B
F9Q, and 812

II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
I - OIL SUPPLY PIPE WITH A HOLLOW BOLT

UNION (TURBOCHARGER SIDE)
114207
104417
Remove the bolt (10) mounting the oil supply pipe on

the cylinder block.
Remove:
- the mounting bolt (7) from the oil supply pipe,
- the hollowo bolt (8) mounting the oil supply pipe
union on the turbocharger.
Unscrew the oil supply pipe unions on:

- the cylinder block,
Unscrew the union (9) from the cylinder block.
- the turbocharger (11) using the (Mot. 1566).
Remove the oil supply pipe, passing it between the

wheels of the turbocharger.
Remove the turbocharger oil supply pipe.
Remove:
Remove:
- the oil return pipe mounting bolts,
- the oil return pipe ,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger bracket mounting nuts,
- the turbocharger.
- the turbocharger.
Note:
In the Parts Department, there is only one part
number for the supply pipe. Only the oil supply
pipe with the hollow bolt union is available.
12B-18
TURBOCHARGING
12B
F9Q, and 812

I - OIL SUPPLY PIPE WITH A HOLLOW BOLT
UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mounting
studs (8 Nm) .
Refit the turbocharger.
(26 Nm) .
Position the oil supply pipe:
- screw (without tightening) the nut mounting the oil
supply pipe union on the cylinder block,
- screw (without tightening) the hollow bolt mounting
the supply pipe,
- screw (without tightening) the bolt mounting the oil
supply pipe on the cylinder block,
Refit the oil return pipe.
Tighten to torque:
114467
When replacing the oil supply pipe:

- remove the end piece from the oil supply union (12)
. This stage prepares the turbocharger for the supply pipe to be refitted with a hollow bolt union.
REFITTING
- the hollow bolt mounting the turbocharger supply pipe (22.5 Nm) ,
- the nut mounting the oil supply pipe on the cylinder block (22.5 Nm) ,
- the bolt mounting the oil supply pipe on the cylinder block (25 Nm)
- the turbocharger oil return pipe mounting bolt
(12 Nm) .
Note:
During factory fitting, 2 types of oil supply pipe
may be fitted to this turbocharger.
The refitting procedure for the turbocharger
depends on the type of pipe fitted.
WARNING
completely or partially blocked by scale.
Also check that it is perfectly sealed. If not,
replace it.
Always replace:
- the oil supply pipe with a hollow bolt union, turbocharger side (depending on version),
- the seals for the oil supply pipe with a nut union,
turbocharger side (depending on version),
- the seals on the turbocharger oil return pipe.
12B-19
TURBOCHARGING
12B
F9Q, and 812

II - OIL SUPPLY PIPE WITH NUT UNION

(TURBOCHARGER SIDE)
Refit the exhaust pipe, aligning the marks made before.
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- leave the engine to idle,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
114467
Always replace the seal on the end piece of the

union (13) , if the end piece is removed.
Tighten to torque:
- the turbocharger mounting studs (8 Nm) ,
- the turbocharger union end piece (26 Nm) , if removed.
(26 Nm) .
Position the oil supply pipe:
- screw (without tightening) the oil supply pipe mounting nuts,
- screw (without tightening) the bolt mounting the oil
supply pipe on the cylinder block,
Refit the oil return pipe.
Tighten to torque:
- using the tool, the oil supply pipe mounting nut,
turbocharger side (22.5 Nm) ,
- the oil supply pipe mounting nut, cylinder block
side (22.5 Nm) ,
- the turbocharger oil return pipe mounting bolts
(12 Nm)
III - AFTER REFITTING
12B-20

(4 Nm) .
TURBOCHARGING
12B
F4R, and 776
Equipment required
diagnostic tool
Tightening torquesm
bolts for the oil return
pipe (to the cylinder
block)
12 Nm
turbocharger cooling
duct bolts
12 Nm
turbocharger cooling
duct bolts
27 Nm
turbocharger mountings
15 Nm + 75
oil supply pipe hollow

mounting bolt
45 Nm
oil supply pipe union
25 Nm
3
2
4
21927
Disconnect:
- the wastegate control solenoid valve pipe (1) ,
- the solenoid valve turbocharger pipe (2) ,
- the braking solenoid valve pipe (3) .
oil return pipe mounting

bolts
8 Nm
oil return and oil supply

pipes mounting bolt
21 Nm
Remove the air filter - turbocharger pipe (4) .
REMOVAL
Note:
To loosen the turbocharger mounting nuts on the
exhaust manifold, spray some releasing agent
onto the nuts while they are still warm, just
before removal.
21928

terminal.
Removal of the turbocharger requires the engine to
be removed (see 10A, Engine and peripherals,
Engine - gearboxes ).
Catalytic converter ).
12B-21
Place the hose clamp and remove the turbocharger

cooling hoses (5) .
TURBOCHARGING
12B
F4R, and 776
21929
Remove:
21931
Remove:
- the heat shield bolt (6) ,

- the engine cover mounting and the turbocharger
strut (7) ,
- the turbocharger - intercooler air duct.
- the mounting bolts (8) from the turbocharger oil return pipe,
- the turbocharger oil return pipe (10)
- the turbocharger oil supply pipe (9) .
21930
Remove the starter heat shield.
21933
Remove:
- the nuts (11) securing the turbocharger to the inlet
manifold,
- the turbocharger.
12B-22
TURBOCHARGING
12B
F4R, and 776
REFITTING
WARNING
If there has been a fault in the turbocharger,
check that the intercooler is not full of oil. If this is
the case, remove it, rinse with a cleaning agent
and then let it dry.
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
21931
Fit and finger tighten:

- the turbocharger mountings on the exhaust manifold,
- the oil supply pipe mountings on the turbocharger,
- the fuel return pipe to the cylinder block,
- the turbocharger-intercooler air pipe,
- the turbocharger strut mounting.
22809
On the workbench, refit and tighten to torque:

- the bolts for the oil return pipe (to the cylinder
block) (12 Nm) (12) ,
- the oil return pipe bolt (13) .
Pretighten the turbocharger cooling duct bolts
(12 Nm) (14) ,
Tighten to torque the turbocharger cooling duct
bolts (27 Nm) .
106273
Tighten:
- the clip (15) on the intercooler-turbocharger pipe to
position the turbocharger,
- the turbocharger strut (16) .
12B-23
TURBOCHARGING
12B
F4R, and 776
WARNING
All removed seals must be replaced including
those on the cooling pipe as well as the intercooler-turbocharger air pipe.
Fill and bleed the cooling system (see 19A, Cooling, Filling - Bleeding ).
WARNING
WARNING
21933
- Before starting the engine, connect the diagnostic tool (CLIP) and lock the injection system.
- Activate the starter motor until the oil pressure
warning light goes out (wait a few seconds)
then unlock the injection system.
- Start the engine then accelerate with no load
several times.
- Switch off the ignition and check there are no oil
leaks.
- Run the engine at idle speed until the engine
cooling fan starts up:
- Accelerate several times with no load then carry
out a road test.
- Clear the faults using the diagnostic tool
(CLIP).
- Switch off the ignition and check there are no oil
leaks.
21931
Tighten to torque:
- the turbocharger mountings (15 Nm + 75) (18) ,
- the oil supply pipe hollow mounting bolt (45
Nm) (19) ,
- the oil supply pipe union (25 Nm) (20) ,
- the oil return pipe mounting bolts (8 Nm) (21) ,
- the oil return and oil supply pipes mounting
bolt (21 Nm) (22) .
12B-24
TURBOCHARGING
12B
F9Q, and 804
Equipment required
diagnostic tool
Tightening torquesm
nuts
37 Nm
turbocharger oil supply

pipe hollow mounting
bolts
22.5 Nm
hollow bolts mounting

the oil supply pipe on
the housing
44 Nm
bolt mounting the oil

supply pipe on the housing
25 Nm

pipe
12 Nm

bolts
4 Nm
111866
Remove the turbocharger cooling hoses.
REMOVAL
terminal.
Drain the cooling system (see 19A, Cooling, Cooling system: Draining - filling ).
Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ).
12B-25
111860
Remove the air duct from the turbocharger.
TURBOCHARGING
12B
F9Q, and 804
111869
111868
Remove the duct between the turbocharger and the

air filter.
Remove the starter motor (see 16A, Starting-Charging, Starter motor: Removal - Refitting ).
Disconnect the turbocharger underpressure hoses.
111867
111865
Remove the turbocharger oil return pipes.
12B-26
Remove the turbocharger heat shield.
TURBOCHARGING
12B
F9Q, and 804
111870
112457
Remove the turbocharger oil supply pipes.
112458
111871
Remove the turbocharger.
Remove the turbocharger mounting nuts.

Remove the oil return pipe union if the turbocharger
is replaced.
REFITTING
WARNING
completely or partially blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
12B-27
TURBOCHARGING
12B
F9Q, and 804


(4 Nm) .
Always replace:

system: Draining - filling ).
- the turbocharger oil supply pipe,

- the oil supply pipe hollow mounting bolts,
- the seals on the turbocharger oil return pipe,

- the sealant between the turbocharger and the exhaust manifold,
Note:
The turbocharger - manifold gasket has a direction of fitting.
The tab of the gasket should be on the turbocharger side.
Tighten to torque:
- the turbocharger mounting nuts (37 Nm) ,
- the turbocharger oil supply pipe hollow mounting bolts (22.5 Nm) ,
- the hollow bolts mounting the oil supply pipe
on the housing (44 Nm) ,
- the bolt mounting the oil supply pipe on the
housing (25 Nm) ,
- the turbocharger oil return pipe (12 Nm) .
Refit:
Starter motor: Removal - Refitting ).
- the catalytic pre-converter (see 19B, Catalytic
pre-converter: Removal - Refitting ).
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- leave the engine to idle,
- check that there are no oil leaks.
Connect the diagnostic tool and clear the stored
faults.
12B-28
TURBOCHARGING
12B
K9K, and 732
Tightening torquesm
studs
9 Nm
bolts
26 Nm
bolts securing the oil

inlet pipe on the turbocharger
22.5 Nm
bolts securing the oil

inlet pipe on the cylinder
head
22.5 Nm
oil return pipe mounting

bolts
12 Nm
104246
Remove:
REMOVAL
112811
Pull out the clip.
104343
Remove:
12B-29
TURBOCHARGING
12B
K9K, and 732

CONCERNED
112991
Remove the mounting bolt (4) from the stainless

steel pipe.
102079
Move the air inlet duct (5) to one side.
Disconnect the hose from the turbocharging pressure regulation valve, pressure regulation valve side.

Remove:
- the bolt (8) securing the oil inlet pipe on the turbocharger,
- the bolt the securing the oil inlet pipe on the cylinder head,
- the oil inlet pipe,
- the oil return pipe (9) ,
- the turbocharger upper mounting nuts (10) ,
- the turbocharger lower upper mounting nuts,
- the turbocharger.
112816
Disconnect:
- the oil vapour rebreathing pipe (6) , rocker cover side,
- the air inlet duct (7) , turbocharger side.
12B-30
TURBOCHARGING
12B
K9K, and 732
REFITTING
Refit:
- the oil return pipe,

- the oil return pipe mounting bolts.
It is essential to clean the joint faces carefully.
Tighten to torque the oil return pipe mounting

bolts (12 Nm) .
WARNING
Ensure that no foreign bodies enter the turbine or
Connect the hose to the turbocharging pressure regulation valve.

partially or completely blocked by the scale.
Check that there are no leaks. If there are,
replace the part.

Connect:
- the air inlet duct, turbocharger side.
WARNING
Check that the intercooler is not full of oil. If it is,
remove and rinse it with the cleaning agent, then
let it drip dry.
- the oil vapour rebreathing pipe, rocker cover side.

WARNING
All damaged heat shields must be replaced.
Note:
Make sure that there is no contact between the
catalytic converter and the turbocharger oil return
pipe.

CONCERNED
Tighten to torque the turbocharger mounting
studs (9 Nm) .
Fit the new turbocharger seal.
Refit the clip on the stainless steel pipe, if necessary.

Refit:
Refit:
- the turbocharger.
- the turbocharger mounting nuts.
Tighten to torque the turbocharger mounting bolts

(26 Nm) .

Refit:
- the new oil inlet pipe,
- the bolt securing the oil inlet pipe on the turbocharger,
- the bolt securing the oil inlet pipe on the cylinder

head.
Tighten to torque:

- the bolts securing the oil inlet pipe on the turbocharger (22.5 Nm) ,
- the bolts securing the oil inlet pipe on the cylinder head (22.5 Nm) .
Position the new oil return pipe seals.
12B-31
TURBOCHARGING
12B
M9R, and 700
Equipment required
IMPORTANT

tweezers
REMOVAL
diagnostic tool
Tightening torquesm
stud on the exhaust
manifold
9 Nm
14.5 Nm
turbocharger strut
mounting bolts, flywheel
end
25 Nm
turbocharger
mounting nuts
lower
28 Nm
turbocharger upper
mounting nut
28 Nm
turbocharger
mounting bolt
side
25 Nm
turbocharger strut
mounting bolt, timing
end
25 Nm
heat shield mounting

bolts
7.4 Nm
lifting eye mounting

bolts, timing end
25 Nm
air inlet duct mounting

bolts
8 Nm
air inlet duct clip, turbocharger side
5.5 Nm

pipe on the turbocharger
10 Nm
hollow bolt securing the

oil pipe on the cylinder
block
16 Nm
bolt securing the oil

pipe on the cylinder
block
25 Nm

grille ).
104343
Remove:
12B-32
TURBOCHARGING
12B
M9R, and 700
104246
Remove:
114982
Remove:
- the bolts (6) mounting the oil pipe on the turbocharger,
- the oil pipe mounting bolt (7) on the cylinder block,
- the hollow bolt (8) mounting the turbocharger oil
pipe on the cylinder block,
- the turbocharger oil pipe.
114845
Remove:
- the mounting bolt (4) from the scuttle panel partition,
- the mounting nut (5) from the scuttle panel partition,
113277
Remove the lower mounting nuts (9) from the turbocharger.
12B-33
TURBOCHARGING
12B
M9R, and 700
114846
Disconnect:
- the turbocharging pressure regulator hose (10)
from the control diaphragm,
- the oil vapour rebreathing hose (11) from the oil separator.
113155
Remove the bolts (13) mounting the air inlet duct on

the inlet manifold.
Loosen the clip on the air duct, turbocharger side.

Disconnect the air inlet duct, turbocharger side.
Move the air duct to one side, towards the intercooler.
113282
Rotate the clip (12) securing the air duct on the turbocharger.
114984
Remove:
- the mounting bolts (14) from the lifting eye, timing
end,
- the timing end lifting eye,
12B-34
TURBOCHARGING
12B
M9R, and 700
114983
114848
Remove:
Remove:
- the heat shield mounting bolts (15) ,
- the turbocharger.
- the heat shield.
- the gasket between the turbocharger and the exhaust manifold.

CONCERNED
114471
Remove:
113277
- the mounting bolts (18) from the turbocharger strut,

- the turbocharger strut.
Remove:
- the turbocharger upper mounting nut (16) on the
exhaust manifold,
- the side mounting bolt (17) from the turbocharger,
12B-35
TURBOCHARGING
12B
M9R, and 700
REFITTING
Clean and degrease the bearing faces:
- of the exhaust manifold,
- of the turbocharger if reused.
Remove the stud on the exhaust manifold using a
roller-type stud removal tool.
Refit the new stud on the exhaust manifold using a
Tighten to torque the stud on the exhaust manifold (9 Nm) .
Remove the turbocharger studs if the turbocharger
is being reused.
Refit the new studs onto the turbocharger if the turbocharger is being reused.
Tighten to torque the studs on the turbocharger
(14.5 Nm) .
115069
Refit the new turbocharger air inlet duct seal.

Note:
Check that the seal (19) on the turbocharger air
inlet duct is fitted the correct way round.
115068
Remove the turbocharger air inlet duct seal using a

tweezers.
12B-36
TURBOCHARGING
12B
M9R, and 700

- the new turbocharger upper mounting nut,

CONCERNED
- the new turbocharger lower mounting nuts.

Tighten to torque:
- the s turbocharger lower mounting nuts (28 Nm)
,
- the turbocharger upper mounting nut (28 Nm) .
Undo the turbocharger strut mounting bolt on the timing end (20) .
Tighten to torque:
- the turbocharger side mounting bolt (25 Nm) ,
- the turbocharger strut mounting bolt, timing
end (25 Nm) (20) .
Refit:
114471
Fit the new turbocharger strut.
- the heat shield,

- the heat shield mounting bolts.
Finger tighten the mounting bolts (20) and (21) on

the turbocharger strut.
Tighten to torque the heat shield mounting bolts

(7.4 Nm) .
Refit:
WARNING
- the timing end lifting eye,
The turbocharger strut must move freely.

Fit the turbocharger without its seal and hold the turbocharger flat against the exhaust manifold.
Push the turbocharger strut until it is pressing
against the turbocharger at the flywheel end.
Slowly tighten the turbocharger strut mounting bolt
on the timing end (20) .
- the bolts securing the timing end lifting eye.

Tighten to torque the lifting eye mounting bolts, timing end (25 Nm) .
Rotate the air inlet duct retaining clip to return the retaining clip to its housing.
Clip the air inlet duct onto the turbocharger.
Refit the bolts mounting the air inlet duct on the inlet
manifold.
WARNING
Do not tighten the bolt too quickly to prevent the
turbocharger strut from rotating.
Tighten to torque the air inlet duct mounting bolts

(8 Nm) .
Move the turbocharger to one side.

Tighten to torque the turbocharger strut mounting
bolts, flywheel end (25 Nm) (21) .
Position a new seal between the turbocharger and
Finger tighten the new turbocharger side mounting
bolt by several turns.
Tighten until contact:
12B-37
Connect:
- the air inlet duct onto the turbocharger.
- the oil vapour rebreathing hose onto the oil separator.
Tighten to torque the air inlet duct clip, turbocharger side (5.5 Nm) .
Connect the turbocharging pressure regulator hose
onto the control diaphragm.
TURBOCHARGING
12B
M9R, and 700

Position the turbocharger oil pipe, first fitting it inside
the cylinder block (21) .
WARNING
Do not rotate the turbocharger oil pipe O-ring at
the cylinder block end when inserting.
After fitting, check that the turbocharger oil pipe
O-ring has not come out of its housing.
Check for the two copper seals on the oil supply
union, cylinder block end.
Finger tighten:
114845
- the mounting bolts (22) on the turbocharger oil pipe,
Refit:
- the hollow bolt (23) securing the oil pipe on the cylinder block,
- the bolt (24) securing the oil pipe on the cylinder

block.
- the scuttle panel partition mounting nut,
Tighten to torque:
- the scuttle panel partition mounting bolt.
- the bolts mounting the oil pipe on the turbocharger (10 Nm) (22) ,
- the hollow bolt securing the oil pipe on the cylinder block (16 Nm) (23) ,
- the bolt securing the oil pipe on the cylinder
block (25 Nm) (24) .
Refit:
114982
Lubricate the new turbocharger oil pipe O-ring, cylinder block end.
WARNING
Check for the gasket between the turbocharger
and the turbocharger oil pipe.
Remove the protective plug on the oil supply union,
cylinder block end.
12B-38
TURBOCHARGING
M9R, and 700
WARNING
Disconnect the injector rail pressure regulator
connector (disables engine starting).
Run the starter motor until the oil pressure warning light goes out (do this for a few seconds).
Connect the pressure regulator connector to the
injection rail.
Start the engine.
Let the engine idle then depress the accelerator
several times under no load.
Make sure that there are no oil leaks.
Connect the diagnostic tool and clear the stored faults.
12B-39
12B
TURBOCHARGING
Intercooler: Removal - Refitting
12B
F4R, and 776 K9K, and 722 or 728 or 732 F9Q, and 804 or 812
Car. 1363
Trim removal lever.
Tightening torquesm
clips
5.5 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm

bolts
4 Nm
102504
Disconnect the two connectors (1) .

Remove:
WARNING
- the clip (3) ,

intercooler:

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

- do not use degreasing agent, brake cleaning product or any other product,
- clean the intercooler bearing face and the hoses
using a dry lint-free cloth,
- if the hoses are not being replaced, replace the
clip on the same marking,
- it is essential to replace the hoses and/or the intercooler in the event of damage,
- it is essential to replace the clip.
REMOVAL
terminal.
Remove:
- the bumper mountings,
- the fog lights connector (if fitted to the vehicle),
- the headlight washer pipes (if fitted to the vehicle),
- the bumper.
12B-40
TURBOCHARGING
12B
F4R, and 776 K9K, and 722 or 728 or 732 F9Q, and 804 or 812
REFITTING
WARNING
Check that the intercooler is not full of oil. If this
is the case, clean it with a cleaning agent and
then let it dry.

Torque tighten the clips (5.5 Nm) .
Torque tighten:
Nm) ,
Nm) ,
- the battery cover mounting bolts (4 Nm)
102473

WARNING
Note:
essential to initialise the system; see 80C,
7
102474
Remove:
Disconnect the inlet (6) and outlet (7) ducts from the
intercooler.
Remove the intercooler.
12B-41
TURBOCHARGING
12B
M9R, and 700

Car. 1363
Trim removal lever.
Tightening torquesm
pipe clips
5.5 Nm

pipe clip on the intercooler side
5.5 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
114933
REMOVAL
Remove:
112658
Remove:
(2) ,
12B-42
TURBOCHARGING
12B
M9R, and 700

CONCERNED
115585

Remove:
- the clips (5) ,
115703
Undo the turbocharger outlet air pipe clip (8) on the

intercooler side.
Detach the turbocharger outlet air pipe using the

(Car. 1363).
Disconnect the turbocharger outlet air pipe on the intercooler side.
102365
Remove:
12B-43
TURBOCHARGING
12B
M9R, and 700
REFITTING
Use a dry, lint-free cloth to clean the mating faces of:
- the intercooler, if it is to be reused,
- the intercooler outlet air pipe,
- the turbocharger outlet air pipe.
WARNING
Check that the intercooler is not full of oil. If it is,
clean it using a cleaning tray or water jet then dry
it using a compressed air gun and let it drip dry.
CONCERNED
Clip on the intercooler, positioning it correctly in the
cooling radiator tabs.
115023
Connect the intercooler outlet air pipe on the intercooler side.

Tighten to torque the intercooler outlet air pipe
clips (5.5 Nm) .
Refit the bolt mounting the intercooler outlet air pipe
on the cooling radiator.
Connect the turbocharger outlet air pipe on the intercooler side.
Tighten the intercooler outlet air pipe clip on the
intercooler side (5.5 Nm) .
Refit:
115702
Remove the mounting bolt (9) from the cooling radiator intercooler outlet air pipe.
Loosen:
- the intercooler outlet air pipe clip (10) on the intercooler side,
- the intercooler outlet air pipe clip (11) on the damper valve side.
Disconnect the intercooler outlet air pipe on the intercooler side.

Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Unclip the intercooler.
12B-44
TURBOCHARGING
M9R, and 700
Refit:
- the engine component unit cover mounting bolts.
Refit:
Adjust the xenon headlights (if fitted to the vehicle),
(see 80C, Xenon bulbs, Xenon headlight: Adjustment ).
12B-45
12B
FUEL SUPPLY
Petrol supply circuit
13A
Operating diagram of the petrol supply circuit
5
2
4
3
6
19310
The fuel system does not have a return.

The fuel pressure does not vary with engine load.
The circuit comprises:
- a rail (1) without a union to return pipes and without a
supply pressure regulator,
- a single pipe (2) coming from the tank,
- from a supply assembly pump - dipstick - fuel filter
fitted with a pressure regulator (3) , pump (4) and fuel
filter (5) (all located in the reservoir),
- a fuel vapour recirculation absorber (6) .
13A-1
FUEL SUPPLY
13A
K9K, and 722 or 724 or 728

Operating diagram of the diesel fuel supply circuit
102847
It is forbidden:
- a gauge (1) ,
- to dismantle the interior of the pump or injectors. Only

the fuel flow actuator, the diesel fuel temperature sensor and the Venturi tube can be replaced,
- a priming pump (2) ,

- a fuel filter (3) that may be fitted with a water detection
sensor,
- a high pressure pump (4) with a built-in mechanical
low pressure pump (transfer pump),
- to remove the pressure sensor from the fuel rail (for

circuit contamination faults). If the pressure sensor
fails, the pressure sensor, the rail and the five high
pressure pipes must be replaced.
- a fuel flow actuator (5) ,

- an injector rail (6) fitted with a diesel fuel pressure
sensor (7) ,
- four solenoid injectors (8) fitted with discharge valves,
- a Venturi tube (9) ,
- various sensors,
- an injection computer.
IMPORTANT
Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
13A-2
FUEL SUPPLY
13A
F9Q, and 804 or 812

100821

- a priming pump (1) (located in the engine compartment),
sensor,
- a high pressure regulator (3) mounted on the pump,
- a high pressure pump (4) ,
sensor and a pressure limiter (6) ,
- four solenoid injectors (7) ,
- a fuel temperature sensor (8) (only for F9Q 812),
IMPORTANT
13A-3
FUEL SUPPLY
13A
K9K, and 732

114450
It is forbidden:
- a gauge (1) ,
- to dismantle the interior of the pump or injectors. Only

the fuel flow actuator, the diesel fuel temperature sensor and the Venturi tube can be replaced,
- a priming pump (2) ,

sensor,
- a high pressure pump (4) with a built-in mechanical
low pressure pump (transfer pump),
- to remove the pressure sensor from the fuel rail (for

circuit contamination faults). If the pressure sensor
fails, the pressure sensor, the rail and the five high
pressure pipes must be replaced.
- a fuel flow actuator (5) ,

sensor (7) ,
- four solenoid injectors (8) fitted with discharge valves,
- various sensors,
IMPORTANT
13A-4
FUEL SUPPLY
Petrol filter: General information
102299
The fuel filter is located in the fuel tank; it is integrated

into the pump-sender-filter assembly and cannot
be removed.
WARNING
The pump-sender-filter assembly must be replaced if one of the components is faulty.
The filter is intended to have a long service life.
Checking the fuel supply pressure and the pump delivery rate is the equivalent of running fault finding on the
pump-sender-filter assembly.
13A-5
13A
FUEL SUPPLY
Diesel filter: Removal - Refitting
13A
K9K, and 722 or 728
Tightening torquesm
bolts
wheel bolts
4 Nm
130 Nm
IMPORTANT
- watch out for diesel fuel splashing when disconnecting the supply union,
cap kit.
WARNING
104544
- Protect sensitive areas from fuel leakage.
Remove:
- Strictly observe the cleanliness guidelines.
The diesel filter is located behind the right-hand headlight. It is contained in a removable cartridge. This cartridge has a built-in diesel fuel heater, comprising a
resistor and temperature switch.
Note:
Remove the diesel filter assembly to remove the
cartridge.
REMOVAL
Then disconnect the battery, starting with the negative terminal.
13A-6
- the wheel arch liner clips,

- the wheel arch liner.
FUEL SUPPLY
13A
K9K, and 722 or 728
102124
Prime the fuel system with the priming pump (1)

(automatic degassing).
104560
Remove the diesel filter from its holder, pushing it

upwards.
WARNING
Disconnect all the filter pipe unions.

Cap the openings.

(4 Nm) .
WARNING
Keep the pipe unions away from contaminated
areas.
REFITTING
Fit the new diesel filter (do not remove the caps until
the last moment).
Reconnect the pipe unions.
13A-7
FUEL SUPPLY
K9K, and 722 or 728
3
2
21749
Note:
- Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug (2) .
- Some vehicles have a sensor for detecting
water in the diesel fuel (3) , located on the filter.
If water is detected, the injection fault warning
light comes on.
13A-8
13A
FUEL SUPPLY
13A
F9Q, and 804 or 812
Tightening torquesm
bolts
wheel bolts
4 Nm
130 Nm
IMPORTANT
- watch out for diesel fuel splashing when disconnecting the supply union,
- order the special high-pressure injection circuit
plug kit.
WARNING
101539
- Protect sensitive areas from fuel leakage.
Remove:
- Follow the cleanliness guidelines closely.
The diesel filter is located behind the right-hand headlight. It is contained in a removable cartridge. This cartridge has a built-in diesel fuel heater, comprising a
resistor and temperature switch.
- the mounting bolts (1) from the wheel arch liner,

- the wheel arch liner clips using an unclipping tool,
- wheel arch liner (2) .
Note:
Remove the diesel filter assembly to remove the
cartridge.
REMOVAL
terminal.
104560
Unclip the diesel filter from its mounting by pushing it

upwards.
13A-9
FUEL SUPPLY
13A
F9Q, and 804 or 812
102477
19317
Disconnect the diesel heater connector (3) from the

diesel filter.
Mark the position of the diesel filter cover in relation

to the bowl (6) .
Remove the mounting bolt (7) from the cover on the
bowl.
WARNING
Keep the pipe unions away from contaminated
areas.
Open the diesel filter and replace:
Disconnect from the diesel filter:

- the filter element,
- the pipe (4) coming from the tank,
- the seal,
- the engine supply pipe (5) .

fit plugs to the pipes and the filter.
Remove the diesel filter.
REFITTING
Always replace the filter element O-ring.
Refit the cover over the bowl.
WARNING
Align the marking on the cover, fitted with blanking plugs, with the marking on the bowl.
Tighten the mounting bolt on the cover over the
bowl.
Clip the diesel filter onto the mounting.
Reconnect to the diesel filter:
- the fuel supply pipes,
- the diesel fuel heater connector,
13A-10
FUEL SUPPLY
13A
F9Q, and 804 or 812
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting water
in the diesel fuel, located in the diesel filter. If
water is detected in the circuit, the injection fault
warning light on the instrument panel comes on.
Tighten to torque the wheel bolts (130 Nm)
19317
102124
Reprime the supply circuit:

- Turn the air bleed screw (8) 360 degrees,
- operate the manual priming pump (9) until the fuel
runs without air bubbles,
- retighten the bleed screw (8) ,
- activate the manual priming pump (9) once more.
WARNING
(4 Nm) .
13A-11
FUEL SUPPLY
13A
K9K, and 724 or 732 M9R, and 700

CONCERNED
Tightening torquesm
wheel mounting bolts
130 Nm
WARNING
During this operation:
union,
Note:
Make sure you have a new diesel filter before opening the fuel circuit.
114559
Remove the diesel filter from its mounting on the

body by pushing the filter - metal strap assembly
upwards.
REMOVAL
Disconnect all the unions from the fuel supply pipes

on the diesel filter.

Note:
Make preparations for fuel outflow.
WARNING
Prevent the hose unions from coming into contact with a polluted environment.
Take the diesel filter out of the vehicle.
Note:
Only use cloths with the part number 77 11 211
707 to clean the filter and the pipes once the fuel
circuit is opened.
REFITTING
104544
Remove:

CONCERNED
Connect the fuel supply pipes onto the new diesel filter.
- the front right-hand wheel arch liner (1) .
13A-12
FUEL SUPPLY
13A
K9K, and 724 or 732 M9R, and 700

Refit the filter - metal strap assembly on its
mounting on the body.
Note:
Check that the filter is correctly fixed and positioned on its mounting by shaking it: the filter must
not move.
If necessary, remove the filter and gently manipulate the retaining brackets of the metal straps on
its mounting.
114731
Check there are no leaks at the unions on the filter.

Note:
- Regularly drain the water from the diesel filter
via bleed plug (3) .
102124
Prime the fuel circuit using the manual priming pump

(2) (automatic degassing).
- Some vehicles have a sensor for detecting

water in the diesel fuel, located in the base of
the filter. If water is detected in the circuit, a
fault warning light on the instrument panel
comes on.
Refit:
Tighten to torque the wheel mounting bolts (130
Nm) .
13A-13
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting
13A
K4J, and 730
Tightening torquesm
injector rail mounting
bolts
9 Nm

bolts
4 Nm
REMOVAL

terminal.
101802
Disconnect:
- the injector and pinking sensor wiring harness (3) .
IMPORTANT

supply union,
101801
Remove the nuts (1) securing the injector rail guard.

IMPORTANT
13A-14
FUEL SUPPLY
13A
K4J, and 730
REFITTING
The O-rings and the injector mounting clips must
always be replaced with new ones.
Fit the injector rail.
Tighten to torque the injector rail mounting bolts
(9 Nm) .
WARNING

(4 Nm) .
101493
Remove:
ON THE WORKBENCH
101492
Remove:
- the injector clips (5) ,
- the injectors (6) .
13A-15
FUEL SUPPLY
13A
F4R, and 770 or 771 or 776

- the injector and pinking sensor wiring harness (3) .
Tightening torquesm
bolts
9 Nm

bolts
4 Nm
F4R, and 776
REMOVAL
4

terminal.
F4R, and 770 or 771
5
106787
Disconnect:
- the vacuum pipe from brake servo (5) ,
- the oil vapour recirculation pipe (6) .
7
101801
Remove the nuts (1) securing the injector rail guard.

3
106271

rail.
102728
Disconnect:
13A-16
FUEL SUPPLY
13A
F4R, and 770 or 771 or 776

ON THE WORKBENCH
IMPORTANT
supply union,
IMPORTANT
10
9
102737
Remove:
REFITTING
(9 Nm) .
102730
Remove:


WARNING
(4 Nm)
13A-17
FUEL SUPPLY
13A
K4M, and 761 or 782
Tightening torquesm
bolts
9 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove:

- the inlet manifold (see 12A, Fuel mixture, Inlet
manifold ).
101810
IMPORTANT
Disconnect the injector wiring harness (1) .
Remove:



supply union,
ON THE WORKBENCH
IMPORTANT
4
3
101816
Remove:
REFITTING
13A-18
FUEL SUPPLY
K4M, and 761 or 782
(9 Nm) .
WARNING
(4 Nm) .
13A-19
13A
FUEL SUPPLY
Fuel pressure regulator:Checking
13A
F4R, and 770 or 771 or 776 K4J, and 730
Mot. 1311-01
Fuel pressure test kit.
Mot. 1311-08
Union for measuring

fuel pressure.
IMPORTANT
near the working area,
union,
3
IMPORTANT
Wear goggles with side protectors for this operation.
101496
Disconnect the petrol inlet duct from the injector rail.

Connect:
IMPORTANT
- the pipe (1) fitted with the pressure gauge contained in the inspection kit (Mot. 1311-01) , with the
T union of the (Mot. 1311-08) (2) ,
- the T union to the rail,

- the fuel supply duct (3) to the T union.
13A-20
FUEL SUPPLY
Fuel pressure regulator:Checking
K4M, and 761 or 782
2
3
101803
Disconnect the petrol inlet pipe from the injector rail.

Connect:
- the pipe (1) fitted with the pressure gauge contained in the inspection kit (Mot. 1311-01) , with the
T union of the (Mot. 1311-08) (2) ,
- the fuel supply pipe (3) to the T union.
Start the vehicle to activate the fuel pump.

Determine the pressure.
- The pressure must be constant (3.5 bar 0.06).
- It may take a few seconds to obtain a correct injector rail pressure reading.
13A-21
13A
FUEL SUPPLY
13A
F4R, and 770 or 771 or 776 K4J, and 730
Mot. 1311-01
Mot. 1311-08
Union for measuring

fuel pressure.
IMPORTANT
During this operation, be sure to:

union,
101496
Disconnect the fuel inlet pipe on the injection rail.

Connect:
- pipe (1) fitted with a pressure gauge and located in
test kit (Mot. 1311-01) , to the T union of tool
(Mot. 1311-08) (2) ,
- the fuel inlet pipe to the T union.
Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the ignition off.
13A-22
FUEL SUPPLY
13A
K4M, and 761 or 782
2
3
102502
101803
Move the electrical connector (4) to one side without

disconnecting it.
Disconnect the fuel inlet pipe on the injection rail.

Connect:
- pipe (1) fitted with a pressure gauge and located in
test kit (Mot. 1311-01) , to the T union of tool
(Mot. 1311-08) (2) ,

- the fuel inlet pipe to the T union.
Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
This procedure must be carried out with the ignition off.
Remove the Protection and Switching Unit cover.

102503
Disconnect the brown connector (5) from the Protection and Switching Unit.
13A-23
FUEL SUPPLY
12
102501
Connect terminal (5) of the brown connector to the

battery positive feed
Note:
The flow reading should be 80 to 120 l/hr .
13A-24
13A
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728
Equipment required
diagnostic tool
Engine
Vehicle
type
Type
Suffix
Engine speed (rpm)

Idling
speed
Maximum
unladen
Smoke opacity
Maximum
laden
Homologation
value (m-
Legal maximum (m -1)
1)
JM0F
5000
150
722
JM0T
805 50
K9K
JM02
728
JM13
4950
150
4800
100
1.5
Description
Make - type
Special notes
High pressure pump
DELPHI
Pressure from 0 to 1400 bar
Low pressure pump
DELPHI
Built into the high pressure pump
Injection computer
DELPHI
112-track computer (A 32, B 48, C

32)
Diesel fuel rail pressure sensor
DELPHI
Built into the rail

Resistance not measurable
Feed voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel fuel rail pressure sensor
earth
- 3: + 5 V feed
Injectors
DELPHI / MNS HP
Solenoid injector
Maximum pressure 1600 bar
Feed voltage: + 14 V
2-track connector:
- 1: control + injector
- 2: control - injector
13B-1
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728

Description
Make - type
Special notes
Diesel fuel flow actuator
DELPHI
Located on the high pressure pump

Feed voltage: + 5 V
2-track connector:
- 1: + battery feed via protection
and switching unit
- 2: actuator control
Engine speed and position sensor
MGI
Variable reluctance sensor

Resistance: 760 at 20C (K9K
722)
Resistance: 680 at 20C (K9K
728)
2-track connector
- A: + signal
- B: - signal
Pre-postheating unit
NAGARES BED 7-12
Pre-postheating function managed

by the computer
9-track connector
- 1: heater plug no. 3 feed
- 3: + batter y feed
- 6: spark plug no. 1 feed
- 7: plug no. 2 feed
- 8: injection computer control
- 9: fault finding
Heater plugs
CHAMPION ou BERU
13B-2
Resistance: 0.6
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728

Description
Make - type
Special notes
CTS

Resistance
- gang 1: tracks 3 and 5: 1700
900
1025
6-track connector:
- 1: gang 2 signal
- 2: + 5 V feed, gang 2
- 3: + 5 V feed, gang 1
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Cylinder reference sensor
SAGEM
Hall effect sensor

3-track connector:
- 1: cylinder reference sensor earth
- 2: signal
- 3: + battery feed via protection
and switching unit
Diesel temperature sensor
DELPHI
Located on the high pressure pump

Negative temperature coefficient
thermistor
Resistance: 2.2 k at 25C
2-track connector:
- 1: signal
- 2: diesel fuel temperature sensor
earth
Atmospheric pressure sensor
DELPHI
Built into the computer
Accelerometer
SAGEM

2-track connector:
- 1: signal
- 2: accelerometer earth
13B-3
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728

Description
Make - type
Special notes
Engine coolant temperature sensor
ELTH

thermistor
Resistance:
- 75780 7000 at - 40C
- 12460 1128 at - 10C
- 2252 112 at 25C
- 810 38 at 50C
- 282 8 at 80C
- 115 3 at 110C
- 88 2 at 120C
4-track connector:
- 3: engine coolant temperature
sensor signal
- 4: engine coolant temperature
sensor earth
Turbocharging air temperature and

pressure sensor
BOSCH / LDF6T 20-250
Pressure sensor with a negative

temperature coefficient thermistor
Feed voltage: + 5 V
Resistance:
- 20376 1110.5 at - 25C
- 15614 829 at - 20C
- 9426 475 at - 10C
- 5887 281.5 at 0C
- 3791 172.5 at 10C
- 2511 109 at 20C
- 1715.5 71 at 30C
- 1200 47 at 40C
- 851 32 at 50C
- 612 22 at 60C
- 446 15 at 70C
- 330 11 at 80C
4-track connector:
- 1: earth
- 2: air temperature sensor signal
- 3: + 5 V feed
- 4: pressure sensor signal
13B-4
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728

Description
Make - type
Special notes
Exhaust gas recirculation solenoid

valve
PIERBURG
Feed voltage: + 13.5 V

valve position potentiometer
PIERBURG
Resistance: tracks 1 and 5: 8

0.5 at 20C
Built into the exhaust gas recirculation solenoid valve
Feed voltage: + 5 V
Resistance:
- tracks 2 and 4: 4 k 1.6 at 20C
6-track connector:
- 1: solenoid valve + battery feed
via protection and switching unit
- 2: + 5 V potentiometer supply
- 3: Not used
- 4: potentiometer earth
- 5: solenoid valve earth
- 6: potentiometer signal
Refrigerant pressure sensor
TEXAS INSTRUMENTS
Feed voltage: + 5 V
3-track connector:
- A: earth
- B: + 5 V feed
- C: signal
Water in diesel fuel sensor
PRESSAC
3-track connector:
- 1: feed
- 2: signal
- 3: earth
Inlet air flowmeter (K9K 728)
SIEMENS / AG
Air flowmeter with built in air temperature sensor

6-track connector:
- 1: air temperature signal
- 2: flow and air temperature earth
- 3: + 5 V reference feed
- 4: + 12 V
- 5: air flow signal
- 6: battery earth
13B-5
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728

Description
Make - type
Special notes
Turbocharging pressure regulation

solenoid valve (K9K 728)
BITRON
Proportional solenoid valve

Feed voltage: 13.5 V
2-track connector:
- 1: feed
- 2: signal
Fault finding
diagnostic tool : CLIP only
13B-6
DIESEL INJECTION
Specifications
13B
F9Q, and 812
Equipment required
diagnostic tool
Engine
Vehicles
Gearbox
JM0G
ND0
Type
Suffix
Bore
(mm)
Stroke
(mm)
Cubic capacity (cc)
Compression ratio
F9Q
812
80
93
1870
19:1
JM1G
Engine speed (rpm)

Idling speed
Maximum unladen
Smoke opacity
Maximum laden
Homologation
value
800 50
4850 150
4500 100
(m-1)
1.9 (54%)
Legal maximum
(m -1)
3 (70%)
Description
Brand - Type
Special notes
High pressure pump
BOSCH CP3
Diesel fuel pressure sensor
BOSCH
Screwed onto the rail
Injectors
BOSCH
Solenoid injector
Operating pressure up to 1300 bar
Pressure regulator
BOSCH
Screwed onto the high pressure

pump
Injection computer
BOSCH EDC 16
112-track computer
Pre-postheating unit (located

behind the front left-hand wheel
arch liner)
NAGARES BED/7-12
With pre-postheating function

managed by computer
Heater plugs
BERU ou CHAMPION
Resistance: 0.6 connector disconnected
Engine speed and TDC sensor
MGI
Camshaft sensor
ELECTRIFIL
Accelerator potentiometer
CTS

Resistance:
- gang 1: 1700 900
- gang 2: 3875 1025
Inlet air temperature sensor
SIEMENS
Built into the air flowmeter
13B-7
DIESEL INJECTION
Specifications
13B
F9Q, and 812

Description
Brand - Type
Special notes
Diesel fuel temperature sensor
ELTH
Resistance: 2050 at 25C
ELTH
Air flowmeter
SIEMENS
Air flowmeter with integrated air

temperature sensor
- track 1: air temperature
- track 2: earth
- track 3: 5 V reference feed
- track 4: + 12 V after injection relay
feed
- track 5: air flow signal
- track 6: earth
Turbocharging pressure sensor
BOSCH
Output voltage, with ignition on and

engine switched off (between tracks
2 and 3):
- = 1.6 V for an atmospheric pressure of 1013 mbar
- > 1.6V for an atmospheric pressure > 1013 mbar
- < 1.6 V for an atmospheric pressure < 1013 mbar
Always replace the seal each time it
is removed

valve
PIERBURG
Gang resistance: 8 0.5 at 20C

(tracks 1 and 5)
Sensor resistance: 4 k at 20C
(tracks 2 and 4)
Damper flap solenoid valve (engine

stop solenoid valve)
BITRON ou EATON

solenoid valve
PIERBURG
Fault finding
13B-8
DIESEL INJECTION
Specifications
13B
F9Q, and 804
Equipment required
diagnostic tool
Engine
Engine speed (rpm)
Smoke opacity
Vehicle type
Type
Suffix
Idling
speed
Maximum
unladen
Maximum
laden
Homologation value
(m -1)
Legal maximum (m -1)
JM0L
F9Q
804
800 50
4850
150
4500
100
1.9 (54%)
3 (70%)
JM1D
JM14
Description
Brand - Type
Special notes
High pressure pump
BOSCH CP3.2
Pressure 1600 bar Max
Diesel fuel pressure sensor
BOSCH
Screwed onto the rail

Tightening torque: 3.5 5 Nm
Injectors
BOSCH
Solenoid injector
Operating pressure up to: 1600 bar
Pressure regulator
BOSCH
Screwed onto the high pressure

pump
Injection computer
BOSCH EDC 16
112-track computer
Pre-postheating unit (located

behind the front left-hand wheel
arch liner)
NAGARES BED/7-12
With pre-postheating function

managed by computer
Heater plugs
BERU ou CHAMPION
Resistance: 0.6 connector disconnected
MGI
Resistance: 800 at 20C
Camshaft sensor
ELECTRIFIL
Hall effect type
Accelerator potentiometer
CTS

Resistance:
- track 1: 1700 900
- gang 2: 2850 2050
Inlet air temperature sensor
SIEMENS
Built into the air flowmeter
ELTH
13B-9
DIESEL INJECTION
Specifications
13B
F9Q, and 804

Description
Brand - Type
Special notes
Air flowmeter
SIEMENS
Air flowmeter with integrated air

temperature sensor
- track 1: air temperature
- track 2: earth
- track 3: 5 V reference feed
- track 4: + 12 V after injection relay
feed
- track 5: air flow signal
- track 6: earth
BOSCH
Output voltage, with ignition on and

engine switched off (between tracks
2 and 3):
- = 1.6 V for an atmospheric pressure of 1013 mbar
- > 1.6V for an atmospheric pressure > 1013 mbar
- < 1.6 V for an atmospheric pressure < 1013 mbar
Always replace the seal each time it
is removed

valve
SIEMENS
Gang resistance: 2.96 10 % at

20C (tracks 1 and 5)
Sensor resistance: 6.5 k 40% at
20C (tracks 2 and 4)

solenoid valve
PIERBURG
Turbocharger
GARRET
Calibration
- For an underpressure of 265
mbar , the rod should have a
stroke of between 0.5 and 3.5 mm
- for an underpressure greater than
600 mbar the rod should be at the
stop
Fault finding
13B-10
DIESEL INJECTION
Specifications
13B
K9K, and 732
Equipment required
diagnostic tool
Engine
Engine speed (rpm)
Vehicle
type
Type
Suffix
Idling
speed
Maximum
unladen
Maximum
laden
JM1E
K9K
732
800 50
5000 150
5000 150
Smoke opacity
Homologation
value
1.5 m
-1
Legal
maximum
2m
-1
Emissions
standard
Euro IV
Description
Make - type
Special notes
High pressure pump
SIEMENS VDO
Low pressure pump
SIEMENS VDO
Built into the high pressure pump
Injection computer
SIEMENS VDO
128-track computer (A 32, B 48, C

48)
Diesel fuel rail pressure sensor
SIEMENS VDO
Built into the rail

Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: earth
- 3: supply
Injectors
SIEMENS VDO
6-hole piezoelectric injector

Supply voltage: 150 V
2-track connector:
- 1: supply
- 2: earth
Flow regulation solenoid valve
SIEMENS VDO
Built into the high-pressure pump

Cannot be removed
Supply voltage: + 12 V
Pressure regulation solenoid valve
SIEMENS VDO
Built into the high-pressure pump

Cannot be removed
Supply voltage + 12 V
13B-11
DIESEL INJECTION
Specifications
13B
K9K, and 732

Description
Make - type
Special notes
SIEMENS VDO
Variable reluctance sensor

2-track connector:
- 1: + signal
- 2: - signal
NAGARES
With pre-postheating function controlled by the injection computer

8-track connector:
- 3: fault finding
- 4: + batter y feed
- 8: injection computer control
Heater plugs
CHAMPION ou BERU
Resistance: 0.6
CTS

Resistance:
900
1025
6-track connector:
- 1: gang 2 signal
- 2: + 5 V feed, gang 2
- 3: + 5 V feed, gang 1
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
JCAE
Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: feed
13B-12
DIESEL INJECTION
Specifications
13B
K9K, and 732

Description
Make - type
Special notes
ELTH
Situated on the diesel return pipe at

the high pressure pump outlet
2-track connector:
- 1: signal
- 2: earth
SIEMENS VDO
SIEMENS VDO
built into the flowmeter

thermistor
Resistance:
- 44373 3118 at - 40C
- 15141 871 at - 20C
- 9202 486 at - 10C
- 5774 276 at 0C
- 3714 161 at 10C
- 1671 58 at 30C
- 1150 36 at 40C
- 817 22 at 50C
- 583 14 at 60C
- 316 6 at 80C
- 183 2 at 100C
BOSCH / LDF6 20-300
Feed voltage: + 5 V
3-track connector:
- 1: feed
- 2: earth
- 3: signal
Damper valve
JCAE
Solenoid valve position potentiometer built into the damper valve.

Solenoid valve feed voltage: + 13.5
V
Potentiometer feed voltage: + 5 V
13B-13
DIESEL INJECTION
Specifications
13B
K9K, and 732

Description
Make - type
Special notes
ELTH

thermistor
Resistance:
- 75780 7000 at - 40C
- 12460 1128 at - 10C
- 2252 112 at 25C
- 811 38 at 50C
- 282 8 at 80C
- 115 3 at 110C
- 88 2 at 120C
4-track connector:
- 1: not used
- 2: earth
- 3: signal
- 4: not used

valve
PIERBURG

valve position potentiometer
PIERBURG
Feed voltage: + 13.5 V

Resistance: tracks 2 and 6: 2.3
Built into the exhaust gas recirculation solenoid valve
Feed voltage: + 5 V
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: Not used
- 5: potentiometer signal
- 6: solenoid valve earth
TEXAS INSTRUMENTS
Feed voltage: + 5 V
3-track connector:
- A: earth
- B: feed
- C: signal
13B-14
DIESEL INJECTION
Specifications
13B
K9K, and 732

Description
Make - type
Special notes
Water in diesel fuel sensor
PRESSAC
Located on the diesel filter

3-track connector:
- 1: feed
- 2: signal
- 3: earth
Inlet air flowmeter
SIEMENS VDO
Air flowmeter with built in air temperature sensor

6-track connector:
- 1: air temperature signal
- 2: earth
- 3: Not used
- 4: + 12 V feed
- 5: + 5 V feed
- 6: air flow signal

solenoid valve
BIRTON
Proportional solenoid valve

Feed voltage: + 12 V
2-track connector:
- 1: computer output
- 2: feed
Fault finding
13B-15
DIESEL INJECTION
Diesel injection: Precautions for repair
13B
K9K, and 722 or 724 or 728 or 732 F9Q, and 804 or 812 M9R, and 700
I - RISKS LINKED TO CONTAMINATION
2 - Blanking plugs
The high-pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are:
The blanking plugs are used to cap the fuel circuit once
it is opened and to therefore prevent contaminants
from entering.
- damage to or destruction of the high-pressure injection system,
A set of blanking plugs should be used once only and

used plugs must be discarded after use: once used,
the plugs are soiled and cleaning them is not sufficient
to make them reusable.
- a component seizing,
- a component not being properly sealed.
All After-Sales operations must be performed under
very clean conditions. Having carried out an operation
in good conditions means that no impurities (particles a
few microns in size) have penetrated the system during
dismantling.
The cleanliness principle must be applied from the filter
to the injectors.
Unused plugs must also be discarded and not used

again for any other operation on an injection system.
Blanking plug set part number:
- F9Q: 77 01 208 229
- K9K ( DELPHI injection): 77 01 206 804
- K9K ( SIEMENS injection): 77 01 476 857
- M9R: 77 01 209 062
What are the sources of contamination?

- metal or plastic chips,
3 - Protective bags
- paint,
Use hermetically-resealable plastic bags, using adhesive tape, for example, to store components which will
be refitted and reused. Stored parts will therefore be
less subject to the risk of impurities.
- fibres:
cardboard,
These bags must be used once only: once they have

been used, they are to be discarded.
brushes,
paper,
4 - Cleaning products
clothing,
Two cleaning products can be used:
cloth,
- foreign bodies such as hair,
- an injector cleaner (part number 77 11 224 188 ),
- ambient atmosphere,
- an aerosol spray brake cleaner (part number 77 11

226 128 ).
- etc.
To use the injector cleaner, be sure to have a clean

brush in good condition (the brush must not lose any
bristles) as well as a clean container which has no impurities in it.
WARNING
Cleaning the engine using a high-pressure washer
is prohibited because of the risk of damaging connections. In addition, moisture may collect in the
connectors and create electrical connection faults.
Note:
Use a new injector cleaner each time work is carried out (a used cleaning agent will contain impurities).
1 - Cleaning cloths
Use lint free cleaning cloths (part number 77 11 211
707 ).
The use of rags or ordinary paper towels is prohibited:
these produce lint and lose fibres, which then contaminate the fuel circuit.
Each cloth must only be used once.
II - ADVICE TO BE FOLLOWED BEFORE ANY

OPERATION
1) Carry out the work in a clean working area and take
care to protect removed components from dust using
plastic bags which are hermetically-resealable, for
example.
13B-16
DIESEL INJECTION
13B
2) Always order the following from the Parts Department before carrying out work:
- une collection de bouchons de propret neuve ,
specific to the engine,
- a sufficient number of lint-free lingettes de nettoyage .
- one of the two produits de nettoyage for the fuel
pipe unions,
- les pices remplacer systmatiquement after
each removal and which are mentioned in the work
procedures specific to each vehicle (see the relevant
Workshop Repair Manual).
3) Wear safety goggles fitted with side shields to prevent the cleaning product from splashing the eyes.
4) Wear latex safety gloves to avoid prolonged contact
with the skin.
When replacing a component with a new one or when

refitting it after storing it in a plastic bag, do not unpack
it until it is time to fit it on the vehicle.
IV - CLEANING
There are currently two procedures for cleaning the
fuel circuit before opening it in order to carry out work in
the workshop.
These procedures enable the fuel circuit to be cleaned
to prevent contamination from entering: they both have
the same end result and neither is preferred over the
other.
1 - Using the injector cleaning agent
Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Pour the injector cleaning agent into a container which
is free from impurities.
Note:
If wearing leather protective gloves, cover these
with latex gloves.
IMPORTANT
5) Before any operation on the injection system protect

(using plastic bags or clean cloths for example):
Wear latex safety gloves when using the cleaning

agent.
- the accessories and timing belts,

- the electrical accessories (starter, alternator, powerassisted steering pump, sensors and electrical connectors),
Dip a clean brush, which is not shedding bristles, into

the container of injector cleaning agent.
IMPORTANT
- the flywheel face.
Wear safety goggles fitted with side shields during

this operation.
III - INSTRUCTIONS TO BE FOLLOWED DURING

THE OPERATION
Wash your hands before and while carrying out the
work.
Change the latex safety gloves if they become soiled or
damaged.
All components removed from the injection system
must be stored in a hermetically sealed plastic bag
once they have been capped.
Reseal the bag hermetically using adhesive tape, for
example, even if the bag must be opened shortly afterwards: the ambient atmosphere can be a source of
pollution.
Clean the unions carefully using the brush and the injector cleaning agent.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Make sure
there are no brush bristles remaining and that the area
is clean.
Wipe the sections that were cleaned with fresh cleaning cloths.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.
After opening the fuel circuit, the use of brushes, cleaning agents, air blow guns, rifle-type brushes or standard cloths is strictly prohibited: These items are likely
to allow impurities to enter the system.
13B-17
WARNING
Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessar y.
DIESEL INJECTION
2 - Using the brake cleaning agent
Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
IMPORTANT
Wear latex safety gloves when using the cleaning
agent.
IMPORTANT
Wear safety goggles fitted with side shields during
this operation.
Spray the brake cleaning agent onto the unions to be
opened.
Clean the unions carefully using fresh cleaning cloths.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Make sure
there are no brush bristles remaining and that the area
is clean.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.
WARNING
Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessar y.
13B-18
13B
DIESEL INJECTION
V - INSTRUCTIONS FOR FITTING THE PLUGS
K9K, and 722 or 724 or 728
13B-19
13B
DIESEL INJECTION
part no. 77 01 206 804
13B-20
13B
DIESEL INJECTION
13B
20977
13B-21
DIESEL INJECTION
K9K, and 732
13B-22
13B
DIESEL INJECTION
part no. 77 01 476 857
13B-23
13B
DIESEL INJECTION
13B
113430
13B-24
DIESEL INJECTION
F9Q, and 804 or 812
13B-25
13B
DIESEL INJECTION
part no. 77 01 208 229
13B-26
13B
DIESEL INJECTION
13B
104561
13B-27
DIESEL INJECTION
M9R, and 700
13B-28
13B
DIESEL INJECTION
part no. 77 01 209 062
13B-29
13B
DIESEL INJECTION
13B
113737
13B-30
DIESEL INJECTION
13B
K9K, and 722 or 728
20
19 17 18
4 5
16 15 14
13 12 11
10
104543
(1)
Pr iming pump
(2)
(3)
Turbocharger
(4)
Exhaust gas recirculation solenoid valve
(5)
Injector
(6)
Turbocharging air temperature

and pressure sensor
(7)
Injection computer
(8)
Air filter unit
(9)
Protection and switching unit
(10)
Air flow sensor with integrated

temperature sensor (K9K 728)
(11)
Turbocharging pressure regulation solenoid valve (K9K 728)
(12)
(13)
(14)
Rail pressure sensor
(15)
Spherical injector rail
(16)
Accelerometer
(17)
(18)
Diesel flow actuator
(19)
High pressure pump
(20)
Diesel filter
21
101811
13B-31
DIESEL INJECTION
13B
K9K, and 722 or 728

(21)
Injection computer
24
26
30
22
25
28
29
27
102084
101105
(22)
Protection and switching unit
(24)
Venturi
(25)
Fuel flow actuator
(26)
(27)
(28)
Spherical injector rail
(29)
Accelerometer
(30)
Injector
23
K9K, and 722
31
32
102085
(23)
High pressure pump
33
102082
13B-32
DIESEL INJECTION
13B
K9K, and 722 or 728

(31)

and pressure sensor
(34)

and pressure sensor
(32)
(35)
(33)
(36)
Speed and position sensor
(37)
K9K, and 728
34
35
36
110327
37
110319
13B-33
DIESEL INJECTION
13B
K9K, and 722 or 728
38
19654-1
(38)
Cylinder marking sensor
39
41
40
20796
(39)
(40)
Speed and position sensor (K9K

722)
102204
(41)
13B-34
DIESEL INJECTION
13B
K9K, and 722 or 728
44
102124
(44)
Priming pump
42
102125
(42)
43
45
102128
(45)
104954
(43)
Diesel filter
13B-35
DIESEL INJECTION
K9K, and 722 or 728
47
46
102077
(46)
Catalytic converter
(47)
Turbocharger
K9K, and 728
48
101889
(48)
Turbocharging pressure regulation solenoid valve
13B-36
13B
DIESEL INJECTION
13B
F9Q, and 812
104542
(16)
(17)
Diesel temperature sensor (fuel

return)
(1)
Diesel filter
(2)
Pr iming pump
(3)
Cylinder position sensor
(18)
Diesel pressure regulator
(4)
(19)
High-pressure pump
(5)
(7)
Engine stop system solenoid

valve
(6)
Solenoid injectors
(8)
Engine stop system vacuum

reserve
(9)
Turbocharger regulation solenoid valve
(10)
Flowmeter with air temperature

sensor
(11)
Injection computer
(12)
Protection and Switching Unit
(13)
Engine damper flap control

diaphragm
(14)
Engine damper flap
(15)
Pressure limiter (on injector rail)
13B-37
DIESEL INJECTION
13B
F9Q, and 812
18297-1
(20)
(21)
High-pressure pump
(22)
Injection common rail
(23)
Injector
(24)
Pressure regulator
(25)
Pressure sensor
(26)
(27)
Pressure limiter
102485
(28)
13B-38
DIESEL INJECTION
13B
F9Q, and 812
16181
(29)
101891
(32)
102479
(30)
Turbocharger
(31)
Catalytic converter
101889
(33)
13B-39
Turbocharging pressure regulation solenoid valve
DIESEL INJECTION
13B
F9Q, and 812
101892
(34)
Damper unit (engine damper

flap)
(35)
Engine damper flap control

diaphragm
104953
(37)
Engine damper flap solenoid

valve
104557
104421
(36)
Engine stop system vacuum

reserve
13B-40
(38)
Priming pump
DIESEL INJECTION
13B
F9Q, and 812
104954
(39)
Diesel filter
104413
(42)
Engine coolant temperature

sensor
104420
102352
(40)
(41)
(43)
Exhaust gas recirculation intercooler
13B-41
DIESEL INJECTION
F9Q, and 812
102204
(44)
13B-42
13B
DIESEL INJECTION
13B
F9Q, and 804
104542
(1)
Diesel filter
(2)
Pr iming pump
(3)
(4)
(5)
Solenoid injectors
(6)
Exhaust gas recirculation solenoid valve unit
(7)
Turbocharger regulation solenoid valve
(8)
Flowmeter with air temperature

sensor
(9)
Injection computer
(10)
(11)
Pressure limiter
(12)
Turbocharger pressure sensor
(13)
(14)
High pressure pump
(15)
Diesel pressure regulator
13B-43
DIESEL INJECTION
13B
F9Q, and 804
18297-1
(16)
High pressure pump
(17)
Injection common rail
(18)
Injectors
(19)
Pressure regulator
(20)
Pressure sensor
(21)
(22)
Pressure limiter
102485
(23)
13B-44
DIESEL INJECTION
13B
F9Q, and 804
16181
(24)
101891
(27)
111864
(25)
Turbocharger
(26)
Catalytic pre-converter
101889
(28)
13B-45
Turbocharging pressure regulator solenoid valve
DIESEL INJECTION
13B
F9Q, and 804
111887
(29)
Throttle valve unit.
(30)
Injector rail protector.
104954
(32)
Diesel filter
111964
104557
(31)
(33)
Exhaust gas recirculation solenoid valve unit
(34)
Exhaust gas recirculation intercooler
Pr iming pump
13B-46
DIESEL INJECTION
13B
F9Q, and 804
111886
(35)
(37)
111856
(36)
102204
13B-47
DIESEL INJECTION
13B
K9K, and 732
114186
(1)
Manual priming pump
(2)
High pressure pump
(3)
(4)
Turbocharger
(5)
Injectors
(6)
(7)
Turbocharging air pressure sensor
(8)
Air flowmeter
(9)
Air filter unit
(10)
(11)
Injection computer
(12)
(13)
(14)
Injector rail
(15)
Injector rail pressure sensor
(16)
(17)
Diesel filter
101811
(18)
13B-48
Injection computer
DIESEL INJECTION
13B
K9K, and 732
101105
(19)
111748
(20)
High pressure pump
13B-49
112994
(21)
(22)
Damper valve
(23)
Pressure regulation solenoid

valve
(24)
Flow regulation solenoid valve
DIESEL INJECTION
13B
K9K, and 732
114348
(25)
Diesel injector fuel return rail
(26)
(27)
High pressure pipe between the

rail and injector
(28)
High pressure pipe between the

pump and rail
(29)
High pressure rail
(30)
(31)
Diesel injector
(32)
Injector clamp
(33)
Spacer between the cylinder

head and injector clamp
102204
(34)
13B-50
DIESEL INJECTION
13B
K9K, and 732
102124
(37)
Priming pump
102125
(35)
113840
104954
(36)
Diesel filter
13B-51
(38)
Catalytic converter
(39)
Turbocharger
DIESEL INJECTION
K9K, and 732
114185
(40)
13B-52
13B
DIESEL INJECTION
Flow regulation solenoid valve: Removal - Refitting
K9K, and 732
114078
The flow regulation solenoid valve (1) is joined to the

high pressure pump.
Replace the high pressure pump - flow regulation solenoid valve assembly if there is a fault with the flow regulation solenoid valve (see 13B, Diesel injection,
High pressure pump: Removal - Refitting ).
13B-53
13B
DIESEL INJECTION
Pressure regulation solenoid valve: Removal - Refitting
K9K, and 732
114077
The pressure regulation solenoid valve (1) is joined to

the high pressure pump.
Replace the high pressure pump - pressure regulation
solenoid valve assembly if there is a fault with the pressure regulation solenoid valve (see 13B, Diesel injection, High pressure pump: Removal - Refitting ).
13B-54
13B
DIESEL INJECTION
13B
K9K, and 722 or 728

Vehicles using the DELPHI high pressure diesel fuel
system are equipped with fault warning symbols and
written warning messages, depending on the level of
severity of the faults detected, to inform the customer
and guide the fault finding procedure.
The faults are associated with:
The injection computer controls the illumination of warning lights and display of messages on the instrument
panel. The fault warning lights come on:
of the engine speed sensor,
- delayed stop: the fuel flow actuator (loop discrepancy

and overpressure),
- immediate stop:
the diesel fuel flow actuator,

the rail pressure sensor,
- during the preheating phase,
the supply to all the injectors,
- if there is an injection fault,
the sensor feed voltage,
- if the engine is overheating.
an internal computer fault.
The warning signals are sent to the instrument panel

via the multiplex network.
WARNING LIGHT ACTIVATION PRINCIPLE.
During the starting phase (Start button pressed, the
orange preheating symbol is lit during the preheating
phase, then goes out (see 13C, Preheating, Pre-postheating control ).
In the event of an injection fault (level 1), the message
Check injection is displayed and then the
Service warning light comes on. This means a reduced level of operation and a limited safety level.
If the engine overheats, the engine coolant temperature fault symbol appears with the message Engine
overheating (only on information display) followed by
the Stop warning light and buzzer. If this happens,
the vehicle will stop immediately.
On board diagnostics excess pollution orange
warning light
The orange warning light, represented by an engine,
comes on when the ignition is switched on for approximately 5 seconds then goes out. It is never displayed
when the engine is running (not operational).
Repairs should be carried out as soon as possible.

These faults are associated with:
- the engine immobiliser,
- a C2I (individual injector correction) coding error,
- an injector,
- the injector controls,
- the diesel fuel supply (injector leak, etc.),
- an engine speed sensor target fault,
- the injection locking relay,
- the exhaust gas recirculation solenoid valve or position sensor,
- the accelerator pedal potentiometer (gangs 1 and 2),
- the accelerator pedal potentiometer supply,
- the turbocharging pressure sensor (in the event of
overpressure),
- water in the diesel fuel or a water detection sensor
fault (if fitted to the vehicle).
If there is a serious injection fault (level 2), the red engine symbol and the word Stop appears (only on information display), with the message Injection
faulty , followed by the Stop warning light and
buzzer.
13B-55
DIESEL INJECTION
F9Q, and 804 or 812
(see MR 372 Fault finding, 13B, Diesel injection,
System operation ).
(see MR 372 Fault finding, 13B, Diesel injection,
Fault summary table ).
13B-56
13B
DIESEL INJECTION
Injection / air conditioning programming
13B
K9K, and 722 or 728

The air conditioning management is shared between
several computers that communicate via the multiplex
network.
The injection computer is responsible for:
- managing the request for cold air in response to passenger compartment controls and the circuit pressure
value.
- determining the power absorbed by the compressor
using the circuit pressure value,
- authorising the fan unit control according to vehicle
speed and circuit pressure.
- authorising or disabling the compressor clutch.
When the air conditioning is switched on, the air conditioning control panel requests authorisation to engage
the compressor clutch.
The injection computer either authorises or disables
the compressor clutch, actuates the fan unit via the
UPC and adopts a fast idle speed of 900 rpm .
The injection computer authorises operation of the air
conditioning compressor and the fan unit (both powered by the Protection and Switching Unit), according to
the following conditions:
I - AIR CONDITIONING COMPRESSOR OPERATION

PROGRAMMING
During certain phases of operation, the injection computer disables the compressor.
1 - Engine start programming
Air conditioning compressor operation is inhibited for 1
second after the engine has started.
2 - Thermal protection programming
The air conditioning compressor is not engaged if the
engine temperature is above 115C or above 110C at
high engine speeds, 4500 rpm for more than 10 seconds .
3 - Fan unit control programming
With the engine idling or when driving, with the air conditioning on, the fan unit is activated at high or low
speed, according to the refrigerant pressure and the
vehicle speed.
4 - Recovery of performance
If the accelerator pedal is depressed firmly (greater
than 75 % of its travel), the compressor is disengaged
for 5 seconds .
- engine coolant temperature,

- vehicle speed,
- air conditioning.
5 - Recovery of output when the vehicle is moving

off
The signals used for the air conditioning function are

transmitted via:
- track A A4 multiplex line HIGH multiplex connection,
- track A A3 multiplex line LOW multiplex connection.
The connections between the injection computer and
the refrigerant pressure sensor are:
- C C3 refrigerant pressure sensor signal,
- C C4 refrigerant pressure sensor supply,
- C G3 refrigerant pressure sensor earth.
Note:
To help the vehicle move off smoothly, the air conditioning compressor is disengaged if the accelerator pedal
position is above 30 % and the engine speed is less
than 1250 rpm .
6 - Anti-stalling function
The air conditioning compressor is disengaged if the
engine speed is less than 740 rpm .
7 - Engine overspeed timed protection
programming
engine speed is above 4500 rpm for more than 3 seconds .
The value of parameter ( PR044 ) power absorbed by the air conditioning compressor is never 0,
whatever the status of the air conditioning compressor. The minimum reading is approximately 250 W .
Note:
There is always a delay of more than 10 seconds
after the air conditioning compressor is disengaged
before it can be disengaged again.
The air conditioning compressor is of the variable

displacement type.
13B-57
DIESEL INJECTION
13B
K9K, and 722 or 728

- and vehicle speed less than 2.4 mph (4 km/h) ,
II - PASSENGER COMPARTMENT HEATING

RESISTORS OPERATION PROGRAMMING
- and gearbox in neutral.
To reduce the heating time, fit air heating resistors

known as passenger compartment heating
resistors in the passenger compartment heating circuit.
Exit conditions:
- engine speed above 2600 rpm ,
- or vehicle speed greater than 3.6 mph (6 km/h) ,
The UCH determines the need to actuate the heating

resistors, in accordance with the user's request.
- or a gear is engaged.
The injection computer determines:
4 - Stalling prevention programming
- the number of heating resistors supplied (power control limitation) depending on the alternator charge,
When the engine speed falls below 760 rpm , the passenger compartment heating resistors are temporarily
disabled. When engine speed rises above 750 rpm ,
the passenger compartment heating resistors are
reauthorised.
- whether resistor operation should be disabled, according to engine speed, load and vehicle speed.
The heating resistors are supplied by the Protection
and Switching Unit.
At the request of the resistors, the fast idle speed becomes 900 rpm .
III - PASSENGER COMPARTMENT HEATING
RESISTORS OPERATION PROGRAMMING
During certain operating phases, the injection computer disables the passenger compartment heating resistors.
The operation of passenger compartment heating resistors is prohibited for 20 seconds after the engine is
started.
2 - Performance return programming under heavy
load
Under heavy load at low idle, the heating resistors are
temporarily disabled.
Entry conditions:
- engine speed less than 3000 rpm ,
- and vehicle speed less than 78 mph (130 km/h) .
Exit conditions:
- engine speed above 3500 rpm ,
- and vehicle speed greater than 90 mph (150 km/h)
(for your information).
3 - Performance return programming for hill starts
To assist hill starts, the heating resistors are temporarily disabled.
Entry conditions:
- engine speed less than 900 rpm ,
13B-58
DIESEL INJECTION
13B
F9Q, and 812

The air conditioning management is shared between
several computers that communicate via the multiplex
network.
When the air conditioning is switched on, the air conditioning control panel requests authorisation to engage
the compressor clutch.
II - PASSENGER COMPARTMENT HEATING

RESISTOR OPERATION PROGRAMMING
During certain operating phases, the injection computer disables the heating resistors.
The injection computer authorises or inhibits the compressor clutch, and controls the fan assembly via the
UPC.
The heating resistors are disabled while the heater

plugs are in operation.
When the air conditioning function is selected, the

idling speed is not altered.
When the engine starts, the heating resistor supply is

authorised after a delay that depends on the engine
coolant temperature.
This compressor is the variable output type.

Engine coolant temperature
I - AIR CONDITIONING COMPRESSOR OPERATION

PROGRAMMING
(C 1)
During certain operating phases, the injection computer disables the compressor.
Delay
(seconds)
-30
30
-20
25
-10
15
15
10
15
20
15
30
10

Air conditioning compressor operation is inhibited for 2
seconds after the engine has started.
2 - Thermal protection programming
The air conditioning compressor is not engaged if the
engine coolant temperature is above 115C , it is reengaged if the engine coolant temperature falls below
110C .
This vehicle is equipped with heating resistors located
in the air conditioning unit.
These heating resistors are designed to heat up the air
which is then directed to the passenger compartment.
When the heating resistors are activated, the injection
computer adopts a fast idle speed. This engine speed
is 900 rpm .
2 - Stalling prevention programming

When the engine speed falls below 780 rpm , the heating resistors are temporarily disabled. When the engine speed rises above 855 rpm , the heating resistors
are authorised.
3 - Recovery of output when the vehicle is moving

off
To help the vehicle move off smoothly, the air conditioning compressor clutch is disengaged if the accelerator
pedal position is above 25 % , if the engine speed is
below 1350 rpm and if the vehicle speed is below 3
mph (5 km/h) .
4 - Anti-stalling function
engine speed is below 750 rpm .
It is reengaged if the engine speed is greater than 780
rpm .
13B-59
DIESEL INJECTION
Idling speed
13B
K9K, and 722 or 728

The computer calculates the idling speed to maintain
the idling speed at the recommended level and to compensate for any variation in the mechanical or electrical
torque as a function of:
- the coolant temperature,
- the battery voltage,
- the gear selected,
- the electrical consumers (air conditioning, fan unit,
passenger compartment heating electrical resistors,
etc.),
- any faults found.
Note:
II - IDLE SPEED CORRECTION IN THE EVENT OF

AN ACCELERATOR PEDAL POTENTIOMETER
FAULT
- If one of the two accelerator pedal potentiometer
gangs is faulty, the injection computer defaults to an
idle speed of 1300 rpm . This defect mode limits performance. The Check injection message lights up,
followed by the Service warning light.
- If the accelerator pedal potentiometer is jammed, no
longer supplied, or is no longer sending an output signal, the injection computer imposes an idle speed of
1300 rpm . This defect mode limits performance. The
Check injection message lights up, followed by
the Service warning light.
- If there is inconsistency between the accelerator pedal potentiometer signal and the brake switch signal,
the injection computer imposes an idling speed of
1300 rpm .
At normal engine operating temperature, without

major electrical consumers, the engine idling speed
is 805 50 rpm .
III - IDLE SPEED CORRECTION IN THE EVENT OF

AN INJECTOR C2I CODING ERROR
I - IDLE SPEED CORRECTION ACCORDING TO

ENGINE COOLANT TEMPERATURE
In the event of an injector C2I coding error (individual

adjustment of the injector flow), the injection computer
forces an idling speed of 1300 rpm . This defect mode
limits performance. The Check injection message
lights up, followed by the Service warning light.
IV - IDLE SPEED CORRECTION WHEN THE
VEHICLE IS BEING DRIVEN
At normal engine operating temperature, the idling
speed is modified according to the gear engaged:
- in neutral, the speed is 805 rpm ,
- in 1stand 2ndgear, the engine speed is 875 rpm ,
- in 3rdand 4thgear, the engine speed is 900 rpm ,
- in 5thgear, the engine speed is 950 rpm .
103122
X: Engine idling speed (rpm)

Y: Engine coolant temperature (C)
13B-60
DIESEL INJECTION
Idling speed
F9Q, and 812
I - IDLE SPEED CORRECTION ACCORDING TO
ENGINE COOLANT TEMPERATURE
In all cases, this engine idling speed correction is deactivated 10 minutes after the engine is started and
adopts a value of 800 rpm .
103129
X: Engine idling speed (rpm)

Y: Engine coolant temperature (C)
II - IDLE SPEED CORRECTION IN THE EVENT OF

AN ACCELERATOR PEDAL POTENTIOMETER
FAULT
If one of the two accelerator pedal potentiometer gangs
are faulty, the injection computer forces an idle speed
of 1400 rpm . When the brake pedal is depressed, the
idling speed returns to 1000 rpm .
If there is inconsistency between the accelerator pedal
potentiometer signals and the brake switch, the idling
speed increases to 1400 rpm .
III - ENGINE IDLE SPEED CORRECTION WHEN THE

VEHICLE IS BEING DRIVEN
The engine idling speed when the vehicle is being driven is:
- 870 rpm if 1stor 2ndgear is engaged,
- 900 rpm when a gear above 2ndgear is engaged.
13B-61
13B
DIESEL INJECTION
Centralised coolant temperature management
F9Q, and 812
ENGINE COOLANT TEMPERATURE WARNING
LIGHT
The warning light is actuated by the injection computer
The warning light is continuously lit if the coolant temperature exceeds 120C . It goes out when the coolant
temperature drops below 115C .
13B-62
13B
DIESEL INJECTION
Centralised coolant temperature management
K9K, and 722 or 728
The coolant temperature sensor is a 2-track sensor:
- 1 track for the coolant temperature signal to the computer (track B H3 ),
- 1 track for the coolant temperature sensor earth (track
B H2 ).
The instrument panel warning light is switched on and
off via the multiplex network.
This system allows the engine cooling fan to be controlled by the injection computer. It consists of a single
temperature sensor used in the injection system, engine cooling fan, temperature indicator and engine coolant temperature warning light functions in the
instrument panel.
The request to operate the engine cooling fan is made
by the injection computer via the multiplex network.
I - FAN UNIT OPERATION WITH THE ENGINE
RUNNING
The fan unit is controlled:
- at low speed if the engine coolant temperature exceeds 99 C or in the event of a coolant temperature
sensor fault, and is stopped when the temperature
falls below 96 C ,
- at high speed if the engine coolant temperature exceeds 102 C or if the low speed is defective, and is
stopped when the temperature falls below 99 C .
The fan unit low and high speeds are controlled when
the air conditioning function is selected on the instrument panel.
The fan will operate at high speed if low speed is faulty,
and under the low speed operating conditions.
II - OPERATION OF THE ENGINE COOLANT
TEMPERATURE WARNING LIGHT
The warning light is actuated by the injection computer
The warning light is continuously lit if the coolant temperature exceeds 118 C . It goes out when the temperature drops below 115 C .
13B-63
13B
DIESEL INJECTION
13B
K9K, and 722 or 728

After programming, reprogramming or replacing the
computer:
Equipment required

diagnostic tool
- start and then stop the engine (to initialise the computer) and wait for 30 seconds ,
WARNING
- switch on the ignition again.
- Switch on the diagnostic tool (connect to the

mains or the cigarette lighter).
- Use the diagnostic tool :

carry out the SC001 Write saved data command to restore the C2I and engine parameters,
- Check the condition of the battery.

- Connect a battery charger (throughout the duration of computer (re)programming, the engine cooling fan is automatically engaged).
Enter the VIN using the VP010 Write VIN

command,
correct all computers of any faults indicated by the
diagnostic tool ,
- Keep to the engine coolant temperature guidelines

supplied in the diagnostic tool before carrying
out any (re)programming.
clear the computer memory,

carry out a road test,
carry out a new check with the diagnostic tool.
PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
The system can also be programmed and reprogrammed through the diagnostic socket using the
diagnostic tool (see Technical Note 3585A, New
procedure for programming and reprogramming
computers, 01B, General vehicle information,
Programming - Reprogramming ) or follow the instructions supplied by the diagnostic tool.
Before programming, reprogramming or replacing
the computer, save the following data in the diagnostic tool :
WARNING
- The injection computer retains the immobiliser
code for life.
- The system has no security code.
- It is prohibited to run tests with computers borrowed from the Parts Department or from another vehicle which must then be returned.
- These computers are permanently coded.
- the C2I parameters (individual injector correction),

- the engine adaptives using command SC003
Save computer data .
13B-64
Note:
If commands SC001 and SC003 are forgotten or
do not work, the C2I codes for each injector must
be entered manually after the computer has
been replaced or reprogrammed by reading the
C2I code on each injector (see 13B, Diesel
injection, Injectors: Configuration and programming .
DIESEL INJECTION
13B
F9Q, and 812

After programming, reprogramming or replacing the
computer:
Equipment required

diagnostic tool
- start and then stop the engine (to initialise the computer) and wait for 30 s ,
WARNING
- switch on the ignition again.
- Connect the diagnostic tool to the mains or the

cigarette lighter.
- Use the diagnostic tool :

run the SC001 Write saved data command
to restore the IMA (injector flow correction) codes
and engine parameters,
- Check the condition of the battery.

- Connect a battery charger (throughout the duration of computer (re)programming, the engine cooling fan is automatically engaged).
enter the VIN using the VP010 Write VIN

command,
- Comply with the engine coolant temperature

values given in the diagnostic tool before
carrying out any (re)programming.
rectify any faults in computers indicated by the

diagnostic tool ,
clear the computer memory,
carry out a road test,
COMPUTER PROGRAMMING, REPROGAMMING

OR REPLACEMENT OPERATIONS
carry out a new check using the diagnostic tool.
The system can be programmed and reprogrammed

via the diagnostic socket using the diagnostic tool
(see Technical Note 3585A, New computer programming and reprogramming procedure, 01B,
General vehicle information, Programming - Reprogramming ) or follow the instructions given by
the diagnostic tool.
Before programming, reprogramming or replacing
the computer, save the following data in the diagnostic tool :
WARNING
code for life.
- Running tests with computers borrowed from
the Parts Department or from another vehicle
which must then be returned is prohibited.
- These computers are permanently coded.
- the IMA codes (injector flow correction),

- the engine parameters using the SC003 Save
computer data is not present.
Note:
If commands SC001 and SC003 are not run or
cannot be run following programming, reprogramming or replacement of the computer, write
the IMA (injector flow correction) code of each
injector manually, reading the codes on the injectors (see 13B, Diesel Injection, Injectors: Configuration and programming ).
13B-65
DIESEL INJECTION
High pressure pipe: Checking
K9K, and 722 or 728
Equipment required
diagnostic tool
WARNING
After any operation, check that there are no diesel
fuel leaks.
Reprime the diesel circuit using the manual priming
pump.
Note:
The diagnostic tool can be used for testing the
high pressure circuit with the engine running.
This command can be used to run fault finding
on a leak due to an incorrectly fitted or tightened
union. This command only works if the engine
coolant temperature is above 60C . The fault finding procedure will not reveal small leaks due to
incorrect tightening.
Run command AC029 high pressure circuit sealing test , in the LPG/fuel circuit tab.
WARNING
Do not leave anything on the side of the engine
housing during the test phase (significant vibration).
Note:
The engine automatically runs a cycle of four
accelerations and decelerations to lower the rail
pressure.
Check that there are no leaks in the high pressure
circuit.
Deal with the causes of any leaks.
13B-66
13B
DIESEL INJECTION
13B
K9K, and 732
Equipment required
diagnostic tool
WARNING
After any operation, check that there are no diesel
fuel leaks.
Reprime the diesel circuit using the manual priming
pump.
112811
Pull the clip.
112815

(1) .
one side.
112991
Remove the stainless steel pipe mounting bolt (4) .

13B-67
DIESEL INJECTION
13B
K9K, and 732

Run command AC029 high pressure circuit sealing test , in the LPG/fuel circuit tab.
WARNING
Do not leave anything on the side of the engine
housing during the test phase (significant vibration).
Note:
The engine automatically runs a cycle of four
accelerations and decelerations to lower the rail
pressure.
Check that there are no leaks in the high pressure
circuit.
Deal with the causes of any leaks.
Disconnect:
112992
Unclip the injector rail protector cover (6) .
Remove:
- the air inlet pressure sensor connector.
protector cover,
Loosen the clip and move the air inlet duct to one side.
- the injector rail protector cover,
Pull out the clip from the stainless steel pipe.
Remove the air inlet duct.

Refit:

bolt,
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,

Refit:
Note:
- the air inlet duct on the damper valve.
The diagnostic tool can be used for testing the

high pressure circuit with the engine running.
Tighten the clip.

Connect:
This command can be used to run fault finding

on a leak due to an incorrectly fitted or tightened
union. This command only works if the engine
coolant temperature is above 60C . The fault finding procedure will not reveal small leaks due to
incorrect tightening.
- the air inlet pressure sensor connector,

13B-68
DIESEL INJECTION
Diesel injector: check
K9K, and 722 or 728
The command AC029 high pressure circuit sealing test on the fuel/LPG tab also enables
the leakage rate of each injector to be checked in order to determine an internal leak in one or several injectors. This test only works when the engine
temperature is above 60C .
Disconnect the return pipes of the four injectors.
Connect the four transparent hoses with an internal
diameter of 4 mm and a length of 50 cm in the place
of the return pipes.
Immerse these hoses into four graduated measuring
cylinders (or use the measuring tool found in the
capped rail kit).
Start the engine.
Allow the engine to run for 2 minutes at idle speed.
Run command AC029 high pressure circuit sealing test on the fuel/LPG tab. The engine will
automatically carry out a cycle of four accelerations
and decelerations to increase the pressure in the rail
and check whether there are internal leaks on the injectors' return circuit.
When the cycle is complete, the test must be run
again, to obtain a correct reading of the flow of each
injector.
At the end of the two cycles, the flow of each injector
should be 35 ml .
Replace the faulty injector.
IMPORTANT
Never leave a tool or other object on the side of
the engine housing during the four cycles (significant vibration).
13B-69
13B
DIESEL INJECTION
Leak flow from injectors: Check
K9K, and 722 or 728
Mot. 1711
Kit for measuring

injector leak rate.
Remove the front engine covers.

Connect the four transparent hoses of the (Mot.
1711) to the injectors instead of the injector fuel return pipes.
Fit the correct blanking plugs, in particular onto the
venturi pipe to prevent depriming the circuit.
Insert these hoses in the four graduated measuring
cylinders of the (Mot. 1711).
IMPORTANT
Do not leave any object (tools etc.) on the side of
the engine housing during the entire operation.
Position the tools so that they do not fall during
the engine running phase of the test.
Follow the procedures described in the Fault finding
MR (see MR 372 Fault finding, 13B, Diesel injection, Fault finding - Tests ).
Disconnect:
- the four transparent hoses of the (Mot. 1711).
Refit the injector fuel return pipes.
Refit the front engine covers.
13B-70
13B
DIESEL INJECTION
13B
K9K, and 732

Mot. 1771
Kit for measuring SIEMENS injector leak

rate.
Mot. 1711
Kit for measuring

injector leak rate.
Switch off the ignition and wait 30 seconds before

working on the injection system.
112811
Pull the clip.
112815

(1) .
Loosen the clip (2) and move the air inlet duct (3)
aside .
112991

steel pipe.
Move the air inlet duct (5) to one side .
13B-71
DIESEL INJECTION
13B
K9K, and 732

Connect:
IMPORTANT
Disconnect:
112992
Loosen the clip and move the air inlet duct aside.
Remove:
protector cover,
- the dipstick,
- the dipstick,
Disconnect the four transparent pipes from the (Mot.

1771).
Disconnect the four fuel return pipes of the four injectors (see 13B, Diesel injector fuel return rail:
Place the correct blanking plug on the injector fuel
return connectors.
Remove:

Connect the four injector fuel return pipes.
Refit:
- the dipstick,
bolt,
Refit:
Clip on the injector rail protector cover.
- the dipstick tube mounting bolts,
- the dipstick.
Tighten the clip.
Tighten the clip.
13B-72
Refit:
DIESEL INJECTION
K9K, and 732
Connect:
Reprime the fuel circuit with the manual priming
pump.
13B-73
13B
DIESEL INJECTION
High pressure pump: Removal - Refitting
13B
K9K, and 722 or 728

WARNING
Mot. 1672
Mot. 1606
High pressure pumppulley retaining tool.
Tighten to a torque of 38 Nm the pump-rail and

rail-injectors high pressure pipes with the following part numbers:
Mot. 1525
Extractor for timing

gear with tapered hub.
- 77 01 207 025 ,
Mot. 1525-02
Adapter sockets for

Mot.1525.
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
Equipment required
- 77 01 207 029 .
For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
diagnostic tool
Tightening torquesm
IMPORTANT
high pressure injection

pump pulley mounting
nut
55 Nm
rail mounting nuts
28 Nm
that the injector rail is not under pressure,
union at the rail end
24 Nm
that the fuel temperature is not too high.
union at the pump end
24 Nm

bolts
4 Nm
- It is essential to respect the safety and cleanliness

advice given in this document whenever work is
carried out on this system.
- Loosening a high pressure pipe union when the

WARNING
WARNING
- Obtain a set of special high pressure injection circuit plugs.
- a new set of blanking plugs (part no.: 77 01 206

804 ),
- Always replace any high pressure pipe or high

pressure pipe clip removed with a new one.
- cleaning cloths (part no.: 77 11 211 707 ),

- cleaning product (part no.: 77 11 224 188 .
WARNING
normal operating direction.
13B-74
DIESEL INJECTION
13B
K9K, and 722 or 728
REMOVAL
II - PROCEDURE FOR HIGH PRESSURE PUMPS

WITH A PULLEY BEARING A NUMBER OTHER
THAN 070 575
I - PROCEDURE FOR HIGH PRESSURE PUMPS

WITH A PULLEY BEARING NUMBER 070 575
21265
21265
Remove the engine covers
WARNING
Removing any high pressure pump pulley bearing the number 070 575 is strictly prohibited.
Replace the pump-pulley assembly, following
the removal procedure for the high pressure pump
not fitted with a pulley 070 575 .
Remove:
Timing belt ),
104343
Remove:
- the pump-pulley assembly.

- the scuttle panel support mounting bolt (2) .
13B-75
DIESEL INJECTION
13B
K9K, and 722 or 728
K9K, and 728
104246
Remove:
K9K, and 722
110325
Pull the clip.
102120
Disconnect the air inlet duct (4) .
110323
Undo the bolt (5) .

13B-76
DIESEL INJECTION
13B
K9K, and 722 or 728
102361
102360
Remove the dipstick guide tube (7) .
Disconnect:
Plug the opening on the engine block.
- the fuel return pipe connecting the injectors to the

pump (13) ,
Disconnect:
- the rail pressure sensor (14) ,
- the accelerometer (15) ,
- the injectors,
- the oil level sensor (16) ,
- the fuel flow actuator electrical connector (9) ,
- the cylinder marking sensor (17) on the timing cover.
Unclamp the electrical harness and move it to one

side.
- the fuel supply and return pipes (11) .
Remove the channel located on the injector rail.
102362
Remove the diesel fuel splash plate (12) .
13B-77
DIESEL INJECTION
13B
K9K, and 722 or 728
102083
102114
Remove the (19) pump-rail high pressure pipe

(see 13B, Diesel injection, High pressure pipe:
Replacing ).
Mark the location of the cover mounting bolts on the

suspended mounting.
Slacken the rail mounting nuts (18) by a few turns.

Loosen the nut at the pump end, then the nut at the
rail end.
Slide the nut down the tube keeping the olive in contact with the taper.
Plug the openings on the injection circuit.
19626
Position the (Mot. 1672) (1) .
13B-78
Remove the right-hand suspended mounting support along with its cover.
DIESEL INJECTION
13B
K9K, and 722 or 728
19654
Remove the upper timing cover by unclipping the

tabs (20) .
13B-79
DIESEL INJECTION
K9K, and 722 or 728
102115
Remove the engine tie-bar mounting bolts (21) on

the gearbox and on the engine sub-frame.
Raise the engine a few centimetres to access the
suspended mounting attachments on the cylinder
head and the high pressure pump pulley.
WARNING
Do not disconnect the right-hand driveshaft when
raising the engine.
13B-80
13B
DIESEL INJECTION
13B
K9K, and 722 or 728
19654-1
Remove:
- the camshaft marking sensor (22) ,
13B-81
DIESEL INJECTION
13B
K9K, and 722 or 728
19654-2
Remove the suspended mounting (25) on the cylinder head.
23167
Position the engine at top dead centre. The camshaft pulley hole (26) should be opposite the cylinder
head hole (27) .
13B-82
DIESEL INJECTION
13B
K9K, and 722 or 728
23168

If necessary, turn the engine slowly to adjust the position of the locking tool on the pump pulley teeth.
Remove the high pressure pump pulley nut (28) holding the pulley with an open-jawed spanner.
13B-83
23169
Fit the (Mot. 1525) (3) fitted with the (Mot. 152502).
WARNING
Check that the tool pushrod is correctly oriented
and is pressing against the high pressure pump
shaft.
DIESEL INJECTION
13B
K9K, and 722 or 728

Before fitting the new high pressure pipe, lightly lubricate the union threads with the oil from the applicator provided in the new parts kit.
WARNING
Some pipes are supplied with applicator and
some without.
The pipes supplied without applicator are selflubricating pipes.
102085
Remove the high pressure pump mounting bolts

(29) .
Screw down the pushrod of the (Mot. 1525).
Separate the pulley - pump assembly.
Remove:
- the high pressure pump,
- the high pressure pump extractor tool.
REFITTING
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Check that the pulley clamping pin is still in place.
Fit the high pressure injection pump.
Tighten to torque the high pressure injection
pump pulley mounting nut (55 Nm) .
WARNING
Always replace all the high pressure pipes removed.
13B-84
DIESEL INJECTION
13B
K9K, and 722 or 728

If replacing the high pressure pump, reprime the diesel circuit using the diagnostic tool.
Note:
For VDiag numbers earlier than VDiag 48 , it is
essential to reprogram the injection computer.
If reprogramming is not carried out, do not apply
the procedure detailed below but prime the fuel
circuit using the priming bulb.
WARNING
Never start the engine until the pump has been
reprimed.
Also comply with the operation instructions provided to prevent the high pressure pump from
being damaged internally, due to running with no
load and no diesel lubrication.
110404
Refit the high pressure pipe; to do this:
Connect the diagnostic tool to the vehicle.
- remove the protective plugs,
Establish dialogue with the diesel injection computer.
- insert the high pressure pipe olive in the pump outlet taper,
Activate the command AC212 FILL UP NEW

PUMP HOUSING .
- insert the high pressure pipe olive in the rail inlet taper.
Follow the instructions on the diagnostic tool until

the command is completed.
Finger tighten the high pressure pipe unions, starting with the one located at the rail end.
Start the engine.
Tighten to torque the rail mounting nuts (28 Nm) .
Note:
The starting phase can last up to 20 seconds .
- the union at the rail end (24 Nm) ,

- the union at the pump end (24 Nm) .
If the engine does not start or if the start-up sequence is interrupted:
Refit the engine cover on the suspended mounting

in accordance with the markings.
- wait for 30 seconds ,
Prime the diesel fuel supply circuit with the priming

pump (automatic degassing).
(4 Nm) .
13B-85
- restart the engine.

Using the diagnostic tool , clear any faults stored
by the injection computer.
DIESEL INJECTION
K9K, and 722 or 728
Check the high pressure circuit sealing after the repair operation (see 13B, Diesel injection, High
pressure pipe: Test ).
WARNING
Check that there are no diesel fuel leaks:
- let the engine run at idle speed until the engine
cooling fan starts to operate,
- check that there is no diesel fuel escaping.
13B-86
13B
DIESEL INJECTION
13B
F9Q, and 812

Mot. 1668
IMPORTANT
Locking high pressure

pump sprocket.
Mot. 1525

Mot. 1525-03

Adapter sockets for

Mot.1525. (for 33-tooth
pulley).
Mot. 1746
Mot. 1566

Offset spanner for

tightening high pressure pump pipes.
WARNING

Ensure that any high pressure pipe removed is

replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high pressure pump

and the injectors is prohibited.
Tightening torquesm
high pressure pump
mounting bolts on the
pump supports
30 Nm
high pressure pump

pulley nut
50 Nm
high pressure pump

support mounting bolts
on the cylinder head
20 Nm + 80
high pressure pump

rear support mounting
bolts on the cylinder
block
44 Nm

nuts
22 Nm
pump-rail high pressure

pipe nut on the pump
side
29 Nm

pipe nut on the rail side
25 Nm

bolts
4 Nm
Always read the repair precautions (see 13B, Diesel

injection, Diesel injection: Repair precautions ).
REMOVAL
terminal.
Remove:
engine, Accessories belts ),
Timing belt ),
), if fitted to the vehicle.
13B-86
DIESEL INJECTION
13B
F9Q, and 812
102352
102353
Disconnect:
Remove the pump-rail high pressure pipe.
- the diesel heater from the diesel filter,
Plug the openings.
- the heater plugs,

- the pressure regulator (1) ,
- the pressure sensor (2) (version without injector rail
protector).
102348
Remove the high pressure pump mounting bolts (3)

on the high pressure pump rear support.
102351
Disconnect the diesel supply and return pipes.

Plug the openings.
Remove the retaining clip from the diesel pipes.
13B-87
DIESEL INJECTION
13B
F9Q, and 812
102350
Remove:
- the high pressure pump mounting bolts (4) on the
high pressure pump front support,
- the high pressure pump with the high pressure
pump support.
102894
Fit the pulley extractor (Mot. 1525) in place; fitted

with claws (Mot. 1525-03) (2) for pulleys with thirtythree teeth.
Extract the pulley by tightening the pulley extractor
thrust bolt (6) .
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.
1668).
102893

102345
Remove the high pressure pump pulley nut (5) .

Remove:
- the mounting bolts (7) from the high pressure

pump,
- the high pressure pump.
13B-88
DIESEL INJECTION
13B
F9Q, and 812
REFITTING
II - REFITTING THE PUMP-RAIL HIGH PRESSURE

PUMP
Undo the injector rail mounting bolts (the injector rail
should be loose ).
WARNING
WARNING
Refit the high pressure pump on the pump support.

Tighten to torque:
- the high pressure pump mounting bolts on the
pump supports (30 Nm) ,
- Be careful not to allow oil into the high pressure

pipes.
- Do not lubricate pipes supplied without an applicator, these high pressure pipes are self-lubricating.
- the high pressure pump pulley nut (50 Nm) by

immobilising the pulley with the (Mot. 1668).
WARNING
Do not remove the plugs from each component
until the last moment.
Insert the high pressure pipe olive in the pump outlet
taper.
Insert the high pressure pipe olive in the pump inlet
taper.
Finger tighten the high pressure pipe nuts, starting
with the one at the rail end.
Slightly pretighten the high pressure pipe nuts.
Tighten to torque the injector rail mounting nuts
(22 Nm) .
Tighten to torque using the (Mot. 1746) or (Mot.
1566) :
- the pump-rail high pressure pipe nut on the
pump side (29 Nm) ,
102349
Push the ring (8) back as shown in the diagram.
- the pump-rail high pressure pipe nut on the rail

side (25 Nm) .
Loosen the two high pressure pump rear support

mounting bolts (9) on the cylinder block.
Refit the high pressure pump assembly and the

pump support.
Tighten to torque the high pressure pump support
mounting bolts on the cylinder head (20 Nm +
80) .
I - REFITTING THE HIGH PRESSURE PUMP REAR
SUPPORT
Tighten the mounting bolts by hand to press the support against the high pressure pump and the cylinder
block.
Tighten to torque the high pressure pump rear
support mounting bolts on the cylinder block (44
Nm) .
13B-89
DIESEL INJECTION
F9Q, and 812
Refit:
Timing belt ),
engine, Accessories belts ).
For versions with injector rail protectors:
- Refit the air duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ).
Note:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
Prime the diesel circuit using the manual priming
pump.
WARNING
Battery, Battery: Removal - Refitting ).
WARNING
- Run the engine at idle speed,
- Accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.
(4 Nm) .
- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ),
- Refit the air inlet duct (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting ).
13B-90
13B
DIESEL INJECTION
13B
F9Q, and 804

Mot. 1668
IMPORTANT
Locking high pressure

pump sprocket.
Mot. 1525

Mot. 1525-03

Adapter sockets for

Mot.1525. (for 33-tooth
pulley).
Mot. 1746
Mot. 1566

Offset spanner for

WARNING

Ensure that any high pressure pipe removed is

replaced.
Equipment required
WARNING
diagnostic tool
Dismantling the interior of the high pressure pump

and the injectors is prohibited.
Tightening torquesm
high pressure pump
pump supports
30 Nm
high pressure pump

pulley nut
50 Nm
high pressure pump

support mounting bolts
on the cylinder head
20 Nm + 80
high pressure pump

rear support mounting
bolts on the cylinder
block
44 Nm
high pressure pump

rear pump support
30 Nm

bolts
22 Nm

pipe nut on the pump
side
29 Nm

pipe nut on the rail side
25 Nm

bolts
4 Nm

REMOVAL
terminal.
Remove:
Timing belt ).
13B-91
DIESEL INJECTION
13B
F9Q, and 804
111888
Remove the injector rail protector (see 13B, Diesel

injection, Injector rail protector: Removal - Refitting ).
Disconnect:
102353
- the diesel heater from the diesel filter,
Remove the pump - rail high pressure pipe (3) .
- the heater plugs,
Plug the openings.
- the pressure regulator (1) .
102351
Disconnect the diesel supply and return pipes (2) .

Plug the openings.
Remove the retaining clip from the diesel pipes.
13B-92
102348
Remove the mounting bolts (4) securing the high

pressure pump to the high pressure pump rear support.
DIESEL INJECTION
13B
F9Q, and 804
102350
102894
- the mounting bolts (5) securing the high pressure

pump front support,
Fit the pulley extractor (Mot. 1525) in place; fitted

with claws (Mot. 1525-03) (8) for pulleys with thirtythree teeth.
- the high pressure pump, with the high pressure

pump support.
Remove the pulley by tightening the pulley extractor

thrust bolt (9) .
Remove:
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.

1668).
102893
Set up (Mot. 1668) (6) .

Remove the nut (7) from the high pressure pump
pulley.
102345
Remove:
- the high pressure pump mounting bolts (10) ,
13B-93
DIESEL INJECTION
13B
F9Q, and 804
REFITTING

rear pump support (30 Nm) .
WARNING
II - REFITTING THE PUMP/RAIL HIGH PRESSURE

PUMP

Refit the high pressure pump on the pump support.
Tighten to torque:
Undo the injection rail mounting bolts (the injection

rail should be loose ).

pump supports (30 Nm) ,
WARNING
- Be careful not to allow oil into the high pressure
pipe.
- the high pressure pump pulley nut (50 Nm) by

immobilising the pulley with the (Mot. 1668).
- Do not put high pressure pipes under stress.
WARNING
Do not remove the caps from each component
Refit a new pump/rail high pressure pipe.
with the one at the rail end.
(22 Nm) .
Tighten to torque using (Mot. 1746) or (Mot. 1566) :
- the pump-rail high pressure pipe nut on the
pump side (29 Nm) ,
- the pump-rail high pressure pipe nut on the rail
side (25 Nm) .
102349
Push the ring (11) back as shown in the diagram.

Undo the two mounting bolts on the high pressure
pump rear support on the cylinder block.
Refit the high pressure pump - pump support assembly.
Tighten to torque the high pressure pump support
mounting bolts on the cylinder head (20 Nm +
80) .
I - REFITTING THE HIGH PRESSURE PUMP REAR
SUPPORT
Tighten the mounting bolts by hand to press the support against the high pressure pump and the cylinder
block.
Tighten to torque:
- the high pressure pump rear support mounting
bolts on the cylinder block (44 Nm) ,
13B-94
DIESEL INJECTION
F9Q, and 804
Refit:
Timing belt ),
- the air inlet duct (see 12A, Fuel mixture, Air inlet
Note:
Prime the diesel circuit using the manual priming
pump.
WARNING
WARNING
- Run the engine at idle speed,
- Accelerate several times under no load,
- Switch off the ignition,
Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ).
Refit the air inlet duct (see 12A, Fuel mixture, Air
(4 Nm) .
13B-95
13B
DIESEL INJECTION
13B
K9K, and 732

Mot. 855
Timing gear locking

strap.
Mot. 1525

Mot. 1768
Injection pump-pulley
extractor claws.
Mot. 1566

Mot. 1746
Offset spanner for

IMPORTANT
It is essential to respect the safety and cleanliness
REMOVAL
Equipment required
diagnostic tool

32 mm offset wrench

Tightening torquesm
high pressure pump
pulley
55 Nm
high pressure pump

mounting bolts
21 Nm
high pressure pipe nuts
24 Nm
Remove:
WARNING
WARNING
104343
- the high pressure pipe between the high pressure

pump and the injector rail.
Remove:
- the scuttle panel grille (see 371 Bodywork, 55A,
Exterior protection, Scuttle panel grille ).
13B-96
DIESEL INJECTION
13B
K9K, and 732
104246
Remove:
- the mounting bolts (3) from the plenum chamber
partition,
112811

Pull the clip.

Timing belt ).
112815

(4) .
one side.
112991

steel pipe.
Move the air inlet duct to one side (8) .
13B-97
DIESEL INJECTION
13B
K9K, and 732

112992
112994
Unclip injector rail protector cover (9) .

Disconnect:
Remove:
protector cover,

(16) ,

- the dipstick,

112993
Disconnect:
13B-98
DIESEL INJECTION
K9K, and 732
112656
Protect the alternator from fuel outflow.

IMPORTANT
IMPORTANT
WARNING
Disconnect:

new cloths.
13B-99
13B
DIESEL INJECTION
13B
K9K, and 732

new cloths.
CONCERNED
111748

Remove:
nuts (23) ,
- the injector rail protector support.
112789
Remove:
IMPORTANT
- the high pressure pump mounting bolts (24) ,
REFITTING
soak the brush with cleaning product and clean the

high pressure pipe unions between the high pressure pump and the injector rail

1 - Remove the high pressure pump pulley
IMPORTANT
WARNING
If the high pressure pump is being replaced,

recover the high pressure pump pulley and refit it
to the new high pressure pump.
WARNING
Remove the high pressure pipe between the high
pressure pump and the injector rail and dispose of it
in a bin.
WARNING
When loosening the connector of the high pressure pipe, the intermediate nut must be secured
on the pump using a lock wrench.
13B-100
DIESEL INJECTION
13B
K9K, and 732

Fit the (Mot. 1525) equipped with (Mot. 1768) on the
high pressure pump pulley.
Protect the points of contact between the (Mot.
1768) and the high pressure pump pulley.
Extract the high pressure pump pulley.
WARNING
Take care not to mark the high pressure pump
pulley when removing it with the (Mot. 1525) fitted with (Mot. 1768).
A damaged high pressure pump pulley must
always be replaced.
WARNING
Only remove the blanking plugs immediately
before connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;
dispose of the whole set after use.
111743
Hold the high pressure pump in a vice, using the

lower securing point on the pulley side.
2 - Refitting the high pressure pump pulley
Immobilise the high pressure pump pulley using a 32

mm offset wrench and remove the pulley mounting
nut (25) .
Take the high pressure pump out of its plastic bag.

WARNING
If replacing a high pressure pump, only remove
the new high pressure pump from its original
packaging when it is about to be fitted.
Refit the high pressure pump pulley mounting nut.
Immobilise the high pressure pulley using a 32 mm
offset wrench or using the (Mot. 855).
Tighten to torque the high pressure pump pulley
(55 Nm) .
II - REFITTING PART CONCERNED
Take the high pressure pump out of its plastic bag.
WARNING
If replacing a high pressure pump, only remove
the new high pressure pump from its original
packaging when it is about to be fitted.
111744
Refit:
- the high pressure pump,
Note:
- the high pressure pump mounting bolts.
The high pressure pump pulley can also be

immobilised with the (Mot. 855).
Tighten to torque the high pressure pump mounting bolts (21 Nm) .
13B-101
DIESEL INJECTION
13B
K9K, and 732


Fit the new high pressure pipe between the injector
rail and the high pressure pump.

Refit:
Note:
If the new pipes kit does not contain an applicator, it is not necessary to lubricate the pipe
threads (as they are self-lubricating pipes).

with the one at the injector rail side.
Tighten to torque the high pressure pipe nuts (24
Nm) using the (Mot. 1566) or (Mot. 1746) and starting with the injector rail side.
Tighten the clip.

Refit:
Timing belt ),
Refit:

Connect:

Connect:

pump.

valve,
Refit:
- the dipstick,
bolt,
13B-102
DIESEL INJECTION
K9K, and 732
by the injection computer, before restarting the engine.
WARNING
- check the sealing after repair (see 13B, Diesel
injection, High pressure pipe: Test),
- accelerate several times under no load,
- carry out a road test,
- check that there are no diesel fuel leaks.
Using the diagnostic tool , check that there are no
stored faults; clear them if necessary.
13B-103
13B
DIESEL INJECTION
Diesel injector: Removal - Refitting
13B
K9K, and 722 or 728

Mot. 1566

WARNING
Always replace any high pressure pipe or high pressure pipe clip removed with a new one.
It is forbidden:
Equipment required
- to remove the injector filter rods,
diagnostic tool
- to open the injectors.
low torque wrench

high-pressure pipe wrench (DM19)
Injectors may be replaced individually. Only remove

the high pressure pipe concerned.
pipe socket for tightening injector-rail high pressure

pipes ("Crowfoot 18-17" wrench)
REMOVAL
pipe socket for tightening the pump-rail high-pressure pipe (19-17 mm Crowfoot spanner)
Tightening torquesm
injector mounting clamp
rail nuts
28 Nm

terminal.
Remove the rail-injector high pressure pipes (see
13B, Diesel injection, High pressure pipe: Replacing ).
28 3 Nm
nut on the injector side
38 Nm
nut on the rail side
38 Nm

bolts
4 Nm
IMPORTANT
advice whenever work is carried out on this system (see 13B, Diesel injection, Cleanliness guidelines ).
20803
Disconnect the diesel return pipe from the injector.

Plug the openings.
If reusing an injector, always mark a removed injector in relation to its cylinder.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector clamp mounting bolt (1) ,
13B-104
DIESEL INJECTION
13B
K9K, and 722 or 728

- the injector and its clamp,
Tighten to torque the injector mounting clamp (28

Nm) .
- the heat protection washer.
Before fitting the new high pressure pipe, lightly lubricate the nut threads with the oil from the applicator provided in the new parts kit.
REFITTING
I - CLEANING THE INJECTORS
WARNING
- Some pipes are supplied with applicator and
some without.
WARNING
- The pipes supplied without applicator are selflubricating pipes. The torque is still the same
(38 Nm) .
It is strictly forbidden to clean the injectors with:

- a wire brush,
- an emery cloth,
Fit the high pressure pipe:
- an ultrasonic cleaner.
- remove the protective plugs,

- insert the high pressure pipe olive in the injector inlet taper,
Soak the injectors in degreaser.

Wipe with new cloths, part number 77 11 211 707 .
II - REFITTING THE INJECTORS
- insert the high pressure pipe olive in the rail outlet

taper.
Finger tighten the nut, first at the injector end then
the rail end.
WARNING
Pretighten slightly.
Do not remove the plugs from each component

Fit a new clip supplied with the new pipe onto the
high pressure pipes:
Using cloths part number 77 11 211 707 soaked in

fresh solvent, clean:
- insert the first half-shell using adjustable pliers,

- insert the second half-shell using adjustable pliers.
- the injector wells,

- the injector bodies,
WARNING
- the injector clamps.
Observe the direction of fitting of the second

shell. The lugs located in the centre of the clip
will only engage in one position.
Use a new cloth to dry components that have been

cleaned.
Replace the heat protection washer with a new one.
Note:
If one or more injectors are replaced, note the
alphanumeric code (C2I) and the cylinder on
which it is fitted.
Refit the injector with its clamp.
13B-105
DIESEL INJECTION
13B
K9K, and 722 or 728
19723
Tighten to torque the rail nuts (28 3 Nm) .
19724
Program the alphanumeric code (C2I) (2) for the replaced injector(s) using the diagnostic tool (see
13B, Diesel injection, Injectors: Configuration ).
WARNING
- Do not touch the pipes with the spanner when
tightening.
- When tightening the high pressure pipes, make
sure the central union of the injector is held
secure.
WARNING
- Let the engine run at idle speed until the engine
cooling fan starts up.
- Accelerate several times at no load.
- the nut on the injector side (38 Nm) ,
- Carry out a road test.
- the nut on the rail side (38 Nm) ,
- Switch off the ignition.
using the (Mot. 1566) , possibly equipped with one

of the following:

(4 Nm)
- low torque wrench ,

- high-pressure pipe wrench (DM19) ,
- pipe socket for tightening injector-rail high
pressure pipes ("Crowfoot 18-17" wrench) ,
- pipe socket for tightening the pump-rail highpressure pipe (19-17 mm Crowfoot spanner).
Prime the diesel circuit using the priming pump.
WARNING
13B-106
DIESEL INJECTION
13B
F9Q, and 804 or 812

For versions without injector rail protectors:

Mot. 1566

Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
Tightening torquesm
injector clamp bolt
25 Nm
nut on the injector side
25 Nm
nut on the rail side
29 Nm

bolts
4 Nm
IMPORTANT
During each operation, always read the precautions for
repair (see 13B, Diesel injection, Diesel injection:
Repair precautions ).
WARNING
Opening the injectors is prohibited.
Injectors may be replaced individually. Only remove
the high pressure pipe concerned.
REMOVAL
terminal.
injection, Injector rail protection: Removal - Refitting ), if fitted to the vehicle.
13B-107
- remove the inlet duct (see 12A, Fuel mixture, Air

inlet duct: Removal - Refitting ), if necessary.
DIESEL INJECTION
13B
F9Q, and 804 or 812
18297-1
Disconnect the injector connector.

Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the return rail.
Fit blanking plugs into the openings.
13B-108
DIESEL INJECTION
13B
F9Q, and 804 or 812
REFITTING
I - CLEANING INJECTORS (IF THEY ARE REUSED)
WARNING
- a wire brush,
- an emery cloth,
Clean, using new cloths soaked in cleaning product
(see 13B, Diesel injection, Diesel injection: Repair precautions ):
- the injector wells,
- the injector bodies,
- the injector clamps.
1327
Use a new cloth to dry components that have been

cleaned.
Remove the injector-rail high pressure pipe

using the (Mot. 1566) or (Mot. 1746).
II - REFITTING THE INJECTOR
WARNING
The injector filter rod must not be removed.
WARNING
WARNING
When loosening the injector pipe unions (1) on
the injectors, be sure to hold the filter rod retaining nuts (2) with a lock wrench.
If reusing an injector, always mark a removed injector in relation to its cylinder.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector clamp mounting bolt,
- the injector and its clamp,
13B-109

DIESEL INJECTION
F9Q, and 804 or 812
1326
Replace the heat protection washer (3) with a new

one.
Note:
If one or more injectors have been replaced, note
down the alphanumeric code (IMA) that is written
on the new injector and the cylinder it is fitted on.
Refit the injector with its clamp.
Tighten to torque the injector clamp bolt (25 Nm) .
WARNING
Do not put high pressure pipes under stress.
WARNING
Be sure to replace all high pressure pipes removed.
Tighten by hand the high pressure pipe nuts until
contact is made with the rail and injector.
WARNING
Always hold the filter rod mounting nuts on the
injector holder with a lock wrench when tightening.
Tighten to torque using the (Mot. 1566) or (Mot.
1746) :
- the nut on the injector side (25 Nm) ,
- the nut on the rail side (29 Nm) ,
13B-110
13B
DIESEL INJECTION
13B
F9Q, and 804 or 812
18297-1
Program the alphanumeric code (IMA) for the injector(s) replaced using the diagnostic tool (see MR
372 Fault finding, 13B, Diesel injection, Fault finding - Replacement of components ).
Refit the return rail (4) .

Push the return rail end piece vertically.
Throw away the plug set upon completion of the
operation.
inlet duct: Removal - Refitting ), if removed.
WARNING
- Run the engine at idle speed.
- Accelerate several times under no load.
Note:

- Refit the inlet duct without refitting the injector
rail protector or replacing the duct seal.

(4 Nm)
WARNING
- Refit the injector rail protector (see 13A, Diesel injection, Injector rail protector: Removal - Refitting ),

- Refit the inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).
13B-111
DIESEL INJECTION
13B
K9K, and 732

Mot. 1566

Mot. 1746
Offset spanner for

IMPORTANT
Equipment required
diagnostic tool
Tightening torquesm
REMOVAL
injector clamp mounting

bolt
30 Nm

nuts
28 Nm
high-pressure pipe nuts
24 Nm

WARNING
WARNING
- all the high-pressure pipes which have been removed.
- any injector that has been opened, contrary to instructions,
- any damaged mounting clips for the fuel return
pipe on the injector.
13B-112
112815

(1) .
Loosen the clip and (2) move the air inlet duct aside
(3) .
DIESEL INJECTION
13B
K9K, and 732
112811
Pull the clip.
112992

Remove:
protector cover,
- the dipstick,
- the mounting bolts (8) from the dipstick duct.
Move the dipstick duct to one side.
IMPORTANT
Soak the brush with cleaning product, then clean the
unions:
112991

steel pipe.
13B-113
- of the high-pressure pipes between the injector rail

and the injectors
- the fuel return connectors of the injectors.
DIESEL INJECTION
13B
K9K, and 732

IMPORTANT
WARNING
1327
WARNING
When the high-pressure pipe unions (10) on the
injector holder are loosened, it is imperative to
hold the filter rod retaining nut (11) with a lock
wrench.
Remove:
- the nut of the high-pressure pipe between the injector rail and the injector on the rail end,
114075
- the nut of the high-pressure pipe between the injector rail and the injector on the injector end,
Remove the high-pressure pipe in question and discard it.
Note:
new cloths.
13B-114
DIESEL INJECTION
13B
K9K, and 732

CONCERNED
111749
Using a thin, flat-blade screwdriver, push the lower

bracket of the retaining clip (12) of the fuel return
connector on the injector towards the rocker cover.
WARNING
Ensure that you do not remove the clip completely from its housing in order to prevent piercing it
during contact with the rocker cover.
111746
Remove:
- the injector clamp mounting bolt (13) ,
- the injector clamp,
- the spacer between the cylinder head and the injector clamp,
- the injector,
- the heat protection washer situated at the bottom of
the injector well in the cylinder head.
111751
Extract the fuel return connector from the injector

while pushing the lower bracket of the retaining clip
downwards.
Fit the correct blanking plug.
Remove the fuel return pipe from the injector.
13B-115
DIESEL INJECTION
13B
K9K, and 732
114010
112993
Disconnect:
Note:
If the injector is jammed in its well and does not

come out, turn the injector at the flat support surfaces of the injector clamp using a 13 mm open
end wrench.
Fit the appropriate blanking plug on the injector's nose.

WARNING
If it is to be reused, keep the injector(s) in a sealed plastic bag until required.
WARNING
Ensure that no impurities enter into the cylinder
via the injector well in the cylinder head: plug the
orifice using a clean cloth.
Removal of four injectors
Note:
This procedure only applies if removing all the
injectors and, after having removed them all, in
preparation for refitting them.
13B-116
DIESEL INJECTION
13B
K9K, and 732
112994
Disconnect:
112656

IMPORTANT

(18) ,

- the diesel fuel temperature sensor connector (20) ,

Detach the retaining clip (21) from the electrical harness.
Remove the mounting nut (22) from the electrical
harness clip.

IMPORTANT

WARNING
Disconnect:
Note:
new cloths.
13B-117
DIESEL INJECTION
13B
K9K, and 732

Remove the injector from its plastic bag.
WARNING
If replacing the injector, do not remove it (them)
from its (their) packaging until just before you refit
it (them).
Remove the blanking plugs on the nose of the injector.
CONCERNED
Refit:
111748
- a new heat protection washer at the bottom of the

injector well in the cylinder head.
- the injector,
Remove:
- the spacer between the cylinder head and the injector clamp,
- the mounting nuts and bolt (25) from the injector

rail protector support,
- the injector clamp,
- the injector clamp mounting bolt.
Loosen the injector rail mounting nuts by a few turns

(the injector rail should be loose).
Tighten to torque the injector clamp mounting bolt

(30 Nm) .
Fit the new high-pressure pipe(s) between the injector rail and the injector.
REFITTING
Note:
Cleaning the injectors

with the one at the injector rail end.
WARNING
1 - Refitting the four high-pressure pipes
- a wire brush,

(28 Nm) .
- an emery cloth,
Refit:
Leave the injectors to soak in degreaser.
Clean using new wipes.
Clip the diesel evacuation pipe into place.
WARNING
13B-118

Connect:
DIESEL INJECTION
13B
K9K, and 732

Refit:
Connect:
Tighten the clip.
Connect:


valve,

pump.

- the heater plugs connector,

WARNING
2 - All types
Tighten to torque the high-pressure pipe nuts (24

Nm) using the (Mot. 1566) or (Mot. 1746) and starting at the injector rail end.
Push the retaining clip of the fuel return connector
on the injector to the front of the vehicle in order to
place it in its initial position.

injection, High pressure pipe: Test ),
Clip on the fuel return connector of the injector.
WARNING
Check the condition of the seal on the fuel return
connector of the injector.
Change the diesel return rail if one of its components is damaged.

Refit:
- the dipstick duct mounting bolts.
- the dipstick,
bolt,
Clip the injector rail protector cover into place.
13B-119

DIESEL INJECTION
Diesel injector adjustment value
13B
F9Q, and 812
Equipment required
note:
diagnostic tool
This command is valid for both one-off entry and

batch entry.
REPLACING THE INJECTORS
note:
A 6-character alphanumeric code known as the
IMA (Injector Flow Correction) is marked on the
injectors. This code is specific to each injector, and
takes into account manufacturing dispersion and
specifies the flow of the injector.
When replacing one or more injectors, program the
code of the new injector or injectors into the computer.
If this operation is not carried out then the engine
speed will be limited to 1800 rpm .
These correction values are etched onto the bakelite
body of each alphanumeric injector and then entered into the computer, which can then control each injector in view of their variations in manufacture.
The system can be coded via the diagnostic socket
using the diagnostic tool.
When replacing one or more injectors, replace the IMA
codes. To do this, re-enter the IMA codes into the computer using the following command:
- SC002 Enter injector codes
107035
Note down the IMA codes etched on the bakelite body

of each injector, and follow the on-screen instructions.
13B-120
DIESEL INJECTION
Diesel injector adjustment value
K9K, and 722 or 728
REPLACING THE INJECTORS
Note:
The C2I (individual injector correction) parameters
are set in production for each injector to adjust the
flow of each injector precisely, taking into account
variations in manufacture.
The correction values are written on a label affixed to
each injector then entered in the computer which can
then control each injector by taking account of their differences in manufacture.
The system can be configured using the diagnostic
socket with the RENAULT CLIP diagnostic tool.
When replacing one or more injectors, replace the C2I
parameters. To do this, re-enter the C2I parameters
into the computer using the following commands:
- To enter the four C2Is when replacing the computer,
run the SC002 Enter injector codes command.
- To enter an individual C2I parameter, when replacing
one or more injectors, enter the following commands:
cylinder 1 injector: control VP001 (flywheel end cylinder),
cylinder 2 injector, command: control VP002 ,
cylinder injector 3: control VP003 ,
cylinder injector 4: control VP004 .
By using the relevant command, the technician can reenter the new C2I parameters for the injector replaced
and delete the old C2I parameters.
Note:
Only after replacing all four injectors at once, reset
the injector programming adaptives using the
RZ004 Pressure regulation adaptives command.
13B-121
13B
DIESEL INJECTION
High-pressure pipe between the pump and rail: Removal - Refitting
13B
K9K, and 732


Mot. 1566

Mot. 1746
Offset spanner for


Equipment required
diagnostic tool
Tightening torquesm
24 Nm
112815
WARNING

(1) .
Loosen the clip and (2) move the air inlet duct (3)
aside .

WARNING
IMPORTANT
It is essential to respect the safety advice and
cleanliness guidelines specified in this document
whenever work is carried out on this system (see
13B, Diesel injection, Cleanliness guidelines ).
REMOVAL
13B-122
112811
Pull the clip.
DIESEL INJECTION
13B
K9K, and 732

112991
112993

steel pipe.
Disconnect:

112992

Remove:
protector cover,
- the dipstick,
- the mounting bolts (8) of the dipstick tube.
13B-123
DIESEL INJECTION
13B
K9K, and 732
112994
112656
Disconnect:
Pour the cleaning product into a container.

(13) ,
- the diesel fuel temperature sensor connector (15) ,
Unclip the retaining clip (16) from the wiring harness.
Remove the mounting nut (17) from the wiring harness clip.
IMPORTANT
Wear protective gloves when using the cleaning
product.
dry using fresh wipes.
IMPORTANT
WARNING
Disconnect:

fresh wipes.
13B-124
DIESEL INJECTION
13B
K9K, and 732

CONCERNED
Remove the high-pressure pipe between the highpressure pump and the injector rail and dispose of it
in a bin.
WARNING
When loosening the connector of the high-pressure pipe, the intermediate nut must be secured

fresh wipes.
111748

Remove:
- the mounting nuts and bolt (20) from the injector
rail protector support,
REFITTING

Pour the cleaning product into a container.
IMPORTANT
WARNING
Wear protective gloves when using the cleaning

product.


unions:

- on the high-pressure pump fuel return pipe, taking

care not to soak the diesel fuel temperature sensor,
Take the new high-pressure pipe out of its plastic

bag.
- on the high-pressure pipe between the high-pressure pump and the injector rail.

dry using fresh wipes.
CONCERNED
IMPORTANT
Fit the new high-pressure pipe between the injector

rail and the high-pressure pump.
Wear protective goggles.
WARNING
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unnecessar y (as they are self-lubricating pipes).
Finger tighten the high-pressure pipe nuts, starting
Tighten to torque the high-pressure pipe nuts (24
Nm) using the (Mot. 1566) or (Mot. 1746) and starting with the injector rail side.
13B-125
DIESEL INJECTION
13B
K9K, and 732

Refit:

pump.


Connect:
WARNING
- Check the sealing after repair (see 13B, Diesel

injection, High-pressure pipe: Check ),

Refit the mounting nut of the wiring harness clip.

Clip on the retaining clip of the wiring harness.
Connect:
- the diesel fuel temperature sensor connector,

valve,
- the connector on the injectors.
Refit:
- the dipstick,
bolt,
Refit:
- the inlet manifold on the damper valve.
Tighten the clip.
Connect:
13B-126

stored faults; and clear them if necessary.
DIESEL INJECTION
13B
K9K, and 722 or 728
REMOVAL

Mot. 1746
Offset spanner for


Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
Equipment required
diagnostic tool
K9K, and 722
Tightening torquesm
high pressure pipe
24 Nm
IMPORTANT
before carrying out any work on the injection circuit,
check using the diagnostic tool :
102120
During each operation, always respect the repair

precautions relating to diesel injection.

engine is running is prohibited.
K9K, and 728
WARNING
- a new plug kit (part no.: 77 01 206 804 ),
- cleaning cloths (part no.: 77 11 211 707 ).
WARNING
Torque tighten to (38 Nm) the pump-rail and
injector rail high pressure pipes with one of the
following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 028 .
for high pressure pipes with different part numbers,
tighten to a torque of (24 Nm) .
13B-127
110325
Pull the clip.
DIESEL INJECTION
13B
K9K, and 722 or 728
REFITTING
110323
Undo the bolt (2) .

20960
WARNING
Unclip the dipstick.
Before fitting a new high pressure pipe, lightly

lubricate the nut threads with oil from the applicator provided in the new part.
Remove the dipstick.

CONCERNED
Be careful not to allow oil into the high pressure

pipe.
Clean the pump-rail pipe (see 13B, Diesel injection, Diesel injection: Repair precautions ).
Loosen:
Do not lubricate high pressure pipes supplied

without an applicator, as these high pressure
pipes are self-lubricating.
- the high pressure pipe nut at the pump end,

- the high pressure pipe nut at the injector rail end.
WARNING

Throw away the pipe.
13B-128
DIESEL INJECTION
K9K, and 722 or 728
CONCERNED
Insert the high pressure pipe olive in the high pressure pump high pressure outlet taper.
Insert the high pressure pipe olive into the injector
rail inlet taper.
with nut at the rail end.
Tighten to torque the high pressure pipe (24 Nm)
Insert the dipstick.
K9K, and 722
Connect the air inlet duct.
Tighten the clip.
K9K, and 728

Position the air inlet duct on to the turbocharger.
Fit the clip.
Tighten the air inlet duct bolt on the rocker cover.
Connect the battery (see 80A, Battery: Removal Refitting ).

Check that there are no diesel leaks by checking the
seal after repair (see 13B, Diesel injection, High
pressure pipe: Check ).
WARNING
Check that there are no diesel leaks:
- run the engine at idle speed,
- confirm that there is no diesel leak.
13B-129
13B
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
13B
K9K, and 732
REMOVAL

Mot. 1566

Mot. 1746
Offset spanner for

Equipment required

diagnostic tool
Tightening torquesm
nuts
28 Nm
24 Nm
WARNING
112815


(1) .
Loosen the clip and (2) move the air inlet duct (3) to
one side.
WARNING
- all the high pressure pipes which have been removed.
IMPORTANT
carried out on this system (see 13B, Diesel injection, Cleanliness guidelines ).
112811
Pull the clip.
13B-130
DIESEL INJECTION
13B
K9K, and 732

IMPORTANT
Soak the brush with cleaning product then clean the
high pressure pipe unions between the injector rail
and the injectors.
IMPORTANT
112991
WARNING

steel pipe.

is open, otherwise impurities may enter the system. Use cloths if necessary.

CONCERNED
112992

Remove:
1327
protector cover,
WARNING
When loosening the high pressure pipe unions
(9) on the injector holder, it is essential to hold
the filter rod retaining nut (10) with a lock wrench.

- the dipstick,
13B-131
DIESEL INJECTION
13B
K9K, and 732

Remove:
- the nut of the high pressure pipe between the injector rail and the injector on the rail end,
- the nut of the high pressure pipe between the injector rail and the injector on the injector end,
Remove the high pressure pipe in question and discard it.
Note:
new cloths.
Removing the four high pressure pipes
Note:
112994
This procedure only applies if removing all the

high pressure pipes and, after having removed
them all, in preparation for refitting them.
Disconnect:
(15) ,
112993
Disconnect:
- the heater plug connector (12) .
13B-132
DIESEL INJECTION
13B
K9K, and 732
111748

Remove:
nuts (22) ,
112656
Loosen the injector rail mounting nuts by a few turns

IMPORTANT
REFITTING

WARNING
IMPORTANT

Take the new high pressure pipe out of its plastic

bag.
WARNING
is open, otherwise impurities may enter the system. Use cloths if necessary.
Disconnect:

CONCERNED
rail and the injector.

Note:
Note:
new cloths.
If the new pipes kit does not contain an applicator, do not lubricate the pipe threads (as they are
self-lubricating pipes).
13B-133
DIESEL INJECTION
13B
K9K, and 732

Refit:
1 - Refitting the four high pressure pipes

(28 Nm) .
Refit:
Tighten the clip.
Connect:

Connect:

pump.


Refit the mounting nut of the wiring harness clip.
WARNING
Connect:
- Check the seal after repair (see 13B, Diesel

injection, High pressure pipe: Check ),



valve,

- the damper valve connector,
- check that there are no diesel leaks.
Using diagnostic tool , check that there are no stored faults; clear them if necessary.

2 - All types
Tighten to torque the high pressure pipe nuts (24
Nm) using (Mot. 1566) or (Mot. 1746) and starting
with the injector rail side.
Refit:
- the dipstick,
- the mounting nut and bolt of the injector rail protector cover,
13B-134
DIESEL INJECTION
K9K, and 732
13B-135
13B
DIESEL INJECTION
13B
K9K, and 722 or 728
Equipment required
WARNING
diagnostic tool
Torque tighten to 38 Nm the pump-rail and

injector rail high pressure pipes with one of the
following part numbers:
Tightening torquesm
- 77 01 207 025 ,
nuts
28 Nm
pump-rail high
pressure pipe nuts
24 Nm

of the injector rail
24 Nm
nut of the neck on the

rail
21 Nm

bolts
4 Nm
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
REMOVAL
IMPORTANT
K9K, and 722

During each operation, always respect the repair
precautions relating to diesel injection.
engine is running is prohibited.
WARNING
- a new plug kit (part no.: 77 01 208 804 ),
- cleaning cloths (part no.: 77 11 211 707 ).
102120
Disconnect air inlet duct (1) .
13B-136
DIESEL INJECTION
13B
K9K, and 722 or 728
K9K, and 728
102362
Remove the diesel splash plate (4) .

110325
Pull the clip.
102361
110323
Remove the dipstick guide (5) .
Undo the bolt (2) .
Plug the openings.
Disconnect:
- the heater plugs (6) ,
- the injectors,
- the high pressure pump electrical connectors (7) ,
- the diesel supply and return pipes (8) .
13B-137
DIESEL INJECTION
13B
K9K, and 722 or 728
102360
19724
Disconnect:
- the diesel return pipe (9) connecting the injectors to
the high pressure injection pump,
- the rail pressure sensor (10) ,
- the accelerometer (11) ,
- the oil level sensor (12) ,
- the cylinder marking sensor (13) from the timing
cover.
Release the wiring harness on the side.
Remove the neck located on the injector rail.
WARNING
Be sure to hold the intermediate injector union
(14) in place with a spanner when loosening the
Do not damage the injector leak return nozzle
(15) .
20803
Loosen the injector rail mounting nuts by several

turns (16) .
Remove the clips (17) connecting the high pressure
pipes to one another.
CONCERNED
Clean the pipe(s) to be removed (see 13B, Diesel
13B-138
DIESEL INJECTION
13B
K9K, and 722 or 728
REFITTING
Loosen:
- the high pressure pipe nut at the injector end,
- the high pressure pipe nut at the injector rail end.

Note:
Loosen the nuts pipe by pipe.
Move the nuts along the tube, keeping the olive in
contact with the taper.
20960
WARNING
Before fitting a new high pressure pipe, lightly
lubricate the nut threads with oil from the applicator provided in the new part.
20803
Be careful not to allow oil into the high pressure

pipe.
Remove the high pressure pipes (18) one by one.

Plug the openings.
Do not lubricate high pressure pipes supplied

without an applicator, as these high pressure
pipes are self-lubricating.
Throw away the pipe(s).
WARNING
Do not remove the blanking plug from each component until the last moment.
If replacing the four high pressure pipes:
- remove the anti-splash cover mounting,
- Undo the injector rail mounting nuts by a few turns
CONCERNED
Insert the high pressure pipe olive in the injector high
pressure inlet taper.
13B-139
DIESEL INJECTION
13B
K9K, and 722 or 728

Insert the high pressure pipe olive into the rail high
pressure outlet taper.
with the nut at the injector end.
Check the sealing after repair (see 13B, Diesel injection, High pressure pipe: check ).
WARNING
Note:

The order of fitting the injector-rail high pressure pipes is not important.

Fit the new clip provided with the new high pressure
pipe.
If replacing the four high pressure pipes, torque tighten the injector rail mounting nuts (28 Nm) .
Tighten to torque and in order the pump-rail
high pressure pipe nuts (24 Nm) :
- pump end,
- rail end.
Tighten to torque and in order the high pressure
pipe nuts of the injector rail (24 Nm) .
- injectors end,
- rail end.
Note:
Tighten a pipe fully before moving on to the next
pipe.
Refit the neck to the injector rail and torque tighten
the nut of the neck on the rail (21 Nm) .
(4 Nm) .
13B-140
- confirm that there is no diesel leak.
DIESEL INJECTION
Injector rail: Removal - Refitting
13B
K9K, and 722 or 728
REMOVAL
Equipment required

terminal.
diagnostic tool
low torque wrench
Remove:
- the rail-injector high-pressure pipes (see 13B, Diesel injection, High-pressure pipe: Replacement
).
Tightening torquesm
neck nut on the rail
bolts
21 Nm
- the mounting bolts for the spherical injector rail,
4 Nm
- the spherical injector rail.
REFITTING
IMPORTANT
WARNING
Only remove the blanking plugs at the last

moment.

WARNING
Always replace all the high-pressure pipes removed.
Fit a new high-pressure rail on the studs.
Finger tighten the nuts.
WARNING
Note:
- Ensure that you have a special high pressure

injection circuit blanking plugs kit.
- Fit the pump-rail pipe before the injector-rail

pipes.
- Always replace any high pressure pipe or high

pressure pipe clip removed with a new one.
- To remove the high-pressure pipes (see 13B,

Diesel injection, High-pressure pipe: Replacement ).
WARNING
- Working on the injectors is not permitted.
- The injector filter rod must not be removed.
- Be sure to replace any injector that has been opened.
- Separating the pressure sensor from the rail is
prohibited.
13B-141
DIESEL INJECTION
K9K, and 722 or 728
Tighten to torque the neck nut on the rail (21 Nm)
using the low torque wrench.
WARNING
(4 Nm)
WARNING
injection, High-pressure pipe: Test ),
13B-142
13B
DIESEL INJECTION
F9Q, and 812
Mot. 1566

Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
Tightening torquesm
bolts
25 Nm
nuts on the injector side

and the nut on the injector pump side
25 Nm
nuts on the rail side
29 Nm

bolts
4 Nm
IMPORTANT
- Loosening a high-pressure pipe union when the
REMOVAL
terminal.
Remove:
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ),
), if fitted to the vehicle.
13B-143
13B
DIESEL INJECTION
13B
F9Q, and 812
18297-1
Plug the openings.
Disconnect:
- the pressure sensor connector (1) ,
- the fuel temperature sensor connector,
- the fuel return pipe on the injection pump side,
- the fuel return pipe on the diesel temperature sensor side.
Move the diesel temperature sensor (3) to one side.
Note:
The diesel temperature sensor is an integral part
of the fuel return pipe; these two components are
connected and cannot be removed separately.
Remove the diesel return pipe (4) .
13B-144
DIESEL INJECTION
13B
F9Q, and 812

Position the injector rail.
Pretighten the injector rail bolts, leaving clearance
between the bolt heads and the rail.
Refit the injector rail pipes and the rail-pump pipe:
- screw, by hand, the high-pressure pipe nuts onto
the pump and injector side,
6
7

the rail side.
Tighten to torque using the (Mot. 1566) or the (Mot.
1746) :
- the injector rail mounting bolts (25 Nm)
- the nuts on the injector side and the nut on the
injector pump side (25 Nm)
- the nuts on the rail side (29 Nm) .
WARNING
1327
Remove the high-pressure diesel pipes using the

(Mot. 1566) or the (Mot. 1746).
WARNING
Plug the openings.
Remove:
- the injector rail bolts,
- the injector rail (5) .
REFITTING
WARNING
Do not remove the protective plugs from each
Always replace any high-pressure pipe removed
with a new one.
13B-145
Do not put high-pressure pipes under stress.

Always hold the filter rod retaining nuts on the
injector holder when tightening.
DIESEL INJECTION
13B
F9Q, and 812
18297-1
Refit the return rail (8) :

- do not remove the clip from the injector,
WARNING
- press the injector clip,
- push the return rail end piece vertically.

operation.

(4 Nm) .
Note:

- Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle,

WARNING
13B-146
DIESEL INJECTION
13B
F9Q, and 804

Mot. 1566

Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
Tightening torquesm
111965

bolts
25 Nm
nuts on the injector end

and the nut on the injection pump end
25 Nm
nuts on the rail end
29 Nm
Disconnect:
Plug the openings.

bolts
4 Nm

Remove the diesel return pipe (3) .
IMPORTANT
Plug the openings.
REMOVAL
terminal.
Remove:
).
13B-147
DIESEL INJECTION
13B
F9Q, and 804
REFITTING
WARNING
Do not remove the protective plugs from each
Always replace any high pressure pipe removed
with a new one.
Tighten the injector rail bolts, leaving clearance
between the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
the pump and injector side,
the rail side.
1327
Remove the high-pressure diesel pipes using the

(Mot. 1566) or the (Mot. 1746).
Tighten to torque using the (Mot. 1566) or the (Mot.

1746) :
- the injector rail mounting bolts (25 Nm) ,
WARNING
- the nuts on the injector end and the nut on the

injection pump end (25 Nm) ,
- the nuts on the rail end (29 Nm) .
WARNING
Plug the openings.
Do not put high pressure pipes under stress.
Remove the oil separator.
Do not touch the high pressure pipes with the

spanner when tightening them to torque.
Always hold the filter rod retaining nuts on the
injector holder when tightening.
111859
Remove:
- the injector rail bolts (6) ,
- the injector rail (7) .
13B-148
DIESEL INJECTION
13B
F9Q, and 804

111965
Refit the return rail (8) :

- do not remove the clip from the injector,
- press the injector clip,
- push the return rail end piece vertically.
operation.
Note:
WARNING
WARNING
- confirm that there is no diesel fuel leak.
(4 Nm) .
13B-149
DIESEL INJECTION
13B
K9K, and 732

Mot. 1566

Mot. 1746
Offset spanner for

IMPORTANT
Equipment required
diagnostic tool
Tightening torquesm
REMOVAL

nuts
28 Nm

between the injector rail
and the injectors
24 Nm

between the injector rail
and the high-pressure
pump
24 Nm

Remove the engine covers
WARNING
WARNING
112815

(1) .

13B-150
Loosen the clip (2) and move aside the air inlet duct
(3) .
DIESEL INJECTION
13B
K9K, and 732
112811
Pull the clip.
112992

Remove:
bolt (7) ,
- the dipstick,
- the dipstick duct mounting bolts (8) .
Move the dipstick duct to one side.
112991

steel pipe.
112993
Disconnect:
13B-151
DIESEL INJECTION
13B
K9K, and 732

- the heater plug connector (10) .
112656
112994
Disconnect:

- the pressure regulating solenoid valve connector
(13) ,
IMPORTANT
- the flow regulating solenoid valve connector (14) ,



Detach the wiring harness retaining clip (16) .

Remove the wiring harness clamp mounting nut (17)
.
IMPORTANT
WARNING
Disconnect:

new cloths.
13B-152
DIESEL INJECTION
13B
K9K, and 732
111748

Remove:
- the injector rail protector support mounting nuts
and bolt (20) ,
1327

WARNING
IMPORTANT
unions:
- of the high-pressure pipes between the injection
rail and the diesel injectors
- the high-pressure pipe between the injector rail and
the high-pressure pump.
When loosening the high-pressure pipe unions

(21) on the injector holders, it is essential to hold
the filter rod mounting nut (22) with a lock
wrench.
Remove:
- the nuts from the four high-pressure pipes between
the injector rail and the injector on the rail end,
- the nuts from the four high-pressure pipes between
the injector rail and the injector on the injector end,
Remove the four high-pressure pipes and dispose of
them in a bin.
Note:
IMPORTANT

new cloths.

WARNING
13B-153
DIESEL INJECTION
13B
K9K, and 732

Remove the high pressure pipe between the high
pressure pump and the injector rail and dispose of it
in a bin.
REFITTING
WARNING
When loosening the connector of the high pressure pipe, the intermediate nut must be secured
WARNING
Note:
new cloths.
Take the injector rail out of its plastic bag.
WARNING

CONCERNED
If an injector rail is being replaced, only remove

the new one from its original packaging when it is
about to be fitted.

CONCERNED
Finger tighten the injector rail mounting bolts.
rail and the high pressure pump.
Note:
Remove:

- the injector rail mounting nuts (23) ,
- the injector rail.
Fit the new high-pressure pipes between the injector

rail and the injectors.
111745
WARNING
If the injector rail is to be reused, keep it in a sealed plastic bag all the time it is disconnected.
Note:
(28 Nm) .
13B-154
DIESEL INJECTION
13B
K9K, and 732

Tighten to torque:
Refit:
- the high-pressure pipe nuts between the injector rail and the injectors (24 Nm) using the (Mot.
1566) or the (Mot. 1746) starting with the rail end.
- the high-pressure pipe nuts between the injector rail and the high-pressure pump (24 Nm)
using (Mot. 1566) or (Mot. 1746) starting with the
high-pressure pump end.

Tighten the clip.
Connect:
- the connector to the air inlet pressure sensor,

pump.
Refit:


WARNING
Connect:

injection, High pressure pipe: Test ),


Connect:
- the connector to the flow regulation solenoid valve,

- the connector to the pressure regulation solenoid
valve,
Refit:
- the dipstick duct mounting bolts.
- the dipstick,
bolt,
13B-155

DIESEL INJECTION
Rail pressure sensor: Removal - Refitting
13B
F9Q, and 812

For versions with injector rail protector covers:

Mot. 997-01
Tool for removing/refitting injector holder fitted with cable.
- Remove the air inlet duct (see 12A, Fuel mixture,

Air inlet duct: Removal - Refitting ),
- Remove the injector rail protector (see 13B, Diesel
Equipment required
diagnostic tool
Before the operation, clean (see 13B, Diesel injection, Diesel injection: Repair precautions ):
- around the pressure sensor, using a brush and
some cleaning product,
Tightening torquesm
pressure sensor (M12)
35 Nm
pressure sensor (M18)
80 Nm

bolts
4 Nm
WARNING
Once the warranty period for the injector rail has
expired, only the pressure sensor can be replaced.
During the injector rail warranty period, the injector
rail should be completely replaced if the pressure
sensor fails.
The injector rail may be fitted with 2 types of sensor:
- a sensor with an M12 diameter thread, fitted with a
seal,
- a sensor with an M18 diameter thread, fitted without a
seal.
The 2 types of sensor have different tightening torques.
IMPORTANT
During each operation, always read the repair precautions (see 13B, Diesel injection, Diesel injection:
REMOVAL
Disconnect the battery starting with the negative terminal.
13B-156
- wipe the area cleaned with new cloths,

- blow the area cleaned dry using a compressed air
gun.
DIESEL INJECTION
13B
F9Q, and 812
18297-1
Disconnect the pressure sensor connector (1) .

Remove the pressure sensor using the (Mot. 99701).
II - PRESSURE SENSOR WITH AN M18 DIAMETER

THREAD (WITHOUT SEAL)
REFITTING
I - PRESSURE SENSOR WITH M12 DIAMETER
THREAD AND SEAL
Be sure to replace the seal.
Tighten the pressure sensor by hand.
using the (Mot. 997-01) , torque tighten the pressure sensor (M12) (35 Nm) .
112662
Check the condition of the lip seal (2) :

- if the lip seal is marked, the pressure sensor must
be replaced.
using the (Mot. 997-01) , torque tighten the pressure sensor (M18) (80 Nm) .
13B-157
DIESEL INJECTION
F9Q, and 812
III - CONTINUATION OF REFITTING PROCEDURE
Note:
WARNING
(4 Nm) .
WARNING
- check that there is no diesel escaping.
- Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ),
13B-158
13B
DIESEL INJECTION
13B
F9Q, and 804

Mot. 997-01
Tool for removing/refitting injector holder fitted with cable.

Equipment required
diagnostic tool
Tightening torquesm
pressure sensor
bolts
80 Nm
111888
4 Nm

WARNING
Before the operation, clean (see 13B, Diesel injection, Diesel injection: Repair precautions ):
Once the warranty period for the injector rail has

expired, only the pressure sensor can be replaced.
- around the pressure sensor, using a brush and

some cleaning product,
During the injector rail warranty period, the injector

rail should be completely replaced if the pressure
sensor fails.
- wipe the area cleaned with new cloths,

- blow the area cleaned dry using a compressed air
gun.
IMPORTANT
Remove the pressure sensor using the (Mot. 99701).

REFITTING
During each operation, always read the repair precautions (see 13B, Diesel injection, Diesel injection:
REMOVAL
Disconnect the battery starting with the negative terminal.
Remove the front engine cover.
112662
Check the condition of the lip seal (1) :

- if the lip seal is marked, the pressure sensor must
be replaced.
13B-159
DIESEL INJECTION
F9Q, and 804
Using the (Mot. 997-01) , tighten to torque the pressure sensor (80 Nm) .
Note:
Refit the air inlet duct without refitting the injector
rail protector or replacing the duct seal.
WARNING
(4 Nm) .
WARNING
- check that there is no fuel escaping.
13B-160
13B
DIESEL INJECTION
K9K, and 732
114076
The injector rail pressure sensor (1) cannot be separated from the injector rail.
In the event of an injector rail pressure sensor fault, replace the injector rail pressure sensor - injector rail assembly (see 13B, Diesel injection, Injector rail:
13B-161
13B
DIESEL INJECTION
K9K, and 722 or 728
102086
The pressure sensor (1) cannot be removed from

the spherical injector rail.
In the event of a pressure sensor fault, replace the
rail pressure sensor and high pressure pipe assembly (see 13B, Diesel injection, Injector rail ).
13B-162
13B
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting
13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench
1
Tightening torquesm
flow actuator mounting
bolts
5.5 0.6 Nm

bolts
4 Nm
102120
Disconnect:
IMPORTANT
- the battery, starting with the negative terminal,
- the air inlet duct (1) .


WARNING
- Obtain a set of special high-pressure injection circuit plugs.
- Always replace any high-pressure pipe or highpressure pipe clip removed with a new one.
REMOVAL
102362
Remove the diesel anti-splash plate (2) .
13B-163
DIESEL INJECTION
13B
K9K, and 722
6
3
4
7
102514
Disconnect:
102315
Remove the high-pressure pipe (6) from injector no.

4 (see 13B, Diesel injection, High-pressure pipe:
Replacement ).
- the heater plugs,

- the injector connectors (3) from cylinders 3 and 4,
- the pump electrical connectors (4) ,

Loosen the two bracket bolts (7) .
- the supply and return pipes (5) .
Remove the fuel flow actuator (by hand with small

successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
13B-164
DIESEL INJECTION
13B
K9K, and 722
REFITTING
WARNING
WARNING
Only unpack the new component when you are ready to fit it.

injection, High-pressure pipe: Test ).
WARNING
Do not damage the seal when refitting.

Note:
Do not lubricate the seals with grease or old diesel fuel. Use the applicator provided in the kit for
the new part.
Fit the actuator.
Finger tighten the mounting bolts.
Tighten to torque the two flow actuator mounting
bolts (5.5 0.6 Nm) using the low torque wrench.
Refit a new high-pressure pipe to injector no. 4 (see
13B, Diesel injection, High-pressure pipe: Replacement ) and a new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
WARNING
(4 Nm) .
13B-165
DIESEL INJECTION
13B
K9K, and 728
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
flow actuator mounting
bolts
5.5 0.6 Nm

bolts
4 Nm
IMPORTANT
110325
Pull the clip.

2
1
WARNING
- Always replace any high-pressure pipe or highpressure pipe clip removed with a new one.
REMOVAL
terminal.
110323
Loosen bolt (1) .

13B-166
DIESEL INJECTION
13B
K9K, and 728
102362
102315
Remove the high pressure pipe (7) from injector no.

4 (see 13B, Diesel injection, High-pressure pipe:
Replacement) .
Remove the diesel anti-splash plate (3) .

Loosen the bracket bolts (8) .
Remove the fuel flow actuator (by hand with small

successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
6
5
102514
Disconnect:
- the heater plug connectors (4) for cylinders n3 and
n4,
- the injector connectors from cylinders nos. 3 and 4,
- the fuel flow actuator connector (5) ,
- the supply and return pipes (6) .
13B-167
DIESEL INJECTION
13B
K9K, and 728
REFITTING
WARNING
WARNING
Only unpack the new component when you are ready to fit it.

injection, High-pressure pipe: Test ).
WARNING
Do not damage the seal when refitting.

Note:
Do not lubricate the seals with grease or old diesel fuel. Use the applicator provided in the kit for
the new part.
Fit the actuator.
Finger tighten the mounting bolts.
Tighten to torque the two flow actuator mounting
bolts (5.5 0.6 Nm) using the low torque wrench.
Refit a new high-pressure pipe to injector no. 4 (see
13B, Diesel injection, High-pressure pipe: Replacement ) and a new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
WARNING
(4 Nm) .
13B-168
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting
13B
F9Q, and 812

Equipment required
low torque wrench
WARNING
diagnostic tool
Once the warranty period for the high-pressure

pump has expired, only the pressure regulator can
be replaced separately.
Tightening torquesm
regulator bolts
6 Nm

bolts
4 Nm
Whilst the warranty period for the high-pressure

pump is still valid, the high-pressure pump should
be replaced as a whole if the pressure regulator
displays a fault.
REMOVAL
18297-1

terminal.
Remove:
Blast the area with compressed air to clean impurities from around the fuel pressure regulator.
- the fuel pressure regulator (remove manually: do

not use a tool to lever it out).
Disconnect the fuel pressure regulator connector.

Clean the area with cleaning product (see 13B, Diesel injection, Diesel injection: Repair precautions ).
13B-169
- the fuel pressure regulator bolts (1) ,
DIESEL INJECTION
F9Q, and 812
REFITTING
Clean the fuel pressure regulator pressure face on
the high-pressure pump, taking care not to introduce
any impurities.
Wipe the pressure face of the fuel pressure regulator
on the high-pressure pump using fresh wipes (see
13B, Diesel Injection, Diesel injection: Repair
precautions ).
Prepare the new regulator:
- remove the protective cap,
- check the position of the seals,
- lubricate the O-rings with clean diesel fuel.
Note:
Lubrication is very important to avoid external
leaks.
Offer up the regulator, rotating it slightly.
Push the regulator gently in until it engages fully.
Pretighten the new regulator bolts (3 Nm) .
Tighten to torque the regulator bolts (6 Nm) using
a low torque wrench.
Clean the area with fresh wipes.
Fit the fuel pressure regulator connector.
WARNING
(4 Nm) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool if
necessary.
WARNING
13B-170
13B
DIESEL INJECTION
13B
F9Q, and 804
REMOVAL
Equipment required
low torque wrench
diagnostic tool
Tightening torquesm
regulator bolts
6 Nm

bolts
4 Nm

WARNING
Once the warranty period for the high-pressure
pump has expired, only the pressure regulator can
be replaced separately.
Whilst the warranty period for the high-pressure
pump is still valid, the high-pressure pump should
be replaced if the pressure regulator displays a
fault.
111887

terminal.
Blast the area with compressed air to clean impurities from around the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with cleaning product (see 13B, Diesel injection, Diesel injection: Repair precautions ).
Remove:
- the fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not use
any tool for leverage).
13B-171
DIESEL INJECTION
F9Q, and 804
REFITTING
Clean the fuel pressure regulator pressure face on
the high-pressure pump, taking care not to introduce
any impurities.
Wipe the pressure face of the fuel pressure regulator
on the high-pressure pump using fresh wipes (see
13B, Diesel Injection, Diesel injection: Repair
precautions ).
Prepare the new regulator:
- remove the protective cap,
- check the position of the seals,
- lubricate the O-rings with clean diesel fuel.
Note:
Lubrication is very important to avoid external
leaks.
Offer up the regulator, rotating it slightly.
Push the regulator gently in until it engages fully.
Pretighten the new regulator bolts (3 Nm) .
Tighten to torque the regulator bolts (6 Nm) using
a low torque wrench.
Clean the area with fresh wipes.
Fit the fuel pressure regulator connector.
WARNING
(4 Nm) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool if
necessary.
WARNING
13B-172
13B
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting
13B
K9K, and 722
Equipment required
diagnostic tool
Tightening torquesm
diesel temperature sensor
15 Nm

bolts
4 Nm
102120
IMPORTANT


WARNING
- Always replace any high-pressure pipe and highpressure pipe clips that have been removed.
102514
REMOVAL
terminal.
Disconnect:
- the heater plugs from cylinders no. 3 and 4,
- the injectors (2) from cylinders no. 3 and 4,
- the diesel fuel temperature sensor connector (3) .
13B-173
DIESEL INJECTION
13B
K9K, and 722

(4 Nm) .
WARNING
102317
Remove the diesel fuel temperature sensor (4) .

REFITTING
WARNING
Lubricate the O-ring with lubricant from the applicator supplied with the new part.
WARNING
Do not damage the O-ring when refitting.
Fit the diesel fuel temperature sensor.
Tighten to torque the diesel temperature sensor
(15 Nm) .
Reconnect the electrical connector.
WARNING
13B-174
DIESEL INJECTION
13B
K9K, and 728
Equipment required
diagnostic tool
low torque wrench
forked endpiece
Tightening torquesm
diesel temperature sensor
15 Nm

bolts
4 Nm
IMPORTANT
102317
Remove the diesel fuel temperature sensor (1) .


REFITTING

WARNING
WARNING
WARNING
Do not damage the O-ring when refitting.
REMOVAL
terminal.
Fit the diesel fuel temperature sensor.
Torque tighten the diesel temperature sensor (15

Nm) using the low torque wrench and the forked
endpiece.
Disconnect the diesel temperature sensor connector.
Reconnect the electrical connector.

WARNING
13B-175
DIESEL INJECTION
K9K, and 728
(4 Nm) .
WARNING
13B-176
13B
DIESEL INJECTION
K9K, and 732
111747
The diesel temperature sensor (1) is attached to the

diesel injector fuel return rail.
Replace the diesel injector fuel return rail and diesel
temperature sensor assembly if there is a diesel temperature sensor fault (see 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refitting ).
13B-177
13B
DIESEL INJECTION
K9K, and 722 or 728
Mot. 1711
Kit for measuring

injector leak rate.

Fit the correct blanking plugs, in particular onto the
venturi pipe to prevent depriming the circuit.
IMPORTANT
Disconnect:
- the four transparent hoses of the (Mot. 1711).
Refit the injector fuel return pipes.
13B-178
13B
DIESEL INJECTION
13B
K9K, and 732

Mot. 1771
Kit for measuring SIEMENS injector leak

rate.
Mot. 1711
Kit for measuring

injector leak rate.

112811
Pull the clip.
112815

(1) .
Loosen the clip (2) and move the air inlet duct (3)
aside .
112991

steel pipe.
Move the air inlet duct (5) to one side .
13B-179
DIESEL INJECTION
13B
K9K, and 732

Connect:
IMPORTANT
Disconnect:
112992
Loosen the clip and move the air inlet duct aside.
Remove:
protector cover,
- the dipstick,
- the dipstick,
Disconnect the four transparent pipes from the (Mot.

1771).
Disconnect the four fuel return pipes of the four injectors (see 13B, Diesel injector fuel return rail:
Place the correct blanking plug on the injector fuel
return connectors.
Remove:

Connect the four injector fuel return pipes.
Refit:
- the dipstick,
bolt,
Refit:
Clip on the injector rail protector cover.
- the dipstick.
Tighten the clip.
Tighten the clip.
13B-180
Refit:
DIESEL INJECTION
K9K, and 732
Connect:
pump.
13B-181
13B
DIESEL INJECTION
Accelerometer: Removal - Refitting
13B
K9K, and 722 or 728
REFITTING

Emb. 1596
2 4 mm socket for
removing/refitting
clutch master cylinder.
Equipment required
low torque wrench
WARNING
Tightening torquesm
accelerometer
20 Nm

bolts
Tighten to torque the accelerometer (20 Nm) using

the low torque wrench.
4 Nm
REMOVAL
2
1
102086

terminal.
Disconnect the accelerometer connector (1) .
Remove the accelerometer (2) using the (Emb.
1596).
13B-182

(4 Nm) .
DIESEL INJECTION
13B
K9K, and 722 or 728
Equipment required
K9K, and 722
diagnostic tool
low torque wrench
1
Tightening torquesm
Venturi mounting bolt
bolts
5.5 Nm
4 Nm
IMPORTANT
102120

advice whenever work is carried out on this system.
WARNING
- Obtain a set of special high pressure injection circuit plugs.
REMOVAL
terminal.
102514
Disconnect the supply and return pipes (2) .
13B-183
DIESEL INJECTION
13B
K9K, and 722 or 728

(4 Nm) .
3
WARNING
102316
Disconnect the return pipe (3) connecting the injector to the pump.
Remove:
- the venturi mounting bolt (4) ,
- the venturi.
Fit a plug over the opening.
REFITTING
WARNING
Do not damage the O-ring when fitting the venturi.
Fit the venturi.
Tighten to torque the Venturi mounting bolt (5.5
Nm) using the low torque wrench.
Connect the various pipes.
WARNING
13B-184
DIESEL INJECTION
Diesel injector fuel return rail: Removal - Refitting
13B
K9K, and 732
Equipment required
diagnostic tool
WARNING
112815
WARNING

(1) .
one side.
- all the high pressure pipes which have been removed.
IMPORTANT
carried out on this system (see 13B, Diesel injection, Cleanliness guidelines ).
REMOVAL
13B-185
112811
Pull the clip.
DIESEL INJECTION
13B
K9K, and 732

IMPORTANT
unions:
- of the injector fuel return connectors,
- of the fuel pipe on the high pressure pump, taking
care not to soak the diesel temperature sensor.
IMPORTANT
112991

steel pipe.
WARNING

112992

Remove:
- the injector rail protector cover mounting bolt and
mounting nut (7) ,
- the dipstick,
13B-186
DIESEL INJECTION
13B
K9K, and 732


CONCERNED
Unclip the return rail assembly from the rocker cover.

Remove the fuel return rail.
WARNING
If it needs to be reused, keep the fuel return rail
in a sealed plastic bag.
REFITTING
111749
Using a fine, flat-blade screwdriver, push the lower

section of the clip (9) holding the fuel return connector on the injector towards the rocker cover.
WARNING
WARNING

Ensure that the clip is not fully removed from its

housing to prevent it from being twisted when
touching the rocker cover.
Remove the fuel return rail from its plastic bag.
WARNING
When replacing a fuel return rail, only remove it
from its packaging just before it is to be refitted.

CONCERNED
Refit the fuel return rail.
Clip the return rail assembly onto the rocker cover.
111751
Extract the fuel return connector from the injector

while pushing the lower section of the retaining clip
downwards.
Connect:
Remove the fuel return pipe from the injector.
- the return pipe on the high pressure pump,
Repeat the operation on the other fuel return connectors.
- the return pipe to the diesel temperature sensor.


Disconnect:
- the diesel return pipe from the diesel temperature
sensor,
Push the clip holding the fuel return connector on the

injector towards the front of the vehicle to restore it
to its original position.
- the fuel return pipe from the high pressure pump.
Repeat the operation on the other injectors.
13B-187
DIESEL INJECTION
13B
K9K, and 732

Clip on the fuel return connector of the injector.
WARNING
Check the condition of the seal on the fuel return
connector of the injector. Replace the fuel return
pipe assembly if any of its components are
damaged.
Repeat the operation on the other injectors.

WARNING
- Check the seals after repair (see 13B, Diesel
injection, High pressure pipe: Check ),

Refit:
- the dipstick,
- Check that there are no diesel leaks.

bolt,
Refit:
Tighten the clip.
Connect:
- the air inlet pressure sensor connector,
pump.
13B-188
Using diagnostic tool , check that there are no stored faults; clear them if necessary.
DIESEL INJECTION
Injector rail protector: Removal - Refitting
F9Q, and 804 or 812
Tightening torquesm
injector rail protector
mounting bolts
8 Nm

terminal.
Remove the air inlet duct (see 12A, Fuel mixture,
Air inlet duct: Removal - Refitting ).
111888
Disconnect the rail pressure connector (1) .

Remove:
- the injector rail protector mounting bolts (2) ,
- the injector rail protector.
REFITTING
Refit the injector rail protector.
Tighten to torque the injector rail protector mounting bolts (8 Nm) .
Connect the rail pressure sensor connector.
Reconnect the battery, starting with the positive terminal.
13B-189
13B
DIESEL INJECTION
Accelerator pedal sensor general information
K9K, and 722 or 728 or 732 F9Q, and 804 or 812
The accelerator pedal potentiometer is incorporated in
the accelerator pedal. If it is replaced, the accelerator
pedal must also be replaced.
There are two types of pedal: with or without a kickdown point.
Vehicles fitted with the cruise control/speed limiter
have an accelerator pedal with a kickdown point at the
end of travel.
This kickdown point makes it possible to exit the speed
limiter function if the driver has to increase speed.
WARNING
A pedal fitted with a kickdown point may be fitted in
place of a pedal without a kickdown point. However,
fitting a pedal without a kickdown point in place of a
pedal with a kickdown point is prohibited.
13B-190
13B
DIESEL INJECTION
Accelerator pedal potentiometer: Removal - Refitting
13B
K9K, and 722 or 728 or 732 F9Q, and 804 or 812
REFITTING
Refit the accelerator pedal mounting bolts (1) .
Tightening torquesm
bolts
4 Nm
Refit the accelerator pedal.

REMOVAL
WARNING
Disconnect:


- the accelerator pedal connector.

(4 Nm) .
Note:
A fault on the accelerator pedal position potentiometer results in changes in the idling speed or
engine operation.
102204
Remove:
- the pedal mounting bolts (1) ,
- the pedal.
13B-191
DIESEL INJECTION
Diesel injection computer: Removal - Refitting
13B
K9K, and 724 or 732 F9Q, and 804 M9R, and 700
Tightening torquesm
bolt securing the computer mounting
21 Nm
WARNING
code for life.
- It is forbidden to perform tests with computers borrowed from the Parts Department or from another
vehicle, that must then be returned. These computers are permanently coded.
When replacing the computer (see MR 372 Fault finding, Diesel injection, Fault finding - Replacement
of components ).
112659
Disconnect the connectors (1) from the computer.
REMOVAL
Unclip:
- the battery negative terminal wiring harness,
Remove the battery (see 80A, Battery, Battery: Removal - Refitting ).
Remove:
- the upper mounting bolt (3) from the computer
mounting,
- the mounting bolts (4) from the computer mounting,
- the computer and its mounting.
13B-192
DIESEL INJECTION
K9K, and 724 or 732 F9Q, and 804 M9R, and 700

CONCERNED
101890
Remove:
- the mounting nuts (5) from the computer,
- the computer from its mounting.
REFITTING
CONCERNED
Refit:
- the computer onto its mounting,
- the mounting nuts to the computer.
Refit the mounting bolt to the computer mounting.
Tighten to torque the bolt securing the computer
mounting (21 Nm) .
Refit the upper mounting bolt on the computer
mounting.
Clip on:
- the wiring harness.
Connect the computer connectors.
Refit:
13B-193
13B
DIESEL INJECTION
13B
K9K, and 722 or 728 F9Q, and 812
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
WARNING
code for life.

- It is forbidden to perform tests with computers borrowed from the Parts Department or from another
vehicle, that must then be returned. These computers are permanently coded.
When replacing the computer (see MR 372 Fault finding, 13B, Diesel injection, Fault finding - Replacement of components ).
101822
Disconnect the connectors (1) from the computer.

Move the turbocharger pressure regulation solenoid
valve to one side.
REMOVAL
Remove:
- the nut (3) from the wiring harness.
101888

terminal.
Remove the battery.
101811
Remove the computer and its mounting (4) .
13B-194
DIESEL INJECTION
13B
K9K, and 722 or 728 F9Q, and 812
REFITTING
101890
101887
Remove:
- the mounting nuts (5) from the computer,
- the computer from its mounting.
Make sure you refit the battery tray properly on the

computer mounting
(21 Nm) .
Connect the battery, starting with the positive terminal
WARNING
(4 Nm) .
13B-195
DIESEL INJECTION
Engine speed and position sensor: Removal - Refitting
13B
M9R, and 700

Lubricate the engine speed and position sensor
seal.
Tightening torquesm
engine speed and position sensor mounting
bolt
10 Nm

CONCERNED
Refit the engine speed and position sensor.
REMOVAL
Position the engine speed and position sensor so it

is pressing against the cylinder block.
Tighten the engine speed and position sensor

mounting bolt until contact is made.
Tighten to torque the engine speed and position
sensor mounting bolt (10 Nm) .

Move the engine speed and position sensor heat insulation to one side,
CONCERNED
Connect the engine speed and position sensor connector.

Refit:
- the heat insulation around the engine speed and
position sensor,
114979
Disconnect the engine speed and position sensor

connector.
Remove:
- the mounting bolt (1) from the engine speed and
position sensor,
- the engine speed and position sensor (2) .
REFITTING
Replace the engine and position speed sensor Oring, if the engine speed and position sensor is being
reused.
13B-196
PREHEATING
Pre/postheating unit: Removal - Refitting
13C
F9Q, and 804 or 812 K9K, and 722 or 728 or 732 M9R, and 700
CONCERNED
Tightening torquesm
wheel bolts
130 Nm
Note:
It is located behind the front left-hand wheel arch
liner.
REMOVAL
102125
Disconnect the pre-postheating unit connector.

Remove:
- the pre-postheating unit mounting bolt ,
- the pre-postheating unit (1) .
REFITTING
CONCERNED
Connect the pre-postheating unit connector.
Refit:
101823
- the pre-postheating unit,
Remove:
- the pre-postheating unit mounting bolt.
- the front left-hand wheel,

- the front left-hand wheel arch liner.
Refit:
- the front left-hand wheel arch liner,
- the front left-hand wheel,
13C-1
PREHEATING
Heater plugs Removal - Refitting
13C
K9K, and 722

Use a hose to untighten the plugs completely.
Tightening torquesm
heater plugs
bolts
WARNING
Ensure that no foreign bodies enter the cylinder
during this operation.
15 Nm
4 Nm
REFITTING
REMOVAL

Tighten to torque the heater plugs (15 Nm) .

terminal.

WARNING
(4 Nm) .
102120
Disconnect the air duct.
15762
Disconnect the electrical connector from the heater

plugs.
Clean around the outside of the heater plugs with a
compressed air gun to prevent contamination of the
cylinders.
Undo then remove the plugs using a 10 mm diameter long socket connected to a universal joint.
13C-2
PREHEATING
13C
F9Q, and 804 or 812

Tightening torquesm
heater plugs
bolts
WARNING
15 Nm
4 Nm
REFITTING
REMOVAL

terminal.

WARNING
F9Q, and 804

Remove:

(4 Nm) .
- the inlet duct (see 12A, Fuel mixture, Inlet duct:

- the injection rail protector (see 13B, Diesel injection, Injection rail protector: Removal - Refitting
).
15762

plugs.
cylinders.
13C-3
PREHEATING
13C
K9K, and 728
Tightening torquesm
heater plugs
bolts
15 Nm
4 Nm
REMOVAL
terminal.
110323
Loosen the bolt (1) .

110325
Pull the clip.
15762

plugs.
cylinders.
WARNING
13C-4
PREHEATING
K9K, and 728
REFITTING
WARNING
(4 Nm) .
13C-5
13C
PREHEATING
13C
K9K, and 732
Tightening torquesm
heater plugs
15 Nm
REMOVAL
112811
Pull the clip.
112815

(1) .
one side.
112991

steel pipe.
13C-6
PREHEATING
13C
K9K, and 732

CONCERNED
112992

112993
Remove:
Disconnect the connector from the heater plug.
protector cover,
Note:
- the dipstick,
Do not pull on the plug cable.

cylinders.
WARNING
REFITTING
CONCERNED
Refit the heater plugs using the hose.
Connect the connector to the heater plugs.
13C-7
PREHEATING
K9K, and 732
Refit:
- the mounting bolts to the dipstick tube,
- the dipstick,
- the injection rail protector mounting bolt and mounting nut.
Clip on the injection rail protector cover.
Clip the stainless steel pipes onto the turbocharger.
Refit:
Tighten the clip.
Connect:
13C-8
13C
PREHEATING
13C
K9K, and 722 or 728

The pre/post heating function is controlled by the injection computer.
b - Fixed preheating
After the warning light goes out, the heater plugs continue to be supplied for a fixed period of 5 seconds .
PRE/POST HEATING OPERATING PRINCIPLE

2 - Starting
1 - Switching on the ignition preheating
The plugs remain supplied while the starter is being activated.
a - Variable preheating
3 - Engine running postheating
The time for which the warning light is lit and of the supply to the heater plugs depends on the coolant temperature and the battery voltage.
During this phase the plugs are supplied continuously

according to coolant temperature.
At idling speed with no depression of the accelerator
pedal.
103123
X: Time in seconds
103124
Y: Coolant temperature in C
X: Time in seconds
K9K, and 722

Whatever the situation, the heater plug warning light
cannot remain lit for more than 10 seconds (except in
the event of a coolant temperature sensor fault).
K9K, and 728

Whatever the situation, the heater plug warning light
cannot remain lit for more than 12 seconds (except in
the event of a coolant temperature sensor fault).
13C-9
PREHEATING
13C
F9Q, and 812

The pre/post heating function is controlled by the injection computer.
At altitude, the postheating time may reach 45 seconds .
PRE/POST HEATING OPERATING PRINCIPLE

1 - Switching on the ignition preheating
a - Variable preheating
The time for which the warning light is lit and of the supply to the heater plugs depends on the coolant temperature and the battery voltage.
101188
X: Time in seconds
101189
X: Time in seconds
In all cases, the period that the preheating warning light
is lit cannot exceed 12 seconds .
b - Fixed preheating
After the warning light goes out, the spark plugs continue to be supplied for a set period of 10 s .
2 - Starting
The plugs remain supplied while the starter is being activated.
3 - Engine running postheating
During this phase the plugs are supplied continuously
according to coolant temperature.
At idling speed with the accelerator pedal not being depressed.
13C-10
ANTIPOLLUTION
Petrol vapour rebreathing: Operation
14A
I - OPERATING DIAGRAM OF THE CIRCUIT
F4R, and 770 or 771 K4J, and 730 K4M, and
761 or 782
6
5
106679
(1)
Inlet manifold
(2)
Fuel vapour absorber bleed

solenoid valve
(3)
Fuel vapour absorber
(4)
Tank
(5)
Breather
(6)
Non-return valve (only 776)
102724
F4R, and 776
106278
14A-1
ANTIPOLLUTION
Petrol vapour rebreathing: Operation
14A
The variation in the passage opened for fuel vapour in
the solenoid valve results from the balance between
the magnetic field created by the supply to the winding
and the return spring force attempting to close the solenoid valve.
102734
(3)
(6)
Recirculation of fuel vapour from

the tank
(7)
Recirculation of fuel vapours

going to the engine
(8)
Tank breather
WARNING
The breather should not be blocked during normal
engine operation.
II - OPERATING PRINCIPLE
The tank is vented by means of the fuel vapour absorber.
Fuel vapour is trapped by the active charcoal contained in the absorber as it passes through.
Fuel vapour trapped in the absorber is eliminated and
burnt by the engine.
To do this, the fuel vapour absorber and inlet manifold
are connected via the solenoid valve. This solenoid
valve is located on the shock absorber cup.
The principle behind the solenoid valve is to open a
passage of variable size (according to the opening cyclic ratio signal sent by the injection computer).
14A-2
ANTIPOLLUTION
Fuel vapour recirculation circuit: check
14A
II - FUEL VAPOUR ABSORBER BLEEDING
CONDITIONS
Equipment required
The petrol vapour absorber bleed solenoid valve is

controlled by track C-E1 of the computer if:
diagnostic tool
- the coolant temperature is above 55C ,

I - CHECKING THE OPERATION OF THE FUEL
VAPOUR ABSORBER BLEED
- the air temperature is above 10C ,

- the engine is not at idle speed,
- a given load threshold is reached,
Note:
- the throttle potentiometer is not in the no load

position.
A fault with this system may result in rough idling

or the engine stalling.
During on board diagnostic fault finding, fuel vapour absorber bleeding is not authorised.
The opening cyclic ratio of the fuel vapour absorber
bleed solenoid valve can be displayed using the diagnostic tool (CLIP) by referring to parameter
PR102: Fuel vapour absorber bleed solenoid valve OCR .
The solenoid valve is closed at values below 1.2 % .
6
5
106679
(1)
Inlet manifold
(2)
Fuel vapour absorber bleed

solenoid valve
(3)
(4)
Tank
(5)
Breather
(6)
Anti-return valve (only 776)
Check the conformity of the circuit (see 14A, Antipollution, Fuel vapour rebreathing: Operation ).
Check the condition of the pipes to the tank.
14A-3
ANTIPOLLUTION
Fuel vapour canister: Removal - Refitting
14A
The absorber is located on the fuel tank under the vehicle.
REMOVAL
102734
Disconnect:
- the pipe (2) bringing the fuel vapour from the tank,
- the pipe (3) taking the fuel vapours towards the solenoid valve,
102483
Remove the absorber (1) from the fuel tank retaining

notch by pushing in the direction of the arrow.
- the breather pipe (4) .

Remove the absorber.
REFITTING
14A-4
ANTIPOLLUTION
Fuel vapour canister:Checking
Mot. 1311-01
CHECKING THE FUEL VAPOUR

ABSORBER
On the fuel vapour absorber, plug the circuit coming
from the fuel tank.
Connect the pressure gauge of tool (Mot. 1311-01)
to the absorber breather outlet.
With the engine idling check that there is no vacuum
at the absorber breather outlet (in the same way, the
command value displayed by the diagnostic tool in
parameter: Fuel vapour absorber bleed solenoid
valve OCR remains minimal X no more than 1.5
% ).
Is there a vacuum?
- Yes: with the ignition off, use a vacuum pump to
apply a vacuum of 500 mbar to the outlet solenoid
valve. The vacuum should not vary by more than
10 mbar over 30 seconds .
Does the pressure change?
Yes: replace the solenoid valve as it is faulty.
No: there is an electrical fault, check the circuit.
- No: in bleeding conditions (see Bleeding
conditions ), the vacuum should increase (at the
same time the parameter value on the diagnostic
tool should increase).
CHECKING THE FUEL VAPOUR

ABSORBER TANK CONNECTION
Check this connection by connecting a vacuum
pump to the pipe going to the absorber.
14A-5
14A
ANTIPOLLUTION
14A
K4J, and 730

I - PRESENTATION OF COMPONENTS
101495
(1)
Oil vapour rebreathing aperture
(2)
Oil vapour recovery plate located on the rocker cover
(3)
Calibrated jet
3
2
2
101499
101869
14A-6
ANTIPOLLUTION
14A
K4J, and 730

To dismantle the oil vapour recovery plate (2) , see
(11A, Top and front of engine).
II - PRESENTATION OF THE CIRCUIT
A: Under low loads, the oil vapours are rebreathed
in small quantities through the calibrated jet (7).
2
1
101956
B: At medium and heavy loads, the oil vapours are

rebreathed in large quantities by the gas valve.
6
2
101957
(1)
Engine
(2)
Oil vapour recovery plate
(4)
Motorised throttle
(5)
Air distributor
(6)
Inlet air intake
(7)
Calibrated jet
To ensure the emission control system works properly,

the oil vapour rebreathing circuit must be kept clean
and in good condition.
Air unit
III - CHECK
(3)
14A-7
ANTIPOLLUTION
14A
K4M, and 761 or 782

102305
(1)
Oil vapour rebreathing pipe
(2)
Calibrated jet
3
4
3
101820
(3)
(4)
Oil vapour rebreathing aperture
102073
To dismantle the oil vapour recovery plate (3) , (see

11A, Top and front of engine ).
14A-8
ANTIPOLLUTION
14A
K4M, and 761 or 782

II - PRESENTATION OF THE CIRCUIT
A: At low loads, the oil vapours are rebreathed in
small quantities through the calibrated jet (6)
(6)
Calibrated jet

2
1
102308
B: At medium and heavy loads, the oil vapours are

rebreathed in large quantities through the gas
throttle valve.
Air intake
III - CHECK
(5)
3
5
2
1
102309
(1)
Engine
(2)
(3)
Motorised throttle valve
(4)
Inlet manifold
14A-9
ANTIPOLLUTION
14A
K9K, and 722 or 724 or 728 or 732

I - PRESENTATION OF THE CIRCUIT
B: At medium or high load, the vacuum pressure prevailing in the air inlet duct pulls the valve diaphragm,
small quantities of oil vapour are rebreathed in via a calibrated jet.
1
2
II - CHECK
20965
1
2
20965-1
(1)
Rocker cover
(2)
Oil vapour rebreathing duct
(3)
Oil vapour rebreathing valve
(4)
Air inlet duct
(5)
Turbocharger
(6)
Atmospheric pressure
A: At low load, the vacuum pressure prevailing in the

air inlet duct is below the spring calibration. Large
quantities of oil vapour are sucked back in by the vacuum prevailing in the air inlet duct.
14A-10
ANTIPOLLUTION
14A
F9Q, and 804 or 812

F9Q, and 812
3
4
6
1
100053
(1)
Engine
(2)
Oil separator
(3)
Air filter unit
(4)
Air duct
(5)
Turbocharger
(6)
Inlet manifold
100054
II - CHECK
14A-11
(7)
Oil vapour rebreathing pipe connected to the intake pipes
(8)
Cylinder block outlet oil vapour

rebreathing pipe
(9)
Oil separator return pipe
ANTIPOLLUTION
14A
F4R, and 770 or 771

102723
(1)
Oil vapour rebreathing duct
(3)
(2)
Oil vapour recirculation valve
3
4
102729
14A-12
102738
ANTIPOLLUTION
14A
F4R, and 770 or 771

For dismantling, (see 11A, Top and front of engine ).
(4)
Throttle upstream oil vapour

recirculation aperture
II - OIL VAPOUR RECIRCULATION CIRCUIT
5
9
8
10
102745
(5)
Air duct
(6)
Throttle valve
(7)
Inlet manifold
(8)
Throttle upstream oil vapour

recirculation aperture
(9)
(10)
Oil vapour recirculation valve
III - CHECK
14A-13
ANTIPOLLUTION
14A
F4R, and 776

COMPONENTS
2
1
106629
(1)
Circuit upstream of turbocharger, used for medium and high

loads. The vapour is sucked
back in by the prevailing vacuum
pressure in the inlet manifold
(2)
Circuit downstream of throttle

valve, used for low loads. The
vapour is sucked back in by the
prevailing vacuum pressure
between the throttle and engine
106588
Oil vapour recovery plate located on the rocker cover.
14A-14
ANTIPOLLUTION
F4R, and 776
102738
To dismantle the oil vapour recovery plate (see 11A,

Top and front of engine ).
II - CHECK
14A-15
14A
ANTIPOLLUTION
Exhaust gas recirculation: Description
14A
K9K, and 722 or 728

I - PRESENTAION OF THE CIRCUIT
Note:
3
A
The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation
of the quantity of engine inlet air.
IV - OPERATING CONDITIONS
4
1
The following parameters determine activation of the

exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- accelerator pedal position,

- diesel injection flow,
- engine speed.
102364
Operating point for checking the exhaust gas

recirculation solenoid valve
(1)
Engine
(2)
Air filter unit
(3)
Air distributor
(4)
Exhaust manifold
(5)

with solenoid valve
- the air temperature is between - 30C and 67C inclusive,
(6)
Turbocharger
(7)
Injection computer
- or the coolant temperature is between 0C and 127C

inclusive,
(8)
Heat exchanger
- the engine speed is above 500 rpm ,
(A)
Air inlet
(B)
Exhaust gas outlet
The exhaust gas recirculation solenoid valve is activated if:
- the diesel fuel injection flow is between 10 and 31

mg/stroke inclusive,
- atmospheric pressure is greater than 421 mbar .
II - PURPOSE OF THE EXHAUST GAS

RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the concentration of nitrogen oxides (NOx) in exhaust fumes.
The computer regulates the passage of gases by actuating a solenoid valve.
If so, the diagnostic tool indicates an exhaust gas recirculation solenoid valve position opening cyclic ratio value equal to 4 and 60 % .
Exhaust gas recirculation is cut off if:
- the mapping (engine speed - load) exceeds a threshold,
- the air conditioning compressor is activated.
The solenoid valve is controlled by an opening cyclic

ratio signal issued by the injection computer. The opening cyclic ratio signal modulates the opening of the
solenoid valve, and consequently the quantity of exhaust gas directed back to the inlet manifold.
The computer runs a constant test to keep track of the
position of the exhaust gas recirculation solenoid valve.
The exhaust gas recirculation solenoid valve is not

supplied after starting for 2 seconds .
The exhaust gas recirculation solenoid valve is no longer supplied if there is a fault on:
- the exhaust gas recirculation solenoid valve,
- the turbocharging pressure sensor,
14A-16
ANTIPOLLUTION
K9K, and 722 or 728
15761
Track
Description
Solenoid supply
Position potentiometer supply
Not used
Position potentiometer earth
Solenoid earth control
Position potentiometer signal
14A-17
14A
ANTIPOLLUTION
14A
F9Q, and 812

7
5
8
10
11
2
1
23244

(1)
Engine
(2)
Injection computer
(3)
Inlet manifold
(4)
Exhaust manifold
(5)
Turbocharger
(6)
(7)
Air flowmeter
(8)
Air intake
(9)
Exhaust pipe
(10)
Intercooler inlet

(11)
Intercooler outlet
- battery voltage,

- the engine speed,

Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
- air temperature,
The injection computer allows gas to pass by actuating

a solenoid valve.
- vehicle speed.
Exhaust gas recirculation is cut off if:
- the battery voltage is below 9 V ,
14A-18
ANTIPOLLUTION
14A
F9Q, and 812

- the engine speed is above 3650 rpm ,
Note:
There is no exhaust gas recirculation at altitude (>
1,200m).
- mapping (engine speed-load) exceeds a given threshold,
- after 40 seconds , if:
the vehicle speed is below 7 mph (12 km/h) ,
the engine speed is below 1000 rpm .
the coolant temperature is above 60C ,
the air temperature is above 15C for 60 seconds .
The exhaust gas recirculation solenoid valve is not
controlled after engine start-up depending on coolant
temperature mapping.
15761
103127
Time in seconds
Track
Description
Solenoid supply + 12 v
Sensor supply + 5 V
Sensor earth
Solenoid earth
Sensor output
The exhaust gas recirculation solenoid valve is supplied for 40 seconds each time the engine returns to
idling speed if the air temperature is above 15C. .
- the air flowmeter,
- the exhaust gas recirculation solenoid valve.
- the coolant temperature sensor,

- the air temperature sensor,
- the turbocharger pressure sensor,
- the atmospheric pressure sensor.
14A-19
ANTIPOLLUTION
F9Q, and 804
I - DIAGRAM
114451
(1)
Engine
(2)
Exhaust gas cooler
(3)
(4)
Inlet manifold
(5)
Exhaust manifold
(6)
Turbocharger

Exhaust gas recirculation is used to reduce the nitrogen oxide (NO X) content of the exhaust gases.
The injection computer authorises gas passage by running an electric motor which activates a valve by linking
the exhaust manifold and the inlet manifold.
The principle of the exhaust gas recirculation consists
of reinserting part of the exhaust fumes in the engine
air breathing cycle.
The EGR valve is controlled by a direct current motor.
14A-20
14A
ANTIPOLLUTION
14A
K9K, and 732


Note:
The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation
of the quantity of engine inlet air.
- air temperature,
102364
(1)
Engine
(2)
Air filter unit
(3)
Inlet manifold
(4)
Exhaust manifold
(5)

with solenoid valve
(6)
Turbocharger
(7)
Injection computer
(8)
Intercooler
(A)
Air inlet
(B)
Exhaust gas outlet
- engine speed.

Exhaust gas recirculation is used to reduce the concentration of nitrogen oxides (NOx) in exhaust fumes.
14A-21
ANTIPOLLUTION
14A
M9R, and 700

113323

(1)
Engine
(2)
Air filter unit
(3)
Turbocharger
(4)
Intercooler
(5)
Damper valve
(6)
EGR solenoid valve
(7)
Inlet manifold
(8)
Exhaust manifold
(9)
EGR cooler
(10)
Computer

The computer continuously carries out a test to detect
the position of the EGR valve.
The parameters which determine the activation of the
EGR solenoid valve are as follows:
II - ROLE OF THE EGR SYSTEM

Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
- air temperature,
- engine speed.
14A-22
ANTIPOLLUTION
M9R, and 700
Operating points for testing the EGR valve:
The operating points for the EGR valve test are shown
in the Fault Finding Manual (see MR 372 Fault finding, 13B, Diesel injection, Fault finding - System
operation ).
14A-23
14A
ANTIPOLLUTION
Exhaust gas recirculation: List and location of components
14A
K9K, and 732
112326
114189
(1) Exhaust gas recirculation solenoid valve

(2) Intercooler cooler
(3) Rigid exhaust gas recirculation pipe
(4) Cooler support, flywheel end
(5) Cooler support, timing end
14A-24
ANTIPOLLUTION
Exhaust gas recirculation unit: Removal - Refitting
14A
K9K, and 722

Mot. 1567

EGR duct clips.
Tightening torquesm
exhaust gas recirculation unit mounting bolt
21 Nm

mounting bolt
21 Nm
lifting eye (timing end)
21 Nm
mounting bolts for the

heat shield on the
exhaust gas recirculation solenoid valve
12 Nm

bolts
4 Nm
104246
Remove:
partition,
- the plenum chamber partition.
REMOVAL
terminal.
2
102120
104343
Remove:
55A, Exterior protection, Scuttle panel grille ,
- the plenum chamber mounting bolt (2) .
14A-25
ANTIPOLLUTION
14A
K9K, and 722
11
13
12
102126
102074
Remove:
- the heat shield (11) on the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation tube (12) ,
- exhaust gas recirculation unit mounting bolts (13) ,

- the exhaust gas recirculation unit.
REFITTING
Replace the exhaust gas recirculation tube complete

with new clips.
10
Tighten the new clips using tool (Mot. 1567).

102119
Disconnect:
Replace the O-rings on the air inlet metal tube.

Tighten to torque:
- the valve pipe (6) on the turbocharging pressure regulation from the air duct,

bolt (21 Nm) ,
- the air inlet pipe (7) from the exhaust gas recirculation unit.
- the metal air inlet tube mounting bolt (21 Nm) ,
Remove:
- the lifting eye (timing end) (21 Nm) ,
- the bracket (8) ,

- the engine lifting eye (9) ,
- the mounting bolts for the heat shield on the exhaust gas recirculation solenoid valve (12 Nm) .
- the air inlet metal tube (10) .

WARNING
Battery: Removal: refitting ).
(4 Nm) .
14A-26
ANTIPOLLUTION
14A
K9K, and 728

Mot. 1567

EGR duct clips.
Tightening torquesm
exhaust gas recirculation unit mounting bolt
21 Nm

mounting bolt
21 Nm
lifting eye (timing end)
21 Nm
mounting bolts for the

heat shield on the
12 Nm

bolts
4 Nm
104246
Remove:
partition,
- the plenum chamber partition.
REMOVAL
terminal.
2
1
110325
Pull the clip.

104343
Remove:
- the mounting bolt (2) from the plenum chamber.
14A-27
ANTIPOLLUTION
14A
K9K, and 728
10
8
5
4
11
102119
Disconnect:
- the turbocharging pressure regulation valve pipe
(7) from the air duct,
110323
Unscrew the bolt (4) .

- the air inlet pipe (8) from the exhaust gas recirculation unit.
Remove:
- the bracket (9) ,
- the engine lifting eye (10) ,
- the air inlet metal tube (11) .
14
12
102126

13
102074
Remove:
- the exhaust gas recirculation solenoid valve (12)
heat shield,
- the exhaust gas recirculation tube (13) ,
- exhaust gas recirculation unit mounting bolts (14) ,
- the exhaust gas recirculation unit.
14A-28
ANTIPOLLUTION
K9K, and 728
REFITTING
Replace the exhaust gas recirculation tube complete
with new clips.
Tighten the new clips using tool (Mot. 1567).
Replace the O-rings on the air inlet metal tube.
Tighten to torque:
bolt (21 Nm) ,
- the metal air inlet tube mounting bolt (21 Nm) ,
- the lifting eye (timing end) (21 Nm) ,
- the mounting bolts for the heat shield on the exhaust gas recirculation solenoid valve (12 Nm) .
WARNING
Battery: removal: refitting ).
(4 Nm) .
14A-29
14A
ANTIPOLLUTION
14A
F9Q, and 812

Mot. 1202-01

clips.
Mot. 1202-02
1
2

clips.
Tightening torquesm
exhaust gas recirculation intercooler mounting bolts
10 Nm
bleed valve mounting

bolt
9 Nm
exhaust gas recirculation pipe mounting bolts
20 Nm

bolts
4 Nm
104343
REMOVAL
terminal.
Remove the battery.
104246
Drain the cooling system via the cooling radiator

lower hose using tool (Mot. 1202-01) or tool (Mot.
1202-02).
Remove:
14A-30

ANTIPOLLUTION
14A
F9Q, and 812
102500
101811
Remove the injection computer (6) and its mounting.
8
4
101822
101808
Disconnect injection computer connectors (4) .
Remove:
Remove:
- air inlet sleeve (7) ,
- air duct (8) ,
- the wiring harness strap.
- air filter unit (9) .

14A-31
ANTIPOLLUTION
14A
F9Q, and 812
12
16
10
18
17
17
11
13
19
104424
104420
Disconnect:
Disconnect the exhaust gas recirculation exchanger

(16) .
- the exhaust gas recirculation connector (10) ,
Remove:
- clips (17) ,
- the vacuum (12) inlet and outlet pipes,
- the mounting bolts (1 8) from the pipe fitted

between the exhaust manifold and the unit,
- the turbocharger pressure regulation valve (13) pipe.
- the mounting bolts (19) from the exhaust gas recirculation solenoid valve / gas recirculation exchanger assembly ,
- the exhaust gas recirculation solenoid valve / gas
recirculation exchanger assembly.
14
15
104421
Remove the vacuum tank (14) .

Disconnect the scuttle panel (15) hose.
14A-32
ANTIPOLLUTION
14A
F9Q, and 812
23
22
20
21
106211
II - ON THE WORKBENCH: REPLACE THE

EXHAUST GAS RECIRCULATION EXCHANGER.
WARNING
Remove:
Never remove the exhaust gas recirculation solenoid valve (20) from the unit (21) .
- the hose (23) , mark its position for refitting,

- the bleed valve mounting bolt (22) ,
I - ON THE WORKBENCH: REPLACE THE

EXHAUST GAS RECIRCULATION SOLENOID
VALVE.
- the exchanger mounting bolts (21) on the exhaust

gas recirculation unit,
Remove:
- the exhaust gas recirculation exchanger mounting
bolts from the unit (21) .
- the bleed valve mounting bolt (22) ,

- the exhaust gas recirculation exchanger mounting
bolts from the unit (21) .
WARNING
make sure that no foreign bodies enter the manifolds.
Replace:
- the pipe seals fitted between the exhaust manifold and the unit,
- clips (17) ,
- the seal between the exhaust gas recirculation
intercooler and the unit (21) .
14A-33
ANTIPOLLUTION
F9Q, and 812
REFITTING
Tighten to torque:
- the exhaust gas recirculation intercooler mounting bolts (10 Nm) ,
- the bleed valve mounting bolt (9 Nm) ,
- the exhaust gas recirculation pipe mounting
bolts (20 Nm) .
WARNING
(4 Nm) .
14A-34
14A
ANTIPOLLUTION
14A
F9Q, and 804
Tightening torquesm
25 Nm
exhaust gas recirculation pipe mounting bolts
18 Nm

bolts
4 Nm
REMOVAL
terminal.
104246
Remove:
Remove the air duct (see 12A, Fuel mixture, Inlet
4
2
104343
Remove:
111861
Remove the mounting bolts (4) from the exhaust gas

recirculation pipe.

14A-35
ANTIPOLLUTION
14A
F9Q, and 804

Tighten to torque:
bolts (25 Nm) ,
- the exhaust gas recirculation pipe mounting
bolts (18 Nm) .

WARNING
(4 Nm) .
111964
113177
Remove the mounting bolts (5) from the exhaust gas

recirculation unit.
WARNING
Never remove the exhaust gas recirculation solenoid valve from the unit.
REFITTING
14A-36
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
K9K, and 722 or 728
Mot. 1729
Pin wrench for removing the EGR valve.
Tightening torquesm
mounting bolts
12 Nm
EGR solenoid valve

mounting stud
4 Nm
The exhaust gas recirculation solenoid valve is fitted

into the exhaust gas recirculation unit.
REMOVAL
Disconnect the EGR solenoid valve.
Remove the turbocharger outlet pipe and move it to
one side.
Remove:
- the heat shield,
- the bolts securing the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve by gradually turning it using the (Mot. 1729).
REFITTING
WARNING
Always replace the seal of the exhaust gas recirculation solenoid valve with a new one.
solenoid valve mounting bolts (12 Nm) .
If the EGR solenoid valve mounting stud is replaced,
tighten to torque the EGR solenoid valve mounting stud (4 Nm) .
14A-37
14A
ANTIPOLLUTION
14A
K9K, and 732

Mot. 1729
Pin wrench for removing the EGR valve.

Equipment required
diagnostic tool
Tightening torquesm
mounting bolts
10 Nm
104246
Remove:
REMOVAL

terminal.
grille ).
2
1
112816
Remove the oil vapour rebreathing pipe (4) .
104343
Remove:
14A-38
ANTIPOLLUTION
14A
K9K, and 732
112811
112812
Pull the clip
Disconnect the exhaust gas recirculation solenoid

valve connector (5) .
Remove the inlet duct mounting bolt.
Remove:
Move the inlet duct to one side.
- the exhaust gas recirculation solenoid valve mounting bolts (6) ,

- the exhaust gas recirculation solenoid valve using
the (Mot. 1729) ,
- the seal between the exhaust gas recirculation solenoid valve and the cooler mounting on the
flywheel side.
Note:
When removing the exhaust gas recirculation
solenoid valve with the (Mot. 1729) , gently move
the solenoid valve until it comes away from its
mounting.
REFITTING
Refit the exhaust gas recirculation solenoid valve
with its new seal.
solenoid valve mounting bolts (10 Nm) .
14A-39
ANTIPOLLUTION
K9K, and 732
WARNING
Before restarting the engine, use the diagnostic
tool to clear any faults stored by the injection computer.
14A-40
14A
ANTIPOLLUTION
F9Q, and 804
112665
The exhaust gas recirculation solenoid valve is joined to the exhaust gas recirculation unit.
Replace the EGR unit - EGR solenoid valve
assembly if the EGR solenoid valve is faulty (see
14A, Emission control, EGR unit ).
14A-41
14A
ANTIPOLLUTION
14A
M9R, and 700
Equipment required
tweezers
Tightening torquesm
bolts mounting the
EGR solenoid valve on
the inlet manifold
21 Nm
bolts mounting the air

inlet duct between the
turbocharger and the
intercooler on the inlet
manifold
8 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
104343
Remove:
REMOVAL
grille ).
104246
Remove:
14A-42
ANTIPOLLUTION
14A
M9R, and 700
115585

114933
Remove:
- the clips (8) ,
- the upper front end panel mounting bolts (9) ,

102365
Remove:
112658
Remove:
- the lower mounting bolts (10) from the front end panel,
- the mounting bolts (5) from the engine accessories

unit,
14A-43
- the damper valve (see 12A, Fuel mixture, Damper valve: Removal - Refitting ).
ANTIPOLLUTION
14A
M9R, and 700

CONCERNED
113282
Pivot the air duct retaining clip (11) between the turbocharger and the intercooler on the turbocharger
side.
115721
Disconnect the EGR solenoid valve connector (13) .

Remove:
- the bolts (14) mounting the EGR solenoid valve on
the inlet manifold,
- the EGR solenoid valve,
- the EGR solenoid valve seal.
113155
Remove the mounting bolts (12) from the air inlet

duct between the turbocharger and the intercooler
on the inlet manifold.
Move aside the air inlet duct between the turbocharger and the intercooler.
Remove the EGR rigid pipe between the EGR solenoid valve and the EGR cooler (see 14A, Emission
control, Exhaust gas recirculation rigid pipe: Removal - Refitting ).
14A-44
ANTIPOLLUTION
14A
M9R, and 700
REFITTING
115069
Fit the new seal to the air inlet duct between the turbocharger and the intercooler on the turbocharger
side.
115068
Remove the air inlet duct seal between the turbocharger and the intercooler on the turbocharger side
using a tweezers.
Note:
Check that the seal (15) on the air inlet duct
between the turbocharger and the intercooler on
the turbocharger side is fitted in the correct direction.
Clean the pressure faces:
- of the plenum chamber,
- of the EGR solenoid valve if it is to be re-used.
WARNING

CONCERNED
Fit:
- the new seal to the EGR solenoid valve,
- the EGR solenoid valve.
Finger tighten the mounting bolts until they make
contact with the EGR solenoid valve.
Tighten to torque the bolts mounting the EGR solenoid valve on the inlet manifold (21 Nm) .
Connect the EGR solenoid valve connector.
14A-45
ANTIPOLLUTION
14A
M9R, and 700

Refit the EGR rigid pipe between the EGR solenoid

valve and the EGR cooler (see 14A, Emission control, Exhaust gas recirculation rigid pipe: Removal - Refitting ).
Pivot the air inlet duct retaining clip between the turbocharger and the intercooler on the turbocharger
side.
Clip on the air inlet duct between the turbocharger
and the intercooler on the turbocharger side
Refit the bolts mounting the air inlet duct between
the turbocharger and the intercooler on the inlet manifold.
Tighten to torque the bolts mounting the air inlet
duct between the turbocharger and the intercooler on the inlet manifold (8 Nm) .
Refit:
Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Refit:
14A-46

- if replacing or removing - refitting the EGR solenoid
valve, reprogram by following command scenario
SC036 (see MR 372 Fault finding, 13B, Diesel injection, Fault finding - Interpretation of commands ) and (see MR 372 Fault finding, 13B,
Diesel injection, Fault finding - Replacement of
components ),
Adjustment ),
ANTIPOLLUTION
14A
K9K, and 732

Ms. 583
Hose clamp pliers.
Mot. 1567

EGR duct clips.
Equipment required
diagnostic tool
Tightening torquesm
bolts mounting the
intercooler on its two
supports
12 Nm
bolts mounting the two

intercooler supports on
the cylinder head
25 Nm
rigid exhaust gas recirculation pipe mounting

bolts
35 Nm
lifting bracket mounting

bolts
10 Nm
bolts mounting the two

intercooler supports on
the cylinder head
12 Nm
104343
Remove:
REMOVAL
104246
Remove:

14A-47
ANTIPOLLUTION
14A
K9K, and 732
112816
Disconnect:
- the connector (6) from the exhaust gas recirculation solenoid valve,
- the oil vapour rebreathing pipe (7) on the rocker cover side.
112991

steel pipe.
112815
112811

(8) .
Loosen the clip and (9) move the air inlet duct (10) to
one side.
Pull the clip.
Remove the damper valve (see 12A, Fuel mixture,

Damper valve: Removal - Refitting ).
14A-48
ANTIPOLLUTION
14A
K9K, and 732
113475
114341
Remove the mounting bolts (11) from the injector rail

protector cover mounting bracket.
Position the (Ms. 583) on the exhaust gas cooler inlet and outlet hoses.
Remove the mounting bolts (12) from the exhaust
gas coolant circulation cover.
Move the exhaust gas coolant circulation cover to
one side.
Remove the seals on the exhaust gas coolant circulation cover.
Note:
Make preparations for coolant outflow.
112329
Remove:
- the lifting bracket mounting bolts (13) from the timing end,
- the lifting bracket on the timing end (14) ,
14A-49
ANTIPOLLUTION
14A
K9K, and 732

- the metal air inlet tube (15) ,
REFITTING
- the mounting bolts (16) from the rigid exhaust gas

recirculation pipe,
All the bearing faces on each removed part must be

carefully cleaned.
- the mounting bolts (17) from the exhaust gas recirculation unit assembly,
WARNING
- the exhaust gas recirculation unit assembly.
Take care not to damage the bearing faces to

prevent any risk of coolant leaks.

CONCERNED
WARNING
Always replace:
- the metal air inlet tube and its O-rings,
- the exhaust gas inlet pipe, its mounting bolts, its
seal and its snap-fit clamp,
- the seals of the cooler on its supports,
- the seals of the coolant circulation cover within
the intercooler,
- the seal between the downstream duct of the
cut-off valve and the intercooler support,
- the seal between the catalytic converter and the
turbocharger.
112326
At the workbench, remove:

- the bolt (18) mounting the intercooler on its two
supports,

CONCERNED
Refit the intercooler on its two supports fitted with
new seals.
- the intercooler,
- the snap-fit clamp (19) from the rigid exhaust gas
recirculation pipe,
WARNING
Ensure that the seals between the cooler and its

two supports are correctly positioned to avoid
any coolant leaks.
14A-50
ANTIPOLLUTION
14A
K9K, and 732

112326
Refit:
112329
- the mounting bolts to the cooler, without making

contact so that the cooler can move,
Refit:
- the exhaust gas recirculation unit assembly with its

cooler, onto the cylinder head.
- the new rigid exhaust gas recirculation pipe (21)

with a new seal,
- the bolts mounting the two intercooler supports on

the cylinder head.
Finger tighten the mounting bolts of the two intercooler supports.

bolts,
Adjust the intercooler in relation to its two supports.
WARNING
Tighten the mounting bolts of the intercooler on its

two supports until they make contact, in order to immobilise it.
Ensure that you do not constrain the rigid

exhaust gas recirculation pipe before fitting the
snap-fit clamp.
Remove the exhaust gas recirculation unit assembly

with its cooler.
Fit the new snap-fit clamp.
At the workbench, tighten to torque the bolts mounting the intercooler on its two supports (12 Nm) .
Tighten the rigid exhaust gas recirculation pipe

mounting bolts until they make contact.
Refit:
- the exhaust gas recirculation unit assembly with its
cooler, onto the cylinder head.
- the mounting bolts for the intercooler supports.
Tighten to torque the bolts mounting the two intercooler supports on the cylinder head (25 Nm) .
Adjust the rigid exhaust gas recirculation pipe in relation to the cooler support on the timing end.
Torque tighten the rigid exhaust gas recirculation
pipe mounting bolts (35 Nm) .
Refit:
- the metal air inlet tube,
- the lifting bracket on the timing end,
- the mounting bolts to the lifting bracket.
14A-51
ANTIPOLLUTION
14A
K9K, and 732

Tighten to torque the lifting bracket mounting
bolts (10 Nm) .
Refit:
WARNING
Clear any faults stored by the computer using the

diagnostic tool.
Ensure that the water inlet and outlet hoses of

the intercooler are correctly aligned so that they
are not kinked.
Fit the new seal to the exhaust gas coolant circulation cover.
Refit the mounting bolts on the exhaust gas coolant
circulation cover.
Tighten to torque the bolts mounting the two intercooler supports on the cylinder head (12 Nm) .
Remove the (Ms. 583) on the intercooler inlet and
outlet hoses.
Refit:
mounting bolts,
Tighten the clip.
Refit the mounting bolt to the stainless steel pipe.
Connect:
- the oil vapour rebreathing pipe on the rocker cover
side,
- the exhaust gas recirculation solenoid valve connector.
Refit:
Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).
14A-52
ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting
K9K, and 732
For removing and refitting the supports for the intercooler (see 14A, Emission control, Intercooler: Removal - Refitting ).
14A-53
14A
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting
14A
K9K, and 732
REFITTING

Mot. 1567

EGR duct clips.

All the bearing faces must be carefully cleaned.
CONCERNED
Tightening torquesm
mounting bolts of the
rigid exhaust gas recirculation pipe on the
manifold
35 Nm
Refit:
- the new rigid exhaust gas recirculation pipe with a
new seal,
bolts,
REMOVAL
Fit a new snap-fit clamp.

WARNING
Ensure that you do not squeeze the exhaust gas

pipe before fitting the snap-fit clamp.
Tighten the mounting bolts of the rigid exhaust gas

recirculation pipe on the manifold until they make
contact.

Remove:
Adjust the rigid exhaust gas recirculation pipe in relation to the cooler support on the timing end.
- the engine undertrays,
- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - refitting ).
Tighten to torque the mounting bolts of the rigid

exhaust gas recirculation pipe on the manifold
(35 Nm) .

CONCERNED

Refit:
- the catalytic converter (see 19B, Exhaust, Catalytic converter ),
113842
Remove:
- the mounting bolts (1) from the exhaust gas recirculation pipe,
- the snap-fit clamp (2) using the (Mot. 1567) ,
14A-54
ANTIPOLLUTION
14A
M9R, and 700
REMOVING THE EGR RIGID PIPE

BETWEEN THE EXHAUST MANIFOLD
AND THE EGR COOLER
Tightening torquesm
bolts securing the EGR
rigid pipe on the EGR
cooler
35 Nm

rigid pipe on the exhaust
manifold
35 Nm
bolt securing the EGR

rigid pipe on the cylinder
head
10 Nm

rigid pipe heat shield on
the cylinder head
10 Nm

rigid pipe heat shield on
the exhaust manifold
10 Nm
air filter unit outlet air

pipe clips
5.5 Nm

solenoid valve
25 Nm

cooler
25 Nm
positive terminal mounting nut
8 Nm

pipe clips
5.5 Nm
turbocharger pressure
sensor mounting nut
8 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm

Remove:
104343
Remove:
IMPORTANT
14A-55
ANTIPOLLUTION
14A
M9R, and 700
104246
113294
Disconnect the diesel temperature sensor connector

(7) .
Remove:
- the plenum chamber (see 19A, Cooling, Plenum
chamber: Removal - Refitting ).
114846
Disconnect:
115714
- the turbocharger pressure regulating hose (4) on

the air filter unit outlet pipe,
Disconnect the high pressure pump pressure regulator connector (8) .
- the oil vapour rebreathing hose (5) from the oil separator.
Detach the wiring harness from the high pressure

pump pressure regulator and the diesel temperature
sensor.
Move aside the turbocharger pressure regulating solenoid valve (6) .

Undo the clips on the air filter unit outlet air pipe.
Disconnect the air filter unit outlet air pipe.
14A-56
ANTIPOLLUTION
14A
M9R, and 700
113280
114478
Remove the EGR rigid pipe heat shield (11) .

CONCERNED
113295
Remove:
- the bolt (9) securing the EGR rigid pipe heat shield
on the exhaust manifold,
- the bolt (10) securing the EGR rigid pipe heat
shield on the cylinder head.
113295
Remove the bolt (12) securing the EGR rigid pipe on

the cylinder head.
14A-57
ANTIPOLLUTION
14A
M9R, and 700
113311
114477
Remove the bolts (13) securing the EGR rigid pipe

on the EGR cooler.
Remove the EGR rigid pipe (15) between the exhaust manifold and the EGR cooler.
REMOVING THE EGR RIGID PIPE

BETWEEN THE EGR SOLENOID VALVE
AND THE EGR COOLER
113281
Remove the bolts (14) securing the EGR rigid pipe

on the exhaust manifold.
14A-58
Remove:
ANTIPOLLUTION
14A
M9R, and 700
115585

114933
Remove:
- the clips (5) ,

102365
Remove:
112658

Remove:
(2) ,
14A-59
ANTIPOLLUTION
14A
M9R, and 700
115701
115702
Disconnect the turbocharger pressure sensor connector (8) .

damper valve end.
Remove the nut (9) securing the turbocharger pressure sensor.
Disconnect the intercooler outlet air pipe.
114860
115023
Remove the bolt (10) securing the intercooler outlet

air pipe on the cooling radiator.
intercooler end.
14A-60
Disconnect the alternator connector (13) .

Remove the positive terminal mounting nut (14) .
ANTIPOLLUTION
14A
M9R, and 700

CONCERNED

- the bolts securing the EGR rigid pipe on the exhaust manifold,
- the bolts securing the EGR rigid pipe on the EGR
cooler,
- the bolt securing the EGR rigid pipe on the cylinder
head.
Tighten to torque:
- the bolts securing the EGR rigid pipe on the
EGR cooler (35 Nm) ,
- the bolts securing the EGR rigid pipe on the exhaust manifold (35 Nm) ,
- the bolt securing the EGR rigid pipe on the cylinder head (10 Nm) .
Refit the EGR rigid pipe heat shield.
114037
Remove:
- the bolt securing the EGR rigid pipe heat shield on

the cylinder head,
- the EGR rigid pipe mounting bolts (15) between the

EGR solenoid valve and the EGR cooler,
- the bolt securing the EGR rigid pipe heat shield on

Tighten to torque:
- the EGR rigid pipe.
- the bolt securing the EGR rigid pipe heat shield

on the cylinder head (10 Nm) ,
REFITTING THE EGR RIGID PIPE

BETWEEN THE EXHAUST MANIFOLD
AND THE EGR COOLER
- the bolt securing the EGR rigid pipe heat shield

on the exhaust manifold (10 Nm) .
Connect:
- the high pressure pump pressure regulator connector,

Remove the EGR rigid pipe seals.
- the diesel fuel temperature sensor connector.
Clean:
Clip the wiring harness on the high pressure pump

pressure regulator and the diesel temperature sensor.
- the EGR rigid pipe seal faces if reusing,

- the EGR cooler seal face,
Connect the air filter unit outlet air pipe.
- the exhaust manifold seal face.
Torque tighten the air filter unit outlet air pipe

clips (5.5 Nm) .
Connect:
WARNING
- the oil vapour rebreathing hose onto the oil separator.

- the turbocharger pressure regulator hose on the air

inlet duct between the turbocharger and the air filter unit.

CONCERNED
Position the turbocharger pressure regulating solenoid valve.
Refit the EGR rigid pipe with new seals.
14A-61
ANTIPOLLUTION
14A
M9R, and 700

Refit:
- the plenum chamber (see 19A, Cooling, Plenum
chamber: Removal - Refitting ),
Refit the positive terminal mounting nut.
Tighten to torque the positive terminal mounting

nut (8 Nm) .
Connect:
- the alternator connector,
- the intercooler outlet air pipe.

Torque tighten the intercooler outlet air pipe clips

(5.5 Nm) .

Refit the bolt securing the intercooler outlet air pipe

on the cooling radiator.
Refit the turbocharger pressure sensor mounting
nut.
Tighten to torque the turbocharger pressure sensor mounting nut (8 Nm) .
REFITTING THE EGR RIGID PIPE

BETWEEN THE EGR SOLENOID VALVE
AND THE EGR COOLER
Connect the turbocharger pressure sensor connector.

Refit:
Remove the EGR rigid pipe seals.
Clean:
- the EGR rigid pipe seal faces if reusing,
Tighten to torque:
- the EGR cooler seal face,

Nm) ,
- the EGR solenoid valve seal face.

Nm) .
WARNING


Refit the clips.

CONCERNED

Refit the EGR rigid pipe with new seals.
Refit:

solenoid valve,
cooler.
Tighten to torque:
EGR solenoid valve (25 Nm) ,
EGR cooler (25 Nm) .
14A-62

ANTIPOLLUTION
M9R, and 700
Halogen headlight: Adjustment ).
14A-63
14A
STARTING - LOAD
General alternator information
16A
K4J K4M F4R K9K F9Q M9R

I - OPERATION
Engine
These vehicles are fitted with an alternator with internal

ventilation and a built-in regulator, plus a warning light
on the instrument panel, which operates as follows:
Alternator
Current
strength
VALEO : TG11 C018
- when the ignition is switched on, the warning light comes on,
VALEO : TG11 C040
- when the engine starts, the warning light goes out,
VALEO : TG11 C049
- if the warning light comes on while the engine is running, this indicates a battery charge fault.
VALEO : SG12 B078
110 A
VALEO : SG12 B081

F9Q
II - IDENTIFICATION
125 A
VALEO : SG15 B092
VALEO : SG15 B098
Engine
Alternator
Current
strength
BOSCH : LIE8 0 124 525

101
VALEO : TG11 C011

K4J and
K4M
150 A
BOSCH : 0 124 525 044
110 A
VALEO : TG11 C027
BOSCH : LIE8 0 124 525
028
VALEO : SG15 L027
155A
BOSCH : LIE6 0 124 0AC

473B
120 A
VALEO : TG15 C059
150 A
MELCO : 8GM A004 TJ0

281
210 A
150 A
VALEO : TG11 C040

M9R
110 A
VALEO : TG11 C049
F4R
VALEO : SG12 B092
125 A
VALEO : SG12 B098
VALEO : TG11 C041
Note:
110 A
There is a configuration in the Protection and Switching Unit for the alternator fitted onto the vehicle
(see 87G, Engine compartment connection unit,
Protection and Switching Unit ).
VALEO : TG11 C034

BOSCH : LIE8 0 124 525
082
150 A
K9K
BOSCH : LIE8 0 124 525

081
581
210 A
481
16A-1
STARTING - LOAD
Alternator: Removal - Refitting
16A
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL

- the side reinforcements (1) .

Disconnect:
- the electrical connections.
Remove the alternator harness.
Remove:
- the front wheels,
102008
Remove:
Note:
When fitting the safety strap, take care:
- the mounting nut and bolts (2) from the half sub-frame,

using the safety belt.
16A-2
STARTING - LOAD
16A
F4R, and 770 or 771 or 776
109537
19703
Disconnect:
Note:
- the pressostat connector (3) ,
Take care not to constrain the compressor air

conditioning pipes during this operation.
- the air conditioning compressor connector (4) ,

Move the electric wiring harness to one side.

bolts (6) .
Remove the air conditioning compressor and attach
it using a safety belt.
111851
Remove:
- the air conditioning compressor bracket mounting
bolts (5) ,
- the air conditioning compressor bracket.
16A-3
STARTING - LOAD
16A
F4R, and 770 or 771 or 776
REFITTING

CONCERNED
19703
18987
WARNING
Do not damage the cooling unit vanes (radiator,
condenser, etc.) during handling.
Refit the rings (8) using pliers or a vice.

CONCERNED
Note:
Refit:
To ease alternator removal, move the cooling

system towards the front slightly.
- the alternator,
- the alternator mounting bolts.
Remove:

Nm) .
- the mounting bolts (7) from the alternator,

- the alternator.

Refit:
- The air conditioning compressor,
- the air conditioning compressor mounting bolts.
Refit:
- the air conditioning compressor bracket,
- the air conditioning compressor bracket mounting
bolts.
Connect:
- the pressostat connector,
- the air conditioning compressor connector.
16A-4
STARTING - LOAD
F4R, and 770 or 771 or 776
of engine, Accessories belt ).
Apply a drop of LOCTITE - FRENEBLOC on the
sub-frame mounting bolts.
Refit:
- the side reinforcements.
Tighten to torque:
Refit:
- the front wheels.
Connect:
- the electrical connections,
16A-5
16A
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 732
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL

REMOVAL PREPARATION OPERATION

Disconnect:
Remove:
- the front wheels,
102008
Remove:
Note:
- the mounting nuts and bolts (2) from the half subframe,

16A-6
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 732
19703
109537
Disconnect:
Note:


bolts (5) .

16A-7
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 732

OPERATION FOR REMOVAL OF PART
CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING
- the free pulley support mounting bolts (6) ,

- the free pulley support.
Note:
Remove:
- the alternator.
16A-8
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 732
REFITTING
BASIC HEATING
Refit:
- the free pulley support,
- the free pulley support mounting bolts.

Refit:
Tighten to torque:
18987
Refit:

CONCERNED

Refit:
- the front wheels.
- the alternator,

Nm) .
Connect:

Refit:
Connect:
16A-9
STARTING - LOAD
16A
F9Q, and 804 or 812
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL


Disconnect:
Remove:
- the front wheels,
102008
Remove:
Note:
- the mounting nut and bolts (2) from the half sub-frame,

16A-10
STARTING - LOAD
16A
F9Q, and 804 or 812
109537
19703
Disconnect:
Note:


bolts (5) .
16A-11
STARTING - LOAD
16A
F9Q, and 804 or 812
REFITTING

CONCERNED
19703
18987
WARNING

CONCERNED
Note:
Refit:

- the alternator,
Remove:

Nm) .

- the alternator.

Refit:
Connect:
16A-12
STARTING - LOAD
F9Q, and 804 or 812
Refit:
Tighten to torque:
Refit:
- the front wheels.
Connect:
16A-13
16A
STARTING - LOAD
16A
K4J, and 730
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL


Disconnect:
Remove:
- the front wheels,
102008
Remove:
Note:
- the half sub-frame mounting nuts and bolts (2) ,

16A-14
STARTING - LOAD
16A
K4J, and 730
19703
109537
Disconnect:
Note:


bolts (5) .

16A-15
STARTING - LOAD
16A
K4J, and 730

CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING

Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator mounting bolts (7) ,
- the alternator.
16A-16
STARTING - LOAD
16A
K4J, and 730
REFITTING
BASIC HEATING
Refit:

Apply a drop of LOCTITE - FRENEBLOC on the half
Refit:
Tighten to torque:
18987
Refit:

CONCERNED

Refit:
- the front wheels.
- the alternator,

Nm) .
Connect:

Refit:
Connect:
16A-17
STARTING - LOAD
16A
K4M, and 761 or 782
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL


Disconnect:
Move the alternator harness to one side.
Remove:
- the front wheels,
102008
Remove:
Note:
- the half sub-frame mounting nuts and bolts (2) ,

16A-18
STARTING - LOAD
16A
K4M, and 761 or 782
19703
109537
Disconnect:
Note:


bolts (5) .

16A-19
STARTING - LOAD
16A
K4M, and 761 or 782

CONCERNED
BASIC HEATING
19703
111079
Remove:
WARNING

Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator.
16A-20
STARTING - LOAD
16A
K4M, and 761 or 782
REFITTING
BASIC HEATING
Refit:

Apply a drop of LOCTITE - FRENEBLOC on the half
Refit:
Tighten to torque:
18987
Refit:

CONCERNED

Refit:
- the front wheels.
- the alternator,

Nm) .
Connect:

Refit:
Connect:
16A-21
STARTING - LOAD
16A
M9R, and 700
Tightening torquesm
alternator mounting
bolts
25 Nm
positive terminal mounting nut
8 Nm
air inlet pipe clip on the

damper valve
5.5 Nm
air inlet pipe clip on the

intercooler
5.5 Nm
turbocharger pressure
sensor mounting nut
8 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
right-hand side reinforcement mounting bolts
21 Nm
101212
Remove:
- the right-hand side reinforcement mounting bolts,
- the right-hand side reinforcement (1) ,
REMOVAL
I - REMOVAL PREPARATION STAGE

Remove:
114933
16A-22
STARTING - LOAD
16A
M9R, and 700
102365
Remove:
112658
Remove:
(3) ,
114409
Disconnect the turbocharging pressure sensor connector (9) .

115585
Remove:
(4) .
- the turbocharging pressure sensor mounting nut,

- the damper valve stay turbocharger pressure sensor.
Undo the air inlet pipe clip on the damper valve.
Remove:
- the clips (6) ,
16A-23
STARTING - LOAD
16A
M9R, and 700

CONCERNED
114649
Undo the air inlet pipe clip (10) on the intercooler.

114860
Remove:
Disconnect the alternator connector (12) .
- the air inlet clip mounting bolt (11) on the cooling

radiator,
Remove the positive terminal mounting nut (13) .

Remove the cooling assembly from its housing and
move the assembly forwards.
114859
Remove:
- the alternator.
16A-24
STARTING - LOAD
M9R, and 700
REFITTING
18987
Refit the rings (15) using pliers or a vice to facilitate

fitting.
CONCERNED
Refit:
- the alternator,
Tighten to torque the alternator mounting bolts
(25 Nm) .
Refit the positive terminal mounting nut.
Tighten to torque the positive terminal mounting
nut (8 Nm) .
Connect the alternator connector.
16A-25
16A
STARTING - LOAD
16A
M9R, and 700

- the right-hand side reinforcement mounting bolts.
Refit the cooling assembly into its housing.
Tighten to torque the right-hand side reinforcement mounting bolts (21 Nm) .
Refit the air inlet duct.
Refit:
Tighten to torque:
- the air inlet pipe clip on the damper valve (5.5
Nm) ,
- the air inlet pipe clip on the intercooler (5.5 Nm)
.
Tighten the air inlet duct mounting bolt on the cooling radiator.
Refit:
- the turbocharger pressure sensor on the damper
valve stay,
- the turbocharger pressure sensor mounting nut.
Tighten to torque the turbocharger pressure sensor mounting nut (8 Nm) .
Connect the turbocharging pressure sensor connector.
Refit:
Tighten to torque:
Nm) ,
Nm) .
Refit the clips.
Refit:
Refit:
- the right-hand side reinforcement,
16A-26

STARTING - LOAD
Starter: Identification
16A
F4R, and 770 or 771 or 776 F9Q, and 804 or 812 K4J, and 730 K4M, and 761 or 782 K9K, and 722 or 728
Engine
Starter motor
K4J and K4M
VALEO D7E27
K9K
MITSUBISHI
F9Q and F4R
VALEO D7R49
16A-27
STARTING - LOAD
16A
F4R, and 770 or 771 K4J, and 730 K4M, and 761 or 782
Disconnect:
- the oil level sensor connector,
Tightening torquesm
starter mounting bolts
bolts
- the starter electrical connections.
44 Nm
4 Nm

CONCERNED
REMOVAL
Remove:
- the scuttle panel grilles.
14853
Remove:
- the starter mounting bolts (2) ,
- the starter.
REFITTING
104343
Remove:
Check that the centring dowel is in place.
- the two air filter access panel mounting bolts (1) ,

- the air filter access panel.

CONCERNED
Refit the starter.
K4J
Tighten to torque the starter mounting bolts (44

Nm) .
Remove the air resonator.

F4R K4M
Remove the air filter outlet duct.

(4 Nm) .
16A-28
STARTING - LOAD
16A
K9K, and 722
Tightening torquesm
44 Nm
wheel bolts
130 Nm

bolts
4 Nm
REMOVAL
104246
Remove:
Remove:
1
4
2
6
104175
Remove:
- catalytic converter stay (4) ,
- catalytic converter stay (5) on the gearbox,
104343
- the catalytic converter (6) (see 19B, Exhaust, Catalytic converter ).
Remove:
- the scuttle panel mounting bolts (2) .
16A-29
STARTING - LOAD
K9K, and 722
CONCERNED
102268
Disconnect the starter electrical connections.

Remove:
- the starter mountings (7) ,
- the starter (8) .
REFITTING
CONCERNED
Refit the starter.
Nm) .
Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ).
Tighten to torque:
16A-30
16A
STARTING - LOAD
16A
F9Q, and 812

- the scuttle panel mounting bolts (2) ,
Tightening torquesm
44 Nm

bolts
wheel bolts
4 Nm

130 Nm

- the battery tray,
REMOVAL
- the air hose between the air filter and turbocharger

duct.

Remove the scuttle panel grille (see MR 371 Bodywork, Exterior protection, Scuttle panel grille
).
102421
Remove:
104343
- the air hose (3) and gently separate the hose (4) ,
104246
Remove:
16A-31
STARTING - LOAD
16A
F9Q, and 812
101120
102427
Remove:
Remove:
- the stay (5) ,
- the catalytic converter (6) mounting plate on the

gearbox,
- the starter.
- the catalytic converter (7) (see 19B, Exhaust, Catalytic converter ).
REFITTING
Nm) .

CONCERNED

WARNING
Carry out the necessary programming (80A, Battery: Removal - Refitting).
Tighten to torque:
16A-32
STARTING - LOAD
16A
F4R, and 776

CONCERNED
Tightening torquesm
38 Nm
catalytic converter
downstream stay nut
21 Nm
heat shield mountings
8.5 Nm
REMOVAL
Removal of the starter requires the engine to be removed (see 10A, Engine and peripherals, Engine/
Gearbox ).

Catalytic converter ).
21921
Remove:
- the starter.
REFITTING
2
1
4
106249
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream stay (2) .
21935
Check that the centring dowel (4) is in place.
16A-33
STARTING - LOAD
F4R, and 776
CONCERNED
Refit the starter.
Nm) .
Connect the starter electrical connections.
Tighten to torque:
- the catalytic converter downstream stay nut (21
Nm) ,
- the heat shield mountings (8.5 Nm) .
Refit the battery (see 80A, Battery, Battery: Removal - Refitting ).
16A-34
16A
STARTING - LOAD
16A
K9K, and 728
Tightening torquesm
44 Nm

bolts
4 Nm
REMOVAL
106203
Disconnect the gearbox earth.
106201
1
Disconnect the oil level sensor.
106205
Disconnect:
- the starter electrical connections (1) ,
- the rail pressure sensor (2) .
16A-35
STARTING - LOAD
K9K, and 728
CONCERNED
106191
Remove:
- the starter mountings,
- the starter.
REFITTING

CONCERNED
Refit the starter.
Nm) .

(4 Nm) .
16A-36
16A
STARTING - LOAD
16A
F9Q, and 804
Tightening torquesm
44 Nm

bolts
4 Nm
wheel bolts
130 Nm
REMOVAL

Remove the scuttle panel grille (see MR 371 Bodywork, Exterior protection, Scuttle panel grille
).
Remove:
111865
Remove the turbocharger oil return pipe (6) .

CONCERNED

- the battery tray,
- the air hose between the air filter and turbocharger
duct.
Remove the catalytic pre-converter. (see 19B; Exhaust, Catalytic pre-converter: Removal - Refitting ).
7
4
5
111868

Remove the starter mounting bolts (7) .
Remove the starter.
111860
Remove the turbocharger air duct.
16A-37
STARTING - LOAD
F9Q, and 804
REFITTING
CONCERNED
Refit the starter.
Nm) .
Tighten to torque:
16A-38
16A
STARTING - LOAD
16A
K9K, and 732
Tightening torquesm
44 Nm
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment; underbody lift ).
Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
113863
106201
Disconnect:
- the oil pressure sensor connector (1) ,
- the oil level sensor connector (2) ,
16A-39
STARTING - LOAD
16A
K9K, and 732
REFITTING
Check that the centring dowel is in place and ensure
it is positioned correctly.
CONCERNED
Refit:
- the starter,
- the starter mounting bolts.
Nm) .
Refit the starter nuts.
106205
Remove the starter nuts (3) .
Connect:
Disconnect the injector rail pressure sensor connector.
- injector rail pressure sensor connector,
Move the wiring harness against the cylinder block.
- the oil level sensor connector,

- the oil pressure sensor connector.

CONCERNED

106191
Remove:
- the starter mounting bolts (4) .
- the starter.
16A-40
STARTING - LOAD
16A
M9R, and 700
Equipment required
filling station
Tightening torquesm
44 Nm
starter base mounting

nut
8 Nm
solenoid excitation
mounting nut
5 Nm
mounting bolt of the air

conditioning
pipe
between the air dehydration canister and air
conditioning compressor
8 Nm

bolts
21 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
112658
Remove:
(1) ,
REMOVAL
Remove:
- the front bumper (see MR 371 Bodywork, 55A Exterior protection, Front bumper ).
115585

(2) .
Remove:
- the clips (4) ,
16A-41
STARTING - LOAD
16A
M9R, and 700
114933
112659
Disconnect:
Unclip:
- the injection computer connector wiring harness (9)
,
harness,
102365
- the air filter unit turbocharger regulation solenoid

valve,
Remove:
- the wiring harness.
Remove:

- the wiring harness mounting nut (11) .
mounting.
16A-42
STARTING - LOAD
16A
M9R, and 700

CONCERNED
109537
Remove the mounting bolt from the air conditioning

pipe (12) between the air dehydration canister and
air conditioning compressor, on the air conditioning
compressor side.
114628
Remove:
- the mounting nut (13) from the starter base,
- the mounting nut (14) from the solenoid excitation.
Note:
Plugs must be fitted to the pipe and the compressor to prevent moisture from entering the system.
Remove the air conditioning pipe between the air
dehydration canister and air conditioning compressor, on the air conditioning compressor side.
114998
Remove the earth wire mounting bolt (15) on the

starter.
Move the starter wiring harness to one side.
16A-43
STARTING - LOAD
M9R, and 700
113312
Remove:
- the starter mounting bolts (16) .
- the starter.
REFITTING
CONCERNED
Refit:
- the starter,
- the starter mounting bolts
Nm) .
Fit the starter wiring harness.
Refit:
- the starter base mounting nut,
- the solenoid excitation mounting nut,
- the earth wire mounting bolt.
Tighten to torque:
- the starter base mounting nut (8 Nm) ,
- the solenoid excitation mounting nut (5 Nm) .
16A-44
16A
STARTING - LOAD
16A
M9R, and 700

Refit:
Refit the clips.
- the air conditioning pipe between the air dehydration canister and air conditioning compressor, on
the air conditioning compressor side.
- the mounting bolt to the air conditioning pipe

between the air dehydration canister and air conditioning compressor, on the air conditioning compressor side.
Tighten to torque the mounting bolt of the air conditioning pipe between the air dehydration canister and air conditioning compressor (8 Nm) .

Refit:
Refit:
Refit the battery tray with the injection computer

mounting.
Refit:

(21 Nm) .
Fit:
- the wiring harness,
- the air filter unit turbocharger regulation solenoid
valve,
harness,
- the injection computer connector wiring harness.
Connect:
Refit:
Tighten to torque:
Nm) ,
Nm) .
16A-45
STARTING - LOAD
Alternator pulley: Removal - Refitting
16A
K4J or K4M or K9K, and AIR CONDITIONING

Mot. 1732
Kit for replacing alternator freewheels.
Tightening torquesm
alternator decoupling
pulley
80 Nm

- the tensioning roller,
- the tensioning roller mounting bolts.
essential equipment
110266
- tool box for removing and refitting the alternator pulley

(Mot. 1732)
Hold the alternator in a vice.

CONCERNED
110276
It is essential to replace an alternator decoupling

pulley with a decoupling pulley.
110267
Fit the hexagon socket (1) (from the tool box for removing and refitting the alternator pulley (Mot. 1732)
) into the alternator pulley.
REMOVAL
Remove the alternator (see 16A, Starting - Charging, Alternator: Removal - refitting ).
16A-46
STARTING - LOAD
16A
110268
110270
Fit the drive (2) from the tool box for removing and
refitting the alternator pulley (Mot. 1732) (corresponding to the alternator mark) into the hexagon socket
(3) .
Hold the hexagon socket (6) using an open-jawed

spanner (7) .
Loosen the decoupling pulley (8) using a ratchet (9)
(turning the ratchet clockwise).
Remove the decoupling pulley.
110269
Position the drive adapter (4) in socket (5) .
16A-47
STARTING - LOAD
16A
REFITTING
CONCERNED
110269
Position:
110267
Screw the new decoupling pulley onto the alternator

rotor.
- the hexagon socket (10) in the alternator,

- the drive (11) (corresponding to the socket in the
alternator rotor),
- the drive adapter (12) on the adapter (11) .
Note:
Check that the torque wrench is capable of tightening in a leftwards direction.
16A-48
STARTING - LOAD
110266
Tighten to torque the alternator decoupling pulley

(80 Nm) using a torque wrench.
Refit the alternator to the vehicle (see 16A, Starting
- Charging, Alternator: Removal - Refitting ).
16A-49
16A
IGNITION
17A
K4J, and 730 K4M, and 761 or 782 F4R, and 770 or 771 or 776
REMOVAL
Tightening torquesm
ignition coil mounting
bolts
15 Nm

bolts
4 Nm
K4J, and 730 K4M, and 761 or 782 F4R, and

770 or 771
The power module is integrated into the injection computer. The ignition system uses the same sensors as
the injection system.
2
101490
14851
There are four ignition coils, and they are mounted

directly onto the spark plug by a bolt on the rocker
cover.

Disconnect:
- the ignition coil connectors (1) .
The coils are in supplied in series two by two by the

injection computer:
Remove the coil mounting bolts (2) .
- track C M4 for cylinders 1 and 4,

- track C M3 for cylinders 2 and 3.
17A-1
IGNITION
F4R, and 776
106589
Remove the coil mounting bolts (3) .
Note:
Be sure to replace any damaged connectors.
REFITTING
17A-2
17A
IGNITION
17A
106443
Apply to the four ignition coils a bead (4) of FLUORINE GREASE (PART NO. 82 00 168 855) , 2 mm in
diameter around the inner edge of the high-tension
cap.
If necessary, replace the coil O-rings.
Tighten to torque:
- the ignition coil mounting bolts (15 Nm) ,
17A-3
IGNITION
Spark plugs
K4J K4M F4R
Ele. 1382
Spark plug spanner

Tightening torques
Spark plugs
25 to 30 Nm
Remove:
- the ignition coils (see 17A, Ignition, Coils ),
- the spark plugs using the (Ele. 1382).
Engines
Brand
Type
EYQUEM
RFN58LZ
CHAMPION
RC87YCL
K4J and K4M

Flat seat with seal
Gap: 0.95 ( 0.05 mm)
F4R 770/771
CHAMPION
RC87YCL
Flat seat with seal

Gap: 0.90 ( 0.05 mm)
F4R 776
NGK
PFR6G-9
Flat seat with seal

Gap: 0.90 (+0 / -0.1 mm)
17A-4
17A
PETROL INJECTION
Fuel injection parts description
17B
J84, and F4R, and 770 or 771 or 776 J84, and K4M, and 761 or 782 J84, and K4J, and 730
K4J, and 730
104539
(1)
Fuel vapour recirculation solenoid valve
(2)
(3)
Ignition coil
(4)
(5)
(6)
Injection computer
(7)
(8)
(9)
Pinking sensor
(10)
Injector rail and injectors
17B-1
PETROL INJECTION
17B
K4M, and 761 or 782
104540
(1)
(5)

valve
(2)
(3)
Ignition coil
(6)
Camshaft position sensor
(9)
(10)
Injection computer
(11)
(7)
(8)
Pinking sensor
(4)
(12)
17B-2
PETROL INJECTION
17B
F4R, and 770 or 771
104541
(1)
(2)
(3)
Ignition coil
(4)
(5)

valve
(6)
Pinking sensor
(7)
(8)
(9)
(10)
(11)
Injection computer
17B-3
PETROL INJECTION
17B
F4R, and 776
106078
(1)
Ignition coil
(2)
(3)
(4)
Injection computer
(5)
(6)
(7)
(8)
Pinking sensor
(9)
(10)
(11)
(12)
Electric coolant pump
K4J, and 730
101101
17B-4
PETROL INJECTION
17B
(1)
(2)
(3)
Ignition coils
(4)
101105
(7)
101800
(5)
101498
101811
(6)
Injection computer
17B-5
(8)
(9)
Pinking sensor
PETROL INJECTION
17B
101493
(10)
Injector rail
(10)
Injectors
102144
(12)
101798
102204
(11)
(13)
17B-6
Upstream oxygen sensor
PETROL INJECTION
17B
J84, and K4M, and 761 or 782
101501
(14)
Downstream oxygen sensor
(15)
Catalytic converter
101796
(1)
(3)
(11)
(4)
Ignition coils
102483
(16)
Fuel vapour recirculation absorber
101809
17B-7
PETROL INJECTION
17B
(10)
Pinking sensor
(2)

valve
(5)
Camshaft position sensor
(9)
101105
(8)
102735
(6)
101810
101811
(7)
Injection computer
17B-8
(12)
Injector rail
(12)
Injectors
PETROL INJECTION
17B
102144
(13)
101798
(15)
101501
102204
(14)
17B-9
(16)
(17)
Catalytic converter
PETROL INJECTION
17B
(3)
Ignition coils
(4)
102483
(18)
102732
(5)

valve
(6)
Pinking sensor
F4R, and 770 or 771
102735
102724
(1)
(2)
17B-10
(7)
PETROL INJECTION
17B
101105
(8)
102730
(10)
Injector rail
(10)
Injectors
102733
(9)
102204

(12)
17B-11
PETROL INJECTION
17B
102485
(13)
106278
(3)
F4R, and 776
106787
(1)
Ignition coils
(2)
101811
(4)
17B-12
Injection computer
PETROL INJECTION
17B
106269
(7)
Injector rail
(7)
Injectors
101105
(5)
101809
(8)
106633
(6)
17B-13
Pinking sensor
PETROL INJECTION
17B
102483
(13)
102204
(15)
106244
(16)
102485
(14)
17B-14
PETROL INJECTION
21926
(17)
17B-15
17B
PETROL INJECTION
Oxygen sensors: Removal - Refitting
17B
J84, and F4R, and 770 or 771 J84, and K4M, and 761 or 782 J84, and K4J, and 730
II - DOWNSTREAM OXYGEN SENSOR

Mot. 1495-01
22 mm socket for
Tightening torquesm
oxygen sensors
45 Nm
REMOVAL
I - UPSTREAM OXYGEN SENSORS
101501
Remove the sensor.
REFITTING
Tighten to torque the oxygen sensors (45 Nm)
using a 24 mm fork socket for the downstream oxygen sensor and using tool (Mot. 1495-01) for the
upstream oxygen sensor.
101798
Remove the sensor using tool (Mot. 1495-01).
17B-16
PETROL INJECTION
Oxygen sensors: Removal - Refitting
17B
J84, and F4R, and 776

II - DOWNSTREAM OXYGEN SENSOR

Mot. 1495-01
22 mm socket for
Tightening torquesm
oxygen sensors
34 Nm
REMOVAL
I - UPSTREAM OXYGEN SENSORS
1
21926

Disconnect the oxygen sensor connector.
Remove oxygen sensor (2) using tool (Mot. 149501).
REFITTING
106244
Remove the engine cover.

Disconnect the oxygen sensor connector.
Remove oxygen sensor (1) using tool (Mot. 149501).
17B-17

Tighten to torque the oxygen sensors (34 Nm)
using a 24 mm fork socket for the downstream oxygen sensor and using tool (Mot. 1495-01) for the
upstream oxygen sensor.
PETROL INJECTION
Accelerator pedal potentiometer: Removal - Refitting
17B
REMOVAL
Tightening torquesm
bolts
4 Nm
The accelerator pedal potentiometer is incorporated in

the accelerator pedal. Its replacement therefore requires replacement of the pedal.
There are two types of pedal: with or without kickdown point .
Vehicles equipped with cruise control/speed limiter
have an accelerator pedal with a kickdown point at the
end of their travel.
This kickdown point is used for exiting the speed limiter
function if the driver has to increase his speed.
Note:
A pedal fitted with a kickdown point may be fitted in
place of a pedal without a kickdown point. Fitting a
pedal without a kickdown point in place of a pedal
with a kickdown point is not permitted.
102204
Disconnect:
- the accelerator pedal connector.
Remove:
- the pedal mounting bolts,
- the pedal.
REFITTING
(4 Nm) .
17B-18
PETROL INJECTION
17B
J84, and F4R, and 770 or 776 J84, and K4M, and 782 J84, and K4J, and 730
Equipment required
F4R, and 770 F4R, and 776
diagnostic tool
K4J, and 730 K4M, and 782
1
102485
Program the flywheel target after replacing the

speed and position sensor (1) or the flywheel.
102144

In third gear, accelerate twice in succession to 4000

rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, during
deceleration under no load and the injection cut out,
the computer authorises injection again.
Use the diagnostic tool (CLIP) to check that this
programming has been correctly completed ET089:
Flywheel target programming .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is working correctly.
17B-19
PETROL INJECTION
J84, and F4R, and 771 J84, and K4M, and 761
Equipment required
diagnostic tool
102144

In third gear, decelerate twice in succession from
4000 rpm to the power take-up speed.
Note:
Do not shift the gear lever to D (Automatic
transmission versions).
Power take-up speed is the moment when, during
deceleration under no load and the injection cut out,
Use the diagnostic tool (CLIP) to check that this
programming has been correctly completed ET089:
Flywheel target programming .
Check that the vehicle is working correctly.
17B-20
17B
PETROL INJECTION
Petrol injection computer: Removal - Refitting
17B
Equipment required
diagnostic tool
Tightening torquesm

bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
K4J, and 730
101822
Remove the battery.

Remove:

Disconnect the electric wiring harnesses from the
battery tray.
102107

Remove:
- the bolts securing the computer to the mounting,
- the computer.
17B-21
PETROL INJECTION
Petrol injection computer: Removal - Refitting
17B
REFITTING
Tighten to torque:
- the battery tray mounting bolts (21 Nm) ,
- the battery tray mounting bolts (4 Nm) .
WARNING
Note:
101811
Remove the injection computer and its mounting (5)
When the ignition is switched on, the motorised

throttle valve should go through a cycle of programming for its minimum and maximum positions.
Using the diagnostic tool (CLIP), check that programming has been carried out correctly ET051:
Throttle valve programming .
Perform flywheel target programming during a road
test.
The power take-up point is the moment when under
deceleration with no load and the injection cut off,
Using the diagnostic tool (CLIP), check that programming has been carried out correctly ET089:
Engine flywheel target programming .
Check that the vehicle is functioning correctly.
101890
Remove the computer mounting bolts.
17B-22
PETROL INJECTION
17B
The S 3000 injection system manages the lighting of
three warning lights and the display of warning messages according to the severity of the faults detected,
with the aim of informing the customer and directing
fault finding.
The injection computer controls the lighting of the warning lights and message displays on the instrument panel. These warning lights are lit during the starting
phase, in the event of an injection fault or engine overheating.
The signals to light up the warning lights reach the instrument panel via the multiplex network.
5 - When a fault causing excessive exhaust gas

pollution levels is detected
The on board diagnostic indicator light depicting an
engine lights up:
- flashing in the event of a fault which might cause
destruction of the catalytic converter (destructive misfires). In this case the vehicle must be stopped immediately.
- continuously in the event that depollution standards have not been adhered to (polluting engine
misfires, catalytic converter fault, oxygen sensor fault,
inconsistency between the oxygen sensors and fuel
vapour absorber fault).
WARNING LIGHT OPERATING PRINCIPLE

1 - During the starting phase, press the starter
button ( start )
The on board diagnostic indicator light comes on
for approximately 3 seconds , then goes out.
2 - When there is an injection fault (level 1)
The check injection message lights up, followed by
the service warning light. This means a reduced level of operation and a limited safety level. Repairs
should be carried out as soon as possible.
These faults are linked to:
- the motorised throttle valve,
- the accelerator pedal potentiometer,
- the inlet pressure sensor,
- the computer,
- the actuator supply,
- the computer supply.
3 - When there is a severe injection fault (level 2)
The red symbol depicting an engine and the stop
message (display with matrix only) appears with the
faulty injection text message followed by the
stop warning light and a buzzer.
4 - When the engine is overheating
The engine temperature fault symbol (display with matrix only) lights up with the engine overheating text
message followed by the stop warning light and a
buzzer. In this case the vehicle must be stopped immediately.
17B-23
PETROL INJECTION
Immobiliser function
This vehicle is equipped with an immobiliser which involves a specific method for replacing the computer.
REPLACING AN INJECTION COMPUTER
To programme the immobiliser code (see 82A, Engine immobiliser, Programming ).
WARNING
- The injection computer retains its immobiliser
code for life.
- It is forbidden to perform tests with computers
borrowed from the Parts Department or from
another car which must then be returned.
- These computers cannot be recoded.
17B-24
17B
PETROL INJECTION
Throttle valve: Operating
17B
I - THROTTLE VALVE
The throttle valve ensures that idle speed regulation
and engine air intake modulation are performed correctly. It is composed of an electric motor and two
throttle position potentiometers.
When the engine is idling, the throttle position is regulated according to the idle speed setpoint. This setpoint
takes into account the major power consumers (air
conditioning) and operating conditions (air temperature
and coolant temperature).
according to the position of the accelerator. Therefore,

the maximum engine speed under full load or in neutral
is 2500 rpm .
4 - Pedal information mode
If the signal from the inlet manifold vacuum is lost, opening of the throttle valve is directly proportional to pressure on the accelerator pedal.
When the driver depresses the accelerator pedal, their

request is translated into an angle of throttle opening.
However, to improve driving pleasure, the throttle opening is not directly proportional to the drivers request.
To eliminate bucking, facilitate gear changes and perform the safety functions, the throttle valve modulates
the engine torque.
II - THROTTLE VALVE DEFECT MODES
There are four types of defect mode for the throttle valve.
1 - Reduced performance mode
This mode covers electrical faults for which there is a
viable backup solution for the injection system (loss of
one of the two tracks on the pedal potentiometer or the
throttle valve). This mode limits acceleration and restricts maximum throttle opening (maximum speed of 56
mph (90 km/h) (manual gearbox) and 62 mph (100
km/h) (automatic transmission).
2 - Loss of driver intervention mode
This mode is also known as electrical defect mode
. This mode is applied when the accelerator pedal signal disappears completely, but the injection computer
still controls the intake of air to the engine (automatic
throttle control is still operational). In this mode, the injection computer imposes a set accelerator pedal position for each gearbox ratio and imposes the idle speed
when the brake pedal is depressed. In this case the
maximum engine speed in neutral is 2500 rpm .
3 - Mechanical limp home mode
This mode covers faults resulting in loss of automatic
throttle control (i.e. it is impossible to operate the throttle). In this case, the throttle is returned to its mechanical rest position, the injection computer limits the
engine speed by cutting out the injection and limits torque by cutting out the cylinders (ignition and injection)
17B-25
Note:
Each of these modes results in the injection fault
warning light on the instrument panel coming on.
PETROL INJECTION
Special notes on the system (when driving)
17B
Equipment required
Note:
diagnostic tool
All electrical faults which result in exceeding the

pollution limit cause the OBD warning light to come
on.
I - INTRODUCTION
This vehicle is equipped with an On Board
Diagnostic system (OBD).
III - OBD SYSTEM OPERATIONAL FAULT FINDING

PROCEDURES
When a fault causing excessive exhaust gas pollution

is detected, a warning light on the instrument panel lights up (OBD warning light).
The operational fault finding procedures used for OBD

are:
This computer fault finding program operates as follows:

Only engine misfiring is the subject of continuous fault
finding. The other emission control components are
tested once while driving (i.e. fault finding is not continuous). However, these test sequences are not always
performed. The vehicle must be driven under certain
conditions for the test sequences to be carried out:
- misfiring which damages the catalytic converter fault

finding,
- pollutant misfiring fault finding,
- upstream oxygen sensor fault finding,
- catalytic converter fault finding.
Note:
Fault finding of misfiring takes precedence over all
other fault finding. It is performed practically continuously as soon as the necessary driving conditions are reached.
- temperature conditions,
- speed conditions (threshold, stability, etc.),
- timed starting period,
- engine conditions (inlet manifold vacuum, engine
speed, throttle angle, etc.).
WARNING
At the end of each test, read the result on the diagnostic tool (CLIP) before switching off the ignition. Switching off the ignition will lead to the results
being misinterpreted.
The OBD management program supplements the management of conventional electrical faults. To meet this
standard the requirements are:
- making the OBD warning light come on or flash,
IV - FAULTS CAUSING ON BOARD FAULT FINDING

WARNING LIGHT TO LIGHT UP
- storing OBD faults.
1 - Electrical fault
II - IMPLICATIONS FOR FAULT FINDING AND

REPAIR
Due to the complexity of the system, it is essential to
question the customer about the conditions which led
to the warning light coming on. This information will
enable faults to be found more quickly.
To prevent the OBD warning light from coming on once
the vehicle has been returned to the customer, after
any repairs (replacing the catalytic converter, oxygen
sensor, etc.), it is essential to confirm the repair by
carrying out a road test, observing the driving conditions specific to each component. This is because certain faults only appear while driving, when the
adaptives have been programmed.
Warning light is constantly lit after fault has been detected several times (depending on the component).
2 - Rate of combustion misfiring which can destroy
the catalytic converter
Immediate illumination and flashing of the warning light.
3 - Catalytic converter or oxygen sensor fault,
polluting combustion misfiring
Light comes on continuously after a fault is detected
three times consecutively.
17B-26
PETROL INJECTION
Special notes on the system (when driving)
WARNING
Fault finding on the catalytic converter and the upstream oxygen sensor is sequential and takes place:
- once when driving (they last several seconds per
test),
- only under certain specific driving conditions.
Under certain driving conditions (for example, traffic
jams), certain functions may not be diagnosed.
V - MANAGEMENT OF THE ONBOARD

DIAGNOSTIC WARNING LIGHT (OBD)
1 - Warning light on
If the same OBD fault is detected during three consecutive journeys or there is an electrical fault.
2 - Warning light flashes
If misfiring leading to catalytic converter damage is detected.
3 - Warning light goes out
If the OBD fault does not reappear during three consecutive journeys, the warning light goes out and the fault
is stored in the injection computer.
The fault must not be detected for 40
consecutive journeys before its is cleared from the
computer memory without the use of the diagnostic tool.
Note:
The fault may not be re-detected:
- if the fault is temporary,
- due to the driving style of the customer, which may
not always incorporate all the fault detection conditions.
17B-27
17B
PETROL INJECTION
Conditions for carrying out fault finding (when driving)
17B
I - CONDITIONS FOR ENTERING FAULT FINDING
MODE
If, when the ignition is switched on and when driving,
the air temperature read by the temperature sensor is
not between -7.5C and 119.39C , if the coolant temperature read by the sensor is not between -7.5C and
119.39C , or if the difference between 1046 mbar and
the manifold pressure is greater than 273 mbar (altitude of about 2500 metres), OBD is not authorised until
the ignition is switched on again.
Power take-up speed is the moment when, during deceleration under no load and the injection cut out, the
computer authorises injection again.
2 - Programming of richness adaptive parameters
To perform this programming, the vehicle must be driven within the pressure ranges.
In order for the OBD system to function correctly, there

must be no electrical faults in the injection system,
even if the OBD warning light is not lit.
Fault finding of the oxygen sensor and the catalytic
converter can never be performed at the same time.
When the catalytic converter and oxygen sensor fault
finding procedures are in progress, the fuel vapour absorber bleed is closed and the richness adaptive parameters are frozen at their last value.
II - TEST PROCEDURE
Before performing the tests, carry out the following in
the sequence shown
- resolve all electrical faults,
- clear all faults,
- carry out injection system programming,
- check the OBD system.
III - COMPLETE INITIALISATION OF THE OBD
In order to reinitialise the OBD function, it is necessary
to carry out following operations:
- clear stored faults,
- clear OBD faults,
- clear all programming.
IV - PROGRAMMING NECESSARY FOR OBD
Programming must be re-performed when replacing:
- an injection computer,
- an engine flywheel target,
- an engine speed sensor.
1 - Engine flywheel target programming
17B-28
PETROL INJECTION
Combustion misfire fault finding
17B
IV - CONDITIONS FOR DETECTION
Equipment required
Check that programming has been correctly carried

out.
diagnostic tool
The purpose of detecting misfiring is to detect any malfunctions which could cause hydrocarbon pollutant
emissions to exceed the OBD limit, or cause deterioration of the catalytic converter.
Check that the prerequisites for switching on the ignition and for detecting misfiring correspond.
Detection is carried out as soon as the coolant temperature is above - 7.5C , in three operating ranges
between idle speed and 4500 rpm .
The pollutant misfiring test can also be carried out by
maintaining the engine at idle speed with all the power
consumers on for 10 minutes .
Note:
- In comparison to the Sagem 2000 injection,
Sagem 3000 has the following functions:
WARNING
At the end of this test, it is essential that the ignition
is not switched off before the result is read on the
diagnostic tool. Switching the ignition off will lead to
the results being misinterpreted.
injection cut-off to cylinders causing misfiring,

appearance of a fault indicating non-conformance of the flywheel target.
- If distortion of the target is too marked, the computer cannot implement an adjustment that is sufficient to detect misfiring correctly.
V - REPAIR CONFIRMATION
Using the diagnostic tool (CLIP):
I - THE FAULT FINDING SYSTEM CAN DETECT:

- clogging or flooding of a spark plug,
- clogging of the injectors or an injector flow fault,
- incorrect operation of the supply system (pressure regulator, fuel pump, etc.),
- a faulty connection in the petrol or injection circuits
(coil secondary, etc.).
II - MEASUREMENT OF ENGINE MISFIRINGS
Fault finding is performed by measuring the instantaneous variations in engine rotation speed.
ET 057
Misfiring on cylinder 1
No
ET 058
No
ET 059
No
ET 060
No
If after the test, the tool has detected combustion misfiring DF065 , DF059 , DF060 , DF061 , DF062 , refer to
the fault finding procedure for this fault.
If a drop in torque is detected, this is an indication of

misfiring. Misfiring results in a drop in engine torque
below a predetermined threshold.
This fault finding is practically continuous while the car
is being driven. If it is not carried out, or if a fault is detected, all other OBD fault finding (catalytic converter
and upstream oxygen sensor) will be prevented.
III - THE FAULT FINDING STRATEGY ENABLES
TWO TYPES OF FAULT TO BE DISTINGUISHED:
- Destructive misfiring - over 15% - results in catalytic
converter damage. Such misfiring causes the injection warning light to switch on immediately and flash.
- Pollutant misfiring - below 15% - causes the OBD pollution limit to be exceeded. These cause the injection
warning light to come on if they are detected during
three consecutive journeys.
17B-29
PETROL INJECTION
Catalytic converter fault finding
17B
The purpose of catalytic converter fault finding is to detect a fault which could cause hydrocarbon pollutant
emissions to exceed the OBD limit.
The catalytic converter's capacity to store oxygen is indicative of its condition. As the catalytic converter
ages, its capacity to store oxygen reduces along with
its ability to treat pollutant gases.
III - REPAIR CONFIRMATION

If after the test, the tool has detected a catalytic converter fault DF110: Catalytic converter refer to the
fault finding procedure for this fault.
I - CONDITIONS FOR STARTING FAULT FINDING

Fault finding on the catalytic converter can only be carried out after the engine has been running for about
16.5 minutes , and if all the necessary conditions for
switching on the ignition are still met:
- no electrical faults,
- no misfiring detected,
- no catalytic converter fault finding performed since
the ignition was switched on,
- programming has been carried out,
- main loop and double loop active,
- coolant temperature higher than 75C ,
- engine speed read by the diagnostic tool as between
1472 rpm and 3868 rpm .
II - FAULT DETECTION
Fault finding is carried out when driving under stabilised conditions.
When the conditions for starting fault finding are met,
richness excitation peaks are applied, which has the
effect of sending bursts of oxygen into the catalytic
converter.
1 - If the catalytic converter is functioning normally
It absorbs oxygen and the voltage of downstream oxygen sensor PR099 will remain at an average value.
2 - If it needs replacing
It rejects the oxygen and downstream oxygen sensor
PR099 starts to pulse. The oxygen sensor voltage fluctuates (the OBD warning light comes on after three
journeys).
WARNING
diagnostic tool. Switching off the ignition will lead to
17B-30
PETROL INJECTION
Oxygen sensor fault finding
17B
The purpose of fault finding on the upstream oxygen
sensor is to detect faults that would cause emissions of
hydrocarbon, carbon monoxide or nitrogen oxide to exceed the OBD limit. It is carried out by measuring and
comparing periods of upstream oxygen sensor vibration.
WARNING
diagnostic tool. Switching off the ignition will lead to
I - POSSIBLE CAUSES OF FAULTS

V - REPAIR CONFIRMATION
There are two types of possible fault in the upstream

oxygen sensor:
- mechanical damage to an electrical component
(breakage, cut in wire) which leads to an electrical
fault,
If, after the test, the diagnostic tool has detected a fault
in the upstream oxygen sensor DF092: Upstream
oxygen sensor circuit refer to the fault finding procedure for this fault.
- chemical damage to the component, which causes

the response time of the sensor to slow down, thus increasing its switching period.
II - CONDITIONS FOR STARTING FAULT FINDING

When test conditions are reached, the computer takes
an average of sensor cycle readings PR121
Average upstream oxygen sensor cycle , taking
away the effects of interference, which is compared to
an average OBD limit cycle.
III - TEST CONDITIONS

Fault finding on the oxygen sensor can only be carried
out after the engine has been running for about 15 minutes , and if all the necessary conditions for switching
on the ignition are still met:
- no electrical faults detected,
- programming has been carried out,
- no oxygen sensor fault finding performed since the
ignition was switched on,
- no misfiring detected,
- coolant temperature higher than 75C ,
- engine speed given by the diagnostic tool as between
1472 rpm and 3868 rpm .
- manifold pressure between 292 mbar and 900 mbar .
IV - FAULT DETECTION
Fault finding is carried out when driving, according to
the conditions previously outlined, and prevents fuel
vapours bleeding from the absorber.
17B-31
LPG INJECTION
LPG injection: Precautions for repair
17C
K4M, and 764

Apply leak detecting product (part number 77 11 143
071 ) to the open union(s).
Note:
Fill the fuel tank with a few litres of LPG , if it has been
bled (with the ignition switched off).
It is essential that you follow the following safety

advice before carrying out any operation on a vehicle equipped with the LPG system.
Check that the gas unions are not leaking.

Start the engine, switch to gas mode and check again
that there is no leak.
I - SPECIALLY EQUIPPED WORKSHOP

Repairs to the LPG system must only be carried out in
workshops that meet the requirements for this type of
operation.
Only workshops equipped with an LPG igniter for draining the system may carry out work on the LPG tanks.
Fill the fuel tank (80% of total volume). Start the engine, run it in gas mode and check that there are no
leaks.
After refitting, check that none of the rubber and sheathed steel hoses is touching a component likely to cause wear, and consequently create a gas leak (use pins
to keep the hoses separate).
II - AUTHORISED STAFF
Staff authorised to carry out work on a vehicle's LPG
system must have completed a special training program enabling them to do so.
V - OPERATION ON THE TANK

Before carrying out any work on the LPG system, drain
the pipes.
Drain the tank (see 17C, LPG injection, LPG tank:
Draining ).
III - GENERAL SAFETY ADVICE

Any work on the LPG system must be carried out in a
ventilated area of a specially equipped workshop, by
personnel who have undergone special training.
Only workshops equipped with an LPG igniter may
drain the system.
Other types of operation associated with a source of

heat:
- in the event of an operation requiring the use of a
blowpipe, drain the pipes and the LPG tank.
When carrying out any type of work on the LPG system, do not wear clothes containing acrylic or any other
material which could generate static electricity.
- if the vehicle must be subjected to high temperatures

(above 80C), drain the pipes and the LPG tank and
remove the LPG tank (see 17C, LPG injection, LPG
injection: LPG tank: Removal - Refitting ).
Keep naked flames and all ignition sources (sparks, cigarettes, mobile phones, etc.) away from the work
area.
After any work is carried out on the LPG system, test

the sealing on the entire gas supply circuit using the
leak detector product (part number 77 11 143 071 ).
Carry out all work with the battery disconnected.

Never attempt to remove the fuel tank or any of its fixed
components, without first having bled it (risk of explosion).
If a major gas leak occurs, the vehicle must be isolated
in the open air, away from buildings.
The emergency services may be required to intervene
if the situation cannot be controlled.
Do not attempt to open the expansion valve in order to
repair it. It is not adjustable.
Do not wash the engine compartment with a pressurised system using detergent. These can cause the expansion valve membranes to deteriorate.
IV - OPERATION ON THE PIPES
After working on a gas union, check that it is not leaking after refitting.
17C-1
LPG INJECTION
LPG tank - pipe neck: Removal - Refitting
17C
K4M, and 764
Tightening torquesm
filler neck-tank pipe
mounting bolt
21 Nm
nut securing the filler

neck-tank pipe on the
LPG filler neck
25 Nm
nut securing the filler

neck-tank pipe on the
safety solenoid valve
8 Nm

protector mounting bolts
2 Nm
REMOVAL
114227
WARNING
Disconnect the safety solenoid valve connector (3) .
It is essential to read the repair precautions

before carrying out any work on the LPG circuit.
Read the repair precautions (see 17C, LPG injection, LPG injection: Precautions during repair ).
Disconnect the battery (see MR 370 Mechanical,
80A, Battery, Battery: Removal - Refitting ).
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch trim.
114225
Remove:
- the mounting bolts (1) from the safety solenoid valve protector,
- the safety solenoid valve protector (2) .
17C-2
LPG INJECTION
LPG tank - pipe neck: Removal - Refitting
17C
K4M, and 764

Manually tighten:
- the mounting bolt (7) on the filler neck-tank pipe,
- the nut (6) securing the filler neck-tank pipe on the
LPG filler neck,
- the nut (5) securing the filler neck-tank pipe on the
safety solenoid valve.
Clip on the filler neck-tank pipe at (4) .
Tighten to torque:
114228
- the filler neck-tank pipe mounting bolt (21 Nm)

at (7) ,
- the nut securing the filler neck-tank pipe on the
LPG filler neck (25 Nm) ,
- the nut securing the filler neck-tank pipe on the
safety solenoid valve (8 Nm) .
Connect the safety solenoid valve connector (3) .
Refit:
- the safety solenoid valve protector (2) ,
- the safety solenoid valve protector mounting bolts
(1) .
Tighten to torque the safety solenoid valve protector mounting bolts (2 Nm) .
Refit:
114223
- the rear right-hand wheel arch trim.
Disconnect the filler neck-tank pipe at (5) .
- the rear right-hand wheel.

WARNING
Connect the battery (see MR 370 Mechanical, 80A,
When disconnecting the filler neck-tank pipe,

take care not to damage the sealing ring.
Unclip the filler neck-tank pipe at (4) .
Disconnect the filler neck-tank pipe from the LPG
filler neck at (6) .
Remove:
Carry out a sealing check on all unions which have

been loosened (see 17C, LPG injection, LPG injection: Precautions during repair ).
Start the engine running and spray the leak detection product ( part number 77 11 143 071 ) onto the
loosened unions.
- the mounting bolt (7) from the filler neck-tank pipe,

- the filler neck-tank pipe (8) .
Let the engine run for 5 minutes .
REFITTING
If no air bubbles form around the unions which were

loosened, they can be considered leak-tight.
Position the filler neck-tank pipe (8) .
17C-3
LPG INJECTION
LPG tank: Removal - Refitting
17C
K4M, and 764
Equipment required
component jack
Tightening torquesm
LPG tank mounting
bolts
21 Nm
exhaust pipe central

support mounting bolt
8 Nm
silencer rear support

mounting bolts
8 Nm
tank-filler neck pipe

mounting nut
25 Nm
Remove:
gas supply pipe mounting nut
25 Nm
- the mounting bolts (1) from the safety solenoid valve protector (2) ,

2 Nm
114225
REMOVAL
WARNING
114227
Disconnect:
- the safety solenoid valve connector (3) ,
- the gas filling pipe (4) ,
- the gas supply pipe (5) .
WARNING
When disconnecting the gas filling pipe, take
care not to damage the sealing ring.
Allow any gas inside the pipes to escape.
17C-4
LPG INJECTION
17C
K4M, and 764
114368
114366
Remove:
- the mounting bolts (8) from the silencer heat shield
(9) ,
- the silencer heat shield (9) .
114367
Remove:
- the mounting bolts (6) from the exhaust pipe central support,
- the mounting bolts (7) from the silencer rear support.
114229
Remove:
- the bolts (10) mounting the heat shield (11) on the
LPG tank,
- the heat shield (11) from the LPG tank.
Fit the component jack.
17C-5
LPG INJECTION
17C
K4M, and 764

Tighten to torque the LPG tank mounting bolts (21
Nm) .
Refit:
- the heat shield (11) to the LPG tank,
- the bolts (10) mounting the heat shield (11) on the
LPG tank.
Refit:
- the silencer heat shield (9) ,
- the mounting bolts (8) on the silencer heat shield
(9) ,
- the mounting bolts (7) to the silencer rear support,
- the mounting bolts (6) to the exhaust pipe central
support.
Tighten to torque:
- the exhaust pipe central support mounting bolt
(8 Nm) ,
114242
- the silencer rear support mounting bolts (8 Nm)

.
Connect:
- the gas filling pipe (4) ,
- the gas supply pipe (5) .
WARNING
When connecting the gas filling pipe, take care
not to damage the sealing ring.
Tighten to torque:
- the tank-filler neck pipe mounting nut (25 Nm)
(4) ,
- the gas supply pipe mounting nut (25 Nm) (5) .
Refit:
114243

- the mounting bolts (1) to the safety solenoid valve
protector.
Remove:
- the mounting bolts (12) from the LPG tank,
- the LPG tank.

REFITTING

Fit the component jack.

Refit:
Start the engine running and spray the leak detection product ( part number 77 11 143 071 ) onto the
loosened unions.
- the LPG tank,

- the mounting bolts (12) on the LPG tank.
17C-6
LPG INJECTION
K4M, and 764
17C-7
17C
LPG INJECTION
LPG tank: Draining
17C
K4M, and 764
DRAINING
1 - Connections
To connect the pilot flame hose:
- Clip the expansion valve onto the bottle. The valve
must be closed.
WARNING
- Connect the quick-release union onto the end piece of the pilot flame.
Park the vehicle outside.
- Position the tank to be emptied more than 10 m

away from the flare.
Disconnect the battery.
To connect the LPG circuit:

- Connect the self-sealing union on the end of the
hose to the flare connection end piece, with the valve closed.
- Fitting the special pipes onto the LPG tank output.
The connection to the tank must be made in accordance with the recommendations of the vehicle
manufacturer's After-Sales procedures.
- Connect the self-sealing union on the end of the
hose to the special pipes connection end piece.
To connect the nitrogen circuit:
- Position the nitrogen bottle near the LPG tank.
114225
- Attach the expansion valve onto the nitrogen bottle

and tighten the expansion valve union.
- the mounting bolts (1) from the safety solenoid valve protector (2) ,
- Connect the special nitrogen pad to the LPG filling

opening and tighten it manually. (make sure there
is a seal).
Remove:
- After checking that everything is tightened and correctly sealed, the installation is ready for start-up.
There are two types of igniter approved by Renault

available:
- AEM flare,
2 - Starting the installation
- ALSIA flare.
Check that all the valves and all the circuits are
closed.
I - AEM IGNITER
Lighting the pilot flame (operator correctly attired):
Note:
- Open the TWINY bottle expansion valve

switch.
Refer to the Owner's Manual for the AEM LPG

igniter, along with the fitting procedure described
below.
- Place a flame for lighting the pilot flame in the opening provided on the flare cylinder.
- Check that the pilot flame is correctly lit.
Position the flare securely on the flare area.

Position the TWINY bottle more than 5 m away
from the flare.
If it has not lit:

- Air present in the hose: Continue trying to light the
pilot flame.
Note:
- Empty gas bottle: replace it.
The propane bottle is not supplied.
- Blocked injector: Remove and clean it.
17C-8
LPG INJECTION
LPG tank: Draining
17C
K4M, and 764

- Try to open the progressive flow control valve
slowly so as to not trigger the tank safety valve. If
the valve triggers, start the operation again, closing
the progressive flow control valve.
- After the flow has equalised, open the nitrogen
bottle and adjust the expansion valve to a pressure
1 bar greater than the tank pressure (but not greater than 7 bar ).
Note:
Carry out this operation when the tank pressure
gauge shows approximately 2 bar . At this point,
add the nitrogen to a pressure of 3 bar until the
end of the flare procedure.
After the main flame has been extinguished, allow
the nitrogen flare to sweep at the rate of 1 min per
10 litres capacity (e.g.: for a 60 litre tank: sweeping
time = 6 min ).
114227
WARNING
The tank has not been degassed, the liquid
phase has been evacuated, the gaseous zone
contains mainly nitrogen, which is a neutral gas.
3 - Switching off the installation

Close the tank solenoid valve and remove the magnet.
Close the nitrogen circuit by resetting the expansion
valve and closing the tap on the on the N2 bottle.
Shut off the pilot flame by closing the expansion valve switch on the TWINY gas bottle.
106518
To light the igniter:
Close the progressive flow control valve.
- The operator must be at least 10 m away from the

flare and must ensure that this precaution is respected by everyone.
WARNING
The flare must remain where it is until it has cooled down completely. Move the flare using the
two side handles.
- Remove the safety solenoid valve (1) .

- Control the tank solenoid valve using a magnet (2) .
- Open the progressive flow control valve to position
1 (the highest position is 5).
4 - Removal
- The igniter starts.
Disconnect the special nitrogen pad from the LPG

filling opening.
- Check the passage of liquid gas through the circulation indicator.
Remove the nitrogen expansion valve union.
- Adjust the opening of the progressive flow control

valve, increasing its opening to position 2 or 3 until
the flow lines equalise through the circulation indicator.
17C-9
Loosen the special union from the tank and disconnect on the self-sealing union side.
Disconnect the quick-release union from the end
piece of the igniter.
LPG INJECTION
LPG tank: Draining
K4M, and 764
Disconnect the quick-release union from the end
piece of the pilot flame.
Unclip the expansion valve from the TWINY bottle.
Wind up the hoses.
Put away the equipment.
II - ALSIA IGNITER
Note:
Refer to the Owner's Manual for the ALSIA LPG
igniter, along with the fitting procedure described
below.
17C-10
17C
LPG INJECTION
LPG tank: Draining
17C
K4M, and 764
114227
100014
17C-11
LPG INJECTION
LPG tank: Draining
17C
K4M, and 764
106518
Control the safety solenoid valve using a magnet (9)

.
Check that the gas unions between the fuel tank and
the igniter are not leaking.
100015
Connect the tank to earth.

Disconnect the gas supply pipe (1) .
Place the igniter 20 m away from any flammable object (buildings, fuel and combustible matter etc.).
Open the pilot flame valve on igniter (6) and ignite it

by putting a flame to light (7) .
Check that the igniter is sufficiently far away from the
vehicle and any flammable material.
Open the main igniter valve (5) gradually.
Connect the igniter to earth.
The flame can reach 3 to 4 m during 30 minutes .
Connect the safety solenoid valve output (2) onto

the igniter (8) (supplied with 10 m of pipe ), after having first checked the compatibility of the sealing
unions.
As the igniter sucks the gas from the fuel tank, the
flame gradually changes colour.
Check that gas taps (5) and (6) are closed.

Once the main flame has gone out, let the pilot flame
burn until it, too, goes out so there is no more pressure in the fuel tank.
Close the main tap (5) to end the bleed with the pilot
flame.
Remove the safety solenoid valve (4) .
Try to reignite the pilot flame to check that the fuel

tank has been bled.
Finally, close the tap (6) and the pilot flame.
17C-12
LPG INJECTION
LPG tank: Draining
K4M, and 764
100009
If necessary, sweep the tank using the nozzle (10)

and a nitrogen canister (11) .
Connect the nozzle to the filler neck and adjust the
flow to a pressure of between 5 and 8 bar .
Open the main valve (5) .
Allow the bottle to discharge for 5 minutes .
Close the nitrogen bottle and disconnect the solenoid valve from the fuel tank.
17C-13
17C
LPG INJECTION
LPG level gauge: Removal - Refitting
K4M, and 764
114226
(1) LPG level gauge.

(2) Safety solenoid valve.
WARNING
The LPG level gauge is not removable.
Only the safety solenoid valve (2) is removable.
17C-14
17C
LPG INJECTION
LPG expansion valve: Removal - Refitting
17C
K4M, and 764

Ms. 583
Hose clamp pliers.
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Tightening torquesm
expansion valve unit
mounting bolt
8 Nm

2 Nm
114227
Disconnect the safety solenoid valve connector (3) .
REMOVAL
Remove the LPG computer (see 17C, LPG injection, LPG computer: Removal - Refitting ).
WARNING
Remove the battery (refer to MR 370 Mechanical,
114356
Disconnect the connectors (4) from the pressure

sensor and the expansion valve solenoid valve.
114225
Remove:
- the mounting bolts (1) from the safety solenoid valve protector,
17C-15
LPG INJECTION
17C
K4M, and 764
114357
114358
Disconnect the gas supply pipe (5) .
Position the (Ms. 583) on the coolant inlet and outlet

pipes (9) .
Remove the clip (6) .
Remove:
Disconnect:
- the clips (10) from the coolant inlet and outlet pipes
(Mot. 1448) ,
- the expansion valve-LPG injection rail pipe (7) ,

- the reference pressure pipe (8) .
- the coolant inlet and outlet pipes (9) ,

- the mounting bolt (11) from the expansion valve
unit,
- the expansion valve unit.
REFITTING
Refit the expansion valve unit.
Tighten to torque the expansion valve unit mounting bolt (8 Nm) .
Refit:
- the coolant inlet and outlet pipes (9) ,
- the clips (10) to the coolant inlet and outlet pipes
(Mot. 1448).
Remove the (Ms. 583) from the coolant inlet and
outlet pipes.
Connect the reference pressure pipe (8) .
Replace the clip (6) .
Connect:
- the expansion valve-LPG injection rail pipe (7) ,
- the gas supply pipe (5) ,
17C-16
LPG INJECTION
K4M, and 764
- the connector (4) to the pressure sensor and the
expansion valve solenoid valve.
Refit the LPG computer (see 17C, LPG injection,
LPG computer: Removal - Refitting ).
Refit:
- the mounting bolts (1) to the safety solenoid valve
protector.
Refit the battery (refer to MR 370 Mechanical, 80A,
Fill the cooling circuit (see MR 370 Mechanics, 19A,
Cooling, Cooling circuit: Draining-refilling ).
Bleed the cooling circuit (see MR 370 Mechanics,
19A, Cooling, Cooling circuit: Bleeding ).
17C-17
17C
LPG INJECTION
LPG pressure sensor: Removal - Refitting
17C
K4M, and 764

Mot. 1608
Torque screwdriver.
Tightening torquesm
pressure sensor mounting bolts
1.6 Nm
battery tray mountings
21 Nm
petrol injection computer support mountings
21 Nm
REMOVAL
WARNING
114364
Disconnect the connectors (1) from the petrol injection computer.

Remove:
- the support mountings (2) from the petrol injection
computer,
- the petrol injection computer along with its support,
- the battery tray mountings (3) .
Unclip the wiring harness from the battery tray.
17C-18
LPG INJECTION
LPG pressure sensor: Removal - Refitting
17C
K4M, and 764

Start the engine and spray the leak detection product ( part number 77 11 143 071 ) onto the pressure sensor.
If no air bubbles form around the pressure sensor, it
can be considered leak-tight.
114353
Disconnect the connector (4) from the pressure sensor (6) .

Remove:
- the pressure sensor mounting bolts (5) ,
- the pressure sensor (6) .
REFITTING
Refit:
- the pressure sensor (6) ,
- the pressure sensor mounting bolts (5) .
Using the (Mot. 1608) tighten to torque the pressure sensor mounting bolts (1.6 Nm) .
Connect the pressure sensor connector (4) .
Refit the battery tray.
Tighten to torque the battery tray mountings (21
Nm) .
Clip the wiring harness onto the battery tray.
Refit the petrol injection computer along with its support.
Tighten to torque the petrol injection computer
support mountings (21 Nm) .
Connect the petrol injection computer connectors (1)
.
Refit the battery (see MR 370 Mechanical, 80A,
Carry out a sealing check on the LPG pressure sensor.
17C-19
LPG INJECTION
LPG expansion valve solenoid valve: Removal - Refitting
17C
K4M, and 764
Tightening torquesm
expansion valve solenoid valve mounting bolt
2 Nm
21 Nm
21 Nm
REMOVAL
WARNING
Read the repair precautions (see 17C, LPG injection: Precautions during repair ).
114364

Remove:
computer,
17C-20
LPG INJECTION
LPG expansion valve solenoid valve: Removal - Refitting
K4M, and 764
114355
Disconnect the connector (4) from the expansion

valve solenoid valve (6) .
Remove the expansion valve solenoid valve mounting bolt (5) .
Remove the expansion valve solenoid valve (6) .
REFITTING
Refit the expansion valve solenoid valve (6) .
Tighten to torque the expansion valve solenoid
valve mounting bolt (2 Nm) .
Connect the expansion valve solenoid valve connector (4) .
Nm) .
Connect the petrol injection computer connectors (1)
.
17C-21
17C
LPG INJECTION
LPG expansion valve outlet union: Removal - Refitting
17C
K4M, and 764

Refit the expansion valve unit (see 17C, LPG injection, Expansion valve unit: Removal - Refitting ).
Tightening torquesm
LPG expansion valve
outlet union mounting
bolts

2.5 Nm

REMOVAL
Start the engine and spray the leak detection product ( part number 77 11 143 071 ) onto the loosened unions.
WARNING


Remove the expansion valve unit (see 17C, LPG injection, Expansion valve unit: Removal - Refitting ).
114239
Remove:
- the mounting bolts (1) from the LPG expansion valve outlet union,
- the LPG expansion valve outlet union (2) .
REFITTING
Refit the LPG expansion valve outlet union
Tighten to torque the LPG expansion valve outlet
union mounting bolts (2.5 Nm) .
17C-22
LPG INJECTION
Coolant circuit union: Removal - Refitting
17C
K4M, and 764
REFITTING
Refit the cooling circuit unions.
Tightening torquesm
cooling circuit union
mounting bolts
2.5 Nm
WARNING
Replace the cooling circuit union sealing rings.
REMOVAL
Tighten to torque the cooling circuit union mounting bolts (2.5 Nm) .
WARNING
Refit the expansion valve unit (see 17C, LPG injection, Expansion valve unit: Removal - Refitting ).




Remove the expansion valve unit (see 17C, LPG injection, Expansion valve unit: Removal - Refitting ).
Start the engine and spray the leak detection product ( part number 77 11 173 071 ) onto the loosened unions.
114239
Remove:
- the mounting bolts (1) from the cooling circuit
unions,
- the cooling circuit unions (2) .
17C-23
LPG INJECTION
LPG injection rail: Removal - Refitting
17C
K4M, and 764
Tightening torquesm
LPG and petrol injection rail mounting nuts
10 Nm
injection rail protector

mounting nuts
21 Nm
injection rail wiring harness mounting bolt
10 Nm
REMOVAL
WARNING
114361
Remove:
- the mounting bolt (2) from the injection rail wiring
harness,
- the mounting nuts (3) from the injection rail protector,
- the injection rail protector (4) .
Note:
Take care not to damage the cooling radiator
when removing the protector (4) .
114363
Remove the cooling radiator mountings (1) .
17C-24
LPG INJECTION
17C
K4M, and 764
114362
114360
Remove the mounting nuts (5) from the LPG injection rail.
Disconnect the petrol supply union (6) from the petrol injection rail.
Shift the LPG injection rail forwards.

WARNING
Beware of splashes of petrol when disconnecting
the petrol supply union: protect the alternator.
Disconnect the petrol injector connectors (7) .
Remove the petrol injection rail (8) .
WARNING
When removing the injectors and the petrol injection rail, be aware that there will be some fuel in
the rail and the unions.
17C-25
LPG INJECTION
17C
K4M, and 764
REFITTING
Note:
When refitting, lightly lubricate the LPG injector
O-ring and seals. Use the engine oil to lubricate
as it prevents sticking.
Connect the gas pipe between the expansion valve
unit and the LPG injection rail.
Refit the clip to the gas pipe between the expansion
valve unit and the LPG injection rail.
WARNING
Always replace the snap-on clip (9) on the gas
pipe between the expansion valve unit and the
LPG injection rail.
Refit:
114359
Disconnect the LPG injector connectors (11) .
- the LPG injectors,

- the LPG injection rail.
Remove the LPG injector (12) .
Connect the LPG injector connectors.

Refit the petrol injection rail.
Note:
Tighten to torque the LPG and petrol injection rail

Remove the LPG injector using a flat-blade

screwdriver, inserted between the LPG injector
and the cylinder head. The LPG injectors can
then be removed from their housing by rotating
the handle.
Connect:
- the petrol injector connectors.
- the petrol supply union to the petrol injection rail.
Remove the clip (9) from the gas pipe between the
expansion valve unit and the LPG injection rail.
Disconnect the gas pipe (10) between the expansion
valve unit and the LPG injection rail.
Refit the injection rail protector.

Tighten to torque:
- the injection rail protector mounting nuts (21
Nm) .
- the injection rail wiring harness mounting bolt
(10 Nm)
IMPORTANT
Beware of escaping gas when disconnecting the
gas pipe between the expansion valve unit and
the LPG injection rail.
Angle the gas pipe between the expansion valve
unit and the LPG injection rail upwards to allow
the gas from the engine compartment to escape
without coming into contact with any hot components or persons nearby.
Remove the LPG rail along with the injectors.
17C-26
LPG INJECTION
K4M, and 764
114363
Refit the cooling radiator mountings (12) .

Carry out a sealing check on the injectors (see 17C,
LPG injection, LPG injection: Check ).
17C-27
17C
LPG INJECTION
LPG injector: Removal - Refitting
17C
K4M, and 764
REMOVAL
Refit the LPG injection rail (see 17C, LPG Injection,

Injection rail: Removal - Refitting ).
WARNING


Carry out a sealing check on the injectors (see 17C,

LPG injection, LPG injection: Test ).
Remove the LPG injection rail (see 17C, LPG Injection, Injection rail). Removal - Refitting ).
114352
Remove:
- the clips (1) from the LPG injector hoses,
- the LPG injectors.
WARNING
The hoses connected to the LPG injection rail
and the LPG injectors are marked with a line at
each end. These marks help you to correctly
position the different components during refitting.
Before removing a component, note its position
in relation to the mark on the hose.
REFITTING
WARNING
It is essential to replace the LPG injector clips
and hoses.
Refit:
- the LPG injectors,
- the LPG injector hose clips.
17C-28
LPG INJECTION
LPG injector: Check
K4M, and 764
Note:
After any work is carried out on the LPG injectors, a
sealing check must be carried out.
Two types of leak can be detected:
Scenario no. 1 : test for sealing between the injectors
and the flexible pipes:
- start the engine,
- press the gas button on the instrument panel to
enter gas mode,
- allow the engine to run in gas mode for 5 minutes
,
- wait approximately 5 minutes ,
- start the engine,
enter gas mode,
- allow the engine to run in gas mode.
If none of the indicator lights on the instrument panel
are lit, the sealing between the injectors and the flexible pipes is considered correct.
If an indicator light on the instrument panel is lit, replace the faulty parts.
Scenario no. 2 : test for sealing between the injectors
and the cylinder head:
- start the engine,
enter gas mode,
- allow the engine to run in gas mode for 5 minutes
,
- check that the idling speed is correct.
If the idling speed is correct, the sealing between the
injectors and the cylinder head is considered good.
If the idling speed is abnormally high, replace the faulty
injector.
17C-29
17C
LPG INJECTION
LPG computer: Removal - Refitting
17C
K4M, and 764
Tightening torquesm
LPG computer mounting nut
8 Nm
21 Nm
21 Nm
REMOVAL
114354
Disconnect the connector (4) from the LPG computer.

Remove the mounting nut (5) from the LPG computer.
Remove the LPG computer.
REFITTING
Refit the LPG computer.
114364
Tighten to torque the LPG computer mounting nut

(8 Nm) .
Connect the LPG computer connector.
Remove:

computer,

Nm) .


Connect the petrol injection computer connectors.
17C-30
COOLING SYSTEM
Engine cooling: Parts and consumables for the repair work
CONSUMABLES
Use GLACEOL RX (TYPE D) coolant.
Note:
Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guidelines marked on the container.
19A-1
19A
COOLING SYSTEM
Engine cooling
19A
IMPORTANT
- that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
air.
The circuits are designed to be pressurised; take

care at high temperatures (risk of serious scalding).
Vehicles in the current range have cooling circuits with

the following basic specifications:
Never remove the valve from the expansion bottle

while the engine is hot.
- Pressurised sealed circuit (expansion bottle valve),
Take care when carrying out a repair under the bonnet, as the radiator fan(s) may start to operate
without warning.
Note:
Do not open the bleed screw(s) with the engine running.
Expansion bottle valve with:
Summary of expansion bottle valve ratings.
a yellow hand: 1.4 bar

a white hand: 1.6 bar
a grey hand: 1.8 bar
WARNING
The coolant helps to keep the engine running properly (heat exchange).
- circuit using type D coolant only.
The system does not operate using pure water.
Note:
Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guidelines marked on the container.
WARNING
Drain with the engine warm.
Flush and refill with the engine cold or warm.
Never flush a hot engine (risk of major thermal
shock).
WARNING
When carrying out a repair that requires a complete
circuit drain, it is essential to flush the circuit with
clean water, blow compressed air through the circuit to eliminate water, fill and drain the circuit and
then measure the effective protection.
The criteria to be met are:
- Protection down to - 25C 2 for cold and temperate climates,
- Protection down to - 40C 2 for very cold climates.
Note:
Refer to the vehicle's maintenance service booklet
for information on cooling circuit service intervals.
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drive
belt,
19A-2
COOLING SYSTEM
Specifications
19A
Grade and quantity of coolant

Engine
Suffix
Quantity
(litres)
K4J
730
761
6.5
782
770
Grade
K4M
F4R
771
6.5
Only use
776
K9K
722
5.3
728
6.5
732
7.5
804
7.6
812
6.5
700
7.5
F9Q
M9R
Thermostat
Engine
Start of opening (C)
End of opening (C)
K4J
89
99 2
K4M
89
99 2
K9K
89
99 2
F9Q
89
99 2
F4R
89
99 2
M9R
89
99 2
GLACEOL
(TYPE D)
19A-3
coolant
fluid
RX
COOLING SYSTEM
Checking
II - CHECKING THE CIRCUIT SEALING

Mot. 1700
19A
Fault finding and filling-bleeding cooling

system.
Note:
The expansion bottle valve must be replaced if
coolant is leaking from the valve.
I - RECOMMENDATIONS FOR REPAIR

Checking the cooling system and the expansion
bottle valve
IMPORTANT
Never remove the valve from the expansion
bottle while the engine is hot.
Take care when carrying out a repair under the
bonnet, as the radiator fan(s) may start to operate without warning.
Do not open the bleed screw(s) with the engine
running.
107138
Check the cooling system and the expansion bottle

valve using the cooling system diagnostic and filling
tool (Mot. 1700). For guidance on the use of this tool
(see NT 3857A, How to use the cooling circuit
19A-4
diagnostic and filling tool ).
COOLING SYSTEM
Diagram
19A
K4J, and 730 K4M, and 761 or 782
7
3
7
1
5
4
9
10
105003
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screw
(8)
9 mm choke
(9)
6 mm choke for automatic transmission (if fitted to the vehicle)
(10)
Water-oil heat exchanger for the

automatic transmission (if fitted
to the vehicle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-5
COOLING SYSTEM
Diagram
19A
K9K, and 722 or 728
7
3
7
1
4
9
6
10
105004
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Coolant pump
(6)
Thermostat
(7)
Bleed screw
(8)
11 mm choke (K9K 722)
(9)
9 mm by-pass choke (K9K 728)
(10)
Water-oil heat exchanger
Note:
bar .
19A-6
COOLING SYSTEM
Diagram
19A
F9Q, and 812
7
3
11
1
4
7
6
10
9
2
105002
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screw
(8)
8 mm choke
(9)
9 mm choke
(10)
(11)
Exhaust gas cooler
Note:
bar .
19A-7
COOLING SYSTEM
Diagram
19A
F4R, and 770 or 771
7
3
7
5
8
6
9
2
10
105005
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screw
(8)
8.3 mm choke
(9)
6 mm choke
(10)
Water-oil heat exchanger for

automatic transmission (if fitted
to the vehicle)
Note:
bar .
19A-8
COOLING SYSTEM
Diagram
19A
F4R, and 776
7
3
12
1
13
8
7
6
10
9
2
11
106628
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screw
(8)
9 mm choke
(9)
16 mm choke
(10)
(11)
(12)
Turbocharger
(13)
Thermostat mounting
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEM
Diagram
19A
F9Q, and 804
13
12
3
7
4
6
7 14
10
9
2
11
112266
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Coolant pump
(6)
Thermostat
(7)
Bleed screw
(8)
8 mm choke
(9)
16 mm choke
(10)
Coolant-oil heat exchanger
(11)
(12)
Turbocharger
(13)
Thermostat mounting
(14)
Exhaust gas cooler
Note
The expansion bottle valve rating is 1.4 bar .
19A-10
COOLING SYSTEM
Diagram
19A
K9K, and 732
7
7
9
5
112268
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screw
(8)
Water-oil intercooler
(9)
Exhaust gas cooler
Note:
bar .
19A-11
COOLING SYSTEM
Diagram
19A
M9R, and 700
114452
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Coolant pump
(6)
Thermostat
(7)
Choke
(8)
Choke
(9)
Bleed screws
(10)
Coolant-oil heat exchanger
(11)
Note:
bar .
19A-12
COOLING SYSTEM
Cooling circuit: Draining - Refilling
WARNING

Car. 1363
Trim removal lever
Mot. 1202-01
Clip pliers for hose clips (large

model)
Mot. 1202-02
Clip pliers for hose clips (small

model)
Mot. 1448
Remote operation clip pliers for

cooling system hose clips
Mot. 1700
19A

circuit drain, it is essential to flush the circuit with
clean water, blow compressed air through the circuit to eliminate water, fill and drain the circuit and
- Protection down to - 25C 2 for cold and temperate climates,
- Protection down to - 40C 2 for very cold climates.
Cooling system filling and diagnostic tool
Note:
IMPORTANT
Before carrying out any operation, protect electrical

equipment using plastic bags.

Note:
without warning.
The engine must be switched off and the air conditioning system deactivated to prevent the engine
cooling fans operating as soon as the engine is
started.
DRAINING
WARNING
Use the following tools:
The coolant helps to keep the engine running properly (heat exchange).
- (Car. 1363) ,
- (Mot. 1202-01) ,
The system does not operate using pure water.
- (Mot. 1202-02) ,
- (Mot. 1448) .
WARNING
Remove the expansion bottle valve.

Open the cooling system at the cooling radiator bottom hose using the (Car. 1363) .

shock).
Blast compressed air into the circuit through the expansion bottle valve orifice to remove as much coolant as possible.
CLEANING
For cleaning (see 19A, Cooling, Cooling system:
Cleaning ).
FILLING
Use GLACEOL RX (TYPE D) coolant.
19A-13
COOLING SYSTEM
Cooling circuit: Draining - Refilling
Refill the cooling system using the cooling system filling and diagnostic tool (Mot.1700) . For guidance
on the use of this tool (see Technical Note 3857A,
Using the cooling system diagnostic and filling
tool ).
Fill up the expansion bottle until the coolant overflows.
Refit the expansion bottle valve.
Bleed the circuit (see 19A, Cooling system, Cooling circuit: Bleeding, page 19A-16) .
19A-14
19A
COOLING SYSTEM
Engine cooling circuit: Cleaning
IMPORTANT
without warning.
WARNING
shock).
CLEANING THE COOLING SYSTEM
To clean the cooling system, fill with coolant via the
expansion bottle.
Note:
In some cases it will be necessary to disconnect
the radiator top hose to correctly flush the engine
cooling radiator.
Blow compressed air into the circuit through the expansion bottle valve orifice to remove as much coolant as possible.
Connect the top and bottom hoses.
19A-15
19A
COOLING SYSTEM
Cooling circuit: Bleeding
Equipment required
pedal press
IMPORTANT
The circuits are designed to be pressurised, take
Never remove the valve from the expansion
bottle while the engine is hot.
Take care when carrying out a repair under the
bonnet, as the radiator fan(s) may start to operate without warning.
Do not open the bleed screw(s) with the engine
running.
BLEEDING
Use the pedal press.
Start the engine.
Check that the air conditioning system is not activated.
K9K, and 722 or 728 or 732

Run the engine at 1500 rpm , rapidly varying the engine speed (until maximum speed is reached) 2 to 3
times approximately every 2 minutes until the engine cooling fan starts up for a second time.

770 or 771 or 776 F9Q, and 804 or 812 M9R,
and 700
Run the engine at 2500 rpm , until the engine cooling fan has run three times (time required for automatic degassing).
Check that the heating is operating correctly.

Allow the engine to cool until the coolant temperature is less than 50C .
Top up the coolant level in the expansion bottle if necessary.
19A-16
19A
COOLING SYSTEM
Cooling radiator: Removal - Refitting
19A
or 732
Remove:

Car. 1363
Trim removal lever.
- the front wheels,
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Disconnect:
Mot. 1448

hose clips.
- the headlight washer pipes (if fitted to the vehicle).
- the wheel arch liners.
- the fog lights connector (if fitted to the vehicle),
Remove the bumper (see MR 371, Bodywork, 55A,

Tightening torquesm
intercooler hose clip
5.5 Nm
wheel bolts
130 Nm
REMOVAL
1
F4R, and 776 F9Q, and 804 or 812 K9K, and
722 or 728 or 732
4
3
WARNING
102504

intercooler:
Disconnect the two connectors (1) .

Remove:
- do not use degreasing agent, brake cleaner or

any other product,
- the clip (3) ,
- clean the mating faces on the intercooler and

on the hose with a dry, lint-free cloth,
- the fastener (4) .

- replace the clip in the same position if the hose

is not replaced,
- it is essential to replace the hose and/or the
intercooler in the event of damage,
- it is essential to replace the clip.
19A-17
COOLING SYSTEM
19A
or 732

722 or 728 or 732
5
102365
Remove the front cross member (5) .
Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Filling ).
Disconnect:
- the cooling radiator top hose,
- the cooling radiator expansion bottle hoses,
102473
- the engine cooling fan connector.
7
102474
Disconnect the inlet ducts (6) and the outlet ducts (7)
from the intercooler.
Remove the intercooler.
19A-18
COOLING SYSTEM
19A
or 732
Separate the condenser from the cooling radiator (if
fitted to the vehicle).
WARNING
pipes.
Remove the cooling radiator.
Separate the engine cooling fan from the cooling radiator.
REFITTING
722 or 728 or 732
Tighten to torque the intercooler hose clip (5.5
Nm) .
Refit the hose clips, using:

- hose clip pliers (Mot. 1202-01) ,
- hose clip pliers (Mot. 1202-02) ,
- remote operation hose clip pliers (Mot. 1448).
WARNING
Ensure that the fins of the cooling radiator, the
condenser or the cooler are not damaged during
refitting; protect them if necessary.
system: Draining - Filling ).
Drain the cooling system (see 19A, Cooling, Cooling system: Bleeding ).
Refit:
- the front wheels,
- the front wheel bolts
Note:
essential to initialise the system; see 80C,
19A-19
COOLING SYSTEM
Water pump: Removal - Refitting
19A
F4R, and 770 or 771 or 776 F9Q, and 804 or 812
REFITTING
Tightening torquesm
coolant pump mounting bolts
9 Nm

bolts
130 Nm
IMPORTANT
Wear goggles.
REMOVAL
Removal - Refitting .
Clean the sealing faces using DECAPJOINT to dissolve any seal still adhering.
Replace the coolant pump seal every time the coolant pump is removed.
Remove:
WARNING


Remove:
Note:
Apply two drops of LOCTITE FRENETANCH to
the coolant pump mounting bolts.
Refit:
- the coolant pump,
- the coolant pump mounting bolts.
102422
Remove:
- the coolant pump mounting bolts (6) ,
- the coolant pump.
19A-20
COOLING SYSTEM
F4R, and 770 or 771 or 776 F9Q, and 804 or 812
102422
Tighten to torque and in order the coolant pump

Refit:
Fill the cooling system (see 19A, Cooling, Draining
- Filling the cooling system ).
Bleed the cooling system (see 19A, Cooling, Bleeding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel bolts.
Tighten to torque the front right-hand wheel bolts
(130 Nm) .
19A-21
19A
COOLING SYSTEM
19A
K9K, and 722 or 728 or 732
Tightening torquesm
11 Nm

bolts
130 Nm
REMOVAL
Remove:
102267
Disconnect the alternator electrical connections.
Remove the alternator upper mounting (1) .

Cooling system: Draining- Filling ).
Undo the alternator lower mounting (2) .

Tilt the alternator forward.
Remove:
102266
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
19A-22
COOLING SYSTEM
19A
K9K, and 722 or 728 or 732

CONCERNED

CONCERNED
102262
102262
Remove:
WARNING
- the coolant pump.

REFITTING
Note:
Apply two drops of LOCTITE FRENETANCH to

the coolant pump mounting bolts.
IMPORTANT
Refit:
- the coolant pump,
Wear goggles.
- the coolant pump mounting bolts (1) to (5) .

Clean the sealing faces using DECAPJOINT to dissolve any seal still adhering.
Replace the coolant pump seal every time the coolant pump is removed.
19A-23
COOLING SYSTEM
K9K, and 722 or 728 or 732
102266
Refit:
- the inner timing cover (5) ,
- the inner timing cover mounting bolts.
Put the alternator in position.
Refit:
- the alternator mounting bolts,
Bleed the cooling system (see 19A, Cooling, Bleeding the cooling system ).
Refit:
- the engine cover,
(130 Nm)
19A-24
19A
COOLING SYSTEM
19A
K4J, and 730 K4M, and 761 or 782

Mot. 1448

hose clips.
Tightening torquesm
M8 coolant
mounting bolts
pump
22 Nm
M6 coolant
mounting bolts
pump
10 Nm

bolts
130 Nm
REMOVAL
14505

terminal.
Remove:
- the timing tension wheel,
Drain the engine cooling system via the engine cooling radiator bottom hose using the (Mot. 1448).
- the coolant pump.
REFITTING
Remove:
Timing belt ).
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
- Clean the sealing faces using DECAPJOINT to
dissolve any seal still adhering.
- Apply the product to the section to be cleaned;
wait approximately ten minutes, then remove
the residue using a wooden spatula.
19A-25
COOLING SYSTEM
19A
K4J, and 730 K4M, and 761 or 782

Pretighten the M6 coolant pump mounting bolts to 8
Nm and the M8 coolant pump mounting bolts to 8
Nm .
- the M8 coolant pump mounting bolts (22 Nm) ,
- the M6 coolant pump mounting bolts (10 Nm) ,
Refit:
10063
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm

to 1 mm wide.
Bleed the cooling system (see 19A, Cooling, Bleeding the cooling system: ).
Refit the front right-hand wheel
Refit:
(130 Nm) .
14505
Note:
Apply one to two drops of LOCTITE FRENETANCH to the coolant pump mounting bolts (1)
and (4) .
Refit:
- the coolant pump,
- the coolant pump mounting bolts.
19A-26
COOLING SYSTEM
19A
M9R, and 700
REMOVAL

Mot. 1390


Tightening torquesm
25 Nm
coolant pump pulley

mounting bolts
21 Nm

mounting bolts
44 Nm


mounting bolts
21 Nm
right-hand side reinforcement mounting bolts
21 Nm
Remove:

WARNING
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
- protection down to - 25 C 2 for cold and temperate countries,
- protection down to - 40 C 2 for "extreme cold"
countries.
IMPORTANT
101212

Remove:
Do not remove the cap from the expansion bottle

- the right-hand side reinforcement mounting bolts,
When working under the bonnet, be aware that the

radiator cooling fan(s) may start without warning.
- the right-hand side reinforcement (1) ,

Suspended engine mounting, Rear suspended
engine mounting: Removal - Refitting ),
19A-27
COOLING SYSTEM
19A
M9R, and 700
115585

114933
Remove:
- the clips (6) ,
102365
Remove:
112658
Remove:
(3) ,

Clean the engine cooling system (see 19A, Cooling, Engine cooling system: Cleaning ).
Remove the cooling radiator - condenser intercooler assembly from its housing and move it
towards the front of the vehicle.
Rest the engine on the two pads of the (Mot. 1390).
19A-28
COOLING SYSTEM
19A
M9R, and 700
116055
Remove:
- the sound insulation mounting bolt (9) ,
- the sound insulation.
Unclip the manual priming pump from its support.
Mark the right-hand suspended engine mounting in
relation to the bodywork.
Remove:
- the manual priming pump support,
- the bolt (10) securing the right-hand suspended engine mounting on the engine stand,
- the bolts (11) securing the right-hand suspended
engine mounting on the body,
- the upper engine tie-bar (12) .
19A-29
114863
Move the (Mot. 1390) towards the front of the vehicle while lifting the right-hand suspended engine
mounting (13) , until the air conditioning compressor
pulley (14) is flush with the end of the RH side member.
COOLING SYSTEM
19A
M9R, and 700

CONCERNED
114858
Remove:
- the coolant pump pulley mounting bolts (15) ,
- the coolant pump pulley (16) .
114863
Remove:
- the coolant pump.
REFITTING
Clean:
- the cylinder block gasket face,
- the coolant pump sealing face if it is to be reused,
- the coolant pump housing if it is to be reused,
WARNING
The sealing faces and housing must be clean,
dr y and free from grease (avoid finger marks).
19A-30
COOLING SYSTEM
M9R, and 700
CONCERNED
Fit a new seal into the coolant pump housing.
Apply soapy water to the seal before refitting the
coolant pump.
Refit the coolant pump.
Note:
Check that the coolant pump is in contact with
the cylinder block before tightening the mounting
bolts.
114863
Fit the coolant pump mounting bolts without tightening them.

Refit the coolant pump pulley.
Fit the coolant pump pulley mounting bolts without tightening them.
Tighten to torque the coolant pump pulley mounting bolts (21 Nm) .
19A-31
19A
COOLING SYSTEM
19A
M9R, and 700

Position:
- the engine - gearbox assembly on the vehicle,

- the cooling radiator - condenser - intercooler
assembly on the half sub-frame.
Refit the clips.

Position the bonnet opening cable
Refit:

Refit:
- the right-hand suspended engine mounting bolts

on the body,

- the bolts securing the right-hand suspended engine mounting on the engine stand.
Tighten to torque:
- the engine accessories unit cover mounting bolts,
- the upper engine tie-bar mounting bolts (see 19D,

Engine mounting, Suspended engine mounting: Tightening torque ),

- the bolts securing the right-hand suspended engine mounting on the body (see 19D, Engine mounting, Suspended engine mounting: Tightening
torque ),

mounting: Removal - Refitting ),
- the bolts securing the right-hand suspended engine mounting on the engine stand (see 19D, Engine
mounting, Suspended engine mounting: Tightening torque ),
- the right-hand side reinforcement,

- the right-hand side reinforcement mounting bolts.
Tighten to torque the right-hand side reinforcement mounting bolts (21 Nm) .
Refit the manual priming pump support.

Clip on the manual priming pump.
Refit:
Refit:
- the sound insulation,
- the sound insulation mounting bolt.

Tighten to torque the sound insulation mounting bolt
(see 19D, Engine mounting, Suspended engine
mounting: Tightening torque ),
Fill the cooling system (see 19A, Cooling, cooling
system: Draining - Filling ).

Refit the front end panel.

Fit without tightening:
- bleed the cooling system (see 19A, Cooling, Cooling system: Bleeding ),

Tighten to torque:
Nm) ,
Nm) .
19A-32

Adjustment ),
COOLING SYSTEM
Plenum chamber: Removal - Refitting
19A
M9R, and 700


Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.

Exterior protection, Front bumper removal - refitting ).
Engine cooling system: Draining - Refilling ).
Clean the engine cooling system (see 19A, Cooling, Engine cooling system: Cleaning ).
Tightening torquesm
coolant outlet unit
mounting bolts
11 Nm

bolts
21 Nm
WARNING
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
- protection down to - 25 C 2 for cold and temperate countries,
- protection down to - 40 C 2 for "extreme cold"
countries.
112659
Disconnect:
IMPORTANT

Do not remove the cap from the expansion bottle

Unclip:
- the wiring harness (2) from the injection computer
connector,
When working under the bonnet, be aware that the

radiator cooling fan(s) may start without warning.
REMOVAL
- the regulation solenoid valve wiring harness from

the turbocharger and the air flowmeter,
- the wiring harness from the injection computer connectors and the air flowmeter and turbocharger regulation solenoid valve.
Remove:
Remove:
19A-33
COOLING SYSTEM
19A
M9R, and 700

support.
Unclip the breather pipe from the gearbox.
113291
Remove:
- the mounting bolts (8) from the coolant outlet unit,
- the coolant outlet unit.
114934
Disconnect the coolant temperature sensor connector (5) .
REFITTING

CONCERNED
Clean:
- the cylinder head gasket face,
- the coolant outlet unit gasket face if needed to be
reused,
- the coolant outlet unit gasket housing if needed to
be reused.
WARNING
The gasket faces and housing must be clean, dry
and free from grease (in particular, avoid finger
marks).
113293
II - REFITTING PART CONCERNED
Unpick the wiring harness (6) from the coolant outlet

unit.
Position a new seal in the coolant outlet unit housing.
Move the cooling hose clips away from the coolant

outlet unit (7) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448).
Refit the coolant outlet unit.
Disconnect the cooling hoses from the coolant outlet

unit.
19A-34
Screw on the coolant outlet unit mounting bolts without tightening them.
COOLING SYSTEM
19A
M9R, and 700

Attach the wiring harness to the coolant outlet unit.
Connect the coolant temperature sensor connector.
Clip the breather pipe onto the gearbox.
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining - Refilling ).
Refit the battery tray with the injection computer support.
113291
Tighten to torque and in order the coolant outlet

unit mounting bolts (11 Nm) .
Refit:
Connect the coolant outlet unit cooling hoses.

Position the coolant outlet unit cooling hose clips
using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).

(21 Nm) .
Clip:
- the wiring harness to the injection computer connectors and the air flowmeter and turbocharger regulation solenoid valve,
- the regulation solenoid valve wiring harness to the
turbocharger and the air flowmeter,
- the wiring harness to the battery negative terminal,
Connect:
Refit:
19A-35
COOLING SYSTEM
Electric water pump: Removal - Refitting
19A
F9Q, and 804

Remove the hose clamps (Ms. 583).
Reconnect the electric water pump connector.

Ms. 583
Hose clamp pliers.
Mot. 1202-01

clips.
Mot. 1202-02

clips.
Mot. 1448

hose clips.
Bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ).
WARNING
REMOVAL
terminal.
1
2
111919
Disconnect the electric water pump connector (1) .

Fit the hose clamps (Ms. 583) in accordance with
the marks (2) .
Disconnect the cooling hoses using tool (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448).
Remove the electric water pump.
REFITTING
Refit the electric water pump.
Reconnect the electric water pump cooling hoses
using tool (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448).
19A-36
EXHAUST
General information
Cut zone 1

Mot. 1199-01
19B
35/50 mm diameter
and 50/95 mm diameter exhaust pipe cutting tool. Complete
assembly in kit.
The whole exhaust pipe is made of stainless steel.

The catalytic converter reaches high temperatures; do
not park the vehicle close to flammable materials.
WARNING
Any damaged heat shields must be replaced.
The sealing between the exhaust manifold gasket
face and the catalytic converter must be perfect.
All seals that have been removed must be replaced.
Take care not to damage the catalytic converter
during removal and refitting.
101504
Cut zone 2
SPECIAL NOTES ON THE EXHAUST PIPE

1 - Cutting the exhaust pipe
The exhaust pipe is a single unit type.
When replacing one of the components, cut the exhaust pipe.
Correctly identify the area to be cut.
Use the cutting tool (Mot. 1199-01) correctly.
Position the after sales sleeve correctly.
2 - Identifying the cut zone
Two punch marks on the exhaust pipe indicate the cut
zone (see 19B, Exhaust, Exhaust pipe assembly ).
101503
19B-1
EXHAUST
General information
19B
STANDARD CHASSIS
D
P1
Special notes on the replacement part

P2
X1
101960
100649
WARNING
Before cutting the pipe, mark the midpoint (D) between

the two marks (P1) and (P2) .
When replacing the middle section of the exhaust

pipe (pipe on diesel version, expansion chamber on
petrol versions), the replacement part needs to be
shortened by 60 mm .
The distance between the two marks is (X1) = 90 mm .
3 - Using tool Mot. 1199-01
4 - Fitting the after sales sleeve

Apply exhaust pipe mastic inside the sleeve.
To prevent any exhaust leaks, position the sleeve correctly on both lugs.
Position the sleeve on the worn section of the pipe.
Adjust the clip diameter by tightening slightly.
102118
Position the tool on the pipe.

Tighten the two bolts on the cutting tool so that the cutting tool grips the exhaust pipe.
Turn the cutting tool with the handle while gripping the
pipe.
As the cut is made, continue to tighten the two bolts of
the tool (do not overtighten the tool against the pipe, to
prevent deformation during the cutting operation).
19B-2
EXHAUST
General information
19B
Cut zone 2
95478
101500
Place the sleeve end on the worn section of the pipe.

Adjust the sleeve diameter by tightening gently.
5 - Special notes about cut zone 2
Cut zone 1
Remove the bolt securing the rubber mounting bush

(2) onto the body.
Lower the exhaust pipe.
Position the (Mot. 1199-01) on the pipe.
Cut the exhaust pipe .
WARNING
Do not reuse a used clip.
WARNING
Do not reuse a used sleeve.
The sleeve bolt and tightening nut must be positioned so that they cannot come into contact with the
underbody.
101501
Tighten to torque the exhaust sleeve nut (25 Nm) .

When tightening to torque, a click indicates that the torque of (25 Nm) has been reached.
Check:
- there is no contact with the underbody,
- the presence and correct positioning of all the exhaust pipe heat shields.
19B-3
EXHAUST
Pipe assembly
19B
K4J, and 730 K4M, and 761 or 782 F4R, and 770 or 771 or 776 K9K, and 722 or 728 or 732 F9Q, and 804
or 812 M9R, and 700
K4J, and 730
112063
19B-4
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
K4M, and 761 or 782
112062
19B-5
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
F4R, and 770 or 771 or 776
112061
19B-6
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
K9K, and 722
112060
19B-7
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
K9K, and 728 or 732 M9R, and 700
112059
19B-8
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
F9Q, and 804
112058
19B-9
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Pipe assembly
19B
or 812 M9R, and 700
F9Q, and 812
112059
19B-10
(1)
Cut zone 1
(2)
Cut zone 2
EXHAUST
Catalytic pre-converter: Removal - Refitting
19B
F4R, and 776
REMOVAL
Tightening torquesm
downstream oxygen
sensor
34 Nm
catalytic converter nuts

(on the turbocharger)
40 Nm
upstream stay mounting bolts (on the

engine)
38 Nm
upper bracket mounting bolt (on the exhaust

manifold)
8 Nm
d ownstream stay
mounting nut on the
gearbox
44 Nm
catalytic converter
mounting bolt (on the
upstream stay)
8 Nm
upper bracket mounting bolt (on the catalytic

converter)
8 Nm
catalytic converter
downstream stay
8 Nm
exhaust bracket studs
8 Nm
106246
Remove:
upstream oxygen sensor
- the heat shield mounting bolts (1) ,

- the heat shield.
34 Nm
Remove the engine in order to remove the catalytic

pre-converter (see 10A, Engine and peripherals, Engine - gearbox ).
5
21926
Disconnect the oxygen sensor connector (2) .

Remove:
- the upper bracket mounting bolts,
- the upper bracket (3) ,
- the upstream stay mounting bolts,
19B-11
EXHAUST
19B
F4R, and 776

- the upstream stay (4) ,
Refit the upstream oxygen sensor connector on the

catalytic converter.
- the downstream stay mounting nut and bolt,
Tighten to torque the upstream oxygen sensor (34

Nm) .
- the downstream stay (5) ,

turbocharger,
Note:
Make sure there is no contact between the catalytic converter and the turbocharger oil return
pipe.
On the workbench, remove the oxygen sensors.
REFITTING
On the workbench, refit the downstream oxygen

sensor on the catalytic converter.
Tighten to torque the downstream oxygen sensor
(34 Nm) .
WARNING
Be sure to replace all the exhaust bracket and
turbocharger seals.
Tighten in order and until contact:
- the upstream stay mounting bolt (on the engine),
- the upper bracket mounting bolts,
- the nuts securing the catalytic converter to the turbocharger,
- the catalytic converter mounting bolt on the upstream stay,
- the downstream stay mounting nut on the gearbox,
- the catalytic converter mounting bolt on the downstream stay,
- the catalytic converter nuts (on the turbocharger) (40 Nm) ,
- the upstream stay mounting bolts (on the engine) (38 Nm) ,
- the upper bracket mounting bolt (on the exhaust manifold) (8 Nm) ,
- the downstream stay mounting nut on the gearbox (44 Nm) ,
- the catalytic converter mounting bolt (on the
upstream stay) (8 Nm) ,
- the upper bracket mounting bolt (on the catalytic converter) (8 Nm) ,
- the catalytic converter mounting bolt on the
downstream stay (8 Nm) ,
- the exhaust bracket studs (8 Nm) .
19B-12
EXHAUST
19B
F9Q, and 804

Equipment required
IMPORTANT
During this operation, secure the vehicle to the
lift with a safety belt , to prevent it from becoming unbalanced.
safety belt
Tightening torquesm
connector clip between
the turbocharger and
the catalytic pre-converter
20 Nm
catalytic pre-converter
upstream stay mounting nuts on the engine
30 Nm
upstream stay mounting nuts on the catalytic pre-converter
30 Nm
gearbox side downstream stay mounting
bolts on the engine
50 Nm
gearbox side downstream stay mounting
bolts on the catalytic
pre-converter
50 Nm
timing end downstream
stay mounting bolt on
the engine
50 Nm
timing end downstream
stay mounting nuts on
the catalytic pre-converter
30 Nm
output exhaust bracket
studs
7 Nm

bolts
For the strap fitting procedure, (see 02A, Lifting

Remove:
terminal.
Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle panel
grille).
104343
Remove:
21 Nm
4 Nm
19B-13
EXHAUST
19B
F9Q, and 804

- the turbocharger - catalytic pre-converter connector clip mounting bolts (5) .
104246
Remove:
6
7
111864
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal Refitting ),
Remove:
- the catalytic pre-converter downstream stay mounting nuts (6) on the timing end,
- the exhaust bracket nuts,
- the catalytic pre-converter downstream stay mounting bolts (7) on the timing end,
- the catalytic pre-converter downstream stay on the

timing end,
- the catalytic pre-converter downstream stay mounting bolts on the gearbox side,
- the catalytic pre-converter downstream stay on the
gearbox side,
- the catalytic pre-converter.
REFITTING
WARNING
Always replace:
- the catalytic converter seal,
111862
- the connector clip between the turbocharger

and the catalytic pre-converter.
On the workbench, refit the gearbox-side downstream stay to the catalytic pre-converter.
Remove:
- the catalytic pre-converter upstream stay mounting
bolts (4) ,
- the catalytic pre-converter upstream stay,
19B-14
Tighten the gearbox-side downstream stay mounting bolts on the catalytic pre-converter so that they
make contact.
EXHAUST
19B
F9Q, and 804

Fit the catalytic pre-converter to the engine.
Tighten the gearbox-side downstream stay mounting bolts on the engine so that they make contact.
- the connector clip between the turbocharger

and the catalytic pre-converter (20 Nm) .
Refit:
- the connector clip between the turbocharger and
the catalytic pre-converter,
- the catalytic pre-converter upstream stay

mounting nuts on the engine (30 Nm) ,
- the catalytic pre-converter upstream stay
mounting nuts on the catalytic pre-converter
(30 Nm) ,
- the catalytic pre-converter upstream stay.

nuts on the engine,
nuts on the catalytic pre-converter,
Loosen then tighten in order and until they make
contact:
- the catalytic pre-converter gearbox-side downstream stay mounting bolts on the engine,
- the catalytic pre-converter gearbox-side downstream stay mounting bolts on the catalytic pre-converter.
Refit the catalytic pre-converter downstream stay on
the timing end.
- the catalytic pre-converter gearbox side downstream stay mounting bolts on the engine (50
Nm) ,
- the catalytic pre-converter gearbox side downstream stay mounting bolts on the catalytic preconverter (50 Nm) ,
- the catalytic pre-converter timing end downstream stay mounting bolt on the engine (50 Nm)
,
- the catalytic pre-converter timing end downstream stay mounting nuts on the catalytic preconverter (30 Nm) .
Note:
- the catalytic pre-converter timing-end downstream

stay mounting bolt on the engine,
- the catalytic pre-converter timing-end downstream
stay mounting nuts on the catalytic pre-converter,
- the connector clip between the turbocharger and
the catalytic pre-converter.
Make sure there is no contact between the catalytic pre-converter and the turbocharger oil return
pipe.
Tighten to torque:
- the catalytic pre-converter output exhaust bracket studs (7 Nm) .
Make sure there is no contact with the underbody.
WARNING
WARNING
(4 Nm) .
19B-15
EXHAUST
Catalytic converter: Removal - Refitting
19B
F9Q, and 812
Tightening torquesm
nuts securing the catalytic converter to the turbocharger
30 Nm
stay nut
30 Nm
stay mounting bolt
44 Nm
stay mounting nuts and

bolts
21 Nm
7 Nm
21 Nm
104343
bolt securing the

engine tie-bar to the
engine
180 Nm
bolt securing the

engine tie-bar to the
sub-frame
105 Nm
bolt securing the

exhaust pipe bracket to
the body
21 Nm

bolts
4 Nm
Remove:
REMOVAL
terminal.
104246
Remove:
19B-16
EXHAUST
19B
F9Q, and 812
6
4
101118
102117
Remove the (6) silencer rubber mounting bush bolt.
Remove the exhaust bracket nuts (4) .

vehicle.
Note:
Mark the position of the exhaust rubber mounting
bush supports on the vehicle body with a pen.
102479
Remove the catalytic converter stay mounting bolts

(7) .
102116
Remove the mounting bolt (5) of the exhaust pipe rubber mounting bush on the body.
19B-17
EXHAUST
19B
F9Q, and 812
10
8
101120
101121
Remove:
Remove:
- the catalytic converter stay mountings (8) ,
- the engine lifting bracket,
- the catalytic converter stay.

turbocharger,
- the catalytic converter from underneath the vehicle.
REFITTING
WARNING
The order for fitting the catalytic converter stays
must be observed.
WARNING
The gaskets must always be replaced.
Refit and tighten to torque the nuts securing the
catalytic converter to the turbocharger (30 Nm) .
102313
Remove the engine tie-bar (9) .
19B-18
Refit the catalytic converter stays observing the order of fitting.
EXHAUST
19B
F9Q, and 812

Refitting the stay at the timing end
Refitting the stay at the flywheel end
14
15
13
11
12
101120
Refit the stay, finger tightening nut (11) and bolt (12)
, (without tightening fully).
- the stay nut (30 Nm) (11) ,
102479
Refit the catalytic converter stay mountings by hand

(without tightening fully) and in the correct tightening
order.
Tighten to torque and in order the stay mounting
nuts and bolts (21 Nm) .
- the stay mounting bolt (44 Nm) (12) .
Note:
pipe.
Tighten to torque:
- the exhaust bracket studs (7 Nm) ,
- the exhaust bracket nuts (21 Nm) ,
- the bolt securing the engine tie-bar to the engine (180 Nm) ,
- the bolt securing the engine tie-bar to the subframe (105 Nm) ,
- the bolt securing the exhaust pipe bracket to
the body (21 Nm) ,
19B-19
EXHAUST
F9Q, and 812
WARNING
(4 Nm) .
19B-20
19B
EXHAUST
19B
K9K, and 722 or 728 or 732
Tightening torquesm
turbocharger outlet
studs
7 Nm
26 Nm
bolts securing the upstream stay to the engine
44 Nm
bolts securing the

downstream stay to the
gearbox
21 Nm
bolt securing the upstream stay to the catalytic converter
25 Nm
bolt securing the

downstream stay to the
catalytic converter
21 Nm
bolt securing the

exhaust pipe bracket to
the body
21 Nm
catalytic converter outlet exhaust bracket

studs
7 Nm
104343
Remove:
21 Nm

with their springs
21 Nm

bolts
4 Nm
104246
Remove:
REMOVAL
- the scuttle panel mounting bolts (3) ,

terminal.
19B-21
EXHAUST
19B
K9K, and 722 or 728 or 732
102076
Remove:
102116
Remove the mounting bolt (7) from the exhaust pipe

rubber mounting bush on the body.
- the exhaust bracket mountings (4) ,

- the catalytic converter downstream stay mounting
(5) .
Loosen the other stay mountings on the gearbox.
Remove the catalytic converter downstream stay (6)
.
Note:
102117
Remove the silencer rubber mounting bush mounting bolt (8) .

vehicle.
19B-22
EXHAUST
19B
K9K, and 722 or 728 or 732
REFITTING
WARNING
Always replace:
- the catalytic converter seals,
- the turbocharger - catalytic converter bracket
studs.
Tighten to torque the turbocharger outlet studs (7
Nm) .
Fit the catalytic converter.
10

- the upstream stay bolts on the engine,
- the upstream stay bolts on the catalytic converter,
9
102077
Remove:
- the catalytic converter upstream stay mounting
bolts,
- the catalytic converter upstream stay (9) ,
turbocharger,
- the downstream stay bolts on the gearbox,

- the downstream stay bolts on the catalytic converter,
- the catalytic converter - turbocharger mounting
nuts.
- the nuts securing the catalytic converter to the
turbocharger (26 Nm) ,
- the bolts securing the upstream stay to the engine (44 Nm) ,
- the bolts securing the downstream stay to the
gearbox (21 Nm) ,
- the bolt securing the upstream stay to the catalytic converter (25 Nm) ,
- the bolt securing the downstream stay to the
catalytic converter (21 Nm) ,
- the bolt securing the exhaust pipe bracket to
the body (21 Nm) ,
Note:
pipe.
K9K, and 722 or 728

Tighten to torque:
- the catalytic converter outlet exhaust bracket
studs (7 Nm) ,
19B-23
EXHAUST
K9K, and 722 or 728 or 732
K9K, and 732


WARNING
WARNING
(4 Nm) .
19B-24
19B
EXHAUST
19B
Mot. 1495-01
22 mm socket for
Tightening torquesm
oxygen sensor
45 Nm
7 Nm
exhaust bracket mounting nuts
21 Nm

bolts
4 Nm
REMOVAL
101793
Remove:

terminal.
- the mounting nuts (1) from the exhaust bracket,

REFITTING

770 or 771
Remove the downstream oxygen sensor.
WARNING
Do not reuse an old sleeve.
Cut the exhaust pipe (see 19B, Exhausts, General

information ).
The sleeve tightening nuts and bolts must be

positioned so that they cannot come into contact
with the underbody.
Refit the downstream oxygen sensor.
Tighten to torque the oxygen sensor (45 Nm) using
the (Mot. 1495-01).
Refit and tighten to torque if necessary the exhaust
bracket studs (7 Nm) .
Fit:
- the catalytic converter,
- the sleeve (see 19B, Exhausts, General information ).
19B-25
EXHAUST
WARNING
Always replace:
- the exhaust bracket seal,
- all the disconnected air inlet plastic pipes.
Tighten to torque the exhaust bracket mounting
nuts (21 Nm) .
Tighten the sleeve while easing the exhaust pipe to
ensure alignment.
Reconnect the oxygen sensor.
WARNING
(4 Nm) .
19B-26
19B
EXHAUST
19B
M9R, and 700
REMOVAL
Equipment required
safety belt

Tightening torquesm
14.5 Nm
bolts securing the catalytic converter mounting

clamp to the cylinder
block
21 Nm

studs
19.5 Nm
21 Nm
catalytic converter halfclamp mounting bolts
21 Nm
bolt securing the stay to

8 Nm
nuts securing the stay

to the cylinder block
21 Nm
nuts securing the stay

to the catalytic converter
21 Nm
bolts of the ball joint

bracket with springs
21 Nm
silencer rubber mounting bush mounting bolt
21 Nm
exhaust pipe rubber

mounting bush mounting bolt
21 Nm
Remove:
104343
Remove:
IMPORTANT
104246
Remove:
19B-27
EXHAUST
19B
M9R, and 700

- the nuts (7) securing the stay on the cylinder block,
- the catalytic converter stay,
- the catalytic converter studs using a roller-type
stud removal tool.
114986
Remove:
turbocharger,
114991
Remove the bolts from the ball joint bracket (8) with
their springs.
114771
Remove:
- the lower engine tie-bar (see 19D, Engine mounting, Rear suspended engine mounting: Removal - Refitting ),
- the catalytic converter stay mounting bolt (5) ,
- the catalytic converter stay mounting nuts (6) ,
19B-28
EXHAUST
19B
M9R, and 700
102116
114985
Remove:
- the mounting bolt (11) from the gearbox controls
retaining bracket,
- the gearbox controls retaining bracket.
CONCERNED
102117
Note:
Remove:
- the exhaust pipe rubber mounting bush mounting
bolt (9) ,
Remove:
- The silencer rubber mounting bush mounting bolt

(10) .
- the catalytic converter half-clamp mounting bolts

(12) ,
Remove the exhaust pipe.
- the catalytic converter half-clamps (13) .
19B-29
114980
EXHAUST
19B
M9R, and 700

Remove the catalytic converter at the timing end.
REFITTING
Fit the catalytic converter using a safety belt to the

lifting eye on the timing end.

Remove the seal from the ball joint bracket.
Remove the turbocharger studs using a roller-type
stud removal tool.
Clean and degrease the bearing faces:
- on the exhaust pipe,
- on the catalytic converter in case of reuse,
- on the turbocharger,
Refit the new studs onto the turbocharger using a
Tighten to torque the studs on the turbocharger
(14.5 Nm) .
Fit the new catalytic converter mounting clamps onto
the cylinder block.
Finger tighten the bolts securing the catalytic converter mounting clamp to the cylinder block until contact is made.
114981
Remove:
- the catalytic converter mounting clamp mounting
bolts (14) ,
- the catalytic converter mounting clamps.
Move the engine towards the front of the vehicle.
114843
Remove the catalytic converter.
19B-30
Tighten to torque the bolts securing the catalytic

converter mounting clamp to the cylinder block
(21 Nm) .
EXHAUST
19B
M9R, and 700

- the catalytic converter half-clamp mounting
bolts (21 Nm) ,

CONCERNED
- the bolt securing the stay to the catalytic converter (8 Nm) ,

- the nuts securing the stay to the cylinder block
(21 Nm) ,
- the nuts securing the stay to the catalytic converter (21 Nm) .
Refit:
- the gearbox controls retaining bracket,
- the mounting bolt for the gearbox controls retaining
bracket.
mounting, Rear suspended engine mounting:
114844
Move the engine towards the front of the vehicle.
Tighten to torque the lower engine tie-bar (see 19D,

Refit the new seal to the ball joint bracket.
Fit:
Fit the exhaust pipe.
- the new seal between the turbocharger and the catalytic converter,
Refit:
- the exhaust pipe rubber mounting bush mounting

bolt, aligning the marks,
Refit the catalytic converter onto the turbocharger.
- the silencer rubber mounting bush mounting bolt,

aligning the marks,
Fit:
- the new catalytic converter nuts onto the turbocharger,
- the new catalytic converter half-clamps.
Refit the new studs onto the catalytic converter
using a roller-type stud removal tool.
Tighten to torque the catalytic converter studs
(19.5 Nm) .
Refit:
- the ball joint bracket bolts with springs.

Tighten to torque:
- the bolts of the ball joint bracket with springs
(21 Nm) ,
- the silencer rubber mounting bush mounting
bolt (21 Nm) ,
- the exhaust pipe rubber mounting bush mounting bolt (21 Nm) .
Refit:
- the catalytic converter half-clamp mounting bolts,
- the catalytic converter stay,
- the catalytic converter stay mounting bolt,
- the stay mounting nuts onto the catalytic converter,
- the stay mounting nuts onto the cylinder block.
Tighten to torque:

- the nuts securing the catalytic converter to the

turbocharger (21 Nm) ,
19B-31
EXHAUST
M9R, and 700
19B-32
19B
EXHAUST
Expansion chamber: Removal - Refitting
19B
REFITTING
Fit:
Tightening torquesm
rubber mounting support bolt on the expansion chamber
8 Nm
rubber mounting support bolt on the body
21 Nm
- the expansion chamber,

- the sleeve (see 19B, Exhaust, General Vehicle
Information ).
WARNING
Cut the new expansion chamber pipe (see 19B,
Exhaust, General Vehicle Information ).
REMOVAL
Tighten to torque:
- the rubber mounting support bolt on the expansion chamber (8 Nm) ,

Cut the exhaust pipe (see 19B, Exhaust, General
Vehicle Information ).
- the rubber mounting support bolt on the body

(21 Nm) .
Tighten the sleeve, while easing the exhaust pipe to
ensure the correct alignment of the pipe.
WARNING
- Any damaged heat shields must be replaced.
- Do not reuse an old sleeve.
101818
Remove:
- the mounting bolts (1) securing the expansion
chamber to the rubber mounting support,
- the expansion chamber.
Note:
If the rubber mountings are damaged, mark the
position of the support on the body, then replace
the support/rubber mounting assembly.
19B-33
- The sleeve bolts and tightening nuts must

be positioned so that they cannot come into
contact with the underbody.
EXHAUST
Silencer: Removal - Refitting
19B
Tighten to torque:
- the rubber mounting support bolt on the silencer (8 Nm) ,
Tightening torquesm
rubber mounting support bolt on the silencer
8 Nm
- the rubber mounting support bolt on the body

(21 Nm) .
rubber mounting support bolt on the body
21 Nm
Tighten the sleeve, while easing the exhaust pipe to

ensure the correct alignment of the pipe. 19B, Exhaust, General Vehicle Information ).
REMOVAL
Cut the exhaust pipe (see 19B, Exhaust, General
Vehicle Information ).

WARNING
- Any damaged heat shields must be replaced.
- Do not reuse an old sleeve.
- The sleeve tightening nut and bolts must be
positioned so that they cannot come into contact with the underbody.
101817
Remove:
- the silencer mounting bolts (1) on the rubber mounting support,
- the silencer.
Note:
If the rubber mountings are damaged, mark the
position of the support on the body, then replace
the support / rubber mounting assembly .
REFITTING
Fit:
- the silencer,
- the sleeve (see 19B, Exhaust, General Vehicle
Information ).
19B-34
EXHAUST
Particle filter: Function
19B
F9Q, and 804

the particle filter clogging level depends on the user's
driving style:
Equipment required
- during an average trip (mixed cycle type and motorway of more than 15 min ), the particle filter automatically burns the particles without the customer
noticing (apart from some white smoke): this is
spontaneous regeneration ,
diagnostic tool
I - SAFETY ADVICE
Due to the dangers of high temperatures, be sure to
observe the following instructions:
- Never open or separate the pressure measurement
circuit, except at unions on the exhaust line (only the
supplier can ensure that the pressure measurement
circuit is correctly sealed),
- Position the pressure pipes correctly. If the pipes are
not positioned correctly, their flexible sections may be
twisted which will create low points and this may result in the pipes rupturing when fluid freezes and expands.
- when the operating temperature is not high enough to

trigger spontaneous regeneration, clogging increases
until it reaches 35 g (min) ; an acceleration request to
trigger spontaneous regeneration is then sent to the
driver via an instrument panel warning light; the same
happens if several attempts to regenerate have failed.
- if these conditions are still not met and clogging reaches 45 g (min) . Static regeneration , using diagnostic tool must be performed in the workshop (
SERVICE warning light comes on and the
CHECK ANTIPOLLUTION message appears:
(see 19B, Exhaust, Particle filter: Cleaning ).
IMPORTANT
Do not park and run the engine in a place where
combustible substances and materials such as
grass or leaves can come into contact with the hot
exhaust system.
II - OPERATING PRINCIPLE
The particle filter, placed underbody on the catalytic
pre-convertor outlet, limits the polluting emissions by
accumulating the unburnt particles from the exhaust fumes (loading or filtering phase), then these particles
are eliminated by combustion (regeneration phase).
Using sensors, the injection computer measures the
temperature as well as the pressure of the exhaust fumes upstream and downstream of the particle filter.
The injection computer permanently continuously evaluates the level of clogging of the particle filter using the
pressure difference upstream and downstream of the
particle filter. When it is loaded, the two temperature
values inform the injection computer that the temperature conditions are high enough (approximately 600C
) to trigger regeneration.
Regeneration consists of burning the particles held in
the particle filter: to do this, the injection goes over to
delayed injection mode and the fuel not burned in
the combustion chambers burns the residues contained in the particle filter cells.
19B-35
EXHAUST
Particle filter: Parts description
19B
F9Q, and 804
107038
(1)
Connection hose
(2)
Particle filter
(3)
Rubber mounting
(4)
Particle filter pressure sensor
(5)
Upstream pressure measurement tapping
(6)
Downstream pressure measurement tapping
(7)
Upstream particle filter temperature sensor
(8)
Downstream particle filter temperature sensor
19B-36
EXHAUST
Particle filter: Removal - Refitting
19B
F9Q, and 804
Equipment required
diagnostic tool
Tightening torquesm
nut securing the rubber
mounting bush support
on the particle filter
25 Nm

between the connection
hose and the catalytic
pre-converter
21 Nm
rubber mounting bush

nuts on the sub-frame
25 Nm
exhaust sleeve nut
25 Nm
adapter
44 Nm
downstream pressure
measurement tapping
on its adapter
21 Nm
connection clip bolt

between the silencer
and the particle filter
25 Nm
exhaust flange nuts

between the connection
hose and the catalytic
pre-converter
21 Nm
nuts mounting the rubber mounting bush support on the sub-frame
25 Nm
106673
Remove the downstream pressure pipe (1) from its

adapter (2) bolted to the exhaust pipe.
WARNING
When the pressure measurement tapping is
removed, the adapter must be held (2) with a
lock wrench.
WARNING
The pressure measurement circuit must never be
opened except at the adapters on the exhaust
pipe.
REMOVAL
terminal.
Make a cut in the exhaust pipe, behind the particle
filter (see 19B, Exhaust, General information ).
19B-37
EXHAUST
19B
F9Q, and 804
111881
Remove the heat shield mounting clip (3) .
111882
Disconnect the particle filter pressure sensor connector (4) .
Move the heat shield to one side slightly.
Remove the retaining clip (5) from the wiring harness on the particle filter pressure sensor mounting.
Unpick:
- the downstream pressure measurement tapping
heat shield,
- the downstream temperature sensor wiring harness.
Pass the downstream pressure measurement tapping into the engine compartment whilst leaving the
pressure sensor complete.
B
A
6
111885
Disconnect the upstream and downstream temperature sensor offset connectors (6) .
Unpick the upstream and downstream temperature
sensor offset connectors (6) .
19B-38
EXHAUST
F9Q, and 804
7
111885
Remove:
- the mounting bolt (7) from the particle filter pressure sensor mounting.
- the particle filter pressure sensor assembly (8) and
its mounting.
19B-39
19B
EXHAUST
19B
F9Q, and 804
10
107038
Remove:
REFITTING
- the mounting nuts (9) on the exhaust flange

between the connection hose and the catalytic preconverter,
- the sub-frame rubber mounting bolts (10) ,
WARNING
Always replace:
- the particle filter.
- the seal between the hose and particle filter,
Once the particle filter has been removed, remove:
- the seal between the hose and the catalytic preconverter,
- the rubber mounting,

- the upstream and downstream temperature sensors from their adapters on the exhaust line (see
19B, Exhaust, Particle filter temperature sensor: Removal - Refitting ).
- the upstream pressure measurement tapping at its
adapter on the exhaust pipe (see 19B, Exhaust,
Particle filter pressure sensor: Removal - Refitting ).
- the connection hose (see 19B, Exhaust, Connection hose: Removal - Refitting ).
19B-40
- any adapter on the exhaust line that has been

removed,
WARNING
Always clean the bearing surfaces of the connection hose - par ticle filter flanges thoroughly.
Once the particle filter has been removed, refit:
- the connection hose and its new seals (see 19B,
Exhaust, Connection hose: Removal - Refitting
).
EXHAUST
19B
F9Q, and 804

- the upstream and downstream temperature sensors at their adapters on the exhaust line (see 19B,
Exhaust, Particle filter temperature sensors:
adapter on the exhaust line (see 19B, Exhaust,
- the rubber mounting on the particle filter.
Torque tighten the nut securing the rubber mounting bush support on the particle filter (25 Nm) .
Place the pressure sensor and its mounting in the
engine compartment before fitting the particle filter.
12
Tighten to torque:
- the exhaust bracket nuts between the connection hose and the catalytic pre-converter (21
Nm) .
- the rubber mounting bush nuts on the sub-frame (25 Nm) .
Fit the exhaust sleeve (see 19B, Exhaust, General
information ), applying a mastic seal.
Tighten to torque the exhaust sleeve nut (25 Nm)
at the same time as making sure that the exhaust
pipe is correctly aligned.
WARNING
When fitting the particle filter, be sure to pass the
downstream pressure measurement tapping
behind the heat shield.
Coat the downstream pressure measurement tapping threads with ANTI-SEIZE high temperature
grease.
WARNING
Make sure that the grease does not flow beyond
the threading.
19B-41
106673
WARNING
Always replace any adapter (12) that has been
removed from the exhaust line.
If it has been replaced, tighten to torque the adapter
(44 Nm) .
EXHAUST
19B
F9Q, and 804
106672
Fit the rigid part of the downstream pressure measurement tapping then position it so that it is parallel (
3) to the exhaust pipe longitudinal axis.
Tighten to torque the downstream pressure
measurement tapping on its adapter (21 Nm) bolted to the exhaust pipe.
WARNING
Make sure, after tightening the pressure measurement tappings, that the whole of the pressure
measurement tapping has no low points (siphon)
susceptible to water accumulation.
To do this:
Tighten to torque:
- the connection clip bolt between the silencer
and the particle filter (25 Nm) ,
- the exhaust flange nuts between the connection hose and the catalytic pre-converter (21
Nm) ,
- the nuts mounting the rubber mounting bush
support on the sub-frame (25 Nm) .
- check that the rigid sections of the pressure

pipes are correctly positioned in relation to the
exhaust pipe longitudinal axis,
- at the retaining clips, manipulate the pressure
measurement tappings on the heat shield (turn
the tapping in the clip so as to avoid the low
points).
WARNING
19B-42
EXHAUST
F9Q, and 804
WARNING
WARNING
With the engine running, carry out a leak test and
check, using a leak detector for 5 minutes , that
there is no leak on the adapters on the exhaust
pipe.
REINITIALISING THE PARTICLE FILTER
PARAMETERS
Command RZ008: ADAPTATIVES AFTER
REPLACEMENT OF THE PARTICLE FILTER
Note:
This command is only carried out after replacing
the particle filter.
Command SC030 enables the parameters to be reset to 0 depending on the type of operation carried
out. Select:
- PR391 : distance travelled since the particle filter
was last replaced,
- PR415 : distance travelled since the last regeneration
- PR412 : time since the last regeneration,
- PR383 : mass of soot in the particle filter.
Once the command has finished, check that the parameters are at 0, so that the computer establishes
a new regeneration strategy when driving and can
signal the system faults.
After repairing: Repeat the conformity check from
the start.
19B-43
19B
EXHAUST
Particle filter pressure sensor: Removal - Refitting
19B
F9Q, and 804
Equipment required
Tightening torquesm
diagnostic tool
adapter, if it has been

replaced
44 Nm
upstream pressure
measurement tapping
on its union screwed
into the exhaust pipe
21 Nm
C
B
107038
(A) Particle filter pressure sensor.

(B) Upstream pressure measurement tapping end
piece.
(C) Downstream pressure measurement tapping
end piece.
REMOVAL
Remove the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ).
19B-44
EXHAUST
19B
F9Q, and 804
2
3
4
6
1
106670
Remove the upstream pressure measurement tapping (1) from its adapter (2) screwed into the exhaust pipe.
111885
Remove:
- the mounting nut (3) from the particle filter pressure
sensor mounting (4) ,
- the particle filter pressure sensor:
WARNING
When the pressure measurement tapping (1) is
removed from its adapter, the adapter (2) must
be held with a lock wrench.
WARNING
Never separate the pressure measurement tappings (5) from the particle filter pressure sensor
(6) . Replace the sensor-pipes-end pieces as
a unit, supplied assembled by the Parts Department (see 19B, Exhaust, Particle filter: Function ).
WARNING
The pressure measurement circuit must never be
opened except at the adapters on the exhaust
pipe.
19B-45
EXHAUST
F9Q, and 804
REFITTING
106673
WARNING
removed from the exhaust pipe.
Tighten to torque the adapter, if it has been replaced (44 Nm) .
Coat the upstream pressure measurement tapping
threads with ANTI-SEIZE high temperature grease.
WARNING
the threading.
19B-46
19B
EXHAUST
19B
F9Q, and 804
106672
Fit the rigid part of the upstream pressure measurement tapping then position it so that it is parallel (
3) to the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measurement tapping on its union screwed into the exhaust pipe (21 Nm) .
Refit the particle filter (see 19B, Exhaust, Particle
filter: Removal - Refitting ).
WARNING
Make sure, after tightening the pressure measurement tappings, that this pressure measurement
line assembly has no low points (siphon) susceptible to water accumulation.
To do this:
- check that the rigid sections of the pressure
pipes are correctly positioned in relation to the
exhaust pipe longitudinal axis,
- at the retaining clips, manipulate the pressure
measurement tappings on the heat shield (turn
the tapping in the clip so as to avoid the low
points).
19B-47
EXHAUST
Particle filter temperature sensors: Removal - Refitting
19B
F9Q, and 804
Equipment required
Tightening torquesm
diagnostic tool
adapter, if it has been

replaced
44 Nm
upstream particle filter

temperature sensor
30 Nm
downstream particle filter temperature sensor
30 Nm
107038
(A) Upstream particle filter temperature sensor.

(B) Downstream particle filter temperature sensor.
I - (A) UPSTREAM PARTICLE FILTER
TEMPERATURE SENSOR
1 - Removal
Remove the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ).
19B-48
EXHAUST
19B
F9Q, and 804

- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
II - (B) DOWNSTREAM PARTICLE FILTER
TEMPERATURE SENSOR
1 - Removal
terminal.
1
106671
Remove the upstream particle filter temperature

sensor (1) from its adapter (2) screwed into the exhaust pipe.
WARNING
When the upstream particle filter temperature
sensor (1) is removed, the adapter must be held
(2) with a lock-wrench.
2 - Refitting
WARNING
111882

Disconnect the downstream particle filter temperature sensor offset connector (3) .

Coat the threads on the upstream particle filter temperature sensor with ANTI-SEIZE high-temperature
grease.
WARNING
the threading.
Tighten to torque the upstream particle filter temperature sensor (30 Nm) .
Check:
- that there is no contact with the wiring harness,
19B-49
EXHAUST
19B
F9Q, and 804

2 - Refitting
WARNING
B
A
Coat the threads on the downstream particle filter

temperature sensor with ANTI-SEIZE high-temperature grease.
WARNING
the threading.
Tighten to torque the downstream particle filter
temperature sensor (30 Nm) .
111885
Unclip the downstream particle filter temperature

sensor offset connector (3) from its mounting.
Check:
- that there is no contact with the wiring harness,
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
5
WARNING
106671
Remove the downstream particle filter temperature

sensor (4) from its adapter (5) screwed into the exhaust pipe.
WARNING
When the downstream particle filter temperature
sensor (4) is removed, the adapter must be held
(5) with a lock wrench.
19B-50
EXHAUST
Connecting hose: Removal - Refitting
19B
F9Q, and 804

Tightening torquesm
21 Nm
Tighten to torque the exhaust bracket nuts (21

Nm) between the connection hose and the particle
filter.
REMOVAL

Remove:
- the particle filter (see 19B, Exhaust, Particle filter: Removal - Refitting ).
- the upstream temperature sensor and its adapter
on the exhaust pipe (see 19B, Exhaust, Particle
filter temperature sensor: Removal - Refitting ).
Remove:
- the nuts from the exhaust between the connection
hose and the particle filter,
- the connection hose.
REFITTING
WARNING
Replace:
- the flange seal between the connection hose
and the catalytic pre-converter,
- the flange seal between the connection hose
and particle filter,
WARNING
Always clean the bearing surfaces thoroughly on:
- the flanges between the connection hose and
the catalytic pre-converter,
- the flange between the connection hose and
the particle filter,
Refit:
- the connection hose with new seals,
- the upstream temperature sensor and its adapter
on the exhaust pipe (see 19B, Exhaust, Particle
filter temperature sensor: Removal - Refitting ).
19B-51
EXHAUST
19B
F9Q, and 803 or 804

I - INSTRUCTIONS FOR CARRYING OUT FORCED
REGENERATION OF THE PARTICLE FILTER

Mot. 1329

(76 mm diameter).
Mot. 1018
Precautions to be taken during forced regeneration

of the particle filter
Sump plug tool.
Two additional equipment kits for workshop exhaust

gas extractors are available (see 2005 garage equipment catalogue ), both are approved for use at the
high temperatures produced during forced regeneration of a particle filter, for example.
Equipment required
kit for particle filter
kit for twin exhaust
These two kits approved for particle filter regeneration are:
diagnostic tool
- the kit for particle filter for use with vehicles

equipped with a single exhaust pipe on the silencer,
Tightening torquesm
engine drain plug
20 Nm

on the body
21 Nm

on the connector pipe
8 Nm
- the kit for twin exhaust for use with vehicles

equipped with a twin exhaust pipe on the silencer.
IMPORTANT
During forced regeneration of the particle filter,
the temperature of the exhaust pipe rises significantly.
Always use one of these kits approved for use at
the high temperatures generated during forced
regeneration, whether this is being carried out in
the workshop with an exhaust gas extractor or
outside the workshop.
Note:
Forced regeneration can only be carried out after
the SERVICE warning light comes on along
with the message REGENERATE PARTICLE
FILTER or the orange CHECK EMISSION
CONTROL warning light (see Driver's Handbook for vehicle concerned ).
Ensure that when in use, the kit is not touching

the rear bumper when carrying out forced regeneration of the particle filter.
19B-52
EXHAUST
19B
F9Q, and 803 or 804

Twin exhaust pipe kit special features
II - PROCEDURE FOR FORCED REGENERATION

OF THE PARTICLE FILTER USING THE CLIP
DIAGNOSTIC TOOL
Connect the diagnostic tool to the vehicle.
IMPORTANT
During forced regeneration of the particle filter,
the temperature of the exhaust pipe rises significantly.
Always use one of these kits approved for use at
the high temperatures generated during forced
regeneration, whether this is being carried out in
the workshop with an exhaust gas extractor or
outside the workshop.
Ensure that when in use the is not touching the
rear bumper when carrying out forced regeneration of the particle filter.
116224
WARNING
To prevent engine racing, check the engine oil
level using the dipstick before running the forced
regeneration command.
Note:
Ensure, when using a kit for twin exhaust (1)
on a single exit exhaust system:
The engine oil level must be between the

MIN and MAX marks on the dipstick.
- that an exhaust gas extractor is fitted to holes

(2) and (3) if forced regeneration is being carried out in the workshop,
For the particle filter forced regeneration procedure,

see MR 372 Fault finding, 13B, Diesel injection,
Fault finding - Interpretation of commands, Particle filter regeneration .
- that hoses (2) and (3) are positioned to direct

the hot exhaust gases away from another vehicle or a person, if the operation is being carried
out outside the workshop.
Note:
If required, the forced regeneration procedure
may be stopped by pressing the engine Start button twice in succession.
Note:
Strong odours and thick smoke are to be expected during forced regeneration of the particle filter.
When forced regeneration of the particle filter is
complete, use the diagnostic tool to:
- deal with the present faults,
- clear the stored faults.
19B-53
EXHAUST
19B
F9Q, and 803 or 804

Position the vehicle on a two-post lift (see MR 370
Mechanics, 02A, Lifting equipment, Towing and
lifting ).
Refit the filler cap.

Wait for 10 minutes .
Check the oil level using the dipstick.
IMPORTANT
Top up, if necessary.
Allow the engine to cool before draining the oil.

Remove the oil filter using the (Mot. 1329) for F9Q
engines.
Coat the new oil filter sealing ring with engine oil.
Note:
The engine oil level must be between the
MIN and MAX marks on the dipstick.
Tighten the oil filter until the seal makes contact with
the engine.
Note:
Tighten the new oil filter manually 3/4 of a turn.
After each particle filter forced regeneration,

always replace the exhaust system connector
pipe rubber mounting bush.
Wipe away any excess oil.

Remove:
- the engine oil filler cap,
- the sump drain plug using the (Mot. 1018) or an 8
mm square male drive drain plug socket .
Allow all the engine oil to flow into a drain tray.
Rubber-lipped seal
102116
Remove:
- the bolt (4) mounting the exhaust system connector
pipe rubber mounting bush on the body,
- the bolts (5) mounting the exhaust system connector pipe rubber mounting bush on the connector pipe.
113765
Refit the new seal (no direction of fitting for rubberlipped seals).
Fit the new exhaust system connector pipe rubber

mounting bush.
Tighten to torque:
Tighten to torque the engine drain plug (20 Nm) .
- the bolt mounting the rubber mounting bush on

the body (21 Nm) ,
Clean any traces of the drained oil from the sump.

- the bolts mounting the rubber mounting bush on

the connector pipe (8 Nm) .
Refill the engine oil.
19B-54
RESERVOIR
19C
K4J K4M F4R

K4M
Mot. 1311-08
Union for measuring

fuel pressure.
IMPORTANT


union,
DRAINING THE FUEL TANK
F4R or K4J
101803
Disconnect the fuel inlet union (1) .
Fit in place a (3) T (Mot. 1311-08) union.
3
Fit onto the T union outlet a pipe (2) long enough
to drain the pump into a container.
WARNING
The ignition must be switched off during this operation.
Remove the Protection and Switching Unit cover.
1
101496
Fit in place, the (3) T union from the kit (Mot.

1311-08).
19C-1
RESERVOIR
19C
K4J K4M F4R
102502
102501
Put the electrical connector (4) to one side, without

disconnecting it.
Plug the brown connector terminal (5) into the + battery feed to run the petrol pump.
Let the petrol flow out until it flows intermittently.
Disconnect the + battery feed from the terminal (5) .
5
Note:
It is also possible to use the pneumatic siphoning
pump for draining the fuel tank (see the Equipment catalogue) at the fuel supply outlet of the
dipstick.
102503
Disconnect the Protection and Switching Unit brown

connector (5) .
19C-2
RESERVOIR
19C
K9K F9Q M9R
Equipment required
petrol or diesel tank drain pneumatic siphoning

pump
IMPORTANT

union,
104617
Remove:
- the clips (1) ,
DRAINING THE FUEL TANK
- the trim (2) .
99641

terminal.
104618
Remove the seat mountings (3) .

Take out the carpet.
Note:
Since diesel vehicles are not fitted with an electrical fuel pump, the petrol or diesel tank drain
pneumatic siphoning pump must be used to
drain the tank.
Remove the rear seats (see MR 371 Bodywork,
76A, Rear seat runners and frames, Second row
complete rear seat ).
19C-3
RESERVOIR
19C
K9K F9Q M9R
104214
Remove the soundproofing pads (4) .
104203
Disconnect the tuner-amplifier (6) (if fitted to the vehicle).
7
104620
Remove the panel (5) .
104204
Remove:
- the tuner-amplifier unit mounting bolts (7) ,
- the tuner-amplifier unit assembly.
19C-4
RESERVOIR
19C
K9K F9Q M9R

Make preparations for fuel outflow.
Connect the suction pipe of the petrol or diesel
tank drain pneumatic siphoning pump in place of
the diesel supply quick-release union (11) .
Place the return pipe of the siphoning pump into a
container.
Run the petrol or diesel tank drain pneumatic siphoning pump.

Let the fuel flow out until it flows intermittently.
WARNING
104545
Remove the inspection flap blanking cover (8) .
10
11
105006
Disconnect:
- the electrical connectors (9) ,
- the quick-release diesel return union (10) and the
diesel supply union (11) .
19C-5
RESERVOIR
Fuel tank: Removal - Refitting
Equipment required
19C
F4R or K4J or K4M

Disconnect the petrol vapour absorber (see 14A,
Emission control, Fuel vapour absorber ).
component jack
Unclip the petrol vapour absorber pipes.

Tightening torquesm
fuel tank mounting bolts
21 Nm

bolt
4 Nm
Disconnect the connectors from the Pump-sender

unit assembly (see 19C, Tank, Pump/sender/filter ).
IMPORTANT
- refrain from smoking or bringing hot objects close

to the work area,
union,
REMOVAL
Drain the tank (see 19C, Tank, Draining the fuel

tank ).

terminal.
102465
Remove:
Remove:
- the reservoir and heat shield (1) mounting bolts,
- the exhaust clamp - manifold mounting nuts,
- the heat shield mounting clips (2) ,
- the expansion chamber - body mounting bolt,

- the silencer or intermediate tube rubber mounting
support connecting bolts,
- the exhaust pipe from the sub-frame and the rear
axle.
Disconnect the headlight height regulator sensor wiring (depending on the equipment level).
Disconnect the headlight height regulator sensor linkage (depending on the equipment level).
19C-6
- the heat shield (3) .
RESERVOIR
19C
102467
Remove the mounting clips (4) from the fuel and brake pipes.
102466
Remove the tank mounting bolts (6) .
Unclip:
- the fuel pipe unions from the catalytic converter,
- the fuel pipe clips.
Move the hoses aside.
102459
Remove the tank by turning it around the exhaust pipe.

Take care not to damage the brake pipes and the
parking brake cable.
5
102468
Remove the tank - neck connection hose clips (5) .

Fit the component jack under the reservoir.
19C-7
Remove the pump/sender/filter assembly (see

19C, Tank, Pump/sender/filter ) for petrol engines
or the gauge (see 19c, Tank, Sender unit ) for diesel engines.
RESERVOIR
REFITTING
Refit the pump/sender/filter assembly (see 19C,
Tank, Pump/sender/filter ) for petrol engines or the
gauge (see 19c, Tank, Sender unit ) for diesel engines.
Reshape the heat shield.
Take care not to bring the heat shield into contact
with the tank.
The tank hose securing clips must always be replaced.
Tighten to torque the fuel tank mounting bolts
(21 Nm) .
Check that the fuel pipe unions click into place.
WARNING
Tighten to torque the battery cover mounting bolt
(4 Nm) .
19C-8
19C
RESERVOIR
19C
F9Q or K9K or M9R
3
1
8
2
4
10
7
5
2
6
110881
No.
Description
Tank
Mounting holes
Filler neck
Neck mounting clips
Brake pipe retaining clips
Fuel supply pipe
Fuel return pipe
Drying the reservoir and leak prevention valve in case of vehicle roll over
Anti-backflow pipe (degassing - filling)
10
Diesel fuel suction assembly
19C-9
RESERVOIR
19C
F9Q or K9K or M9R
13036-1
No.
Description
Breather
Overfill prevention ball
19C-10
RESERVOIR
F9Q or K9K or M9R
No.
Description
Filling anti-backflow pipe
Air outlet hole during filling
Volume of air allowing fuel expansion
Fuel inlet for filling
Usable fuel volume
Drying the reservoir and leak prevention valve in case of vehicle roll over
ROLE OF THE FILLER NECK AND VALVES

1 - Overfill prevention valve and vehicle roll-over
leak prevention valve
The ball acts as an overfill prevention valve.
When the vehicle is stationary, during filling, the ball
rests on its seat, retaining a specific volume of air in the
tank.
When the vehicle is moving, the ball leaves its seat,
thus allowing the reservoir to be open to the air.
When the tank is full, a sufficient volume of air to allow
the diesel fuel contained within it to expand must remain in the tank, but not so much as to make the tank
explode.
The vehicle roll over leak prevention valve prevents the
fuel tank from emptying via the air pipe.
2 - Filler neck
The filler neck for diesel fuel has a sealed type cap.
19C-11
19C
RESERVOIR
19C
F4R or K4J or K4M
1
11
2
2
4
2
12
9
10
13
5
5
6
102487
No.
Description
Tank
Mounting holes
Filler neck
Neck mounting clips
Brake pipe retaining clips
Fuel supply pipe
Petrol vapour supply pipe
Petrol vapour absorber supply pipe (from the tank)
Fresh air vent
10
Petrol vapour absorber
11
Overfill prevention valve and vehicle roll-over leak prevention valve
12
Anti-backflow pipe (degassing - filling)
13
Petrol suction assembly
19C-12
RESERVOIR
19C
F4R or K4J or K4M
3
4
10
13036
No.
Description
Connection to petrol vapour absorber
Overfill prevention ball
19C-13
RESERVOIR
19C
F4R or K4J or K4M

No.
Description
Filling anti-backflow pipe
Restriction valve
Excess pressure/underpressure safety valve
Air outlet hole during filling
Volume of air allowing fuel expansion
Fuel inlet for filling
Usable fuel volume
10
Overfill prevention valve and vehicle roll-over leak prevention valve
ROLE OF THE FILLER NECK AND VALVES
- a valve blocking the filling opening (to prevent petrol

vapour release or backflow of petrol),
1 - Overpressure/underpressure safety valves
- a leak-tight cap.
If the petrol vapour recirculation circuit is blocked, this

valve prevents the fuel tank being subjected to excess
pressure (the tank expands) or underpressure (as fuel
is used, the tank collapses).
2 - Restriction valve
This valve prevents diesel fuel or leaded petrol pump
nozzles from entering the tank.
3 - Overfill prevention valve and vehicle roll-over
leak prevention valve
The ball acts as an overfill prevention valve.
When the vehicle is stationary, during filling, the ball
rests on its seat, retaining a specific volume of air in the
tank.
When the vehicle is moving, the ball leaves its seat,
enabling a connection between the tank and the petrol
vapour absorber.
When the tank is full, a sufficient volume of air to allow
the fuel contained within it to expand must remain in
the tank, but not so much as to make the tank burst.
The vehicle roll-over leak prevention valve prevents
the fuel tank from emptying via the pipe to the petrol
vapour absorber.
4 - Filler neck
The filler neck for unleaded petrol has the following:
- a smaller diameter filling opening (restriction valve).
Leaded petrol damages the toxic fume filter system:
catalytic converter and oxygen sensor,
19C-14
RESERVOIR
Filler neck: Removal - Refitting
19C
Tightening torquesm
bolt
4 Nm
IMPORTANT
- refrain from smoking or bringing hot objects near
the working area,
union,
REMOVAL
Drain the tank (see 19C, Tank, Draining the fuel
tank ).
102469
Remove the filler neck mounting bolts (3) .

terminal.
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch liner.
2
104559
Remove:
- the filler neck mounting bolts (4) ,
- the filler neck.
REFITTING
102468
Disconnect the anti-return pipe (1) .

Remove the filler pipe clips (2) .
Always replace the filler pipe tightening clips with

new ones.
WARNING
19C-15
RESERVOIR
Filler neck: Removal - Refitting
Tighten to torque the battery cover mounting bolt
(4 Nm) .
19C-16
19C
RESERVOIR
Sender unit: Removal - Refitting
19C
K9K F9Q M9R

Mot. 1397
Universal petrol tank

gauge nut wrench.
Tightening torquesm
bolts
3
4 Nm
IMPORTANT
104618


Take out the carpet.

unions,
REMOVAL
terminal.
104214
Remove the soundproofing pads (4) .
1
104617
Remove:
- the clips (1) ,
- the trim (2) .
19C-17
RESERVOIR
19C
K9K F9Q M9R
7
104620
104204
Remove:
- the tuner-amplifier unit mounting bolts (7) ,
- the tuner-amplifier unit assembly.
6
8
104203
Disconnect the tuner-amplifier (6) (if fitted to the vehicle).
104545
Remove the inspection flap blanking cover (8) .
19C-18
RESERVOIR
19C
K9K F9Q M9R
10
105006
Disconnect:
104547
Remove the nut from the sender using the (Mot.

1397) (11) .
- the electrical connector (9) ,
Remove the sender unit, being careful with the float.
- the quick-release unions (10) .

Prepare for fuel outflow.
Fit the correct blanking plugs into the unions (see
MR 370 Mechanical systems, 13B, Diesel injection: Cleanliness guidelines ).
19C-19
WARNING
Refit the sender nut as soon as the sender has
been removed to prevent any deformation of the
fuel tank.
RESERVOIR
K9K F9Q M9R
REFITTING
102470
Replace the O-ring seal.

Refit the sender unit by aligning mark (12) on the
sender with mark (13) on the tank.
Position the nut (15) .
Tighten the nut (15) until mark (14) on the nut is aligned with mark (13) on the tank and mark (12) on
the sender.
Connect the battery starting with the positive terminal (see MR 370 Mechanical systems, 80A, Battery: Removal - Refitting ).
(4 Nm) .
19C-20
19C
RESERVOIR
Petrol filter: General information
102299
The fuel filter is located in the fuel tank; it is integrated

into the pump-sender-filter assembly and cannot
be removed.
WARNING
The pump-sender-filter assembly must be replaced if one of the components is faulty.
The filter is intended to have a long service life.
Checking the fuel supply pressure and the pump delivery rate is the equivalent of running fault finding on the
pump-sender-filter assembly.
19C-21
19C
RESERVOIR
Pump-sender unit-filter: Removal - Refitting
19C
F4R or K4J or K4M

Mot. 1397
Universal petrol tank

gauge nut wrench.
Tightening torquesm
bolts
4 Nm
IMPORTANT
104618


Move the carpet to one side.

union,
REMOVAL
terminal.
104214
Remove the soundproofing (4) .
1
104617
Remove:
- the clips (1) ,
- the trim (2) .
19C-22
RESERVOIR
19C
F4R or K4J or K4M
7
104620
104204
Remove:
- the mounting bolts (7) from the receiver unit,
- the receiver unit assembly.
104203
Disconnect the receiver (6) (if fitted to the vehicle).
104545
Remove the access flap blanking cover (8) .
19C-23
RESERVOIR
19C
F4R or K4J or K4M
10
104546
Disconnect:
104547
Remove the nut from the pump/sender/filter assembly using tool (Mot. 1397) (11) .
- the electrical connectors (9) ,
Remove the pump/sender/filter assembly, being

careful of the float.
- the quick-release union (10) .

Prepare for fuel outflow.
WARNING
Refit the pump/sender/filter assembly nut as
soon as the pump/sender/filter assembly is
removed to prevent any deformation of the tank
19C-24
RESERVOIR
F4R or K4J or K4M
REFITTING
102470
Replace the O-ring seal.

Refit the pump/sender/filter assembly, aligning
mark (12) on the pump/sender/filter assembly
with mark (13) on the tank.
Position the nut (15) .
Tighten the nut (15) until mark (14) on the nut is aligned with mark (13) on the tank and with mark (12)
on the pump/sender/filter assembly.
Connect the battery starting with the positive terminal (see MR 370 Mechanical systems, 80A, Battery: Removal - Refitting ).
(4 Nm) .
19C-25
19C
RESERVOIR
Fuel level sensor: Checking
Checking the gauge sender unit
Value
between terminals A1
and B1 (in
) +/- 10
Capacity
Height H (in
mm) +/- 6 mm
20
Full tank
upper stop
95
Tank 3/4 full
150
106 (170)
Tank 1/2 full
111
245
Tank 1/4 full
72
290
Reserve
40
320
Tank empty
lower stop
MEASURING THE HEIGHT H

Place the removed sender on a flat surface.
H is the height measured between the float pin and
the working plane.
Note:
All these values are given as a guide.
19C-26
19C
ENGINE MOUNTING
Suspended engine mounting: Tightening torque
19D
M9R, and 700
114631
Mark
Description
Tightening torque (Nm)
(1)
Bolt mounting the lower engine tie-bar on the sub-frame
105
(2)
Bolt mounting the lower engine tie-bar onto its support
180
(3)
Lower engine tie-bar support mounting bolts
62
(4)
Bolt mounting the upper engine tie-bar onto the body
105
(5)
Bolt mounting the upper engine tie-bar onto the engine
115
(6)
Bolts mounting the right-hand suspended mounting support on the body
62
(7)
Bolts mounting the right-hand suspended mounting support on the engine
62
(8)
Bolts mounting the left-hand suspended mounting support onto the gearbox
105
(9)
Bolt mounting the left-hand suspended mounting support on the body
62
(10)
Nut mounting the left-hand rubber pad on the gearbox mounting
62
(11)
Bolts mounting the left-hand rubber pad on the body mounting
62
(12)
Acoustic mass mounting bolt
21
19D-1
ENGINE MOUNTING
19D
K4J, and 730 K4M, and 782
7
4
6
3
5
103235
Tightening torques (in Nm)

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
180
(7)
62
19D-2
ENGINE MOUNTING
19D
F4R, and 770 or 776
12
10
11
9
9
5
3
4
2
1
103244

(1)
62
(2)
105
(3)
105
(4)
62
(5)
62
(6)
180
(7)
105
(8)
62
(9)
21 for M8 bolts
62
bolts
(10)
62
(11)
180
(12)
62
for M10
19D-3
ENGINE MOUNTING
19D
F9Q, and 804 or 812
12
10
11
9
9
5
1
103237
Tightening torque (in Nm)

(1)
62
(2)
105
(3)
105
(4)
62
(5)
62
(6)
180
(7)
105
(8)
62
(9)
21 for M8 bolts
62
bolts
(10)
62
(11)
180
(12)
62
for M10
19D-4
ENGINE MOUNTING
19D
K9K, and 722 or 728
103236

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
62
(7)
21 for M8 bolts
62
bolts
(8)
62
(9)
180
(10)
62
for M10
19D-5
ENGINE MOUNTING
19D
K4M, and 761
9
8
4
6
6
3
5
103274

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
21 for M8 bolts
62
bolts
(7)
62
(8)
180
(9)
62
for M10
19D-6
ENGINE MOUNTING
19D
F4R, and 771
12
11
10
9
5
3
9
4
8
1
2
1
103275

(1)
62
(2)
105
(3)
105
(4)
62
(5)
62
(6)
180
(7)
105
(8)
62
(9)
21 for M8 bolts
62
bolts
(10)
62
(11)
180
(12)
62
for M10
19D-7
ENGINE MOUNTING
19D
K9K, and 732
8
10
9
12
10
11
6
3
5
2
1
112652

(1)
62
(2)
21
(3)
62
(4)
105
(5)
115
(6)
62
(7)
105
(8)
180
(9)
62
(10)
62
(11)
62
(12)
62
19D-8
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting
19D
M9R, and 700

Mot. 1390

Tightening torquesm
mounting bolts
44 Nm

mounting bolts
21 Nm
side reinforcement
mounting bolts
21 Nm
REMOVAL
101212
Remove:
- the left-hand side reinforcement mounting bolts,

- the left-hand side reinforcement (1) ,
Remove:


- the front left-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting),
- the left-hand wheel arch liner.
114933
19D-9
ENGINE MOUNTING
19D
M9R, and 700
102365
Remove:
112658
Remove:
unit: Removal - Refitting ).

(3) ,
116580
115585

Remove:
- the clips (6) ,
116581
Position the (Mot. 1390) on the gearbox on the rubber pads (9) and (10) .
19D-10
ENGINE MOUNTING
19D
M9R, and 700

CONCERNED
114656
115208
Remove the left-hand suspended engine mounting

nut (11) .
114633
Mark the left-hand suspended mounting in relation

to the bodywork.
115321
Remove:
Loosen the left-hand suspended mounting rubber

pad mounting nuts (13) .
- the mounting bolts (12) from the gearbox left-hand

suspended engine mounting,
Remove:
- the gearbox suspended engine mounting.
- the bolts (14) and (15) mounting the left-hand suspended engine mounting on the body,
- the mounting bolt (16) for the retaining strut
between the battery tray mounting and the lefthand suspended mounting,
19D-11
ENGINE MOUNTING
19D
M9R, and 700

- the left-hand body suspended mounting fitted with
the rubber pad.
Refit the mounting nut to the left-hand suspended

engine mounting.
Tighten to torque:
REFITTING
- the mounting nut on the left-hand suspended

mounting (see 19D, Engine mounting, Suspended engine mounting: Tightening torque ),

CONCERNED
- the mounting nuts on the left-hand suspended

mounting rubber pad (see 19D, Engine mounting,
Suspended engine mounting: Tightening torque ), aligning the marks.
Refit the left-hand body suspended mounting fitted

with the rubber pad.
Finger tighten the mounting bolts for the left-hand
suspended mounting on the body.
Refit the retaining strut mounting bolt between the

battery tray bracket and the left-hand suspended
mounting.
Refit:
unit: Removal - Refitting ),
Screw on without tightening:
Tighten to torque:
Nm) ,
114633
Tighten to torque the mounting bolts (17) for the lefthand suspended mounting on the body (see 19D,
Engine mounting, Suspended engine mounting:
Tightening torque ).

Nm) .
Tighten the bolt (18) mounting the left-hand suspended mounting on the body. The torque given is only
an example (see 19D, Engine mounting, Suspended engine mounting: Tightening torque ).
Refit the clips.
Refit the left-hand suspended mounting to the gearbox.
Refit:
Screw on the bolts mounting the left-hand suspended mounting on the gearbox without tightening.
Tighten to torque the bolts (19) mounting the lefthand suspended mounting on the gearbox (see
Tighten the bolt (20) mounting the left-hand suspended mounting on the gearbox. The torque given is
only an example (see 19D, Engine mounting, Suspended engine mounting: Tightening torque ).
19D-12


- the left-hand side reinforcement,
- the left-hand side reinforcement mounting bolts.
Tighten to torque the side reinforcement mounting bolts (21 Nm) .
ENGINE MOUNTING
M9R, and 700
Refit:
- the left-hand wheel arch liner,
- the front left-hand wheel (see 35A, Wheels and tyres, Wheel: Removal - Refitting),
19D-13
19D
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting
19D
M9R, and 700
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
CONCERNED
114632
Remove the lower engine tie-bar:

- by pulling it back (3) then lifting it (4) to detach it
from its support,
- by pivoting it (5) to the right.
REFITTING
114650

CONCERNED
Remove:
Refit:
- the lower engine tie-bar mounting bolt (1) from the

sub-frame,

- the lower engine tie-bar mounting bolt onto the
support,
- the lower engine tie-bar mounting bolt (2) from the

support.
- the lower engine tie-bar mounting bolt onto the

sub-frame.
Tighten to torque the lower engine tie-bar bolts (see
19D-14

01 Engine and Peripherals

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

01 Engine and Peripherals

Загружено:

Авторское право:

Доступные форматы

1

Engine and peripherals

ENGINE AND LOWER ENGINE ASSEMBLY

TOP AND FRONT OF ENGINE

All copyrights reserved by Renault.

Renault s.a.s. 2006

X84, and J84

All copyrights reserved by Renault.

Renault s.a.s. 2006

Scnic II - Section 1 ContentsPage

ENGINE AND LOWER ENGINE ASSEMBLY

Oil consumption Check

Oil filter: Removal - Refitting

Air resonator: Removal Refitting

Air filter: Replacement

Air filter: Removal - Refitting

Oil pressure sensor:

Oil level sensor: Removal Refitting

Air filter unit: Removal Refitting

Air inlet duct: Removal Refitting

Sump: Removal - Refitting

Inlet manifold: Removal Refitting

Injector holder shim:

Manifolds: Removal Refitting

Exhaust manifold: Removal Refitting

Throttle valve: Removal Refitting

Air inlet flap: Removal Refitting

Engine stop device

Throttle valve: Cleaning

Oil pump: Removal Refitting

TOP AND FRONT OF ENGINE

Timing chain: Removal Refitting

Tightening the cylinder head

Cylinder head gasket :

Crankshaft seal at timing end

Cylinder head: Removal Refitting

Pressure regulator: Checking

Intercooler: Removal Refitting

Diesel fuel supply circuit

Petrol filter: General

Diesel filter: Removal Refitting

Injector rail - Injectors:

Electric fuel: Checking

Diesel injector: check

Leak flow from injectors:

High pressure pump:

Diesel injector: Removal Refitting

Diesel injector adjustment

High-pressure pipe between

High-pressure pipe between

Injector rail: Removal Refitting

Rail pressure sensor:

Fuel flow actuator: Removal Refitting

Fuel pressure regulator:

Diesel temperature sensor:

Leak flow from injectors:

Accelerometer: Removal Refitting

Venturi: Removal - Refitting

Diesel injector fuel return rail:

Diesel injection: Precautions

Flow regulation solenoid

Pressure regulation solenoid

Injection warning light

Injection / air conditioning