MR364MEGANE1

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 B84 or C84 or G84 or S84
77 11 318 022
FEBRUARY 2003
"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. 2005
19A
COOLING SYSTEM
19B
EXHAUST
19C
RESERVOIR
19D
ENGINE MOUNTING
X84, and B84 or C84 or G84 or S84

77 11 318 022
FEBRUARY 2003
"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. 2005
Mgane II - Section 1
Mgane II - Section 1ContentsPage
Contents
Page
10A

Engine identification
10A-2
Oil consumption Check
10A-3
Oil filter: Removal - Refitting
10A-4
Exchanger: Removal Refitting
10A-10
Oil pressure
10A-16
Oil pressure sensor:

Removal - Refitting
10A-17
Oil level sensor: Removal Refitting
10A-20
Sump: Removal - Refitting
10A-21
Oil pump: Removal Refitting
10A-42
Multifunction support:
Removal - Refitting
10A-45
Engine speed and position

sensor: Removal - Refitting
Crankshaft seal at timing end
Removal - Refitting
11A
10A-1
Engine oil: Draining Refilling
Engine/gearbox assembly:
Removal - Refitting
Timing belt: Removal Refitting
12A

Timing chain: Removal Refitting
11A-116
Cylinder head gasket :

Removal - Refitting
11A-117
Tightening the cylinder head
11A-199
Cylinder head: Removal Refitting
11A-205
FUEL MIXTURE
Specifications
12A-1
Air inlet
12A-11
Air resonator: Removal Refitting
12A-22
Air filter: Replacement
12A-23
Air filter: Removal - Refitting
12A-25
Air filter unit: Removal Refitting
12A-26
Air flowmeter: Removal Refitting
12A-39
Air inlet flap: Removal Refitting
12A-41
Air inlet duct: Removal Refitting
12A-49
Inlet manifold: Removal Refitting
12A-52
11A-1
Injector holder shim:

Removal - Refitting
12A-58
11A-11
Manifolds: Removal Refitting
12A-64
10A-55
10A-131
10A-132

Accessories belt: Removal Refitting
11A
Contents
12A
12B
FUEL MIXTURE
Exhaust manifold: Removal Refitting
12A-67
Throttle valve: Removal Refitting
12A-86
Throttle valve: Cleaning
12A-94
Engine stop device
12A-96
TURBOCHARGING
Turbocharging: Precautions
for repair
Turbocharger: Removal Refitting
Pressure regulator: Checking
Turbocharging pressure
regulation valve
Intercooler: Removal Refitting
13A
13B
13B
DIESEL INJECTION
Diesel injection: Precautions
for repair
13B-16
Description
13B-31
Operation
13B-33
Location of components
13B-36
Immobiliser function
13B-61
Injection warning light
13B-62
Injection / air conditioning

programming
13B-64
Idling speed
13B-67
Centralised coolant
temperature management
13B-69
Computer configuration
13B-71
High pressure pipe:

Checking
13B-73
High pressure pipe:

Replacement
13B-76
Diesel injector: check
13B-83
High pressure pump:

Removal - Refitting
13B-84
12B-1
12B-6
12B-37
12B-43
12B-46
FUEL SUPPLY
Petrol supply circuit
13A-1
Diesel injector: Removal Refitting
Diesel fuel supply circuit
13A-2
Injectors: Configuration
13B-130
Petrol filter: General

information
13A-6
High-pressure pipe between

the rail and injector: Removal
- Refitting
13B-132
Diesel filter: Removal Refitting
13A-7
Injector rail: Removal Refitting
13B-143
Injector rail - Injectors:

Removal - Refitting
13A-14
Rail pressure sensor
13B-160
Electric fuel: Checking
13A-20
Rail pressure sensor:

Removal - Refitting
13B-161
Fuel flow actuator: Removal Refitting
13B-164
Leak flow from injectors:

Check
13B-170
Fuel pressure regulator:

Removal - Refitting
13B-174
DIESEL INJECTION
Specifications
Diesel injection:
Specifications
13B-1
13B-11
13B-113
Contents
13B
14A
DIESEL INJECTION
Diesel temperature sensor:
Removal - Refitting
13B-179
Accelerometer: Removal Refitting
13B-189
Venturi: Removal - Refitting
13B-190
Accelerator pedal
potentiometer: General
information
13B-194
Accelerator pedal
potentiometer: Removal Refitting
13B-195
Diesel injection computer:

Removal - Refitting
13B-196
16A
13C
PREHEATING
Pre/postheating unit:
Removal - Refitting
14A
13C-1
Heater plugs Removal Refitting
13C-2
Pre-postheating control
13C-11
ANTIPOLLUTION
Exhaust gas recirculation
solenoid valve: Removal Refitting
14A-29
Intercooler: Removal Refitting
14A-31

mounting: Removal Refitting
14A-36

rigid pipe: Removal Refitting
14A-37
STARTING - LOAD
Alternator: General
information
16A-1
Alternator: Removal Refitting
16A-2
Alternator pulley: Removal Refitting
16A-20
Starter: Identification
16A-24
Starter: Removal - Refitting
16A-25
ANTIPOLLUTION
17A
IGNITION
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
Oxygen sensors: Removal Refitting
17B-14
Accelerator pedal
potentiometer: Removal Refitting
17B-16
Position and speed sensor
17B-17
Exhaust gas recirculation:

Operating diagram
Exhaust gas recirculation:
Description
unit
14A-17
14A-23
17B
Coils Removal - Refitting
17A-1
Spark plugs
17A-5
PETROL INJECTION
17B-1
Contents
17B
Petrol injection computer:

Removal - Refitting
17B-19
Special notes
17B-21
17B-24
17B-25
Injection - air conditioning

programming
17B-26
Throttle valve: Operating
17B-30
Idle speed correction
17B-31
Adaptive idle speed

correction
17B-34
Richness regulation
17B-35
Adaptive richness correction
17B-39
Central coolant temperature

management
17B-41
Camshaft dephaser:
Description
19A
19A
PETROL INJECTION
17B-42
19B
COOLING SYSTEM
Cooling circuit: Draining Refilling
19A-12
Engine cooling circuit:

Cleaning
19A-14
Cooling circuit: Bleeding
19A-15
Cooling radiator: Removal Refitting
19A-16
Water pump: Removal Refitting
19A-22
Plenum chamber: Removal Refitting
19A-40
EXHAUST
General information
19B-1
Pipe assembly
19B-5
Catalytic pre-converter:
Removal - Refitting
19B-10
Fault finding warning light

activation conditions (when
driving)
17B-44
Catalytic converter: Removal

- Refitting
19B-15
Conditions for carrying out

fault finding (when driving)
17B-45
Expansion chamber:
Removal - Refitting
19B-29
Combustion misfire fault

finding
Silencer: Removal - Refitting
19B-30
17B-46
Particle filter: Function
19B-31
Catalytic converter fault

finding
17B-47
Particle filter: Removal Refitting
19B-32
Oxygen sensor fault finding
17B-48
Speed limiter: Operating

principle
Particle filter pressure

sensor: Removal - Refitting
19B-38
17B-49
Particle filter temperature

sensors: Removal - Refitting
19B-42
Connecting hose: Removal Refitting
19B-45
Particle filter: Cleaning
19B-46
COOLING SYSTEM
General information
19A-1
Specifications
19A-2
Checking
19A-3
Diagram
19A-4
Contents
19C
19D
RESERVOIR
Draining the fuel tank
19C-1
Fuel tank: Description
19C-6
Fuel tank: Removal Refitting
19C-12
Filler neck: Removal Refitting
19C-15
Sender unit: Removal Refitting
19C-17
Pump-sender unit-filter:
Removal - Refitting
19C-20
Petrol filter: General

information
19C-22
Fuel level sensor: Checking
19C-23
ENGINE MOUNTING
Suspended engine mounting
19D-1
Suspended engine
mounting: Tightening torque
19D-9
Left-hand suspended engine

19D-12
Right-hand suspended
engine mounting: Removal Refitting
19D-14
Rear suspended engine

19D-16

Engine identification
Vehicle type
Engine type
XM0B
Engine suffix
10A
Cubic capacity (cc)
Bore (mm)
Stroke (mm)
Compression
ratio
1390
79.5
70
10/1
1598
79.5
80.5
9.8/1
1998
82.7
93
730
XM0H
XM1A
K4J
XM08
732
XM0C
760
XM0J
K4M
761
XM1B
XM05
770
XM0U
771
XM1M
F4R
9.8/1
XM1N
XNOW
776
XM0F
722
9.5/1
XM0T
XM02
XM13
728
K9K
17.9/1
1461
76
80.5
XM02
729
XM1E
732
15.3/1
XM0G
800
18.4/1
XM1G
XM0L
F9Q
804
1870
80
93
17/1
XM1D
XM00
808
18.4/1
List of engine Workshop Repair Manuals to be consulted depending on the engine type:
- K4J and K4M engine, Technical Note 3784A,
- K9K engine, Technical note 6006A,
- F9Q engine, Technical Note 3652A,
- F4R engine, Technical Note 3783 A.
10A-1

Engine oil: Draining - Refilling
10A
M9R, and 700

Copper seal
Tightening torquesm
drain plug
44 Nm
Average oil capacity

(check and adjust with
dipstick) (l)
Engine
Draining
Oil change
with oil filter
replacement
M9R
6.4
6.7
I - OIL SERVICE
Remove the oil filler plug and the dipstick.
113764
Place the vehicle on a two-post lift (see 02A, Lifting

equipment, Underbody lift ).
Refit the new seal on the plug, positioning the groove (2) towards the plug.
Remove the engine undertray.
Tighten to torque the drain plug ( 44 Nm ) .

II - FILLING
WARNING
Always check the oil level using the dipstick.
Do not exceed the maximum level on the dipstick
(as this could damage the engine).
Correct the engine oil level if necessary before
delivering the vehicle to the customer.
When filling up the engine oil, always leave at least
10 minutes for the oil to drain down before checking
with a dipstick.
Fill up the engine with oil.
Refit the engine undertray.
114651
Remove the drain plug (1) .

Let the oil run into a drain tray.
10A-2

Oil consumption Check
PROCEDURE FOR MEASURING OIL
CONSUMPTION
1 - Filling to the maximum level
Note:
The operation should be carried out with the
engine warm after the fan unit has started operating.
Turn the engine off.
Wait two minutes for all of the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the "MAX" 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 1,200 miles (2,000 km) in the vehicle without letting the oil level reach the "MIN" mark.
3 - Topping up
Note:
The operation should be carried out with the
engine warm after the fan assembly has started
operating.
Turn the engine off.
Wait two minutes for all of the oil to flow into the oil
sump.
Check the level on the dipstick.
Top up to the "MAX" 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

K9K, and 722 or 728 or 729 or 732
III - FINAL OPERATION
Special tooling required
Top up the engine oil.

Mot. 1329
76 mm diameter oil filter removing tool
Wipe any oil run-off with a cloth.

REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lifting equipment, Underbody lift ).
111850
Position (Mot. 1329) (1) on the oil filter.

II - OPERATION FOR REMOVAL OF PART
CONCERNED
Remove the oil filter.
REFITTING
I - REFITTING PREPARATION OPERATION
Lubricate the oil filter seal with new engine oil.
II - REFITTING OPERATION FOR PART
CONCERNED
Tighten the oil filter until it comes into contact with
the oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
10A-4
10A

10A
F4R, and 770 or 771 or 776

Mot. 1329
Tightening torquesm
air conditioning compressor stay mounting
bolts
44 Nm
REMOVAL
Position the vehicle on the two-post lift (see 02A,
Lifting equipment, Underbody lift ).
111852
Position the (Mot. 1329) (2) on the oil filter.

REFITTING
Lubricate the oil filter seal with new engine oil.
Refit the air conditioning compressor stay.

Tighten to torque the air conditioning compressor
stay mounting bolts ( 44 Nm ) .
Wipe any oil run-off with a cloth.
111851
Remove:
- the mounting bolts (1) from the air conditioning
compressor stay.
- the air conditioning compressor stay.
10A-5

K4M, and 760 or 761 K4J, and 730 or 732
Mot. 1329
REMOVAL
110385
Position tool (Mot. 1329) (1) on the oil filter.

REFITTING
Apply new engine oil to the oil filter seal.
10A-6
10A

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

CONCERNED
114653
Loosen the cover (1) slightly.

Let the engine oil flow out before removing the filter
element - cover 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) in the cover (7) ,
113869
Position the new O-ring (5) correctly on the cover.
- the filter element - cover assembly.
Apply new engine oil to the O-ring.
Tighten to torque the cover ( 25 Nm ) .

10A-8

10A
F9Q
REFITTING

Mot. 1329

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 reduce 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 - Fillingup ).
REMOVAL
Refit:
- the engine undertray,
Remove:
- the engine covers,
- the engine undertray.
Drain the engine oil (see 05A, Draining/Filling-up ).
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.

Exchanger: Removal - Refitting
10A
M9R, and 700
REMOVAL

Mot. 1202-01
Clip pliers for cooling

system hose clips
(large model)

Mot. 1202-02
Pliers for small hose

clips
Disconnect the battery (see 80A, Battery, Battery:

Removal and Refitting )
Mot. 1448
Remote operation clip

pliers for cooling system hose clips
Remove:
- the engine protectors,
Mot. 1495-01
22 mm socket for
removing/refitting oxygen sensors
- the oil filter (see 10A, Engine and peripherals, Oil

filter: Removal - Refitting ).
- the front bumper (see MR365 Bodywork, 55A Exterior protection, Front bumper )
Equipment required
Drain the coolant circuit using filling station (see

62A, Air conditioning, Maintenance ).
filling station
Tightening torquesm
oil cooler mounting
bolts
25 Nm
coolant inlet union

mounting bolts
24 Nm
oil pressure sensor
44 Nm
intercooler downstream duct clip on the

intercooler
5.5 Nm

damper valve
5.5 Nm
intercooler upstream
hose clip
5.5 Nm
front end panel upper

mounting bolts
21 Nm
front end panel lower

mounting bolts
44 Nm
112658
Remove:
- the mounting bolts (1) from the Protection and
Switching Unit,
- the Protection and Switching Unit cover.
10A-10

10A
M9R, and 700
102504
Disconnect the connectors (2) from the Protection

and Switching Unit.
Unfasten the bonnet opening cable (3) .
102365
Remove:
- front end panel mounting bolts (7) ,
- the front end panel,
Remove:
- the air inlet scoop.
- the clips (4) ,
Drain the engine cooling system (see 19A, Cooling,

Engine cooling system: Draining-refilling ).
- the front end panel upper mounting bolts (5) ,

Disconnect the screen washer tubes.
102473
114933
Unclip the air inlet scoop.
Loosen the clip (8) from the intercooler upstream hose.

Disconnect the intercooler upstream hose.
10A-11

10A
M9R, and 700
114649
Remove the bolt (9) mounting the intercooler downstream duct on the cooling radiator.
Loosen:
- the clip (10) on the intercooler downstream duct on
the intercooler,
- the intercooler downstream duct clip on the damper
valve.
Move the downstream duct away from the intercooler.
10A-12
112661
Disconnect:
- the cooling radiator top and bottom hose using
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the fan unit resistor connector (11) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.

10A
M9R, and 700
109537
Disconnect:
- the hoses from the expansion bottle on the cooling
radiator side (12) ,
- the pressure switch connector on the condenser
lower air conditioning pipe (13) .
Unpick the wiring harness from the pressure switch
connector on the fan unit.
Remove the air conditioning pipes from the condenser (14) .
114929
Disconnect the hose (15) from the oil cooler coolant

outlet union.
Remove:
- the oil pressure sensor using the (Mot. 1495-01) ,
- the mounting bolts (16) from the coolant inlet union,
- the coolant inlet union.
Disconnect, using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) :
- the hose (17) from the coolant inlet union on the
union,
Note:
- the hose (18) from the cylinder block coolant inlet

pipe,
Plugs must be fitted to the hoses and the expansion valve to prevent moisture from entering the
system.
Remove the hose from the coolant inlet union.
Remove the cooling assembly.
10A-13

10A
M9R, and 700
REFITTING

CONCERNED
I - REFITTING OPERATION FOR PART

CONCERNED
114928
Remove:
114928
- the mounting bolts (19) from the oil cooler,

Refit:
- the oil cooler.
- the oil cooler,

- the oil cooler mounting bolts.
Tighten to torque and in the order (1) - (3) - (2) - (4)
the oil cooler mounting bolts ( 25 Nm ) .
10A-14

10A
M9R, and 700

II - FINAL OPERATION
Tighten to torque the intercooler upstream hose

clip ( 5.5 Nm ) .
Connect, using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) :
Refit:
- the coolant inlet union hose on the cylinder block,

- the air inlet scoop,
- the coolant inlet pipe hose on the union,

- the coolant outlet union hose to the oil cooler.
Refit:
- the clips,
- the coolant inlet union,

- the coolant inlet union mounting bolts,
- the front end panel mounting bolts.
- the oil pressure sensor.
Tighten to torque:
Tighten to torque:
- the coolant inlet union mounting bolts ( 24 Nm )
,
- the front end panel upper mounting bolts ( 21

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

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

Nm ) .
Refit the cooling assembly.
Connect the Protection and Switching Unit connectors.
Refit the air conditioning pipes to the condenser.

Attach the pressure switch connector wiring harness
to the fan unit.
Clip the bonnet opening cable.

Connect, using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) :

- the expansion bottle hoses on the cooling radiator
side,
Refit:
- the Protection and Switching Unit cover,
- the cooling radiator top and bottom hose.

- the Protection and Switching Unit cover mounting
bolts,
Connect:
- the pressure switch connector on the condenser
lower air conditioning pipe,
- the fan unit connector,
- the fan unit resistor connector,
- the oil filter (see 10A, Engine and peripherals, Oil

Clip the fan unit wiring harness into place.
Refit:
Refit:
- the intercooler downstream duct clip to the intercooler,
valve.

- the front bumper (see MR365 Bodywork, 55A Exterior protection, Front bumper ).
Tighten to torque:
Refill:
- the intercooler downstream duct clip on the intercooler ( 5.5 Nm ) ,
- the coolant circuit using the filling station (see

62A, Air conditioning, Maintenance ),
- the intercooler downstream duct clip on the

damper valve ( 5.5 Nm ) .
Tighten the bolt mounting the intercooler downstream duct on the cooling radiator.
Connect the intercooler upstream hose.
10A-15
- the engine cooling system (see 19A, Cooling,

Cooling system: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Removal - Refitting ).

Oil pressure

Mot. 836-05
10A
Oil pressure gauge kit
Start the vehicle.

Carry out the check.
I - ADAPTERS FOR USE WITH VARIOUS ENGINES
Engine
Adapters
K4J
E+C+F
K4M
E+C+F
F4R
B+F
K9K
E+C+F
F9Q
B+F
M9R
C+F
Check the values.
Engine
K4J
Engine
suffix
730
Minimum pressure
(bar)
Idle
speed
3000 rpm
1.2
3.5
1.2
3.5
1.2
3.5
0.9
760
K4M
782
770
F4R
II - PRECAUTIONS TO TAKE DURING CHECKS
771
776
The oil pressure check must be carried out with the engine warm ( 80C ).
722
K9K
III - CHECKING PROCEDURE

Removal - Refitting ).
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) and the adapters.
Refit the oil pressure sensor (see 10A, Engine and peripherals, Oil pressure sensor: Removal - Refitting
).
87363
Position the (Mot. 836-05) with the appropriate adapters.
10A-16

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

- the engine accessories unit cover.

Mot. 1495-01
22 mm socket for
Tightening torquesm
oil pressure sensor
44 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm
115585
Disconnect the connectors (2) from the engine accessories unit.
REMOVAL

Remove:
Remove:
- the clips (4) ,


- the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ).
114933
Unclip the air inlet scoop (6) .
112658
Remove:
- the engine accessories unit cover mounting bolts
(1) ,
10A-17

10A
M9R, and 700
102365
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
115022

CONCERNED
115021
114061
Remove the oil pressure sensor using the (Mot.

1495-01) (1) .
Disconnect the oil pressure sensor connector (8) .

Note:
Be careful not to damage the air conditioning
compressor connector.
10A-18

M9R, and 700
REFITTING
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.
Refit:
- the upper mounting bolts of the front end panel,
- the lower mounting bolts of the front end panel.
Tighten to torque:
Nm ) ,
Nm ) .
Clip the air inlet scoop into place.
Connect the screen washer pipes.
Position the bonnet opening cable.
Connect the engine accessories unit connectors.
Refit:
- the clips,
- the engine accessories unit cover,
- the engine accessories unit cover mounting bolts,
- the front bumper (see MR 365 Bodywork, 55A Exterior protection, Front bumper ),
- the engine protectors.
10A-19
10A

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

Refit the heat insulating material around the oil level
sensor.
Tightening torquesm
oil level sensor
front right-hand wheel
25 Nm
Refit the front right-hand wheel.

Tighten to torque the front right-hand wheel ( 110
Nm ) .
110 Nm
REMOVAL
Position the vehicle on a two-post lift (see 02A Lifting equipment, Underbody lift ).
Remove the front right-hand wheel.
Move the heat insulating material away from the oil
level sensor.
CONCERNED
114932
Disconnect the oil level sensor (1) .

Remove the oil level sensor.
REFITTING
CONCERNED
Refit the oil level sensor.
Tighten to torque the oil level sensor ( 25 Nm ) .
Connect the oil level sensor.
10A-20

10A
K4J, and 730 or 732 K4M, and 760 or 761
Equipment required
safety belt
Tightening torquesm
sump mounting bolts
14 Nm
sump mounting bolts

are tightened to torque
14 Nm
gearbox - sump mounting bolts
44 Nm
sump mounting bolts
14 Nm
sump mounting bolts

14 Nm
gearbox - sump mounting bolts
44 Nm
bolt mounting the sump

on the multifunction
support
21 Nm
half sub-frame mounting bolts
105 Nm
half sub-frame mounting nuts
21 Nm
wheel bolts
battery cover bolts
101212
Remove the half sub-frame side reinforcements (1) .

Attach the cooling assembly to the upper cross
member using a safety belt .
Note:
When positioning the safety belt , be careful not
to:
- pinch the cooling hoses,
- strap the half sub-frame.
110 Nm
4 Nm
REMOVAL
Drain the engine oil (see 05A, Draining - Filling,
Engine ).
Remove:
- the dipstick,
- the front wheels,
- the wheel arch liners,
10A-21

10A
K4J, and 730 or 732 K4M, and 760 or 761

Apply the product to the section to be cleaned: wait
approximately ten minutes, then remove the residue
using a wooden spatula.
WARNING
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
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.).
2
102008
Remove:
- the mounting nuts from the half sub-frame,
- the mounting bolts from the half sub-frame,
- the half sub-frame (2) .
Remove:
- the mounting bolts of the right-hand driveshaft
bracket on the relay bearing,
- the bolts mounting the relay bearing on the sump.
CA or CAREG
Remove the mounting bolt of the sump on the multifunction support.
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dissolve any seal still adhering.
10A-22

10A
K4J, and 730 or 732 K4M, and 760 or 761

I - FIRST FITTING
3
20167
20170
Refit the oil splash plate onto the cylinder block.
5
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 deformation of the
clutch housing.
4
20166
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVE
SEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE SEALANT at
(5) which are 7 mm in diameter , at the joint
between the crankshaft closure panel and the cylinder block.
10A-23

K4J, and 730 or 732 K4M, and 760 or 761
9 10 11
12 13 14
15
16
20
19 18 17
20171
Refit the oil sump with a new seal.

Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tightening.
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 gearbox - sump mounting
bolts ( 44 Nm ) .
10A-24
10A

10A
K4J, and 730 or 732 K4M, and 760 or 761

bolts ( 44 Nm ) .
II - SECOND FITTING
III - REFITTING (FOR FIRST AND SECOND

FITTINGS)
CA or CAREG
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:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts ( 110 Nm ) .
- the battery cover bolts ( 4 Nm ) .
108881
Proceed in the reverse order to removal.
Top up the engine oil (see 05A, Draining - Filling,

Engine ).
9 10 11 12 13 14
15
16
20 19
18 17
20171

Fit:
bolts ( 14 Nm ) .
Check that all the sump mounting bolts are tightened to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
10A-25

10A
F9Q, and 800 or 804 or 808
Equipment required
safety belt
Tightening torquesm
105 Nm
21 Nm
wheel bolts
battery cover mounting
bolts
110 Nm
4 Nm
REMOVAL
101212




Engine ).
Note:
Remove:

to:
- the dipstick,
- the front wheels,

10A-26

10A
F9Q, and 800 or 804 or 808

WARNING
WARNING
Note:
There are two fitting procedures for preparing the

cylinder block gasket face when refitting:
102008
Remove:
- the first fitting procedure is used if SILICONE

ADHESIVE SEALANT has been used to seal
the crankshaft closure panel,
- the second fitting is used if a seal is used for the
crankshaft closure panel sealing.

Remove:
- the engine tie-bar,
- the sump mountings,
- the sump.
REFITTING
10A-27

10A
F9Q, and 800 or 804 or 808

I - FIRST FITTING
II - SECOND FITTING
15159
15159
Apply a bead of SILICONE ADHESIVE SEALANT :
Apply a bead of SILICONE ADHESIVE SEALANT

at (A) , on the joint between the crankshaft closure
panel and the cylinder block.
- at (A) , both sides of bearing No.1,

- at (B) , the joint between the cylinder block and the
crankshaft closure panel.
Refit the sump fitted with a new seal.
Note
Do not cut the two crankshaft closure panel seal
tabs which sit higher than the cylinder block gasket face (B) .
Refit the sump fitted with a new seal.
10A-28

F9Q, and 800 or 804 or 808
III - REFITTING (FOR THE FIRST AND SECOND
FITTINGS)
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) , (13)
, (18) , (3) , (20) , (2) , (21) , (1) and (22) to ( 15
Nm ).
Refit the lower engine tie-bar (see 19D, Engine
mounting, Suspended engine mounting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) ,
Engine ).
10A-29
10A

10A
K9K, and 722 or 728 or 729 or 732
REMOVAL
Equipment required
safety belt

Tightening torquesm

sump mounting bolts
14 NM
sump mounting bolts

14 NM
sump mounting bolts
44 NM
sump mounting bolts
14 NM
Remove:
sump mounting bolts

14 NM
sump mounting bolts
44 NM
- the front wheels,
bolt mounting the sump

on the multifunction
support
21 Nm
catalytic converter upstream stay mounting

bolts
21 Nm
105 Nm
21 Nm
half sub-frame side

reinforcement mounting
bolts
21 Nm
Remove:
- the dipstick,
wheel bolts
- the wheel arch liners.

Engine ).
110 Nm
10A-30

10A
K9K, and 722 or 728 or 729 or 732
101212
102008
Remove:


Note:

to:
K9K, and 732
Remove:
- the lower engine tie-bar mounting bolts,

- the lower engine tie-bar,
K9K, and 732

Move the diesel drain pipe away from the injection
rail protector.
- the lower engine tie-bar support lower mounting

bolts.
Loosen the lower engine tie-bar upper bolt.
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.
Disconnect the oil level sensor.
10A-31

10A
K9K, and 722 or 728 or 729 or 732
CA or CAREG
Remove the mounting bolt from the sump on the
multifunction support.

CONCERNED
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
3
20167
K9K, and 732
Clean the strainer with a soft, lint-free cloth.
WARNING
WARNING

20166
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVE
SEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE at (5) which
are, 7 mm in diameter , at the joint between the
crankshaft closure panel and the cylinder block.
10A-32

10A
K9K, and 722 or 728 or 729 or 732

CONCERNED
9 10 11
12 13
14
1 - FIRST FITTING
15
6
16
7
5
20 19
18 17
20171

Fit:
20170
Refit the oil splash plate onto the cylinder block.

bolts ( 14 NM ) .
Note:
When refitting the sump, check that:
Check that all the sump mounting bolts are tightened to torque ( 14 NM ) .
- the tabs (6) on the oil splash plate are positioned correctly in the notches (7) ,

bolts ( 44 NM ) .
- the cylinder block and the sump at the flywheel

end are aligned to prevent deformation of the
clutch housing.
10A-33

10A
K9K, and 722 or 728 or 729 or 732

bolts ( 44 NM ) .
2 - SECOND FITTING

Connect the oil level sensor.
CA or CAREG
Refit the bolt mounting the sump on the multifunction
support.
Tighten to torque the bolt mounting the sump on
the multifunction support ( 21 Nm ) .
Refit the catalytic converter upstream stay.
108881
Tighten the mounting bolts of the catalytic converter

upstream stay until contact is made.
Tighten to torque the catalytic converter upstream
stay mounting bolts ( 21 Nm ) .
Refit:
- the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the bolts mounting the right-hand driveshaft bracket on the relay bearing.
K9K, and 732

Refit the lower engine tie-bar support lower mounting bolts (see 19A, Engine mounting, Suspended
engine mounting ).
20171

Fit:
Tighten the lower engine tie-bar support lower

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

bolts ( 14 NM ) .
Check that all the sump mounting bolts are tightened to torque ( 14 NM ) .
10A-34
Note:
Apply a drop of LOCTITE FRENBLOC to the half
sub-frame mounting bolts.

K9K, and 722 or 728 or 729 or 732
Refit:
- the half sub-frame mounting bolts,
- the half sub-frame mounting nuts,
- the half sub-frame.
Tighten to torque:
- the half sub-frame mounting nuts ( 21 Nm ) .
K9K, and 732

Fit the diesel drain pipe to the injection rail protector .
Remove the safety belt .

Refit:
- the half sub-frame side reinforcements,
- the half sub-frame side reinforcement mounting
bolts.
Tighten to torque the half sub-frame side reinforcement mounting bolts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365, Bodywork, 55A,
Exterior protection, Front bumper ),
- the front wheels.
Tighten to torque the wheel bolts ( 110 Nm ) .
Engine ).
Refit:
- the dipstick,
10A-35
10A

10A
F4R, and 770 or 771 or 776
Equipment required
safety belt
Tightening torquesm
105 Nm
21 Nm
wheel bolts (F4R 776)
130 Nm
wheel bolts
110 Nm

bolts
4 Nm
101212
REMOVAL
Remove:

- the half sub-frame side reinforcement mounting

bolts,

- the side reinforcements (1) .

member using the safety belt .

Engine ).
Note:
Remove:

to:

- the dipstick,
- the front wheels,
10A-36

10A
F4R, and 770 or 771 or 776
2
102008
15159

at (A) , at the joint between the crankshaft closure
panel and the cylinder block.
Remove:
Note:
Do not cut the two tabs on the crankshaft closure

panel seal, which sit higher than the joint face of
the cylinder block (B) .
Remove:
- the engine tie-bar,
Refit the sump with a new gasket.
- the sump mountings,

- the sump.
REFITTING
WARNING
WARNING
10A-37

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) ( 18 Nm ).
- Stage 2:
Tighten to torque and in order, bolts (10) , (13) ,
(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18)
, (3) , (20) , (2) , (21) , (1) and (22) ( 15 Nm ).
Tighten to torque:
- the wheel bolts (F4R 776) ( 130 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Engine ).
10A-38
10A

10A
M9R, and 700

Mot. 1716
Removes housing with

silicone seals.
Tightening torquesm
sump mounting bolts
16 Nm
105 Nm
21 Nm
the side reinforcement

lower mounting bolts
21 Nm
REMOVAL
102008
Remove:

Position the vehicle on a lift (see 02A, Lifting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery :
Remove:
- the dipstick,
- the front wheels,
- the front wheel arch liners,
10A-39
- the lower mounting bolts (1) from the side reinforcements,

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

10A
M9R, and 700

CONCERNED
Check that the base plate is not scratched.
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mixture of sealant and fluid could cause damage to
cer tain components (engine, radiator, etc.).
WARNING
The sealing surfaces must be clean, dry and free
114997
Remove the sump mounting bolts.

CONCERNED
Remove the sump using the (Mot. 1716) .

Remove the lower cover.
REFITTING
Check that the sump is not:
- scratched,
- deformed.
If this is the case, replace the sump.
114410

(77 11 227 484) with a diameter of 5 mm 2 to the
sump to make a seal.
Fit the sump.
Tighten the sump mounting bolts until contact is made.
bolts ( 16 Nm ) .
10A-40

M9R, and 700
Refit:
- the half sub-frame,
- the half sub-frame mounting nuts.
Tighten to torque:
Refit the side reinforcement lower mounting bolts.
Tighten to torque the side reinforcement lower
mounting bolts ( 21 Nm ) .
Refit:
- 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,
10A-41
10A

Oil pump: Removal - Refitting
10A
Connect the battery, starting with the positive terminal.

Tightening torquesm
oil pump mounting bolts
25 Nm
battery cover bolts
WARNING
Carry out the necessary programming (see 80A,
Battery: Removal - Refitting ).
4 Nm
Tighten to torque the battery cover bolts ( 4 Nm ) .
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negative
terminal.
Remove the under-engine protectors
Drain the engine oil.
Remove the sump (see 10A, Engine and peripherals, Sump ).
Example for F9Q engine
2
1
23224
Remove:
- the bolt (1) and the oil splash plate,
- the oil pump bolts (2) ,
- the oil pump.
REFITTING
Tighten to torque the oil pump mounting bolts ( 25
Nm ) .
Refit the sump (see 10A, Engine and peripherals,
Sump ).
10A-42

10A
M9R, and 700

CONCERNED
Tightening torquesm
on the cylinder block
25 Nm

on the anti-splash plate
10 Nm
strainer mounting bolts
10 Nm
REMOVAL
Remove the sump (see 10A, Engine and peripherals, Sump: Removal - Refitting ).
113157
Remove:
- the oil pump mounting bolts on the anti-splash plate,
- the oil pump mounting bolts on the cylinder block,
- 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 ,

CONCERNED
- the strainer.
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 oil pump mounting bolts on
the cylinder block (5 Nm) .
Tighten to torque:
- the oil pump mounting bolts on the cylinder
block ( 25 Nm ) ,
- the oil pump mounting bolts on the anti-splash
plate ( 10 Nm ) ,
10A-43

M9R, and 700
113156
Replace the oil strainer O-ring.

Fit the strainer to the oil pump and finger tighten the
two mounting bolts in the following tightening order -.
Tighten the strainer mounting bolts ( 10 Nm ) in
the following tightening order -.
Remove:
- 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.
10A-44
10A

Multifunction support: Removal - Refitting
10A
K4J, and 730 or 732 K4M, and 760 or 761
CA or CAREG
Tightening torquesm
multifunction support
mounting bolts
44 Nm
mounting bolt on the
sump
21 Nm
REMOVAL
Remove the engine protectors.
Disconnect the battery (see 80A, Battery, Battery :
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
102265

Exterior protection, Front bumper: Removal Refitting ),
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting ),
- the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ).
10A-45
Remove:
- the multifunction support mounting bolts (1) ,
- the bolt (2) mounting the multifunction support on
the sump,
- the multifunction support.

10A
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
CHAUFO
CA or CAREG
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-46

K4J, and 730 or 732 K4M, and 760 or 761
CHAUFO
111057
Refit:
Tighten to torque and in order the multifunction
support mounting bolts (44 Nm) .
Refit:
engine, Accessories belt: Removal - Refitting ),
- the front bumper (see MR 365 Bodywork, 55A,
Exterior protection, Front bumper: Removal Refitting ),
- the front wheels.
Refit the engine protectors.
10A-47
10A

10A
K9K, and 722 or 724 or 728 or 729 or 732

CONCERNED
Tightening torquesm
sump
21 Nm
mounting bolts
44 Nm
CA or CAREG
REMOVAL
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal
- Refitting ).
Remove:
- the front wheels,
102265
Remove:

Exterior protection, Front bumper: Removal Refitting ).
engine, Accessories belt: Removal - Refitting ).
10A-48

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

10A
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
CONCERNED
CA or CAREG
111057
Remove:
102265
Refit:
- the multifunction support mounting bolt on the
sump ( 21 Nm ) .
Nm ) ,
10A-49

K9K, and 722 or 724 or 728 or 729 or 732
CHAUFO
111057
Refit:
Tighten to torque and in order the multifunction
support mounting bolts (44 Nm) .
Refit:
- the front wheels.
Connect the battery (see 80A, Battery: Removal Refitting ).
Refit the engine covers.
10A-50
10A

10A
F4R, and 770 or 771 or 776, and CA or CAREG F9Q, and 800 or 804 or 808, and CA or CAREG
Equipment required
filling station
Tightening torquesm
mounting bolts
44 Nm
air conditioning compressor mounting bolts
25 Nm
air conditioning compressor strut mounting

bolts
44 Nm
3
1
battery cover bolts
4 Nm
REMOVAL
109537

Drain the coolant circuit using the filling station
(see 62A, Air conditioning, Maintenance ).
Remove the alternator (see 16A, Starting - Charging, Alternator ).
Disconnect:
- the air conditioning compressor connector,
- the pressure switch connector (1) .
Remove:
- the air conditioning compressor pipe (2) ,
- the air conditioning pipe between the compressor
and the dehydration canister (3) .
Note:
system.
Remove:
- the air conditioning compressor mounting bolts,
- the air conditioning compressor.
10A-51

10A
104337
Remove:
REFITTING
Refit the multifunction support.
Tighten to torque:
Nm ) ,
- the air conditioning compressor mounting
bolts ( 25 Nm ) .
- the air conditioning compressor strut mounting
bolts ( 44 Nm )
Refit the alternator (see 16A, Starting - Charging,
Alternator ).
Fill the coolant circuit using the filling station (62A,
Air conditioning, Maintenance).
10A-52

10A
M9R, and 700

CONCERNED
Tightening torquesm
mounting bolts
44 Nm
25 Nm
REMOVAL
Remove the alternator (see 16A, Starting-Charging, Alternator: Removal - Refitting ).
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 to one side.
Attach the air conditioning compressor to the half
sub-frame.
10A-53

M9R, and 700
REFITTING
CONCERNED
114862
Position the multifunction support.

Finger tighten (until contact is made) the three
mounting bolts in the following order ( (4) - (1) - (2) ).
Finger tighten the two remaining mounting bolts ( (3)
(5) ) until contact is made.
Tighten to torque the multifunction support mounting bolts ( 44 Nm ) in the following tightening order
( (4) - (1) - (2) - (3) - (5) ).
Fit the air conditioning compressor.
mounting bolts ( 25 Nm )
Refit the alternator (see 16A, Starting-Charging,
Alternator: Removal - Refitting ).
10A-54
10A

Engine/gearbox assembly: Removal - Refitting
10A
K4M, and 760 or 761
REMOVAL

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

IMPORTANT
During this operation, secure the vehicle to the
lift with a safety belt , to avoid any imbalance.
Remove:
- the front wheels,
Equipment required
safety belt
filling station
Drain:
hydraulic crane
- the gearbox (see 05A, Draining-Refilling, Gearbox ),
load positioner
- the engine (see 05A, Draining-Refilling, Engine ).

Tightening torquesm
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
battery cover bolts
CA or CAREG
Drain the refrigerant circuit using the filling station
110 Nm
4 Nm
101212
Remove:
- the battery (see 80A, Battery, Battery: Removal Refitting ),
10A-55

10A
K4M, and 760 or 761

- the half sub-frame side reinforcements (1) ,
Exterior protection, Front bumper ).
2
5
7
102504
Disconnect the two connectors (2) .

101795
Unclip the front bonnet opening cable (3) .

Disconnect:
Remove:
- the clip (4) ,
- the petrol inlet pipe from the injector rail (7) ,
- the fastening (5) .

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

102365
11
Remove:
- the front end panel mounting bolts (6) ,

10
109537
Disconnect the hoses from the expansion bottle on

the cooling radiator side (8) .
10A-56

10A
K4M, and 760 or 761
CA or CAREG
Disconnect the pressostat connector on the lower air
conditioning pipe on the condenser (9) .
Remove:
- the air conditioning pipes from the condenser (10) .
- the air conditioning pipe between the air conditioning compressor and the dehydration canister (11)
,
13
14
Note:
system.
101822

Disconnect the computer connectors (13) .
Remove the battery tray mounting bolts (14) .
Remove:
- the battery tray,
- the computer mounting.
12
15
101807
Remove the air filter outlet duct (12) .
104553
Remove the air filter unit (15) .
10A-57

10A
K4M, and 760 or 761
17
101978
Disconnect the wiring harness connectors from the

relay board.
101812
Remove the brake servo pipe (17) .
19
18
16
104240
111051
Disconnect the earth strap on the body.
Disconnect:
- the hoses (18) and (19) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
10A-58

10A
K4M, and 760 or 761
K4M, and 761
K4M, and 760
22
B
A
C
21
A
103409
101743
Remove:
Unclip the lever cables on the gearbox:
- the multifunction switch cable ball joint (21) ,
- grip the gearbox control at (A) ,
- the multifunction switch cable (22) by unlocking the

sleeve stop.
- pull the pin at (B) ,

- raise the gearbox control at (C) .
20
101699
Remove the gearbox controls (20) .
10A-59

10A
K4M, and 760 or 761
K4M, and 760
24
23
102008
Remove:
101740
Pull out clip (23) .
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ),
Disconnect the hydraulic clutch supply pipes.
- the exhaust downpipe mountings,
Note:
Plug the pipes to prevent fluid from escaping.

Position the hydraulic crane fitted with a load positioner or a chain.
10A-60

10A
K4M, and 760 or 761
K4M, and 761
101866
Mark the suspended engine mounting in relation to

the body.
103273
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
K4M, and 760

Rotate the engine and gearbox assembly in order to remove it.
REFITTING
To carry out a normal engine replacement operation
(see Technical Note 3784A, Petrol engine - 4 cylinders - K4, 10A, Engine and peripherals, Normal replacement ).
Position the engine and gearbox assembly in the
vehicle.
Refit:
- the suspended engine mounting (see 19D, Engine
mounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engine mounting, Suspended mounting ),
102112
- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft ).
10A-61

10A
K4M, and 760 or 761

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 ( 110 Nm ) .
Add brake fluid to the brake fluid reservoir.
K4M, and 760

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

- fill up the gearbox oil (see 05A, Draining-Refilling,
Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,
Engine ),
- fill up the cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).
CA or CAREG
Fill the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ).
IMPORTANT
Correctly attach the brake hose and the sensor
wiring for the ABS system.
Do not twist the brake hose.
Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Bleeding ).
10A-62
Note:
If the vehicle is fitted with xenon lamps, it is
essential to initialise the system (see 80C,
Xenon bulbs, Xenon headlights: Adjustment
).
Adjust the headlights (see 80B, Headlights,
Halogen headlights: Adjustment) .

10A
F9Q, and 800 or 808

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

system hose clips
(large model)
Procedure for removing the air inlet duct on the

intercooler:
Mot. 1202-02

clips
- do not use a degreaser, brake cleaning product, or

any other product,
Mot. 1448

- detach the hose, using the (Car. 1363) ,
- clean the intercooler bearing face and the hose

using a dry, lint-free cloth,
- refit the clip in the same recess in the event that
the hoses are not replaced,
Equipment required
- it is essential to replace the hoses and/or the intercooler if they are damaged.
safety belt
If this procedure is not followed the hoses may leak

or come undone.
filling station
hydraulic crane
REMOVAL
load positioner
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm
wheel mounting bolt
110 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
321 Nm
IMPORTANT
Remove:
battery cover bolts
- the front wheels,

4 Nm
Drain:
CA or CAREG
10A-63

10A
F9Q, and 800 or 808
102365
Remove:
101212

Remove:
- the battery (see 80A, Battery, Battery: Removal Refitting ).
7
104338
2
4
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .

102504
WARNING
Disconnect the connectors (2) .
Follow the cleanliness guidelines closely (see

13B, Diesel injection, Cleanliness guidelines
).
Unclip the bonnet release cable (3) .

Remove:
Be aware of the residual pressure and the quantity of diesel fuel in the pipes.
- the clip (4) ,

Disconnect the electrical connector (9) .
Fit plugs into the openings.
10A-64

10A
F9Q, and 800 or 808
CA or CAREG
conditioning pipe from the condenser (12) .
Remove:
.
Note:
10
106275
Disconnect:
system.
- the intercooler hose (10) ,

- the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors.
14
11
15
12
102473
13
Disconnect the air duct from the intercooler (15) .
109537

10A-65

10A
F9Q, and 800 or 808
16
20
19
102500
104245
Remove:
- the Protection and Switching Unit mounting bolt,
- the fuse box (19) ,
- the relay box (20) .
Disconnect the connectors from the Protection and
Switching Unit.
17
18
21
101822
22

Remove:
- the battery tray mounting bolts (18) ,
- the battery tray,
104340
Remove:
- the earth strap (21) ,
- the pre-postheating unit (22) .
10A-66

10A
F9Q, and 800 or 808
23
24
A
C
A
104322
Remove the brake servo pipe (23) from the vacuum

pump.
Disconnect the heater radiator top hose (24) on the
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
25
101699
10A-67
101743

- clip the gearbox control at (A) ,

10A
F9Q, and 800 or 808
26
27
102513
102008
Press the clip (26) .
Remove:
Disconnect the supply pipes.
Remove the clutch hydraulic control at the bulkhead.
Note:

- the upper engine tie-bar.
10A-68

10A
F9Q, and 800 or 808
REFITTING
To replace the engine (see Technical Note 3652A,
High pressure diesel engine - Common Rail 4 cylinder cast iron, 10A, Engine and peripherals,
Normal replacement ).
vehicle.
Refit:
mounting, Suspended mounting ) in accordance
with the marks,
- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting )
- the upper engine tie-bar (see 19D, Engine mounting, Suspended mounting ),
102742
- the front left-hand driveshaft (see 29A, Driveshafts, Front left-hand driveshaft ).
Tighten to torque:
),
),
- the wheel mounting bolt ( 110 Nm ) ,
),
- the half sub-frame rear mounting bolt ( 321 Nm
).
Add the brake fluid to the brake fluid reservoir.
102419

the body.
Remove:
IMPORTANT
- bleed the clutch (see 37A, Mechanical component controls): bleed the clutch circuit
- the suspended engine mounting,

- the gearbox suspended mounting,

Gearbox ),

Engine ),
10A-69

F9Q, and 800 or 808
- fill up the coolant (see 19A, Cooling, Cooling system: Draining-refilling ).
CA or CAREG

Note:
Always initialise the xenon bulb system (if fitted
to the vehicle; see 80C, Xenon bulbs, Xenon
headlight: Adjustment ).
Bleed the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Bleeding ).
Halogen headlights: Adjustment ).
10A-70
10A

10A
K9K, and 722 or 728

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

system hose clips
(large model)

intercooler:
Mot. 1202-02

clips

any other product,
Mot. 1448


Equipment required
safety belt

or come undone.
filling station
hydraulic crane
REMOVAL
load positioner
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm
wheel mounting bolts
110 Nm

mounting bolt
165 Nm
half sub-frame rear

mounting bolt
21 Nm
IMPORTANT
Remove:
battery cover bolts
- the front wheels,

4 Nm
Drain:
CA or CAREG
10A-71

10A
K9K, and 722 or 728
102365
Remove:
101212
Remove:
- the side reinforcements (1) from the half sub-frame
cross member,
3
2
4
102504

Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
10A-72


10A
K9K, and 722 or 728
9
106275
7
8
102514
Remove:
- the fuel supply pipe (7)
WARNING
).
10
102473
Disconnect:
(Mot. 1202-02) or (Mot. 1448) .
10A-73
Remove the intercooler air ducts (9) and (10) .

10A
K9K, and 722 or 728
16
15
14
11
12
13
109537

101822

Remove:
CA or CAREG
conditioning pipe on the condenser (12) .
- the battery tray,

Remove:
K9K, and 728
- the air conditioning pipes on the condenser (13) ,

,
Move the turbocharger pressure regulation solenoid

valve to one side.
Note:
Disconnect:
system.
- the air filter outlet duct,

- the flow meter connector (if fitted to the vehicle).
Remove the cooling radiator assemblies.
10A-74

10A
K9K, and 722 or 728
18
19
17
104553
Remove the air filter unit (17)
104340
Disconnect:
- the pre-postheating unit (18) ,
- the earth strap on the body (19) .
20
101978
21

relay board.
102263

Disconnect the heater radiator hoses from the scuttle panel (21) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
10A-75

10A
K9K, and 722 or 728
B
22
A
C
102264
Disconnect the heater radiator hoses from the scuttle panel (2 2) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
101743

23
101699
24
101701
Remove the clutch hydraulic control (24) .
10A-76

10A
K9K, and 722 or 728
25
102008
101866
Remove:
102112

the body.
Remove:
- the gearbox suspended mounting,
10A-77

10A
K9K, and 722 or 728
REFITTING
High pressure diesel engine Common Rail - 4
cylinder cast iron, 10A, Engine and peripherals,
CA or CAREG

vehicle.
Refit:
Tighten to torque:
),
),
- the wheel mounting bolts ( 110 Nm ) ,
),
- the half sub-frame rear mounting bolt ( 21 Nm ) .
IMPORTANT
- bleed the clutch system (see 37A, Mechanical
component controls, Bleeding the clutch system: ),
Gearbox ),
Engine ),
- fill up the cooling system (see 19A, Cooling, Cooling system: Draining-Refilling .
10A-78
Note:

10A
M9R, and 700

Mot. 1202-01
Tightening torquesm

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Mot. 1390
battery tray bolts

wiring harness mounting nuts
21 Nm
8 Nm
REMOVAL
Support for removing

and refitting the
engine and gearbox
assembly
Remove:
- the engine undertrays,
Equipment required
- the front wheels,
filling station
- the right-hand and left-hand wheel arch liners,

Tightening torquesm
rounded bracket bolts
with their spring
21 Nm
half sub-frame rear

mounting nuts
21 Nm

mounting bolts
105 Nm
hose
5.5 Nm
intercooler
tream pipe
downs-
5.5 Nm
intercooler downstream pipe on the air

inlet valve
8 Nm
air conditioning pipes

on the condenser
8 Nm
air conditioning pipe

between the air conditioning compressor and
the dehydration canister
8 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm

Drain:
- the refrigerant circuit using the filling station (see
10A-79

10A
M9R, and 700
112658
112659
Remove:
bolts (1) ,
Remove:
- the mounting nut (8) from the wiring harness.
Move the wiring harness to one side.

Remove the battery tray.
102504

and Switching Unit.
Remove:
- the clips (4) ,
114933
- upper mounting bolts from the front end panel (5) ,

- the fuse box,
- the relay box.
10A-80

10A
M9R, and 700
102365
Remove:
- the mounting bolts from the lower front end panel
(10) ,
115019

114659
Remove the air resonator (11) .
10A-81
Remove the air inlet duct (12) .
115020
Remove the air filter unit.

M9R, and 700
102473
Loosen the intercooler upstream hose clip (13) .

Disconnect the intercooler upstream hose.
112661
Disconnect:
10A-82
10A

10A
M9R, and 700

Disconnect:
- the fuel supply pipe,
- the fuel return pipe from the diesel filter,
- the fuel return pipe.
WARNING
13B, Diesel injection, Cleanliness guidelines:
Precautions during repair ).
Watch out for diesel fuel splashing when disconnecting the supply union.
Insert plugs into the openings.
115023
Remove the bolt (1 5) mounting the intercooler

downstream pipe on the cooling radiator.
Loosen:
- the clip (16) securing the intercooler downstream
pipe on the intercooler,
- the clip securing the intercooler downstream pipe
on the air inlet valve.
Move aside the intercooler downstream pipe on the
intercooler.
Disconnect:
- the cooling radiator top and bottom hoses using the
(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
radiator side (17) ,
- the pressostat connector on the condenser lower
air conditioning pipe (18) .
Release the wiring harness from the pressostat connector on the fan unit.
Remove:
.
Note:
system.
10A-83
104340
Disconnect:
- the pre-postheating unit connector (21) ,
- the earth strap on the body (22) .

10A
M9R, and 700
115003
Remove the clutch hydraulic control pipe at the bulkhead (23) .
101743

Remove the brake assistance pipe from the vacuum

pump.
Disconnect:
- the heater radiator hose from the scuttle panel outlet,

- the heater radiator hose from the scuttle panel outlet using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
102008
Remove:
- the side reinforcement mounting bolts (25) ,
- the side reinforcements,
115001
- the half sub-frame mounting bolts (26) ,

- the half sub-frame mounting nuts (27) ,
10A-84

M9R, and 700
114650
Remove:
- the rear mounting (28) (see 19D, Engine mounting, Rear mounting: Removal and Refitting )
114991
Remove the rounded bracket bolts with their springs

(29) .
Remove:
10A-85
10A

10A
M9R, and 700

CONCERNED
114989
Position the (Mot. 1390) .
REFITTING
Remove:
- the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ).

CONCERNED
- the mounting nut on the left-hand suspended

mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ).
Position:
- the right-hand suspended mounting in its housing,
- the Engine and gearbox assembly in the vehicle.
Refit:
- the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ).
- the mounting nut on the left-hand suspended
mounting (see 19D, Engine mounting, Left-hand
suspended mounting: Removal - Refitting ).
10A-86

10A
M9R, and 700

pe,
Refit:
- the intercooler upstream hose,
- the rear mounting (see 19D, Engine mounting,

Rear mounting: Removal - Refitting ).
- the intercooler downstream pipe.
- the front left-hand driveshaft (see 29A, Driveshaft,
Front left-hand driveshaft ),
- the rounded bracket bolts with their spring.
Tighten to torque the rounded bracket bolts with
their spring ( 21 Nm ) .
Refit:
Tighten to torque:
- the intercooler upstream hose ( 5.5 Nm ) ,
- the intercooler downstream pipe ( 5.5 Nm ) ,
- the intercooler downstream pipe on the air inlet
valve ( 8 Nm ) .
Refit:
- the air conditioning pipes to the condenser.
- the air conditioning pipe between the air conditioning compressor and the dehydration canister.
Tighten to torque:
- the air conditioning pipes on the condenser ( 8

Nm ) ,
- the half sub-frame mounting nuts.

Tighten to torque:
- the half sub-frame rear mounting nuts ( 21 Nm )
,
- the air conditioning pipe between the air conditioning compressor and the dehydration canister ( 8 Nm ) .
- the half sub-frame front mounting bolts ( 105

Nm ) .
Secure the wiring harness to the pressostat connector on the fan unit.
Refit:
Connect
- the gearbox controls,

radiator side,
- the fuse box,

air conditioning pipe.
- the relay box,

- the earth strap on the body,
Connect:
- the pre-postheating unit connector,
Clip the fan unit wiring harness into place.
- the brake servo pipe from the vacuum pump,
Refit:
- the clutch hydraulic control pipe at the bulkhead,
- the heater radiator hose from the scuttle panel outlet,

- the heater radiator hose from the scuttle panel outlet using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) ,
- the air inlet duct,

- the air resonator,
- the front end panel lower mounting bolts,
- the front end panel upper mounting bolts,
- the fuel return pipe on the diesel filter,
- the clips.
Tighten to torque:

Connect:

Nm ) ,
- the cooling radiator top and bottom hoses using the

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

Nm ) .
- the mounting bolt to the intercooler downstream pi-
Clip on the air inlet scoop.
10A-87

M9R, and 700
Refit:
- the battery tray, the injection computer and its
mounting,
- the battery tray mounting bolts,
- the wiring harness,
- the wiring harness mounting nut.
Tighten to torque:
- the battery tray bolts ( 21 Nm ) ,
- the wiring harness mounting nuts ( 8 Nm ) .
Connect
- the computer connectors,
- the Protection and Switching Unit connectors.
Clip the bonnet opening cable.
Refit:
- the rounded bracket mounting bolts with their
spring (see 19A, Exhaust ),
- the rear mounting (see 19D, Engine mounting,
Rear mounting: Removal - Refitting ).
Gearbox ),
- fill up the engine oil if necessary,
- fill up the refrigerant circuit using the filling station
(see 62A Air conditioning, Maintenance ),
- fill and bleed the cooling circuit (see 19A, Cooling,
Bleeding the cooling circuit ).
Refit:
- the side reinforcement mounting bolts,
- the front wheels,
- the battery (see 80A, Battery, Battery: Removal
and Refitting )
- the engine protector.
10A-88
10A

10A
F4R, and 770 or 771 or 776

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

system hose clips
(large model)

intercooler (F4R 776):
Mot. 1202-02

clips

any other product,
Mot. 1448


- refit the clip in the same recess if the hoses are
not replaced,
Equipment required
safety belt

or come undone.
filling station
hydraulic crane
REMOVAL
load positioner
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm
wheel bolts
110 Nm
wheel bolt (F4R 776)
130 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm

bolts
4 Nm
Note:
During this operation, strap the vehicle to the lift
using a safety belt , to avoid any imbalance.
Remove:
- the front wheels,
Drain:
CA or CAREG
10A-89

10A
F4R, and 770 or 771 or 776
1
102365
Remove:
101212
Remove:

F4R, and 770 or 771

2
4
102504
101795
Disconnect the fuel supply pipe (7) from the injector

rail.

Remove:
- the clip (4) ,
10A-90

10A
F4R, and 770 or 771 or 776
F4R, and 776
10
13
11
12
106271
Disconnect:
- the injector rail (8) from the fuel supply pipe
109536
- the cooling radiator top hose using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) ,
Disconnect:
- the turbocharging pressure sensor connector (10) ,
- the air temperature sensor connector (11) ,

Move the air duct (13) to one side.
F4R, and 776
F4R, and 770 or 771
9
106275
14
Disconnect the intercooler hose (9) .
101807
10A-91

10A
F4R, and 770 or 771 or 776
19
20
18
15
16
17
109537
Disconnect the hoses from the cooling radiator expansion bottle (15) .
101822

CA or CAREG
Remove:
Note:
system.
10A-92

10A
F4R, and 770 or 771 or 776
F4R, and 776
25
21
106280
106278
Remove the computer and its mounting (25) .
24
23
22
106632
104553
Move the fuel vapour recirculation solenoid valve to

one side (21) .
Undo the bolt (22) .
Pull the mounting bracket away from the electric
coolant pump.
Move the electric water pump (23) to one side.
Remove the electric pump mounting (24) .
10A-93

10A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
27
101978

relay board.
101812

Disconnect the downstream oxygen sensor connector.
F4R, and 776
26
28
111051
Disconnect the earth strap (26) .

106787
10A-94

10A
F4R, and 770 or 771 or 776
B
29
30
A
C
104240
Disconnect hoses (29) and (30) using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448) .
101743
Unclip the two gear lever cables on the gearbox:

F4R, and 770 or 776

F4R, and 771
33
31
101699
32
Remove the control cables from the gearbox (31) .
103409
Remove:
10A-95

10A
F4R, and 770 or 771 or 776

- the multifunction switch cable (33) by loosening the
sleeve stop.
F4R, and 770 or 776
34
102008
Remove:
33
101740
Place a cloth under the master cylinder.

Remove the clip (33) from the union on the master

cylinder return.
Disconnect the pipes from the slave cylinder.
Withdraw the slave cylinder feed pipes.
10A-96

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

the body.
103273
F4R, and 770 or 776

REFITTING
(see Technical Note 6027A, Petrol engine - 4 cylinders - F4, 10A, Engine and peripherals, Normal replacement ).
vehicle.
Refit:
with the marks,
102112
10A-97

10A
F4R, and 770 or 771 or 776

Tighten to torque the battery cover mounting bolts

( 4 Nm ) .

Tighten to torque:
Note:

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

),
- the wheel bolt (F4R 776) ( 130 Nm ) ,
),
IMPORTANT
Correctly attach the flexible brake pipe and ABS
sensor wiring.
Do not twist the brake hoses.
F4R, and 770 or 776

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

- fill up the gearbox oil (see 05A, Draining-refilling,
Gearbox ),
- fill up the engine oil (see 05A, Draining-refilling,
Engine ),
CA or CAREG

10A-98


10A
K9K, and 729, and DP0

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

system hose clips
(large model)

intercooler:
Mot. 1202-02

clips

any other product,
Mot. 1448


not replaced,
Equipment required
safety belt

or come undone.
filling station
hydraulic crane
REMOVAL
load positioner
Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
210 Nm
wheel bolts
110 Nm

bolts
IMPORTANT
Remove:
- the front wheels,
4 Nm
Drain:
CA or CAREG
10A-99

10A
1
102365
Remove:
101212
Remove:
2
4
102504

Remove:
- the clip (4) ,
10A-100


10A
106275
7
8
102514
Remove:
WARNING
).
10
102473
Disconnect:
(Mot. 1202-02) or (Mot. 1448) .
10A-101
Disconnect the intercooler hoses (9) and (10) .

10A
14
15
11
12
101807
13
109537
CA or CAREG
16
17
Remove:
- the air conditioning hoses from the condenser (13)
,
- the air conditioning hose between the air conditioning compressor and the dehydration canister (14)
.
101822
Note:
system.

Move the turbocharger pressure solenoid valve to
one side.
Remove:
- the battery tray,
- the computer and its support.

Disconnect the flowmeter connector (if fitted to the
vehicle).
10A-102

10A
104245
Disconnect:
104553
- the relay plate harness connectors,

- the relay,
- the fuse box,
- the earth strap from the body,
20
21
18
103409
Remove:
19
102263
Remove the brake servo pipe from the vacuum

pump (18) .
Disconnect the heater radiator hose from the scuttle
panel (19) using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) .
10A-103
- the multifunction switch cable (21) by unlocking the

sleeve stop.
Disconnect:
- the engine speed sensor,
- the connector by releasing the slide from the connector.

10A
22
23
25
26
110681
103749
Disconnect:
Remove:
- the pre-postheating unit (22) ,
- the exhaust mounting nuts (25) ,
- the automatic transmission computer connector

(23) .
- the lower engine tie-bar (26) .
24
103413
Open the gearbox computer wiring harness mounting bracket (24) .
10A-104

10A
27
102008
102114
Remove:
Position the hydraulic crane fitted with a load positioner .
103273

the body.
Remove:
- the suspended gearbox mounting,
10A-105

10A
REFITTING
CA or CAREG

vehicle.
Refit:
with the marks,
- the lower engine tie-bar (see 19D, Engine mounting, Suspended mounting ).

( 4 Nm ) .
Note:

headlights: Adjustment ).


Tighten to torque:
),
),
),
- the half sub-frame rear mounting bolt ( 210 Nm
).
IMPORTANT
sensor wiring.
Gearbox ),
Engine ),
- fill up the coolant circuit (see 19A, Cooling, Bleeding the cooling circuit ),
10A-106

10A
K4J, and 730 or 732
REMOVAL

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

IMPORTANT
Remove:
- the front wheels,
Equipment required
safety belt
filling station
Drain:
hydraulic crane
load positioner

Tightening torquesm
mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
wheel bolt
battery cover bolts
CA or CAREG
110 Nm
4 Nm
101212
Remove:
10A-107

10A
K4J, and 730 or 732

3
7
2
101802
Disconnect the fuel supply union (7) .

Disconnect:
102504

Remove:
- the clip (4) ,

11
6
8
102365
Remove:
10
109537

10A-108

10A
K4J, and 730 or 732
CA or CAREG
Remove:
13
14
Note:
system.
101822

Remove:
- the battery tray,
12
101103
Remove:
- the air resonator mounting bolt (12) ,
- the air resonator.
101978

relay board.
10A-109

10A
K4J, and 730 or 732
17
18
15
111051
Disconnect the earth strap from the body.
104240
Disconnect:
- the hoses (17) and (18) using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
16
C
A
101812
101743

10A-110

10A
K4J, and 730 or 732
19
21
101699
102008
Remove:
20
101740
Pull out clip (20) .

Note:
10A-111

10A
K4J, and 730 or 732
REFITTING
(see Technical Note 3784A, Petrol engine - 4 cylinders - K4, 10A, Engine and peripherals, Normal replacement ).
vehicle.
Refit:
101866
Tighten to torque:
),
),
),
102112

the body.
Remove:

Gearbox ),
Engine ),
- fill up the coolant circuit (see 19A, Cooling, Bleeding the cooling circuit ).

IMPORTANT
Remove the engine and gearbox assembly .
10A-112

K4J, and 730 or 732
Bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit: ).
CA or CAREG

Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the xenon bulb system (see
80C, Xenon bulbs, Xenon headlights: ).
Adjustment ).
Halogen headlights: Adjustment) .
10A-113
10A

10A
F9Q, and 804

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

system hose clips
(large model)

intercooler:
Mot. 1202-02

clips

any other product,
Mot. 1448

Mot. 1390

and refitting the
engine and gearbox
assembly

not replaced,
or come undone.
Equipment required
REMOVAL
safety belt
filling station
Tightening torquesm
IMPORTANT

mounting bolt
21 Nm

mounting bolt
44 Nm

mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm
During this operation, strap the vehicle to the lift

using a safety belt , to avoid any imbalance.
Remove:
wheel bolt
bolts
- the front wheels,

Drain:
130 Nm
4 Nm

CA or CAREG

10A-114

10A
F9Q, and 804

Remove:
CA or CAREG
- the scuttle panel grille (see MR 371 Bodywork,

55A, Exterior protection, Scuttle panel grille ).
Disconnect the pressostat connector from the lower

air conditioning pipe on the condenser.
Remove:
- the two air conditioning pipes from the condenser,
2
Note:
system.
4
3
102504

Remove:
- the clip (3) ,
102365
Remove:
101212
Remove:
10A-115

10A
F9Q, and 804
8
9
7
10
104338
106275
Remove:
Disconnect.
Disconnect:
- the intercooler hose (10)

WARNING
).
Watch out for diesel fuel splashing when disconnecting the supply union.

radiator side.
Disconnect the electrical connector (9) .

Insert plugs into the openings.
11
102473
Disconnect the duct (11) .
10A-116

10A
F9Q, and 804
12
13
17
16
102500
104245
Disconnect the connector (12) .
Remove:

- the fuse box (16) ,
- the relay box (17) .
Disconnect the connectors from the Protection and
Switching Unit.
14
15
19
18
101822

Remove:
- the battery tray,
104340
Remove:
- the earth strap (18) ,
- the pre-postheating unit (19) .
10A-117

10A
F9Q, and 804
20
23
21
104322

pump.
Disconnect the heater radiator hoses (21) from the
scuttle panel side using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) .
101740
Pull the clip (23) from the clutch pipes.

Note:
24
22
104085
Remove the gearbox controls (2 2) , using a

screwdriver.
102008
Remove:
10A-118

10A
F9Q, and 804

111879
102742
111880
102419

the body.
Remove:
Remove the engine and gearbox assembly .
10A-119

10A
F9Q, and 804
REFITTING
High pressure diesel engine - Common Rail 4 cylinder cast iron, 10A, Engine and peripherals,
- fill up the coolant circuit (see 19A, Cooling, Bleeding the cooling circuit ).
CA or CAREG

vehicle.

Refit:
with the marks,
Tighten to torque:
),
),
),
IMPORTANT
sensor wiring.
Gearbox ),
Engine ),
10A-120

( 4 Nm ) .
Note:
If the vehicle is fitted with xenon bulbs, it is
essential to initialise the system (see 80C,
Xenon bulbs, Xenon headlights: ). Adjustment ).

10A
K9K, and 732

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

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Mot. 1390

and refitting the
engine and gearbox
assembly

intercooler (there is a danger of leakage and dislocation if this procedure is not complied with):
- detach the hose using the (Car. 1363) ,
any other product,
- clean the bearing face on the intercooler and on
the hose with a dry, lint-free cloth,
- always replace the clip with a new one,
- replace the new 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,
Equipment required
filling station
REMOVAL
Tightening torquesm
mounting bolt
105 Nm
half sub-frame rear

mounting bolt
21 Nm

mounting bolt
21 Nm

mounting bolt
44 Nm
wheel bolts
IMPORTANT
lift with a strap, to avoid any imbalance.
Remove:
110 Nm
- the front wheels,

Drain:
- the gearbox, if necessary,
- the engine, if necessary.
CA or CAREG
Drain the coolant circuit using the filling station .
10A-121

10A
K9K, and 732
102504
Remove:
- the relay plate cover mounting bolts.
101212
Remove:
- the relay plate cover.

Disconnect the connectors (2) from the relay board.
- the battery,
Unclip the bonnet opening cable (3) ,
- the side reinforcements (1) ,

Remove:
- the clip (4) ,
102365
Remove:
Drain the cooling system (see 19A, Cooling, Cooling system: Draining-refilling ).
10A-122

10A
K9K, and 732
106275
112656
Remove:
WARNING
- Follow the cleanliness guidelines closely.
- Beware of diesel fuel splashing when disconnecting the supply unions.
Place plugs in the holes (see 13B, Diesel injection,
Cleanliness guidelines ).
112661
Disconnect:
- the hoses from the intercooler (9) ,
(Mot. 1202-02) or (Mot. 1448) .
10A-123

10A
K9K, and 732
109537
101822

Unclip:
- the wiring harness from the battery negative terminal,
CA or CAREG
Disconnect the pressostat connector from the lower
air conditioning pipe on the condenser. (12)
- the wiring harness.

Remove:
Remove:
.

- the battery tray with the computer and its support.
Move the turbocharger pressure solenoid valve to
one side.
Disconnect:
Note:
- the connector from the flowmeter,
system.
- the air duct between the air filter unit and the turbocharger.
10A-124

10A
K9K, and 732
112657
101978

relay board.
104553
Loosen the air filter unit upstream air duct retaining

tabs slightly (17) .
Remove:
- the air filter unit upstream air duct,
- the air filter unit (18) .
104340
Disconnect:
- the pre-postheating unit connector (19) ,
- the earth strap from the body (20) .
10A-125

10A
K9K, and 732
112946

pump.
101743
Remove the gearbox controls.
Disconnect:
WARNING
- the heating radiator hose from the scuttle panel

(22) using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) ,
Do not touch the gearbox control slides.
- the heating radiator hose (23) using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448) .
101740
Pull clip (24) .

Disconnect the clutch hydraulic control.
Remove:
10A-126

K9K, and 732
CONCERNED
112814
112813
10A-127
10A

10A
K9K, and 732

Rotate the engine and gearbox assembly in order to
remove it.
Remove the engine and gearbox assembly.
REFITTING
CONCERNED
Position the engine and gearbox assembly in the vehicle.
Refit:
113927
- the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ),
- the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting:
Removal - Refitting ),
- the rear suspended mounting (see 19D, Engine
suspension, Rear suspended mounting: Removal / Refitting ).
Remove the (Mot. 1390) .
Refit:
- the half sub-frame mounting bolts.
Tighten to torque:
112655

the body.

),
Remove:
Refit:
- the rear suspended mounting (see 19D, Engine

suspension, Rear suspended mounting: Removal - Refitting ),
- the left-hand suspended mounting (see 19D, Engine mounting, Left-hand suspended mounting:
Removal - Refitting ),
- the right-hand suspended mounting (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ),
10A-128
IMPORTANT
sensor wiring.

10A
K9K, and 732

Connect:
- the clutch hydraulic control.
CA or CAREG
- the heater radiator hose using the (Mot. 1202-01)

or (Mot. 1202-02) or (Mot. 1448) .
Connect:
- the air conditioning pipes to the condenser.
- the heater radiator hose from the scuttle panel

using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
Refit the gearbox controls.

air conditioning pipe
Connect:
- the pre-postheating unit connector,
- the earth strap on the body,
Refit the fan unit wiring harness.
- the relay plate harness connectors.
Refit:
Refit:
- the front end panel mounting bolts,
- the air filter unit,
- the two cooling assembly guide clips.
- the air duct upstream of the air filter.
- the mounting bolts,

Connect:
- the front bonnet opening cable clip.
- the air duct between the air filter unit and the turbocharger.
Tighten to torque:
- the connector from the flowmeter.

),
Reposition the turbocharging pressure regulating

solenoid valve.
Refit:

).
Connect:
- the battery tray,
- the connectors to the relay board,
- the battery tray bolts,
- the screen washer tubes.
Connect the computer connectors.
Refit:
Refit:
- the front bumper (see Workshop Repair Manual

365 Bodywork, 55A, Exterior protection, Front
bumper ),
- the negative terminal wiring harness,

Connect:
- the front wheels,
Prime the diesel circuit using the priming pump.
- the relay plate cover,
Connect:
- the relay plate cover mounting bolts.

- the cooling radiator hoses,
- the intercooler hoses,
Connect the battery ( 80A, Battery, Battery: Removal - refitting) .
10A-129

K9K, and 732
CA or CAREG

component controls, Clutch system: Bleeding
),
Gearbox ),
Engine ),
Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ).
Adjust the headlights (see, depending on equipment, 80B, Headlights, Halogen headlights: Adjustment or 80C, Xenon bulbs, Xenon headlights:
Adjustment ).
You must initialise the xenon bulb system (if fitted
to the vehicle).
10A-130
10A

Engine speed and position sensor: Removal - Refitting
10A
M9R, and 700

IV - FINAL OPERATION
Refit:
Tightening torquesm
engine speed and position sensor mounting
bolt
10 Nm
- the heat insulating material around the engine

speed and position sensor,
REMOVAL
Move the heat insulating material to one side.
CONCERNED
114979
Disconnect the engine speed and position sensor.

Remove:
- the engine speed and position sensor mounting
bolt (1) ,
- the engine speed and position sensor (2) .
III - REFITTING OPERATION FOR PART
CONCERNED
Refit the engine speed and position sensor.
Tighten the engine speed and position sensor
mounting bolt until contact is made.
Tighten to torque the engine speed and position
sensor mounting bolt ( 10 Nm ) .
10A-131

Crankshaft seal at timing end Removal - Refitting
10A
M9R, and 700

CONCERNED
Tightening torquesm
the crankshaft timing
end sealing ring
47 Nm
REMOVAL
Remove:
- the front right-hand wheel,
114853
- the front right-hand wheel arch liner.
Remove the crankshaft sealing ring using the (2)

supplied in the spare parts kit for the new gasket.
101212
Remove:
- the right-hand side reinforcement mounting bolts
on the half sub-frame cross member,
- the right-hand side reinforcement from the half subframe cross member (1) ,
10A-132

10A
M9R, and 700
REFITTING

CONCERNED
114850
113656
Position the sealing ring notches opposite the notches in the timing cover.
WARNING
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.
10A-133

M9R, and 700
114852
Using tool supplied in the new gasket spare parts kit

tighten to torque the crankshaft timing end sealing ring ( 47 Nm ) .
Refit:
- the right-hand side reinforcements on the half subframe,
- the front right-hand wheel arch liner,
- the front right-hand wheel.
10A-134
10A

Accessories belt: Removal - Refitting
11A
K4J, and 730 or 732, and CA or CAREG K4M, and 760 or 761, and CA or CAREG C84 or G84 or S84, and
K9K, and 722 or 728 or 729 or 732, and CA or CAREG
Tightening torquesm
tensioning roller mounting bolt
wheel bolts
battery cover bolts
40 Nm
110 Nm
4 Nm
IMPORTANT
Wear protective gloves during every operation.
1
WARNING
Never turn the engine in the opposite direction to its
normal operation.
101212
Remove the right-hand side reinforcement (1) .
WARNING
It is imperative to replace the accessories belt and
the tensioning rollers.
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.
Remove:
- the accessories belt,
- the tensioning roller.
11A-1

11A
K4J, and 730 or 732, and CA or CAREG K4M, and 760 or 761, and CA or CAREG C84 or G84 or S84, and
K9K, and 722 or 728 or 729 or 732, and CA or CAREG
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 ) .
22
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 groove (2) remains free.
Refit the accessories belt.
Rotate the crankshaft twice to position the accessories belt correctly.
Tighten to torque:
11A-2

11A
K9K, and 722 or 728 or 729, and CHAUFO K4J, and 730 or 732, and CHAUFO K4M, and 760 or 761, and
CHAUFO

Mot. 1638
Accessories belt tensioning tool
Mot. 1505
Belt tension setting

tool (frequency meter)
Mot. 1715

Tightening torquesm
wheel bolts
35 Nm
110 Nm

bolts
4 Nm
101212
IMPORTANT
Remove the side reinforcement (1) .
Wear protective gloves during the operation.
Loosen the tensioning roller bracket mounting bolts.

Remove:
WARNING

normal operation.
REFITTING
WARNING
WARNING
- The two Torx mounting bolts of the tensioning
roller must be replaced by M8 x 20 bolts (part
number 77 03 002 059 ).
WARNING

Refit the tensioning roller fitted with new bolts.
REMOVAL
Remove:
11A-3

11A
K9K, and 722 or 728 or 729, and CHAUFO K4J, and 730 or 732, and CHAUFO K4M, and 760 or 761, and
CHAUFO
20845
WARNING
The accessories belt has five teeth, but the pulleys have six grooves. It is essential to check that
groove (2) remains free when the belt is fitted.
21861
Tension the accessories belt using the (Mot. 1638)

by tightening nut (3) (with the two tensioning roller
mounting bolts loosened).
Check (4) and 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) . If not,
readjust the tension.
bolt ( 35 Nm ) .
Proceed in the reverse order to removal
Tighten to torque:
11A-4

11A
Tightening torquesm
wheel bolts
battery cover bolts
50 Nm
110 Nm
4 Nm
IMPORTANT
Wear gloves throughout the operation.
WARNING
normal operation.
101212
Remove the right-hand side reinforcement (1) .

WARNING
WARNING
REMOVAL
Remove:
104339
Turn the accessories belt auto tensioning roller anticlockwise using a 16 mm spanner.

Remove:
REFITTING
11A-5

11A
bolt ( 50 Nm ) .
Rotate the crankshaft twice to position the accessories belt correctly.
Tighten to torque:
11A-6

11A
M9R, and 700

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

Mot. 1770
Crankshaft pulley locking tool

CONCERNED
Tightening torquesm
44 Nm
25 Nm
crankshaft accessories
pulley mounting bolt
50 Nm + 85
6
REMOVAL
114854
Place a 3 mm Allen key in the tensioning roller hole

(2) .
Move accessories belt tensioning pulley clockwise

until the Allen key is fully inserted.
Remove the accessories belt.
101212
Remove:
- the front right-hand wheel arch liner;
11A-7

11A
M9R, and 700
114856
114849
Remove:
Remove:
- the tensioning roller mounting bolts (3) ,
- the crankshaft accessories pulley mounting bolt

using the (Mot. 1770) (1) ,
- the washer,
- the crankshaft accessories pulley.
114857
Remove:
- the fixed roller mounting bolt plastic cover (4) ,
- the fixed roller mounting bolts (5) ,
- the fixed roller (6) .
11A-8

11A
M9R, and 700
REFITTING

CONCERNED
Refit the fixed roller.


bolt ( 44 Nm )
Refit the plastic cover on to the fixed roller mounting
bolt.
WARNING
Only use brushes with plastic or non-corrosive
metal (brass) bristles.
Note:
The Parts Department supplies the tensioning
roller pin.
WARNING
Do not run the engine without the accessories
belt so as not to damage the crankshaft accessories pulley.

.
bolt ( 25 Nm ) .
WARNING
Refit the crankshaft accessories pulley by inserting it

onto the two crankshaft flat surfaces.
When replacing the accessories belt recommended by the manufacturer, always replace:
Refit the washer inside the crankshaft accessories

pulley by inserting it onto the two crankshaft flat surfaces.

- the tensioning roller and fixed roller,
- the crankshaft accessories pulley bolt,
WARNING
- the crankshaft accessories pulley.
Check that the washer fits properly on the

crankshaft flat surfaces.
Finger tighten the crankshaft accessories pulley
mounting bolt.
Tighten to torque and angle the crankshaft accessories pulley mounting bolt ( 50 Nm + 85 6 )
using the (Mot. 1770) .
Remove the tensioning roller pin.
Turn the crankshaft twice.
Check that the accessories belt V-blocks are well
positioned in the V-grooves of all the pulleys.
11A-9

M9R, and 700
Refit:
- the right-hand side reinforcement from the half subframe cross member.
- the front right-hand wheel arch liner;
11A-10
11A

Timing belt: Removal - Refitting
11A
K4J, and 730 or 732

Tightening torquesm
tensioning roller mounting nut
27 Nm
40 Nm + 145
15
Additional winder nut

on engine lift support
Mot. 1453
27 Nm
Mot. 1489
TDC locating pin
27 Nm
Mot. 1368
Tool for tightening tensioner bolt. 8 mm Torx

wrench 12.7 mm
square
fixed roller mounting

bolt
45 Nm
27 Nm
27 Nm
Mot. 1453
Multiple-adjusting
engine mounting support with retaining
straps
Mot. 1453-01
Mot. 799-01
Timing gear wheel

immobiliser
Mot. 1496
Camshaft setting tool
Mot. 1750
Adapter for camshaft

setting tool Mot. 1496
accessories
mounting bolt
pulley
40 Nm + 115
15
Mot. 1490-01
Locking and adjusting

camshaft pulleys
new camshaft pulley

nuts
30 Nm + 84
4
Mot. 1487
Tool for refitting camshaft covers (57 mm

diameter)
27 Nm
TDC setting pin plug
20 Nm
upper timing cover bolts

and nuts
41 Nm
Mot. 1488

diameter)
wheel bolts
bolts
Tightening torquesm
bolt
45 Nm
27 Nm
40 Nm + 145
15
27 Nm
27 Nm

bolt
45 Nm
110 Nm
4 Nm
IMPORTANT
Wear protective gloves during every operation.
WARNING
normal operation.
WARNING
The belt must be replaced with a new one if it has
been removed.
11A-11

11A
K4J, and 730 or 732
WARNING
When replacing the belt, be sure to replace the tensioning rollers and fixed rollers.
Note:
The timing belt procedure is the same for engines
with or without camshaft dephasers
REMOVAL
102450

Remove:
102451
Position the (Mot. 1453) and the (Mot. 1453-01) with

retaining straps.
11A-12

11A
K4J, and 730 or 732
101866

the body.
Remove:
101103
Remove:
- the air resonator mounting,
- the engine and suspended engine mounting

assembly,
- the lower engine tie-bar.
WARNING
Do not damage the air conditioning pipe.
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,
- the TDC pin plug (1) ,
- the engine lifting eye (flywheel end),
11A-13

11A
K4J, and 730 or 732

ADJUSTING THE TIMING
14490
14491-1
Position the camshaft grooves (2) almost horizontally and offset downwards, turning the crankshaft in its
normal operating direction (timing end clockwise).
Check that the camshaft grooves are horizontal and

offset downwards.
Screw in the TDC setting pin (3) (Mot. 1489) .
4
14487
Remove:
14489
Turn the crankshaft in its operating direction (timing

end clockwise), until the crankshaft comes into contact with TDC setting pin.
11A-14
- the crankshaft accessories pulley (4) , locking the

flywheel with a screwdriver,
- the upper timing cover (5) ,
- the lower timing cover (6) .

11A
K4J, and 730 or 732
REFITTING - PROCEDURE 1
I - PROCEDURE FOR ENGINES FITTED WITH A
TIMING COVER WITHOUT FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any 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.
101872
Undo the nut (7) on the tensioning roller to slacken

the timing belt.
Remove:
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the fixed roller (8) using the (Mot. 1368) ,

- the timing belt, taking care not to drop the crankshaft sprocket,
- the timing sprocket,
- the contact surfaces of the crankshaft and

accessories pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
14490
Set the camshaft grooves horizontally and below the

centre line by turning the camshafts with the (Mot.
799-01) if necessary.
11A-15

11A
K4J, and 730 or 732
111337
14489
Fit the (Mot. 1496) with the (Mot. 1750) (9) .
108875
111336
Fix the (Mot. 1496) fitted with the (Mot. 1750) on the
end of the camshafts.
11A-16
Position the TDC setting pin (Mot. 1489) (10) .

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

11A
K4J, and 730 or 732

2 - REFITTING
14487-2
108879
Tighten to torque the fixed roller mounting bolt (

45 Nm ) using the (Mot. 1368) .
Refit the tensioning roller by positioning the tensioning roller lug in rib (12) .
3 - BELT TENSION
14487-3
Refit:
103263
Using a 6 mm Allen key, bring the adjustable index

(15) opposite the notch (16) , by turning the eccentric (17) clockwise.
- the crankshaft timing sprocket (13) ,

- the timing belt,
11A-17

11A
K4J, and 730 or 732

nut ( 27 Nm ) .
4 - CHECKING THE TIMING AND TENSION
Refit the crankshaft accessories pulley.
a - Checking the tension

Rotate the crankshaft clockwise through two revolutions (timing end).
(crankshaft in contact with TDC setting pin)
Screw in the TDC setting pin (Mot. 1489) .
Remove:
Move the crankshaft slowly and smoothly to rest on

the TDC setting pin (Mot. 1489) .
- the camshaft setting tool (Mot. 1496) ,
Remove the TDC setting pin.
- the TDC setting pin (Mot. 1489) .
Check the tensioning roller indexes are aligned; if

not readjust the tension by loosening the tensioning
roller eccentric by a single turn.
Rotate the crankshaft clockwise (timing end) through two revolutions and before completing the second revolution.
Correctly align the adjustable index with the fixed index or the notch (depending on the type of tensioning roller).
Screw the TDC setting pin (Mot. 1489) into the cylinder block.

nut ( 27 Nm ) .
Move the crankshaft slowly and smoothly to press

against the TDC setting pin.
b - Checking the timing
Remove the TDC setting pin (Mot. 1489) .
Check that the tensioning roller indexes are correctly

positioned before checking the timing setting.
Move the crankshaft slowly and smoothly until it is
resting against the pin.
103263
Check that adjustable index (18) is opposite the

notch (19) .
Loosen the tensioning roller nut by up to one turn,
holding the adjustable index with a 6 mm Allen key.
Gradually move the adjustable index (18) facing the
notch (19) turning the eccentric (20) in a clockwise
direction.
nut ( 27 Nm ) .
11A-18

11A
K4J, and 730 or 732

II - PROCEDURE FOR ENGINES FITTED WITH
TIMING COVER WITH FLAP
WARNING
roller.
WARNING
14490
Fit the camshaft adjusting tool (Mot. 1496) without

forcing (the camshaft grooves must be horizontal
and below the centre line).

- the contact surfaces of the crankshaft and
accessories pulley.
WARNING
The timing adjustment and tensioning operation
must be repeated if the camshaft setting tool
does not engage.
14490

centre line by turning the camshafts with the (Mot.
799-01) , if necessary.
11A-19

11A
K4J, and 730 or 732
111337
14489
108875
111336
end of the camshafts
11A-20
Position the TDC setting pin (Mot. 1489) (22) .


11A
K4J, and 730 or 732

2 - REFITTING
3 - TIMING BELT TENSION
108879
Refit the tensioning roller by positioning the tensioning roller lug in rib (24) .
Refit the crankshaft timing sprocket.
103263
Bring the adjustable index (26) opposite the notch

(27) , by turning the eccentric (28) clockwise using a
6 mm Allen key.
nut ( 27 Nm ) .
14487-3
Refit:
109054
- the timing belt,
Refit the lower timing cover.
- the timing fixed roller (25)

11A-21

11A
K4J, and 730 or 732

Rotate the crankshaft twice in a clockwise direction,
on the timing end, before aligning the markings (on
the camshaft dephaser) already made by the operator.
the TDC setting pin.
109055

(crankshaft in contact with TDC setting pin).
109052
Remove the cover plate from the lower timing cover.

Remove:
11A-22

11A
K4J, and 730 or 732

Check through the lower timing cover window that
the index and the notch of the timing tensioning roller are aligned; if not, readjust the tension by loosening the tensioning roller nut on the eccentric by a
single turn.
Align the adjustable index with the notch.
109051

nut ( 27 Nm ) .
Ensure that the index and the notch on the timing
tensioning roller are in the correct position before
checking the timing.
the TDC setting pin.
103263
Check through the lower timing cover window that

the adjustable index (30) is opposite the notch (29) ,
if not, loosen the timing tensioning roller screw by a
single turn while holding the eccentric using a 6 mm
Allen key.
direction.
nut ( 27 Nm ) .
Check that dephaser marking is in alignment with
marking already made by the operator.
11A-23

11A
K4J, and 730 or 732
REFITTING -PROCEDURE 2
I - ADJUSTING THE TIMING
The second procedure is used for the replacement
of all components requiring the slackening of one or
more of the camshaft pulleys.
WARNING
If the stud is loosened with the nut (see NT
3887A, Replacing camshaft pulley studs K9 K4, 11A, Top and front of engine, Camshaft ).
WARNING
roller.
14490
Fit (without forcing) the camshaft setting tool (Mot.

1496) (the camshaft grooves must be horizontal and
offset towards the bottom).
WARNING
- the crankshaft accessories pulley bearing
faces,
Note:
does not engage.
- the camshaft ends (timing end),

- the camshaft sprocket bores and contact surfaces.
Refit the camshaft pulleys and the old nuts, tightening to a torque of 15 Nm .
109052
Refit the lower timing cover plate, checking that the

locating pin (32) fits properly in the notch (33) .
11A-24

11A
K4J, and 730 or 732
14490
111337
103261
Position the camshaft grooves horizontally and offset downwards, by turning the camshafts with the
(Mot. 1496) if necessary.
111336
Remove the old camshaft pulley nuts and replace
them with new ones (without tightening the nuts: 0.5
to 1 mm play between nuts and pulleys).
11A-25

11A
K4J, and 730 or 732

II - REFITTING
14489
108879
Refit the tensioning roller by positioning the tensioning roller lug in groove (38) .
14487-1

Position the RENAULT badge (37) etched on the
camshaft pulley spokes vertically at the top.
14487-3
Refit:
- the timing sprocket (39) ,
- the timing belt on the camshaft pulleys (without moving the camshaft pulleys).
11A-26

11A
K4J, and 730 or 732

III - BELT TENSION
101876
Fit the camshaft pulley locking tool (Mot. 1490-01)

(40) (use the timing cover mountings to mount the
tool).
103263

(42) in line with the notch (43) , by turning the eccentric (44) clockwise.
nut ( 27 Nm ) .
Remove camshaft pulley locking 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.
Rotate the timing system through six revolutions
with the exhaust camshaft sprocket, using the (Mot.
799-01) .
14487-3
Refit the fixed roller (41) .

Refit the crankshaft accessories pulley (without tightening the bolt, 2 to 3 mm play between bolt and pulley).
11A-27

11A
K4J, and 730 or 732
103263
14489
Check that adjustable index (45) is opposite the

notch (46) .
WARNING

Check that the crankshaft is in contact with the

TDC setting pin (Mot. 1489) .

direction.
Tighten to torque and angle:

- the accessories pulley mounting bolt ( 40 Nm +
115 15 ) (crankshaft in contact with TDC setting
pin)

nut ( 27 Nm ) .
- the new camshaft pulley nuts ( 30 Nm + 84 4

) starting with the exhaust pulley
Remove:
- the camshaft pulley locking tool (Mot. 1490-01) ,
IV - CHECKING THE TIMING AND TENSION
1 - Checking the tension
screw the TDC setting pin (Mot. 1489) into the cylinder block.
14839
Position the camshaft pulley locking tool (Mot. 149001) .
11A-28
slowly and smoothly position the crankshaft in contact with the TDC setting pin (Mot. 1489) .

11A
K4J, and 730 or 732

Check the tensioning roller indexes are aligned; if
not readjust the tension by loosening the tensioning
roller eccentric by a single turn.
REFITTING
Correctly align the adjustable index with the fixed index or the notch (depending on the type of tensioning roller).
Refit the TDC setting pin plug, applying a drop of

JOINT SILICONE ADHERENT onto the thread hole.
Tighten to torque the TDC setting pin plug ( 20 Nm
).

nut ( 27 Nm ) .
Refit the upper timing cover.

Tighten to torque the upper timing cover bolts and
nuts ( 41 Nm ) .
2 - Checking the timing

Check that the timing pulley indexes are correctly
Move the crankshaft slowly and smoothly and rest it
on the TDC setting pin (Mot. 1489) .
15103-1
Refit:
14490

and offset downwards).

engine, Accessories belt ),
- new inlet camshaft sealing plugs (Mot. 1487) ,
- new exhaust camshaft sealing plugs (Mot. 1488) .
Note:

does not engage.
Tighten to torque:
- the wheel bolts ( 110 Nm )
11A-29

11A
K9K, and 722 or 728 or 729
REMOVAL

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

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

Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Refitting ).
Tightening torquesm
tensioning roller bolt
25 Nm
pulley M12 mounting
bolt
60 Nm + 100
10
pulley M14 mounting
bolt
120 Nm + 95
15
25 Nm
20 Nm
cylinder head suspended mounting bolts
21 Nm
wheel bolts
bolts
102450
110 Nm
4 Nm
WARNING
normal operation.
102451
Position the (Mot. 1453) and (Mot. 1453-01) with retaining straps.
11A-30

K9K, and 722 or 728 or 729
1
102115
Remove the lower tie-bar bolts (1) .

Remove the lower engine tie-bar.
102114
Mark the position of the suspended engine mounting.

Slacken the bolt (2)
WARNING
11A-31
11A

11A
K9K, and 722 or 728 or 729
19654
Remove the upper timing cover by unclipping the

tabs (3) .
11A-32

11A
K9K, and 722 or 728 or 729
19654-1
Remove:
- the cylinder marking sensor on the high pressure
pump (4) ,
- the plastic bolt (6) .
Unclip the tabs (5) .
Remove the lower timing cover.
11A-33

11A
K9K, and 722 or 728 or 729
19654-2
Remove the cylinder head suspended mounting.
Positioning the timing at the adjustment point
8
19702
19650
Remove the TDC setting pin plug.
11A-34
Rotate the crankshaft clockwise (timing end) to position the hole (8) in the camshaft pulley partially in
line with the hole (9) in the cylinder head.

11A
K9K, and 722 or 728 or 729
2
1
19650-1
19655
Insert the pin (2) (Mot. 1430) in the camshaft pulley

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

until the crankshaft comes in contact with the TDC
setting pin (Mot. 1489) .
11A-35

11A
K9K, and 722 or 728 or 729
19656
Remove the crankshaft accessories pulley, locking

the flywheel with a screwdriver.
11A-36

11A
K9K, and 722 or 728 or 729
10
19656-1
Undo the tensioning roller bolt (10) to slacken the timing belt.
REFITTING
Remove:
- the timing belt (take care not to drop the crankshaft
sprocket),
WARNING
It is imperative to replace the timing belt, the tensioning roller and the accessories pulley bolt.

WARNING
- the contact surfaces of the crankshaft accessories pulley.
11A-37

K9K, and 722 or 728 or 729
19710
Refit the crankshaft timing sprocket.
11A-38
11A

11A
K9K, and 722 or 728 or 729

14
13
12
11
15
19656-2
Note:
Check that the tensioning roller lug (11) is correctly positioned in the groove (12) .
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 mark (13) on the high pressure pump
pulley is in line with the bolt head (14) .
14489
Check that the crankshaft is hard against the TDC

setting pin (Mot. 1489) (crankshaft groove (15) facing upwards).
11A-39

11A
K9K, and 722 or 728 or 729
16
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 (16)

opposite the lug using a 6 mm Allen key, turning it
anticlockwise.
Tighten to torque the tensioning roller bolt ( 25 Nm
).
Note:
19 belt tooth spaces between the camshaft

sprocket and pump marks.
Tighten to torque and angle (crankshaft in contact

with the TDC setting pin):
- crankshaft accessories pulley M12 mounting
bolt ( 60 Nm + 100 10 ) ,
- crankshaft accessories pulley M14 mounting
bolt ( 120 Nm + 95 15 ) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
11A-40

11A
K9K, and 722 or 728 or 729
19
20
18
17
19702

Before the camshaft pulley hole (17) comes in line
with the cylinder head hole (18) , screw the TDC setting pin (Mot. 1489) into the cylinder block.
Bring the crankshaft slowly and smoothly into contact with the pin.
19655
Check:
- that the timing pin (Mot. 1430) engages properly in
the camshaft and cylinder head holes,
- that there are 19 belt tooth spaces between the
camshaft sprocket mark (19) and the high pressure
pump sprocket mark (20) .
Remove:
After two turns, the tensioning roller indexes may
be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-41

11A
K9K, and 722 or 728 or 729

First position
Second position
21
23
111083
111082
23
24
111081
111081
Loosen the tensioning roller bolt by no more than

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

one turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index (21) , turning

the Allen key anticlockwise, to the middle of the timing window (22) .
Gradually align the adjustable index (23) , turning

the key clockwise, to the middle of the timing window
(24) .
11A-42

11A
K9K, and 722 or 728 or 729

II - REFITTING
bolt ( 25 Nm ) .
Refit the TDC setting pin plug, applying JOINT SILICONE ADHERENT to the thread hole.
).
19654-2
Refit the cylinder head suspended mounting.

Tighten to torque the cylinder head suspended
11A-43

11A
K9K, and 722 or 728 or 729
19654-1
25
26
19659
Refit the lower timing cover, positioning the tab (25)

in the lower timing cover aperture (26) .
11A-44

11A
K9K, and 722 or 728 or 729
19654
Refit:
- the upper timing cover,
with the marks,
.
Tighten to torque:
11A-45

11A
F9Q, and 800 or 804 or 808

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 timing belt

pretensioning tool
Mot. 1505

Mot. 1715

102450
Tightening torquesm
20 Nm
45 Nm
40 Nm + 110
10
wheel bolts
battery cover bolts
110 Nm
102451
4 Nm
WARNING
normal operation.
REMOVAL
Remove:
- the accessories belt (see 11A, Cylinder head, Accessories belt: Removal - Refitting ).
11A-46

11A
F9Q, and 800 or 804 or 808
102420
Remove:
15102
Remove:
- the TDC setting pin plug.

Mark the position of the suspended engine mounting
in relation to the body.
- the flywheel guard cover plate.
Slacken the bolt (1)

WARNING
Do not damage the air conditioning pipes (if fitted
to the vehicle).
104739
Remove:
- the crankshaft accessories pulley, locking the
- the timing cover mounting bolts (2) ,
- the timing cover.
11A-47

11A
F9Q, and 800 or 804 or 808

104326
104329
Undo the tensioning roller mounting nut (3) to slacken the tensioning roller.
Rotate the crankshaft clockwise (timing end); bring

the camshaft pulley mark to half a tooth before the
mark on the guard.
Remove the timing belt.
REFITTING
WARNING
Replace the timing belt, the tensioning roller, the
crankshaft accessories pulley and bolt.
104330
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-48

11A
F9Q, and 800 or 804 or 808
104336
104327
Refit the tensioning roller, taking care to position it

correctly on the locating pin (4) .
Fit the new timing belt, aligning the marks on the belt
with those on the crankshaft, camshaft and high
pressure pump sprockets (count 28 belt tooth spaces 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 (8) on the tensioning roller mounting.
Note:
The bolt (8) is manufactured locally.
Position the crankshaft accessories pulley bolt.
16187
Check that the TDC setting pin (Mot. 1054) is in place.
Note:
The crankshaft groove (5) must be in the middle
of the two ribs (6) on the crankshaft guard plate.
The crankshaft timing sprocket mark (7) should
be offset one tooth to the left of the vertical axis
of the engine.
11A-49

11A
F9Q, and 800 or 804 or 808
16563
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) .
104331
Mount the timing belt pretensioning tool (Mot. 1543)

fitted with the cover (Mot. 1705) (9) on the crankshaft accessories pulley bolt.
11A-50

11A
F9Q, and 800 or 804 or 808
10
104333
Position the sensor of the (Mot. 1505) o r (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 (10) .
nut (10 Nm) .
105435
Remove the crankshaft accessories pulley bolt.

Refit the crankshaft accessories pulley, without separating its two component parts.
.
Turn the crankshaft through two revolutions.

Refit:
Reposition the TDC setting pin (Mot. 1054) .

Position the timing at its setting point (start pressing
on the pin half a tooth before alignment of the camshaft pulley mark and the cover plate mark, to avoid
going into a camshaft balancing hole).
Refit the TDC setting pin plug, applying a drop of
RHODORSEAL 5661 onto the thread.
).
Apply a pretensioning force 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.

To refit, proceed in the reverse order to removal.

Tighten to torque:

nut ( 45 Nm ) .
11A-51

11A
F4R, and 770 or 771 or 776

Tightening torquesm

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

Mot. 1453
Mot. 1672
Lower engine support
Mot. 1054
TDC setting pin
Mot. 1509
Camshaft
locking tool
Mot. 1509-01
Conversion kit for Mot.

1509
Mot. 799-01
Timing gear wheel

immobiliser
Mot. 1496
Mot. 1487

diameter)
Mot. 1448

sprocket
toothed sprocket nuts
80 Nm
80 Nm
tensioning roller nut
28 Nm
80 Nm
inlet camshaft dephaser mounting bolt
(30 Nm)
exhaust camshaft pulley nut
(30 Nm)
inlet camshaft dephaser mounting bolt
100 Nm
camshaft pulley dephaser blanking cover
25 Nm
86 6

inlet and exhaust camshaft pulley nuts
nuts
Tightening torquesm
80 Nm
86 6
80 Nm
inlet and exhaust camshaft pulley nuts
30 Nm + 86
6
pulley bolt
40 Nm + 110
10
M6 lower timing cover

bolts
80 Nm
80 Nm
80 Nm
50 Nm
M8 lower timing cover

bolts
20 Nm

bolt
M8 upper timing cover

bolts
18 Nm
7 Nm
M10 upper timing cover

bolts
38 Nm
tensioning roller nut

(80 Nm)
old inlet camshaft

dephaser mounting bolt
(30 Nm)
old exhaust camshaft

pulley nut
30 Nm
wheel bolts
(80 Nm)
old inlet and exhaust

camshaft pulley nuts
(30 Nm)

bolts
110 Nm
4 Nm
Note
The timing belt procedure is the same for engines
with or without camshaft dephasers.
11A-52

11A
F4R, and 770 or 771 or 776
WARNING
normal operation.
WARNING
to avoid damaging the crankshaft accessories pulley.
102450
WARNING
On the F4R engine, it is essential to fit the crankshaft sprocket with the integral key.
WARNING
Replace the following parts when they are removed:
- the camshaft pulley nuts,
- the crankshaft accessories pulley,
- the crankshaft accessories pulley bolt.
WARNING
When replacing the belt, it is imperative to replace
the tensioning roller and the fixed roller.
REMOVAL
102451
Remove:
11A-53

11A
F4R, and 770 or 771 or 776
102365
Remove:
106077
Remove:
- the radiator cross member right-hand side reinforcement (1) ,

F4R, and 776
3
2
105432
Position the (Mot. 1672) with retaining straps.
102504

Remove:
- the clip (4) ,
- the fastening (5) ,
11A-54

11A
F4R, and 770 or 771 or 776

- the connector on the lifting bracket.
F4R, and 776
102742

the body.
Remove the suspended mounting assembly.
9
106278
Note:
Remove the fuel vapour recirculation solenoid valve

(9) .
Be careful not to bend the air conditioning pipe.

F4R, and 770 or 771
101807
Remove:
- the air filter outlet duct (7) ,
- the throttle valve (8) ,
11A-55

11A
F4R, and 770 or 771 or 776
10
11
106632
15105
Remove the camshaft sealing plugs.
Loosen the nut (10) .

Pull the mounting bracket away from the electric
coolant pump.
Move the electric coolant pump (11) to one side.

Remove the wiring harness mounting bracket.
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 the TDC setting pin (Mot. 1054) so that it is
between the balancing hole and the crankshaft setting groove.
12
15102
Remove the TDC setting pin plug (12) .
11A-56

11A
F4R, and 770 or 771 or 776

Correct position
15163-2
Turn the engine slightly in the same direction,

pushing in the TDC setting pin (Mot. 1054) until the
setting point is reached.
15163-1
Incorrect position
15163
15106-1
At the setting point, the camshaft grooves must be

horizontal and offset below the centre line, as shown
in the drawing.
11A-57

F4R, and 770 or 771 or 776
106519
15303
Remove:
- the flywheel guard,
- the crankshaft pulley, locking the flywheel with a
screwdriver.
Refit the TDC setting pin (Mot. 1054) .
11A-58
11A

11A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
13
14
18433
Remove:
11A-59

11A
F4R, and 770 or 771 or 776
F4R, and 776
15
106338
16
17
104719
Remove:
- the heat shield (15) ,
11A-60

11A
F4R, and 770 or 771 or 776

18
19
18433-2
Slacken the timing belt by loosening the tensioning

roller nut (18) .
Remove:
WARNING
Never turn the engine in the opposite direction to
its normal operation.
- the fixed roller (19) ,

- the timing belt,
- the crankshaft timing sprocket.
WARNING
When replacing the timing belt, it is imperative to
replace the tensioning roller and the fixed roller.
WARNING
A belt which has been removed MUST be replaced.
11A-61

F4R, and 770 or 771 or 776
II - ADJUSTING THE TIMING
20
104703
WARNING
- the timing sprocket bore and contact surfaces
(20) ,
- the contact surfaces of the crankshaft accessories pulley,
This is to prevent slippage between the timing
gear and the crankshaft.
WARNING
WARNING
In this case, the old camshaft pulley nuts must be
removed in order to correctly set the belt tension.
11A-62
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-63

11A
F4R, and 770 or 771 or 776
26
25
22
27
21
16019
Position the (Mot. 1509) with sprocket (Mot. 150901) .

Position the spacer (21) of the (Mot. 1509-01) on the
stud (22) .
16019-3
Tighten the bolt and the shouldered nut (25) .

Bring the toothed sprockets of the (Mot. 1509) into
contact with the camshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (26) .
Remove:
24
- the inlet camshaft dephaser blanking cover (27) ,

- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
23
- the camshaft pulleys.

Loosen the stud with the nut (see NT 3884A, Replacing F4 camshaft pulley studs, Top and front of
engine, Camshaft ).
16019-1
Fit the upper bolt (23) , positioning the spacer (24)

(Mot. 1509-01) between the tool and the rocker cover (do not tighten the bolt).
11A-64

11A
F4R, and 770 or 771 or 776

Refit the degreased camshaft pulleys with the old
mountings.
F4R, and 776
Tighten to torque the old mountings (15 Nm max.)

WARNING
When removing the timing belt, it is essential to
replace:
28
- the crankshaft accessories pulley,

- the tensioning roller and fixed roller,
- the accessories and timing belts.
29
104711
Install the (Mot. 1509) with its toothed sprocket

(Mot. 1509-01) .
Bring the toothed sprockets into contact with the
camshaft pulleys.
Remove:
- the camshaft pulley nuts,
- the (Mot. 1509) ,
15106-1
- the camshaft pulleys.

Loosen the stud with the nut (see NT 3884A, Replacing F4 camshaft pulley studs, Top and front of
engine, Camshaft ).
11A-65
Position the grooves offset horizontally below the

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

11A
F4R, and 770 or 771 or 776
31
30
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 centered.
The crankshaft groove (30) must be between the
two ribs (31) .
11A-66

11A
F4R, and 770 or 771 or 776
33
32
15201
Refit the tensioning roller, correctly positioning the

(32) of the tensioning roller in the groove (33) .
34
15815-1
Refit:
- the timing belt,
50 Nm ) .
11A-67

11A
F4R, and 770 or 771 or 776

III - ADJUSTING THE TENSION
F4R, and 770 or 771
37
38
35
39
36
15256
104728
Position the (Mot. 1509) with the toothed sprocket

(Mot. 1509-01) for locking the camshaft pulleys.
Note:
Do not rotate the tensioning roller anticlockwise.

Align the marks (35) and (36) on the tensioning roller
using an Allen key (6 mm) in (37) .
Tighten to torque the tensioning roller nut ( 7 Nm )
.
Bring the toothed sprocket nuts into contact with the

camshaft pulleys.
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (39) ,
- the old inlet camshaft dephaser mounting bolt (
(30 Nm) ) ,
- the old exhaust camshaft pulley nut ( 30 Nm ) .
Remove the (Mot. 1509) fitted with the (Mot. 150901) .
11A-68

11A
F4R, and 770 or 771 or 776
F4R, and 776
42
40
41
21877
104711
Make a pencil mark (42) between the camshaft pulleys and the camshaft bearing cap.
Position the (Mot. 1509) for locking the camshaft

pulley.
Remove the following tools:
- camshaft setting tool (Mot. 1496) .

camshaft pulleys.
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (40) ,
- the old inlet and exhaust camshaft pulley nuts (
(30 Nm) ) (41) ,
11A-69
- TDC setting pin (Mot. 1054) ,

11A
F4R, and 770 or 771 or 776

IV - CHECKING THE TIMING AND THE TENSION
15104
Position the camshaft adjustment tool (Mot. 1496) .

15163-2
Before the end of the second revolution (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 adjustment point.
11A-70

11A
F4R, and 770 or 771 or 776
F4R, and 770 or 771
F4R, and 776
43
45
44
46
104728
104711
Position the (Mot. 1509) with the toothed sprockets

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

pulley.
Offer up the toothed sprocket nuts against the camshaft pulleys.
Offer up the toothed sprocket nuts against the camshaft pulleys.
Loosen:
Loosen:
- the old inlet camshaft dephaser pulley mounting

bolt,
- the old inlet camshaft pulley nut,
- the old exhaust camshaft pulley nut.

Remove the (Mot. 1509) with the sprocket (Mot.
1509-01) for locking the camshaft pulleys.
11A-71

Remove the (Mot. 1509) for locking the camshaft
pulley.

F4R, and 770 or 771 or 776
49
47
48
15256
Align mark (47) with mark (48) by loosening the tensioning roller nut by up to one turn, while holding it in
position with a 6 mm (49) Allen key.
Final tighten the tensioning roller nut ( 28 Nm ) .
11A-72
11A

11A
F4R, and 770 or 771 or 776

F4R, and 770 or 771
- camshaft pulley locking tool (Mot. 1509) with toothed sprockets (Mot. 1509-01) .
50
51
104728
Position the (Mot. 1509) with toothed sprockets to

lock the camshaft pulleys.
Bring the toothed sprockets into contact with the
camshaft pulleys.
Remove:
- the old inlet camshaft pulley dephaser bolt,
- a new nut on the exhaust camshaft pulley.
Refit:
- a new bolt on the inlet camshaft pulley,
- a new nut on the exhaust camshaft pulley.
Tighten to torque:
- the inlet camshaft dephaser mounting bolt ( (30
Nm) ) ,
- the exhaust camshaft pulley nut ( (30 Nm) ) .
Remove the camshaft adjustment tool (Mot. 1496) .
Tighten to torque:
- the inlet camshaft dephaser mounting bolt ( 100
Nm ) ,
- the camshaft pulley dephaser blanking cover (
25 Nm )
Tighten to angle the exhaust camshaft pulley nut (
86 6 ) .
11A-73

11A
F4R, and 770 or 771 or 776
F4R, and 776
54
55
52
53
104711
104711

pulley.
camshaft pulleys.
Remove:
Position the camshaft locking tool (Mot. 1509) , torque tightening the nuts ( 80 Nm ) (54) .
Remove the old camshaft pulley nuts and replace
them with new ones.
Tighten to torque and angle the inlet and exhaust
camshaft pulley nuts ( 30 Nm + 86 6 ) .
- (Mot. 1496) ,
- camshaft pulley locking tool (Mot. 1509) .
- the old inlet camshaft pulley nut,
Rotate the crankshaft clockwise through two revolutions.
Refit a new nut onto the inlet and exhaust camshaft

pulley.
Tighten to torque the inlet and exhaust camshaft
pulley nuts 30 Nm .
Remove the camshaft adjustment tool (Mot. 1496) .
Tighten to angle the inlet and exhaust camshaft
pulley nuts ( 86 6 ) .
- camshaft pulley locking tool (Mot. 1509) .
11A-74

11A
F4R, and 770 or 771 or 776

56
57
15104
Position the camshaft setting tool (Mot. 1496) without forcing it. If the tool does not engage, repeat
the timing and tensioning procedure.
15649
Before the end of the second revolution (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).
REFITTING
Check that mark (56) is aligned with mark (57) on

the tensioning roller before checking the timing adjustment.
Refit:
- the lower timing cover,
- the upper timing cover.
WARNING
It is imperative to replace the crankshaft accessories pulley and bolt.
58
15106-1
The offset grooves (58) should be horizontal and below the centre line.
11A-75

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

on the inlet camshaft (Mot. 1487) ,
on the exhaust camshaft (Mot. 1448) ,
WARNING
- the right-hand suspended mounting (see 19D, Engine mounting, Suspended mounting ) in accordance with the marks.
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 ),
- the TDC setting pin plug, applying a drop of RHODORSEAL 5661 to the thread hole.
- the M6 lower timing cover bolts ( 80 Nm ) ,

- the M8 lower timing cover bolts ( 20 Nm ) ,
- the M8 upper timing cover bolts ( 18 Nm ) ,
- the M10 upper timing cover bolts ( 38 Nm ) ,
11A-76

11A
K4M, and 730 or 732

Mot. 1453
Tightening torquesm
Multiple-adjusting
straps
Mot. 1453-01
wheel bolts
bolts

Mot. 1453
110 Nm
4 Nm
WARNING
normal operation.
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
Remove:
Mot. 1750
Adapter for camshaft

setting tool Mot. 1496
Mot. 1490-01

camshaft pulleys
Mot. 1487

diameter)
Mot. 1488

diameter)

Tightening torquesm
pulley bolt
40 Nm + 145
15
timing tensioning roller

nut
27 Nm
45 Nm
30 Nm + 84
4
inlet camshaft pulley

dephaser bolt
75 Nm
TDC pin plug
20 Nm
upper timing cover nuts

and bolts
41 Nm
11A-77

11A
K4M, and 730 or 732
102450
101866

the body.
Remove:
- the engine/suspended engine mounting assembly,
WARNING
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) and the
retaining straps.
101807
Remove:
- the throttle valve (2) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
11A-78

11A
K4M, and 730 or 732

14491
Pierce the centre of the plugs on the end of the

camshaft using a screwdriver.
Remove:
- the sealing plugs at the camshaft end with a
screwdriver,
14491-1
Position the camshaft grooves (5) almost horizontally and offset towards the bottom while turning the
crankshaft in its operating direction (clockwise timing end).
- the TDC setting pin plug (3) .
14489
Turn the crankshaft in its operating direction (timing

end clockwise), until the crankshaft comes into contact with TDC setting pin.
11A-79

11A
K4M, and 730 or 732
10
9
14490
101872
Check that the camshaft grooves are horizontal and

offset downwards.
Remove:
- the pulley (10) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the crankshaft sprocket,

14487
Remove:
- the crankshaft accessories pulley (6) , locking the
11A-80

11A
K4M, and 730 or 732
REFITTING - PROCEDURE 1
I - PROCEDURE FOR AN ENGINE FITTED WITH A
TIMING COVER WITHOUT A FLAP
WARNING
Replace the timing belt, the crankshaft accessories pulley bolt, the tensioning roller and the pulley.
WARNING
111337
Fit the (Mot. 1496) with (Mot. 1750) (11) .

- the accessories pulley contact surfaces,
This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.
Position the camshaft grooves horizontally and below the centre line by turning the camshafts using
the (Mot. 799-01) if necessary.
111336
11A-81

11A
K4M, and 730 or 732
103269
Check that the mark (12) on the dephaser is vertical

and pointing upwards.
Make a mark (13) with a pencil between the dephaser wheel and the rocker cover.
11A-82

11A
K4M, and 730 or 732
14489
14487-3
Check:
Refit:
- that the crankshaft is correctly in contact with the

TDC setting pin (Mot. 1489) (15) with the crankshaft groove (14) facing upwards,

- the timing belt,
- the pulley (17) .
- that the inlet camshaft dephaser wheel is correctly

locked (wheel does not rotate right or left).
Tighten to torque the pulley mounting bolt (45 Nm)

using (Mot. 1368) .
3 - BELT TENSION
2 - REFITTING
103263
108879
Refit the tensioning roller by positioning the tensioning roller lug in the groove (16) .
11A-83

marker (19) opposite the notch (20) , by turning the
eccentric (21) clockwise.

K4M, and 730 or 732
nut (7 Nm)
Tighten to torque and angle the crankshaft accessories pulley bolt ( 40 Nm + 145 15 ) (crankshaft in contact with the TDC setting pin).
Remove:
Rotate the crankshaft through two clockwise revolutions (timing end) before aligning the marks (on the
camshaft dephaser).
103263
Check that the adjustable index marker (22) is opposite the notch (23) .
Gradually move the adjustable indexing marker (22)
opposite the notch (23) turning the eccentric (24) in
a clockwise direction.
11A-84
11A

11A
K4M, and 730 or 732
103267
Tighten to torque the timing tensioning roller nut

(27 Nm) (25) .
Check that the timing pulley index markers are correctly positioned before checking the timing setting.
Check that the dephaser mark (26) is aligned with

the mark (27) .
Move the crankshaft slowly and smoothly until it is

resting against the pin.
Fit the camshaft adjusting the (Mot. 1496) without

and below the centre line).
Rotate the crankshaft through two clockwise revolutions (timing end) before aligning the marks (on the
camshaft dephaser).
Screw in the TDC setting pin (Mot. 1489) .
the TDC setting pin (Mot. 1489) .
Check that the tensioning roller markers are aligned.
If not, repeat the tensioning procedure.
11A-85
WARNING
If the tool cannot be engaged, readjust the timing
and the tension.

11A
K4M, and 730 or 732

II - PROCEDURE FOR AN ENGINE FITTED WITH A
TIMING COVER WITH A FLAP
WARNING
WARNING
111337

This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.
centre line by turning the camshafts using the (Mot.
799-01) if necessary.
111336
11A-86

11A
K4M, and 730 or 732
103269
Check that the mark (29) on the dephaser is vertical

and pointing upwards.
11A-87

11A
K4M, and 730 or 732
14489
14487-3
Check:
Refit:
- that the crankshaft is correctly in contact with the

TDC setting pin (Mot. 1489) (32) with the crankshaft groove (48) facing upwards,
- that the inlet camshaft dephaser wheel is correctly

locked (wheel does not rotate right or left).
- the timing belt,

- the pulley (34) .
.
2 - REFITTING
14487-2
Tighten to torque the pulley mounting bolt (45 Nm)

using (Mot. 1368) .
108879
Refit the tensioning roller by positioning the tensioning roller lug in the groove (33) .
11A-88

11A
K4M, and 730 or 732

3 - BELT TENSION
109055
103263
Move the adjustable index marker (36) opposite the

notch (37) , by turning the eccentric (38) clockwise
using a 6 mm Allen key.
109054
11A-89

Tighten to torque and angle the crankshaft accessories pulley bolt (40 Nm + 145 15) .

11A
K4M, and 730 or 732
109052
109051
Remove the timing flap from the lower timing cover.

Remove:
103263
Using the lower timing cover window, check that the

adjustable index marker (40) is opposite the notch
(39) .
Loosen the timing tensioning roller nut by up to one
turn while holding the eccentric with a 6 mm Allen
key.
Gradually move the adjustable indexing marker (40)
opposite the notch (39) turning the eccentric (41) in
Tighten to torque the timing tensioning roller nut
(27 Nm) .
11A-90

11A
K4M, and 730 or 732

Using the lower timing cover window, check that the
index marker and the timing tensioning roller notch
are aligned.
Reset the tension by loosening the tensioning roller
eccentric nut by up to one turn.
Align the adjustable indexing marker with the notch.
Tighten to torque the timing tensioning roller nut (
27 Nm ) .
14490
Position (without forcing) the camshaft timing tool

(Mot. 1496) (the camshaft end grooves must be horizontal and offset towards the bottom).

Check that the index marker and the timing tensioning roller notch are correctly positioned before
checking the timing.
WARNING
does not engage.

109052
Refit the lower timing cover flap, checking that the

pin (42) fits into the notch properly (43) .
11A-91

11A
K4M, and 730 or 732
REFITTING -PROCEDURE 2
The second procedure is used for the replacement
of all components requiring the loosening of one or
more of the camshaft pulleys.
WARNING
If the stud is loosened with the nut (see Technical Note 3887A, Replacement of K9 -K4 camshaft pulley studs, 11A, Top and front of
engine, Camshaft ).
WARNING
14490
WARNING
Refit the camshaft pulleys and the old nuts, tightening them to a torque of 15 Nm .
103261
Position the camshaft grooves horizontally and offset downwards, by turning the camshafts using the
(Mot. 1496) if necessary.
11A-92

K4M, and 730 or 732
111337
111336
11A-93
11A

11A
K4M, and 730 or 732
14489
103269

11A-94

11A
K4M, and 730 or 732
111338
Fit the camshaft dephaser into a vice with jaws.
111340
Check that the dephaser hub is mechanically secured correctly using a tubular hexagon box spanner
(the hub must not be able to rotate towards the left or
right).
Refit:
- the exhaust camshaft pulley with a new nut,
- the inlet camshaft dephaser with a new bolt.
Position:
- the RENAULT logo (47) engraved on the camshaft
pulley spokes vertically at the top,
- the dephaser marking (48) vertically and at the top.
111339
Fit a bolt in the dephaser hub.
11A-95

11A
K4M, and 730 or 732

II - REFITTING
103265
108879
When refitting the tensioning roller, ensure that the

tensioning roller lug fits correctly into the groove (50)
.
Fit the camshaft pulley locking tool (Mot. 1490-01)

(52) (use the timing cover mountings to fit the tool).
14487-3
Refit the pulley (53) .

14487-3
Tighten to torque the pulley mounting bolt ( 45 Nm

) using the (Mot. 1368) .
Refit:
- the timing belt on the camshaft pulleys (without moving the camshaft pulleys).
11A-96
Refit the crankshaft accessories pulley (without tightening the bolt, leaving 2 to 3 mm play between bolt
and pulley).

11A
K4M, and 730 or 732

III - BELT TENSION
103263
103263

marker (54) opposite the notch (55) , by turning the
eccentric (56) clockwise.
nut (7 Nm).
Remove the 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.
Rotate the timing system through six revolutions
with the exhaust camshaft pulley, using the (Mot.
799-01) .
11A-97
Check that the adjustable index marker (57) is aligned with the fixed index marker (58) .
Gradually move the adjustable index marker (57)
opposite the notch (58) , turning the eccentric (59) in

11A
K4M, and 730 or 732
103268

nut (27 Nm) .
Check that:
- the RENAULT logo (60) engraved on the camshaft
pulley spokes is positioned vertically at the top,
- the dephaser mark (61) is aligned with the mark
(62) already made by the operator.
14839
Fit the camshaft pulley immobilising tool (Mot. 149001) .
11A-98

11A
K4M, and 730 or 732
14489
103265
WARNING
Tighten to torque and angle the exhaust camshaft

pulley nut ( 30 Nm + 84 4 ) .
Check that the crankshaft is pressing against the

TDC setting pin (Mot. 1489) (63) .
Tighten to torque the inlet camshaft pulley dephaser bolt ( 75 Nm ) .
Tighten to torque and angle the crankshaft accessories pulley bolt (40 Nm + 145 15) (crankshaft
in contact with the TDC setting pin).
Refit the new inlet camshaft dephaser blanking cover (64) .

Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool (Mot. 149001) ,
IV - CHECKING THE TIMING AND TENSION

Slowly and smoothly position the crankshaft so that
is in contact with TDC setting pin (Mot. 1489) .
Check that the pulley indexes are aligned, otherwise
continue with the tensioning process.
11A-99

11A
K4M, and 730 or 732

Check that the tensioning roller indexes are correctly
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

and offset downwards).
- the new inlet camshaft sealing plugs (Mot. 1487) ,

- the new exhaust camshaft sealing plugs (Mot.
1488) .
WARNING
If the tool cannot be engaged, readjust the timing
and the tension.
WARNING
Tighten to torque:
REFITTING
- the wheel bolts ( 110 Nm )

Refit the TDC pin plug, applying a drop of SILICONE
ADHESIVE SEAL onto the threading.
Tighten to torque the TDC pin plug ( 20 Nm ) .
Refit the upper timing cover.
Tighten to torque the upper timing cover nuts and
bolts ( 41 Nm ) .
11A-100

11A
K9K, and 732

I - PRECAUTIONS FOR 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 during all operations.
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 break the crankshaft accessories pulley.
When replacing the belt, be sure to replace the
tensioning rollers and pulleys.
Tightening torquesm
camshaft pulley wheel
bolts
14 Nm
tensioning roller bolt
27 Nm
camshaft pulley wheel

bolts
14 Nm
crankshaft pulley M14

bolt
120 Nm + 95
15
II - PARTS AND CONSUMABLES FOR THE REPAIR

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

springs
21 Nm
wheel bolts
- timing belt tensioning roller,

- crankshaft accessories pulley bolts.
Consumables:
- Silicone adhesive seal part no. 77 11 227 484 .
III - ESSENTIAL EQUIPMENT
Equipment:
- Protective gloves,
- Large screwdriver,
110 Nm
- female torx socket ( 14 ),

- Allen key ( 6 mm ),
- Offset spanner ( 18 mm ),
- bolt tightening gauge,
- Torque wrench.
11A-101

11A
K9K, and 732

IV - REMOVAL
1 - REMOVAL PREPARATION OPERATION
- Refitting ).
Remove:
55A, Exterior protection, Scuttle panel grille ),
102450
- the right-hand wheel arch liners,

engine, Accessories belt ).
102451
Fit the (Mot. 1453) and the (Mot. 1453-01) with the
retaining straps.
Remove:
- the exhaust ball joint bracket mounting bolts,
- the lower engine tie-bar mounting bolts.
Detach the manual priming pump.
WARNING
pipes.
11A-102

11A
K9K, and 732
112998
113927
Remove the right-hand suspended mounting (1) and

(2) (see 19D, Engine mounting, Right-hand suspended mounting: Removal - Refitting ).
112989
Undo the cylinder head suspended mounting bolts.

Twist the timing belt slightly (to remove the cylinder
head suspended mounting).
Remove the cylinder head suspended mounting (6) .
112990

Remove:
- the upper timing cover,
- the plastic bolt (4) .
11A-103

11A
K9K, and 732
19650
Remove the TDC pin plug (7) using a torx socket

(14).
19650-1
2 - OPERATION FOR REMOVAL OF PART

CONCERNED
14489
Turn the crankshaft clockwise (timing end) smoothly

until the crankshaft is pressed against the TDC setting pin.
107270
Turn the crankshaft to position the hole (8) of the

camshaft pulley almost opposite the hole (9) in the
cylinder head.
11A-104

11A
K9K, and 732
109049
Engage the pin (11) (Mot. 1430) in the camshaft

pulley and cylinder head holes.
109046
Remove:
Remove:
- the timing belt,
- the timing pin from the camshaft pulley (Mot. 1430)

,
107260
Remove the crankshaft accessories pulley, locking

the engine flywheel using a screwdriver passing it
through orifice under the starter motor.
11A-105
- the timing tensioning roller.

11A
K9K, and 732

V - REFITTING
- the mark on the high-pressure pump (16) is offset

by one tooth to the right of the vertical axis (17) ,
1 - REFITTING PART CONCERNED
- the crankshaft is in contact with the TDC setting pin

(Mot. 1489) (crankshaft timing sprocket collet (18)
at the top).
109042
14489
109043
Refit the timing tensioning roller.
109042
Place the tensioning roller lug (13) in the cylinder

head groove (14) .
Engage the pin (15) (Mot. 1430) in the holes of the
camshaft pulley and cylinder head, turning the
camshaft using an 18 mm offset spanner if necessary.
Check that:
11A-106
Remove one bolt from the camshaft pulley wheel.

Loosen the two other camshaft pulley wheel bolts
(19) by one turn.

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 highpressure pump. There should be 19 tooth spaces
between the sprocket marks and 51 tooth spaces
between the crankshaft sprockets and the high pressure pump.
11A-107

K9K, and 732
19658
Position the tensioning roller adjustable index marker (20) opposite the lug (21) 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-108
11A

11A
K9K, and 732
109045
Refit camshaft pulley wheel bolt (22) .

Tighten to torque the camshaft pulley wheel bolts
( 14 Nm ) .
Remove:
- the timing pin from the camshaft pulley (Mot. 1430)
,
107272
Tighten the old crankshaft accessories pulley bolt fitted with a spacer (23) (which does not cover the timing sprocket mark) onto the crankshaft.
11A-109

11A
K9K, and 732
107270
Rotate the crankshaft twice in a clockwise direction

(timing end) before the camshaft pulley hole (24) is
opposite the cylinder head hole (25) .
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
109049
Set the camshaft pulley using the (Mot. 1430) .
11A-110
109048
If the (Mot. 1430) does not engage:

loosen the camshaft pulley wheel bolts by one turn,
Turn the camshaft pulley hub using an offset spanner to facilitate 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 collet (26)

is positioned vertically facing upwards.
Note:
After two turns, the tensioning roller markers may
be in two different positions.
The rotation of the tensioning roller eccentric
depends on the position.
11A-111

11A
K9K, and 732

b - Second position
a - First position
111083
111082
111081
Loosen the tensioning roller bolt by a maximum of

one turn, holding the tensioning roller using a 6 MM
Allen key.
Gradually align the adjustable index marker (27) to
the middle of the timing window (28) , turning the key
anti-clockwise.
111081
Loosen the tensioning roller bolt by a maximum of

one turn, holding the tensioning roller using a 6 MM
Allen key.
Gradually align the adjustable index marker (29) to
the middle of the timing window (30) , turning the key
clockwise.
Tighten to torque:
- the tensioning roller bolt ( 27 Nm ) ,
- the camshaft pulley wheel bolts ( 14 Nm ) .
11A-112

11A
K9K, and 732

Remove:
Rotate the crankshaft twice in a clockwise direction
(timing end) before the camshaft pulley hole is opposite the cylinder head hole.
Bring the crankshaft slowly and smoothly against the
TDC setting pin.
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 pulley M14
bolt ( 120 Nm + 95 15 )
- timing pin from camshaft pulley (Mot. 1430) .
109049
2 - FINAL OPERATION
Set the camshaft pulley using the (Mot. 1430) .

If this is not possible, repeat the operation for refitting the timing belt.
11A-113
Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEAL .
Tighten to torque the TDC pin plug cap ( 20 Nm ) .

11A
K9K, and 732
112989
112990
Refit the cylinder head suspended mounting (31) .

Tighten to torque the cylinder head suspended
19659
Refit:
- the lower timing cover (32) , positioning the tab (33)
in the hole (34) in the inner timing cover,
- the timing cover plastic bolt (35) .
11A-114

11A
K9K, and 732
112990
Refit the upper timing cover (36)
113927
Refit the right-hand suspended mounting support

(see 19D, Engine mounting, Right-hand suspended engine mounting: Removal - Refitting ).
Remove the (Mot. 1453) and the (Mot. 1453-01) .
Refit the manual priming pump
Refit:
- the rear suspended engine mounting (see 19D,
Engine mounting, Right-hand suspended engine mounting: Removal - Refitting ).
- the exhaust ball joint bracket mounting bolts
Tighten to torque the ball joint bracket mounting
bolts with their springs ( 21 Nm )
Refit:
- the right-hand wheel arch liner,
Tighten to torque the wheel bolts ( 110 Nm )
11A-115

Timing chain: Removal - Refitting
M9R, and 700
REMOVAL
Removing the timing chain requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
To remove the timing chain (see Technical Note
6017A, M9R diesel engine ).
REFITTING
To refit the timing chain (see Technical Note
6017A, M9R diesel engine ).
Refit the engine and gearbox assembly (see 10A,
Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ).
11A-116
11A

Cylinder head gasket : Removal - Refitting
11A
K4J, and 730 or 732

Tightening torquesm
Mot. 1672
plugs
Mot. 1453
Multiple-adjusting
straps
coil mounting bolts (if

the holes are already
threaded)
12 Nm

Mot. 1453

the holes are not threaded)
15 Nm
Mot. 1453-01

camshaft pulleys
inlet manifold mounting

bolts
9 Nm
Mot. 1490-01
battery cover bolts
4 Nm
Mot. 1573
Cylinder head support
Mot. 104
Cylinder head
gning tool
Ele. 1382
ali-
REMOVAL
Spark plug spanner

toolkit 16 & 21 mm torque 1.75 & 28 Nm +
square adapter 9-9.52
for spanner Ele. 1086
Mot. 1491
Camshaft oil seal fitting tool
Mot. 1632
Tool for fit ting the

camshaft seal
Mot. 1487

diameter)
25 to 30 Nm
Remove:
Mot. 1488

diameter)

- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting ).
Drain the engine cooling circuit (see 19A, Cooling,
Cooling circuit: Draining-refilling ).
Equipment required
cylinder head testing tool
Tightening torquesm
rocker cover mounting
bolts 22, 23, 20, 13
12 Nm
oil separator mounting

bolts (new) in the nonthreaded housings
15 Nm
(new or original) oil

separa t o r
mounting
bolts in the pre-threaded
housings
10 Nm
11A-117

11A
K4J, and 730 or 732

Move the fuel supply pipe aside.
1
3
105432
Set up the engine stand (1) (Mot. 1672)

Remove the (Mot. 1453) and (Mot. 1453-01) .
2
18699
101876
Remove the camshaft pulleys using camshaft pulley

locking tool (2) (Mot. 1490-01) .
14889
IMPORTANT
Remove bracket mounting bolt (1) .
Be careful of petrol splashing out when disconnecting the fuel supply union.
Move the bracket to one side.
Loosen the stud with the nut if necessary (see Technical Note 3887A, Replacement of K9 - K4 camshaft pulley studs, 11A, Top and front of engine,
Camshaft ).
Remove:
Remove the wiring harness bracket mounting bolt

(2) .
Disconnect:
- the brake servo vacuum pipe (3) from the inlet manifold.
- the injection rail protector,
- the connector (4) from the coolant temperature

sensor,
- the fuel supply pipe from the injection rail.
- the water unit hoses,
11A-118

11A
K4J, and 730 or 732

Move the bracket/wiring harness assembly aside.
5
9
6
10
104240
18666
Disconnect:
Disconnect the connector (9) from the injectors

Unfasten the clip (10) .
- the ignition coil connectors (5) ,
Remove:
- the inlet manifold pressure sensor connector (7) ,

- the fuel vapour recirculation solenoid valve pipe (8)
,
- the catalytic converter upstream oxygen sensor
connector.
- the ignition coils,

- the plugs,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting ).
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting ).
11A-119

11A
K4J, and 730 or 732
12
15
11
18706
18431
Remove:
Remove:
- the lifting bracket (11) ,
- the oil separator mounting bolts (15) ,
- the inlet manifold mounting bolts (12)
- the oil separator.
- the inlet manifold.
13
16
16
14
103256
101793
Remove:
Remove:
- the rocker cover mounting bolts,
- the catalytic converter/gearbox stay mounting bolts

(13) ,
- detach the rocker cover vertically, tapping the lugs

(16) with a copper hammer.
- the catalytic converter/gearbox stay

- the exhaust pipe mounting nuts (14) .
WARNING
Detach the exhaust pipe.
Do not damage the aluminium surfaces.
11A-120

11A
K4J, and 730 or 732
14498
Remove the inlet and exhaust camshafts.
11A-121

11A
K4J, and 730 or 732

Apply the product to the section to be cleaned; Wait
17
WARNING
18
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 pipes.
Failure to follow this guideline could lead to blockage of the oilways, resulting in rapid and serious
damage to the engine.
II - CHECKING THE GASKET FACE
Use a ruler and feeler gauge to check that there is
no gasket face bow.
14499
Maximum bow: 0.05 mm
Remove:
- the valve rockers (17) ,
WARNING
- the hydraulic tappets (18) .
No regrinding of the cylinder head is permitted.

Test the cylinder head to detect any possible cracks
using the cylinder head testing tool .
Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.
Remove:
For the cylinder head stripping procedure (see

Technical Note 3784A, K4 4-cylinder petrol engine, 10A, Engine and peripherals, Rebuilding the
cylinder head) .
- the cylinder head mounting bolts,
Position the pistons at mid-stroke to prevent any

contact with the valves when refitting the camshafts.
- the cylinder head.
Mount the cylinder head on the cylinder head mounting (Mot. 1573) .
- the cylinder head combustion face,

- the cylinder block combustion face.
Remove the cylinder head gasket from the cylinder

block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
Clean the gasket faces with DCAPJOINT to dissolve any parts of the seal still attached to the lower cover and the cylinder block.
11A-122

11A
K4J, and 730 or 732
20
19
21
14689
14499
Check that the centring dowel is present (19) on the

cylinder block.
Reprime the hydraulic tappets (hydraulic tappets

may empty after a long down time).
Fit the (Mot. 104) (20) onto the cylinder block.
To check if repriming is necessary, press the top of

the tappet (21) with your thumb.
If the tappet piston depresses:
REFITTING
- immerse the tappets in a container full of diesel

fuel,
Fit the new cylinder head gasket.

Refit the cylinder head.
Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket:
Tighten the cylinder head (see 11A, Top and front
of engine, Tightening the cylinder head ).
11A-123
- refit the hydraulic tappets.

Refit:
- the valve rockers,
- the camshafts, oiling the bearings.

11A
K4J, and 730 or 732

I - CAMSHAFT MARKINGS
Inlet camshaft
101880
Position the groove (22) on the end of the camshaft

horizontally (groove below the centre line of the
camshaft).
The cams (23) for cylinder 1 must be located to the
right of the vertical axis (24) , flywheel end view.
11A-124

11A
K4J, and 730 or 732

Exhaust camshaft
101881
Position 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
left of the vertical axis (27) , flywheel end view.
11A-125

11A
K4J, and 730 or 732
28
15106-1
14517
Position the camshaft grooves horizontally and offset downwards.
Using a stipple roller, apply LOCTITE 518 to the

camshaft rocker cover gasket face until it turns reddish.
WARNING
The sealing faces must be clean, dry and free of
grease.
WARNING
could damage certain components (engine,
radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
11A-126
Using a cloth, remove the LOCTITE 518 from (28)

the six camshaft rocker cover bearings.
Refit the rocker cover.

11A
K4J, and 730 or 732

II - TIGHTENING PROCEDURE
14497

- rocker cover mounting bolts 22, 23, 20, 13 , 8
Nm ,
- rocker cover mounting bolts 1 to 12, 14 to 19,
21 to 24 (12 Nm) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order rocker cover mounting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-127

11A
K4J, and 730 or 732
3
2
4
5
1
7
101869
18431
Refit the oil separator.

WARNING
Torque tighten in order
the gasket faces must be clean, dry and free of

grease.
- the oil separator mounting bolts (new) in the

non-threaded housings ( 15 Nm )
- the (new or original) oil separator mounting
bolts in the pre-threaded housings ( 10 Nm )
WARNING
radiator).
gasket face until it is reddish in colour.
11A-128

11A
K4J, and 730 or 732
29
106443
On the four ignition coils, apply a bead (2 9) of

FLUORINATED GREASE 82 00168 855 2 mm in
diameter to the inner circumference of the high-tension cap.
Refit the plugs.
Tighten to torque the plugs ( 25 to 30 Nm ) using
the 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 the holes are not
threaded) ( 15 Nm ) ,
Always replace all the inlet manifold seals.
11A-129

11A
K4J, and 730 or 732
14497-1
Tighten to torque and in order the inlet manifold

Refit:
30

valve: Removal - Refitting ).
unit: Removal - Refitting ).
III - REPLACING THE CAMSHAFT SEALS
There are two types of elastomer camshaft seal
which are easy to identify.
31
20256
The first type of elastomer seal is fitted with a spring

(30) with a lip seal (31) in the shape of a V
11A-130

11A
K4J, and 730 or 732

1 - Fitting the first seal type to the inlet camshaft
34
32
33
35
20257
The second type of elastomer seal is fitted with a flat

lip seal (32) and a protector (33) (which also assists
in fitting the seal to the engine).
Note:
Both seal 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-131
14892
Fit the seals using the (Mot. 1491) (34) and the old
nuts (35) .

11A
K4J, and 730 or 732

2 - Fitting the seal to the exhaust camshaft
38
36
37
105531
18687
WARNING
It is very important to hold the protector (3 6)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (37) in order to prevent any oil
leaks once the seal is fitted to the engine.
38
21687
Screw the stud of (38) the (Mot. 1632) onto the

camshaft.
11A-132

11A
K4J, and 730 or 732
21687-1
21687-3
Fit the protector, with a seal, to the camshaft.
Screw in the collar nut until the cover comes into

contact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of engine, Timing belt: Removal - Refitting ).
39
40
WARNING
Follow the second procedure in the timing belt
refitting procedure.
21687-2
Fit cover (39) and the collar nut (40) of the (Mot.
1632) .
11A-133

K4J, and 730 or 732
15103-1
Refit:
- new inlet camshaft sealing plugs using the (Mot.
1487) ,
- new exhaust camshaft sealing plugs using the
(Mot. 1488) ,
Fill the cooling circuit (see 19A, Cooling, Cooling
circuit: Draining-refilling ).
11A-134
11A

11A
K9K, and 722 or 728 or 729

IMPORTANT
Car. 1363
Trim removal lever
Mot. 1672
Mot. 1453
Multiple-adjusting
straps
Before any operation:
Mot. 1453-01

Mot. 1453
Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

- 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.
WARNING
Procedure for removing the air inlet duct (K9K 728
and 729):
- make a mark on the inlet duct between the stainless steel pipe and the hose,
any other product,
Equipment required
diagnostic tool
- clean the stainless steel pipe and the hose with a

dry, lint-free cloth,

angular tightening wrench
- rotate the clip around its axis to make torque tightening easier,
Tightening torquesm
bolts
10 Nm
turbocharger oil return

pipe
9 Nm
intercooler hose clip

battery cover bolts
- it is essential to replace the hose and/or the stainless steel pipe in the event of damage.
There is a risk of leaks or dislodging if this procedure is not followed.
5.5 Nm
4 Nm
11A-135

11A
K9K, and 722 or 728 or 729
REMOVAL
K9K, and 722
Remove:

5
2
Remove:
- the battery,
102081
Disconnect:
- the air temperature and pressure sensor connector
(1) ,
- the exhaust gas recirculation valve control connector (2) ,
- the air hoses (3) ,
- the air hose (4) ,
- the turbocharging pressure regulation valve rubber
pipe,
- the air sleeve from the air filter unit,
105432
Fit the engine stand (Mot. 1672) .
- the oil vapour rebreathing pipe from the rocker cover.

Remove the air resonator unit mounting stay (5) .
11A-136

11A
K9K, and 722 or 728 or 729
K9K, and 728 or 729
6
9
110325
Pull out the clip.

110326
Disconnect:
11
- the air temperature and pressure sensor connector

(6) ,
- the exhaust gas regulation valve control connector
(7) ,
- the engine speed and position sensor connector
(8) ,
12
10
- the air hose (9) ,

- the rubber hose from the turbocharging pressure
control valve.
110322
Make a mark on the inlet duct between the stainless

steel pipe and the hose (10) .
Undo the bolt (11) .
Remove the air duct (12) .
11A-137

11A
K9K, and 722 or 728 or 729
18
17
13
16
14
15
102086
102263
Disconnect:
Disconnect:
- the injector connectors,
- the water unit hoses (16) using the (Mot. 1202-01)

or (Mot. 1202-02) or (Mot. 1448) ,
- the heater plug connectors,
- the brake servo vacuum pipe (17) on the vacuum

pump side,
- the rail pressure sensor connectors,

- the diesel fuel supply pipe from the pump,
- the coolant temperature sensor connector on the

water unit.
- the diesel return pipe from the pump,

- the fuel temperature sensor (13) ,
- the radiator top hose from the cylinder head water

outlet using the (Mot. 1202-01) or (Mot. 1202-02)
or (Mot. 1448) .
- the fuel flow actuator connector (14) .

Remove the wiring and diesel return pipe support
(15) .
Unclip the heater radiator hose (18) .

Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting ).
11A-138

11A
K9K, and 722 or 728 or 729
21
19
104175
Disconnect the turbocharger oil return pipe (19) .
19711
Remove:
- the rocker cover mounting bolts (21) ,
- the rocker cover.
22
20
22
19712
Remove:
19710
Remove the inner timing cover (20) .
- the cylinder head mounting bolts (22) ,

11A-139

11A
K9K, and 722 or 728 or 729

Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
the cylinder head.
I - CLEANING
Clean the cylinder head.
IMPORTANT
WARNING


- goggles,
- gloves.

of engine, Tightening the cylinder head ) using
the angular tightening wrench .
Clean the gasket faces with DCAPJOINT to dissolve the section of the gasket which is still attached.
Apply the product to the section to be cleaned; wait
WARNING
WARNING
Please make sure, during this operation, that no
foreign bodies enter the oilways (galleries in both
the cylinder block and the cylinder head).
WARNING
squeezed out when parts are tightened. The product-fluid mix may damage some components
(engine, radiator).
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply galleries.
23
Failure to follow this advice could lead to the pipe

blocking, quickly damaging the camshaft.
23
Check for gasket face bow using a ruler and a feeler
gauge.
23
The maximum bow is 0.05 mm .

WARNING
19712-1
Fit the new rocker cover gasket.

Technical Note 6006A, 4 cast iron cylinder High
Pressure Common Rail Diesel Engine, 10A, Engine and peripherals, Rebuilding the cylinder
head ).
REFITTING
Fit the new cylinder head gasket, centred by two
dowels.
11A-140
Apply beads (23) of SILICONE ADHESIVE SEAL 2

mm in diameter.

11A
K9K, and 722 or 728 or 729

Tighten to torque the intercooler hose clip ( 5.5
Nm ) .
Refit:
- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).
2
7

Fill the cooling circuit (see 19D, Cooling, Cooling

Reprime the diesel circuit (see 13B, Fuel supply,

Diesel fuel supply circuit ).
19711

Tighten to torque and in order the rocker cover
Reconnect the turbocharger oil return pipe, fitted
with new seals.
Tighten to torque the turbocharger oil return pipe
( 9 Nm ) .
19709
Reconnect:
- the oil vapour rebreather pipe,
- the new turbocharger air sleeves.
K9K, and 728 or 729
Reconnect the air duct by aligning the marks.
11A-141

11A
F9Q, and 800 or 808

WARNING
Mot. 1672
Mot. 1453
Multiple-adjusting
straps
Mot. 1453-01
Fit plugs in the openings.

Mot. 1453
Mot. 1202-01
Be sure to follow the safety instructions.

Refer to (see 13B, Diesel injection, Cleanliness
guidelines ).
REMOVAL

system hose clips
(large model)
Mot. 1202-02
Mot. 1448
Remove:

clips


Remove:
Equipment required
diagnostic tool
- 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
battery cover bolts
4 Nm
IMPORTANT
- connect the diagnostic tool ,
plug kit.
105432

11A-142

11A
F9Q, and 800 or 808
3
4
7
2
18983
Remove the vacuum tank mounting bolts (7) .
Disconnect:
105511
- the turbocharger pressure regulation solenoid valve pipes,

- the engine damping device solenoid valve connector (8) ,
Disconnect:
- the camshaft sensor connector (9) .
- the air duct (2) towards the turbocharger,
Remove the vacuum tank.
- the oil vapour rebreathing pipe (3) ,

- the engine damping device valve pipe (4) .
Remove:
- the air duct (5) from the inlet manifold,
- the oil vapour rebreathing canister (6) .
11A-143

11A
F9Q, and 800 or 808
10
11
11
18
12
13
12
16
14
15 17
105512
104323
Disconnect:
Disconnect:
- the exhaust gas recirculation solenoid valve connector (10) ,
- the cylinder head outlet water unit hoses using the

(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the injector connectors (11) ,

sensor.
- the heater plug connectors (12) ,

- the rail pressure sensor connector (13) ,
- the high-pressure pump pressure regulator connector (14) ,
- the diesel return temperature sensor connector
(15) ,
- the diesel filter connector,
- the diesel fuel supply pipe (16) ,
- the diesel return pipe (17) .
Insert the blanking plugs.
19
Move the wiring harnesses to one side.
102348
Remove the three high-pressure pump support

mounting bolts (19) .
11A-144

11A
F9Q, and 800 or 808
21
23
22
20
18997
16189
Remove:
Remove the cylinder head mounting bolts (23) .
- the catalytic converter (20) (see 19B, Exhaust,

WARNING
- the oil supply pipe (21) ,
When removing the cylinder head, take care not

to cause any damage to its gasket face as it passes the turbocharger above it.
- the oil return pipe mountings (22) on the turbocharger.
Remove the cylinder head. This operation requires

two people.
I - CLEANING
IMPORTANT
- goggles,
- gloves.
Clean the gasket faces with DCAPJOINT to dissolve the section of the gasket which is still attached.
11A-145

11A
F9Q, and 800 or 808

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 ) ,
WARNING
To prevent any foreign bodies from entering the
oil pipes (pipes in both the cylinder block and
cylinder head).
- the oil return pipe bolts ( 12 Nm ) .

Refit:
WARNING
Failure to follow this advice could block the oil
supply pipes, causing rapid camshaft damage.

WARNING
Reprime the diesel circuit (see 13A, Fuel supply,

The cylinder head bolts must be replaced each

time they are removed and must not be oiled
before being fitted.


gauge.
WARNING
Technical Note 3652A, 4-cylinder Cast Iron High
head ).
REFITTING
the cylinder head.
Fit the cylinder head gasket.
of engine, Tightening the cylinder head ) using a
angular tightening wrench .
11A-146

11A
F4R, and 770 or 771

Tightening torquesm
Mot. 1672
plugs
Mot. 1509
Camshaft
locking tool
sprocket
coils (if holes already

threaded)
12 Nm
Mot. 1509-01
Conversion kit for Mot.

1509
coils (if holes not threaded)
15 Nm
Mot. 1202-01

system hose clips
(large model)
inlet manifold
9 Nm

bolts
4 Nm
Mot. 1202-02

clips
Mot. 1448

Mot. 1573
Mot. 1517
Camshaft seal fitting

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

diameter)
Mot. 1488

diameter)
25 to 30 Nm
REMOVAL
Remove:
Remove
Equipment required

Tightening torquesm
rocker cover bolts 22,
23, 20, 13
(8 Nm)
rocker cover bolts 1 to

12, 14 to 19, 21 to 24
(12 Nm)
new or original oil separator mounting bolts (in

threaded holes)
10 Nm
new oil separator

mounting bolts (in nonthreaded holes)
15 Nm
105432
11A-147

11A
F4R, and 770 or 771
3
2
16019-4
Fit the (Mot. 1509) with the gear (Mot. 1509-01) .
16019-4
Remove:
Tighten the collar nut (1) and the bolt (2) , then bring
the gears of (Mot. 1509) into contact with the camshaft pulleys while torque tightening the nuts (80
Nm) (3) .
Remove the inlet camshaft dephaser blanking cover
using a 14 mm Allen key.

- the inlet camshaft dephaser mounting bolt,
Loosen the nut stud if necessary (see Technical
Note 3887A, Replacement of F4 camshaft pulley
studs, 11A, Top and front of engine, Camshaft ).
4
18699
Remove the bracket mounting bolts (4) .

Move the bracket to one side.
11A-148

11A
F4R, and 770 or 771
8
9
5
8
12
11 10
6
14889
18666
Disconnect:
- the camshaft dephaser connector (10) ,

- the fuel vapour recirculation solenoid valve pipe
(12) ,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Remove:
- the plugs,
102735
Remove the wiring harness bracket mounting bolts

(5) .
Disconnect:
sensor,
- the water unit hoses using the (Mot. 1202-01) or
(Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (7) on the inlet manifold side.
11A-149
- the dephaser solenoid valve.

11A
F4R, and 770 or 771
17
18
13
14
102939
102940
Remove:
Remove:
- the lifting bracket (13) at the timing end,
- the oil separator mounting bolts.

- the oil separator (17) ,
- the inlet manifold mounting bolts (14) ,
- the lifting bracket at the flywheel end (18) .
15
16
101793
Remove:
- the catalytic converter/gearbox stay mounting bolts
(15) ,
- the catalytic converter/gearbox stay,
11A-150

F4R, and 770 or 771
19
19
102941
Remove the rocker cover bolts.

Remove the rocker cover vertically, tapping the lugs
WARNING
Remove the camshaft seals.
11A-151
11A

11A
F4R, and 770 or 771
20
15151
Remove the inlet and exhaust camshafts (20)
11A-152

F4R, and 770 or 771
21
22
14499
Remove:
Note:
11A-153
11A

11A
F4R, and 770 or 771
15153
Remove:
- the cylinder head bolts,
WARNING

oil pipes (pipes in the cylinder block and cylinder
head).
block

gauge.
I - CLEANING

IMPORTANT
WARNING
- goggles,
Clean the gasket faces with DCAPJOINT to dissolve any sections where the seal is still attached.
Test the cylinder head to detect any cracks using the

cylinder head testing tool (see Technical Note
3783A, F4 4-cylinder petrol engine, 10A, Engine
and peripherals, Rebuilding the cylinder head)
for the cylinder head stripping procedure.

for approximately ten minutes, then remove it using
a wooden spatula.

contact with the valves when the camshafts are
being refitted.
- gloves.
11A-154

11A
F4R, and 770 or 771

- The combustion face of the cylinder head,
- the combustion face of the cylinder block.
REFITTING
Check the bolts (see 11A, Top and front of engine,
Tightening the cylinder head ).
of engine, Tightening the cylinder head ) using a
24
25
23
15152
The camshafts are identified by the pulley mountings.

Detailed view of the pulley mountings:
- (24) : exhaust camshaft,
- (25) : inlet camshaft.
14499
Re-prime the hydraulic tappets (hydraulic tappets

may empty if they have been removed for some time).
To check or reprime them, press the top of the tappet at (23) with your thumb.
fuel,
Refit:
11A-155

11A
F4R, and 770 or 771
26
15106-1
14517
Position the camshaft grooves as shown in the diagram.

camshaft rocker cover gasket face until it is reddish
in colour.
WARNING
WARNING
Note:
Using a cloth, remove the LOCTITE 518 from
(26) the camshaft rocker cover bearings.

squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain
components (engine, radiator, etc.).
WARNING
Do not apply oil to the sealing face of the camshaft bearing cap cover.
11A-156

11A
F4R, and 770 or 771
14497

- rocker cover bolts 22, 23, 20, 13 ( (8 Nm) ) ,
- rocker cover bolts 1 to 12, 14 to 19, 21 to 24 (
(12 Nm) ) .
Tighten to torque and in order mounting bolts 22,
23, 20, 13 (12 Nm) .
11A-157

11A
F4R, and 770 or 771
102738
102729

WARNING

- the new or original oil separator mounting bolts

(in threaded holes) ( 10 Nm ) ,
- the new oil separator mounting bolts (in nonthreaded holes) ( 15 Nm ) .
WARNING
components (engine, radiator, etc.).
Using a stipple roller, apply LOCTITE 518 to the joint
face of the oil separator until it is reddish in colour.
11A-158

11A
F4R, and 770 or 771
27
106443

FLUORINATED GREASE 82 00 169 855 2 mm in
diameter to the lower circumference of the high-tension cap.
11A-159

11A
F4R, and 770 or 771
102939
15103-1
Refit the plugs.
Refit:
Tighten to torque the plugs ( 25 to 30 Nm ) .
- the new sealing plugs:
Refit the coils.
on the inlet camshaft (Mot. 1487) ,
Tighten to torque:
on the exhaust camshaft (Mot. 1488) ,

- the right-hand suspended engine mounting (see
19D, Engine mounting, Suspended engine
mounting ).
- the coils (if holes already threaded) ( 12 Nm ) ,

- the coils (if holes not threaded) ( 15 Nm ) .
Refit the inlet manifold with its new gasket.
Tighten to torque and in order the inlet manifold ( 9

Nm ) .
Refit the camshaft offset timer solenoid valve, with a
new seal.
Replace the camshaft seals.

- use the (Mot. 1517) for the inlet camshaft seal.

- use the (Mot. 1512) for the exhaust camshaft seal.
Refit:
- the timing belt (it is essential to follow the procedure (see 11A, Top and front of engine, Timing
belt: Removal - Refitting ).
11A-160

( 4 Nm ) .

11A
K4M, and 760 or 761

Tightening torquesm

Mot. 1672
Mot. 1453
Multiple-adjusting
straps
camshaft dephaser
solenoid valve bolt
plugs
10 Nm
25 to 30 Nm

holes already threaded)
12 Nm

holes not threaded)
15 Nm
Mot. 1669
Fitting cam follower

tappet
Mot. 1453-01

Mot. 1453
camshaft position sensor mounting bolt
10 Nm
Mot. 1490-01

camshaft pulleys

bolts
9 Nm
Mot. 1573
battery cover bolts
4 Nm
Mot. 104
Cylinder head
gning tool
Mot. 1513
Tool for refitting camshaft dephaser solenoid

valve lip seal
Ele. 1382
ali-
REMOVAL
Spark plug spanner

toolkit 16 & 21 mm torque 1.75 & 28 Nm +
square adapter 9-9.52
for spanner Ele. 1086
Mot. 1632
Tool for fit ting the

camshaft seal
Mot. 1487

diameter)
Mot. 1488

diameter)
Remove:
Remove:
Equipment required
Tightening torquesm
bolts 22, 23, 20, 13
12 Nm
oil separator mounting

bolts
15 Nm
11A-161

11A
K4M, and 760 or 761
1
2
105432
Set up the engine stand (1) (Mot. 1672) .

Remove the (Mot. 1453) and (Mot. 1669) .
1
14889
102735
Remove the wiring harness support mounting bolt

(1) .
Disconnect:
sensor,
- the water unit hoses using the (Mot. 1453) or (Mot.
1453-01) or (Mot. 1490-01) ,
- the brake servo vacuum pipe (3) on the inlet manifold side.
11A-162

11A
K4M, and 760 or 761

- the catalytic converter upstream oxygen sensor
connector.
4
5
10
4
11
8
18666
Disconnect:
104240
Disconnect the connector (10) from the injectors
Unfasten the clip (11) .
- the camshaft dephaser solenoid valve connector

(6) ,

- the fuel vapour recirculation solenoid valve pipe (8)
,
Remove:
- the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
101809
Disconnect:
- the camshaft position sensor connector (9) ,
11A-163

11A
K4M, and 760 or 761
12
14
13
15
103272
101793
Remove:
Remove:
- the lifting bracket (12) ,
- the catalytic converter-gearbox stay mounting bolts

(14) ,
- the inlet manifold mounting bolts (13) ,
- the catalytic converter/gearbox strut,

Move the exhaust pipe aside.
Remove the camshaft pulleys using the (Mot. 149001) .
11A-164

11A
K4M, and 760 or 761
16
18
17
18
103255
103256
Remove:
WARNING
- the rocker cover mounting bolts,
Do not remove the bolt (16) as it acts as a stop

for the squared cam tappet.
- detach the rocker cover vertically, tapping the lugs

Remove:
WARNING
- the oil separator mounting bolts (17) ,
- the oil separator.
103258
Remove the inlet and exhaust camshafts.
11A-165

11A
K4M, and 760 or 761

19
WARNING
Do not allow this product to drip onto the paintwork.
20
Clean the cylinder head carefully to prevent

foreign bodies from entering the oil supply and
return pipes.
Failure to follow this guideline could lead to blockage of the oilways, resulting in rapid and serious
damage to the engine.
Use a ruler and feeler gauge to check that there is
no gasket face bow.
14499
Remove:
WARNING

Note:
Remove:

Technical Note 3784A, K4 4-cylinder petrol engine, 10A, Engine and peripherals, Rebuilding the
cylinder head) .
- the cylinder head mounting bolts,

contact with the valves when refitting the camshafts.
- the cylinder head combustion face,

- the cylinder block combustion face.

block.
I - CLEANING THE CYLINDER HEAD
IMPORTANT
- goggles,
- gloves.
Clean the gasket faces with DECAPJOINT to dissolve any parts of the seal still attached to the lower cover and the cylinder block.
11A-166

11A
K4M, and 760 or 761
22
21
23
14689
14499
Check that the centring dowel is present (21) on the

cylinder block.
Reprime the hydraulic tappets (hydraulic tappets

may empty after a long down time).
Fit the (Mot. 104) (22) on the cylinder block.
To check if repriming is necessary, press the top of

the tappet (23) with your thumb.
REFITTING

fuel,

Check the cylinder head tightening bolts (see 11A,
Top and front of engine, Cylinder head gasket:
of engine, Tightening the cylinder head ).
11A-167

Refit:

11A
K4M, and 760 or 761

I - CAMSHAFT MARKINGS
26
Inlet camshaft
27
24
28
29
103685
102507
(24)
The inlet camshaft is fitted with

the camshaft sensor target.
Position the pin (26) of the (Mot. 1669) against the

bottom of the groove by loosening bolt (27) .
Mount the (Mot. 1669) on the rocker cover, correctly
positioning the pin (28) in the rocker cover hole (29) .
Exhaust camshaft
25
30
103684
102506
(25)
The exhaust camshaft is fitted

with the square cam.
11A-168
Fit the rocker cover tool (Mot. 1669) using the bolts
(30) .

11A
K4M, and 760 or 761
32
35
31
34
103687
103686
Tighten the bolt (31) until the pin (32) is hard up

against the bottom of the groove.
Turn the bolt (34) until the pin (35) is hard up against
the bottom of the groove.
Remove the (Mot. 1669) from the rocker cover.
33
103688
Position the bolt of the (Mot. 1669) in place of the

original bolt at (33) to hold the tappet in the compressed position.
11A-169

11A
K4M, and 760 or 761
36
15106-1
14517
Position the camshaft grooves horizontally and offset downwards.

camshaft rocker cover gasket face until it turns reddish.
WARNING
The sealing faces must be clean, dry and free of
grease. (do not leave any finger marks).
WARNING
radiator).
11A-170
Using a cloth, remove the LOCTITE 518 from (36)

on the six camshaft rocker cover bearings.
Refit the camshaft rocker cover.

11A
K4M, and 760 or 761

II - TIGHTENING PROCEDURE
14497

- rocker cover mounting bolts 22, 23, 20, 13 (8
Nm) ,
- rocker cover mounting bolts 1 to 12, 14 to 19,
21 to 24 (12 Nm) .
Tighten to torque and in order rocker cover mounting bolts 22, 23, 20, 13 ( 12 Nm ) .
11A-171

11A
K4M, and 760 or 761
10
9
4
7
3
101820

Tighten to torque and in order the oil separator
102073
WARNING
the sealing surfaces must be clean, dry and free
Remove the bolt (10) of the (Mot. 1669) to release

the tappet.
Refit the original bolt, applying a drop of LOCTITE
FRENETANCH .
WARNING
37

radiator).
gasket face until it is reddish in colour.
16016
Refit:
- the camshaft dephaser solenoid valve seal using
the (Mot. 1513) (37) ,
- the camshaft dephaser solenoid valve.
Tighten to torque the camshaft dephaser solenoid
valve bolt ( 10 Nm ) .
11A-172

11A
K4M, and 760 or 761
38
106443

FLUORINATED GREASE 82 00168 855 2 mm in
diameter to the inner circumference of the high-tension cap.
11A-173

11A
K4M, and 760 or 761
4
3
1
2
5
39
6
103257
103272
Refit the plugs.

Tighten to torque the plugs ( 25 to 30 Nm ) using

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

Tighten to torque
- the coil mounting bolts (if holes already threaded) ( 12 Nm ) ,
- the coil mounting bolts (if holes not threaded) (
15 Nm )
.
Refit the cylinder reference sensor (39) with a new
seal.
Tighten to torque the camshaft position sensor
mounting bolt ( 10 Nm ) .
41
40
Always replace all the inlet manifold seals.
20257
The elastomer seal on these engines is fitted with a

flat lip seal (40) and a protector (41) (also assists in
fitting the seal to the engine).
11A-174

11A
K4M, and 760 or 761

1 - Fitting the seal to the exhaust camshaft
44
42
43
105531
18687
WARNING
It is very important to hold the protector (4 2)
when handling the seal, as this type of seal is
very fragile. It is strictly forbidden to touch the
elastomer seal (43) in order to prevent any oil
leaks once the seal is fitted to the engine.
44
21687
Screw the stud (44) of the (Mot. 1632) onto the

camshaft.
11A-175

11A
K4M, and 760 or 761
21687-1
21687-3
Fit the protector, with a seal, to the camshaft.

2 - Fitting the inlet camshaft seal
45
WARNING
46
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 cover (45) and the collar nut (46) of the (Mot.
1632) .
11A-176

11A
K4M, and 760 or 761
47
48
105531
105532
Fit the protector (47) , with a seal, to the camshaft.

Push the centre of the protector to force the seal into
its housing.
48
105534
Screw the stud (48) of the (Mot. 1632) onto the

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

the seal.
11A-177

11A
K4M, and 760 or 761
49
50
105535
Fit the cover (49) and the collar nut (50) of the (Mot.
1632) .
15103-1
Refit:
- the accessories belt (see Top and front of engine,
Accessories belt: Removal - Refitting ).
- new inlet camshaft sealing plugs using the (Mot.
1487) ,
- new exhaust camshaft sealing plugs using the
(Mot. 1488) ,
IV - REFITTING
Refit the timing belt (see 11A, Top and front of engine, Timing belt: Removal and Refitting )
WARNING
Follow the second procedure in the timing belt
refitting procedure.

circuit: Draining - refilling ).
Connect the battery (see 80A, Battery, Battery: Removal - refitting ).
11A-178

F4R, and 776
WARNING
Removing and refitting the turbocharger requires
careful application of the repair procedures to
ensure the system is properly sealed.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY HAVE SERIOUS SAFETY-RELATED
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 ).
To remove the cylinder head gasket (see Technical
Note 3784A, F4 4-Cylinder Petrol Engine, 10A,
Engine and peripherals, Cylinder head: Stripping - Refitting .
11A-179
11A

11A
F9Q, and 804

terminal.

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Drain the cooling circuit through the cooling radiator

using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448) .
WARNING
Plug the orifices.
Mot. 1448

Mot. 1672
Refer to 13B, Diesel injection, Cleanliness instructions).
Mot. 1453
Multiple-adjusting
straps
Remove the scuttle panel grille (see MR 371 Bodywork, 55A, Exterior Protection, Scuttle Panel
Grille ).
Mot. 1453-01

Mot. 1453
Make sure that you follow all the safety instructions.
Remove:
- air filter access panel mounting bolts,
- the scuttle panel partition mounting bolt,
- the scuttle panel partition mounting bolts,
Equipment required
- the scuttle panel partition,

cylinder head testing equipment
- the battery,
- the battery tray,
Tightening torquesm
bolts.

4 Nm .
Remove the catalytic pre-converter (see 19B, Exhaust, Catalytic Pre-converter: Removal - Refitting ).
Remove:
REMOVING - REFITTING
- the timing belt (see 11A, Top and front of engine:

Timing belt ).
engine, Accessories belt ) ,
IMPORTANT
- connect the diagnostic tool (After-Sales),
- check that the injector rail is depressurised,
- watch out for the fuel temperature,
plug kit.
Remove:
11A-180

11A
F9Q, and 804
105432
Fit the engine support with (Mot. 1672) .

Remove (Mot. 1453) and (Mot. 1453-01) .
111887
111888
Disconnect:
- the oil vapour rebreathing pipe (4)
- the air inlet duct (see 12A, Fuel mixture, Air intake: Removal - Refitting ) (5) .
- the turbocharging pressure connector (7) ,
- the throttle valve connector (8) ,
- the turbocharging pressure solenoid valve connector (9) ,
- the flowmeter connector (10)
- the diesel pressure regulator connector (12) .
Remove:
- the injector rail protector (13) (see 13B, Diesel injection, Injector rail protector ).
11A-181

11A
F9Q, and 804
111889
Disconnect:
- the diesel return temperature sensor connector,
111886
- the high-pressure pump pressure regulator connector,

Disconnect:
- the diesel return pipe (22) ,
- the vacuum pipe (14) from the vacuum pump,
- the diesel fuel supply pipe.
Remove the starter (see 16A, Starting-Charging,

Starter: Removal - Refitting .
- the exhaust gas recirculation connector (16) ,
Remove:
- the coolant temperature sensor (17) ,
- the turbocharger air duct,
- the turbocharger vacuum pipes (18) .
- the turbocharger oil return pipe

- the coolant hoses.
- the turbocharger oil supply pipe.
Disconnect the scuttle panel hoses from the cylinder
head outlet.
111965
Disconnect:
- the camshaft sensor connector (19) ,
11A-182

11A
F9Q, and 804
111861
102348
Remove:
- the high-pressure pump rear mounting bolts (23) ,
- the windscreen wiper mounting,
- the bonnet,
- the cylinder head mounting bolts.
WARNING
Remove the cylinder head.
111863
Remove exhaust gas recirculation pipe mounting

bolts (24) .
Remove the exhaust gas recirculation pipe mounting clip.
Remove the cylinder head mounting bolts.
11A-183

11A
F9Q, and 804

Refit the cylinder head with a new cylinder head gasket.
I - CLEANING
Refit new cylinder head bolts.

of engine, tightening the cylinder head) using a
IMPORTANT
Wear protective goggles.
Refit the catalytic converter (see 19B, Exhaust, Catalytic converter ).
Wear gloves during the operation.

Clean the gasket faces with DECAPJOINT cleaning product to dissolve the part of the gasket
which is stuck to the sump and cylinder cover.
Apply the product to the section to be cleaned;
Wait approximately ten minutes, then remove the
residue using a wooden spatula.
Refit the timing belt (see 11A, Top and front of engine, Timing belt ).
Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt ).
Fill and bleed the cooling circuit (see 19A, Cooling,
Bleeding the cooling circuit .
Diesel supply circuit ).
WARNING
cylinder head).

WARNING
WARNING
from entering the cylinder head oil supply pipes.
Failure to follow this instruction could lead to the
pipes becoming blocked, causing rapid camshaft
damage.

Check for gasket face bow using a ruler and a set of
shims.
The maximum deformation is 0.05 mm .
WARNING
No regrinding is permitted.
using a cylinder head testing equipment .
(see TN 3652A, 4-cylinder Cast Iron High Pressure Common Rail Diesel Engine, 10A, Engine and
peripherals, Rebuilding the cylinder head) for the
cylinder head stripping procedure.
REFITTING
the cylinder head.
Degrease the gasket faces.
11A-184
carry out the necessary programming (see 80A,

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

11A
F9Q, and 804


Mot. 1672
Mot. 1453
Multiple-adjusting
straps
Mot. 1453-01

Mot. 1453
Equipment required
WARNING
Fit plugs in the openings.
Always respect the repair precautions (see 13B,
Diesel injection, Diesel injection: Precautions
during repair ).
Remove:
diagnostic tool
- the battery tray,
cylinder head testing equipment
- the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ).
Tightening torquesm
bolts
4 Nm
Remove:
engine, Accessories belt: Removal - Refitting) ,
REMOVING - REFITTING

IMPORTANT
- connect the diagnostic tool (After-Sales),
plug kit.
105432
Remove:
Fit the engine support using the (Mot. 1672) .

11A-185

11A
F9Q, and 804
13
11
15
5
12
3
14
111887
111886
Disconnect:
- the vacuum pipe from the vacuum pump (11) ,
10

- the exhaust gas recirculation connector (13) ,
- the coolant temperature sensor (14) ,
- the turbocharger vacuum pipes (15) .
9
111888
16
Disconnect:
17

- the air inlet duct (see 12A, Fuel mixture, Air inlet:
Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the turbocharging pressure solenoid valve connector (6) ,
111965
- the air flowmeter sensor connector (7) ,
Disconnect:
- the camshaft sensor connector (16) ,
- the diesel pressure regulator connector (9) .
- the injector connectors (17) .
Remove:
- the injection rail protector (10) (see 13B, Diesel injection, Injection rail protector ).
11A-186
Move the electric wiring harness to one side.

11A
F9Q, and 804
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-187
WARNING

11A
F9Q, and 804

I - CLEANING
IMPORTANT
Do not scratch the aluminium sealing surfaces.
21
- goggles,
- gloves.
Clean the gasket faces with DECAPJOINT to dissolve any part of the gasket which is attached to the
lower cover and cylinder block.
111861

approximately 10 minutes, then remove residue
21
WARNING
cylinder head).
WARNING
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.
Remove the cylinder head mounting bolts.

gauge.

WARNING
No regrinding is permitted.
using a cylinder head testing equipment .
Technical Note 3652A, 4-cylinder Cast Iron High
head) .
11A-188

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 ).
of engine, Accessories belt: Removal - Refitting
).
( 4 Nm ) .
11A-189
11A

11A
K9K, and 732

WARNING
Car. 1363
Trim removal lever
Ele. 1552
Tool for removing rear

screen wiper arm
Before starting work on the vehicle, obtain:
Mot. 1672
- some cleaning cloths ( PART NO. 77 11 211 707) ,
Mot. 1453
Multiple-adjusting
straps
Mot. 1453-01

Mot. 1453
Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Equipment required
- a new plug kit ( PART NO. 77 01 476 857) ,
- cleaning product ( PART NO. 77 11 24 188) .
IMPORTANT
Before carrying out any work on the injection system, check using the diagnostic tool :
- that the injection rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanliness
advice given 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 dislodging if this procedure is not respected):
diagnostic tool
hydraulic crane
load positioner
- do not use degreaser, brake cleaning agents, or

any other products,
- clean the bearing face on the intercooler with a

dry, lint-free cloth,

- place the clip in the same position if the hose is
not replaced,
Tightening torquesm
bolts
10 Nm
alternator mounting
bolts
21 Nm
hose clip on the stainless steel pipe
5.5 Nm

pipe
9 Nm
battery cover bolts
4 Nm
- it is essential to replace the hose and/or the rigid

pipe in the event of damage.
REMOVAL
- Refitting ).
11A-190

11A
K9K, and 732

- the front bumper (see MR365, Bodywork, 55A,

- the catalytic converter (see 19B, Exhaust, Catalytic converter ).
102101
104175
Remove the turbocharger oil return pipe (5) .

Bleed the cooling circuit (see 19A, Cooling, Cooling circuit: Draining-refilling ).
102100
Unclip the trim (1)

Remove:
- the seal (2) ,
- the plastic rivets (3) ,
- the wiper arms (4) using the (Ele. 1552) ,
- the scuttle panel grille.
- the scuttle panel partition.
Remove:
102267

Timing belt ),
11A-191
Remove:
- the alternator upper mounting bolt (26) ,
- the alternator lower mounting bolt (27) ,

11A
K9K, and 732
112815
19710
Remove:
- the inner timing cover mounting bolts (6) ,
- the inner timing cover.
102473
Disconnect the air inlet pressure sensor connector

(7) .
Loosen the clips (8) and (9) .
19626

11A-192

11A
K9K, and 732
112811
112992
Unclip the injection rail protector cover (14) .
Pull out the clip.
Remove:
- the injection rail protector cover,
- the injection rail protector cover mounting bolt and
mounting nut (15) ,
- the dipstick,
- the dipstick guide tube mounting bolts (16) .
Remove the dipstick guide tube.
112991
Make a mark (11) on the air inlet duct between the

stainless steel pipe and the hose using an indelible
pen.
Detach the hose from the stainless steel pipe.
Remove:
- the mounting bolt (12) from the stainless steel pipe,
- the stainless steel pipe (13) .
112993
Disconnect:
11A-193

11A
K9K, and 732

112656
112994
Disconnect:
Clean the fuel return and supply pipe unions (see

13A, Diesel injection, Repair precautions ).
- the connector (19) from the damper valve,

- the cylinder reference sensor connector (20) ,
WARNING
- the pressure regulation solenoid valve connector

(21) ,
Do not blast compressed air once the fuel circuit

is open, otherwise impurities may enter the system. Use wipes if necessary.
- the flow regulation solenoid valve connector (22) ,

- the diesel temperature sensor connector (23) ,
Note:
- the rail pressure sensor connector.
Make preparations for fuel outflow. Clean with

new wipes.
Unclip the wiring harness retaining clip (24) .

Remove the wiring harness clip mounting nut (25) .
Disconnect:
Remove the wiring harness.
Tilt the alternator against the radiator assembly.

Fit plugs.
11A-194

11A
K9K, and 732
112996
Disconnect the oil vapour rebreathing pipe on the

rocker cover side (31) .
113475
Remove:
- the retaining bracket mounting bolts from the exhaust gas recirculation cooler,
- the bracket from the exhaust gas recirculation cooler.
112997
Disconnect:
- the exhaust gas recirculation solenoid valve connector,
- the scuttle panel hoses (33) using the (Mot. 120201) or (Mot. 1202-02) or (Mot. 1448) ,
111748
Remove the injection rail protector cover support

mounting bolt and mounting nuts (30) .
Unclip the drain pipe from the injection rail protector
cover support.
Remove:
- the brake servo vacuum pipe (34) on the vacuum

pump side,
- the temperature sensor connector from the scuttle
panel,
- the radiator top hose from the cylinder head outlet
water unit (35) using the (Mot. 1202-01) or (Mot.
1202-02) or (Mot. 1448) ,
- the injection rail protector cover support,
- the turbocharging pressure regulation solenoid valve hose on the vacuum pump side,
- the damper valve (see 12A, Damper valve: Removal - Refitting .
- the turbocharging pressure regulation solenoid valve hose on the pressure regulation valve side.
11A-195

11A
K9K, and 732
REFITTING
I - CLEANING
IMPORTANT
Wear goggles.
Clean the gasket faces with DECAPJOINT to dissolve any parts of the seal still attached.
Apply the product to the part to be cleaned. Wait approximately ten minutes, then remove the residue
113476
Remove:
WARNING
- the rocker cover mounting bolts (36) ,
Please make sure, during this operation, that no

foreign bodies enter the oil pipes (pipes in both
the cylinder block and the cylinder head).
- the rocker cover.

CONCERNED
WARNING
Protect the oil duct to prevent any foreign bodies
from entering the cylinder head oil supply pipes.
Failure to follow this procedure could lead to the
oil supply pipes becoming blocked, quickly
damaging the camshaft.

gauge.
19712
Remove:
- the cylinder head mounting bolts (37) ,
WARNING
- the cylinder head using a hydraulic crane fitted

with a load positioner .

For the cylinder head stripping procedure see Technical Note 6006A, 4-cylinder cast iron High Pressure Common Rail Diesel Engine, 10A, Engine
and peripherals, Rebuilding the cylinder head . .
11A-196

11A
K9K, and 732

III - REFITTING OPERATION FOR PART
CONCERNED
WARNING
the cylinder head.
Fit the new cylinder head gasket, centred by two
dowels.
Refit the cylinder head using the hydraulic crane fitted with the load positioner .
of engine, Tightening the cylinder head ) using
113476
IV - FINAL OPERATION
Tighten to torque and in order the rocker cover

Fit the new rocker cover gasket.
Connect:
- the turbocharging pressure regulation solenoid valve hose on the pressure regulation valve side.
- the turbocharging pressure regulation solenoid valve hose on the vacuum pump side,
- the radiator top hose from the cylinder head water
outlet unit using the (Mot. 1202-01) or (Mot. 120202) or (Mot. 1448) ,
- the temperature sensor connector to the scuttle panel,
- the brake servo vacuum pipe on the vacuum pump
side,
19712-1
- the scuttle panel hoses using the (Mot. 1202-01) or

(Mot. 1202-02) or (Mot. 1448) ,
WARNING
Refit:

- the air inlet duct between the air filter unit outlet
and the turbocharger inlet,
- the oil vapour rebreathing pipe;
WARNING
components (engine, radiator, etc.)
Apply beads (38) of SILICONE ADHESIVE SEAL 2
mm in diameter.
11A-197
- the damper valve (see 12A, Damper valve: Removal - Refitting ).

- the injection rail protector cover support,
- the injection rail protector cover support mounting
bolt and mounting nuts.
Clip the drain pipe onto the injection rail protector cover support.

11A
K9K, and 732

Refit:
Connect:
- the injection rail protector cover mounting bracket,
- the air pressure sensor,
- the injection rail protector cover retaining bracket

mounting bolts,
- the exhaust gas recirculation solenoid valve connector.
Remove the blanking plugs.
Fit the (Mot. 1453) with the (Mot. 1453-01) .
Connect:
Refit:
- the inner timing cover,
Torque tighten the alternator mounting bolts ( 21

Nm ) .
- the alternator upper mounting bolt,
Connect:
- the alternator lower mounting bolt,

- the turbocharger oil return pipe.
- the rail pressure sensor connector,

- the diesel fuel temperature sensor connector.

( 9 Nm ) .
- the flow regulation solenoid valve connector,
Refit:
- the pressure regulation solenoid valve connector,
- the catalytic converter (see 19B, Exhaust, Catalytic converter ),
- the cylinder reference sensor,

Timing belt ),
- the connector on the damper valve,

- the heater plugs connector,


Position the wiring harness.

Refit the mounting nut of the wiring harness clip.
Clip the retaining clip of the wiring harness.
- the battery,
Refit:
- the dipstick guide tube mounting bolts to the injection rail protector cover support,

- the diesel anti-splash device cover,
Reconnect the battery (see 80A, Battery, Removal

- Refitting ).
- the injection rail protector cover bolt and nuts,
Clip on the injection rail protector cover.
Refit:
- the clip to the stainless steel pipe,
- the stainless steel pipe between the intercooler
hose and the turbocharger, aligning the marks,
- the pipe between the intercooler and the damper
valve.
Tighten to torque the hose clip on the stainless
steel pipe ( 5.5 Nm )
Clip the stainless steel pipe to the turbocharger.
Refit the air duct between the damper valve and the
intercooler
Tighten the clips.
11A-198

11A
K4J, and 730 or 732 K4M, and 760 or 761

CYLINDER HEAD TIGHTENING PROCEDURE
Tightening torquesm
cylinder head mounting bolts
20 Nm
240 6
14500
WARNING
WARNING
Reuse the bolts if the length under the head

does not exceed 117.7 mm (otherwise replace
all the bolts with new ones).

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.
Tighten to torque and in order the cylinder head

Check that all of the cylinder head mounting bolts
are tightened to the correct torque of 20 Nm .
Angle-tighten in order the cylinder head mounting
bolts ( 240 6 ) .
WARNING
Do not retighten the cylinder head bolts after
applying this procedure.
11A-199

K9K, and 722 or 728 or 729
Tightening torquesm
25 Nm
255 10
10
19712
WARNING
WARNING
Always replace all of the cylinder head bolts with
new ones after removal.
tightened, use a syringe to remove any oil that
Do not oil the new bolts.
are tightened to the correct torque (25 Nm) .
bolts ( 255 10 ) .
WARNING
11A-200
11A

11A
F9Q, and 800 or 804 or 808

Tightening torquesm
30 Nm
230 +/- 6
10
16189
WARNING
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.
bolts ( 230 +/- 6 ) .
WARNING
11A-201

11A
F4R, and 770 or 771 or 776

Tightening torquesm
20 Nm
100 6
100 6
9
5
10
1
6
4
2
8
3
7
15153

WARNING
tightened, use a syringe to remove any oil that
WARNING
11A-202
Check that all of the cylinder head bolts are tightened to the correct torque (20 Nm) .
Step 1
bolts ( 100 6 )

F4R, and 770 or 771 or 776
Step 2
bolts ( 100 6 )
WARNING
11A-203
11A

11A
K9K, and 732

Equipment required
low torque wrench
Tightening torquesm
25 Nm
255 10
19712
WARNING
WARNING
tightened, use a syringe to remove any oil which
mounting bolts ( 25 Nm ) with the low torque
wrench .
bolts ( 255 10 ) using the angular tightening
wrench .
WARNING
11A-204

Cylinder head: Removal - Refitting
M9R, and 700
REMOVAL
Removing the cylinder head requires the engine and
gearbox assembly to be removed (see 10A, Engine
and peripherals, Engine and gearbox assembly:
To remove the cylinder head (see Technical Note
6017A, M9R Diesel engine ).
REFITTING
To refit the cylinder head (see Technical Note
6017A, M9R Diesel engine ).
Refit the engine and gearbox assembly (see 10A,
Engine and peripherals, Engine and gearbox assembly: Removal - Refitting ).
11A-205
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)
Cubic
capacity
Compression
ratio
(cc)
ND0
770
XM0U
9.8/1
DP0
XN0W
F4R
ND0
771
82.7
93
1,998
9.5 0.3
776
Test carried out at idle speed(1)
Fuel (2)
Engine
emissions(3)
Pollutant
Type
Suffix
Idling
speed
CO (%)(4)
CO2 (%)
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 2,500 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
2,000 rpm CO should be a maximum of 0.3 %
rating 91 unleaded compatible
Temperatures in C 1
- 10
25
50
80
110
120
Negative temperature coefficient air temperature sensor (resistance in )
10,454
to 8,623
2,174 to
1,928
857 to
763
326 to
292
143
127
112 to
98
Negative temperature coefficient coolant

temperature sensor (resistance in )
13,588
t o 11,
332
2,364 to
2,140
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 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils
SAGEM
Four coils
Primary resistance: tracks 1 and 2 approximately 0.5
Secondary resistance: track 1 and high voltage output: 10.5 +/- 1.5 k
2-track connector:
- 1: + 12 V supply
- 2: earth control
Ignition coils
BERU (F4R 776) only
Four coils
2-track connector:
- 1: + 12 V supply
- 2: earth control
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
(F4R 776) 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 each time it is removed.
3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Manifold pressure sensor

BOSCH (F4R 776) only

3-track connector:
- 1: + 5 V supply
- 2: earth
- 3: signal
Injection order
1-3-4-2
no. 1 flywheel end
Fault finding
diagnostic tool
CLIP only
Accelerator pedal potentiometer
CTS
Dual gang potentiometer

Resistance values:
- circuit 1: tracks 3 and 5: 1,700 900
- gang 2: tracks 2 and 6: 2,850 2,050
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 850C .
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
SAGEM
Resistance: 26 4 to 23C
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
3-track connector:
INSTRUMENTS
- A: earth
- B: + 5 V supply
- C: signal
12A-4
FUEL MIXTURE
Specifications
12A
F4R, and 770 or 771 or 776

Description
Brand-Type
Special notes
VDO EGAS 5
Direct current geared electric motor.
Diameter 60 mm (F4R
770 and 771)
6-track connector:
- 1: potentiometer gang no. 1 signal
- 2: 5 V potentiometer supply
- 3: + motor
- 5: - motor
- 6: common earth
Engine resistance: approximately 2.3 at 23C
Potentiometer resistance:
tracks 2 and 6: 1000 250
Throttle valve
VDO EGAS - T
Direct current geared electric motor.
Diameter 40 mm (F4R
776) only
6-track connector:
- 1: earth
- 3: + motor
- 4: - motor
Engine resistance: approximately 1.57 to 23C
Potentiometer resistance:
tracks 1 and 5: 1,000 250
Camshaft dephaser solenoid

valve
AISIN (F4R 770 and

771)
It is controlled by the opening cyclic ratio.

Resistance: 7.2 0.5 to 20C
2-track connector:
- 1: + 12 V supply
- 2: earth
Spark plug
CHAMPION
Single electrode spark plugs
RC 87 YCL (F4R 770

and 771
Gap: 0.90 0.05 mm

Torque: 25 to 30 Nm
NGK PFR6G - 9
(F4R 776) only
Gap: 0.900 --0.1mm

Torque: 25 to 30 Nm
Catalytic converter
EBERSPCHER
C175
12A-5
FUEL MIXTURE
Specifications
12A
K4J, and 730 or 732 K4M, and 760 or 761
Equipment required
diagnostic tool
Engine
Gear-
Vehicle
Type
Suffix
box
Bore
Stroke
(mm)
(mm)
Cubic
capacity
Compression
ratio
(cc)
730
XM0B
JH3
K4J
79.5
70
1390
732
10 / 1
JH3
XM0C
760
K4M
DP0
79.5
80.5
1,598
761
Test carried out at idle speed(1)
Fuel (2)
Engine
Pollutant emissions(3)
Type
Suffix
Idling
speed
CO (%)(4)
CO2 (%)
HC (ppm)
(minimum
Lambda ()
octane
rating)
(rpm)
K4J
K4M
730
732
760
761
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 2,500 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
2,000 rpm CO should be a maximum of 0.3 %
rating 91 unleaded compatible
Temperatures in C 1
- 10
25
50
80
110
120
Negative temperature coefficient air temperature sensor (resistance in )
10,454
to 8,623
2,174 to
1,928
857 to
763
326 to
292
143
127
112 to
98
Negative temperature coefficient coolant

temperature sensor (resistance in )
13,588
t o 11,
332
2,364 to
2,140
850 to
772
290 to
275
117 to
111
90 to 86
12A-6
FUEL MIXTURE
Specifications
12A
K4J, and 730 or 732 K4M, and 760 or 761
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 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils
SAGEM
Four coils
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors
SIEMENS - DEKA 4

Resistance: 14.5 +/- 0.7 at 20C
2-track connector:
- 1: + 12 V supply
- 2: earth control
SIEMENS - MAP03

3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Injection order
1-3-4-2
no. 1 flywheel end
Fault finding
diagnostic tool
CLIP only
12A-7
FUEL MIXTURE
Specifications
12A
K4J, and 730 or 732 K4M, and 760 or 761

Description
Brand -Type
Special notes
CTS

Resistance values:
- gang 1: tracks 3 and 5: 1,700 900
- gang 2: tracks 2 and 6: 3,875 1,025
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

Resistance: 200 to 270 at 23C
Upstream and downstream

oxygen sensors
BOSCH - LSF 4.2
The sensor heating is interrupted when the exhaust

gas temperature rises above 850C .
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
SAGEM
Resistance: 26 4 to 23C
2-track connector:
- 1: + 12 V supply
- 2: earth control
JAEGER
12A-8
FUEL MIXTURE
Specifications
12A
K4J, and 730 or 732 K4M, and 760 or 761

Description
Brand -Type
Special notes
JAEGER ELTH
or SILEA
Refrigerant sensor
TEXAS
3-track connector:
INSTRUMENTS
- A: earth
- B: + 5 V supply
- C: signal
K4J
Description
Brand-Type
Special notes
Throttle valve
VDO EGAS T
6-way connector
60 mm diameter
- 1: common earth
- 3: - motor
- 4: + motor
Engine resistance: approximately 1.6 to 23C
Potentiometer resistance; tracks 1 and 5: 1,000 250
K4M
Description
Brand-Type
Special notes
Throttle valve
VDO EGAS 5
Direct current geared electronic motor
57 mm diameter
6-way connector
- 3: + motor
- 5: - motor
- 6: common earth
Potentiometer resistance; tracks 2 and 6: 1,000 250
12A-9
FUEL MIXTURE
Specifications
12A
K4J, and 730 or 732 K4M, and 760 or 761
K4M
Description
Brand-Type
Special notes
Camshaft dephaser solenoid valve
DELPHI
It is controlled by the opening cyclic ratio.

Resistance: 7.2 0.5 to 20C
2-track connector:
- 1: + 12 V supply
- 2: earth
Camshaft position sensor
SAGEM
Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: + 12 V supply
Description
Brand-Type
Special notes
Spark plug
EYQUEM RFN 58 LZ
or CHAMPION RC 87 YCL
Gap: 0.95 0.05 mm

Torque: 25 to 30 Nm
Catalytic converter
EBERSPCHER
C150
12A-10
FUEL MIXTURE
Air inlet
12A
K4J, and 730 or 732

Diagram of the air inlet circuit
102071
(1)
Air inlet sleeve
(2)
Air resonator
(3)
Air filter unit
(4)
Air unit
(5)
Throttle valve
(6)
Inlet manifold
(7)
Injector holder plate
(8)
Air inlet
12A-11
FUEL MIXTURE
Air inlet
12A
K4M, and 760 or 761

Diagram of the air intake circuit
6
2
3
7
2
101190
(1)
Air intake sleeve
(2)
Air resonators
(3)
Air filter unit
(4)
Throttle valve
(5)
Inlet manifold
(6)
Injector holder shim
(7)
Air inlet
12A-12
FUEL MIXTURE
Air inlet
12A
K9K, and 722

Diagram of the air intake circuit
2
8
1
102070
(1)
Air intake sleeve
(2)
Air filter unit
(3)
Exhaust gas recirculation unit
(4)
Air resonator
(5)
Metal air intake tube
(6)
Intercooler
(7)
Turbocharger
(8)
Air inlet
12A-13
FUEL MIXTURE
Air inlet
12A
F9Q, and 800

Air intake circuit diagram
1
7
2
102482
(1)
Air inlet
(2)
Air filter
(3)
Flowmeter
(4)
Turbocharger
(5)
Inlet manifold
(6)
Engine shut-off flap
(7)
Air-to-air intercooler
12A-14
FUEL MIXTURE
Air inlet
12A
F4R, and 770 or 771

Air intake circuit diagram
4
5
6
3
2
7
2
102744
(1)
Air intake trunking
(2)
Resonators
(3)
Air filter unit
(4)
Throttle body
(5)
Intake manifold
(6)
Injector mounting plate
(7)
Air intake
12A-15
FUEL MIXTURE
Air inlet
12A
F4R, and 776
4
6
2
5
1
107841
(1)
Air intake
(2)
Air resonator
(3)
Air filter unit
(4)
Turbocharger
(5)
Intercooler
(6)
Inlet manifold
12A-16
FUEL MIXTURE
Air inlet
12A
K9K, and 728 or 729
8
2
1
6
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-17
FUEL MIXTURE
Air inlet
12A
F9Q, and 804

112269
(1)
Air inlet
(2)
Air filter unit
(3)
Flowmeter
(4)
Turbocharger
(5)
Inlet manifold
(6)
Throttle valve
(7)
Intercooler
(8)
Air filter
(9)
EGR unit
12A-18
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-19
FUEL MIXTURE
Air inlet
12A
F9Q, and 808

114617
(1)
Air inlet
(2)
Air filter
(3)
Flowmeter
(4)
Turbocharger
(5)
Inlet manifold
(6)
Engine stop flap
(7)
Intercooler
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

CONCERNED
I - OPERATION FOR REMOVAL OF PART

CONCERNED
Remove the front bumper (see MR 365, Bodywork,
55A, Exterior protection, Front bumper ).
114659
Remove the air resonator (3) starting with the end

piece side of the duct that is upstream of the air filter.
115726
REFITTING
CONCERNED
Refit the air resonator starting with the end piece
side of the duct that is upstream of the air filter.
Refit the left-hand headlight.
Tighten:
115725
Remove:
- the left-hand headlight upper mounting bolt,

- the left-hand headlight lower mounting bolt.
- the left-hand headlight upper mounting bolt (1) ,
Disconnect the left-hand headlight connectors.
- the left-hand headlight lower mounting bolt (2) .
Refit the front bumper (see MR 365, Bodywork,

55A, Exterior protection, Front bumper ).
Disconnect the left-hand headlight connectors.

Remove the left-hand headlight.
12A-22
FUEL MIXTURE
12A
K4J, and 730 or 732

REPLACING THE FILTER ELEMENT
2
1
101104
101103
Remove:
Disconnect brake servo vacuum pipe (2) from the inlet manifold.

WARNING
- the air resonator housing.
Do not damage the vacuum outlet on the inlet

manifold. If it is broken the inlet manifold will
need to be replaced.
Remove:
- the two air filter cover mounting bolts (3) ,
- the filter element.
12A-23
FUEL MIXTURE
12A
F4R, and 770 or 771 or 776 F9Q, and 800 or 804 or 808 K4M, and 760 or 761 K9K, and 722 or 728 or 729 or
732
Tightening torquesm

bolts
4 Nm
REPLACING THE FILTER ELEMENT
106276
1
Remove:
- the cover (2) ,
.
106277
REFITTING
Remove the mounting bolts (1) from the air filter cover.
12A-24

( 4 Nm ) .
FUEL MIXTURE
Air filter: Removal - Refitting
12A
F4R or F9Q or K4M or K9K or M9R
REMOVAL
REFITTING

CONCERNED
Clean the air filter unit.
Refit:
- the air filter,
- the cover.
Tighten the air filter unit mounting bolts.
106277
Remove the mounting bolts (1) from the air filter cover.
CONCERNED
106276
Remove:
- the cover (2) ,
- the air filter.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting
12A
K4J, and 730 or 732

Ele. 1294-01
Windscreen wiper arm

removing tool
Tightening torquesm
air filter unit mounting
bolts
9 Nm

bolts
4 Nm
REMOVAL
terminal.
102101
Unclip the trim (3) .
2
1
102100
Remove:
102105
- the seal (1) ,
Remove wiper arms (4) using tool (Ele. 1294-01) .
- the plastic rivets (2) .
Remove the scuttle panel grille.
12A-26
FUEL MIXTURE
12A
K4J, and 730 or 732
5
5
101487
Remove:
101104
Disconnect brake servo vacuum pipe (7) from the inlet manifold.
- the bulkhead soundproofing mountings (5) ,

- the bulkhead soundproofing material.
WARNING
manifold. If it is damaged, the inlet manifold will
Remove:
- air filter cover mounting bolts (8) ,
101103
Remove:
- the air resonator.
12A-27
FUEL MIXTURE
12A
K4J, and 730 or 732
REFITTING
Replace:
- the throttle valve seal each time it is removed using
grease to make fitting easier,
- the plastic rivets and clips every time they are removed.

Torque tighten the air filter unit mounting bolts ( 9
Nm ) .
10
WARNING
Battery: Removal - refitting ).
101494
Disconnect the oxygen sensor connector. (9)

Remove the retaining bracket (10) .
11
101488
Remove:
- air filter mounting bolts (11) ,
- the air filter unit.
12A-28
Torque tighten the battery cover mounting bolts (

4 Nm ) .
FUEL MIXTURE
12A
M9R, and 700

Mot. 1608
Torque screwdriver
Tightening torquesm
air flowmeter mounting
bolts
4 Nm
air duct clip mounting

bolt between the air filter unit and the turbocharger
5.5 Nm

mounting bolts
44 Nm

mounting bolts
21 Nm
battery tray mounting

bolts
21 Nm
wiring harness mounting nut
8 Nm
112658
Remove:
bolts (1) ,
REMOVAL
Remove
102504

Unpick the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) .
12A-29
FUEL MIXTURE
12A
M9R, and 700
112659
Disconnect the injection computer connectors (6) .
104555
Move the turbocharger regulation solenoid valve

(10) to one side.
Remove:
Remove the air duct between the air filter unit and
the turbocharger.

- the wiring harness mounting nut (8) .
Unpick the battery negative terminal wiring harness
(9) .
Remove the battery tray and the injection computer.
114933
12A-30
FUEL MIXTURE
12A
M9R, and 700

CONCERNED
102365
Remove:
- the lower front end panel mounting bolts (12) .
115019
114659
Remove the air resonator (13) .
115020
Remove the air filter unit (15)
12A-31
FUEL MIXTURE
12A
M9R, and 700

Refit:
- the front end panel clips,
Tighten to torque:
- the air duct clip mounting bolt between the air
filter unit and the turbocharger ( 5.5 Nm ) ,
Nm ) ,
114993

Nm ) .
Remove
Clip on:
- the air flowmeter mounting bolts (16) ,
- the air inlet scoop to the front end panel,
- the air flowmeter (17) .
- the bonnet opening cable
REFITTING
Fit the turbocharger regulation solenoid valve onto

the air filter unit.

CONCERNED
Refit the battery tray and the computer.

Tighten to torque the battery tray mounting bolts (
21 Nm ) .
Refit the air flowmeter onto the air filter unit.

Tighten to torque the air flowmeter mounting bolts
( 4 Nm ) using the (Mot. 1608) .
Refit the wiring harness mounting nut.
Refit the air filter unit.
Tighten to torque the wiring harness mounting nut

( 8 Nm ) .
Connect:
- the injection computer connectors,
- the air flowmeter connector,
- the connectors to the Protection and Switching Unit
box.
Refit:
12A-32
FUEL MIXTURE
12A
K4M, and 760 or 761 F4R, and 770 or 771 or 776
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove the battery (see 80A, Battery: Removal Refitting ).
101811
Remove the injection computer (4) and its mounting.
2
1
101822

Remove:
101737
- the wiring harness strap (3) .

Remove:
Unclip the wiring harnesses from the battery tray.
- the air inlet sleeve (5) ,
- the air ducts (6) ,

12A-33
FUEL MIXTURE
K4M, and 760 or 761 F4R, and 770 or 771 or 776
REFITTING
21 Nm ) .
WARNING
( 4 Nm ) .
12A-34
12A
FUEL MIXTURE
12A
K9K, and 722 or 728 or 729
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
101811
101822

Remove:
101737
Remove:

12A-35
FUEL MIXTURE
K9K, and 722 or 728 or 729
REFITTING
21 Nm ) .
WARNING
( 4 Nm ) .
12A-36
12A
FUEL MIXTURE
12A
F9Q, and 800 or 804 or 808 K9K, and 732
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
101811
101822

Remove:
101737
Remove:

12A-37
FUEL MIXTURE
F9Q, and 800 or 804 or 808 K9K, and 732
REFITTING
21 Nm ) .
WARNING
( 4 Nm ) .
12A-38
12A
FUEL MIXTURE
Air flowmeter: Removal - Refitting
12A
M9R, and 700

Mot. 1608
Torque screwdriver
Tightening torquesm
air flowmeter mounting
bolts on the air filter unit
4 Nm
air inlet duct clip on the

air filter unit side
5.5 Nm

turbocharger side
5.5 Nm
REMOVAL
114990
Loosen:

- the air inlet duct clip (3) on the air filter unit side,
- the air inlet duct clip on the turbocharger side.
Remove the turbocharger - air filter unit duct.
CONCERNED
114846
Unclip:
- the turbocharger regulation solenoid valve hose (1)
from the turbocharger - air filter unit air inlet duct,
- the oil vapour rebreathing duct (2) from the turbocharger - air filter unit air inlet duct.
Unpick the turbocharger regulation solenoid valve
on the air filter unit.
114993
Disconnect the air flowmeter connector.
Remove:
Move the turbocharger regulation solenoid valve

and air flowmeter connector aside.
12A-39
- the air flowmeter mounting bolts (4) from the air filter unit,
FUEL MIXTURE
Air flowmeter: Removal - Refitting
M9R, and 700
- the air flowmeter (5) .
REFITTING
CONCERNED
Refit:
- the air flowmeter,
- the bolts securing the air flowmeter.
Note:
Be sure not to damage the air flowmeter seal.
Replace the seal if necessary.
Tighten to torque the air flowmeter mounting bolts
on the air filter unit ( 4 Nm ) using the (Mot. 1608) .
Refit the air filter unit - turbocharger air inlet duct.
Tighten to torque:
- the air inlet duct clip on the air filter unit side (
5.5 Nm ) ,
- the air inlet duct clip on the turbocharger side (
5.5 Nm ) .
Clip:
- the oil vapour rebreathing duct onto the air filter unit
- turbocharger air inlet duct,
- the turbocharger regulation solenoid valve hose
onto the air filter unit - turbocharger air inlet duct,
Refit the turbocharger regulation solenoid valve onto
the air filter unit.
Connect:
12A-40
12A
FUEL MIXTURE
Air inlet flap: Removal - Refitting
12A
K9K, and 732

CONCERNED
Tightening torquesm
damper flap mounting
nuts
12 Nm
REMOVAL
112810
Disconnect:
- the connector (4) from the damper flap,
- the vacuum pipe from the brake servo.
Remove:
- the damper flap mounting nuts (5) ,
- the damper flap,
- the damper flap seal.
112815

(1) .
Loosen the clip and (2) and move the air inlet duct
(3) to one side.
REFITTING
CONCERNED
Refit:
- the damper flap with a new seal,
- the damper flap mounting nuts.
Tighten to torque the damper flap mounting nuts (
12 Nm ) .
Connect:
- the vacuum pipe from the brake servo,
- the connector to the damper flap.
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
12A-41
FUEL MIXTURE
K9K, and 732
12A-42
12A
FUEL MIXTURE
12A
F9Q, and 804
REFITTING
Tightening torquesm
damper flap mounting
bolts
8 Nm

bolts
4 Nm
Replace the seal.

Tighten to torque the damper flap mounting bolts
( 8 Nm ) .
REMOVAL
WARNING

terminal.
111887
Loosen the air inlet hose clip (1) .

Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the connector (2) from the damper flap,
- the turbocharging pressure sensor connector (3) .
Remove the damper flap.
12A-43

( 4 Nm ) .
FUEL MIXTURE
12A
M9R, and 700
Tightening torquesm
damper flap retaining
strut mounting bolts on
the inlet manifold
12 Nm
damper flap retaining

strut mounting bolts on
the exhaust gas recirculation solenoid valve
12 Nm
downstream intercooler duct clip on the intercooler
5.5 Nm
downstream intercooler duct clip on the damper flap
5.5 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm
Remove:

bolts
21 Nm

bolts (1) ,
wiring harness mounting nut on the battery

tray
8 Nm
112658
REMOVAL
Remove:
115585
Disconnect the Protection and Switching Unit connectors (2) .

Remove:
- the clips (4) ,
- the upper front end panel mounting bolts (5) ,
Disconnect the screen washer pipes.
12A-44
FUEL MIXTURE
12A
M9R, and 700
112659
115701
Disconnect the turbocharger pressure sensor connector (11) .

Remove:
Remove the turbocharger pressure sensor mounting

nut (12) on the damper flap strut.

Unpick the battery negative terminal wiring harness
(9) .
102365
Remove:
- the lower front end panel mounting bolts (13) .
114933
12A-45
FUEL MIXTURE
12A
M9R, and 700

CONCERNED
114649
114406
Disconnect the damper flap connector (17) .

Remove:
- the mounting bolts (18) from the damper flap retaining strut on the inlet manifold,
- the mounting bolts (19) from the damper flap retaining strut on the exhaust gas recirculation solenoid
valve,
- the damper flap,
- the seal between the damper flap and the exhaust
gas recirculation solenoid valve
REFITTING
115702
Remove the mounting bolt (14) from the intercooler

duct (downstream) on the cooling radiator.
Loosen:
- the downstream intercooler duct clip (15) on the intercooler,
- the downstream intercooler duct clip (16) on the
damper flap.
Remove the downstream intercooler duct.
12A-46
Replace the seal between the damper flap and the

exhaust gas recirculation solenoid valve.
FUEL MIXTURE
M9R, and 700
CONCERNED
Finger tighten until contact:
- the damper flap retaining strut mounting bolts on
the inlet manifold,
- the damper flap retaining strut mounting bolts on
the exhaust gas recirculation solenoid valve,
Tighten to torque:
- the damper flap retaining strut mounting bolts
on the inlet manifold ( 12 Nm ) ,
- the damper flap retaining strut mounting bolts
on the exhaust gas recirculation solenoid valve
( 12 Nm ) .
12A-47
12A
FUEL MIXTURE
12A
M9R, and 700


Refit:
- the downstream intercooler duct clip onto the intercooler and the damper flap,
- the downstream intercooler duct mounting bolt

onto the cooling radiator.
Carry out programming by following command scenario SC036 if replacing or removing - refitting the
damper flap (see MR 366 Fault finding, 13B, Fault
finding - Interpretation of commands ) and (see
MR 366 Fault finding, 13B, Fault finding - Replacement of components ).
Tighten to torque:
- the downstream intercooler duct clip on the intercooler ( 5.5 Nm ) ,
- the downstream intercooler duct clip on the
damper flap ( 5.5 Nm ) .
Refit:
- front end panel mounting bolts.
Tighten to torque:
Nm ) ,
Nm ) ,
Clip:
- the bonnet opening cable.
Refit:
- the battery tray,
- the wiring harness mounting nut onto the battery
tray.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut on the battery
tray ( 8 Nm )
Clip the battery negative terminal wiring harness.
Connect:
- the screen washer pipes,
- the Protection and Switching Unit connectors,
- the injection computer connectors.
Refit:
- the clips,
bolts,
12A-48
FUEL MIXTURE
Air inlet duct: Removal - Refitting
12A
F9Q, and 800 or 808
Tightening torquesm
inlet duct mounting
bolts
inlet duct nut
bolt
8 Nm
21 Nm
4 Nm
REMOVAL
101892
Loosen the clip (2) .

Disconnect the air inlet hose.
Separate the air inlet hose.
Disconnect the vacuum hose from the (3)
diaphragm.
1
4
101893
Disconnect:
- the battery, starting with the negative terminal,
- the turbocharging pressure sensor (1) .
101884
Remove:
- inlet duct mounting bolts (4) ,
- the air inlet duct mounting nut (5) ,
- the air inlet duct.
12A-49
FUEL MIXTURE
F9Q, and 800 or 808
REFITTING
8
7
101884
Replace the seal.

Refit the inlet duct.
Tighten to torque in order:
- the inlet duct mounting bolts ( 8 Nm ) ,
- the inlet duct nut ( 21 Nm ) .
WARNING
Torque tighten the battery cover mounting bolt ( 4
Nm ) .
12A-50
12A
FUEL MIXTURE
12A
F9Q, and 804
REFITTING
Replace the seals.
Tightening torquesm
inlet duct mounting
bolts
25 Nm
inlet duct mounting nut
21 Nm

bolts
Refit the inlet duct.

- the inlet duct mounting bolts ( 25 Nm ) ,
- the inlet duct mounting nut ( 21 Nm ) ,
4 Nm

REMOVAL
WARNING

terminal.

( 4 Nm ) .
111887
Disconnect:
- the pressure sensor connector (2) ,
- the inlet duct air duct (3) (4) ,
- the oil vapour rebreather pipe (5) :
on the oil separator,
on the turbocharger upstream air duct.
Remove:
- the inlet duct mounting bolts (6) ,
12A-51
FUEL MIXTURE
Inlet manifold: Removal - Refitting
12A
K4J, and 730 or 732
Tightening torquesm
plenum chamber mounting bolts
9 Nm
throttle valve bolts
13 Nm
air unit bolts
9 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove:
101794
unit ),
Remove:
- the plenum chamber mounting bolts,

valve ).
- the plenum chamber.
REFITTING
Always replace all of the seals.
3
101100
Disconnect:
- the manifold pressure sensor (1) ,
- the ignition coils (2) ,
- the air temperature sensor (3) .
12A-52
FUEL MIXTURE
K4J, and 730 or 732
7
5
1
2
3
101794
Tighten to torque and in order the plenum chamber

Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air unit bolts ( 9 Nm ) ,
WARNING
Battery: Removal - Refitting
( 4 Nm ) .
12A-53
12A
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 760 or 761
Tightening torquesm
inlet manifold bolts
9 Nm
motorised throttle valve

bolts
13 Nm

bolts
4 Nm
REMOVAL
4
2
1
102735
Disconnect:
- throttle valve connector (2) ,
- brake servo vacuum pipe (3) to the inlet manifold.
101807

terminal.
Remove:
Note:
manifold. If it is damaged, the inlet manifold will
Disconnect fuel vapour recirculation pipe (4) to the
throttle valve.

- air duct (1) .
12A-54
FUEL MIXTURE
12A
F4R, and 770 or 771 K4M, and 760 or 761

ON THE WORKBENCH
Remove the throttle valve.
REFITTING
Always replace all of the seals with new ones.
7
6
5
8
6
5
2
1
101795
Disconnect electrical wiring harness (5) .
Pull the electric wiring harness to one side.

Disconnect fuel inlet pipe (6) from the injector rail.
IMPORTANT
102726
Be careful of petrol splashing when disconnecting the supply pipe union from the injector rail.

bolts ( 9 Nm ) .
Unclip fuel vapour recirculation pipe (7) from the inlet manifold.
Tighten to torque the motorised throttle valve

bolts ( 13 Nm ) , tightening each bolt evenly.
WARNING
( 4 Nm ) .
102726
Remove the inlet manifold bolts.
12A-55
FUEL MIXTURE
12A
F4R, and 776
Tightening torquesm
bolts
21 Nm
motorised throttle valve

mounting bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
106633
Remove:
- motorised throttle valve mounting bolts (4) ,
- the motorised throttle valve.
1
5
106270
Remove air duct (1) .

Remove petrol vapour rebreathing pipe (2) .
Disconnect the motorised throttle valve connector.
106787
Disconnect:
- turbocharging pressure sensor connector (5) ,
- vacuum pipe (6) from the brake servo,
- oil vapour recirculation pipe (7) .
106272
Remove air pipe (3) between the turbocharger and

the intercooler.
12A-56
FUEL MIXTURE
12A
F4R, and 776
106271
106337
Disconnect:

- injection rail petrol supply pipe (8) ,
Tighten to torque the motorised throttle valve

- the injector connectors.

WARNING
WARNING
Pull the electric wiring harness to one side.

( 4 Nm ) .
106337
Remove the inlet manifold bolts.
REFITTING
WARNING
Be sure to replace all the sealing joints with new
ones when they are removed.
12A-57
FUEL MIXTURE
Injector holder shim: Removal - Refitting
12A
K4J, and 730 or 732
Tightening torquesm
injector holder shim
mounting bolts 11 and
12
25 Nm

mounting bolts 13 to 20
21 Nm
upper timing cover bolt
44 Nm
suspended mounting
bolt
44 Nm

bolts
4 Nm
3
3
101802
Disconnect:
- fuel supply union (2) ,
REMOVAL
- injectors (3) ,

terminal.
- pinking sensor (4) .
Remove the inlet manifold (see 12A, Fuel mixture,

Inlet manifold ).
IMPORTANT
WARNING
Protect the alternator against fuel spills from the
rail or supply duct.
6
101493
Remove the two injection rail bolts (5)

Pull the injection rail gently towards yourself to remove it.
Remove:
- nut (6) securing the electrical wiring harness,

- oil gauge well (7) .
101801
Remove injector rail protector mounting nuts (1) .

12A-58
FUEL MIXTURE
12A
K4J, and 730 or 732
REFITTING
10
19
20
101792
15
18 14
11
13
12
16
17
Remove the injector holder shim mounting bolts.
101792
The injector holder shim seal must always be replaced.

Insert all the mounting bolts.
Secure:
- the injector holder shim against the upper timing
cover, by tightening bolt (8) by hand,
- the injector holder shim against the engine suspended mounting by tightening bolt (9) by hand.
Position the injector mounting plate against the
cross pieces (10) on the cylinder head cover.
- injector holder shim mounting bolts 11 and 12
( 25 Nm ) ,
- injector holder shim mounting bolts 13 to 20 (
21 Nm ) .
Tighten to torque:
- the upper timing cover bolt ( 44 Nm ) ,
- the suspended mounting bolt ( 44 Nm ) .
Refit the inlet manifold (see 12A, Fuel mixture, Inlet
manifold ).
WARNING
4 Nm ) .
12A-59
FUEL MIXTURE
12A
K4M, and 760 or 761
Tightening torquesm
bolts 5 and 6 on the
25 Nm
bolts 7 to 14 on the
21 Nm
suspended mounting
bolt
44 Nm
44 Nm

bolts
4 Nm
REMOVAL
terminal.
Inlet manifold ).
101810
Disconnect injectors (1) .

Remove:
IMPORTANT
- injector rail mounting bolts (2) ,
- the injector rail, pulling it carefully towards you.
WARNING

102303
Remove injector mounting plate mounting bolts (3) .
12A-60
FUEL MIXTURE
K4M, and 760 or 761
REFITTING
4 Nm ) .
13
10
14
12
11
102303

Secure:
cover, by tightening bolt (3) by hand,
- the injector holder shim against the engine suspended mounting by tightening bolt (4) by hand.
- bolts 5 and 6 on the injector holder shim ( 25
Nm ) ,
- bolts 7 to 14 on the injector holder shim (
21 Nm ) .
Tighten to torque:
- the suspended mounting bolt ( 44 Nm ) ,
- the upper timing cover bolt ( 44 Nm ) .
manifold ).
WARNING
12A-61
12A
FUEL MIXTURE
12A
F4R, and 770 or 771
Tightening torquesm
bolts 7 and 8 of the
25 Nm
bolts 9 to 16 on the
21 Nm
suspended mounting
bolt 6
44 Nm

5
44 Nm

bolts
4 Nm
102728
Disconnect:
- fuel supply union (2) ,
REMOVAL
- injection wiring harness (3) .

terminal.
Inlet manifold ).
IMPORTANT
WARNING
102730
Remove:
- injector rail mounting bolts (4) ,
101801
Remove injector rail protector mounting nuts (1) .

12A-62
FUEL MIXTURE
12A
F4R, and 770 or 771
REFITTING
15
11
16
101792
14
10
12
13
Remove the injector holder shim mounting bolts.
101792

Secure:
cover, by tightening bolt (5) by hand
- the injector holder shim against the suspended engine mounting by tightening bolt (6) by hand.
- bolts 7 and 8 of the injector holder shim ( 25
Nm ) ,
- bolts 9 to 16 on the injector holder shim (
21 Nm ) .
Tighten to torque:
- suspended mounting bolt 6 ( 44 Nm ) ,
- upper timing cover bolt 5 ( 44 Nm ) .
manifold ).
WARNING
4 Nm ) .
12A-63
FUEL MIXTURE
Manifolds: Removal - Refitting
12A
F9Q, and 800 or 808
Tightening torquesm
Manifold mounting stud
8 Nm
manifold mounting nuts,
28 Nm
exhaust gas recirculation valve mounting bolt
8 Nm
engine cover mounting

bolts
4 Nm
REMOVAL
102478

terminal.
Remove:
Disconnect the exhaust gas recirculation solenoid

valve.
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
Remove:
- the turbocharger (See 12B, Turbocharging, Turbocharger ).
- the exhaust gas recirculation solenoid valve (6) ,

- the exhaust gas recirculation pipe (7)
- the engine lifting bracket (8)
- the manifold mounting nuts,

- the manifolds.
REFITTING
2
Replace the gaskets:

- on the manifolds,
102486
- the exhaust gas recirculation solenoid valve,
Disconnect:
- on the air inlet duct.
- the air inlet pipe from the damper (1) ,

- the engine stop solenoid valve (2) connector.
Tighten to torque:
Remove:
- the Manifold mounting stud ( 8 Nm ) ,
- the pipe mountings (3) ,
- the manifold mounting nuts, ( 28 Nm ) ,
- the vacuum canister (4) ,
- the exhaust gas recirculation valve mounting

bolt ( 8 Nm ) .
- the engine stop solenoid valve (5) .
WARNING
Tighten to torque the engine cover mounting bolts
( 4 Nm ) .
12A-64
FUEL MIXTURE
12A
F9Q, and 804
Tightening torquesm
manifold
studs
mounting
8 Nm
manifold mounting nuts
28 Nm

bolts
4 Nm
REMOVAL
terminal.
Position the vehicle on a lift.
Remove:
- the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting
).
111872
Disconnect the exhaust gas temperature before turbocharger sensor (1) .
- the exhaust gas recirculation unit (see 14A, Emission control, Exhaust gas recirculation unit ),
Remove:
- the manifold mounting nuts
- the exhaust gas recirculation pipe,

- the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting ).
- the exhaust manifold (2) .

Starter motor: Removal - Refitting ).
111873
Remove the inlet manifold (3) .
12A-65
FUEL MIXTURE
F9Q, and 804
REFITTING
Replace the manifold gaskets.
Refit the manifolds.
Tighten to torque:
- the manifold mounting studs ( 8 Nm ) ,
- the manifold mounting nuts ( 28 Nm ) ,
Refit:
- the exhaust gas recirculation solenoid valve (see
14A, Emission control, Exhaust gas recirculation unit ),
- the turbocharger (see 12B, Turbocharging, Turbocharger ).
WARNING
Refit the engine lifting bracket.
( 4 Nm ) .
12A-66
12A
FUEL MIXTURE
Exhaust manifold: Removal - Refitting
12A
M9R, and 700
Tightening torquesm
exhaust manifold studs
9 Nm
exhaust manifold
mounting nuts
30 Nm
EGR duct mounting

bolts on the EGR cooler
30 Nm
EGR duct mounting

bolts on the exhaust
manifold
30 Nm
EGR duct mounting

bolt on the cylinder
head
10 Nm
EGR duct heat shield

cylinder head
10 Nm
EGR duct heat shield

exhaust manifold
10 Nm
lower mounting bolts of

the front end panel
44 Nm
- the turbocharger regulation solenoid valve connector.
upper mounting bolts of

the front end panel
21 Nm
Unclip:
air inlet duct clip
5.5 Nm
- the injection computer connector wiring harness,

bolts
21 Nm
- the turbocharger regulation solenoid valve wiring

harness.
112659
Disconnect:
- the injection computer connectors (1) ,
- the battery negative terminal wiring harness (2) ,
Remove:
IMPORTANT
Unpick the wiring harness from the injection computer connectors.
REMOVAL
Remove the battery tray with the injection computer

mounting.

Remove:
12A-67
FUEL MIXTURE
12A
M9R, and 700
114990
Loosen the air inlet duct clip (5) on the air flowmeter
side.
Remove:
112658
Remove:
bolts (7) ,
- the air inlet duct on the air flowmeter side,

102504

114933
Remove:

- the clips (10) ,
- the upper mounting bolts (11) .
12A-68
FUEL MIXTURE
12A
M9R, and 700

- the EGR duct heat shield mounting bolt (14) on the
cylinder head,
- the EGR duct mounting bolts (15) on the cylinder
head.
Move the EGR duct heat shield to one side.
102365
Remove:
113311
Remove the EGR duct mounting bolts (16) on the

EGR cooler.
113280
113281
Remove the EGR duct mounting bolts (17) on the

exhaust manifold.
Move the EGR duct to one side.
Remove:
113295
Remove:
- the gasket between the EGR cooler and the EGR

duct,
- the EGR duct heat shield mounting bolt (13) on the

exhaust manifold,
- the gasket between the EGR duct and the exhaust

manifold.
12A-69
FUEL MIXTURE
12A
M9R, and 700

CONCERNED
113279
113279
Remove:
Note:
- the exhaust manifold mounting nuts,
Check that the manifold gasket is positioned correctly.
- the exhaust manifold spacers,
The tab must be positioned as (18) .
- the exhaust manifold,
Refit the new seal on the exhaust manifold.
- the exhaust manifold gasket.
REFITTING

CONCERNED
Refit:
Clean and degrease the bearing faces:
- the exhaust manifold in case of reuse,
- the spacers.
- the cylinder head face,
Finger tighten the new mounting nuts until they are

in contact with the exhaust manifold.
- the EGR duct,

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 ) .
113279
Tighten to torque and in order the exhaust manifold

mounting nuts (18 Nm) .
mounting nuts ( 30 Nm ) .
12A-70
FUEL MIXTURE
12A
M9R, and 700

Connect the Protection and Switching Unit connectors.

Refit:
- the new gasket between the EGR duct and the exhaust manifold,
- the new gasket between the EGR cooler and the
EGR duct.
Finger tighten until contact:
- the EGR duct mounting bolts on the exhaust manifold,
Refit:
- the Protection and Switching Unit cover,
bolts,
- the EGR duct mounting bolts on the EGR cooler,
- the air inlet duct to the air flowmeter,
- the EGR duct mounting bolts on the cylinder head.
- the air inlet duct clip on the air flowmeter side.
Tighten to torque:
Tighten to torque the air inlet duct clip ( 5.5 Nm ) .
- the EGR duct mounting bolts on the EGR cooler

( 30 Nm ) ,
- the EGR duct mounting bolts on the exhaust
manifold ( 30 Nm ) ,
Refit the battery tray with the injection computer

mounting.
Fit the computer connector wiring harness.
- the EGR duct mounting bolt on the cylinder

head ( 10 Nm ) .
Refit:
Fit the heat shield.
- the wiring harness mounting nut,
Refit:
- the battery tray mounting bolts.
- the EGR duct heat shield mounting bolt to the cylinder head,

21 Nm ) .
- the EGR duct heat shield mounting bolt to the exhaust manifold.
Fit:
Tighten to torque:
- the turbocharger regulation solenoid valve wiring

harness,
- the EGR duct heat shield mounting bolt on the

cylinder head ( 10 Nm ) ,
- the EGR duct heat shield mounting bolt on the
exhaust manifold ( 10 Nm ) .
Refit:
- the battery negative terminal connector wiring harness,

- the injection computer connector wiring harness.
Connect:

- the turbocharger regulation solenoid valve connector,
- the upper mounting bolts of the front end panel,

Tighten to torque:
- the lower mounting bolts of the front end panel
( 44 Nm ) ,
- the upper mounting bolts of the front end panel
( 21 Nm ) .

Refit:

Refit the clips.
Fit the bonnet opening cable.
12A-71
FUEL MIXTURE
K9K, and 722 or 728 or 729
- the exhaust gas recirculation unit,
- the manifold mounting nuts (5) ,

Mot. 1567
Remote operation
pliers for EGR clips
- the manifold.
Tightening torquesm
exhaust manifold studs
9 Nm
exhaust manifold
mounting nuts
26 Nm
exhaust gas recirculation unit mounting bolts
21 Nm
air inlet metal tube

mounting bolts
21 Nm
lifting eye
21 Nm

bolts
4 Nm
REMOVAL
Put the vehicle on a two-post lift.
terminal.
4
5
3
1
5
102074
Remove:
- the lifting eye (2) ,
- the air inlet metal tube (3) ,
- the turbocharger (see 12B, Turbocharging, Turbocharger ),
- the exhaust gas recirculation metal tube (1) ,
- the exhaust gas recirculation unit mounting bolts
(4) ,
12A-72
12A
FUEL MIXTURE
12A
K9K, and 722 or 728 or 729
REFITTING
8
4
2
3
1
5
20848-1
Replace the manifold gasket.

Tighten to torque the exhaust manifold studs ( 9
Nm ) .
Refit the manifold.
Refit the turbocharger (see 12B, Turbocharging,

Turbocharger ).

WARNING
Fit:

- the exhaust gas recirculation unit,

( 4 Nm ) .
- the new exhaust gas recirculation unit tube,

- the new clips on the new exhaust gas recirculation
unit tube.
Tighten the new clips using the (Mot. 1567) .
Tighten to torque:
- the exhaust gas recirculation unit mounting
bolts ( 21 Nm ) ,
- the air inlet metal tube mounting bolts ( 21 Nm )
,
- the lifting eye ( 21 Nm ) .
12A-73
FUEL MIXTURE
12A
K4J, and 730 or 732 K4M, and 760 or 761

Mot. 1495-01
22 mm socket for
Tightening torquesm
manifold nuts.
23 3 Nm
heat shield bolts
10 Nm
oxygen sensors
45 Nm
mounting bolts for the

exhaust pipe brackets to
the body
21 Nm
bolt on the inlet manifold strut
8 Nm
101501
exhaust bracket nuts
20 Nm
Disconnect downstream oxygen sensor (1) .

bolts
4 Nm
REMOVAL
terminal.
K4J
Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit ).
3
2
K4M
Inlet manifold ).
101793
Remove:
- exhaust bracket mounting nuts (2) ,
- exhaust manifold strut (3) .
Note:
Mark with a pen the position of the exhaust
silentbloc supports on the vehicle body.
12A-74
FUEL MIXTURE
12A
K4J, and 730 or 732 K4M, and 760 or 761
7
102116
101798
Remove mounting bolt (4) from the exhaust pipe silentbloc supports on the body.
Remove oxygen sensor (6) using tool (Mot. 149501) .

Remove upper heat shield (7) from the exhaust manifold.
102117
Remove mounting bolt (5) from the silencer silentbloc bracket on the body.
Withdraw the exhaust pipe towards the rear of the
vehicle.
101797
Remove:
- the nine exhaust manifold securing nuts,
- the exhaust manifold.
12A-75
FUEL MIXTURE
12A
K4J, and 730 or 732 K4M, and 760 or 761

ON THE WORKBENCH
5
9
7
4
101797
101502
Remove the lower heat shield.

- the manifold nuts. ( 23 3 Nm ) ,
REFITTING
- the heat shield bolts ( 10 Nm ) ,
Always replace:
- the oxygen sensors ( 45 Nm ) ,
- the manifold gaskets,

- the exhaust bracket gaskets,
- the mounting bolts for the exhaust pipe brackets to the body ( 21 Nm ) ,
- the manifold nuts.
- the bolt on the inlet manifold strut ( 8 Nm ) ,

- the exhaust bracket nuts ( 20 Nm ) .
WARNING
( 4 Nm ) .
12A-76
FUEL MIXTURE
12A
F4R, and 770 or 771

Mot. 1495-01
22 mm socket for
Tightening torquesm
manifold nuts
18 Nm
heat shield bolts
10 Nm
oxygen sensors
45 Nm

exhaust pipe brackets to
the body
21 Nm
bolt on the exhaust

manifold strut on the
gearbox
21 Nm
20 Nm
2
3
101793

bolts
Remove:
- exhaust bracket mounting nuts (2) ,
4 Nm
- the exhaust manifold strut (3) .
REMOVAL
Note:

terminal.
Mark with a pen the position of the exhaust

silentbloc supports on the vehicle body.
1
4
102116
101501
Disconnect downstream oxygen sensor (1) .
12A-77
Remove mounting bolt (4) from the exhaust pipe silentbloc supports on the body.
FUEL MIXTURE
12A
F4R, and 770 or 771
102117
101797
Remove:
Remove mounting bolt (5) from the silencer silentbloc bracket on the body.

vehicle.

ON THE WORKBENCH
7
101798
Remove oxygen sensor (6) using tool (Mot. 149501) .
101502
Remove the lower heat shield.
Remove upper heat shield (7) from the exhaust manifold.
REFITTING
Always replace:
- the manifold gaskets,
12A-78
FUEL MIXTURE
F4R, and 770 or 771
- the exhaust bracket gaskets,
- the manifold nuts.
8
2
9
7
4
101797

- the manifold nuts ( 18 Nm ) ,
- the heat shield bolts ( 10 Nm ) ,
- the mounting bolts for the exhaust pipe brackets to the body ( 21 Nm ) ,
- the bolt on the exhaust manifold strut on the
gearbox ( 21 Nm ) ,
WARNING
( 4 Nm ) .
12A-79
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 sealing ring,
- the exhaust manifold mounting nuts.
REMOVAL
terminal.
Remove:
- the engine and transmission assembly (see 10A,
Engine and peripherals, Engine - gearbox ),
21936
Remove:
12A-80
FUEL MIXTURE
F4R, and 776
2
6
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
Strict adherence to the repair procedures is
required for the removal and refitting of the turbocharger in order to seal the system FAILURE TO
COMPLY WITH THESE INSTRUCTIONS MAY
HAVE SERIOUS SAFETY-RELATED CONSEQUENCES .
12A-81
12A
FUEL MIXTURE
12A
K9K, and 732

Mot. 1567
Remote operation
Tightening torquesm
exhaust manifold
mounting studs
9 Nm
exhaust manifold
mounting nuts
26 Nm
25 Nm
exhaust gas recirculation rigid pipe mounting

bolts
35 Nm
112815
REMOVAL
Put the vehicle on a two-post lift (see 02A, Lifting
- Refitting ).
112810

(1) .
Move aside the air inlet duct between the intercooler
and the damper valve on the damper valve.
Remove the mounting bolt (3) from the damper valve.
Remove:
- the lifting eye mounting bolts on the timing end,
- the lifting eye on the timing end.
12A-82
FUEL MIXTURE
12A
K9K, and 732
113558
Loosen the mounting bolts (7) on the EGR unit by a

few turns.
Move the EGR unit to one side without removing it.
113475
II - REMOVAL OF PART CONCERNED
Remove the mounting bolts (4) from the injection rail

cover mounting bracket.
113561
Remove:
113842
Remove:
- the mounting nuts (8) from the exhaust manifold,
- the clip (5) from the EGR rigid pipe using the (Mot.
1567) ,
- the mounting bolts (6) from the exhaust gas recirculation pipe,
REFITTING
- the exhaust gas inlet pipe .

Always clean the joint faces thoroughly.
12A-83
FUEL MIXTURE
12A
K9K, and 732

CONCERNED
20848-1

mounting studs ( 9 Nm ) .
Fit the new snap-on clip.
Position the new exhaust manifold gasket.
WARNING
Refit:
Ensure that you do not constrain the exhaust gas

recirculation rigid pipe before fitting the snap-on
clip.

- the exhaust manifold mounting nuts.
Tighten to torque the exhaust manifold mounting
nuts ( 26 Nm ) .
Tighten the bolts of the exhaust gas recirculation rigid pipe on the manifold until they make contact.
Adjust the exhaust gas recirculation rigid pipe in relation to the cooler support.
Fit the exhaust gas recirculation unit.
Lock the snap-on clip of the exhaust gas recirculation rigid pipe using the (Mot. 1567) .
Torque tighten the exhaust gas recirculation unit

Tighten to torque the exhaust gas recirculation rigid pipe mounting bolts ( 35 Nm ) .
Refit:
Refit:
- the new exhaust gas recirculation rigid pipe with a

new seal,
- the mounting bolts on the exhaust gas recirculation
pipe,
12A-84
- the lifting eye mounting bolts on the timing end,

- the timing end lifting eye,
- the injection rail protector cover retaining bracket
mounting bolts,
FUEL MIXTURE
K9K, and 732
- the inlet throttle valve mounting bolt,
Connect the damper valve connector.
Refit the air inlet duct between the intercooler and
the inlet throttle valve on the inlet throttle valve.
Tighten the clip on the air inlet duct.
Connect the air inlet pressure sensor connector.
12A-85
12A
FUEL MIXTURE
Throttle valve: Removal - Refitting
12A
K4J, and 730 or 732
Equipment required
diagnostic tool
Tightening torquesm
throttle valve bolts
13 Nm
air filter unit bolts
9 Nm

bolts
4 Nm
REMOVAL
1
101800
Remove:
- mounting bolts (4) ,

- the throttle valve.
101489

terminal.
Remove air filter unit (1) (see 12A, Fuel mixture,
Air filter unit ).
Disconnect:
- fuel vapour recirculation pipe (3) on the control solenoid valve.
12A-86
FUEL MIXTURE
K4J, and 730 or 732
REFITTING
Replace the throttle valve seal each time it is removed (use grease to make it easier to fit).
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air filter unit bolts ( 9 Nm ) .
WARNING
( 4 Nm ) .
In the event of a throttle valve replacement, use the
diagnostic tool CLIP to reinitialise the stop programming
using
command
RZ005
Programming .
When the ignition is switched on, the throttle valve
should go through a cycle of programming the MIN
and MAX throttle stop positions.
Using the diagnostic tool CLIP , check that the
programming has been performed correctly ET051
Throttle stop programming .
12A-87
12A
FUEL MIXTURE
12A
F9Q, and 800 or 808
Tightening torquesm
throttle valve mounting
bolts
8 Nm

bolts
4 Nm
REMOVAL
2
4
101892
Unscrew air inlet hose clip (2) .

Disconnect the air inlet hose.
Separate the air inlet hose.
Disconnect vacuum hose (3) from the diaphragm.
Remove:
101893
- the three mounting bolts (4) ,
Disconnect:
- the throttle valve / diaphragm assembly.

- turbocharging pressure sensor (1) .
REFITTING
Replace the seal.
Tighten to torque the throttle valve mounting bolts
( 8 Nm ) .
WARNING
( 4 Nm ) .
12A-88
FUEL MIXTURE
12A
K4M, and 760 or 761
Equipment required
diagnostic tool
Tightening torquesm
bolts
13 Nm

bolts
4 Nm
REMOVAL
102735
Disconnect:

Remove:
- the four throttle valve mounting bolts (4) ,
101807

terminal.
12A-89
FUEL MIXTURE
K4M, and 760 or 761
REFITTING
Replace the throttle valve seal with a new one each
time it is removed.
( 13 Nm ) , tightening them evenly.
WARNING
( 4 Nm ) .
using
command
RZ005
Programming .
Check using the diagnostic tool CLIP that the
12A-90
12A
FUEL MIXTURE
12A
F4R, and 770 or 771 or 776
Equipment required
diagnostic tool
Tightening torquesm
bolts (F4R 776)
10 Nm

bolts
13 Nm

bolts
4 Nm
REMOVAL
F4R, and 776
106633
Remove:
- motorised throttle valve mounting bolts (3) ,
- the motorised throttle valve.
1
106270

Remove fuel vapour recirculation pipe (2) .
101807
Disconnect the motorised throttle valve connector.

terminal.
12A-91
FUEL MIXTURE
12A
F4R, and 770 or 771 or 776
REFITTING
Replace the throttle valve seal each time it is removed.

(F4R 776) ( 10 Nm ) , tightening them evenly.
( 13 Nm ) , tightening them evenly.

WARNING


( 4 Nm ) .
102735

using
command
RZ005
Programming .

Disconnect:
Remove:
Using the diagnostic tool CLIP , check that the

- the four throttle valve mounting bolts (7) ,

12A-92
FUEL MIXTURE
12A
F9Q, and 804
REFITTING
Tightening torquesm
bolts
8 Nm

bolts
4 Nm
Replace the seal.

Torque tighten the throttle valve mounting bolts (
8 Nm ) .
REMOVAL
WARNING

terminal.
3
2
1
111887
Undo the air inlet hose clip (1) .

Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the turbocharging pressure sensor connector (3) .
Remove the throttle valve.
12A-93

( 4 Nm ) .
FUEL MIXTURE
12A
F4R or K4J or K4M
Equipment required
diagnostic tool
WARNING
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 onto the inside of the valve until all traces of clogging disappear.
WARNING
Do not apply cleaning agent, part number 77 11
171 437 , to the outside of the valve, in the spring
housing or on the connector.
106899
Remove the external O-ring seals from the throttle

valve.
Note:
The Renault carburettor cleaning agent, part
number 77 11 171 437 can damage the seals.
106900
Remove the cleaning product residue and the dirt residue using a cloth, part number 77 11 211 707
12A-94
FUEL MIXTURE
F4R or K4J or K4M
106902
Use a nozzle to direct compressed air at the edges

and outside of the throttle valve.
WARNING
It is essential to replace the throttle valve O-ring
seals.
Note:
If the throttle valve is dropped or receives any
other impact, it will need to be replaced.
Refit the throttle valve (see 12A, Fuel mixture,
Throttle valve ).
WARNING
Using tool diagnostic tool , reinitialise the programming of the throttle stops via the delete command
RZ005 Programming .
Check, using the diagnostic tool , that this programming has been carried out using the command
ET051 Throttle stop programming .
12A-95
12A
FUEL MIXTURE
Engine stop device
12A
F9Q, and 800 or 808

I - OBJECTIVE
The system is intended to stop the engine quickly after
the ignition is switched off.
II - DESCRIPTION
3
2
102486
The system consists of:

- a diaphragm (1) acting on the throttle,
- a throttle (2) ,
- a solenoid valve (3) ,
- a vacuum (4) .
III - OPERATING PRINCIPLE

101892
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.
101894
12A-96
TURBOCHARGING
Turbocharging: Precautions for repair
12B
F9Q
Instructions that must be followed when turbochargers
are replaced due to mechanical damage:
- Replace the turbocharger upstream duct (see diagram)
- damage to the bearing system,
- Clean the turbocharger ducts
- broken shaft,
- Drain the engine oil
- compressor wheel rubbing against the turbocharger

casing,
- broken compressor wheel.
Damage of the kind listed above can lead to impurities
entering the circuits to which the turbocharger is connected.
- Replace the oil filter

- Replace the oil return and supply pipes and their
seals
I - INSTRUCTIONS FOR THE AIR CIRCUIT
FOR THE AIR CIRCUIT:

- Consequences:
Diagram of the air circuit
swarf and metal objects in the ducts upstream and

downstream of the turbocharger,
large volumes of oil in the air circuit (collected in the

intercooler).
- Risks (after replacing the turbocharger):
metal objects found in the compressor wheel (destruction of turbocharger),

engine racing (oil sucked up in the intercooler).
FOR THE LUBRICATION CIRCUIT:
- Consequences:
swarf found in the engine oil circuit,

circulation of swarf within the circuit.
- Risks (after replacing the turbocharger):
premature wear on the bearing system (destruction

of turbocharger).
112666
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
Failure to follow the INSTRUCTIONS listed will lead
to the turbocharger breaking again.
The following must be replaced:
(1)
air filter
(2)
compressor wheel
(3)
intercooler
(4)
turbocharger pressure sensor
(5)
inlet manifold
(6)
turbine wheel
- intercooler,
- turbocharger upstream air duct,
- engine oil,
- oil filter,
- turbocharger oil supply and return pipes,
Remove intercooler (3) if the vehicle is fitted with one

(refer to the Workshop Repair Manual of the vehicle affected 12B, Turbocharging, Intercooler ).
- all seals that have been removed.

DESCRIPTION OF OPERATION
WARNING
- Replace the intercooler
Always replace the intercooler.
12B-1
TURBOCHARGING
12B
F9Q
11
110738
Damage to the compressor wheel results in metal objects entering the air duct (A) between the air filter and
the turbocharger.
Replace the air duct (A) between the air filter and the
turbocharger.
112772
For ducts comprising several components:

- mark the duct (11) so that you can identify where
each component should be positioned when refitting,
- separate all the duct components.
Check that there are no metal objects inside the flowmeter (7) .
Clean the ducts
Remove:
- the air circuit duct (between the turbocharger and the
intercooler) for section (B) ,
- the air circuit duct (between the intercooler and the inlet manifold) for section (C) .
Remove the turbocharger pressure sensor (4) for section (C) , if the duct is fitted with one.
112770
Clean the removed ducts one by one using a cleaning

spray:
- brush as much of the duct interior as possible (only
use brushes with plastic bristles),
- wash the duct with plenty of cleaning liquid,
- let the cleaned duct drain by standing it up vertically
and then start cleaning the next duct.
12B-2
TURBOCHARGING
12B
F9Q
112771
102480
Dry the ducts one by one using a compressed air spray

gun.
For ducts comprising several components:
- assemble the components in the correct order using
the markings (11) that you have previously made.
Refit:
- the turbocharger pressure sensor (4) for section (C) ,
if the duct is fitted with one.
- the air circuit duct (between the turbocharger and the
intercooler) for section (B) ,
- the air circuit duct (between the intercooler and the inlet manifold) for section (C) ,
Refit the new intercooler (3) , if the vehicle is fitted with
one (refer to the Workshop Repair Manual of the vehicle affected 12B, Turbocharging, Intercooler ,).
II - INSTRUCTIONS FOR THE LUBRICATION
CIRCUIT
Replace the oil filter.
111870
Replace:
- the turbocharger oil supply pipe,
- the turbocharger oil return pipe(s).
WARNING
Always replace all seals that have been removed.
12B-3
TURBOCHARGING
F9Q
WARNING
When starting the engine:
- let the engine run at idle speed for 1 minute so
that the oil circuit pressure can reach the required
level,
- accelerate several times under no load.
12B-4
12B
TURBOCHARGING
M9R, and 700
WARNING
With a marker, mark the position of the exhaust rubber mounting bush supports on the bodywork.
WARNING
- Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation.
- Check that the turbocharger oil return pipe is not
completely or partially blocked by scale. Check
that it is not leaking; if it is, replace it.
12B-5
12B
TURBOCHARGING
Turbocharger: Removal - Refitting
12B
K9K, and 722 or 728 or 729
Equipment required
K9K, and 722
diagnostic tool
3
1
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
turbocharger oil inlet

duct socketed bolt on
the turbocharger
22.5 Nm

pipe mounting bolts on
the turbocharger
12 Nm
exhaust gas recirculation solenoid valve heat

shield mounting bolts
12 Nm

bolts
4 Nm
4
5
102081
Disconnect air duct (1) .

Remove air duct (2) from the turbocharger.
Disconnect:
- the turbocharger pressure sensor (3) ,
- the exhaust gas recirculation solenoid valve (4) ,
- the turbocharging duct (5) on the turbocharger,
- the pipe (6) from the turbocharging pressure regulation valve on the air duct.
REMOVAL
terminal.
12B-6
TURBOCHARGING
12B
K9K, and 722 or 728 or 729
K9K, and 728 or 729
10
11
110326
Disconnect:
110325
Pull out the clip.
- the turbocharging pressure sensor connector (9) ,

- the exhaust gas recirculation solenoid valve manifold (10) ,
- the turbocharging duct (11) on the turbocharger,
- the pipe from the turbocharging pressure regulation valve on the turbocharging pressure regulation
solenoid valve.
8
7
110323
Undo bolt (7) .

12B-7
TURBOCHARGING
12B
K9K, and 722 or 728 or 729
14
12
13
102076
Remove:
102116
Remove mounting bolt (14) from the exhaust pipe

rubber mounting bush support on the body.
- the exhaust flange mountings (12) ,

- the stay mounting (13) on the catalytic converter.
Loosen the other stay mountings on the gearbox.
Remove stay (13) .
15
Note:
Mark the position of the exhaust rubber mounting
bush supports on the vehicle body with a pen.
102117
Remove mounting bolt (15) from the silencer rubber

mounting bush support on the body.
vehicle.
12B-8
TURBOCHARGING
12B
K9K, and 722 or 728 or 729
22
20
17
21
16
102077
102079
Remove:
Remove:
- the catalytic converter stay (16) ,
- the oil supply pipe (20) ,
- the four mounting nuts (17) securing the catalytic

converter to the turbocharger,
- the oil return pipe (21) ,
- the catalytic converter.
- the two upper mounting nuts (22) from the turbocharger,

- the lower mounting nut from below,
- the turbocharger.
19
18
102119
Remove:
- the bracket (18) ,
- the exhaust gas recirculation solenoid valve heat
shield (19) .
12B-9
TURBOCHARGING
12B
K9K, and 722 or 728 or 729
REFITTING
Refit the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting ).
WARNING
Ensure that no impurities enter the turbine or
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
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.

Before starting, disconnect the 4 injectors (starting
the engine is prohibited).
Run the starter motor until the oil pressure warning
light goes out (wait for a few seconds).
WARNING
Switch off the ignition.
Always replace:
Reconnect the 4 injector connectors.
- all the O-rings and both copper seals on the turbocharger oil inlet duct,
Start the engine.
- the exhaust flange seal.
Let the engine idle then depress the accelerator several times with no load.
- any damaged heat shield.

Tighten to torque:
Make sure that there are no oil leaks.
- the turbocharger mounting studs on the turbocharger ( 7 Nm ) ,

- the turbocharger mounting studs on the exhaust manifold ( 7 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 turbocharger oil supply pipe on the turbocharger and on the cylinder head, applying new
seals in the process.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cylinder head ( 22.5 Nm ) ,
- the turbocharger oil inlet duct socketed bolt 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.
Torque tighten the turbocharger oil return pipe
mounting bolts on the turbocharger ( 12 Nm )
12B-10
Connect the diagnostic tool and clear the stored

faults.
Make sure that all the exhaust pipe heat shields are
in place and properly secured.
Make sure that there is no contact with the underbody.
( 4 Nm ) .
TURBOCHARGING
12B
F9Q, and 800
Tightening torquesm
studs
8 Nm
turbocharger union end

piece
26 Nm
nuts
26 Nm
oil supply pipe mounting nuts
22.5 Nm
oil supply pipe mounting bolt on the cylinder

block
12 Nm

pipe mounting bolts
12 Nm

bolts
4 Nm
102481
Disconnect the turbocharger air inlet and outlet pipes.
REMOVAL
terminal.
102480
Disconnect the tube (1) from the turbocharging pressure regulation valve control diaphragm.
Remove:
- the turbocharger oil supply pipe (2) ,
- the turbocharger oil return pipe (3) ,
- the turbocharger mounting nuts (4) ,
- the turbocharger.
12B-11
TURBOCHARGING
F9Q, and 800
REFITTING
WARNING
completely or partially blocked by scale.
check that the sealing is perfect; if not, replace it.
Be sure to replace the seals:
- on the turbocharger oil supply pipe,
- on the turbocharger oil return pipe,
- the turbocharger,
12B-12
12B
TURBOCHARGING
12B
F9Q, and 800

made previously.
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
( 4 Nm ) .
114467
Always replace the end piece seal on the union (5) ,

if the end piece has been removed.
Tighten to torque:
- the turbocharger mounting studs ( 8 Nm ) ,
- the turbocharger union end piece ( 26 Nm ) , if
the studs have been removed.
Refit the turbocharger.
( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply pipe
nuts,
mounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- the oil supply pipe mounting nuts ( 22.5 Nm ) ,
- the oil supply pipe mounting bolt on the cylinder block ( 12 Nm ) ,
- the turbocharger oil return pipe mounting bolts
( 12 Nm ) .
Refit the exhaust pipe, aligning it with the marks
12B-13
TURBOCHARGING
12B
F4R, and 776
Equipment required
diagnostic tool
Tightening torquesm
bolts of the oil return
pipe towards the cylinder block
12 Nm
turbocharger cooling
duct bolts (initial torque)
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
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
mounting bolts of the oil

return and supply pipes
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 - Gearbox ).
Catalytic converter ).
12B-14
Fit hose clamps 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 pipe.
- the turbocharger oil return pipe mounting bolts (8) ,

- the turbocharger oil return pipe (10) ,
- the turbocharger oil supply pipe (9) .
21930
21933
Remove the starter motor heat shield.

Remove:
- the nuts (11) securing the turbocharger to the manifold,

- the turbocharger.
12B-15
TURBOCHARGING
12B
F4R, and 776
REFITTING
The turbocharger mounting nuts and studs must be
replaced along with the seals.
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.
15
21931
Fit and finger tighten:

- the turbocharger mountings on the exhaust manifold,
13
14
- the oil supply pipe mountings on the turbocharger,

- the return pipe to the cylinder block,
- the turbocharger - intercooler air pipe,
- the turbocharger strut mounting.
16
22809
On the workbench, refit and tighten to torque:

- the two bolts of the oil return pipe towards the
cylinder block ( 12 Nm ) (13) ,
- the oil return pipe bolt (14) .
17
Pre-tighten the turbocharger cooling duct bolts

(initial torque) ( 12 Nm ) (15) ,
Tighten to torque the turbocharger cooling duct
bolts ( 27 Nm ) .
106273
Tighten:
- the clip (16) from the intercooler - turbocharger
pipe to position the turbocharger,
- the turbocharger strut (17) .
12B-16
TURBOCHARGING
12B
F4R, and 776

All removed seals must be replaced including those
on the cooling pipe as well as the intercooler - turbocharger air pipe.
18

Filling - Bleeding ).
WARNING
18
WARNING
- Before starting the engine, connect the diagnostic tool and lock the injection system.
21933
- Run 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 that 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 perform a road test.
- Clear the faults using the diagnostic tool .
- Switch off the ignition and check that 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 mounting bolts of the oil return and supply
pipes ( 21 Nm ) (22) .
12B-17
TURBOCHARGING
12B
F9Q, and 804

Mot. 1448

Equipment required
diagnostic tool
Tightening torquesm
nuts
37 Nm
turbocharger oil supply

pipe hollow mounting
bolts
22.5 Nm
oil supply pipe hollow

housing
44 Nm
oil supply pipe mounting bolt on the housing
25 Nm

pipe
12 Nm

bolts
4 Nm
112659
Remove:
- the nut (2) ,
- the battery tray.
Bleed the cooling system (see 19A, Cooling, Cooling system: Draining - filling ).
REMOVAL
terminal.
Remove the battery.
12B-18
TURBOCHARGING
12B
F9Q, and 804
111866
Remove, using the (Mot. 1448) :

- the hose - rigid pipe assembly (3) . between
the EGR cooler (4) and the water outlet unit,
111869
Remove the duct between the turbocharger and the

air filter.
Disconnect the turbocharger (7) vacuum pipe.
- the hose - rigid pipe assembly (5) between the

EGR coolant and the heater matrix hose.
Disconnect the upper cooling hose on the turbocharger.
111860
111865
Remove the air duct (6) from the turbocharger.

12B-19
TURBOCHARGING
12B
F9Q, and 804
111868
Remove the starter motor (see 16A, Starting-Charging, Starter motor: Removal - Refitting ).
111870
Remove the turbocharger oil supply pipe (10) .
111871
111867
Remove the heat shield (9) .
12B-20
Remove the turbocharger mounting nuts (11) .
TURBOCHARGING
12B
F9Q, and 804
REFITTING
WARNING
completely or partially blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
Always replace:
- the turbocharger oil supply pipe,
- the oil supply pipe hollow mounting bolts,
- the seals on the turbocharger oil return pipe,
- the seal between the turbocharger and the exhaust
manifold,
112457
Note:
Pay attention to the direction of fitting of the
manifold - turbocharger seal.
The seal tab must 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 oil supply pipe hollow mounting bolt on the
housing ( 44 Nm ) ,
- the oil supply pipe mounting bolt on the housing ( 25 Nm ) ,
- the turbocharger oil return pipe ( 12 Nm ) .
Refit:
112458

Starter motor: Removal - Refitting ).
- the catalytic pre-converter (see 19B, Catalytic
pre-converter: Removal - Refitting ).
Remove the turbocharger (12) .
12B-21
TURBOCHARGING
F9Q, and 804
WARNING
- start the engine,
out,
Connect the diagnostic tool and clear the stored
faults.
( 4 Nm ) .
circuit: Draining - filling ).
12B-22
12B
TURBOCHARGING
12B
K9K, and 732
Tightening torquesm
studs
9 Nm
nuts
26 Nm
bolts mounting the oil

inlet pipe on the turbocharger
22.5 Nm

inlet pipe on the cylinder
head
22.5 Nm

return pipe on the turbocharger
12 Nm
112991
REMOVAL
Loosen the mounting bolt (1) on the air inlet rigid

duct.
Move the air inlet rigid duct to one side (see (2) .

- Refitting ).
112816
Disconnect:
- the air inlet duct (4) on the turbocharger,

CONCERNED
112811
Pull out the clip.
12B-23
Disconnect the turbocharging pressure regulation

valve hose on the regulation valve side.
TURBOCHARGING
12B
K9K, and 732
REFITTING
Always clean the joint faces thoroughly.
WARNING
Ensure that no foreign bodies enter the turbine or
completely or partially blocked by scale. Check
that there are no leaks. If there are, replace the
part.
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.
102079
Remove:
- the bolt (6) mounting the oil inlet pipe on the turbocharger,
- the bolt mounting the oil inlet pipe on the cylinder
head,
- the oil supply pipe ,
- the oil return pipe mounting bolts,
- the oil return pipes (5) ,
- the upper mounting nuts (7) from the turbocharger,
- the lower mounting nut from the turbocharger,
- the turbocharger.
12B-24
WARNING
Replace any damaged heat shield.
TURBOCHARGING
12B
K9K, and 732

CONCERNED
Tighten to torque the turbocharger mounting

studs ( 9 Nm )
Note:
Make sure there is no contact between the catalytic converter and the turbocharger oil return
pipe.
Fit the new turbocharger seal.

Refit:
- the turbocharger.
Refit the clip on the air inlet duct if necessary.
- the turbocharger mounting nuts.
Clip the air inlet rigid pipe on the turbocharger.

( 26 Nm ) .
Refit the air inlet rigid duct mounting bolt.
Refit:
- the air inlet duct on the turbocharger,
- the new oil inlet pipe,
- the oil vapour rebreathing pipe.
- the oil inlet pipe mounting bolt on the turbocharger
- the bolt mounting the oil inlet pipe on the cylinder

head.
Connect:

Tighten to torque:
- the bolts mounting the oil inlet pipe on the turbocharger ( 22.5 Nm ) ,
- the bolts mounting the oil inlet pipe on the cylinder head ( 22.5 Nm )
Fit new seals on the oil return pipe.
Refit:
- the oil return pipe,
- the oil return pipe mounting bolts.
Tighten to torque the bolts mounting the oil return
pipe on the turbocharger ( 12 Nm ) .
Connect the vacuum pipe to the pressure regulation
solenoid valve on the turbocharger.
Refit:
- the oil inlet pipe on the turbocharger,
- the turbocharger oil inlet pipe union on the turbocharger,
Connect:
- the turbocharging pressure regulation valve hose,
- the air inlet duct on the turbocharger side,
- the oil vapour rebreathing pipe on the rocker cover
side.
12B-25
TURBOCHARGING
12B
F9Q, and 808

terminal.

Mot. 1566
Wrench for removing

high-pressure pipes
Tightening torquesm
studs
8 Nm
nuts
26 Nm
hollow mounting bolt on

the turbocharger oil 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 bolts
12 Nm
studs
8 Nm
turbocharger union end

piece
26 Nm
nuts
26 Nm
oil supply pipe mounting nut on the turbocharger side
22.5 Nm
oil supply pipe mounting nut on the cylinder

block
22.5 Nm

pipe mounting bolts
12 Nm

bolts
4 Nm
104424
Disconnect:
- the turbocharging pressure regulation valve (2) pipe.
REMOVAL
12B-26
TURBOCHARGING
12B
F9Q, and 808

I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION
(TURBOCHARGER SIDE)
104421
Disconnect the turbocharger air inlet and outlet pipes (3) .

114207
Remove:
- the mounting bolt (4) from the oil supply pipe,
- the hollow mounting bolt (5) from the oil supply pipe
union on the turbocharger.
Note:
Loosen the union (6) on the cylinder block.
During factory fitting, 2 types of oil supply pipe

can be fitted to the turbocharger.
Remove the oil supply pipe by passing it through the

turbocharger wheels.
The way in which a turbocharger is removed

depends on the type of pipe.
Remove:
- the turbocharger bracket mounting nuts,
- the turbocharger.
12B-27
TURBOCHARGING
12B
F9Q, and 808

II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
114467
In the event that the oil supply pipe is replaced:

104417
- remove the oil supply union end piece (9) . This

step prepares the turbocharger for the supply pipe
to be refitted with the hollow bolt union.
Remove the bolt (7) mounting the oil supply pipe to

the cylinder block.
Undo the oil supply pipe unions on:
- the cylinder block,
REFITTING
- the turbocharger (8) using the (Mot. 1566) .

Remove the turbocharger oil supply pipe.
Note:
Remove:
During factory fitting, 2 types of oil supply pipe

can be fitted to the turbocharger.

The way in which a turbocharger is refitted

depends on the type of pipe.
- the turbocharger bracket mounting nuts,

- the turbocharger.
WARNING
Note:

There is only one supply pipe part number

available as a replacement part. Only the oil supply pipe with a hollow bolt union is available.

completely or partially blocked by scale.
Also check that it is perfectly sealed. If not,
replace it.
Always replace:
- the oil supply pipe with hollow bolt union on the turbocharger side (depending on version),
- the oil supply pipe seals with nut unions on the turbocharger side (depending on version),
- the seals on the turbocharger oil return pipe,
12B-28
TURBOCHARGING
12B
F9Q, and 808

II - THE OIL SUPPLY PIPE WITH NUT UNION
(TURBOCHARGER SIDE)
- the turbocharger seals.

I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT
UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mounting
studs ( 8 Nm ) .
( 26 Nm ) .
- screw on (without tightening) the oil supply union
mounting nut on the cylinder block,
- screw on (without tightening) the supply pipe hollow mounting bolt,
Tighten to torque:
114467
- the hollow mounting bolt on the turbocharger

oil supply pipe ( 22.5 Nm ) ,
Always replace the end piece seal on the union (10)

, if the end piece has been removed.
- the nut mounting the oil supply pipe on the cylinder block ( 22.5 Nm ) ,
Tighten to torque:
- the turbocharger mounting studs ( 8 Nm ) ,
- the bolt mounting the oil supply pipe on the cylinder block ( 25 Nm )
- the turbocharger union end piece ( 26 Nm ) , if it

has been removed.

( 12 Nm ) .

( 26 Nm ) .
mounting nuts,
Tighten to torque:
- using the tool, the oil supply pipe mounting nut
on the turbocharger side ( 22.5 Nm ) ,
- the oil supply pipe mounting nut on the cylinder
block ( 22.5 Nm ) ,
( 12 Nm )
III - CONTINUATION OF REFITTING PROCEDURE
12B-29
TURBOCHARGING
F9Q, and 808
Refit the exhaust pipe, aligning it with the marks
made previously.
- start the engine,
out,
( 4 Nm ) .
12B-30
12B
TURBOCHARGING
12B
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool

tweezers

diagnostic tool

Tightening torquesm
stud on the exhaust
manifold
9 Nm
14.5 Nm
turbocharger strut
flywheel end
25 Nm
lower mounting nuts on

the turbocharger
28 Nm
upper mounting nut on

the turbocharger
28 Nm
turbocharger transverse
mounting bolt
25 Nm
turbocharger strut
timing side
25 Nm
air inlet duct mounting

bolts
8 Nm

turbocharger side
5.5 Nm

pipe on the turbocharger
10 Nm
hollow bolt securing the

oil pipe on the cylinder
block
16 Nm
bolt mounting the oil

pipe on the cylinder
block
25 Nm
114982
Remove:
- the bolts (1) mounting the oil pipe on the turbocharger,
- the oil pipe mounting bolts (2) on the cylinder block,
- the hollow bolt (3) securing the turbocharger oil
pipe to the cylinder block,
- the turbocharger oil pipe.
IMPORTANT
Wear protective gloves during the operation.
12B-31
TURBOCHARGING
12B
M9R, and 700
113282
Rotate the air duct retaining clip (7) on the turbocharger.
113277
Remove the lower mounting nuts (4) from the turbocharger.
114846
Disconnect:
- the hose (5) from the turbocharging pressure regulator on the control diaphragm,
- the oil vapour rebreathing hose (6) on the oil separator.
Loosen the air duct clip on the turbocharger side.
Disconnect the air inlet duct on the turbocharger side.
12B-32
113155
Remove the mounting bolts (8) for the air duct on the
inlet manifold.
Move to one side the air duct towards the intercooler.
TURBOCHARGING
12B
M9R, and 700

- the turbocharger strut.

CONCERNED
REFITTING
- of the exhaust manifold,
- of the turbocharger if reused.
Remove the stud on the exhaust manifold using a
roller-type stud removal tool .
Refit a new stud to the exhaust manifold using a roller-type stud removal tool .
Tighten to torque the stud on the exhaust manifold ( 9 Nm ) .
Remove the turbocharger studs in the event that the
turbocharger is reused.
Refit the new studs on the turbocharger in the event
that the turbocharger is reused.
113277
Remove:
Tighten to torque the studs on the turbocharger (

14.5 Nm ) .
- the turbocharger upper mounting nut (9) on the exhaust manifold,

- the turbocharger mounting bolt (10) ,
- the turbocharger.
- the gasket between the turbocharger and the exhaust manifold.
115068
Remove the air inlet duct seal at the turbocharger

outlet using a tweezers .
114471
Remove:
- the mounting bolts (11) from the turbocharger strut,
12B-33
TURBOCHARGING
M9R, and 700
115069
Refit the new seal to the turbocharger air inlet duct.

Note:
Check that the turbocharger air inlet duct seal
(12) is fitted in the correct direction.
12B-34
12B
TURBOCHARGING
12B
M9R, and 700

- the new upper mounting nut on the turbocharger,

CONCERNED
- the new lower mounting nuts on the turbocharger.

Tighten to torque:
- the lower mounting nuts on the turbocharger (
28 Nm ) ,
- the upper mounting nut on the turbocharger (
28 Nm ) .
Undo the turbocharger strut mounting bolt on the timing end (13) .
Tighten to torque:
- the turbocharger transverse mounting bolt ( 25
Nm ) ,
- the turbocharger strut mounting bolt on the timing side ( 25 Nm ) (13) .
Rotate the retaining clip of the air inlet duct to refit
the retaining clip in its recess.
114471
Fit the new turbocharger strut.

Finger tighten the mounting bolts (13) and (14) of the
turbocharger strut.
Clip the air inlet duct on to the turbocharger.

Refit the air inlet duct mounting bolts on the inlet manifold.
Tighten to torque the air inlet duct mounting bolts
( 8 Nm ) .
WARNING
Connect:
The turbocharger strut must move freely.
- the air inlet duct to the turbocharger,
Fit the turbocharger without its seal and hold the turbocharger flat against the exhaust manifold.
Move the turbocharger strut until it is against the turbocharger at the flywheel end.
Gently tighten the turbocharger strut mounting bolt
on the timing end (13) .
WARNING
Do not tighten the bolt too quickly to prevent the
turbocharger strut from rotating.
Move the turbocharger to one side.
Tighten to torque the turbocharger strut mounting
bolt on the flywheel end ( 25 Nm ) (14) .
Fit a new seal between the turbocharger and the exhaust manifold.
Finger tighten the new turbocharger transverse
mounting bolt by a few turns.
Tighten until contact is made:
12B-35
- the oil vapour rebreathing hose to the oil separator.

Tighten to torque the air inlet duct clip on the turbocharger side ( 5.5 Nm ) .
Connect the turbocharging pressure regulator on the
control diaphragm.
TURBOCHARGING
12B
M9R, and 700

- the hollow bolt securing the oil pipe on the cylinder block ( 16 Nm ) (16) ,
- the bolt mounting the oil pipe on the cylinder
block ( 25 Nm ) (17) .
WARNING
Disconnect the injection 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 injection rail pressure regulator connector.
114982
Lubricate the new turbocharger oil pipe O-ring on

the cylinder block side.
Start the engine.

Let the engine idle then depress the accelerator
several times under no load.
WARNING
Make sure that there are no oil leaks.
Check for the gasket between the turbocharger

and the turbocharger oil pipe.
Remove the protective plug from the oil supply union
on the cylinder block side.
Fit the turbocharger oil pipe, first positioning it in the
cylinder block (14) .
WARNING
Do not rotate the turbocharger oil pipe O-ring on
the cylinder block side when inserting.
After fitting, check that the turbocharger oil pipe
O-ring, on the cylinder block side, has not come
out of its housing.
Check for two copper seals on the oil supply
union on the cylinder block side.
Finger tighten:
- the bolts (15) mounting the oil pipe on the turbocharger,
- the oil pipe hollow bolt (16) on the cylinder block,
- the bolts (17) mounting the oil pipe on the cylinder
block.
Tighten to torque:
- the bolts mounting the oil pipe on the turbocharger ( 10 Nm ) (15) ,
12B-36
Connect the diagnostic tool and clear the stored faults.
TURBOCHARGING
12B
K9K, and 722 or 724 or 728 or 729 or 732
K9K, and 724
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.
3 - Check
TURBOCHARGING PRESSURE REGULATION

VALVE
K9K, and 722
1 - Check
21869
Remove the turbocharger (see 12B, Turbocharging, Turbocharger ).

Note:
The check cannot be carried out with the turbocharger in place.
21869
Use a magnetic holder fitted with a dial gauge located at the end of the regulation valve rod (as far as
possible on the rod shaft).
Gradually apply pressure to the regulation valve

using the pressure and vacuum pump.
Note:
4 - Value
2 - Value
For a pressure value of 1.4 bar , the rod movement
must be 4.3 mm .
12B-37
For a vacuum value of 0.6 bar , the rod movement

must be 7 mm 0.5 .
TURBOCHARGING
K9K, and 722 or 724 or 728 or 729 or 732
K9K, and 728 or 729 or 732

5 - Check
110748

Note:
Use a feeler gauge between the regulation valve rod
and the stop (as far as possible into the rod shaft).
6 - Value
For a vacuum value of 0.5 bar , the rod movement
must be 1.7 mm .
12B-38
12B
TURBOCHARGING
F9Q, and 800 or 808
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
TURBOCHARGING PRESSURE CONTROL VALVE
1 - CHECKING
21869
Remove the turbocharger (See 12B, Turbocharging, Turbocharger ).
Note:
The turbocharger cannot be tested in situ.
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).
using a vacuum/pressure pump.
2 - Value
For a pressure value of 265 mbar , the stem movement must be between 0.5 and 3.5 mm .
For a vacuum value greater than 600 mbar , the
stem is at the stop.
12B-39
12B
TURBOCHARGING
F4R, and 776
WARNING
Adjusting the turbocharger pressure regulation
valve rod is strictly prohibited.
1 - CHECKING
22807
Remove the turbocharger (See 12B, Turbocharging, Turbocharger ).
Note:
The turbocharger cannot be tested in situ.
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).
using a vacuum/pressure pump.
2 - Value
For a pressure value of 331 mbar , the stem movement should be 1 mm .
For a pressure value of 544 mbar , the stem movement must be 5 mm .
12B-40
12B
TURBOCHARGING
F9Q, and 804
WARNING
It is strictly prohibited to adjust the turbocharging
pressure regulation valve rod in the turbocharger.

1 - Checking
21869

Note:
Connect a pressure and vacuum pump (1) to the
pressure regulator (2) .
Gradually apply a vacuum to the pressure regulator
2 - Value
Test points:
- For a pressure value of 200 mbar , the rod movement should be between 2 and 4 mm .
- for a pressure value of 550 mbar , the rod movement should be between 8 and 11 mm. .
12B-41
12B
TURBOCHARGING
M9R, and 700
WARNING
The turbocharging pressure regulator rod must not
be adjusted.
TURBOCHARGING PRESSURE REGULATOR

1 - Check
21869
Remove the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting ).

Note:
Connect a pressure-vacuum pump (1) to the pressure regulator (2) .
Gradually apply a vacuum to the pressure regulator
using the pressure-vacuum pump.
2 - Value
Test points:
- For a vacuum value of 250 mbar , the rod movement should be between 3 and 6 mm .
- for a vacuum value greater than 600 mbar , the rod
should not move.
12B-42
12B
TURBOCHARGING
Turbocharging pressure regulation valve
12B
F9Q, and 800 or 808
WARNING
The turbocharging pressure regulation valve is open in

the rest position. The engine operates as normally aspirated.
If the turbocharger solenoid valve is removed, it is

essential to mark the supply and return pipes on
the solenoid valve.
The solenoid valve, closed in the rest position, is supplied after the engine is started following a delay which
varies according to the coolant temperature.
103128
102480
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.
12B-43
Shaft
Description
Time in seconds
Coolant temperature in C
TURBOCHARGING
12B
F4R, and 776
2
21927
Pressure regulation valve diaphragm (1) is controlled

by a solenoid valve (2) , which is in turn controlled by
the injection computer.
The pressure adjustment valve is closed at rest position.
107010
Solenoid valve (2) is open in the rest position.

In the open position, solenoid valve (2) compares the
turbocharger outlet (turbocharging pressure) and
diaphragm (1) .
Shaft
Description
Time in seconds
Because of this, the turbocharging pressure acts directly on the diaphragm and the pressure adjustment
valve opens.
When 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 at rest and is energised
when the engine is started. However, during a timed
period 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-44
TURBOCHARGING
12B
K9K, and 728 or 732

The turbocharging pressure regulation solenoid valve
is closed in the rest position; it is powered once the engine is started and a delay according to 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 vacuum pressure 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-45
TURBOCHARGING
Intercooler: Removal - Refitting
12B
K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 F4R, and 776 M9R, and 700
REMOVAL

Car. 1363
Trim removal lever

Tightening torquesm
intercooler
5.5 Nm
hose clip
5.5 Nm

damper valve
5.5 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm

bolts
21 Nm

tray
8 Nm

Remove:
F9Q, and 804 K9K, and 732 M9R, and 700
WARNING
intercooler:
- do not use a degreaser, brake cleaning product or
any other product,
112658

Remove the Protection and Switching Unit cover

- replace the clip in the same position if the hose is

not replaced,
- always replace the hose and/or the intercooler if
they have been damaged.
There is a danger of leakage and dislocation if this
procedure is not followed.
12B-46
TURBOCHARGING
12B
CONCERNED
102504
Remove the Protection and Switching Unit cover.

Remove:
102473
- the clips (4) ,
Remove:
- the upper mounting bolts (5) of the front end panel,


Undo the hose clip (8) upstream of the intercooler.

Disconnect the hose upstream of the intercooler.
M9R, and 700
114933
12B-47
TURBOCHARGING
12B
M9R, and 700
102474
Loosen the intercooler downstream duct clip (11) on

the intercooler.
114649
Remove the intercooler downstream duct mounting

bolt (9) on the cooling radiator.
Move the intercooler downstream duct away from

the intercooler.
Loosen:
Remove the intercooler.
- the intercooler downstream duct clip (10) on the intercooler,
REFITTING

valve.
WARNING
If there has been a fault in the turbocharger,
check that the intercooler is not full of oil.
In this is the case:
- remove the intercooler.
- rinse the intercooler with a cleaning agent,
- allow the intercooler to drain.
12B-48
TURBOCHARGING
12B
CONCERNED
Clip on the bonnet opening cable.

Refit:
Connect:
- the intercooler upstream hose,
- the battery tray,
- the intercooler downstream duct onto the intercooler.
Tighten to torque:
- the wiring harness mounting nut on the battery tray.
Tighten to torque:
- the intercooler upstream hose clip ( 5.5 Nm ) .

tray ( 8 Nm )
M9R, and 700

Refit the intercooler downstream duct mounting bolt
Tighten to torque the intercooler downstream duct
clip on the damper valve ( 5.5 Nm ) .
Clip on the battery terminal wiring harness.

Connect:

Refit the Protection and Switching Unit cover.
Refit:
M9R, and 700

Tighten to torque:
Nm ) ,
Refit the Protection and Switching Unit cover mounting bolts.

Nm ) ,
Refit:
M9R, and 700
- the clips,

Note:
You must initialise the xenon bulb system (if fitted
to the vehicle).
12B-49
TURBOCHARGING
12B
B84 or C84, and F4R, and 774
Tightening torquesm
bolts
4 Nm
REMOVAL
Remove:
- the front bumper,
- the headlights.
102474
102476
Remove the air deflectors (1) .
102473
Disconnect the inlet (2) and outlet (3) ducts from the
intercooler.
12B-50
TURBOCHARGING
102475
Lift the intercooler upwards to release it from the

mounting brackets (4) .
REFITTING
Check that the intercooler is not full of oil.
If it is, it must be rinsed with a cleaning agent and
then left to drain properly.
( 4 Nm ) .
12B-51
12B
FUEL SUPPLY
Petrol supply circuit
13A
F4R, and 770 or 771 or 776 K4J, and 730 or 732 K4M, and 760 or 761
Operating diagram of the fuel supply circuit
5
2
3
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 tank (6) .
13A-1
FUEL SUPPLY
13A
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
Operating diagram of the diesel fuel supply circuit
102847

- a gauge (1) ,
WARNING
- a manual priming pump (2) ,
It is not permitted to remove the pressure sensor

from the fuel rail (because this may cause circuit
contamination problems). If the pressure sensor
fails, the pressure sensor, the rail and the five highpressure pipes must be replaced.
- 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),
- a fuel flow actuator (5) ,
K9K, and 722 or 728 or 729
- an injector rail (6) fitted with a diesel pressure sensor

(7) ,
- four solenoid injectors (8) fitted with discharge valves,
- a Venturi tube (9) ,
- various sensors,
- an injection computer.
IMPORTANT
Loosening a high-pressure pipe union when the
engine is running is strictly prohibited.
13A-2
WARNING
Dismantling the interior of the high-pressure pump
and the injectors is prohibited. DELPHI Only the
flow actuator, the diesel fuel temperature sensor
and the Venturi tube can be replaced.
FUEL SUPPLY
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
K9K, and 732
WARNING
Removing the flow regulator solenoid valve and the
pressure regulating solenoid valve from the highpressure pump is prohibited. SIEMENS .
13A-3
13A
FUEL SUPPLY
13A
F9Q, and 800

Operating diagram of the fuel supply circuit
100821

- a priming bulb (1) (located in the engine compartment),
- a fuel filter (2) that may be fitted with a water detection
sensor,
- a high-pressure regulator (3) mounted on the pump,
- a high-pressure pump (4) ,
- an injection rail (5) fitted with a diesel pressure sensor
and a pressure limiter (6) ,
- four solenoid injectors (7) ,
- various sensors,
IMPORTANT
It is strictly forbidden to uncouple a high-pressure
pipe union when the engine is running.
13A-4
WARNING
Dismantling the interior of a high-pressure pump or
the injectors is prohibited.
FUEL SUPPLY
13A
F9Q, and 800 or 804 or 808

Operating diagram of the diesel fuel supply circuit
102307

- a gauge (1)
WARNING
- a manual priming pump, (2)

and the injectors is prohibited.
- a diesel filter (3) consisting of:
Outside the warranty period for the pump, only the

pump pressure regulator can be replaced.
a fuel heater,
a water detection sensor (4) , depending on the version,
- a high-pressure pump (5) consisting of:
a mechanical low-pressure pump,
a pressure regulator, (6)
- an injector rail (7) fitted with a pressure regulator (8) ,
- four solenoid injectors (9) ,
- a diesel fuel temperature sensor (10) for the diesel return circuit,
IMPORTANT
13A-5
During the pump warranty period, the high-pressure

pump should be completely replaced if the pressure
regulator fails.
FUEL SUPPLY
Petrol filter: General information
102299
The fuel filter is located in the fuel tank; it is built 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-6
13A
FUEL SUPPLY
Diesel filter: Removal - Refitting
13A
K9K, and 722 or 728 or 729
Tightening torquesm
wheel bolts
110 Nm
WARNING
Follow the cleanliness instructions closely (see
13B, Diesel injection, Cleanliness guidelines ).
The cartridge assembly must be replaced (the diesel filter is contained in a non-removable cartridge).
Order a set of blanking plugs, part number 77 01 206
804 .
REMOVAL
terminal.
101539
Remove:
- the wheel arch liner mounting bolts (1) .
- the wheel arch liner clips using an unclipping tool,
- the wheel arch liner (2) ,
- the right-hand engine side cover,
- the diesel filter from its mounting by pushing it
upwards.
Disconnect all the filter pipe unions.
Place blanking plugs over the open fuel supply pipes.
WARNING
Keep the pipe unions away from contaminated
areas.
Remove the diesel filter.
REFITTING
Take the blanking plugs off the fuel supply pipes.
Reconnect the pipe unions.
Clip the diesel filter onto the mounting.
13A-7
FUEL SUPPLY
13A
K9K, and 722 or 728 or 729
102124
Prime the fuel system with the priming pump (3)

(automatic degassing).
21749

Regularly bleed out the water in the diesel filter
via the bleed plug (4) .
WARNING
Some vehicles have a sensor for detecting water

in the diesel fuel (5) , located on the filter. If water
is detected in the circuit, the injection fault warning light on the instrument panel comes on.

13A-8
FUEL SUPPLY
13A
F9Q, and 800 or 804 or 808
Tightening torquesm
bolts
wheel bolts
4 Nm
110 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:
- 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.
- the wheel arch liner mounting bolts (1) ,

- the wheel arch liner clips using an unclipping tool,
- the 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 800 or 804 or 808
102477
19317
Disconnect the diesel heater connector (3) from the

diesel heater.
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 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 800 or 804 or 808
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
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.
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) ,
- operate the manual priming pump (9) one last time.
WARNING
( 4 Nm ) .
13A-11
FUEL SUPPLY
13A
K9K, and 724 or 732 M9R, and 700

- the front right-hand wheel arch liner (1) .
Tightening torquesm
wheel bolts

CONCERNED
110 Nm
WARNING
During this operation:
- refrain from smoking or bringing red hot objects
close to the working area,
- beware of fuel splashes when disconnecting the
union,
- protect sensitive areas from fuel outflow.
Note:
Make sure you have a new diesel filter before opening the fuel circuit.
REMOVAL
114559
Remove the diesel filter from its mounting on the

body by pushing the filter - metal strap assembly
upwards.

Disconnect all the fuel pipe unions on the diesel filter.

Note:
Make preparations for the fuel outflow.
WARNING
Prevent the hose unions from coming into contact with a polluted environment.
Remove the diesel filter from the vehicle.
Note:
Only use wipes part number 77 11 211 707 to
clean the filter and pipes once the fuel circuit is
opened.
REFITTING
104544
Remove:

CONCERNED
Connect the fuel pipes onto the new diesel filter.
13A-12
FUEL SUPPLY
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 positioned and
secure in its mounting by shaking it: the filter
must not move.
If necessary, remove the filter and gently
squeeze the metal strap retaining bracket on its
mounting.
102124
Prime the fuel circuit using the manual priming pump

(2) (automatic degassing).
Check there are no leaks from the unions on the filter.
Refit:
Note:
Regularly bleed out water that has accumulated
in the diesel filter through the bleed plug.
in the diesel fuel, located at the bottom of the filter. If water is detected in the circuit, a fault warning light on the instrument panel comes on.
13A-13
13A
FUEL SUPPLY
Injector rail - Injectors: Removal - Refitting
13A
K4M, and 760 or 761
Tightening torquesm
injector rail mounting
bolts
9 Nm

bolts
4 Nm
The injectors are secured to the injector rail by clips.

The fuel circulates constantly around the circumference of the injector body. This sweeping by the fuel prevents the formation of petrol vapour bubbles and helps
warm starting.
1
2
REMOVAL
terminal.
Remove:
101810
Disconnect injector electrical harness (1) .
- the inlet manifold (see 12A, Fuel mixture, Inlet

manifold ).
Remove:
- the two injector rail mounting bolts (2) ,
IMPORTANT
ON THE WORKBENCH
WARNING
101816
Remove:
- injector clips (3) ,
- injectors (4) .
13A-14
FUEL SUPPLY
K4M, and 760 or 761
REFITTING
WARNING
The O-rings and the injector mounting clips must
always be replaced with new ones.
Fit the injector rail.
Torque tighten the injector rail mounting bolts ( 9
Nm ) .
WARNING
4 Nm ) .
13A-15
13A
FUEL SUPPLY
13A
B84 or C84 or G84, and K4J, and 730 or 732
Tightening torquesm
bolts
9 Nm

bolts
4 Nm

warm starting.
101802
REMOVAL
Disconnect:

terminal.
- fuel supply pipe (2)

- injector and pinking sensor electrical harness (3) .

IMPORTANT
WARNING
101801
Remove mounting nuts (1) from the injection rail protector.

101493
Remove:
13A-16
FUEL SUPPLY
B84 or C84 or G84, and K4J, and 730 or 732
ON THE WORKBENCH
101492
Remove:
- injectors (6) .
REFITTING
WARNING
Nm ) .
WARNING
4 Nm ) .
13A-17
13A
FUEL SUPPLY
13A
F4R, and 770 or 771 or 776
Tightening torquesm

bolts
9 Nm

bolts
4 Nm

warm starting.
102728
REMOVAL
Disconnect:

terminal.
- fuel supply pipe (2) ,

- injector and pinking sensor electrical harness (3) .

F4R, and 770 or 771
F4R, and 776
4
6
1
5
101801
Remove the two injection rail guard mounting nuts

(1) .
106787
Disconnect:
- turbocharging pressure sensor connector (4)
- the vacuum pipe from brake servo (5) ,
- oil vapour recirculation pipe (6) .
13A-18
FUEL SUPPLY
13A
F4R, and 770 or 771 or 776

ON THE WORKBENCH
10
106271
Disconnect fuel supply pipe (7) from the injector rail.
102737
IMPORTANT
Remove:
Be careful of petrol splashing out when disconnecting the fuel supply union.

- injectors (10) .
WARNING
REFITTING
Protect sensitive areas from fuel spillage.
WARNING
Nm ) .
WARNING
4 Nm )
102730
Remove:
13A-19
FUEL SUPPLY
13A
K4J, and 730 or 732 K4M, and 760 or 761 F4R, and 770 or 771 or 776
K4M, and 760 or 761
Mot. 1311-01
Fuel pressure test kit
Mot. 1311-08
Union for measuring

fuel pressure
IMPORTANT
During this operation, be sure to:
- refrain from smoking or bringing hot objects close

to the working area,

union,
K4J, and 730 or 732 F4R, and 770 or 771 or 776

101803
Disconnect the petrol inlet pipe from 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 T union to the rail,
- petrol inlet pipe (3) to the T union.
Insert pipe (1) into a 2000 ml measuring cylinder.
IMPORTANT
101496
Disconnect the petrol inlet pipe from the injection

rail.
13A-20
This procedure must be carried out with the ignition off.

Remove the Protection and Switching Unit cover.
FUEL SUPPLY
13A
4
5
1
12
102502
102501
Place the electrical connector (4) to one side without

disconnecting it.
Connect terminal (5) of the brown connector to the

battery positive feed
Note:
The flow reading should be between 80 and 120
l/h .
102503
Disconnect the brown connector (5) from the Protection and Switching Unit.
13A-21
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
Engine
Vehicle type
Type
XM0F
Engine speed (rpm)
Smoke opacity
Suffix
Idling
speed
Maximum
unladen
Maximum
laden
Homologation value
(m-1)
722
805 50
5000 150
4800 100
724
800 50
4900 150
4900 150
Legal maximum (m -1)

3
XM0T
XM1F
K9K
XM02
728
805 50
XM13
XM02
2
1.5
4950 150
4800 100
729
Description
Make - type
Special notes
High pressure pump
DELPHI
Pressure from 0 to 1,400 bar
Low pressure pump
DELPHI
Integrated in the high pressure

pump
Injection computer
DELPHI
112-track computer (A 32, B 48, C

32)
Diesel rail pressure sensor
DELPHI
Integrated in the rail

Resistance not measurable
Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel rail pressure sensor
earth
- 3: + 5 V supply
Injectors
DELPHI / MNS HP
Solenoid injector
Maximum pressure 1,600 bar
2-track connector:
- 1: injector + control
- 2: injector - control
13B-1
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729

Description
Make - type
Special notes
Diesel flow actuator
DELPHI
Located on the high pressure

pump
Resistance: 5.3 0.5 at 20C
2-track connector:
- 1: + battery feed via Protection
and Switching Unit
- 2: actuator control
Engine speed and position sensor
MGI
Var iable reluctance sensor

Resistance: 760 (K9K 722)
Resistance: 680 (K9K 724,
728, 729)
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 supply
- 3: + battery supply
- 8: injection computer control
- 9: fault finding
Heater plugs
CHAMPION or BERU
13B-2
Resistance: 0.6
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729

Description
Make - type
Special notes
CTS

Resistance
- gang 1: tracks 3 and 5: 1700
900
1025
6-track connector:
- 1: gang 2 signal
- 2: gang 2 + 5 V supply
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Cylinder reference sensor
SAGEM
Hall effect sensor

3-track connector:
- 1: cylinder reference 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 temperature sensor
earth
Accelerometer
SAGEM

2-track connector:
- 1: signal
- 2: accelerometer earth
13B-3
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729

Description
Make - type
Special notes
Engine coolant temperature sensor
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:
- 3: 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
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 supply
- 4: pressure sensor signal
Exhaust gas recirculation solenoid valve (K9K 722, 728 and

729)
PIERBURG
Supply voltage: + 13.5 V

Resistance: tracks 1 and 5: 8
0.5 at 20C
13B-4
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729

Description
Make - type
Special notes
Exhaust gas recirculation solenoid valve (K9K 724)
PIERBURG
Supply voltage: 13.5 V
Exhaust gas recirculation solenoid valve position potentiometer

(K9K 724)
PIERBURG
Resistance: tracks 2 and 6: 2.3

at 20C
Integrated in the exhaust gas
recirculation solenoid valve
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: not used
- 5: potentiometer signal
- 6: solenoid valve earth
Exhaust gas recirculation solenoid valve position potentiometer

(K9K 722 728 and 729)
PIERBURG
Integrated in the exhaust gas

Resistance:
- tracks 2 and 4: 4 1.6 k at
20C
6-track connector:
- 1: solenoid valve + battery feed
via Protection and Switching unit
- 2: potentiometer supply + 5 V
- 3: not used
Refrigerant pressure sensor
TEXAS INSTRUMENTS
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
13B-5
DIESEL INJECTION
Specifications
13B
K9K, and 722 or 728 or 729

Description
Make - type
Special notes
Fault finding
diagnostic tool : CLIP only
Turbocharging pressure regulation solenoid valve (K9K 724, 728

and 729)
BITRON
Proportional solenoid valve

Supply voltage: 13.5 V
2-track connector:
- 1: signal
- 2: supply
13B-6
DIESEL INJECTION
Specifications
13B
F9Q, and 800 or 808
Equipment required
diagnostic tool
Engine
Vehicles
Gearbox
Type
XM0G
XM1G
Suffix
Bore
(mm)
Stroke
(mm)
Cubic capacity (cc)
Compression ratio
80
93
1870
19:1
800
ND0
F9Q
XM00
808
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
Make - Type
Special notes
High pressure pump
BOSCH CP3
Pressure from 250 to 1,350 bar
Diesel fuel pressure sensor
BOSCH
Bolted onto the rail
Injectors
BOSCH
Solenoid injector
Operating pressure up to: 1300
bar
Pressure regulator
BOSCH
Bolted 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 sensor
MGI
Resistance: 720 at 880 at 20C
Camshaft sensor
ELECTRIFIL
Accelerator potentiometer
CTS

Resistance:
- gang 1: 1700 900
- gang 2: 3875 1025
13B-7
DIESEL INJECTION
Specifications
13B
F9Q, and 800 or 808

Description
Make - Type
Special notes
Air inlet temperature sensor
SIEMENS
Integrated in the air flowmeter
Diesel fuel temperature sensor
ELTH
Resistance: 2,050 at 25C
ELTH
Resistance: 2252 112 at 25C
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
Turbocharger pressure sensor
BOSCH
Output voltage with ignition on and

engine stopped (between tracks 2
and 3):
- = 1.6 V for an atmospheric pressure of 1,013 mbar
- > 1.6 V for an atmospheric pressure > 1,013 mbar
- < 1.6 V for an atmospheric pressure < 1,013 mbar
Replace the seal each time it is
removed
Atmospheric pressure sensor
Integrated in the computer
Exhaust gas recirculation solenoid

valve
PIERBURG
Gang resistance: 8 0.5 at

20C (tracks 1 and 5)
Sensor resistance: 4 k at 20C
(tracks 2 and 4)
Damper valve solenoid valve

(engine stop solenoid valve)
BITRON ou EATON
Turbocharging pressure regulation

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)
XM0L
F9Q
804
800 50
4850
150
4500
100
1.9 (54%)
3 (70%)
XM1D
XM17
XM14
Description
Make - Type
Special notes
High pressure pump
BOSCH CP3.2
Pressure 1600 bar Max
Diesel fuel pressure sensor
BOSCH
Bolted onto the rail

Tightening torque: 3.5 5 Nm
Injectors
BOSCH
Solenoid injector
Operating pressure up to: 1600 bar
Pressure regulator
BOSCH
Screwed onto the high 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
Resistance: 800 at 20C
Camshaft sensor
ELECTRIFIL
Hall effect type
Accelerator potentiometer
CTS

Resistance:
- gang 1: 1700 900
- gang 2: 2850 2050
Air inlet temperature sensor
SIEMENS
Integrated in the air flowmeter
ELTH
13B-9
DIESEL INJECTION
Specifications
13B
F9Q, and 804

Description
Make - Type
Special notes
Air flowmeter
SIEMENS

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 stopped (between tracks 2
and 3):
- = 1.6 V for an atmospheric pressure of 1,013 mbar
- > 1.6V for an atmospheric pressure > 1013 mbar
- < 1.6 V for an atmospheric pressure < 1013 mbar
Replace the seal each time it is
removed

valve
SIEMENS
Gang resistance: 2.96 10 % at

Sensor resistance: 6.5 k 40% at

solenoid valve
PIERBURG
Turbocharger
GARRET
Calibration
- For an underpressure 265 mbar ,
the rod should have a stroke of
between 0.5 and 3.5 mm
- for a vacuum greater than 600
mbar the rod should be at the
stop
Fault finding
13B-10
DIESEL INJECTION
Diesel injection: Specifications
13B
K9K, and 732
Equipment required
diagnostic tool
Engine
Engine speed (rpm)
Smoke opacity
Vehicle
type
Type
Suffix
Idling
speed
Maximum
unladen
Maximum
laden
X84
K9K
732
800 50
5000
150
5000
150
Homologation
value
1.5 m
Legal
maximum
-1
2m
-1
Depol
lution
standard
Euro
IV
Description
Make - type
Special notes
High pressure pump
SIEMENS VDO
Pressure from 0 to 1600 bar
Low pressure pump
SIEMENS VDO

pump
Injection computer
SIEMENS VDO
128-track computer (A 32, B 48, C

48)
Diesel rail pressure sensor
SIEMENS VDO
Integrated in the rail

3-track connector:
- 1: signal
- 2: diesel rail pressure sensor
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

pump
Cannot be removed
13B-11
DIESEL INJECTION
13B
K9K, and 732

Description
Make - type
Special notes
Pressure regulation solenoid valve
SIEMENS VDO

pump
Cannot be removed
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
- 2: spark plug no. 1 supply
- 3: fault finding
- 4: + batter y supply
- 6: spark plug no. 4 supply
- 8: injection computer control
Heater plugs
CHAMPION ou BERU
Resistance: 0.6
CTS

Resistance
900
1025
6-track connector:
- 1: gang 2 signal
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
13B-12
DIESEL INJECTION
13B
K9K, and 732

Description
Make - type
Special notes
JCAE
Hall effect sensor

3-track connector:
- 1: earth
- 2: signal
- 3: supply
ELTH
Located on the diesel return rail on

the high pressure pump outlet
2-track connector:
- 1: signal
- 2: earth
SIEMENS VDO
SIEMENS VDO
Integrated in flowmeter
thermistor
Resistance:
- 44373 3118 at - 40C
- 15141 871 at - 20C
- 9202 486 at 10C
- 5774 276 at 0C
- 3714 161 at 10C
- 2448 95 at 20C
- 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
3-track connector:
- 1: supply
- 2: earth
- 3: signal
Damper valve
JCAE
Solenoid valve position potentiometer built into the damper valve

Solenoid valve supply voltage: +
13.5V
Potentiometer supply voltage: + 5V
13B-13
DIESEL INJECTION
13B
K9K, and 732

Description
Make - type
Special notes
ELTH

thermistor
Resistance:
- 75780 7000 at - 40C
- 12460 1128 at - 10C
- 2,252 112 at 25C
- 811 38 at 50C
- 282 8 at 80C
- 115 3 at 110C
- 88 2 at 120C
4-track connector:
- 1: not used
sensor signal
sensor earth
- 4: not used

valve
PIERBURG

valve position potentiometer
PIERBURG
Supply voltage: + 13.5 V

Resistance: tracks 2 and 6: 2.3
Integrated in the exhaust gas recirculation solenoid valve
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 4: not used
TEXAS INSTRUMENT
BIRTON
3-track connector:
- A: earth
- B: supply
- C: signal
13B-14
DIESEL INJECTION
13B
K9K, and 732

Description
Make - type
Special notes
Water in diesel sensor
PRESSAC
Located on the diesel filter

3-track connector:
- 1: supply
- 2: signal
- 3: earth
Air inlet flowmeter
SIEMENS VDO

temperature sensor
6-track connector:
- 1: air temperature signal
- 2: earth
- 3: Not used
- 4: + 12 V supply
- 5: supply: + 5 V
- 6: air flow signal

solenoid valve
BIRTON
Proportional solenoid valve

supply voltage + 12 V
2-track connector:
- 1: computer output
- 2: supply
Fault finding
13B-15
DIESEL INJECTION
Diesel injection: Precautions for repair
13B
K9K, and 722 or 724 or 728 or 729 or 732 F9Q, and 800 or 804 or 808 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 contamination.
- fibres from:
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).
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: they both have the same end
result and neither is preferred over the other.
1 - Using the injector cleaning agent
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.
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 protective gloves.
IMPORTANT
5) Before any operation on the injection system protect
(using plastic bags or clean cloths for example):
- the accessories and timing belts,
- the electrical accessories (starter motor, alternator,
power-assisted steering pump, sensors and electrical
connectors),
Wear latex safety gloves when using the cleaning

agent.
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
Clean the unions carefully using the brush and the injector cleaning agent.
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: ambient atmosphere can be a source of pollution.
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
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
Description
F9Q, and 800 or 808
The high pressure direct injection system is intended to
deliver a specific volume of diesel fuel to the engine at
a specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a pressure regulator mounted on the pump,
- a high pressure pump,
- an injection rail fitted with a diesel fuel pressure sensor and a pressure limiter,
- four solenoid injectors,
- various sensors,
13B-31
13B
DIESEL INJECTION
Description
K9K, and 722 or 728 or 729
The high pressure direct injection system is intended to
deliver a specific volume of diesel fuel to the engine at
a specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a high pressure pump combined with a low pressure
pump (transfer pump),
- a pressure regulator mounted on the pump,
- a spherical injection rail,
- a pressure sensor incorporated into the rail,
- four solenoid injectors,
- a diesel fuel temperature sensor,
- a coolant temperature sensor,
- a turbocharging air temperature and pressure sensor,
- a cylinder marking sensor,
- an engine speed sensor,
- an accelerometer,
- an exhaust gas recirculation solenoid valve,
- an accelerator pedal potentiometer,
- an atmospheric pressure sensor,
13B-32
13B
DIESEL INJECTION
Operation
13B
F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
- the needle stroke (determined by a constant for an injector type),
Equipment required
- the nominal hydraulic flow of the injector (specific to

each injector),
diagnostic tool
- the high pressure rail pressure regulated by the computer.
IMPORTANT
The computer manages:

Before carrying out any work on the injection circuit,
check using the diagnostic tool :
- idle speed regulation,
- that the rail is not pressurised,
- the exhaust gas flow reinjected into the inlet,
- the fuel supply (timing, flow and rail pressure),
Every time work is carried out, be sure to follow the

safety and cleanliness advice specified in this document.
- the fan assembly actuation request (function: centralised coolant temperature management),
- the air conditioning,
Loosening a high pressure pipe union when the

- the cruise control-speed limiter function,
The common rail high pressure injection system

operates in sequential mode (based on the multipoint
injection principle for petrol engines).
- the pre/postheating actuation.

The high pressure pump is supplied at low pressure by
a mechanical low pressure pump (transfer pump).
Through its pre-injection process, this injection system

can provide:
The high pressure pump supplies the rail which is pressure-controlled:
- reduced operating noise,
- for loading by the fuel flow actuator,
- a reduction in the amount of pollutant gases and particles,
- for discharge by the injector valves.
- a high engine torque at low engine speeds.
The fuel flow actuator allows the high pressure pump to

supply the exact volume of diesel fuel required to maintain the pressure in the rail. This feature allows heat
generation to be minimised and engine output to be improved.
The high pressure pump generates the high pressure

transmitted to the injection rail. The actuator on the
high pressure pump controls the volume of diesel fuel
supplied according to the demand determined by the
injection computer. The rail supplies each injector
through a steel pipe.
The computer:
- determines the injection pressure value necessary for
the engine to operate correctly and then operates the
fuel flow actuator. It checks that the pressure value is
correct by analysing the value transmitted by the
pressure sensor located on the rail,
- determines the injection time necessary to deliver the
right volume of diesel fuel and the moment when injection should be started,
- electrically actuates each injector individually after
determining these two values.
The flow injected into the engine is determined according to:
- the duration of injector actuation,
- the injector opening and closing speed,
Drops in pressure may also be compensated for.
To discharge the rail, the injection valves are controlled

by small electrical pulses:
- short enough not to open the injector (passing through the return circuit from the injectors),
- long enough to open the valves and discharge the
rail.
The injection computer actuates the fan assembly and
the coolant temperature warning light on the instrument panel (function: centralised coolant temperature
management).
The various vehicle computers communicate via multiplex links. The fault warning lights on the instrument
panel are therefore activated via the multiplex network.
In the event of an impact, the function that cuts off the
diesel fuel supply circuit is managed by the airbag
computer. It gives the command via the multiplex
network to the injection computer to lock the injection
locking relay control.
13B-33
DIESEL INJECTION
Operation
13B
Unlocking is only enabled after the ignition is switched
off for 10 seconds . This operation causes the fault
warning light to come on for longer than usual when
switching on the ignition. The warning light will not return to normal operation until the fault has been cleared
using the diagnostic tool .
WARNING
- The engine must not be run with diesel fuel containing more than 10% diester or petrol, even in
minute quantities.
- Dismantling the interior of the high pressure pump
and the injectors is prohibited. Only the fuel flow
actuator, the diesel fuel temperature sensor and
the Venturi tube can be replaced.
The vehicle speed signal is transmitted to the instrument panel by the ABS computer or the gearbox (vehicle without ABS system) via the multiplex network.
Some vehicles have a sensor for detecting water in the
diesel fuel, which is located in the filter. If there is water
present in the diesel fuel, the orange injection warning
light comes on.
- It is prohibited to remove the pressure sensor from

the injection rail as this could cause contamination
of the circuit. If the pressure sensor is faulty,
replace the assembly consisting of the pressure
sensor, rail, and the five high pressure pipes.
Automatic configuration for cruise control - speed limiter operation and for air conditioning operation.
- It is strictly prohibited to remove any injection

pump pulley bearing the number 070 575. If the
pump is being replaced also replace the pulley.
Injection computer actuating the air conditioning compressor clutch via the UPC.
- Supplying any system component directly with the

+ 12 V is prohibited.
A new electronics casing called the UPC has been

added to the vehicles wiring diagram.
- Ultrasonic decarbonisation and cleaning are prohibited.
The UPC supplies the following with power:

- the air conditioning compressor,
- Never start the engine unless the battery is properly connected.
- the fan assembly,
- Never turn the engine against its operating direction.
- the electrical heating resistors.

The UPC is located in the engine compartment near
the battery. It contributes to the protection of certain
electrical components.
Reprime the circuit using the priming pump.
IMPORTANT
In this capacity, it comprises:
The engine should not be run with diesel fuel containing more than 10% diester.
- fuses,
- several internal relays including:
Note:
the + after ignition feed relay,
After any operation, check that there is no diesel

fuel leakage. Let the engine idle until the engine
cooling fan starts up, then accelerate several times
at no load.
the fan assembly control relays,

the air conditioning compressor relay.
These relays cannot be removed.
If the UPC is replaced, it must be configured using the
diagnostic tool (see 87G, Motor exchange unit,
UPC: Configuration ).
The injection computer receives a continuous signal
via the multiplex network regarding the electrical power
available from the alternator. This therefore prevents
the vehicle's electrical consumption from being in excess of the alternator's capacity. The aim is to give
priority to charging the battery.
The system can inject the diesel fuel into the engine up
to a pressure of 1350 bar . Before each operation
check that the injection rail is no longer pressurised.
Be sure to observe the tightening torque:
- for the high pressure pipes,
- for the injector on the cylinder head,
- for the pressure sensor and pressure regulator.
13B-34
DIESEL INJECTION
Operation
When the high pressure pump, injectors and high pressure supply, outlet and return unions are removed or
repaired, all apertures should be capped with suitable
new blanking covers to prevent contamination.
WARNING
Any pipe removed must be replaced.
When replacing a high pressure pipe, follow the procedure below:
- remove the high pressure pipe, holding the filter rod
on the injector with a lock spanner,
- fit anti-contamination plugs,
- loosen the high pressure rail,
- fit the new high pressure pipe,
- finger tighten the unions until they touch,
- torque tighten the high pressure rail mountings,
- torque tighten the union at the injector end,
- torque tighten the high pressure rail end union.
WARNING
Dismantling the interior of the pump is prohibited.
The fuel return pipe fitted to the injectors must be
replaced when removed.
The diesel fuel temperature sensor cannot be
removed. It is part of the fuel return rail.
engine is running is prohibited.
13B-35
13B
DIESEL INJECTION
13B
K9K, and 722
102072
(1)
Pr iming pump
(2)
(3)
Turbocharger
(4)
Exhaust gas recirculation solenoid valve
(5)
Injector
(6)

and pressure sensor
(7)
Injection computer
(8)
Air filter unit
(9)
Protection and Switching Unit
(10)
(11)
(12)
(13)
Spherical injection rail
(14)
Accelerometer
(15)
(16)
Diesel flow actuator
(17)
High pressure pump
101811
(18)
13B-36
Injection computer
DIESEL INJECTION
13B
K9K, and 722
101105
(19)
102084
(21)
Venturi
(22)
Flow actuator
(23)
(24)
(25)
(26)
Accelerometer
(27)
Injector
102085
(20)
High pressure pump
102082
13B-37
DIESEL INJECTION
13B
K9K, and 722

(28)

and pressure sensor
(29)
(30)
Wastegate valve
19654-1
(31)
13B-38
DIESEL INJECTION
13B
K9K, and 722
20796
(32)
(33)
102125
(35)
102121
102204
(34)
13B-39
(36)
Diesel filter
DIESEL INJECTION
13B
K9K, and 722
102124
(37)
Pr iming pump
102077
102128
(38)
13B-40
(39)
Turbocharger
(40)
Catalytic converter
DIESEL INJECTION
13B
F9Q, and 800 or 808
101883
(16)
Turbocharging pressure sensor
(17)
Diesel temperature sensor (fuel

return)
(1)
Diesel filter
(2)
Manual priming pump
(3)
(18)
High pressure pump
(4)
(19)
Diesel pressure regulator
(5)
Solenoid injectors
(6)
Engine stop system vacuum

reserve
(7)
Engine stop system solenoid

valve
(8)
Exhaust gas recirculation solenoid valve (F9Q 800)
(9)
Turbocharger regulation solenoid valve
(10)
Flowmeter with air temperature

sensor
(11)
Injection computer
(12)
(13)
Engine stop valve diaphragm
(14)
Engine stop valve
(15)
Pressure limiter (on injection

rail)
13B-41
DIESEL INJECTION
13B
F9Q, and 800 or 808
18297-1
(20)
High pressure pump
(21)
Injection rail
(22)
Injector
(23)
Pressure regulator
(24)
Pressure sensor
(25)
(26)
Pressure limiter
27
102485
(27)
13B-42
TDC sensor
DIESEL INJECTION
13B
F9Q, and 800 or 808
28
31
16181
(28)
101891
(31)
Preheating unit
29
32
30
102479
(29)
Turbocharger
(30)
Catalytic converter
101889
(32)
13B-43
Turbocharging pressure regulation solenoid valve
DIESEL INJECTION
13B
F9Q, and 800 or 808
38
33
34
101892
(33)
Engine stop valve
(34)
Engine stop
diaphragm
101886
(38)
Manual priming pump
valve control
35
37
36
39
102486
(35)
Engine stop valve

reserve
vacuum
(36)
Engine stop valve solenoid valve
(37)
Exhaust gas recirculation solenoid valve (F9Q 800)
102121
(39)
13B-44
Diesel filter
DIESEL INJECTION
F9Q, and 800 or 808
40
102352
(40)
102204
(41)
13B-45
13B
DIESEL INJECTION
13B
K9K, and 728 or 729
106343
(1)
Pr iming pump
(2)
(3)
Turbocharger
(4)
(5)
Injector
(6)

and pressure sensor
(7)
Injection computer
(8)
Air filter unit
(9)
UPC
(10)
(11)
(12)
(13)
(14)
Accelerometer
(15)
(16)
Diesel fuel flow actuator
(17)
High pressure pump
(18)
Turbocharging pressure solenoid valve
101811
(19)
13B-46
Injection computer
DIESEL INJECTION
13B
K9K, and 728 or 729
101105
(20)
UPC
102084
(22)
Venturi
(23)
Fuel flow actuator
(24)
(25)
(26)
(27)
Accelerometer
(28)
Injector
102085
(21)
High pressure pump
110327
13B-47
DIESEL INJECTION
K9K, and 728 or 729
110319
(29)

and pressure sensor
(30)
(31)
(32)
101889
(33)
13B-48
13B
DIESEL INJECTION
13B
K9K, and 728 or 729
19654-1
(34)
102204
20796
(35)
13B-49
(36)
DIESEL INJECTION
13B
K9K, and 728 or 729
102124
(39)
Priming pump
102125
(37)
102128
(40)
104954
(38)
Diesel filter
13B-50
DIESEL INJECTION
K9K, and 728 or 729
102077
(41)
Turbocharger
(42)
Catalytic converter
13B-51
13B
DIESEL INJECTION
13B
F9Q, and 804
101883
(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)
UPC
(11)
Pressure limiter
(12)
(13)
(14)
High pressure pump
(15)
Diesel pressure regulator
13B-52
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-53
TDC sensor
DIESEL INJECTION
13B
F9Q, and 804
16181
(24)
101891
(27)
111864
(25)
Turbocharger
(26)
Catalytic converter
101889
(28)
13B-54
Preheating unit
DIESEL INJECTION
13B
F9Q, and 804
111856
(29)
Throttle valve.
(30)
Exhaust gas recirculation solenoid valve unit.
102121
(32)
Diesel filter
102204
101886
(31)
Pr iming pump
13B-55
(33)
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)
Injection rail
(15)
Injection rail pressure sensor
(16)
(17)
Diesel filter
101811
(18)
13B-56
Injection computer
DIESEL INJECTION
13B
K9K, and 732
101105
(19)
111748
(20)
High pressure pump
13B-57
112994
(21)
(22)
Air inlet valve
(24)
Pressure regulation solenoid

valve
(23)
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 bracket
(33)
Spacer between the cylinder

head and injector bracket
102204
(34)
13B-58
DIESEL INJECTION
13B
K9K, and 732
102124
(37)
Priming pump
102125
(35)
113840
114559
(36)
Diesel filter
13B-59
(38)
Catalytic converter
(39)
Turbocharger
DIESEL INJECTION
K9K, and 732
114185
(40)
13B-60
13B
DIESEL INJECTION
K9K, and 722 or 728 or 729 F9Q, and 800 or 804 or 808
These vehicles are fitted with an engine immobiliser
system, controlled by a RENAULT card random rolling
code recognition system, which requires a special procedure for replacing the computer.
REPLACEMENT
For the removal/refitting procedure, (see 13B, Diesel injection, Diesel injection computer ).
For the engine immobiliser functions (see 82A, Engine immobiliser, Operation ).
Injection computers are supplied without a code, but
they can all be programmed with one.
When replacing the computer, program it with the
vehicle code, then check that the engine immobiliser
function is operational.
Switch on the ignition for a few seconds without starting the engine.
Note:
The immobiliser function operates after roughly
10 seconds (the red immobiliser warning light
blinks on the instrument panel).
WARNING
- The injection computer retains the immobiliser
code for life.
- The system has no security code.
- 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.
13B-61
13B
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732

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.
Note:
For vehicles fitted with K9K 732 engines (see MR
370 Mechanics, Scnic II ).
The faults relate to:

Vehicles fitted with the Delphi DDCR high-pressure
diesel fuel system use fault warning symbols and text
warning messages, depending on the level of severity
of the faults detected, to inform the customer and determine the correct fault finding procedure.
- with delayed stop: the fuel flow actuator (loop discrepancy and overpressure),
- with immediate stop:
the engine speed sensor,
The injection computer controls the illumination of warning lights and message displays on the instrument panel. The fault warning lights come on:
the diesel flow actuator,
- during the preheating phase,
the supply to all the injectors,
- if there is an injection fault,
the sensor supply 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 (press the Start button,
the orange preheating symbol is lit during the preheating phase, then goes out) (see 13C, Preheating, Prepostheating 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.
the rail pressure sensor,
If the engine overheats, the engine 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 Diagnostic excess pollution orange
warning light
The orange warning light, represented by an engine,
comes on for approximately 5 seconds then goes out.
It is never displayed when the engine is running (not
operational).
Repairs should be carried out as soon as possible.

These faults are associated with:
- the engine immobiliser,
- a C2l (individual injector correction) coding error,
- an injector,
- the injector controls,
- the diesel fuel supply (injector leak, etc.),
- an engine speed sensor target fault,
- the injection locking relay,
- the exhaust gas recirculation solenoid valve or 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 on vehicle.
13B-62
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808

Vehicles fitted with the Bosch EDC16 high pressure
diesel fuel system use fault warning symbols and text
warning messages, depending on the level of severity
of the faults detected, to inform the customer and determine the correct fault finding procedure.
The injection computer controls the illumination of warning lights and message displays on the instrument panel. The fault warning lights and error messages are
visible:
- an injector fault,
- a rail pressure sensor fault,
- a rail pressure regulator fault.
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. In this case the
vehicle must be stopped immediately.
- during the preheating phase,

On Board Diagnostic excess pollution orange
warning light
- if there is an injection fault,

- if the engine is overheating.
The warning signals are sent to the instrument panel
The orange engine symbol comes on when the ignition

is switched on for around 5 seconds then goes out. It
is never displayed when the engine is running (not operational).
WARNING LIGHT PRINCIPLE

During the starting phase (press on the Start button, the orange preheating symbol is lit during the preheating phase then it goes out) (see 13C, Preheating,
Pre-postheating control ).
In the event of an injection fault (level 1), the message
Check injection is displayed and then the
Service warning light comes on. This means a reduced level of operation and a limited safety level.
- an internal computer fault,
- an immobiliser system fault,
- a speed synchronisation fault,
- an accelerator pedal potentiometer fault,
- an air flowmeter fault,
- a speed sensor fault (see ABS system),
- an EGR solenoid valve fault,
- a fault in the turbocharging pressure regulation solenoid valve,
- a fault in the main relay of the Protection and Switching Unit,
- an injector fault,
- an injector flow correction fault (IMA),
- a sensor power feed fault.
If there is a serious injection fault (level 2), the red engine symbol and the word Stop appears (only on information display), with the message Injection
faulty , followed by the Stop warning light and
buzzer.
- an internal computer fault,
13B-63
DIESEL INJECTION
Injection / air conditioning programming
13B
K9K, and 722 or 728 or 729
Note:
Note:
For vehicles fitted with engine concerned (see MR

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 .
The air conditioning management is shared between

several computers that communicate via the multiplex
network.
The air conditioning compressor is of the variable

displacement type.
It is of the cold loop type.

The injection computer is responsible for:
I - COMPRESSOR OPERATION PROGRAMMING
- managing the cooling request according to passenger

compartment commands and the circuit pressure value,
During certain operating phases, the injection computer disables the operation of the compressor.
- calculating the power absorbed by the compressor

from the circuit pressure value,
1 - Engine starting programming
- authorising engine cooling fan control in accordance

with vehicle speed and circuit pressure,
The operation of the air conditioning compressor is inhibited for 1 second after the engine has started.
- authorising or inhibiting engagement of the compressor clutch.
2 - Thermal protection programming
When the air conditioning is switched on, the air conditioning control panel requests authorisation to engage
the compressor clutch.
The injection computer authorises or inhibits compressor clutch engagement, controls the fan assembly via
the UPC and imposes an increased idle speed.
This engine speed is 900 rpm depending on how much
power is absorbed by the compressor.
The injection computer authorises operation of the air
conditioning compressor and the fan unit (both supplied by the UPC), according to the following conditions:
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.
- engine coolant temperature,
4 - Recovery of performance
- vehicle speed,
- climate control.
If the accelerator pedal is depressed firmly (more than

75 % of its travel), the compressor is disengaged for 5
seconds .
The signals used for the air conditioning function are

transmitted via:
5 - Recovery of power when moving off
- track A A4 CAN HIGH multiplex connection,

- track A A3 CAN LOW multiplex connection.
The connections between the injection computer and
the refrigerant pressure sensor are:
- C C3 refrigerant pressure sensor signal,
- C C4 refrigerant pressure sensor supply,
- C G3 refrigerant pressure sensor earth.
To assist the vehicle moving away, the air conditioning

compressor is disengaged if the accelerator pedal travel is greater than 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 .
13B-64
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

7 - Engine overspeed timed protection
programming
Output conditions:
- engine speed above 3500 rpm ,

engine speed is above 4500 rpm for more than 3 seconds .
- and vehicle speed greater than 90 mph (150 km/h)

(by way of information).
3 - Performance return programming for hill starts
Note:
To assist hill starts, the heating resistors are temporarily disabled.
There is always a delay of more than 10 seconds

after the air conditioning compressor is disengaged
before it can be disengaged again.
Input conditions:
- engine speed less than 900 rpm ,
- 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.
The UCH determines the need to actuate the heating
resistors, according to the user's request.
Output conditions:
- engine speed greater than 2500 rpm ,
- or vehicle speed greater than 3.6 mph (6 km/h)
- or a gear is engaged.
4 - Stalling prevention programming
The injection computer determines:

- the number of heating resistors supplied (power control limitation) depending on the alternator charge,
- whether resistor operation should be disabled, according to engine speed, load and vehicle speed.
When the engine speed falls below 760 rpm , operation of passenger compartment heating resistors is interrupted. When engine speed rises above 750 rpm ,
the passenger compartment heating resistors are reenabled.
The heating resistors are supplied by the UPC.

At the request of the resistors, the fast idle speed becomes 900 rpm .
III - PASSENGER COMPARTMENT HEATING
During certain operating phases, the injection computer disables the passenger compartment heating resistors.
1 - Engine start programming
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 engine speeds the heating resistors are temporarily disabled.
Input conditions:
- engine speed less than 3000 rpm ,
- and vehicle speed less than 78 mph (130 km/h) .
13B-65
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808

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.
The injection computer authorises or inhibits the compressor clutch, and controls the fan assembly via the
UPC.
When the air conditioning function is selected, the
idling speed is not altered.
It is re-engaged if the engine speed exceeds 780 rpm .

II - PASSENGER COMPARTMENT HEATING
During certain operating phases, the injection computer disables the heating resistors.
The heating resistors are disabled while the heater
plugs are in operation.
When the engine starts, the heating resistor supply is
authorised after a delay that depends on the engine
coolant temperature.
The signals used for the air conditioning function are

transmitted via:
- track A A4 CAN HIGH multiplex connection,
- track A A3 CAN LOW multiplex connection.
Engine coolant temperature
This compressor is the variable output type.
Delay
(s)
(C +/- 1)
I - AIR CONDITIONING COMPRESSOR OPERATION
PROGRAMMING
- 30
30
- 20
25
- 10
15
15
Air conditioning compressor operation is inhibited for 2

seconds after the engine has started.
10
15
20
15
30
10
During certain operating phases, the injection computer disables the compressor.

The air conditioning compressor is not engaged if the
engine coolant temperature is above 115 C , it is reengaged if the engine coolant temperature falls below
115 C .
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.
2 - Stalling prevention programming

When the engine speed falls below 800 rpm , operation of the heating resistors is interrupted. When the
engine speed falls below 875 rpm , operation of the
heating resistors is authorised.
When the heating resistors are activated, the injection

computer adopts a fast idling speed. This engine
speed is 900 rpm .
3 - Recovery of power when moving off
To help the vehicle start moving, the air conditioning
compressor is engaged if the accelerator pedal position is above 25 % , the engine speed is below 1350
rpm and the vehicle speed is below 3 mph (5 km/h) .
4 - Anti-stalling function
engine speed is below 750 rpm .
13B-66
DIESEL INJECTION
Idling speed
13B
K9K, and 722 or 728 or 729 or 732

II - IDLE SPEED CORRECTION IN THE EVENT OF
AN ACCELERATOR PEDAL POTENTIOMETER
FAULT
Note:
The injection computer calculates the idling speed needed to maintain it 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 (climate control, fan unit,
passenger compartment heating electrical resistors,
etc.),
- any faults found.
- If one of the two accelerator pedal potentiometer

tracks is faulty, the injection computer forces 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 idle speed of 1300
rpm .
III - IDLE SPEED CORRECTION IN THE EVENT OF
AN INJECTOR C2I CODING ERROR
In the event of an injector C2I coding error (individual
adjustment of the injector flow), the injection computer
forces an idle speed of 1300 rpm . This defect mode limits performance. The Check injection message lights up, followed by the Service warning light.
Note:
At normal engine operating temperature, without
major electrical consumers, the engine idling speed
is 805 50 rpm .
IV - IDLE SPEED CORRECTION WHEN THE

VEHICLE IS BEING DRIVEN
I - IDLE SPEED CORRECTION ACCORDING TO

COOLANT TEMPERATURE
At normal engine operating temperature, the idle

speed is modified according to the gear engaged:
- in neutral, the speed is 805 rpm ,
- in 1stand 2 ndgear, the speed is 875 rpm ,
- in 3rdand 4 thgear, the speed is 900 rpm ,
- in 5thgear, the speed is 950 rpm .
103122
X: Engine idle speed (rpm)

Y: Engine coolant temperature (C)
13B-67
DIESEL INJECTION
Idling speed
B84 or C84 or S84, and F9Q, and 800 or 804
COOLANT TEMPERATURE
In all cases, this engine idling speed correction is deactivated 10 minutes after engine start 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 the two accelerator pedal potentiometer tracks are
defective, the injection computer sets the idling speed
at 1400 rpm . By pressing on the brake pedal, the
idling speed falls back 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 when the 1stor the 2 ndgear is engaged,
- 900 rpm when a higher gear than 2ndis engaged.
13B-68
13B
DIESEL INJECTION
Centralised coolant temperature management
K9K, and 722 or 728 or 729 or 732
Note:
The coolant temperature sensor (injection and coolant
temperature indicator on the instrument panel) is a 3track sensor:
- 2 tracks for the coolant temperature signal to the computer (tracks B H2 and B H3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be controlled by the injection computer. It consists of a single
temperature sensor serving injection, the engine cooling fan, the temperature indicator and the instrument
panel engine coolant temperature warning light.
The request to operate the engine cooling fan is made
by the injection computer through the multiplex
network.
I - FAN ASSEMBLY OPERATION WITH THE

ENGINE RUNNING
The fan assembly is controlled:
- at low speed if the engine coolant temperature exceeds 99 C or in the event of a coolant temperature
sensor fault and stops when the temperature falls below 96 C ,
- at high speed if the engine coolant temperature exceeds 102 C or if the low speed is faulty and stops
when the temperature falls below 99 C .
The fan assembly low and high speeds are controlled
when the air conditioning function is selected on the
instrument panel.
The fan will operate at high speed under the low speed
operating conditions if low speed is faulty.
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 118C . It goes out when the temperature drops below 115 C .
13B-69
13B
DIESEL INJECTION
Centralised coolant temperature management
F9Q, and 800 or 804 or 808
The coolant temperature sensor (injection and coolant
temperature indicator on the instrument panel) is a 3track sensor:
- 2 tracks for the coolant temperature signal to the computer (tracks B E1 and B K3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be controlled by the injection computer. It consists of a single
temperature sensor serving injection, the engine cooling fan, the temperature indicator and the instrument
panel engine coolant temperature warning light.
The request to operate the engine cooling fan is made
by the injection computer through the multiplex
network.
I - FAN ASSEMBLY OPERATION WITH THE
ENGINE RUNNING
The fan assembly is controlled:
- at low speed if the engine coolant temperature exceeds 99C and stops when the temperature drops
below 96C ,
- at high speed if the engine coolant temperature exceeds 102C and stops when the temperature drops
below 99C ,
- The fan assembly low and high speeds are controlled
when the air conditioning function is selected on the
instrument panel.
II - ENGINE COOLANT TEMPERATURE WARNING
LIGHT
The warning light is actuated by the injection computer
The warning light is lit continuously if the coolant temperature exceeds 120C . It goes out if the temperature
falls below 115C .
13B-70
13B
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732

PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
Equipment required
diagnostic tool
The system can be programmed and reprogrammed
via the diagnostic socket using the diagnostic tool .
Before programming, reprogramming or replacing

the computer, save to the diagnostic tool the following data:
- the C2I parameters (individual injector correction),
- the engine adaptives using command SC003
Save computer data .
WARNING
- Connect (to the mains or the cigarette lighter) the
diagnostic tool .
After programming, reprogramming or replacing the

computer:
- Check the condition of the battery.
- Connect a battery charger (throughout the duration of computer (re)programming, the engine cooling fan is automatically engaged).
- start and then stop the engine (to initialise the computer) and wait for 30 seconds ,
- Comply with the engine coolant temperature

values given in the diagnostic tool before
carrying out any (re)programming.
- switch on the ignition again.

- Use the diagnostic tool :
use command SC001 Write saved data t o
restore the C2I and engine adaptives,
enter the VIN using command VP010 Write
VIN ,
rectify any faults in computers indicated by the
diagnostic tool ,
clear the computer memory,
carry out a road test,
carry out a new check using 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.
- The computers are permanently coded.
Note:
If commands SC001 and SC003 are not run or
cannot be run following programming, reprogramming or replacement of the computer, the
C2I of each injector must be written manually,
reading the C2Is on the injectors (see 13B, Diesel Injection, Injectors: Configuration ).
13B-71
DIESEL INJECTION
13B
F9Q, and 800 or 808

using the diagnostic tool , ensure that the computer has not detected any faults relating to the injector codes and that the instrument panel
warning light is off.
Equipment required
diagnostic tool
The system can be programmed and reprogrammed
via the diagnostic socket using the diagnostic tool (refer to Technical Note 3585A ).
WARNING
- Connect the diagnostic tool (to the mains or the
cigarette lighter).
- Check the condition of the battery.
- Connect a battery charger (the engine cooling
fans are automatically activated for the entire
duration of the computer (re)programming ).
- Keep to the engine coolant temperature guidelines
supplied in the diagnostic tool before carrying
out any (re)programming.
PROGRAMMING, REPROGRAMMING OR
REPLACING THE COMPUTER
When a computer is reprogrammed or replaced, it is
necessary to reprogram it with the IMA (Injector
Flow Correction) codes of the four injectors.
There are two possibilities:
- If it is possible to enter into dialogue with the
computer:
download the data from the old computer into the
diagnostic tool ,
replace the computer,
transfer the data from the diagnostic tool to the
new computer,
using the diagnostic tool , ensure that the computer has not detected any faults relating to the injector codes and that the instrument panel
warning light is off.
- If it is not possible to enter into dialogue with the
computer:
read the data from the injectors,
enter it into the computer using the diagnostic
tool ,
reconfigure the computer for the equipment (air
conditioning),
13B-72
DIESEL INJECTION
High pressure pipe: Checking
K9K, and 722 or 728 or 729
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no diesel fuel leakage.
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 for finding 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 in the engine bay 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-73
13B
DIESEL INJECTION
13B
K9K, and 732
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no diesel fuel leakage.
Reprime the diesel circuit using the manual priming
pump.
112811
Pull out the clip.
112815

(1) .
Loosen the clip and (2) move the air inlet duct aside
(3) .
112991
Remove the stainless steel pipe mounting bolt (4) .

Move the air inlet duct to one side (5) .
13B-74
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 in the engine bay 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
Remove:
- the air inlet pressure sensor connector.
- the mounting nut and bolt (7) from the injection rail
protector cover,
Loosen the clip and move the air inlet duct aside.
Pull out the stainless steel pipe clip.
Remove the air inlet duct.
Refit the clip onto the stainless steel pipe if necessary.
Refit:
Clip the stainless steel pipe to turbocharger.
Refit the air inlet duct on the damper valve.
- the injection rail protector cover mounting nut and

bolt,
Tighten the clip.
Clip the injection rail protector cover.
Connect:
Clip the stainless steel pipe to the turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Note:
Tighten the clip.
The diagnostic tool can be used for testing the

high pressure circuit with the engine running.
Connect:
This command can be used for finding 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.

13B-75
DIESEL INJECTION
High pressure pipe: Replacement
13B
K9K, and 722 or 728 or 729 or 732

Mot. 1566
WARNING
Wrench for removing

high-pressure pipes
- Ensure that you have a special high-pressure

injection circuit blanking plugs kit.
- Ensure that any high-pressure pipe or high-pressure pipe clips that have been removed are replaced.
Equipment required
diagnostic tool
pipe socket for tightening the pump-rail high-pressure pipe (19-17 mm Crowfoot spanner)
REMOVAL
terminal.
high-pressure pipe wrench (DM19)

pipe socket for tightening injector-rail high pressure
pipes ("Crowfoot 18-17" wrench)
low torque wrench
K9K, and 722
Tightening torquesm
rail mounting nuts
28 Nm
pump-rail highpressure pipe nuts
38 Nm
rail-injectors highpressure pipe nuts
38 Nm
filler neck nut on the rail
21 Nm

bolts
4 Nm
102120
Disconnect air inlet duct (1) .
Note:
IMPORTANT
that the injector rail is not under pressure,
that the fuel temperature is not too high.
- It is essential to respect the safety and cleanliness
carried out on this system.
- Loosening a high-pressure pipe union when the
13B-76
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732
K9K, and 728 or 729
102362
Remove diesel fuel splash plate (5) .

110325
Pull out clip (2) .
7
3
6
9
102361
110323
Remove dipstick guide tube (6) .
Loosen bolt (3) .
Fit blanking plugs into the openings.
Move aside the air duct (4) .
Carefully disconnect:
- the heater plugs (7) ,
- the injectors,
- the high-pressure pump electrical connectors (8) ,
- the diesel supply and return pipes (9) .
13B-77
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
10
15
14
13
12
11
102360
- the diesel return pipe (10) connecting the injectors
to the high-pressure injection pump,
- the spherical injector rail pressure sensor (11) ,
- the accelerometer (12) ,
- the oil level sensor (13) ,
- the timing cover cylinder marking sensor (14) .
Shift the electrical harness to one side.
Remove filler neck (15) located on the spherical injector rail.
WARNING
- Be sure to hold the intermediate injector union
(18) in place with a spanner when loosening the
high-pressure pipes.
- Do not damage injector leak return nozzle (19) .
13B-78
13B
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732
Note:
Loosen the nuts pipe by pipe.
Move the nuts along the tube, keeping the olive in
contact with the taper.
17
20
16
20803
19
20803
Remove high-pressure pipes (20) one by one.

18
19724
Loosen mounting nuts (16) on the spherical injector

rail by several turns.
Remove clips (17) connecting the high-pressure pipes.
Loosen:
- the high-pressure pipe nut at the injector end using
tool (Mot. 1566) ,
- the high-pressure pipe nut at the injector rail end
using tool (Mot. 1566) .
13B-79
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732
REFITTING
II - REFITTING THE RAIL - INJECTORS HIGHPRESSURE PIPES

Remove the plugs.
Insert the high-pressure pipe olive in the injector
high-pressure inlet taper.
Insert the high-pressure pipe olive in the rail highpressure outlet taper.
Tighten the high-pressure pipe nuts by hand, starting with the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts.
WARNING
When tightening the high-pressure pipes, it is
essential to support the injector central union
(18) .
Note:
20960
The order of fitting the injector rail pipes is not

impor tant.
WARNING
- Before fitting a new high-pressure pipe, lightly
lubricate the nut threads with the oil from the
applicator provided in the new parts kit.
- Be careful not to allow oil into the high-pressure
pipe.
- Do not lubricate high-pressure pipes supplied
without an applicator, as these high-pressure
pipes are self-lubricating.
WARNING
Do not remove the caps from each component
until the last moment.
I - REFITTING THE PUMP - RAIL HIGH

PRESSURE PIPE
19723
Remove the plugs.

Insert the high-pressure pipe olive in the high-pressure pump high-pressure outlet taper.
Insert the high-pressure pipe olive in the spherical
injector rail inlet taper.
Finger tighten the high-pressure pipe nuts, starting
with the one at the rail end.
13B-80
Fit a new clip provided with the new high-pressure

pipe:
- insert the first half-shell using adjustable pliers,
- insert the second half-shell using adjustable pliers.
Note:
Follow the direction of fitting (the lugs only
engage in one position).
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
III - REFITTING THE PUMP - RAIL HIGH
PRESSURE PIPE AND THE RAIL - INJECTOR
HIGH PRESSURE PIPES
Tighten to torque the rail mounting nuts ( 28 Nm ) .
WARNING
- Do not touch the high-pressure pipes with the
spanner when tightening.
- Be sure to hold the injector central union in
place with a spanner when tightening.
13B-81
13B
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 or 732
WARNING
( 4 Nm ) .
WARNING
Confirm that there is no diesel fuel leak:
- check the sealing after repair (see 13B, Diesel
injection, High-pressure pipe: Sealing check
,
- let the engine run at idle speed until the engine
cooling fan starts to operate,
110404
- carry out a road test,

Tighten to torque and in order the pump-rail

high-pressure pipe nuts ( 38 Nm ) :
- check that there is no diesel fuel escaping.
- pump end,
- rail end.
Use the pipe socket for tightening the pump-rail
high-pressure pipe (19-17 mm Crowfoot spanner) or the high-pressure pipe wrench (DM19) .
Tighten to torque and in order the rail-injectors
- injectors end,
- rail end.
Use the pipe socket for tightening injector-rail
high pressure pipes ("Crowfoot 18-17" wrench)
or the high-pressure pipe wrench (DM19) .
Note:
Tighten each pipe fully before moving on to the
next pipe.
Tighten to torque the filler neck nut on the rail ( 21
Nm ) using a low torque wrench .
Connect the battery, starting with the negative terminal.
13B-82
DIESEL INJECTION
Diesel injector: check
K9K, and 722 or 728 or 729
Command AC029 High pressure circuit sealing
test in 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 greater than 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 in the Fuel/LPG tab. The engine will
automatically carry out a cycle of four accelerations /
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.
After 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-83
13B
DIESEL INJECTION
High pressure pump: Removal - Refitting
13B
K9K, and 722 or 728 or 729

WARNING
Mot. 1367-02
Engine support
Mot. 1367
Engine support tool for

replacing cylinder
head
Mot. 1606
High pressure pumppulley retaining tool
Mot. 1525
Tighten to torque 38 Nm the pump-rail and

injection rail high pressure pipes with the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
Extractor for timing

gear with tapered hub
Mot. 1525-02
- 77 01 207 028 ,
- 77 01 207 029 .
Adaptor claws for Mot.

1525
for high pressure pipes with other part numbers,

tighten to a torque of 24 Nm .
Equipment required
diagnostic tool
IMPORTANT
Tightening torquesm
high pressure injection
pump mounting bolts
21 Nm
high pressure injection

pump pulley mounting
nut
55 Nm
rail mounting nuts
that the injection rail is not under pressure,

28 3 Nm
union at the rail end
24 Nm
union at the pump end
24 Nm

bolts
- Loosening a high pressure pipe union when the

WARNING
4 Nm
- Obtain a set of special high pressure injection circuit plugs.

- Always replace any high pressure pipe or high
pressure pipe clip removed with a new one.
WARNING
- a new set of blanking plugs (part no.: 77 01 206
804 ),
WARNING
Never turn the engine against its operating direction.
- cleaning cloths (part no.: 77 11 211 707 ),

- cleaning product (part no.: 77 11 224 188 ).
13B-84
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
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

K9K, and 722
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 ),
- the pump-pulley assembly.
102120
Disconnect:
- the air inlet duct (1) .
13B-85
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
K9K, and 728 or 729
5
7
6
4
102361
Remove dipstick guide tube (4) .

110325
Pull out the clip.
Plug the opening on the engine block.

- the injectors,
- the fuel flow actuator electrical connectors (6) ,
- the supply and return pipes (8) .
110323
Undo the bolt (2) .

102362
Remove the diesel fuel splash plate (9) .
13B-86
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
102360
Disconnect:
- the fuel return pipe connecting the injectors to the
pump (10) ,
102083
Remove the (16) pump-rail high pressure pipe

(see 13B, Diesel injection, High pressure pipe:
Replacing ).
Slacken the rail mounting nuts (15) by a few turns.
- the rail pressure sensor (11) ,
Loosen the nut at the pump end, then the nut at the
rail end.
- the accelerator (12) ,

- the oil level sensor (13) ,
- the cylinder reference sensor (14) on the timing cover.
Slide the nut down the tube, keeping the olive in contact with the taper.
Plug the openings on the injection circuit.
Unclamp the electrical harness and move it to one

side.
Remove the channel located on the spherical injection rail.
19626
Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .
13B-87
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

- the tie-bar and make a mark.
102114
Remove:
- the right-hand suspended mounting support and
cover,
19654
Remove the upper timing cover by unclipping both
13B-88
tabs (17) .
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
102115
Remove the engine tie-bar mounting bolts (18) on

the gearbox and sub-frame.
Raise the engine a few centimetres for access to the
suspended mounting attachments on the cylinder
head and the high pressure pump pulley.
WARNING
Do not dislodge the right-hand driveshaft when
lifting the engine.
103749
Remove the mounting bolts securing (19) the engine

tie-bar on the gearbox and on the engine sub-frame.
Raise the engine a few centimetres for access to the
suspended mounting attachments on the cylinder
head and the high pressure pump pulley.
WARNING
Do not dislodge the right-hand driveshaft when
lifting the engine.
13B-89
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
19654-1
Remove:
- the cylinder reference sensor (20) ,
- the plastic bolt (21) ,
Unclip the three tabs (22) .
13B-90
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
19654-2
Remove the suspended mounting (23) from the cylinder head.
23167
Position the engine at Top Dead Centre. The camshaft pulley hole (24) should be opposite the cylinder
head hole (25) .
13B-91
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
23168
Position the (Mot. 1606) (3) .

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 (26) ,
holding the pulley with an open-jawed spanner.
13B-92
23169
Fit the (Mot. 1525) (4) fitted with the (Mot. 1525-02)
.
WARNING
Ensure that the tool pushrod is correctly oriented
and is pressing against the high pressure pump
shaft.
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

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

(27) .
Screw down the pushrod of the (Mot. 1525) .
Detach the pulley - pump assembly.
Remove:
- the high pressure pump,
- the high pressure pump extractor tool.
REFITTING
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Ensure that the pulley clamping pin is still in place.
Fit the high pressure injection pump.
Tighten to torque the high pressure injection
pump mounting bolts ( 21 Nm ) .
Fit the high pressure injection pump pulley nut.
Tighten to torque the high pressure injection
pump pulley mounting nut ( 55 Nm ) , holding the
pulley with an open-jawed spanner.
WARNING
Always replace all high pressure pipes removed.
13B-93
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

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
that the injection computer is reprogrammed.
If the 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.
Connect the diagnostic tool to the vehicle.

110404
Establish dialogue with the diesel injection computer.
Refit the high pressure pipe - to do this:

- remove the protective plugs,
Run command AC212 FILLING NEW PUMP

CHAMBER .
- insert the high pressure pipe olive in the pump outlet taper,
Follow the instructions on the diagnostic tool until

the command is completed.
- insert the high pressure pipe olive in the rail inlet taper.
Start the engine.
Finger tighten the high pressure pipe unions, starting with the one located at the rail end.
Tighten to torque the rail mounting nuts ( 28 3
Nm ) .
Note:
The star ting phase can last up to 20 seconds .
If the engine does not start or if the start-up sequence is interrupted:
- the union at the rail end ( 24 Nm ) ,
- the union at the pump end ( 24 Nm ) .
- wait for 30 seconds ,
- restart the engine.
Prime the diesel fuel supply circuit with the priming

pump (automatic degassing).
Using the diagnostic tool clear any faults stored by

the injection computer.
Check the high pressure circuit sealing after the repair operation (see 13B, Diesel injection, High
pressure pipe: Test ).

( 4 Nm ) .
WARNING
- let the engine run at idle speed until the engine cooling
fan starts to operate,
13B-94
DIESEL INJECTION
13B
F9Q, and 800 or 808

Mot. 1668
IMPORTANT
Locking high pressure

pump sprocket
Mot. 1525

Mot. 1525-03
- that the injector rail is not under pressure,

Adapter claws for Mot.

1525 (for 33-tooth pulley)
Mot. 1746
Mot. 1566

Offset spanner for

tightening high pressure pump pipe
WARNING
Wrench for removing

high-pressure pipes
Ensure that any high-pressure pipe removed is

replaced.
Equipment required
WARNING
diagnostic tool

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

bolts
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
It is essential to read the repair precautions (see 13A,

Diesel injection, Repair precautions ).
REMOVAL
terminal.
Remove:
Timing belt ).
), if fitted to the vehicle.
13B-95
DIESEL INJECTION
13B
F9Q, and 800 or 808
102352
102353
Disconnect:
Remove the pump-rail high-pressure pipe.
- the diesel fuel 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 two mounting bolts (3) from the highpressure pump on the high-pressure pump rear support.
102351
Disconnect the diesel supply and return pipes.

Plug the openings.
Remove the diesel pipes retaining clip.
13B-96
DIESEL INJECTION
13B
F9Q, and 800 or 808
102350
Remove:
- the three mounting bolts (4) from the high-pressure
pump front support,
- the high-pressure pump, with the high-pressure
pump support.
102894
Fit the pulley extractor (Mot. 1525) (2) with claws

(Mot. 1525-03) for pulleys with thirty-three teeth.
Remove the pulley by tightening the pulley extractor
thrust bolt (6) .
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.
1668) .
102893

102345
Remove the nut (5) from the high-pressure pump

pulley.
Remove:
- the three mounting bolts (7) from the high-pressure
pump,
- the high-pressure pump.
13B-97
DIESEL INJECTION
13B
F9Q, and 800 or 808
REFITTING
II - REFITTING THE PUMP - RAIL HIGH-PRESSURE

PIPE
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 ) ,

pipe.
- Do not lubricate high-pressure pipes supplied
- the high-pressure pump pulley nut ( 50 Nm ) by

immobilising the pulley with (Mot. 1668) .
WARNING
Do not remove the plugs from each component
Insert the high-pressure pipe olive in the pump outlet
taper
Insert the high-pressure pipe olive into the injector
rail inlet taper.
Tighten to torque the injector rail mounting bolts (
22 Nm ) .
Tighten to torque using (Mot. 1746) or (Mot. 1566) :
- the pump-rail high-pressure pipe nut on the
pump side ( 29 Nm ) ,
102349
- the pump-rail high-pressure pipe nut on the rail

side ( 25 Nm ) .
Push the ring (8) back as shown in the diagram.

Undo the two mounting bolts (9) on the high-pressure pump rear support 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 INJECTION
PUMP REAR SUPPORT
Finger tighten the mounting bolts 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-98
DIESEL INJECTION
F9Q, and 800 or 808
Refit:
Timing belt ),
engine, Accessories belts ).
For versions with injector rail protector covers:
- Refit the air inlet 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 ).
13B-99
13B
DIESEL INJECTION
13B
F9Q, and 804

Mot. 1668
Locking high pressure

pump sprocket
Mot. 1525

Mot. 1525-03
Adapter claws for Mot.

1525 (for 33-tooth pulley)
Mot. 1746
Mot. 1566
IMPORTANT
Offset spanner for

WARNING
Wrench for removing

high-pressure pipes

replaced.
Equipment required
WARNING
diagnostic tool

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
25 Nm
pipe nut on the pump
side
29 Nm
pipe nut on the rail side
25 Nm

bolts
4 Nm
It is essential to read the repair precautions (see 13A,

REMOVAL
terminal.
Remove:
engine, Accessories belts ),
Timing belt ).
13B-100
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 fuel 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 diesel pipes retaining clip.
13B-101
102348
Remove the bolts mounting the high-pressure pump

to the high-pressure pump rear support.
DIESEL INJECTION
13B
F9Q, and 804
102350
102894
- the bolts (5) mounting the high-pressure pump

front support,
Set 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

Remove the nut (7) from the high-pressure pump
pulley.
102345
Remove:
- the high-pressure pump mounting bolts (10) ,
13B-102
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 injector rail mounting bolts (the injector rail

should be loose ).

pump supports ( 30 Nm ) ,
WARNING
pipe.
- the high-pressure pump pulley nut ( 50 Nm ) by

immobilising the pulley with (Mot. 1668) .
- Do not put high-pressure pipes under stress.
WARNING
Refit a new pump-rail high-pressure pipe.
Tighten to torque the injector rail mounting bolts (
25 Nm ) .
- the pump-rail high-pressure pipe nut on 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
Finger tighten the mounting bolts 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-103
DIESEL INJECTION
F9Q, and 804
Refit:
Timing belt ),
engine, Accessories belts ),
- the air inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting ).
Note:
pump.
WARNING
WARNING
- Run the engine at idle speed,
- 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-104
13B
DIESEL INJECTION
13B
K9K, and 732

Mot. 855
Timing gear locking

strap.
Mot. 1768
SIEMENS injection
pump pulley extractor
claws
Mot. 1746
Offset spanner for

Mot. 1566
Wrench for removing

high-pressure pipes
IMPORTANT
carried out on this system (see 13B, Diesel injection, cleanliness guidelines ).
REMOVAL
Equipment required
diagnostic tool

Tightening torquesm
high-pressure pump
55 Nm
high-pressure pump
mounting bolts
21 Nm
high-pressure pipe nuts
24 Nm
Switch off the ignition and wait 30 seconds before

starting work on the injection system.
- Refitting .
WARNING
Before starting work on the vehicle, have to hand:
- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING
- the high-pressure pipe between the high-pressure
pump and the injector rail.
112811
Pull the clip

Remove the air inlet duct mounting bolt.
Move the air inlet duct to one side.
Remove:
- the rigid air duct between the intercooler hose and
the turbocharger,
13B-105
DIESEL INJECTION
13B
K9K, and 732

- the injector rail protector cover
Disconnect:
- the fuel flow actuator connector,
- the fuel temperature sensor connector.
Clean (see 13B, Diesel injection, Repair precautions ):
- the fuel return pipe connecting the injectors,
- the fuel inlet pipe.
111748
Disconnect:
high-pressure pump,
- the fuel inlet pipe.
Remove:
- the mounting bolts (3) from the dipstick guide on
the mounting of the diesel anti-splash device.
Note:
- the bolt (4) and mounting nuts (5) from the injector
rail protector cover support.
Make preparations for the fuel outflow,
Clean with new wipes.
Unpick the drain pipe on the injector rail protector

cover support.
WARNING
Clean the high-pressure pipe between the highpressure pump and injector rail (see 13B, Diesel injection, Repair precautions ).
- Strictly observe the cleanliness guidelines.

- Beware of diesel fuel splashing when disconnecting the supply unions.
Remove:
Fit blanking plugs into the openings (see 13B, Diesel injection, Cleanliness guidelines ).
- the injector rail protector cover support,
Remove:
- the high-pressure pipe between the high-pressure

pump and rail.
- the accessories belt (see section 10A, Accessories belt: Removal - Refitting ).
- the timing belt (see section 10A, Timing belt: Removal - Refitting ).
Note:
Make preparations for fuel outflow,
Clean with new wipes.
WARNING
When loosening the union of the high-pressure
pipe on the high-pressure pump, the intermediate nut must be secured on the high-pressure
pump using a lock wrench.
Fit the correct blanking plugs on:
- the high-pressure pump,
- the injector rail.
13B-106
DIESEL INJECTION
13B
K9K, and 732

CONCERNED
REMOVAL OF THE HIGH-PRESSURE PUMP

Remove:
- the high-pressure pump mounting bolts,
WARNING
If the high-pressure pump is to be reused, keep it
in a sealed plastic bag all the time it is disconnected.
REMOVAL OF THE HIGH-PRESSURE PUMP

PULLEY
111744
WARNING
Note:
When replacing a high-pressure pump, retain the

high-pressure pump pulley and refit on the new
pump.
The high-pressure pump pulley can also be

immobilised using the (Mot. 855) .
Fit (Mot. 1768) on the high-pressure pump pulley
then extract the pulley.
Hold the high-pressure pump in a vice, using the

lower securing point on the pulley side.
WARNING
Ensure that you do not mark the high-pressure
pulley when extracting it using the tool.
You must replace any damaged high-pressure
pump pulleys.
REFITTING
WARNING
- Remove the blanking plugs only before reconnecting the fuel circuit pipes
- The plugs are single-use. Do not reuse them
and throw away the complete kit after opening.
111743
Hold the high-pressure pump pulley with a 32 mm

offset wrench then remove the mounting nut from
the pulley.
13B-107
DIESEL INJECTION
K9K, and 732
CONCERNED
1 - REFITTING THE HIGH-PRESSURE PULLEY
Take the high-pressure pump out of its plastic bag.
WARNING
When replacing an injector rail, only remove it
from its packaging just before it is refitted.
Finger tighten the mounting nut of the high-pressure
pump pulley.
Lock the high-pressure pump pulley with the tools
used previously.
Tighten to torque the high-pressure pump pulley
mounting bolt ( 55 Nm ) .
2 - REFITTING THE HIGH-PRESSURE PUMP
Position the high-pressure pump on the cylinder
head.
Tighten to torque the high-pressure pump mounting bolts ( 21 Nm )
Remove: the blanking plugs from the injector rail and
high-pressure pump.
Fit a new high-pressure pipe between the injector
rail and the high-pressure pump.
Note:
If the new parts kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes).
Hand-tighten the nut on the high-pressure pipe on
the pump end, then the one on the rail end.
Tighten to torque the high-pressure pipe nuts ( 24
Nm ) using (Mot. 1746) or (Mot. 1566) and starting
with the high-pressure pump side.
13B-108
13B
DIESEL INJECTION
13B
K9K, and 732

Refit:
WARNING
- the injector rail protector cover support,
Confirm that there are no diesel fuel leaks:
- the injector rail protector cover support mounting

nuts and bolt,
- Check the tightness after repair (see 13B, Diesel injection, High-pressure pipe: test ),
- the dipstick guide,
- run the engine at idle speed,
- the dipstick guide mounting bolts.

- Check that there are no diesel fuel leaks
Note:
Ensure that the injector rail protector support
mounting bolt does not fall under the high-pressure pump.
Connect:
- the drain pipe to the injector rail protector cover
support
- the fuel flow actuator connector,
high-pressure pump,
- the fuel temperature sensor connector.
Reposition the wiring harness.
Refit:
- the mounting nut to the wiring harness retaining
clip,
- the timing belt (see section 10A, Timing belt: Removal - Refitting ),
- the accessories belt (see section 10A, Accessories belt: Removal - Refitting ).
- the injector rail protector cover,
Clip the air inlet duct onto the turbocharger.
Refit the inlet duct mounting bolt.
Refit the battery (see 80A, Battery: Removal - Refitting ).
Reprime the fuel circuit using the priming pump.
Using the diagnostic tool , clear any faults stored
by the injection computer, before restarting the engine.
13B-109
Using diagnostic tool , check that there are no stored faults. Clear them if necessary.
DIESEL INJECTION
13B
M9R, and 700
REMOVAL

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for


advice whenever work is carried out on this system
(see 13B, Diesel injection, Repair precautions).
IMPORTANT
Equipment required
diagnostic tool
Tightening torquesm

high-pressure pump
mounting bolts
25 Nm
high-pressure pipe
union on the high-pressure pump
32 Nm
high-pressure pipe
union on the injector rail
32 Nm
Obtain a set of special high-pressure injection

circuit plugs.
high-pressure pipe
retaining bracket mounting bolts on the bearing cap casing
10 Nm

replaced.
clips on the air filter

duct at the turbocharger inlet
5.5 Nm
bolts securing the turbocharger outlet air duct

on the inlet manifold
8 Nm

WARNING

Remove:
- the engine protector,
Remove the high-pressure pipe between the highpressure pump and the injector rail (see 13B, Diesel
injection, High-pressure pipe: Replacing ).
Disconnect the fuel inlet quick-release union on the
high-pressure pump.
Plug the openings.
Disconnect the fuel return union.
Plug the openings.
Disconnect the pressure regulator connector on the
high-pressure pump.
CONCERNED
Remove:
- the high-pressure pump mounting bolts,
13B-110
DIESEL INJECTION
M9R, and 700
REFITTING
Always replace:
- the high-pressure pump O-ring seal,
- the high-pressure pump mounting bolt.
WARNING
Lubricate the new high-pressure pump seal with engine oil.
CONCERNED
Fit the high-pressure pump.

WARNING
Do not apply pressure to the high-pressure pump
gear teeth.
WARNING
Check that the high-pressure pump is in contact
with the cylinder head before positioning the
bolts.
Finger tighten the high-pressure pump mounting
bolts as far as possible.
Tighten to torque and in order the high-pressure
pump mounting bolts ( 25 Nm ) (1-2-3-4).
13B-111
13B
DIESEL INJECTION
13B
M9R, and 700

WARNING
Remove the wiring harness and fuel pipe assembly.

WARNING
Do not lubricate high-pressure pipes supplied

Do not allow oil into the high-pressure pipe.
Check that the seal is correctly positioned on the
high-pressure pipe.
Finger tighten as far as possible and in order:
- the high-pressure pipe union on the high-pressure
pump,
- the high-pressure pipe union on the injector rail,
- the bolt mounting the high-pressure pipe retaining
bracket on the bearing cap casing.
- the high-pressure pipe union on the high-pressure pump ( 32 Nm ) , using (Mot. 1566) ,
- the high-pressure pipe union on the injector rail
( 32 Nm ) , using (Mot. 1746) ,
- the high-pressure pipe retaining bracket mounting bolts on the bearing cap casing ( 10 Nm ) .
Tighten to torque:
- the clips on the air filter duct at the turbocharger inlet ( 5.5 Nm ) ,
- the bolts securing the turbocharger outlet air
duct on the inlet manifold ( 8 Nm ) .
pump.
WARNING
13B-112

DIESEL INJECTION
Diesel injector: Removal - Refitting
13B
K9K, and 722 or 728 or 729
Equipment required
WARNING
diagnostic tool

804 ),
Tightening torquesm
injector mounting bracket
28 Nm
rail mounting nuts
28 Nm

of the pump-rail
24 Nm

of the injector rail
24 Nm
of the neck on the rail
21 Nm

REMOVAL
Disconnect:
IMPORTANT
- the heater plugs,
Before any operation on the injection circuit, use the

diagnostic tool to check that the injector rail is no
longer under pressure, and that the fuel temperature is not too high.
- the connectors to injectors no. 3 and no. 4.

- injector connectors no. 1 and no. 2.

advice specified in this document whenever work is
WARNING
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 ,
102362
- 77 01 207 029 .
For high-pressure pipes with different part numbers,

tighten to torque 24 Nm .
It is essential to read the repair precautions whenever
work is carried out (see 13B, Diesel injection, Diesel
injection: Precautions during repair ).
13B-113
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
109463
Disconnect the injector diesel return pipe (2) .
109467
Disconnect the high-pressure pump electrical connectors (3) .
Remove the mounting bolts from the neck (4) fixed

to the spherical injector rail.
Pull the electric wiring harness to one side with the
neck on the side.
Loosen the injector rail mounting nuts by several
turns.
Remove the clips connecting the high-pressure pipes.
Clean the high-pressure pipe (see 13B, Diesel injection, Diesel injection: Precautions during repair ).
Remove the injector-rail high-pressure pipe concerned.
13B-114
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

CONCERNED

CONCERNED
WARNING
If removing the four injectors, loosen the mounting
nuts of the injector rail by a few turns (the rail should
be loose).
109462
Undo the injector bracket (5) .

Remove the injector (6) .
If an injector is reused, always mark a removed injector in relation to its cylinder.
Note:
19724
an injector corresponds to a cylinder.
Using cloths (part no.: 77 11 211 707 ) soaked in

fresh solvent, clean:
Pull off the compression washer.
- the injector wells,

- the injector bodies,
REFITTING
- the injector brackets.

I - CLEANING THE INJECTORS
Use a new cloth to dry components that have been

cleaned.
Replace the compression washer with a new one.
WARNING
Position the injector.
It is strictly forbidden to clean the injectors with:
- a wire brush,
Note:
- an emery cloth,
If one or more injectors are replaced, note the

alphanumeric code (C2I) (7) and the cylinder on
which it is fitted.
- an ultrasonic cleaner.
Soak the injectors in degreaser.
Tighten to torque the injector mounting bracket (

28 Nm ) .
Wipe with new cloths (part no.: 77 11 211 707 ).
13B-115
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

If removing the four injectors, torque tighten the rail

pipe nuts of the pump-rail ( 24 Nm ) :
- high-pressure pump end,
- rail end.
pipe nuts of the injector rail ( 24 Nm ) :
- injectors end,
- rail end.
Note:
Tighten a pipe fully before moving on to the next
pipe.
20960
Refit the neck on the injector rail.

WARNING
Before fitting a new high-pressure pipe, lightly
lubricate the nut threads with oil from the applicator provided with the new part.
Be careful not to allow oil into the high-pressure
pipe.
without an applicator; these pipes are self-lubricating.
Torque tighten the nuts of the neck on the rail ( 21

Nm )
Connect:
- the injector diesel fuel return pipe,
- the connectors to injectors no. 1 and no. 2,
- the connectors to injectors no. 3 and no. 4.
- the heater plugs.
WARNING
Insert the high-pressure pipe olive into the rail highpressure conical outlet.

Program the alphanumeric code (C2I) for the replaced injector(s) using diagnostic tool (see 13B, Diesel injection, Injectors: configuration ).

with the nut at the injector end.
WARNING

Note:
- Run the engine until the fan starts up.
The assembly order of the injector-rail highpressure pipes is not important.
- Accelerate several times at no load.

- Switch off the ignition.
Fit the new clip provided with the new high-pressure

pipe.
13B-116
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808

For versions without injector rail protectors:

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
Tightening torquesm
injector bracket bolt
25 Nm
nut on the injector side
25 Nm
nut on the rail side
29 Nm

bolts
4 Nm
IMPORTANT
It is essential to read the repair precautions whenever
work is carried out (see 13B, Diesel injection, Diesel
WARNING
Opening the injectors is prohibited.
Injectors may be replaced individually. Only remove
the high-pressure pipe concerned.
REMOVAL
terminal.
Remove the injector rail protector (see 13B, Diesel
injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle.
13B-117
- remove the inlet duct (see 12A, Fuel mixture, Air

inlet duct: Removal - Refitting ), if necessary.
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808
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.
13B-118
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808
REFITTING
I - CLEANING INJECTORS (IF THEY ARE TO BE
REUSED)
WARNING
- a wire brush,
- an emery cloth,
Clean, using new cloths soaked in cleaning product
(see 13B, Diesel injection, Diesel injection: Repair precautions ) clean:
- the injector wells,
- the injector bodies,
1327
- the injector brackets.
Remove the injector-rail high-pressure pipe

using (Mot. 1566) or (Mot. 1746) .
WARNING
Use a new cloth to dry components that have been

cleaned.
II - REFITTING THE INJECTOR
The injector filter rod must not be removed.
WARNING
WARNING
When loosening the injector pipe unions (2) on
the injectors, be sure to hold the filter rod retaining nuts (3) with a lock wrench.
If an injector is reused, always mark a removed injector in relation to its cylinder.
Note:
an injector corresponds to a cylinder.
Remove:
- the injector bracket mounting bolt,
- the injector and its bracket,
- the compressor washer.
13B-119
Do not remove the protective caps from each

DIESEL INJECTION
F9Q, and 800 or 804 or 808
1326
Replace the heat shield washer (4) 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 bracket.
Tighten to torque the injector bracket bolt ( 25 Nm
).
WARNING
Do not fit high-pressure pipes without mountings.
WARNING
Always replace any high-pressure pipe removed
with a new one.
Screw, by hand, the high-pressure pipe nuts on the
rail and injector.
WARNING
Always hold the filter rod mounting nuts on the
injector holder with a lock wrench when tightening.
- the nut on the injector side ( 25 Nm ) ,
- the nut on the rail side ( 29 Nm ) ,
13B-120
13B
DIESEL INJECTION
13B
F9Q, and 800 or 804 or 808
18297-1
Program the alphanumeric code (IMA) for the injector(s) replaced using the diagnostic tool (see MR
366 Fault finding, 13B, Diesel injection, Fault finding - Replacement of components ).
Refit the return rail (5) .

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.
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 13B, Diesel injection, Injector rail protector: Removal - Refitting ).

- Refit the inlet duct (see 12A, Fuel mixture, Air inlet duct: Removal - Refitting ).
13B-121
DIESEL INJECTION
13B
K9K, and 732

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

IMPORTANT
Equipment required
diagnostic tool
Tightening torquesm
REMOVAL
injector bracket mounting bolt
30 Nm

nuts
28 Nm
24 Nm
air inlet duct clip
5.5 Nm

WARNING
WARNING
112815
- all the high-pressure pipes which have been removed.

(1) .
- any injector that has been opened, contrary to instructions,
(3) .
- Any damaged mounting clips for the fuel return

pipe on the injector must be replaced.
- the compressor washer.
13B-122
DIESEL INJECTION
13B
K9K, and 732
112811
Pull out the clip.
112992
Unclip injector rail protector cover (6) .

Remove:
- the mounting nut and bolt (7) from the injector rail
protector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
Protect the alternator from fuel outflow.
Clean (see 13B, Repair precautions ). :
- the high-pressure pipes between the injector rail
and the injectors,
- the fuel return connectors of the injectors.
112991

13B-123
DIESEL INJECTION
13B
K9K, and 732

- 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:
Make preparations for the fuel outflow. Clean with
new wipes.
Fit blanking plugs,
114075
Disconnect the injector connector (9) .
111749
Using a fine, flat-blade screwdriver, push the lower

section of the clip (12) holding the fuel return connector on the injector towards the rocker cover.
WARNING
Ensure that the clip is not fully removed from its
housing to prevent it from being twisted when
touching the rocker cover.
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.
111751
Remove:
- the nut of the high-pressure pipe between the injector rail and the injector on the rail end,
13B-124
Extract the fuel return connector from the injector

while pushing the lower bracket of the retaining clip
downwards.
DIESEL INJECTION
13B
K9K, and 732

Fit the correct blanking plug.
Remove the fuel return pipe from the injector.
CONCERNED
114010
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 bracket using a 13 mm open
end wrench.
111746
Remove:
- the injector bracket mounting bolt (13) ,
Fit the appropriate blanking plug on the injector's nose.
- the injector bracket,

- the spacer between the cylinder head and the injector bracket,
WARNING
- the injector,
If it is to be reused, keep the injector(s) in a sealed plastic bag until required.
- the compression washer located at the bottom of

the injector well in the cylinder head.
WARNING
Ensure that no impurities enter into the cylinder
via the injector well in the cylinder head: plug the
orifice using a clean cloth.
Remove four injectors
Note:
This procedure only applies if removing all the
injectors and, after having removed them all, in
preparation for refitting them.
13B-125
DIESEL INJECTION
13B
K9K, and 732
112993
112994
Disconnect:
Disconnect:
- the injector connector (14) ,
- the heater plugs connector (15) .
- the cylinder marking sensor connector (17) ,

(18) ,
13B-126
DIESEL INJECTION
13B
K9K, and 732

- the injector rail protector support.
Undo the injector rail mounting nuts by a few turns
(the injector rail should be loose).
REFITTING
Cleaning the injectors
WARNING
- a wire brush,
- an emery cloth,
112656
Leave the injectors to soak in cleaner fluid.
Clean the fuel supply and return pipe unions (see

13B, Repair Precautions ).
Clean using new wipes.
Disconnect:
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.
Note:
Make preparations for the fuel outflo w. Clean with
new wipes.
Remove the injector from its plastic bag.
Fit blanking plugs,
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:
- a new compression washer at the bottom of the injector well in the cylinder head,
111748
Unclip the diesel evacuation pipe.
- the injector,
- the spacer between the cylinder head and the injector bracket,
Remove:
- the injector rail protector support bolt and mounting
nuts (25) ,
13B-127
- the injector bracket,

- the injector bracket mounting bolt.
DIESEL INJECTION
13B
K9K, and 732

Tighten to torque the injector bracket mounting

bolt ( 30 Nm ) .
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.

Fit the new high-pressure pipe(s) between the injector rail and the injector.
Clip on the fuel return connector of the injector.
Note:
WARNING
If the new pipes kit does not contain an applicator, lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes).
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.

with the one at the injector rail side.
1 - Refit the four high-pressure pipes

Tighten to torque the injector rail mounting nuts (
28 Nm ) .
Refit:
- the dipstick tube mounting bolts.
Refit:
- the injector rail protector support,
- the dipstick,
- the mounting nuts and bolt of the injector rail protector support.
- the injector rail protector cover mounting nut and

bolt,
Clip the diesel evacuation pipe.
Clip injector rail protector cover.
Refit:
Connect:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning the

markings,
- fuel return pipe.

Fit the wiring harness.
- the air inlet duct clip between the turbocharger and

the intercooler.

Clip on the retaining clip of the wiring harness.
Tighten the air inlet duct clip ( 5.5 Nm ) .
Connect:

- the diesel fuel temperature sensor connector,
Refit:
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoid

valve,
- the cylinder marking sensor connector,
Tighten the clip.
Connect:
- the injectors' connector.
2 - All types
at the injector rail end.
13B-128
Reprime the fuel circuit with the manual priming

pump.
DIESEL INJECTION
K9K, and 732
WARNING
- Check the tightness after repair (see 13B, Diesel injection, High-pressure pipe: Check ),
- check for leaks and for diesel fuel outflow.
Using diagnostic tool , check that there are no stored faults; clear if necessary.
13B-129
13B
DIESEL INJECTION
K9K, and 722 or 728 or 729 or 732
REPLACING THE INJECTORS
Note:
The C2I (individual injector correction) parameters
are a factory calibration carried out on each injector
to adjust the flow of each injector precisely, taking
into account differences 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 at the diagnostic socket
using the RENAULT CLIP diagnostic tools.
The C2I parameters must be renewed after an injector
is replaced. To do this, the C2I parameters must be reentered into the computer using the following commands:
- To enter the four C2Is when replacing the computer,
run the SC002 Enter injector codes .
- To enter an individual C2I parameter, when replacing
one or more injectors, enter the following commands:
cylinder 1 injector: control VP001 (flywheel end 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 .
13B-130
13B
DIESEL INJECTION
13B
F9Q, and 800 or 808

reconfigure the computer for the equipment (air conditioning),
Equipment required
make sure, using the diagnostic tool CLIP, that the

computer has not detected any faults relating to the
injector codes and that the instrument panel warning
light is off.
diagnostic tool
INJECTORS
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 one or more injectors is replaced, the code of the
new injector(s) must be programmed into the computer. If this operation is not carried out then the engine
speed will be limited to 1800 rpm .
Follow the procedure described below:
- Replace the faulty injector(s) and establish dialogue
with the computer:
read the data on the replaced injector(s),
enter them into the computer using the diagnostic
tool CLIP,
light is off.
- When a computer is reprogrammed or replaced, it is
necessary to program the codes of the four injectors
into the new computer.
There are two possibilities:
- if it is possible to enter into dialogue with the computer
again:
download the data from the old computer into the
diagnostic tool CLIP,
transfer the data from the diagnostic tool CLIP to
the new computer,
light is off.
- if it is not possible to establish dialogue with the
computer:
read the data from the injectors,
enter them into the computer using the diagnostic
tool CLIP,
13B-131
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting
13B
K9K, and 732
REMOVAL

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

Equipment required

diagnostic tool
Tightening torquesm
nuts
28 Nm
24 Nm
WARNING
112815


(1) .
Loosen the clip (2) and move the air inlet duct aside
(3) .
WARNING
IMPORTANT
112811
Pull out the clip.
13B-132
DIESEL INJECTION
13B
K9K, and 732

Move the dipstick pipe to one side.
Clean the high-pressure pipe unions between the injector rail and injectors (see 13B, Repair precautions ).
CONCERNED
112991
Remove:
- the stainless steel pipe mounting bolt (4) ,
1327
WARNING
When the high-pressure pipe unions (9) on the
injector holder are loosened, it is imperative to
hold the filter rod retaining nut (10) with a lock
wrench.
Remove:
- the nut of the high-pressure pipe between the injector rail and the injector on the rail end,
112992
- 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.
Unclip the injector rail protector cover (6) .

Remove:
protector cover,
Note:
new wipes.

- the dipstick,
- the dipstick pipe mounting bolts (8) .
Fit blanking plugs,
13B-133
DIESEL INJECTION
13B
K9K, and 732

Removing the four high-pressure pipes
Note:
This procedure only applies if removing all the
high-pressure pipes and, after having removed
them all, in preparation for refitting them.
112994
Disconnect:
(15) ,
112993
Disconnect:


13B-134
DIESEL INJECTION
13B
K9K, and 732
111748

Remove:
- the injector rail protector support bolt and mounting
nuts (22) ,
112656
- the fuel supply and return pipes.
Clean the fuel supply and return pipes unions (see

13B, Repair Precautions ).
Clean the unions (see 13B, Repair precautions ):
Disconnect:
- of the fuel return pipe on the high-pressure pump

and injector rail,
- the fuel inlet pipe (20) ,
- on the high-pressure pipe between the high-pressure pump and the injector rail,

Note:
REFITTING

new wipes.
Fit blanking plugs,

WARNING
Take the new high-pressure pipe out of its plastic
bag.
13B-135
DIESEL INJECTION
13B
K9K, and 732

CONCERNED
Fit the new high-pressure pipe between the injector

rail and the injector.
Refit:
Note:
- the dipstick,


bolt,
1 - Refit the four high-pressure pipes

28 Nm ) .
Refit:
Refit:

Tighten the clamp.

Connect:
Connect:
- fuel return pipe.

Clip the retaining clip of the wiring harness into place.

pump.
Connect:

- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoid
valve,
WARNING


2 - All types

with the injector rail side.
13B-136
Use diagnostic tool to check for stored faults. Clear

them if necessary.
DIESEL INJECTION
13B
K9K, and 722 or 724 or 728 or 729
Equipment required
WARNING
diagnostic tool

Tightening torquesm
- 77 01 207 025 ,
nuts
28 Nm
pump-rail highpressure pipe nuts
24 Nm

of the injector rail
24 Nm
nuts of the neck on the

rail
21 Nm
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
REMOVAL
IMPORTANT

advice whenever work is carr ied out on this system.
engine is running is prohibited.
WARNING
112331

804 ),
Remove the turbocharging duct retaining pin (1)

from the turbocharger.
Remove the duct mounting bolt on the cylinder

head.
Move the duct to one side.

Disconnect the inlet air pressure sensor (2)
Loosen the clip (3) and remove the inlet duct (4) .
13B-137
DIESEL INJECTION
13B
K9K, and 722 or 724 or 728 or 729
K9K, and 724
K9K, and 722 or 728 or 729
109473
102362
109470
Remove the dipstick mounting bolts (5) .

Place the dipstick to one side.
Remove the injector rail protector cover (6) .
109466
Remove the connectors (8) :

- the heater plugs,
- the injectors.
13B-138
DIESEL INJECTION
13B
K9K, and 722 or 724 or 728 or 729
REFITTING
109467
Disconnect the high-pressure pump electrical connectors (9) .

Remove the mounting bolts from the neck (10) fixed
to the spherical injector rail.
20960
Move the electric wiring harness and neck to the

side as shown by the arrow.
WARNING
Loosen the injector rail mounting nuts by several

turns.
Before fitting a new high-pressure pipe, lightly

lubricate the nut threads with oil from the applicator provided in the new part.
Remove the clips connecting the high-pressure pipes.
Be careful not to allow oil into the high-pressure

pipe.

Clean the pipe(s) to be removed (see 13B, Diesel
injection, Diesel injection: Repair precautions .
Loosen:
WARNING
- the high-pressure nut at the injector end,
Leave removal of the blanking plugs from any

component until last.
- the high-pressure pipe nut at the injector rail end.

If replacing the four high-pressure pipes:
Throw away the pipe.
- remove the anti-splash cover mounting,

- Undo the injector rail mounting nuts by a few turns
(the injector rail should be loose).
CONCERNED
13B-139
DIESEL INJECTION
13B
K9K, and 722 or 724 or 728 or 729

Insert the high-pressure pipe olive in the rail highpressure outlet taper.
with the nut at the injector end.
Fit the turbocharger air duct.

Lock the air duct between the turbocharger and the
intercooler air inlet pipe.
Tighten the bolt of the air duct on the rocker cover.
Note:
The assembly order of the injector-rail highpressure 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
WARNING
- check the seal after repair,
- pump end,
- rail end.
- confirm that there is no diesel fuel leak.

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 nuts of the neck on the rail ( 21 Nm ) .
Connect the connectors:
- on the accelerometer
- of the injectors,
- of the heater plugs.
K9K, and 724
Refit the injector rail protector cover.
Insert the dipstick.
Refit the dipstick mounting bolts.
Refit the inlet duct and tighten its clip.

Connect the inlet air pressure sensor
13B-140
DIESEL INJECTION
13B
M9R, and 700

- the oil separator (see 13B, Diesel injection, Oil
separator: Removal - Refitting ).

Mot. 1566
Wrench for removing

high-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
rail-injector highpressure pipe mounting
nuts
32 Nm
diesel return pipe

rocker cover
10 Nm
113142
Remove the bolt mounting the diesel return pipe on

the rocker cover.
Disconnect the quick-release union from the diesel
return pipe.
WARNING
Lift the mobile section of the diesel return pipe on the

injectors.
Before carrying out any work on the injection system, use the diagnostic tool to check that:
Remove the diesel return pipe.
- the rail is not under pressure,

The cleanliness and safety advice specified in this
document must be followed during each operation.
WARNING
Obtain the special high-pressure injection circuit
plug kit.
Always replace any high-pressure pipe or highpressure pipe clip removed with a new one.
REMOVAL
Remove:
).
13B-141
DIESEL INJECTION
13B
M9R, and 700

CONCERNED

CONCERNED
Fit:
- the high-pressure pipe olive in the injector taper,
- the high-pressure pipe olive into the injector rail
outlet taper.
Finger tighten until contact the high-pressure pipe
nuts, starting with the nut at the injector rail side.
Tighten to torque and in order, using (Mot. 1566) ,
the rail-injector high-pressure pipe mounting
nuts ( 32 Nm ) :
- on the injectors,
- on the injector rail.
113134
Using (Mot. 1566) , loosen:
Refit:
- the high-pressure nut at the injector end,
- the diesel return pipe,
- the high-pressure pipe nut at the injector rail end.
- the bolt mounting the diesel return pipe on the rocker cover
Drive the mobile section of the diesel return pipe into
the injectors.
Note:
Tighten to torque the diesel return pipe mounting

bolt on the rocker cover ( 10 Nm ) .
Loosen the nuts pipe by pipe.

Move the nuts along the tube, keeping the olive in
contact with the taper.
Connect the quick-release union to the diesel return

pipe.
Remove the high-pressure pipes one by one.
Refit:
Plug the openings.
- the oil separator (see 13B, Diesel injection, Oil

separator: Removal - Refitting ).
).
REFITTING
WARNING
Do not lubricate the high-pressure pipes supplied
without an applicator, these high-pressure pipes
are self-lubricated.
Do not allow oil into the high-pressure pipe.
WARNING
13B-142
DIESEL INJECTION
Injector rail: Removal - Refitting
13B
K9K, and 722 or 728 or 729

Mot. 1746
Offset spanner for

Mot. 1566
Wrench for removing

high-pressure pipes
WARNING
- 77 01 207 025 ,
- 77 01 207 026 ,
Equipment required
- 77 01 207 027 ,
diagnostic tool
- 77 01 207 028 ,
- 77 01 207 029 .
Tightening torquesm
nuts
28 Nm

between the injector rail
and the injectors
24 Nm

and the high-pressure
pump
24 Nm

REMOVAL
Position the vehicle on a lift (see 02A, Lifting equipment, Underbody lift ).
It is essential to read the repair precautions whenever work is carried out (see 13B, Diesel injection,
Diesel injection: Precautions during repair ).
WARNING
Before starting work on the vehicle, make sure you
have:
- a new blanking plug kit ( PART NO. 77 01 206 804
),
WARNING
- some wipes ( PART NO. 77 11 211 707 ),

- cleaning product ( PART NO. 77 11 224 188 ).
- that the rail is not under pressure,

WARNING


13B-143
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729
109466
Disconnect the injector connectors (1) and the heater plugs (2) .
109467
Disconnect:
- the connectors (4) for the flow actuator and the diesel fuel temperature sensor,
- the spherical rail pressure sensor (5) .
Move the electric wiring harness and channel to the
side as shown by the arrow.
Remove the mountings from the channel (6) fixed on
the spherical rail.
Clean the high-pressure pipes (see 13B, Diesel injection, Diesel injection: Precautions during repair ).
WARNING
Do not blast with compressed air once the fuel
circuit is open, otherwise impurities may enter
the system. Use wipes if necessary.
102362
13B-144
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

CONCERNED
20803
Remove the clips between the high-pressure pipes.

20803
Loosen the nuts securing the high-pressure pipes

between the injector rail and the injector.
Remove:
Remove the four high-pressure pipes and discard.
- the injector rail mounting nuts (8) ,

Note:
new wipes.
WARNING
If the injector rail is to be reused, keep it in a sealed plastic bag all the time it is disconnected.

Remove the high-pressure pipe between the highpressure pump and the injector rail (7) .
REFITTING
Note:
new wipes.
WARNING
The plugs are single-use. Do not reuse them and
throw away the complete kit after opening.
Take the injector rail out of its plastic bag.
WARNING
If an injector rail is being replaced, only remove
the new one from its original packaging when it is
about to be fitted.
13B-145
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729

CONCERNED
Reprime the fuel circuit.


Tighten the injector rail mounting bolts (the injector
rail should be loose).

- check the seal after repair (see 13B, Diesel injection, Diesel injection: Repair precautions ),
Remove the blanking plugs from:

- the high-pressure pump,
- the injector rail fuel inlet opening.
Fit a new high-pressure pipe between the injector

Use diagnostic tool to check for stored faults. Clear

them if necessary.
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes).
Finger tighten the high-pressure pipe nuts until they
make contact.
Remove the blanking plugs from:
- the rail injector fuel return openings,
- the injector fuel inlet.
Fit the new high-pressure pipes between the rail and
the injectors.
Note:
If the new pipe kit does not contain an applicator,
lubrication of the pipe threads will be unnecessary (as they are self-lubricating pipes).
Finger tighten the high-pressure pipe nuts until they
make contact.
Tighten to torque:
- the injector rail mounting nuts ( 28 Nm ) ,
- the high-pressure pipe nuts between the injector rail and the injectors ( 24 Nm ) using (Mot.
1746) or (Mot. 1566) starting at the injector end,
- the high-pressure pipe nuts between the injector rail and the high-pressure pump ( 24 Nm )
using (Mot. 1746) or (Mot. 1566) starting at the
high-pressure pump end.
Refit:
- the wiring harness with the neck,
- the neck mountings.
Connect the electrical connectors.
13B-146
DIESEL INJECTION
F9Q, and 800 or 808
Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
Tightening torquesm
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

bolts
4 Nm
IMPORTANT
It is essential to read the repair precautions (see 13B,
REMOVAL
Disconnect the battery, starting with the positive terminal.
Remove:
- the air inlet duct (see 12A, Fuel mixture, Air inlet
), if fitted to the vehicle.
13B-147
13B
DIESEL INJECTION
13B
F9Q, and 800 or 808
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-148
DIESEL INJECTION
13B
F9Q, and 800 or 808
REFITTING
Position the injector rail.
WARNING


with a new one.
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,
the rail side.
1327
Remove the high-pressure diesel pipes using (Mot.

1566) or (Mot. 1746) .

- the injector rail mounting bolts ( 25 Nm ) ,
- the nuts on the injector end and the nut on the
injection pump end ( 25 Nm ) ,
WARNING
- the nuts on the rail end ( 29 Nm )

WARNING
Plug the openings.
Do not put high-pressure pipes under stress.
Remove:
Always hold the filter rod retaining nuts on the

injector holder when tightening.
- the injector rail bolts,

- the injector rail (5) .
13B-149
DIESEL INJECTION
13B
F9Q, and 800 or 808
18297-1
Refit the return rail (4) :

- do not remove the clip from the injector,
WARNING
- press the injector clip,
- push the return rail end piece vertically.

operation.

( 4 Nm ) .
Note:

protector or refitting the duct seal.
- Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ), if fitted to the vehicle,

WARNING
13B-150
DIESEL INJECTION
13B
F9Q, and 804

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

Equipment required
diagnostic tool
3
Tightening torquesm
111965

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
Disconnect:
Plug the openings.

bolts
4 Nm

Remove the diesel return pipe (3) .
IMPORTANT
Plug the openings.
It is essential to read the repair precautions (see 13B,
REMOVAL
terminal.
Remove:
).
13B-151
DIESEL INJECTION
13B
F9Q, and 804
REFITTING
WARNING
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 (Mot.

1566) or (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
Plug the openings.
WARNING
Do not put high-pressure pipes under stress.
Do not touch the high-pressure pipes with the
spanner when tightening them.
Always hold the filter rod retaining nuts on the
injector holder when tightening.
Remove the oil separator.
111859
Remove:
- the injector rail bolts (6) ,
- the injector rail (7) .
13B-152
DIESEL INJECTION
13B
F9Q, and 804

Refit the injector rail protector (see 13B, Diesel injection, Injector rail protector: Removal - Refitting ).
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
( 4 Nm ) .
13B-153
DIESEL INJECTION
13B
K9K, and 732

Mot. 1566
Wrench for removing

high-pressure pipes
Mot. 1746
Offset spanner for

IMPORTANT
Equipment required
diagnostic tool
Tightening torquesm
REMOVAL

nuts
28 Nm

and the injectors
24 Nm

and the high-pressure
pump
24 Nm
air inlet duct clip
5.5 Nm

Remove the engine covers
WARNING
112815
WARNING

(1) .
(3) .
13B-154
DIESEL INJECTION
13B
K9K, and 732
112811
Pull out the clip.
112992

Remove:
protector cover,
- the dipstick,
112991
Remove the stainless steel pipe mounting bolt (4)

112993
Disconnect:
13B-155
DIESEL INJECTION
13B
K9K, and 732

112656
112994
Disconnect:

Clean (see 13B, Repair precautions ):

(13) ,
Disconnect:


new wipes.

13B-156
Fit blanking plugs,
DIESEL INJECTION
13B
K9K, and 732
111748

Remove:
- the injector rail protector support mounting bolt and
mounting nuts,
1327
- the injector rail protector support.

Clean (see 13B, Repair precautions ):
WARNING
- the high-pressure pipes between the injector rail

and the injectors,
- the high-pressure pipes (19) between the highpressure pump and the injector rail.
When loosening the high-pressure pipe unions

(21) on the injector holder, 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:
new wipes.
Fit blanking plugs,
13B-157
DIESEL INJECTION
13B
K9K, and 732

Remove the high-pressure pipe between the highpressure 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
on the pump using a lock wrench.
WARNING
Note:
new wipes.
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.
Fit the new high-pressure pipe between the injector
Note:
Remove:

- the injector rail mounting nuts (23) ,
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:
If the new pipes kit does not contain an applicator, lubrication of the nut threads will be unnecessar y (as they are self-lubricating pipes).
28 Nm ) .
13B-158
DIESEL INJECTION
13B
K9K, and 732

Tighten to torque:
- the high-pressure pipe nuts between the injector rail and the injectors ( 24 Nm ) using (Mot.
1566) or (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.

bolt,
Refit:
markings,
- the clamp of the air inlet duct between the turbocharger and the intercooler.
Refit:
Tighten the air inlet duct clip ( 5.5 Nm ) .

Refit:
Note:
Ensure that the injector rail protector support
mounting bolt does not fall under the high-pressure pump.

Tighten the clamp.
Connect:
Connect:
- the connector to the air inlet pressure sensor,
- fuel return pipe.


pump.

Clip the retaining clip of the wiring harness.
Connect:


- the connector of the flow control solenoid valve,
- the connector of the pressure control solenoid valve,
WARNING
Refit:
- the dipstick,
Using diagnostic tool , check that there are no stored faults; clear if necessary.
13B-159
DIESEL INJECTION
K9K, and 722 or 724 or 728 or 729 or 732
1
102086
Pressure sensor (1) cannot be removed from the spherical injector rail.
In the event of a pressure sensor fault, the rail pressure sensor and high-pressure pipe assembly must
be replaced (see 13B, Diesel injection, Injector rail ).
13B-160
13B
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting
F9Q, and 800
Equipment required
diagnostic tool
Tightening torquesm
pressure sensor to torque
3.5 daNm +/0.5

bolts to torque
0.4 daNm
IMPORTANT
Before starting any work on the injection circuit, use
the diagnostic tool to check that:
the injection rail is no longer pressurised,
the fuel temperature is not too high.
- Whenever work is carried out, it is essential to respect the safety and cleanliness advice given in this
document.
- It is strictly forbidden to undo a high-pressure pipe
union when the engine is running.
WARNING
- Obtain a set of special high-pressure injection circuit plugs.
- All high-pressure pipes must be replaced and any
removed high-pressure pipe clips.
13B-161
13B
DIESEL INJECTION
13B
F9Q, and 800
REMOVAL
18297-5
Disconnect:
- the battery, starting with the negative terminal.
- the pressure sensor.
Unscrew the pressure sensor.
13B-162
DIESEL INJECTION
F9Q, and 800
REFITTING
Replace the seal.
Screw in the sensor.
Tighten the pressure sensor to torque ( 3.5 daNm
+/- 0.5 ) .
Connect the connector.
WARNING
Connect the battery; carry out the necessary programming (see (see 8, Electrical equipment) ).
Tighten the battery cover mounting bolts to torque ( 0.4 daNm ) .
WARNING
Check that there are no diesel leaks:
- run the engine at idle speed until the fan starts
up,
- check that there is no diesel leak:
13B-163
13B
DIESEL INJECTION
Fuel flow actuator: Removal - Refitting
13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench
1
Tightening torquesm
fuel flow actuator
mounting bolts
5.5 0.6 Nm
battery cover securing

bolts
4 Nm
102120
Disconnect:
IMPORTANT

check using the diagnostic tool CLIP:
- the air intake duct (1) .
that the injection rail is no longer under pressure,

WARNING
- Always replace any high pressure pipe and high
pressure pipe clips removed with new ones.
REMOVAL
102362
Remove diesel splash plate (2) .
13B-164
DIESEL INJECTION
13B
K9K, and 722
6
3
102514
Disconnect:
102315
Remove the high-pressure pipe (6) on injector no. 4

(see 13B, Diesel injection, High pressure pipes:
Replacement ).
- the heater plugs,

- the injector connectors (3) from cylinders no. 3 and
no. 4,
Cap the openings.

Undo bracket bolts (7) .
- the pump electrical connectors (4) ,
Withdraw the fuel flow actuator (by hand using small

successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
13B-165
DIESEL INJECTION
13B
K9K, and 722
REFITTING
WARNING
WARNING
Do not remove the blanking plugs from any component until the last moment.
Only unpack the new component when you are ready to fit it.
Confirm that there is no diesel fuel leakage:

- check the sealing after repair (see 13B, High
pressure pipe: Fuel-tightness check ).
- Let the engine run at idle speed until the engine
cooling fan starts up.
- Accelerate several times under no load.
WARNING
- Carry out a road test.
Do not damage the seal when refitting.

Note:
Do not lubricate the seals with grease or used
diesel fuel. Use the applicator provided in the kit
for the new part.
Fit the actuator.
Finger-tighten the two mounting bolts.
Tighten to torque the two fuel flow actuator mounting bolts ( 5.5 0.6 Nm ) using tool low torque
wrench .
Refit a new high-pressure pipe to injector no. 4 (see
13B, High pressure pipes: Replacement ) and a
new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
WARNING
Tighten to torque the battery cover securing bolts
( 4 Nm ) .
13B-166
DIESEL INJECTION
13B
K9K, and 728 or 729
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
flow actuator mounting
bolts
5.5 0.6 Nm

bolts
4 Nm
Note:
For vehicles with a K9K 732 engine (see MR 370
Mechanical, Scnic II ).
110325
Pull the clip.

IMPORTANT
Before carrying out any work on the injection system, check using the CLIP diagnostic tool :

WARNING
- Always replace any high-pressure pipe or highpressure pipe clip removed with a new one.
110323
Undo bolt (1) .
REMOVAL

terminal.
13B-167
DIESEL INJECTION
13B
K9K, and 728 or 729
102362
102315
Remove the high-pressure pipe (7) from injector no.

4 (see 13B, Diesel injection, High-pressure pipes: Replacing ).
Remove the diesel splash plate (3) .

Undo bracket bolts (8) .
Withdraw the fuel flow actuator (by hand using small

successive turns).
WARNING
Do not use the electrical connector as a lever
ar m.
6
5
102514
Disconnect:
- the heater plugs,
- the injector connectors (6) from cylinders n3 and
n4,
- the pump electrical connectors (4) ,
13B-168
DIESEL INJECTION
13B
K9K, and 728 or 729
REFITTING
WARNING
WARNING
Only unpack the new component when you are ready to fit it.

- Check the tightness after repair (see 13B,
High-pressure pipe: Sealing check ).
- Let the engine run at idle speed until the engine
cooling fan starts to operate.
WARNING
- Carry out a road test.
Do not damage the seal when refitting.

Note:
Do not lubricate the seals with grease or used
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 low torque wrench .
Refit a new high-pressure pipe on injector no. 4 (see
13B, High-pressure pipes: Replacement ) and a
new clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
WARNING
( 4 Nm ) .
13B-169
DIESEL INJECTION
Leak flow from injectors: Check
K9K, and 722 or 728 or 729
Mot. 1711
Kit for measuring

injector leak rate

Connect the four transparent hoses of (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 or other) 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 (Mot. 1711) .
Refit the injector fuel return pipes.
13B-170
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 out the clip.
112815

(1) .
(3) .
112991

13B-171
DIESEL INJECTION
13B
K9K, and 732

Connect:
IMPORTANT
Do not leave any object (tools or other) 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:
112992
- the air inlet pressure sensor connector.
Remove:
Loosen the clip and move the air inlet duct aside.
protector cover,
Pull out the clip from the stainless steel pipe.
Remove:
- the dipstick,
- the dipstick,
Disconnect the four fuel return pipes of the four injectors (see 13B, Diesel injector fuel return rail:
Disconnect the four transparent pipes from (Mot.

1771) .
Refit:
Connect the transparent hoses of (Mot. 1771) to the
injectors instead of the injector fuel return pipes.
Fit the correct blanking plug to the injector fuel return

connectors.
- the dipstick,
Insert these hoses in the four graduated measuring

cylinders of the (Mot. 1711) .

bolt,
Refit:
- the dipstick.

Refit:
Refit the air inlet duct on the damper valve.
Tighten the clamp.
Tighten the clamp.
13B-172
DIESEL INJECTION
K9K, and 732
Connect:
pump.
13B-173
13B
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting
F9Q, and 800 or 808
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts
6 Nm

bolt
4 Nm
IMPORTANT
WARNING
- Be sure to replace any high pressure pipe and
high pressure pipe clips that have been removed.
13B-174
13B
DIESEL INJECTION
13B
F9Q, and 800 or 808
REMOVAL
18297-1

terminal.
Blow the area with compressed air to clean impurities away from the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
- fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not use
any tool for leverage).
13B-175
DIESEL INJECTION
13B
F9Q, and 800 or 808
REFITTING
Clean the fuel pressure regulator bearing face on
the high pressure pump, taking care not to introduce
any impurities.
Wipe the fuel pressure regulator bearing face on the
high pressure pump, taking care not to introduce any
impurities.
WARNING
cooling fan starts up,
Connect the battery.

Rinse the fuel pressure regulator housing in the high
pressure pump, with the ignition on for a few seconds.
Disconnect the battery.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- lubricate the O-rings with clean diesel fuel.
Note:
Lubrication is very important to avoid external
leakage.
Offer up the regulator, rotating it slightly.
Push the regulator gently in until it engages fully.
Pretighten the new regulator bolts to 3 Nm .
Tighten to torque the three regulator bolts ( 6 Nm )
using a low torque wrench .
Clean the area with cleaning cloths.
Fit the fuel pressure regulator connector.
WARNING
Nm ) .
Switch on the ignition.
Clear the fault shown in the diagnostic tool CLIP if
necessary.
13B-176
DIESEL INJECTION
13B
F9Q, and 804
REMOVAL
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts
6 Nm

bolts
4 Nm
IMPORTANT

111887


terminal.
Blow compressed air into the area to clean dirt from
around the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
WARNING
- Obtain the special high-pressure injection cap kit.
- fuel pressure regulator bolts (1) ,
- Be sure to replace any high-pressure pipe removed.
- the fuel pressure regulator manually (do not use

any tool for leverage).
13B-177
DIESEL INJECTION
13B
F9Q, and 804
REFITTING
Clean the fuel pressure regulator bearing face on
the high-pressure pump, taking care not to introduce
any impurities.
Wipe the fuel pressure regulator bearing face on the
high-pressure pump, taking care not to introduce
any impurities.
WARNING
Flush the fuel pressure regulator housing in the

high-pressure pump, with the ignition on for a few
seconds.

terminal.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- 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
low torque wrench .
Clean the area with cleaning cloths.
Fit the fuel pressure regulator connector.
WARNING
( 4 Nm ) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool if
necessary.
13B-178
DIESEL INJECTION
Diesel temperature sensor: Removal - Refitting
13B
K9K, and 722
Equipment required
WARNING
diagnostic tool

804 ),
Tightening torquesm
diesel temperature sensor
15 Nm
batter cover mounting

bolts
4 Nm

REMOVAL
IMPORTANT


WARNING
- Always replace any high-pressure pipe and highpressure pipe clips that have been removed.
WARNING
injector rail high-pressure pipes with one of the
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
13B-179
102120
Disconnect air aspiration hose (1) .
DIESEL INJECTION
13B
K9K, and 722
REFITTING
WARNING

Lubricate the O-ring with the 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.
102514
Disconnect:
- the heater plugs from cylinders n 3 and 4,
Tighten to torque the batter cover mounting bolts

( 4 Nm ) .
- the injectors (2) on cylinders 3 and 4,
Check the sealing after repair (see 13B, Diesel injection, High-pressure pipe: Check sealing ).
- the diesel fuel temperature sensor connector (3) .

WARNING

102317
Clean the sensor (see 13B, Diesel injection, Diesel

Remove the fuel temperature sensor (4) .
13B-180
DIESEL INJECTION
13B
K9K, and 728 or 729
Equipment required
WARNING
diagnostic tool

804 ),
Tightening torquesm
15 Nm

bolts
4 Nm

REMOVAL
IMPORTANT

WARNING
- Always replace any high-pressure pipe and highpressure pipe clips that have been removed.
110325
WARNING
Pull the clip.

injector rail high-pressure pipes with one of the
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
13B-181
DIESEL INJECTION
13B
K9K, and 728 or 729
2
1
110323
102317
Unscrew bolt (1)
Clean the sensor (see 13B, Diesel injection, Diesel

Remove the diesel fuel temperature sensor (5) .

REFITTING
WARNING
Lubricate the O-ring with the lubricant from the applicator supplied with the new part.
WARNING
102514
Disconnect:
Fit the diesel fuel temperature sensor.
- the heater plugs from cylinders n 3 and 4,

- the injectors (3) on cylinders 3 and 4,

15 Nm ) .
- the fuel temperature sensor connector (4) .
Reconnect the electrical connector.

( 4 Nm ) .
13B-182
DIESEL INJECTION
K9K, and 728 or 729
Check the sealing after repair (see 13B, Diesel injection, High-pressure pipe: Check sealing ).
WARNING
13B-183
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-184
13B
DIESEL INJECTION
13B
K9K, and 724
REMOVAL
Equipment required
diagnostic tool

Tightening torquesm
15 Nm
IMPORTANT
- that the injection rail is not under pressure,
advice whenever work is carr ied out on this system.
112331
Remove the pin securing the turbocharger pipe on

the turbocharger (1) .
Remove the bolt mounting the pipe on the cylinder
head.
WARNING
Move the pipe to one side.

Disconnect the inlet air pressure sensor (2)
Tighten to a torque of 38 Nm the pump-rail and

rail-injectors high pressure pipes with the following part numbers:

Move the inlet air duct to one side (4) .
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 ,
For high pressure pipes with different part numbers,
tighten to a torque of 24 Nm .
WARNING
- a new blanking plug kit ( PART NUMBER 77 01
206 804 ),
- cleaning cloths ( PART NUMBER 77 11 211 707 ).
During each operation, always read the precautions for
repair (see 13B, Diesel injection, Diesel injection:
Precautions for repair ).
13B-185
DIESEL INJECTION
13B
K9K, and 724
109470
Remove:
109465
Remove the high pressure pump protectors (8) and

(9)
- the dipstick,
- the dipstick pipe mounting bolts.
Unclip the clips (5) from the injection rail protector.
Remove:
- the mounting bolts (6) from the injection rail protector,
- the injection rail protector (7) .
102514
Clean the pipes (see 13B, Diesel injection, Diesel

injection: Precautions for repair ).
Disconnect the diesel supply and return pipes (10) .
Note:
new cloths.
Fit the correct blanking plugs.
13B-186
DIESEL INJECTION
13B
K9K, and 724
REFITTING
Lubricate the O-ring with lubricant from the applicator supplied with the new part.
Note:
Do not lubricate the diesel temperature sensor
seals with grease or used diesel. Use the applicator supplied with the kit.
WARNING
102514
Disconnect the diesel temperature sensor connector

(11) .
II - REFITTING PART CONCERNED

Refit the diesel temperature sensor.

15 Nm ) .

Connect:
- the diesel supply and return pipes.
Refit:
- the high pressure pump protectors,
- the injection rail protector.
Refit the air inlet duct and tighten the clip.
Connect the inlet air pressure sensor
102317
Fit the turbocharger air duct.
Clean the diesel temperature sensor (see 13B, Diesel injection, Diesel injection: Precautions for repair ).
Lock the air duct onto the turbocharger and the intercooler inlet air pipe.
Remove the diesel temperature sensor (12) .
Tighten the bolt of the air duct on the rocker cover.

13B-187
DIESEL INJECTION
K9K, and 724
Check the sealing after repair (see 13B, Diesel injection, High pressure pipe: check ).
WARNING
- check that there is no diesel fuel leaking.
13B-188
13B
DIESEL INJECTION
Accelerometer: Removal - Refitting
13B
K9K, and 722 or 728 or 729
REFITTING

Emb. 1596
2 4 mm socket for
removing/refitting
clutch master cylinder
Tighten to torque the accelerometer ( 20 Nm )

using tool low torque wrench .
Equipment required
low torque wrench
WARNING
Tightening torquesm
accelerometer
20 Nm

bolts
4 Nm
REMOVAL
102086
Disconnect the accelerometer connector (1) .

Remove the accelerometer using tool (Emb. 1596) .
13B-189

( 4 Nm ) .
DIESEL INJECTION
13B
K9K, and 722
Equipment required
diagnostic tool
low torque wrench
1
Tightening torquesm
Venturi mounting bolt
5.5 Nm 0.6

bolts
4 Nm
102120
IMPORTANT
Disconnect:

- the intake duct (1) .

advice whenever work is carried out on this system.
WARNING
- Always replace any high pressure pipe and high
pressure pipe clips removed with new ones.
REMOVAL
102514
Disconnect the fuel supply and return pipes (2) .
13B-190
DIESEL INJECTION
13B
K9K, and 722
REFITTING
WARNING
Do not remove the blanking plugs from any component until the last moment.
Lubricate the O-ring with the lubricant from the applicator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5
Nm 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
4
WARNING
102316
Disconnect the return pipe (3) connecting the injector to the pump.

( 4 Nm )
Remove:
- the Venturi mounting bolt (4) ,
WARNING
- the Venturi.

- check the sealing after repair (see 13B, Diesel
injection, High pressure pipe: Fuel tightness
check ),
cooling fan starts up,
13B-191
DIESEL INJECTION
13B
K9K, and 728 or 729
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
Venturi mounting bolt
5.5 Nm 0.6

bolts
4 Nm
IMPORTANT
110325
Pull the clip.

advice whenever work is carried out on this system.
2
1
WARNING
- Be sure to replace any high-pressure pipe and
high-pressure pipe clips that have been removed.
REMOVAL
110323
Undo bolt (1) .

13B-192
DIESEL INJECTION
13B
K9K, and 728 or 729
REFITTING
WARNING
Lubricate the O-ring with the lubricant from the applicator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5
Nm 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
Connect the battery, starting with the positive terminal
102514
WARNING
Disconnect the fuel supply and return pipes (3) .

( 4 Nm )
4
WARNING
- Check the tightness after repair (see 13B, Diesel injection, High-pressure pipe: Sealing
check ),

102316
Disconnect the return pipe (4) connecting the injector to the pump.
Remove:
- the Venturi mounting bolt (5) ,
- the Venturi.
13B-193
DIESEL INJECTION
Accelerator pedal potentiometer: General information
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 cruise control / speed limiter have
an accelerator pedal with a kickdown point at the end
of their travel ( kick-down ).
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-194
13B
DIESEL INJECTION
Accelerator pedal potentiometer: Removal - Refitting
13B
REFITTING
Tightening torquesm
bolt
4 Nm

WARNING
REMOVAL

Disconnect:
- the accelerator pedal connector.
Note:
A fault on the accelerator pedal position potentiometer results in changes in the idle speed or
engine operation (see 13B, Diesel injection,
Idle speed ).
Nm ) .
102204
Remove:
- pedal mounting bolts (1) ,
- the pedal.
13B-195
DIESEL INJECTION
Diesel injection computer: Removal - Refitting
13B
K9K, and 722 or 728 or 729 F9Q, and 800 or 808
Equipment required
diagnostic tool
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
Note:
When programming, reprogramming or replacing a
computer, it is necessary to program the C2I parameters (individual injector correction) and the
engine parameters into the new computer using the
diagnostic tool RENAULT CLIP tool.
There are two procedures for doing this (see 13B, Diesel Injection, Injectors: Configuration and programming ):
- an automatic procedure which can be used if it is possible to read the information contained in the old computer,
- a manual procedure for when it is not possible to read
the information contained in the old computer.
3
101822

Remove:
- the wiring harness bracket (3) .
Detach the wiring harnesses from the battery tray.
REMOVAL

terminal.
Remove the battery.
101811
Remove the injection computer and its support (4) .
13B-196
DIESEL INJECTION
13B
K9K, and 722 or 728 or 729 F9Q, and 800 or 808
REFITTING
5
101890
Remove:
101887
- the computer mounting bolts (5) ,
- the computer.
21 Nm ) .
Make sure you refit the battery tray correctly on the
computer support.
WARNING
( 4 Nm ) .
Respect the programming instructions for the C2I
parameters (individual injector correction) and engine adaptives (see 13B, Diesel injection, Computer
configuration ).
Switch on the ignition and read the fault codes using
the diagnostic tool .
If necessary, repair the faults indicated.
Clear the faults.
Check that the vehicle is operating correctly.
13B-197
DIESEL INJECTION
13B
K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700
Tightening torquesm
computer support
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 ).
115720
REMOVAL
Unclip:
- the wiring harness (2) from the battery negative terminal,

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

Remove:
- the upper mounting bolt (3) from the computer support,
- the mounting bolt (4) from the computer support
- the mounting nut (6) from the wiring harness,
- the computer (5) and its support.
CONCERNED
Remove:
- the computer mounting nuts,
- the computer from its support.
REFITTING
CONCERNED
Refit:
- the computer on its support,
- the computer mounting nuts.
13B-198
DIESEL INJECTION
K9K, and 724 or 728 or 729 F9Q, and 804 M9R, and 700
Refit the mounting bolt to the computer support.
Tighten to torque the mounting bolt on the computer support ( 21 Nm ) .
Refit the upper mounting bolt to the computer support.
Clip on:
- the wiring harness to the battery negative terminal,
Connect the computer connectors.
Refit:
13B-199
13B
PREHEATING
Pre/postheating unit: Removal - Refitting
13C
F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732 M9R, and 700
Tightening torquesm
bolts
wheel bolts
4 Nm
110 Nm
Note:
It is located behind the front left-hand wheel arch
liner.
REMOVAL
terminal.
102125
Disconnect the pre-postheating unit connector.
Remove:
- the pre-postheating unit mounting bolt,
- the pre-postheating unit.
REFITTING
WARNING
101823
Remove:
Tighten to torque:
- the front left-hand wheel,
- the front left-hand wheel arch liner.

.
13C-1
PREHEATING
Heater plugs Removal - Refitting
13C
K9K, and 722
Tightening torquesm
heater plugs
bolts
15 Nm
4 Nm
The resistance of a heater plug is 0.6 (connector disconnected).

The heater plugs are removed without opening the
high pressure diesel circuit.
REMOVAL
15762
Disconnect the electrical connector from the heater

plugs.

terminal.
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 radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
WARNING
Ensure that no foreign bodies enter the cylinder
during this operation.
REFITTING
102120
Disconnect the air duct.

Tighten to torque the heater plugs ( 15 Nm ) .
WARNING
( 4 Nm ) .
13C-2
PREHEATING
13C
K9K, and 728 or 729
Tightening torquesm
heater plugs
bolts
15 Nm
4 Nm
REMOVAL
terminal.
110323
Undo the bolt (1) .

Move the air duct aside (2) .
110325
Pull the clip.
15762

plugs.
cylinders.
WARNING
13C-3
PREHEATING
K9K, and 728 or 729
REFITTING
WARNING
( 4 Nm ) .
13C-4
13C
PREHEATING
13C
F9Q, and 800 or 804 or 808
Tightening torquesm
heater plugs
bolts
15 Nm
4 Nm
The resistance of a heater plug is 0.6 (connector disconnected).

The heater plugs are removed without opening the
high pressure diesel circuit.
REMOVAL
15762

plugs.

terminal.

cylinders.
F9Q, and 804
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct:
- the injection rail protector (see 13B, Diesel injection, Injection rail protector: Removal - Refitting
)
WARNING
REFITTING
WARNING
( 4 Nm ) .
13C-5
PREHEATING
F9Q, and 804
UD replaced with 11,05,08,02-01,37-001,016 on 08/
06/2005
13C-6
13C
PREHEATING
13C
K9K, and 732

Car. 1363
Trim removal lever
Tightening torquesm
heater plugs
15 Nm
WARNING
Procedure for removing the air inlet duct (risk of
leaking and slipping if this procedure is not observed):
112815

(1) .

any other product,
Loosen the clip (2) and move the air inlet duct aside
(3) .
- clean the bearing face on the intercooler and on

- place the clip in the same position if the hose is
not replaced,
- always replace the hose and/or the intercooler if
damaged.
REMOVAL
112811
Pull out the clip.
13C-7
PREHEATING
13C
K9K, and 732

- the dipstick,
- the dipstick pipe mounting bolts (9) .
CONCERNED
112991
Make a marking (4) 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 (5) from the stainless steel pipe,
112993
Disconnect the connector from the heater plug.

Note:
Do not pull on the plug cable.
cylinders.
WARNING
112992
REFITTING

Remove:
- the mounting nut and bolt (8) from the injection rail
protector cover,

CONCERNED
13C-8
Refit the heater plugs using the hose.
PREHEATING
K9K, and 732
Connect the connector to the heater plugs.
Refit:
- the mounting bolts to the dipstick pipe,
- the dipstick,
- the injection rail protector mounting bolt and mounting nut.
Clip on the injection rail protector cover.
Refit:
marking,
Clip the stainless steel pipes onto the turbocharger.
Refit:
Tighten the clip.
Connect:
13C-9
13C
PREHEATING
13C
M9R, and 700
REFITTING
Equipment required
CONCERNED
socket wrench for removing/refitting preheating

plugs
Refit the heater plugs.

Tightening torquesm
heater plugs
WARNING
16.5 Nm
REMOVAL
Bring the heater plugs just into contact.
Tighten to torque the heater plugs ( 16.5 Nm ) using

a socket wrench for removing/refitting preheating plugs or a 1/4-inch square drive long socket 10
mm in diameter connected to a universal joint.
Remove the front engine cover.

WARNING
Disconnect the heater plug connectors.
The heater plugs are damaged by being tightened to any torque greater than 19 Nm .
Clean and blast the outside of the plugs to prevent

any contamination of the cylinders.
CONCERNED
Connect
Unscrew then remove the plugs using a socket

wrench for removing/refitting preheating plugs
or a 1/4-inch square drive long 10 mm socket with a
universal joint.
If necessary, use a hose to unscrew the plugs completely.
13C-10

Refit the engine cover.
PREHEATING
13C
F9Q, and 800 or 808

The pre/post heating function is controlled by the injection computer.
PRE/POST HEATING OPERATING PRINCIPLE
1 - Switching on the ignition preheating
a - Variable preheating
The duration the indicator light is lit and of the supply to
the heater plugs depends on the coolant temperature
and the battery voltage.
101188
X: Time in seconds
Y: Coolant temperature in C
101189
X: Time in seconds
In all cases the preheating warning light should light up
for more than 12 seconds .
b - Fixed preheating
After the warning light goes out the plugs remain supplied for a fixed period of 10 seconds .
2 - Starting
The plugs continue to be 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 no depression of the accelerator
pedal.
13C-11
PREHEATING
13C
K9K, and 722 or 728 or 729 or 732

The pre-postheating function is controlled by the injection computer.
At idling speed with no depression of the accelerator

pedal.
PRE-POSTHEATING OPERATING PRINCIPLE

1 - Ignition on preheating
a - Variable preheating
The time taken for the warning light to come on and for
supply to the heater plugs depends on the coolant temperature and the battery voltage.
103124
X: Time in seconds
103123
X: Time in seconds
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).
b - Fixed preheating
After the warning light goes out, the heater plugs continue to be supplied for a fixed period of 5 seconds .
2 - Starting
The plugs remain supplied while the starter motor is
being activated.
3 - Engine running postheating
During this phase the plugs are supplied continuously
according to the coolant temperature.
13C-12
ANTIPOLLUTION
Petrol vapour rebreathing: Operation
14A
I - OPERATING DIAGRAM OF THE CIRCUIT
F4R, and 776
6
5
8
3
4
106679
106278
(1)
Inlet manifold
(2)
Fuel vapour absorber bleed

solenoid valve
(3)
Fuel vapour absorber
(4)
Tank
(5)
Breather
(6)
Anti-return valve (F4R 776 only)
(8)

solenoid valve
7
10
11
12
102734
102724
(7)

solenoid valve
14A-1
(9)
(10)
Fuel vapour recirculation coming

from the tank
ANTIPOLLUTION
Petrol vapour rebreathing: Operation
(11)
Recirculation of fuel vapours

going to the engine
(12)
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, connect the fuel vapour absorber and the inlet manifold 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).
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.
14A-2
14A
ANTIPOLLUTION
Fuel vapour recirculation circuit: check
14A
I - CHECKING THE OPERATION OF THE FUEL
VAPOUR ABSORBER BLEED
II - FUEL VAPOUR ABSORBER BLEEDING

CONDITIONS
The fuel vapour absorber bleed solenoid valve is
controlled by track C-E1 of the computer if:
Note:
- the coolant temperature is above 55C ,
A fault with this system may result in rough idling

or the engine stalling.
- the air temperature is above 10C ,

- the engine is not at idle speed,
- a given load threshold is reached,
- the throttle potentiometer is not in the no load

position.
During on board diagnostic fault finding, fuel vapour absorber bleeding is not authorised.
The opening cyclic ratio of the fuel vapour absorber
bleed solenoid valve can be displayed using the diagnostic tools by referring to parameter PR102: Fuel
vapour absorber bleed solenoid valve OCR .
6
5
The solenoid valve is closed for values below 1.2 % .
3
4
106679
(1)
Inlet manifold
(2)

solenoid valve
(3)
(4)
Tank
(5)
Breather
(6)
Anti-return valve (F4R 776 only)
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
2
102734
Disconnect:
- pipe (2) bringing the fuel vapour from the tank,
- pipe (3) taking the fuel vapours to the solenoid valve,
102483
Release absorber (1) from the fuel tank retaining

notch by pushing it in the direction of the arrow.
- breather pipe (4) .

Remove the absorber.
REFITTING
14A-4
ANTIPOLLUTION
Fuel vapour canister:Checking
Mot. 1311-01
Fuel pressure test kit
CHECKING THE FUEL VAPOUR

ABSORBER
On the fuel vapour absorber, cap the circuit coming
from the tank.
Connect a pressure gauge on tool (Mot. 1311-01) to
the absorber breather outlet.
With the engine at idle speed, check that there is no
vacuum at the absorber breather outlet (under the
same conditions, the command value read by the
diagnostic tool in parameter: Fuel vapour absorber
bleed solenoid valve OCR remains minimal ( X
lower than or equal to 1.5 % ).
Is there a vacuum?
- Yes: with the ignition off, use a vacuum pump to
apply a vacuum of 500 mbar to the solenoid valve
outlet . The vacuum pressure should not vary by
more than 10 mbar over 30 seconds .
Does the pressure vary?
Yes: the solenoid valve is faulty, replace it.
No: there is an electrical fault, check the circuit.
- No: under bleeding conditions (see bleeding
conditions ), the vacuum should increase (at the
same time the parameter value on the diagnostic
tool should also 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
B84 or C84 or S84, and K4J, and 730 or 732

I - LOCATION OF COMPONENTS
101495
(1)
Oil vapour breather port
(2)
Oil vapour recovery plate located on the cylinder head cover
(3)
Sized port
2
101499
101869
14A-6
ANTIPOLLUTION
14A
B84 or C84 or S84, and K4J, and 730 or 732

For information on removing oil vapour recovery plate
(2) , (see 11A, Top and front of engine, Tightening
the cylinder head ).
II - OPERATING DIAGRAM
A: At low loads, small quantities of oil vapour are
sucked back in via sized opening (7).
5
2
1
101956
B: At medium and high loads, large quantities of oil

vapour are sucked in by the gas throttle.
6
2
101957
(1)
Engine
(2)
Oil vapour recovery plate
(4)
Motorised throttle valve
(5)
Inlet manifold
(6)
Air inlet
(7)
Sized port
To ensure the antipollution system works properly, the

oil vapour rebreathing circuit must be kept clean and in
good condition.
Air unit
III - CHECKING
(3)
14A-7
ANTIPOLLUTION
14A
K4M, and 760 or 761

I - LOCATION OF COMPONENTS
102305
(1)
Oil vapour breather pipe
(2)
Sized opening
3
4
101820
(3)
Oil vapour recovery plate on the

cylinder head cover
(4)
102073
For information on removing oil vapour recovery plate

(3) , (see 11A, Top and front of engine, Cylinder
head gasket ).
14A-8
ANTIPOLLUTION
14A
K4M, and 760 or 761

II - OPERATING DIAGRAM
A: At low loads, the oil vapours are rebreathed in
small quantities through the sized opening (6)
(6)
Sized opening

good condition.
102308
B: Under average and heavy loads, the oil vapours

are rebreathed in large quantities through the gas
throttle valve.
Air inlet
III - CHECKING
(5)
3
5
102309
(1)
Engine
(2)
(3)
Motorised throttle
(4)
Inlet manifold
14A-9
ANTIPOLLUTION
14A
K9K, and 722 or 728 or 729 or 732

I - PRESENTATION OF THE CIRCUIT
B : Under medium or high load, the pressure in the air

inlet duct pulls the valve diaphragm, the oil vapours are
rebreathed in small quantities via a sized opening.
II - CHECK
To ensure the correct operation of the anti-pollution

system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
20965
1
2
6
4
20965-1
(1)
Cylinder head cover
(2)
(3)
Oil vapour rebreathing valve
(4)
Air inlet duct
(5)
Turbocharger
(6)
Atmospheric pressure
A : Under low load, the vacuum in the air inlet duct is

below the spring calibration. The oil vapours are rebreathed in large volumes by the vacuum in the air inlet
duct.
14A-10
ANTIPOLLUTION
14A
F9Q, and 800 or 808

I - CIRCUIT PRESENTATION
1
3
2
4
4
5
3
1
100054
100053
(1)
Oil vapour rebreathing pipe connected to the intake pipes
(2)
Cylinder block outlet oil vapour

rebreathing pipe
Air duct
(3)
Separator filter oil return pipe
(5)
Turbocharger
(4)
Oil separator
(6)
Inlet manifold
(1)
Engine
(2)
Oil separator
(3)
Air filter unit
(4)
II - CHECK
To ensure the correct operation of the anti-pollution
system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
14A-11
ANTIPOLLUTION
14A
F4R, and 770 or 771 or 776

I - PRESENTATION OF COMPONENTS
102723
(1)
(3)
(2)
Oil vapour recirculation valve
102729
14A-12
Oil vapour recovery plate on the

cylinder head cover
ANTIPOLLUTION
14A
F4R, and 770 or 771 or 776
F4R, and 776
106629
(A)
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
(B)
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-13
ANTIPOLLUTION
14A
F4R, and 770 or 771 or 776

For removal, (see 11A, Top and front of engine, Cylinder head gasket ).
II - OIL VAPOUR RECIRCULATION CIRCUIT
102738
(4)
Throttle upstream oil vapour

recirculation aperture
9
8
10
102745
14A-14
ANTIPOLLUTION
F4R, and 770 or 771 or 776
(5)
Air duct
(6)
Throttle valve
(7)
Inlet manifold
(8)
Throttle valve upstream oil

vapour rebreathing port
(9)
(10)
Oil vapour rebreathing valve
III - CHECKING
good condition.
14A-15
14A
ANTIPOLLUTION
14A
F9Q, and 804

I - THE CIRCUIT
100054
100053
(1)
Oil vapour rebreathing pipe connected to the inlet pipes
(2)
Cylinder block outlet oil vapour

rebreathing pipe
Air duct
(3)
Oil separator filter return pipe
(5)
Turbocharger
(4)
Oil separator
(6)
Inlet manifold
(1)
Engine
(2)
Oil separator
(3)
Air filter unit
(4)
II - CHECK
good condition.
14A-16
ANTIPOLLUTION
Exhaust gas recirculation: Description
14A
K9K, and 722 or 728 or 729

I - THE CIRCUIT
Note:
The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation
of the quantity of air admitted by the engine.
IV - OPERATING CONDITIONS
The following parameters determine actuation of the

exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- accelerator pedal position,

- diesel injected,
- engine speed.
102364
(1)
Engine
(2)
Air filter unit
(3)
Plenum chamber
(4)
Exhaust manifold
(5)

with solenoid valve
Operating point for checking the exhaust gas

The exhaust gas recirculation solenoid valve is actuated if:
- the air temperature is between -30C and 67 C , inclusive,
- or the coolant temperature is between 0C and 127C
inclusive,
(6)
Turbocharger
(7)
Injection computer
- the engine speed is above 500 rpm ,
(8)
Intercooler
(A)
Air inlet
- the diesel fuel injection flow is between 10 and 31

mg/stroke inclusive,
(B)
Exhaust gas outlet
- the atmospheric pressure is above 421 mbar .

If so, the diagnostic tool indicates an exhaust gas recirculation solenoid valve position opening cylinder ratio
value equal to 4 and 60% .
II - PURPOSE OF THE EXHAUST GAS

RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
Exhaust gas recirculation is cut off if:
The computer regulates the passage of gases by actuating a solenoid valve.
- the engine speed is below 500 rpm ,
- the battery voltage is below 9 V ,
- the mapping (engine speed - load) exceeds a threshold,

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 air conditioning compressor is actuated.

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-17
ANTIPOLLUTION
K9K, and 722 or 728 or 729
15761
Track
Description
Solenoid supply
Position potentiometer supply
Not used
Position potentiometer earth
Solenoid earth control
Position potentiometer signal
14A-18
14A
ANTIPOLLUTION
14A
F9Q, and 800 or 808

I - THE CIRCUIT
4
6
10
3
11
2
23244

(1)
Engine
(2)
Injection computer
(3)
Inlet manifold
(4)
Exhaust manifold
(5)
Turbocharger
(6)
(7)
Air flowmeter
(8)
Air inlet
(9)
Exhaust gas outlet
(10)
Intercooler inlet
The following parameters determine activation of the

(11)
Intercooler outlet

- the air temperature,

- the injection flow,
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
The injection computer allows gas to pass by actuating
a solenoid valve.
- the engine speed.

Exhaust gas recirculation is cut off if:
- the battery voltage is below 9 V ,
14A-19
ANTIPOLLUTION
14A
F9Q, and 800 or 808

- If the engine speed is above 2,950 rpm when the pedal is released (low pedal value),
Note:
There is no exhaust gas recirculation at altitude (>
1,200m).
- if the 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 1,000 rpm .
the coolant temperature is above 60 C .
The exhaust gas recirculation solenoid valve is not
controlled after engine start-up depending on coolant
temperature mapping.
15761
Track
Description
Solenoid supply
Sensor feed
Sensor earth
Solenoid earth
Sensor output
103127
Time in seconds
The exhaust gas recirculation solenoid valve is no longer supplied if there is a fault on:
- the coolant temperature sensor,
- the air temperature sensor,
- the turbocharging pressure sensor,
- the atmospheric pressure sensor.
14A-20
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 actuates a valve linking
the exhaust manifold and the inlet manifold.
The principle of the exhaust gas recirculation consists
of reintroducing some of the exhaust fumes into the engine air breathing cycle.
The EGR valve is controlled by a direct current motor.
14A-21
14A
ANTIPOLLUTION
14A
K9K, and 732

I - THE CIRCUIT
Note:
The position of the exhaust gas recirculation solenoid valve is a determining factor in the calculation
of the quantity of air admitted by the engine.
The following parameters determine actuation of the
- air temperature,
- accelerator pedal position,
- diesel injected,
- engine speed.
102364
(1)
Engine
(2)
Air filter unit
(3)
Plenum chamber
(4)
Exhaust manifold
(5)

with solenoid valve
(6)
Turbocharger
(7)
Injection computer
(8)
Intercooler
(A)
Air inlet
(B)
Exhaust gas outlet

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.
14A-22
ANTIPOLLUTION
14A
K9K, and 722

Mot. 1567
Remote operation
Tightening torquesm
exhaust gas recirculation unit mounting bolt
21 Nm
metal air inlet tube

mounting bolt
21 Nm
lifting eye (timing end)
21 Nm

heat shield on the
exhaust gas recirculation solenoid valve
12 Nm

bolts
4 Nm
102126
Disconnect the wiring harness (2) .

REMOVAL
terminal.
7
102119
Disconnect:
- turbocharging pressure regulation valve pipe (3)

from the air duct,
- air inlet pipe (4) on the exhaust gas recirculation
unit.
Remove:
102120
- bracket (5) ,
Remove:
- engine lifting eye (6) ,
- air intake metal pipe (7) .
- the air duct (1) .
14A-23
ANTIPOLLUTION
K9K, and 722
10
102074
Remove:
- exhaust gas recirculation solenoid valve heat
shield (8) ,
- exhaust gas recirculation pipe (9) ,
- the two exhaust gas recirculation unit mounting
bolts (10) ,
- the exhaust gas recirculation unit.
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
Tighten to torque the engine cover mounting bolts
( 4 Nm ) .
14A-24
14A
ANTIPOLLUTION
14A
K9K, and 728 or 729 or 732

Mot. 1567
Remote operation
2
Tightening torquesm
21 Nm
metal inlet air tube

mounting bolts
21 Nm
lifting eye (timing end)
21 Nm
exhaust gas recirculation solenoid valve heat

shield mounting bolts
12 Nm
front engine cover

mounting bolts
4 Nm
110323
Undo bolt (1) .

Note:
For vehicles fitted with the K9K 732 engine (see
Workshop Repair Manual 370 Mechanics, Scnic II ).
REMOVAL
terminal.
102126
Disconnect the wiring harness (3) .

110325
Pull the clip.
14A-25
ANTIPOLLUTION
14A
K9K, and 728 or 729 or 732
REFITTING
Replace the exhaust gas recirculation tube complete
with new clips.
6
7
Tighten the new clips using (Mot. 1567) .

Replace the O-rings on the metal air inlet tube.
Tighten to torque:

bolts ( 21 Nm ) ,
- the metal inlet air tube mounting bolts ( 21 Nm )
,
- the lifting eye (timing end) ( 21 Nm ) ,

102119
Disconnect:
- the exhaust gas recirculation solenoid valve

heat shield mounting bolts ( 12 Nm ) .
- the turbocharging pressure regulation valve pipe

(4) from the air duct,
- the air inlet pipe (5) on the exhaust gas recirculation unit.

WARNING
Remove:
- the bracket (6) ,
Tighten to torque the front engine cover mounting

bolts ( 4 Nm ) .
- the engine lifting eye (7) ,

- the air inlet metal tube (8) .
11
9
10
102074
Remove:
- the exhaust gas recirculation solenoid valve heat
shield (9) ,
- the exhaust gas recirculation pipe (10) ,
- the two exhaust gas recirculation unit mounting
bolts (11) ,
- the exhaust gas recirculation unit.
14A-26
ANTIPOLLUTION
14A
F9Q, and 804
Tightening torquesm
25 Nm
exhaust gas recirculation pipe mounting bolts
18 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove the battery.
Remove the air duct (see 12A, Fuel mixture, Inlet
111964
111861
Remove the mounting bolts (1) from the exhaust gas

recirculation pipe.
113177

recirculation unit.
WARNING
Never remove the exhaust gas recirculation solenoid valve from the unit.
REFITTING
14A-27
ANTIPOLLUTION
F9Q, and 804
Tighten to torque:
bolts ( 25 Nm ) ,
- the exhaust gas recirculation pipe mounting
bolts ( 18 Nm ) .
WARNING
Reconnect the connectors.
( 4 Nm ) .
14A-28
14A
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
Mot. 1729
Pin spanner for removing the EGR valve
Tightening torquesm
mounting bolts
9 Nm
Note:
For vehicles fitted with the K9K 732 engine (see
Workshop Repair Manual 370 Mechanics, Scnic II ).
The exhaust gas recirculation solenoid valve is fitted
into the exhaust gas recirculation unit.
REMOVAL
Remove:
- the heat shield,
- the exhaust gas recirculation solenoid valve mounting bolts,
- the exhaust gas rebreathing solenoid valve by unscrewing it gradually,
- the exhaust gas recirculation solenoid valve by gradually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve seal with a new one
Tighten to torque the exhaust gas recirculation
solenoid valve mounting bolts ( 9 Nm ) .
14A-29
14A
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting
F9Q, and 800 or 808
Mot. 1729
Pin spanner for removing the EGR valve
Tightening torquesm
9 Nm
The exhaust gas recirculation solenoid valve is fitted

into the exhaust gas recirculation unit.
REMOVAL
Remove:
- the inlet and exhaust manifolds (see 12A, Fuel
mixture, Manifold ),
- the bolts securing the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation solenoid valve by gradually turning it using tool (Mot. 1729) .
REFITTING
WARNING
Always replace the exhaust gas recirculation
solenoid valve gasket with a new one
Tighten to torque the mounting bolts on the exhaust gas recirculation solenoid valve ( 9 Nm ) .
14A-30
14A
ANTIPOLLUTION
14A
K9K, and 732

Ms. 583
Hose clamps
Mot. 1567
Remote operation
Equipment required
diagnostic tool
Tightening torquesm
bolts mounting the
exhaust gas cooler on
its two supports
12 Nm
bolt mounting the

exhaust gas cooler supports on the cylinder
head
25 Nm
mounting bolts of the

rigid exhaust gas recirculation pipe
35 Nm
coolant circulation
cover mounting bolts
10 Nm
bolts mounting the lifting bracket on the

timing end
10 Nm
112816
Remove the oil vapour rebreather pipe (1) .

Disconnect the connector (2) from the oil vapour recirculation solenoid valve.
REMOVAL
112811
Remove:
Pull out the clip.

- Refitting ).
14A-31
ANTIPOLLUTION
14A
K9K, and 732
112991
113475
Remove the mounting bolt (3) from the stainless

steel pipe.
Remove the mounting bolts (7) from the injection rail

protector cover mounting bracket.
Move the air inlet duct (4) to one side.
112815
Disconnect the connector (5) from the air inlet pressure sensor.
Loosen the clip (6) and move the air inlet duct aside.
Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting ).
14A-32
ANTIPOLLUTION
14A
K9K, and 732

- the air inlet metal tube (11) ,
- the mounting bolts from the exhaust gas inlet pipe
(12) ,
- the mounting bolts from the exhaust gas recirculation unit assembly (13) ,
- the exhaust gas recirculation unit assembly.
CONCERNED
114341
Position the (Ms. 583) on the exhaust gas cooler inlet and outlet hoses.
coolant recirculation cover.
Move the exhaust gas coolant recirculation cover to
one side.
112326
At the workbench, remove:
Remove the seals from the cover.
- the bolt mounting the exhaust gas cooler on its two

supports,
Note:
- the exhaust gas cooler,
Make preparations for coolant outflow.
- the exhaust gas inlet pipe snap-fit clamp,

- the exhaust gas inlet pipe.
112329
Remove:
- the lifting bracket mounting bolts (9) from the timing
end,
- the lifting bracket on the timing end (10) ,
14A-33
ANTIPOLLUTION
14A
K9K, and 732
REFITTING
All the bearing faces on each removed part must be
carefully cleaned.
WARNING
Take care not to damage the bearing faces to
prevent any risk of coolant leaks.
WARNING
112326
Always replace:
- the metal air inlet tube and its O-rings,
Refit:
- the exhaust gas inlet pipe, its mounting bolts, its

seal and its snap-fit clamp,
- the mounting bolts to the cooler, without making

contact so that the cooler can move,
- the cooler seals and its supports,
- the exhaust gas recirculation unit assembly, with its

cooler, onto the cylinder head.
- the seals of the coolant circulation cover within

the exhaust gas cooler,
- the mounting bolts for the two exhaust gas cooler

supports.
- the seal between the downstream duct of the

cut-off valve and the exhaust gas cooler support,
Tighten the bolts mounting the two exhaust gas cooler supports on the cylinder head until they make
contact.
- the seal between the catalytic converter and the

turbocharger.
Adjust the exhaust gas cooler on its two supports so

that it is immobilised.
CONCERNED
Refit the exhaust gas cooler on its two supports fitted with new seals.
Tighten the mounting bolts of the exhaust gas cooler

on its two supports until they make contact, in order
to immobilise it.
Remove the exhaust gas recirculation unit assembly
with its cooler.
WARNING
At the workbench, tighten to torque the bolts mounting the exhaust gas cooler on its two supports (
12 Nm ) .
Ensure that the seals between the cooler and its

two supports are correctly positioned to avoid
any coolant leaks.
WARNING
Ensure that the seals between the cooler and its
two supports are correctly positioned to avoid
any coolant leaks.
Refit the exhaust gas recirculation unit assembly on
the cylinder head with its cooler.
Refit the bolts mounting the exhaust gas cooler supports on the cylinder head.
Tighten to torque the bolt mounting the exhaust
gas cooler supports on the cylinder head ( 25
Nm ) .
14A-34
ANTIPOLLUTION
14A
K9K, and 732

Refit:
Tighten:
- the new rigid exhaust gas recirculation pipe with a

new seal,
- the bolts mounting the rail protector mounting bracket on the exhaust gas cooler assembly,
- the new exhaust gas recirculation pipe mounting

bolts,
- the nut mounting the rail protector on the mounting

bracket.
Fit the new snap-fit clamp.
Refit the damper valve (see 12A, Fuel mixture,

Damper valve: Removal - Refitting ).
Connect the air inlet pressure sensor connector.
WARNING
Refit the clip on the air inlet duct if necessary.
Ensure that you do not squeeze the exhaust gas

inlet pipe before fitting the snap-fit clamp.
Position the air inlet duct.

Clip the air inlet duct onto the turbocharger.
Tighten the rigid exhaust gas recirculation pipe

mounting bolts until they make contact.
Adjust the rigid exhaust gas recirculation pipe in relation to the cooler support on the timing end.
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 the air inlet duct mounting bolt.

Tighten the air inlet duct bolt.
Connect the exhaust gas recirculation solenoid valve connector.
Refit the oil vapour rebreathing pipe.
Connect the battery (see 80A, Battery: Removal Refitting).
Bleed the coolant (see 19A, Cooling, Cooling circuit: Bleeding ).
III - FINAL OPERATIONS
Refit:
Refit:
- the coolant circulation cover
Clear any faults stored by the computer using the

diagnostic tool .
- the coolant circulation cover mounting bolts
WARNING
Ensure that the water inlet and outlet hoses of
the exhaust gas cooler are correctly aligned so
that they do not bend.
Tighten to torque the coolant circulation cover
Refit:
- the lifting bracket on the timing end,
- the bolts mounting the lifting bracket on the timing
end.
Tighten to torque the bolts mounting the lifting
bracket on the timing end ( 10 Nm )
Loosen the nut mounting the rail protector on the
mounting bracket.
Refit the bolts mounting the rail protector mounting
bracket on the exhaust gas cooler assembly.
14A-35
ANTIPOLLUTION
Exhaust gas recirculation mounting: Removal - Refitting
K9K, and 732
For removing and refitting the supports for the exhaust
gas recirculation (see 14A, Emission control, Exhaust gas cooler: Removal - Refitting ).
14A-36
14A
ANTIPOLLUTION
Exhaust gas recirculation rigid pipe: Removal - Refitting
14A
K9K, and 732
REFITTING

Mot. 1567
Remote operation

All the bearing faces must be carefully cleaned.
Tightening torquesm
mounting bolts of the
rigid exhaust gas recirculation pipe on the
manifold
WARNING
35 Nm
Always replace:
- the exhaust gas inlet pipe, its seal on the cylinder head and its snap-fit clamp,
- the seals between the catalytic converter and
the turbocharger.
REMOVAL

CONCERNED
Refit:
- the rigid exhaust gas recirculation pipe with a new

seal,
Disconnect the battery (see 80A, Battery: Removal Refitting
- the new exhaust gas recirculation pipe mounting

bolts,
Remove:
Fit a new snap-fit clamp.

- the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - refitting ).
WARNING
Ensure that you do not squeeze the exhaust gas
inlet pipe before fitting the snap-fit clamp.

CONCERNED
Tighten the mounting bolts of the rigid exhaust gas

recirculation pipe on the manifold until they make
contact.
Adjust the exhaust gas inlet pipe in relation to the
cooler support on the timing end.
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 on the manifold (
35 Nm ) .
Refit:
113842
Remove:
- the mounting bolts (1) from the exhaust gas recirculation pipe,
- the catalytic converter (see 19B, Exhaust, Catalytic converter ),

- the snap-fit clamp (2) using the (Mot. 1567) ,
- the rigid exhaust gas recirculation pipe (3) .
14A-37
STARTING - LOAD
Alternator: General information
16A
F4R or F9Q or K4J or K4M or K9K or M9R

I - OPERATION
Engine
These vehicles are fitted with an alternator with internal

ventilation and incorporated regulator, plus a warning
light on the instrument panel, which operates as follows:
Alternator
Current
strength
VALEO : TG11 C018

VALEO : TG11 C040
- when the ignition is switched on, the warning light comes on,
110 A
VALEO : TG11 C049
- when the engine starts, the warning light goes out,
VALEO : SG12 B078
- if the warning light comes on while the engine is running, this indicates a charge fault.
VALEO : SG12 B081

F9Q
125 A
VALEO : SG15 B092
II - IDENTIFICATION
VALEO : SG15 B098
Engine
Alternator
BOSCH : LIE8 0 124 525

101
Current
strength
BOSCH : 0 124 525 044
VALEO : TG11 C011

K4J and
K4M
110 A
VALEO : TG11 C027
BOSCH : LIE8 0 124 525
028
150 A
150 A
M9R
VALEO : TG11 C040

110 A
VALEO : TG11 C049
F4R
VALEO : SG15 L027
155A
BOSCH : LIE6 0 124 0AC

473B
120A
VALEO : TG15 C059
150 A
MELCO : 8GM A004 TJ0

281
210 A
VALEO : SG12 B092

125 A
VALEO : SG12 B098
Note:
VALEO : TG11 C041
There is a configuration in the Protection and Switching Unit for the alternator fitted to the vehicle (see
87G, Engine compartment connection unit, Protection and Switching Unit ).
110 A
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
K9K, and 722 or 724 or 728 or 729 or 732

Fit the cooling assembly to the upper cross member
using the safety belt .
Equipment required
safety belt
Tightening torquesm
alternator mounting
bolts
21 Nm
21 Nm
free pulley support

mounting bolts
21 Nm
105 Nm
21 Nm
wheel bolts
110 Nm
101212
Remove:
REMOVAL
- the side stiffener mounting bolts,

REMOVAL PREPARATION OPERATION
- the side reinforcements (1) .
Remove the engine cover.

Disconnect:
- the electrical connections.
Remove the alternator harness.
Remove:
- the front wheels,
102008
Note:
Remove:
When fitting the safety strap, take care:

- not to crush the cooling hoses,
- the half sub-frame mounting nuts and bolts (2) ,
- not to strap up the half sub-frame.
16A-2
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 729 or 732
CA or CAREG
19703
109537
Disconnect:
Note:
Take care not to constrain the compressor air
conditioning pipes during this operation.
- the pressostat connector (3) ,

- the air conditioning compressor connector (4) ,
Remove the air conditioning compressor mounting

bolts (5) .
Remove the air conditioning compressor and attach

it using a safety belt .
16A-3
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 729 or 732

OPERATION FOR REMOVAL OF PART
CONCERNED
CHAUFO
19703
111079
Remove:
WARNING
- the free pulley support mounting bolts (6) ,
Do not damage the cooling unit vanes (radiator,

condenser, etc.) during handling.
- the idler pulley support.
Note:
To ease alternator removal, slightly move the
cooling system towards the front.
Remove:
- the alternator mounting bolts (7) ,
- the alternator.
16A-4
STARTING - LOAD
16A
K9K, and 722 or 724 or 728 or 729 or 732
REFITTING
CHAUFO
Refit:
- the free pulley support,
- the free pulley support mounting bolts.
Tighten to torque the free pulley support mounting bolts ( 21 Nm ) .

Apply a drop of LOCTITE - FRENEBLOC on the
sub-frame mounting bolts.
Refit:
- the side reinforcements.
Tighten to torque:
18987
Refit the rings (8) using pliers or a vice.

Refit:

CONCERNED
Refit:
- the alternator,
- the alternator mounting bolts.
- the front wheels.

Nm ) .

Connect:
- the electrical connections,
CA or CAREG
Refit:
- The air conditioning compressor,
- the air conditioning compressor mounting bolts.
Connect:
- the pressostat connector,
- the air conditioning compressor connector.
16A-5
STARTING - LOAD
16A
F4R, and 770 or 771 or 776
Tightening torquesm
alternator mounting
bolts
25 Nm

bolts
4 Nm
wheel bolts
110 Nm
REMOVAL

terminal.
101212
Remove:
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)
at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pipes.
16A-6
STARTING - LOAD
16A
F4R, and 770 or 771 or 776
F4R, and 776
3
2
102504
104342
Remove:
- intercooler air duct (7) ,
- the accessories belt tension wheel.
6
102365

Remove:
- the clip (4) ,
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the accessories belt (See 11A, Top and front of
Disconnect the alternator electrical connections.
16A-7
STARTING - LOAD
16A
F4R, and 770 or 771 or 776
REFITTING
19703
18987
Remove:
Refit the rings (9) using pliers or a vice to facilitate fitting.

- the alternator using a screwdriver.
WARNING
WARNING

tension wheels and idler pulleys.
Do not force it against the air conditioning hose:

there is a risk of refrigerant fluid escaping.

Nm ) .
Note:
Replace the accessories belt.
To facilitate removal of the alternator, shift the

cooling assembly gently forward (be careful not
to deform the condenser pipes).
Tension the accessories belt (see 11A, Top and

front of engine, Accessories belt ).
WARNING
Tighten to torque:
16A-8
STARTING - LOAD
16A
F9Q, and 800 or 804 or 808
Tightening torquesm
alternator mounting
bolts
25 Nm
wheel bolts
110 Nm
2
bolts
4 Nm
REMOVAL
102504

terminal.
1
102365

Remove:
- the clip (4) ,
101212
- the mounting (5) ,
Remove:
- the front wheels,


- the half sub-frame side reinforcement (1) ,
- the bumper (see MR 365 Bodywork, 55A, Exterior protection, Front bumper ).
Remove the accessories belt tensioning roller.
16A-9
STARTING - LOAD
16A
F9Q, and 800 or 804 or 808
REFITTING
19703
18987
Remove:
- the alternator mountings (7) ,
Refit the rings (8) using a vice to facilitate fitting.
Refit the alternator.
To facilitate removal of the alternator, shift the cooling assembly forward gently (be careful not to damage the condenser pipes).

Nm ) .
WARNING
( 4 Nm ) .
16A-10
STARTING - LOAD
16A
K4J, and 730 or 732 K4M, and 760 or 761
Tightening torquesm
alternator mounting
bolts
21 Nm
alternator strut mounting bolts
21 Nm
nut securing the strut to

the stud on the engine
side
21 Nm

bolts
4 Nm
wheel bolts
110 Nm
REMOVAL
101212

terminal.
Remove:
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)
at the windscreen washer fluid reservoir end.
Remove:
- the bumper.
Disconnect the windscreen washer fluid reservoir pipes.
16A-11
STARTING - LOAD
16A
K4J, and 730 or 732 K4M, and 760 or 761
3
2
5
102504
19703
Remove:

WARNING
102365
Do not force it against the air conditioning hose:

there is a risk of refrigerant fluid escaping.

Note:
Remove:
To facilitate removal of the alternator, shift the

cooling assembly gently forward (be careful not
to deform the condenser pipes).
- the clip (4) ,

- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the accessories belt (See 11A, Top and front of
Remove the alternator retaining strut.
16A-12
STARTING - LOAD
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
18987
WARNING
tension wheels and idler pulleys.
Tighten to torque:
- the alternator mounting bolts ( 21 Nm ) ,
- the alternator strut mounting bolts ( 21 Nm ) .
- the nut securing the strut to the stud on the engine side ( 21 Nm ) ,
Replace the accessories belt.
Tension the accessories belt (see 11A, Top and
front of engine, Accessories belt ).
WARNING
Tighten to torque:
16A-13
16A
STARTING - LOAD
16A

Tightening torquesm
alternator mounting
bolts
bolts
25 Nm
130 Nm
4 Nm
REMOVAL
Note:
The tensioning roller and the inertia reel must be
replaced when the accessories belt is replaced.
102504
102365

Remove:
- the clip (4) ,
- the mounting (5) ,
- the impact cross member mounting bolt (6) ,
106077

Remove the accessories belt tensioning roller.
Remove:
- the right-hand wheel arch liner,
- the side stiffener (1) ,
- the fog lights connector,
16A-14
STARTING - LOAD
16A
19703
Remove:
18987
- the alternator mountings (7) ,
Refit:

To ease alternator removal, slightly move the cooling system toward the front (be careful not to bend
the condenser pipes).
REFITTING
- the alternator,
- the alternator mounting bolts.
Tighten to torque the alternator mounting bolts (
25 Nm ) .
Refit the new accessories belt.
of engine, Accessories belt: Removal - Refitting
).
WARNING
The belt must be replaced with a new one if it
has been removed.
Tighten to torque the wheel mounting bolts ( 130

Nm ) .
Connect the battery (see 80A, Battery, Battery: Removal - Refitting .
( 4 Nm ) .
16A-15
STARTING - LOAD
16A
M9R, and 700
Tightening torquesm
alternator mounting
bolts
25 Nm
positive terminal mounting nut
8 Nm
air inlet hose clip on the

damper valve
5.5 Nm
air inlet hose clip on the

intercooler
5.5 Nm
turbocharger pressure
sensor mounting nut
8 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm
101212
Remove:
- the right-hand sub-frame side stiffener (1) ,
REMOVAL
I - REMOVAL PREPARATION STAGE

Remove:
114855

16A-16
STARTING - LOAD
16A
M9R, and 700
102504

and Switching Unit.
114933
Remove:
- the clip (6) ,
- the front end panel upper mounting bolt (7) .

102365
Remove:
112658

16A-17
- the front end panel lower mounting bolts (8) ,

Remove the cooling radiator - condenser intercooler assembly from its housing and push it
forwards.
STARTING - LOAD
16A
M9R, and 700

CONCERNED
114409
Disconnect the turbocharging pressure sensor connector (9) .

Remove the turbocharger pressure sensor mounting
nut on the air inlet valve stay.
114860
Disconnect the alternator's electrical connector (12)

.
Remove the positive terminal mounting nut (13) .
Undo the air inlet hose clip on the damper valve.
114859
114649
Remove:
Remove the alternator mounting bolts (14) .

Remove the alternator.
- the air inlet duct clip (10) from the intercooler,

- the air inlet clip mounting bolt (11) from the condenser,
16A-18
STARTING - LOAD
16A
M9R, and 700
REFITTING
Refit the Cooling radiator - condenser intercooler group in its housing.

CONCERNED
Refit the air inlet duct.

Tighten to torque:
- the air inlet hose clip on the damper valve ( 5.5
Nm ) ,
- the air inlet hose clip on the intercooler ( 5.5 Nm
).
Tighten the air inlet clip mounting bolt on the condenser.
Refit the turbocharger pressure sensor on the damper valve stay.
Tighten to torque the turbocharger pressure sensor mounting nut ( 8 Nm ) .
Connect the turbocharging pressure sensor connector.
Refit:
18987
Refit the rings (15) using pliers or a vice to facilitate

fitting.

- front end panel mounting bolts,
Fit the alternator in place.
Tighten to torque:
Tighten to torque

Nm ) ,
- the alternator mounting bolts ( 25 Nm ) ,

Nm ) .
- the positive terminal mounting nut ( 8 Nm ) .

Connect the alternator electrical connector.
Clip:
- the bonnet opening cable,
Refit clips.
Refit:
engine, Accessories belt: Removal - Refitting )
- the half sub-frame side stiffener,
16A-19
STARTING - LOAD
Alternator pulley: Removal - Refitting
16A
K4J or K4M or K9K, and CA

Mot. 1732
Tool for removing and

refitting the alternator
pulley
Tightening torquesm
alternator decoupling
pulley
80 Nm

- the tensioning roller,
- the tensioning roller mounting bolts.
essential equipment
110266
Hold the alternator in a vice.
- tool box for removing and refitting the alternator pulley

(Mot. 1732)

CONCERNED
110276
It is essential to replace an alternator decoupling

pulley with a decoupling pulley.
REMOVAL
Remove the alternator (see 16A, Starting - Charging, Alternator: Removal - Refitting ).
16A-20
110267
Fit the hexagon socket (1) from the tool box for removing and refitting the alternator pulley (Mot. 1732)
into the alternator pulley.
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-21
STARTING - LOAD
16A
REFITTING
CONCERNED
110269
Fit:
110266
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) onto the drive (11) .
Note:
Check that the torque wrench is capable of tightening in an anticlockwise direction.
16A-22
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-23
16A
STARTING - LOAD
Starter: Identification
Engine
Starter motor
K4J and K4M
VALEO : D7E27
K9K
MITSUBISHI
F9Q and F4R
VALEO : D7R49
16A-24
16A
STARTING - LOAD
16A
F4R, and 770 or 771
REFITTING
Tightening torquesm
starter mounting bolts
bolts
38 Nm
4 Nm
REMOVAL
terminal.
101482
Check that the centring dowel (1) is in place.

WARNING
Tighten to torque:
14853
- the starter mounting bolts ( 38 Nm ) ,

Disconnect:
- the oil level sensor connector,
- the starter connections,
Remove:
- the starter motor mounting bolts,
- the starter motor.
16A-25
STARTING - LOAD
16A
F9Q, and 800 or 808
Tightening torquesm
wheel bolts
110 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove:
- the front right wheel,
- the battery,
- the battery tray,
101120
- the air hose between the air filter and turbocharger

duct,
Remove:
- the bracket (3) ,
- the catalytic converter (4) mounting plate on the
gearbox,
- the catalytic converter (5) (see 19B, Exhaust, Catalytic converter ).
Disconnect the starter motor electrical connections.
6
102421
Remove:
- the air hose (1) and gently separate the hose (2) ,
- the engine tie-bar.
102427
Remove:
- the starter motor mounting bolts (6) ,
16A-26
STARTING - LOAD
F9Q, and 800 or 808
REFITTING
Check that the centring dowel is in place.
WARNING
Tighten to torque:
- the engine cover mounting bolts ( 4 Nm ) .
16A-27
16A
STARTING - LOAD
16A
K9K, and 722
Tightening torquesm
44 Nm
wheel bolts
110 Nm

bolts
4 Nm
REMOVAL
terminal.
Remove:
102268
Remove:
- the starter mountings (4) ,
- the starter (5) .
REFITTING

Tighten to torque the starter mounting bolts ( 44
Nm ) .
1
104175
Remove:
WARNING
Tighten to torque:
- catalytic converter stay (2) on the gearbox,
- the catalytic converter (3) (see 19B, Exhaust, Catalytic converter ).

Disconnect the starter motor electrical connections.
16A-28
STARTING - LOAD
16A
K4J, and 730 or 732 K4M, and 760 or 761
REFITTING
Tightening torquesm
bolts
38 Nm
4 Nm
REMOVAL
1
terminal.
101482

WARNING
Battery: Removing - refitting ).
Tighten to torque:
14853
Remove:
- the air resonator mounting (K4J),
- the air filter outlet duct (K4M),
Disconnect:
- the starter connections,
Remove:
- the starter motor mounting bolts,
16A-29
STARTING - LOAD
16A
F4R, and 776
Tightening torquesm
38 Nm
the catalytic converter

downstream strut nut
21 Nm
heat shield mounting

bolts
8.5 Nm

bolts
4 Nm
REMOVAL
The engine needs to be removed if the starter motor
is being replaced (see 10A, Engine and peripherals, Engine - gearbox ).
21921
Remove:
1
106249
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
16A-30
STARTING - LOAD
F4R, and 776
REFITTING
21935

Tighten to torque:
- the the catalytic converter downstream strut
nut ( 21 Nm ) ,
- the heat shield mounting bolts ( 8.5 Nm ) .
WARNING
( 4 Nm ) .
16A-31
16A
STARTING - LOAD
16A
K9K, and 728 or 729
Tightening torquesm
44 Nm

bolts
4 Nm
REMOVAL
terminal.
106203
Disconnect the gearbox earth.
106201
Disconnect the oil level sensor.
106205
Disconnect:
- the starter electrical connections (1)
- the rail pressure sensor (2) .
16A-32
STARTING - LOAD
K9K, and 728 or 729
106191
Remove:
- the starter mountings,
REFITTING
Tighten to torque the starter mounting bolts ( 44
Nm ) .
WARNING
( 4 Nm ) .
16A-33
16A
STARTING - LOAD
16A
F9Q, and 804
Tightening torquesm
starter motor mounting
bolts
44 Nm

pipe mounting bolts
12 Nm

bolts
4 Nm
wheel bolts
110 Nm
REMOVAL
terminal.
Remove:
111865

- the battery,
- 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 ).
111868
Disconnect the wiring harness from the starter motor.

Remove the starter motor mounting bolts (3) .
111860
Remove the air duct (1) from the turbocharger.
Remove the starter motor.
REFITTING
Tighten to torque the starter motor mounting bolts
( 44 Nm ) .
16A-34
STARTING - LOAD
F9Q, and 804
Replace the turbocharger oil return pipe seals.
WARNING
Tighten to torque:
16A-35
16A
STARTING - LOAD
16A
M9R, and 700
Equipment required
filling station
Tightening torquesm
bolts
44 Nm
starter base mounting

nut
8 Nm
solenoid excitation
mounting nut
5 Nm

intercooler
5.5 Nm

damper valve
5.5 Nm

mounting bolts
21 Nm

bolts (1) ,

mounting bolts
44 Nm

bolts
21 Nm

tray
8 Nm
112658
Remove:
REMOVAL
Remove:
102504

and Switching Unit.


Remove:

Drain the coolant circuit using the filling station
16A-36
- the clips (4) ,

STARTING - LOAD
16A
M9R, and 700
102365
Remove:
112659
Disconnect the injection computer connector (6) .

Remove:
Unclip the wiring harness (9) from the battery - terminal.
114649
Remove the intercooler downstream duct mounting

bolt (12) on the cooling radiator.
Loosen:
- the intercooler downstream duct clip (13) on the intercooler,
valve.
Remove the intercooler downstream duct from the
intercooler.
114933
16A-37
Remove the cooling assembly from its housing and

push the assembly forwards.
STARTING - LOAD
16A
M9R, and 700

CONCERNED
109537
Remove the air dehydration canister conditioning

pipe mounting bolt (14) from the air conditioning
compressor.
114628
Remove:
- the mounting nut (15) from the starter base,
Note:
- the mounting nut (16) from the solenoid excitation.
Plugs must be fitted to the pipe and the compressor to prevent moisture from entering the system.
Remove the air dehydration canister conditioning
pipe from the air conditioning compressor.
114998
Remove the earth wire mounting bolt (17) on the

starter.
Move the starter motor wiring harness to one side.
16A-38
STARTING - LOAD
M9R, and 700
113312
Remove:
- the starter mounting bolts (18) .
REFITTING
CONCERNED
Fit the starter.
( 44 Nm ) .
Refit:
- the starter base wire,
- the starter base mounting nut,
- the solenoid excitation wire,
- the solenoid excitation mounting nut,
- the earth wire,
- the earth wire mounting bolt.
Tighten to torque:
- the starter base mounting nut ( 8 Nm ) ,
- the solenoid excitation mounting nut ( 5 Nm ) .
16A-39
16A
STARTING - LOAD
16A
M9R, and 700

Refit:
Refit:
- the air dehydration canister conditioning pipe onto

the air conditioning compressor,
- the clips,
- the air dehydration canister conditioning pipe

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

bolts,
Fit the cooling assembly.
Refit:
- the intercooler downstream duct onto the intercooler and damper valve,
- the intercooler downstream duct mounting bolt
Tighten to torque:
- the intercooler downstream duct clip on the
damper valve ( 5.5 Nm ) .
Refit:
Tighten to torque:
Nm ) ,
Nm ) ,
Clip:
- the bonnet opening cable.
Refit:
- the battery tray,
- the wiring harness mounting nut onto the battery
tray.
Tighten to torque:
tray ( 8 Nm )
Clip the battery - terminal wiring harness.
Connect:
16A-40

Fill the coolant circuit using the filling station (see
STARTING - LOAD
16A
K9K, and 732
Tightening torquesm
bolts
44 Nm
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lifting equipment; underbody lift ).
Remove the engine cover.
- Refitting ).
113863
106201
Disconnect:
- the oil pressure sensor connector (1) ,
- the oil level sensor connector (2) .
Unclip the diesel fuel drain pipe.
16A-41
STARTING - LOAD
16A
K9K, and 732
REFITTING
CONCERNED
Refit:
- the starter motor,
- the starter mounting bolts.
( 44 Nm ) .
Refit the starter nuts.
Clip on the diesel fuel drain pipe.
106205
Remove the starter electrical connections (3) .
Connect:
- injection rail pressure sensor connector,
Disconnect the injector rail pressure sensor connector.

Move the wiring harness against the cylinder block.

- the oil pressure sensor connector.

CONCERNED
106191
Remove:
- the starter mounting bolts (4) .
16A-42
STARTING - LOAD
16A
Tightening torquesm
starter mountings
38 Nm
catalytic converter
downstream stay nut
44 Nm
heat shield mountings
8.5 Nm
REMOVAL
Removal of the starter requires the engine to be removed (see 10A, Engine and peripherals, Gearbox - motor assembly: Removal - Refitting ).
21921
Remove:
106249
Remove:
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
16A-43
STARTING - LOAD
REFITTING
21935

Tighten to torque:
- the starter mountings ( 38 Nm ) ,
- the catalytic converter downstream stay nut (
44 Nm ) ,
- the heat shield mountings ( 8.5 Nm ) .
16A-44
16A
IGNITION
17A
F4R, and 770 or 771 K4J, and 730 or 732 K4M, and 760 or 761
REMOVAL
Tightening torquesm
ignition coil mounting
screws to torque
1.5 daNm
the battery cover mounting bolts to
0.4 daNm
The power module is incorporated in the injection computer. The ignition system uses the same sensors as
the injection system.
1
2
101490

Disconnect:
- the battery starting with the negative terminal.
14851
- the connectors (1) from the ignition coils.
There are four ignition coils secured directly onto the

spark plugs by bolts on the cylinder head cover.
WARNING
The coils are in series in pairs by the injection computer:
Damaged connectors must be replaced.
- track C M4 for cylinders 1 and 4,
Remove the coil mounting screws (2) .
- track C M3 for cylinders 2 and 3.
REFITTING
To refit, proceed in the reverse order of removal.
If necessary, replace the coil O-rings.
Tighten the ignition coil mounting screws to torque ( 1.5 daNm ) .
WARNING
Connect the battery; carry out the necessary programming ( (see 80A, Battery) ).
Tighten the battery cover mounting bolts to ( 0.4
daNm ) .
17A-1
IGNITION
17A
REMOVAL
Tightening torquesm
ignition coil mounting
bolts
15 Nm

bolts
4 Nm
The power module is built into the injection computer.

The ignition system uses the same sensors as the injection system.
101490

Disconnect:
14851
There are four ignition coils, and they are mounted

directly onto the spark plug by a bolt on the rocker
cover.
The coils are supplied in series two by two by the injection computer:
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
17A-2
- the ignition coil connectors (1) .

Remove the coil mounting bolts (2) .
IGNITION
F4R, and 776
106589
Remove the coil mounting bolts (3) .
WARNING
Be sure to replace any damaged connectors.
REFITTING
17A-3
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-4
IGNITION
Spark plugs

Ele. 1382
Spark plug kit
Tightening torque
Spark plugs
25 to 30 Nm
Remove:
- the ignition coils (see 17A, Ignition, Coils ),
- the spark plugs.
Engines
Brand
Type
EYQUEM
RFN58LZ
CHAMPION
RC87YCL
K4J and K4M

Flat skirt with seal
Gap: 0.95 ( 0.05 mm )
F4R 770 / 771
CHAMPION
RC87YCL

Gap 0.90 ( 0.05 mm )
F4R 776
NGK
PFR6G-9

Gap 0.85 ( 0.05 mm )
17A-5
17A
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
K4J, and 730 or 732
10
9 8
101099
(1)
Fuel vapour recirculation solenoid valve
(2)
(3)
(4)
Ignition coil
(5)
Injection computer
(6)
(7)
(8)
Pinking sensor
(9)
(10)
Injector rail and injectors
17B-1
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
K4M, and 760 or 761
11 12
13
14
15
17
18
16
22
21
20
19
101804
(11)
(12)

valve
(13)
(14)
Ignition coil
(15)
(16)
(17)
Injection computer
(18)
(19)
(20)
Pinking sensor
(21)
(22)
K4J, and 730 or 732
23
102107
(23)
17B-2
Injection computer
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
27
25
29
25
30
24
28
101493
(24)
Injector rail
(25)
Injectors
26
101101
(27)
(28)
(29)
(30)
Ignition coils
101800
(26)
31
32
101498
17B-3
(31)
(32)
Pinking sensor
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
40
K4M, and 760 or 761
41
34
42
34
33
39
101809
101810
(33)
Injector rail
(34)
Injectors
35
(39)
Pinking sensor
(40)

valve
(41)
(42)
36
43
38
38
37
101796
(35)
(36)
(37)
(38)
Ignition coils
101811
(43)
17B-4
Injection computer
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
K4M, and 760 or 761
44
46
102144
(46)
102735
(44)
47
45
102204
(47)
101105
(45)
17B-5
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761
48
51
101798
(48)
Upstream oxygen sensor
(51)
49
50
101501
(49)
Downstream oxygen sensor
(50)
Catalytic converter
102483
17B-6
Fuel vapour recirculation absorber
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
F4R, and 770 or 771
11
10
102722
(1)
(2)

valve
(3)
(4)
Ignition coil
(5)
(6)
Injection computer
(7)
(8)
(9)
Pinking sensor
(10)
(11)
17B-7
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
F4R, and 776
12
23
22
21
13
20
19
14
18
17
15
16
106078
(12)
Ignition coil
(13)
(14)
Injection computer
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Pinking sensor
(22)
(23)
Electric water pump
24
106280
(24)
17B-8
Injection computer
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
F4R, and 770 or 771
32
26
27
28
25
31
102732
101809
(25)
Pinking sensor
(26)

valve
(27)
(28)
(31)
Pinking sensor
(32)

valve
33
34
36
36
30
35
30
102724
29
102730
(29)
Injector rail
(30)
Injectors
17B-9
(33)
Fuel recirculation solenoid valve
(34)
(35)
(36)
Ignition coil
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
F4R, and 776
37
39
40
102735
(37)
Throttle valve
101809
(39)
Pinking sensor
(40)
42
38
41
106269
102144
(38)
17B-10
(41)
Injector rail
(42)
Injectors
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
46
43
45
106787
(45)
(46)
Ignition coils
106633
(43)
48
47
44
106279
106278
(44)
17B-11
(47)
(48)
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
51
49
101105
(49)
102483
(51)
Fuel vapour recirculation absorber
F4R, and 770 or 771
50
52
102204
(50)

101798
(52)
17B-12
PETROL INJECTION
17B
F4R, and 770 or 771 or 776
56
53
54
101501
(53)
(54)
Catalytic converter
(56)
F4R, and 776
55
106244
(55)
106253
17B-13
PETROL INJECTION
Oxygen sensors: Removal - Refitting
17B
F4R, and 770 or 771 K4M, and 760 or 761 K4J, and 730 or 732
II - DOWNSTREAM OXYGEN SENSOR

Mot. 1495-01
22 mm socket for
2
Tightening torquesm
oxygen sensor
45 Nm
REMOVAL
I - UPSTREAM OXYGEN SENSORS
101501
Remove lambda sensor. (2)
REFITTING

Tighten to torque the oxygen sensor ( 45 Nm )
using a 24 mm fork socket for the downstream sensor and tool (Mot. 1495-01) for the upstream oxygen
sensor.
101798
Remove lambda sensor (1) using the tool (Mot.

1495-01) .
17B-14
PETROL INJECTION
Oxygen sensors: Removal - Refitting
17B
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
Remove:
- the oxygen sensor (2) using (Mot. 1495-01) .
REFITTING
106244
Remove the front engine cover.

Disconnect the oxygen sensor.
Remove the oxygen sensor (1) using the tool (Mot.
1495-01) .
17B-15
Tighten to torque the oxygen sensors ( 34 Nm )

using tool (Mot. 1495-01) .
PETROL INJECTION
Accelerator pedal potentiometer: Removal - Refitting
17B
F4R, and 770 or 771 or 776 K4M, and 760 or 761 K4J, and 730 or 732
- the pedal.
Tightening torquesm
bolts
REFITTING
4 Nm
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 resistance point .
Vehicles equipped with cruise control/speed limiter
have an accelerator pedal with a point of resistance at
the end of their travel (kickdown)
This kickdown point is used for exiting the speed limiter
function if the driver has to increase his speed.

WARNING
Note:
A fault on the accelerator pedal position potentiometer results in changes in the idle speed or
engine operation (see 17B, Petrol injection, Idle
speed correction ).
WARNING
4 Nm ) .
A pedal fitted with a kickdown point may be fitted in

place of a pedal without a kickdown point. Fitting a
pedal without a resistance point in place of a pedal
with a resistance point is not permitted.
REMOVAL
102204
Disconnect:
- the accelerator pedal connector.
Remove:
- pedal mounting bolts ,
17B-16
PETROL INJECTION
17B
Equipment required
F4R, and 776
diagnostic tool
F4R, and 770 K4M, and 760 K4J, and 730 or

732
1
1
102485
Program with the engine flywheel target after replacing speed and position sensor (1) or the engine
flywheel
102144
Program the engine flywheel target, after replacing

speed and position sensor (1) or the engine
flywheel.
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 with the injection cut out,
the computer authorises injection again.
Use the diagnostic tool to check that programming
has been carried out correctly ET089: Program
engine flywheel target .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is working correctly.
17B-17
PETROL INJECTION
F4R, and 771 K4M, and 761
Equipment required
diagnostic tool
102144
Program the engine flywheel target, after replacing

speed and position sensor (1) or the engine
flywheel.
Note:
Do not shift the gear lever to D
Check that the vehicle is operating correctly.
17B-18
17B
PETROL INJECTION
Petrol injection computer: Removal - Refitting
17B
Equipment required
F4R, and 770 or 771 or 776
diagnostic tool
Tightening torquesm
bolts
21 Nm

bolts
4 Nm
REMOVAL
terminal.
4
K4M, and 760 or 761 K4J, and 730 or 732
101822
Remove the battery.

Remove:
- the battery tray (3) mounting bolts,

- the electrical wiring harness (4) .
102107

Remove:
- the bolts securing the computer to the mounting,
- the computer.
17B-19
PETROL INJECTION
Petrol injection computer: Removal - Refitting
17B
REFITTING
21 Nm ) .
WARNING
Note:
When the ignition is switched on, the motorised
throttle valve should go through a cycle of programming for its minimum and maximum positions.
101811
Use the diagnostic tool to check that this programming has been completed correctly ET051: Throttle
stop programming .
Perform flywheel target programming during a road
test.
Check that the vehicle is functioning correctly.
( 4 Nm ) .
101890
Remove the four computer mounting bolts.
17B-20
PETROL INJECTION
Special notes
17B
SPECIAL NOTES FOR MULTIPOINT INJECTION
SAGEM S3000
6 - Idle speed (warm engine)

Nominal idle speed
1 - 128-track computer
It is marked SAGEM and is a type S3000 FLASH
EEPROM controlling the injection and ignition.
2 - Multipoint injection functioning in sequential

mode.
Engine
Engine speed (rpm)
K4J 730 /
732
750 +/- 50
K4M 760
700 +/- 30
K4M 761
F4R 770
750 +/- 50
F4R 771
F4R, and 770 or 771 or 776 K4J, and 730 or 732
F4R 776
Without cylinder n1 marking sensor on the camshaft
Therefore, engine phasing is carried out by software
using the TDC sensor. Starting the engine in semi-sequential mode (for engine phasing) then entering
phased sequential mode.
The idle speed is corrected depending on:

- the engine coolant temperature,
- the battery voltage,
- the air conditioning,
- the engine oil pressure (K4M engine).
- the position of the automatic gearbox selector lever
(F4R engine).
K4M, and 760 or 761

With cylinder n1 marking sensor on the camshaft Therefore, engine phasing (cylinder n1 recognition) is carried out using the cylinder marking sensor signal.
Starting the engine in semi-sequential mode (for engine phasing) then entering phased sequential mode.
7 - Maximum speed
a - Engine overspeed protection, cold engine
K4J, and 730 or 732
When the coolant temperature is below 60C or for 10
seconds after starting, the cut-off value is 5800 rpm .
3 - Injection warning light on the instrument panel

Installation of a special injection warning light (OBD indicator light On Board Diagnostic ) warning light. It
is part of the on board diagnostic OBD fault finding
system.
K4M, and 760 or 761

When the coolant temperature is below 75C or for 10
seconds after starting, the cut-off value is 5800 rpm .
4 - Special notes relating to the engine immobiliser

Installation of a third generation engine immobiliser, involving a specific computer replacement procedure.
F4R, and 770 or 771 or 776

When the coolant temperature is below 75C or for a
maximum of 17 minutes after starting, the cut-off value
is 5900 rpm .
5 - Fuel circuit without return to the tank.

The pressure regulator is located on the pump/sender unit assembly.
17B-21
PETROL INJECTION
Special notes
17B
b - Engine overspeed protection, warm engine
11 - Operation of the fuel pump
Once the engine is warm, the cut-off returns to its normal value:
The request is made by the injection computer. It receives its power supply from the Protection and Switching
Unit.
K4J, and 730 or 732 K4M, and 760 or 761
12 - Cruise control / speed limiter
The cut-off speed is 6500 rpm whichever gear is engaged (manual or automatic gearbox).
The configuration of the cruise control / speed limiter

and the air conditioning is automatic.
13 - Oxygen sensor
Use of two oxygen sensors located upstream and
downstream of the catalytic converter.
F4R, and 770 or 771 or 776

The cut-off speed is 6000 rpm whichever gear is engaged (manual gearbox), and 6300 rpm (automatic gearbox).
14 - Throttle valve
Correction of the air flow and the idle speed is carried
out by the motorised throttle valve.
15 - Protection and switching unit
8 - Camshaft dephaser
It supplies:
K4M, and 760 or 761
- the fuel pump,
It is continuously varied from 0 to 43 of the crankshaft.

It is controlled by a solenoid valve supplied by an opening cyclic ratio signal operated by the injection computer.
- the air conditioning compressor,

- the fan assembly,
- various injection actuators (injectors, fuel vapour absorber solenoid valve, etc.).
The protection and switching unit is located in the engine compartment near the battery. It contributes to the
protection of certain electrical components.
F4R, and 770 or 771 or 776

It is controlled by a solenoid valve which is supplied by
an all or nothing system from the injection computer.
In this capacity, it comprises:

- fuses,
- several internal relays including:
the + after ignition feed relay,
9 - Operation of the engine cooling fan and the

coolant temperature warning light
the fuel pump relay,
The request is made from the injection computer through the multiplex network (coolant temperature centralised control function). The engine cooling fan is
supplied by the Protection and Switching Unit.
the engine cooling fan relays,
the air conditioning compressor relay
the starter relay (starter motor solenoid operation)

These relays cannot be removed.
10 - Air conditioning compressor operation
16 - Injection computer
The request is made by the injection computer through

the multiplex network. The request depends on the air
conditioning , but also the coolant temperature. The air
conditioning compressor is supplied by the Protection
and Switching Unit.
It constantly receives from the multiplex network, the

signal indicating the electrical power available from the
alternator. This is to prevent the vehicle's electrical
consumption from exceeding the capacity of the alternator. The aim is to give priority to charging the battery.
17B-22
PETROL INJECTION
Special notes
17 - Accelerator pedal
Replacement of the accelerator pedal poses no particular problems.
The computer adopts the value read when the ignition
was switched on as the no load position reference value.
A twin-track potentiometer is used to inform the computer of the accelerator pedal position. It has two tracks
with different resistance values. The first track supplies
a voltage of ( 0 to 5 V ) which is double the second
track ( 0 to 2.5 V ). The comparison between the two
provides a check on the consistency of the signal supplied.
18 - Idle speed
It is increased by a maximum of 160 rpm if the battery
voltage is below 12.7 V .
If a manifold pressure sensor fault is present or stored,
the idle speed setpoint is:
- 896 rpm (K4J and K4M engines),
- 1024 rpm (F4R engine).
17B-23
17B
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 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). If this happens, the vehicle will stop 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. If this happens, the vehicle will stop immediately.
17B-24
PETROL INJECTION
This vehicle is equipped with an immobiliser which requires a specific procedure for replacing the computer.
REPLACING AN INJECTION COMPUTER
To program the immobiliser code (see 82A, Engine
immobiliser, Injection computer: 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 vehicle which must then be returned.
- These computers are permanently coded.
17B-25
17B
PETROL INJECTION
Injection - air conditioning programming
17B
F4R, and 770 or 771 or 776

I - INJECTION COMPUTER - AIR CONDITIONING
COMPUTER CONNECTION
II - COMPRESSOR FUNCTION PROGRAMMING

In certain operating phases, the injection computer disables the air conditioning compressor.
Climate control is managed by several computers.

- managing the request for cold air in response to passenger compartment controls and the circuit pressure
level.
- determining the power absorbed by the air conditioning compressor based on the pressure of the circuit,
- authorising the fan assembly control according to vehicle speed and circuit pressure.
- authorising or disables the compressor clutch.
When climate control is activated, the climate control
panel requests authorisation for air conditioning compressor operation.
The injection computer authorises or prevents:

To facilitate starting on a hill, operation of the air conditioning compressor is prevented for 20 seconds .
2 - Maximum engine speed protection
programming
Operation of the air conditioning compressor is prevented if:
- the instantaneous engine speed is above 6300 rpm ,
- the constant engine speed is above 5760 rpm for
more than 10 seconds .
- air conditioning compressor operation,
Operation of the air conditioning compressor is prevented if the coolant temperature is above 115C at high
speed and high load.
- fan assembly operation,

- an accelerated idle speed.
Entry conditions:
This speed depends on the power absorbed by the

compressor:
- Engine speed greater than 4512 rpm ,
- 900 rpm .
- and inlet manifold pressure below 700 mbar .
The request to run the fan assembly and compressor is

made by the injection computer via the multiplex
network. This request depends on the air conditioning
but also on the coolant temperature and vehicle speed.
Exit conditions:
The engine cooling fan and the compressor are supplied by the Protection and Switching Unit.
- for a time of 10 seconds ,

- and certain conditions of the coolant temperature
centralised management function.
The data used for the function is exchanged via the

multiplex network:
- Track A A4 CAN HIGH multiplex connection,
- Track A A3 CAN LOW multiplex connection.
The injection computer also receives the refrigerant
pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
WARNING
The value of parameter PR044: power absorbed
by the AC compressor is never 0 , irrespective
of the status of the compressor. The minimum value
reading is approximately 250 to 300 W .
17B-26
PETROL INJECTION
17B
K4J, and 730 or 732


COMPUTER CONNECTION

level.
- determining the power absorbed by the air conditioning compressor based on the pressure value of the
circuit,

To facilitate starting on a hill, operation of the air conditioning compressor is prevented for 10 seconds .
programming
The compressor does not work if:
- the instantaneous engine speed is above 6688 rpm ,
- the constant engine speed is above 6112 rpm for
more than 10 seconds .
The compressor does not work if the coolant temperature is above 119C at high speed and high load.
Entry conditions:
- engine speed greater than 6496 rpm ,

compressor:

Exit conditions:
- 850 rpm .
multiplex network:
- engine speed below 6496 rpm ,

- and coolant temperature below 119C ,
4 - Performance return programming
The compressor is prevented from operating for 5 seconds .
Entry conditions:
- throttle fully open,
- and engine speed below 2016 rpm ,
- and engine speed below 10 mph (16 km/h) .
Exit conditions:
- throttle not fully open,
- or for a time of 5 seconds ,
- or engine speed at or above 2048 rpm ,

- or vehicle speed greater than 16 mph (26 km/h) .
WARNING

To facilitate hill-starting, under certain load and engine
operating conditions, operation of the air conditioning
compressor is prevented for 5 seconds .
17B-27
PETROL INJECTION
K4J, and 730 or 732
programming
The air conditioning compressor does not work if the
engine speed is above 6496 rpm .
coolant temperature is above 119C at high speed and
high load.
17B-28
17B
PETROL INJECTION
17B
K4M, and 760 or 761


COMPUTER CONNECTION

level.
- determining the power absorbed by the air conditioning compressor based on the pressure value of the
circuit,

The compressor is prevented from operating for 10 seconds after engine start.
2 - Performance return programming
The compressor is prevented from operating for 5 seconds .
Entry conditions:
- throttle fully open,

- and engine speed below 2016 rpm ,

- and engine speed below 10 mph (16 km/h) .
Exit conditions:
- throttle not fully open,
- or for a time of 5 seconds ,
- or engine speed at or above 2048 rpm ,

compressor:
- or vehicle speed greater than 16 mph (26 km/h) .
- 850 rpm .

To facilitate hill-starting, under certain load and engine

operating conditions, operation of the air conditioning
compressor is prevented for 5 seconds .

programming

multiplex network:

engine speed is above 6496 rpm .


coolant temperature is above 119C at high speed and
high load.

WARNING
17B-29
PETROL INJECTION
Throttle valve: Operating
17B
I - THROTTLE BODY
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).
ding 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 is directly proportional to pressure
on the accelerator pedal.
When the driver depresses the accelerator pedal, his

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 misfires, 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 gear 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 (ie 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 injection and limits torque by
cutting out the cylinders (ignition and injection) accor-
17B-30
Note:
Each of these modes results in the injection fault
warning light on the instrument panel lighting up.
PETROL INJECTION
F4R, and 770 or 771 or 776
COOLANT TEMPERATURE
Coolant temperature
Engine speed
( C )
( rpm )
- 20
1072
20
976 (1)
40
896
80
752
100
752
120
848
(1) Except when starting between 15C and 30C .

II - ELECTRICAL CORRECTION ACCORDING TO
BATTERY VOLTAGE AND ELECTRIC POWER
BALANCE
The purpose of this correction is to compensate for the
drop in voltage due to a power consumer being switched on when the battery is not sufficiently charged. It
starts when the voltage falls below 12.7 V and may increase the engine speed by a maximum of 160 rpm ,
i.e. 910 rpm .
III - IDLE SPEED ADJUSTMENT WHEN THERE IS A
MANIFOLD PRESSURE SENSOR FAULT
In the event of a manifold pressure sensor fault is set at
1024 rpm .
Note:
If the engine is started when the coolant temperature is between 15C and 30C and, as a result, the
engine speed remains at idle speed, the engine
speed will decrease progressively. This drop in
engine speed is due to an antipollution function
when the engine is started (oxygen sensor heating
resistors starting).
17B-31
17B
PETROL INJECTION
K4J, and 730 or 732
COOLANT TEMPERATURE
Coolant temperature
Engine speed
( C )
( rpm )
- 20
1152
20
1008 (1)
40
960
80
752
100
752
120
896

BALANCE
i.e. 910 rpm .
If the manifold pressure sensor is faulty, the idle speed
is set at 896 rpm .
Note:
17B-32
17B
PETROL INJECTION
K4M, and 760 or 761
COOLANT TEMPERATURE
Coolant temperature
Engine speed
( C )
rpm )
- 20
1150
20
944 (1)
40
850
80
700
100
700
120
752

BALANCE
i.e. to 860 rpm .
If the manifold pressure sensor is faulty, the idle speed
is set at 896 rpm .
Note:
17B-33
17B
PETROL INJECTION
Adaptive idle speed correction
17B
I - ADAPTIVE IDLE SPEED CORRECTION
WARNING
Principle
In normal warm-engine operating conditions, the idle
speed OCR PR091 varies between a high and low value to obtain the nominal idle speed.
It is possible that following variations in the operation of
the vehicle (running in, fitting the engine, etc.), that the
idle speed opening cyclic ratio could approach to the
highest or lowest values.
Adaptive correction PR090 on the idle speed OCR
enables the engine's air requirement to be varied
slowly by bringing the opening cyclic ratio back to an
average nominal value.
This adjustment only takes effect if the coolant temperature is above 75C and for 1 minute after engine
start and during the idle speed regulation phase.
II - IDLE SPEED OPENING CYLIC RATIO AND ITS
ADAPTIVE CORRECTION
- PR055: engine speed
750 rpm
- PR032: Intake pressure
300 mbar < or = X < or = 400 mbar
- PR091: idle speed regulation theoretic opening
cyclic ratio
6 % < or = X < or = 22 %
- PR090: Idling speed regulation programmed
value
minimum stop: - 6.25 %
maximum stop: + 6.25%
III - INTERPRETATION OF THESE PARAMETERS
If there is excess air (air leak, incorrectly adjusted
throttle stop, etc.), the engine speed increases at idling
speed. The idle opening cyclic ratio value decreases to
return to nominal idle speed; the idle opening cyclic ratio adaptive correction decreases to recentre the idle
opening cyclic ratio.
If there is insufficient air (clogging, etc.), the logic is
reversed: the idle opening cyclic ratio and the adaptive
correction increase, to refocus operation of the idle
speed regulation.
17B-34
After the computer memory has been cleared, it is

imperative to start the engine, stop it, then leave it
running at idle speed so that the adaptive correction
can recalibrate itself correctly.
PETROL INJECTION
Richness regulation
17B
F4R, and 770 or 771 or 776 K4M, and 760 or 761

III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: downstream oxygen
sensor voltage on the diagnostic tool
diagnostic tool
An engine operating with the S 3000 computer is fitted
with two oxygen sensors called the upstream sensor
and the downstream sensor after their position on the
catalytic converter.
I - SENSOR HEATING
Oxygen sensor heating is controlled by the computer if
all of the following conditions are met:
- the inlet manifold pressure is below a threshold which
depends on a function table of the engine speed,
- the road speed is below ( 84 mph (135 km/h) ,
- after a certain mapped engine operating time which
depends on the engine's top dead centre (excluding
no load operation) and the coolant temperature.
The value read represents the voltage supplied to the

computer by the oxygen sensor located upstream of
the catalytic converter, expressed in millivolts.
The function of this sensor is to locate faults on the catalytic converter and to perform a second, more precise, check on the richness. This second richness check
is called the slow regulation loop . This function is
activated only after the engine has been operating for a
certain time.
When the engine is looped (when the computer
corrects the richness according to the two sensors, the
engine is said to be looped ), the voltage should be
in the region of 600 mV (except at idle speed when it
may be difficult to stabilise). When the vehicle is decelerating, the voltage should be approximately 100 mV .
Oxygen sensor heating is stopped if the following conditions are met:
Note:
Do not take into account the voltage on the diagnostic tool at idle speed.
- the vehicle speed is greater than 85 mph (140 km/h)

(value given for information only),
- when the engine is under heavy load.
IV - RICHNESS CORRECTION
II - UPSTREAM SENSOR VOLTAGE

Reading parameter PR098: upstream oxygen
the catalytic converter. It is expressed in millivolts. With
a looped engine (when the engine corrects the richness according to the two sensors, the engine is said to
be looped ); the voltage should oscillate quickly
between two values:
The richness correction value read on the diagnostic

tool i n
p a r a m e t e r PR 138: RICHNESS
CORRECTION represents the average of the richness corrections applied by the computer depending
on the richness of the fuel mixture as determined by
the oxygen sensor located upstream of the catalytic
converter (the oxygen sensor in fact analyses the oxygen content of the exhaust gas).
The centre point of the correction value is 50% and the
end value 0 to 100% .
- value less than 50% : request for decrease in richness,
- 100 mV and 450 mV for a lean mixture,

- value above 50% : request for increase in richness.
- 450 mV and 900 mV for a rich mixture.
V - ENTERING RICHNESS REGULATION MODE
Note:
The smaller the difference between the minimum
and maximum values, the poorer the signal from
the sensor.
If the difference is small, check the sensor heater.
1 - Loop mode
Richness regulation starts after a maximum delay of 10
seconds and if the coolant temperature is above 10C
(manual gearbox) and 2.5C (automatic gearbox).
17B-35
PETROL INJECTION
Richness regulation
F4R, and 770 or 771 or 776 K4M, and 760 or 761
2 - Non-loop mode
In mixture regulation mode, the phases of operation
during which the computer ignores the value of the voltage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN
SENSOR FAULT
When the voltage from the oxygen sensor is incorrect
(varying only slightly or not at all) during mixture regulation, the computer will only enter defect mode if the
fault has been recognised as present for 3 minutes .
When this happens, parameter PR138: RICHNESS
CORRECTION is 45 or 60% .
If an oxygen sensor fault is present and recognised
and if the fault has already been stored, the system enters the open loop mode directly.
17B-36
17B
PETROL INJECTION
Richness regulation
17B
K4J, and 730 or 732

III - DOWNSTREAM SENSOR VOLTAGE
Equipment required
Reading parameter PR099: downstream oxygen
diagnostic tool
An engine operating with the S 3000 computer is fitted
with two oxygen sensors called the upstream sensor
and the downstream sensor after their position on the
catalytic converter.
I - SENSOR HEATING
Oxygen sensor heating is controlled by the computer if
all of the following conditions are met:
- the inlet manifold pressure is below a threshold which
depends on a function table of the engine speed,
- the speed is below ( 84 mph (135 km/h) ,
- after a certain mapped engine operating time which
depends on the engine's top dead centre (excluding
no load operation) and the coolant temperature.

the catalytic converter, expressed in millivolts.
The function of this sensor is to locate faults on the catalytic converter and to perform a second, more precise, check on the richness. This second richness check
is called the slow regulation loop . This function is
activated only after the engine has been operating for a
certain time.
When the engine is looped (when the computer
corrects the richness according to the two sensors, the
engine is said to be looped ), the voltage should be
in the region of 600 mV (except at idle speed when it
may be difficult to stabilise). When the vehicle is decelerating, the voltage should be approximately 100 mV .
Note:
Oxygen sensor heating is stopped if the following conditions are met:
Do not take into account the voltage on the diagnostic tool at idle speed.
- the vehicle speed is greater than 85 mph (140 km/h)

(value given for information only),
IV - RICHNESS CORRECTION
- when the engine is under heavy load.

II - UPSTREAM SENSOR VOLTAGE
Reading parameter PR098: upstream oxygen
the catalytic converter. It is expressed in millivolts. With
a looped engine (when the engine corrects the richness according to the two sensors, the engine is said to
be looped ); the voltage should oscillate quickly
between two values:
- 100 mV and 450 mV for a lean mixture,
- 450 mV and 900 mV for a rich mixture.
Note:
The smaller the difference between the minimum
and maximum values, the poorer the signal from
the sensor.
If the difference is small, check the sensor heater.
The richness correction value read on the diagnostic

tool i n
p a r a m e t e r PR 138: RICHNESS
CORRECTION represents the average of the richness corrections applied by the computer depending
on the richness of the fuel mixture as determined by
the oxygen sensor located upstream of the catalytic
converter (the oxygen sensor in fact analyses the oxygen content of the exhaust gas).
The centre point of the correction value is 50% and the
end value 0 to 100% .
- value less than 50% : request for decrease in richness,
- value above 50% : request for increase in richness.
V - ENTERING RICHNESS REGULATION MODE
1 - Loop mode
The start of richness regulation is effective following a
period which depends on the engine coolant temperature when the engine is started. At 20C , the start of
the richness loop is effective after approximately 8 seconds .
17B-37
PETROL INJECTION
Richness regulation
K4J, and 730 or 732
2 - Non-loop mode
In mixture regulation mode, the phases of operation
during which the computer ignores the value of the voltage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN
SENSOR FAULT
When the voltage from the oxygen sensor is incorrect
(varying only slightly or not at all) during mixture regulation, the computer will only enter defect mode if the
fault has been recognised as present for 3 minutes .
When this happens, parameter PR138: RICHNESS
CORRECTION is 45 or 60% .
If an oxygen sensor fault is present and recognised
and if the fault has already been stored, the system enters the open loop mode directly.
17B-38
17B
PETROL INJECTION
17B
K4J, and 730 or 732 K4M, and 760 or 761

Pressure zones which must be passed through
during the test
I - PRINCIPLE
In looping phase, the richness regulation corrects the
injection time to obtain fuel dosing as close as possible
to a richness of 1. Richness correction value PR138 is
close to 50% , with stop values of 0 and 100% .
There are five pressure zones to scan during road testing. These zones are defined by the following calibrations:
Adaptive richness corrections PR143 and PR144 allow

the injection map to be shifted to recentre richness regulation at 50 % .
Adaptive corrections take 50% as the average value
after reinitialising the computer (clearing the memory),
and have end values.
Deactivation of the adaptive programs in the case

of prolonged idle speed regulation with a hot
engine
If the coolant temperature is above 90C while idling for
more than 10 minutes (K4M engine) and 1 minute
(K4J engine), the adaptives are fixed until the end of
idling.
Programming conditions for adaptive richness
correction
Following this test the adjustments will be operational.

The test should be followed by normal, smooth and varied driving over a distance of 3 to 6 miles (5 to 10 km)
. After the test, read the adaptive values. Initially 50% ,
they should have changed. If not, take the readings
again, taking care to observe the test conditions strictly.
30%
< or = X < or =
98%
Richness adaptive
gain
25%
< or = X < or =
63%
PR144
Richness adaptive
offset
258 to 458
Average 358
N2
458 to 536
Average 497
n3
536 to 614
Average 575
N4
614 to 692
Average 653
N5
692 to 813
Average 752
In the event of a lack of fuel (injectors clogged, pressure and fuel flow too low, etc), the richness regulation increases to obtain a richness as close as possible to 1
and the richness adaptive corrections increase until the
richness correction is again fluctuating around 50% .
- disconnect the fuel vapour absorber by the solenoid

valve or block the inlet pipe on the engine.
PR143
N1
II - INTERPRETING VALUES OBTAINED FROM A

ROAD TEST
- do not exceed an engine speed of 4640 rpm
Richness correction
mbar
If there is an excess of fuel, the logic is inverted.
- Warm engine: coolant temperature above 80C ,
PR138
Range
25%
< or = X < or =
63%
17B-39
PETROL INJECTION
17B
F4R, and 770 or 771 or 776

Pressure zones which must be passed through
during the test
I - PRINCIPLE
In looping phase, the richness regulation corrects the
injection time to obtain fuel dosing as close as possible
to a richness of 1. Richness correction value PR138 is
close to 50% , with stop values of 0 and 100% .
There are five pressure zones to scan during road testing. These zones are defined by the following calibrations:
Adaptive richness corrections PR143 and PR144 allow

the injection map to be shifted to recentre richness regulation at 50 % .
Adaptive corrections take 50% as the average value
after reinitialising the computer (clearing the memory),
and have end values.
Deactivation of the adaptive programs in the case

of prolonged idle speed regulation with a hot
engine
If the coolant temperature is above 80C while idling for
more than 1 minute , the adaptives are fixed until the
end of idling.
Range
mbar
N1
276 to 398
Average 337
N2
398 to 516
Average 457
n3
516 to 637
Average 576
N4
637 to 753
Average 695
N5
753 to 872
Average 812
II - INTERPRETING VALUES OBTAINED FROM A

ROAD TEST
Programming conditions for adaptive richness

correction
In the event of a lack of fuel (injectors clogged, pressure and fuel flow too low, etc), the richness regulation increases to obtain a richness as close as possible to 1
and the richness adaptive corrections increase until the
richness correction is again fluctuating around 50% .
- Warm engine: coolant temperature above 80C ,
If there is an excess of fuel, the logic is inverted.
- Do not exceed an engine speed of 4512 rpm .

- disconnect the fuel vapour absorber by the solenoid
valve or block the inlet pipe on the engine.
Following this test the adjustments will be operational.
The test should be followed by normal, smooth and varied driving over a distance of 3 to 6 miles (5 to 10 km)
. After the test, read the adaptive values. They should
have changed from their original value of 50 % . If not,
take the readings again, taking care to observe the test
conditions strictly.
PR138
Richness correction
23%
< or = X < or =
74%
PR143
Richness adaptive
gain
12.5%
< or = X < or =
87.5%
PR144
Richness adaptive
offset
32%
< or = X < or =
87.5%
17B-40
PETROL INJECTION
Central coolant temperature management
The fan assembly is controlled by the injection computer.
I - ANTI-PERCOLATION FUNCTION
The anti-percolation function is controlled by the injection computer.
The coolant temperature signal used is that from the injection system.
K4J, and 730 or 732 K4M, and 760 or 761

After switching the ignition off, the system enters monitoring mode. If the coolant temperature exceeds the
threshold 103C for 5 minutes after the engine has
been switched off, the low-speed fan assembly is activated.
F4R, and 770 or 771 or 776

After switching the ignition off, the system enters monitoring mode. If the coolant temperature exceeds 110C
for 2 minutes after the engine has been switched off,
the low-speed fan assembly is activated.
If the coolant temperature falls below 100C again, the

fan assembly relay is cut-out (the fan assembly cannot
be activated for more than 10 minutes ).
II - FAN ASSEMBLY OPERATION

The fan unit is operated at low speed if the coolant temperature exceeds 98C and stops when the temperature falls below 96C .
The fan assembly is operated at high speed if the coolant temperature exceeds 102C and stops when the
temperature falls below 99C .
III - OPERATION OF THE TEMPERATURE

WARNING LIGHT
The temperature warning light comes on if the coolant
temperature exceeds 119C and goes out when the
temperature falls below 115C .
17B-41
17B
PETROL INJECTION
Camshaft dephaser: Description
17B
F4R, and 770 or 771 K4M, and 760 or 761

I - SPECIAL NOTES
The supply by a variable opening cyclic ratio signal

(amplitude 12 V , frequency 250 Hz ) enables oil to be
distributed to the mechanism and the dephaser angle
to be adjusted.
F4R, and 770 or 771 K4M, and 760 or 761

Its role is to modify the valve timing.
To improve cylinder filling at all speeds, K4M and F4R
engines are fitted with an inlet camshaft dephaser (1) .
15200
The operation of the camshaft dephaser varies continuously.

The computer supplies the solenoid valve with a variable opening cyclic ratio proportional to the desired dephasing.
Dephasing is varied continuously from 0 to 43 of the
crankshaft.
102943
Dephasing at the moment when the inlet valves close

optimises filling according to engine speed. Midrange
torque and output are improved.
Leaving the inlet valves open for longer at high engine
speed allows the mixture to be continually admitted
owing to its high speed.
However, at lower engine speeds the gases do not
have a high level of inertia. It is therefore preferable to
close the inlet valves earlier to avoid incorrect filling
and a loss of torque due to the reflux of fresh gases.
The higher the engine speed, the later the inlet valves
must be closed.
101814
The camshaft dephaser control solenoid valve is controlled if the following conditions are met:
- no speed sensor fault,
- no camshaft position sensor fault,
II - OPERATION AND PROGRAMMING
- no injection system faults,

- after the engine has started,
K4M, and 760 or 761
- outside idling speed and no load,
The oil is supplied to the dephaser by a solenoid valve

(2) located on the cylinder head.
- threshold of mapping according to load and engine

speed reached,
17B-42
PETROL INJECTION
Camshaft dephaser: Description
17B
F4R, and 770 or 771 K4M, and 760 or 761

- coolant temperature between 10 and 120C ,
- engine oil temperature too high.
Note:
Defect modes:
Up to 1,500 rpm , the solenoid valve is no longer

supplied. The mechanism is locked by the piston.
As soon as the solenoid valve is supplied, at
speeds above 1,500 rpm , the oil pressure pushes
the locking piston and releases the mechanism.
- dephaser returns to initial position,

- zero dephasing.
WARNING
A solenoid valve jammed open causes an unstable
idle speed, manifold pressure which is too high at
idle speed and significant engine operating noise.
III - OPERATION AND PROGRAMMING
F4R, and 770 or 771

The dephaser is controlled in an all or nothing system
by the injection computer using a solenoid valve (3) located on the rocker cover.
102736
At rest, the solenoid valve is in the closed position. It

authorises the flow of oil to control the dephaser when
the following conditions are met:
- no speed sensor fault,
- no camshaft position sensor fault,

- no injection system faults,
- after the engine has started,
- outside idling speed,
- battery voltage > 11.4 V ,
- coolant temperature above 30C ,
- engine speed between 1,500 and 4,300 rpm ,
- charge > 87% (approximately 900 mbar ).
102732
From 1,500 to 4,300 rpm , the computer supplies the

solenoid valve.
Above 4,300 rpm , the solenoid valve is not supplied.
The position of the mechanism improves filling at high
speeds. In this position, a locking piston locks the mechanism.
17B-43
WARNING
A solenoid valve which is blocked open leads to an
unstable idle speed and too high a pressure in the
manifold at idling speed.
PETROL INJECTION
Fault finding warning light activation conditions (when driving)
17B
I - FAULTS CAUSING ACTIVATION OF THE

ONBOARD DIAGNOSTIC WARNING LIGHT
Note:
1 - Electrical fault
The fault may not be re-detected:
Continuous illumination of the light after several consecutive detections of a fault (depending on the component).
- if the fault is fleeting in nature,
2 - Combustion misfiring that could destroy the

catalytic converter
Immediate illumination and flashing of the warning light.
3 - Catalytic converter or oxygen sensor fault,
polluting misfires
Continuous illumination of the light after a fault is detected three times consecutively.
WARNING
The diagnostics of the catalytic converter and upstream oxygen sensor are sequential and are run:
- once when driving (they take several seconds per
test),
- only under certain specific driving conditions.
Under certain driving conditions, it may be the case
that fault finding for certain functions are not performed (e.g. when in a traffic jam).
II - MANAGEMENT OF THE ONBOARD

DIAGNOSTIC (OBD) WARNING LIGHT
1 - Warning light comes on
If the same OBD fault is detected during three consecutive journeys or there is an electrical fault.
2 - Warning light flashes
If misfires that could destroy the catalytic converter are
detected.
3 - Light goes out
If the OBD fault does not reappear in three consecutive
journeys the warning light goes out, but the fault will be
stored in the injection computer.
The fault must not be detected for 40
consecutive journeys for the a stored fault to be cleared from the computer without using the fault finding tool.
17B-44
- due to the driving style of the customer, which may

not always cover all of the fault detection conditions.
PETROL INJECTION
Conditions for carrying out fault finding (when driving)
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.
17B
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 (see 17A, Petrol injection, Adaptive richness correction ).
In order for the On Board Diagnostic system to function

correctly, there must be no electrical fault in the injection system, even if the OBD warning light does not
come on.
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:
- repair all electrical faults,
- clear all faults,
- carry out injection system programming,
- check the OBD system.
III - COMPLETE INITIALISATION OF THE OBD
In order to reinitialise the OBD function, it is necessary
to carry out following operations:
- clear stored faults,
- clear OBD faults,
- clear all programming.
IV - PROGRAMMING NECESSARY FOR OBD
Programming must be reinitialised when replacing:
- an injection computer,
- an engine flywheel target,
- an engine speed sensor.
1 - Engine flywheel target programming
17B-45
PETROL INJECTION
Combustion misfire fault finding
17B
IV - CONDITIONS FOR DETECTION

Check that programming has been correctly carried
out.
Equipment required
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 damage
to 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 4,500 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
injection cut-off to cylinders causing misfiring,
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.
appearance of a fault indicating non-conformity

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 tool diagnostic tool , check:
I - THE FAULT FINDING SYSTEM CAN DETECT:

- clogging or flooding of a spark plug,
ET 057
Misfiring on cylinder 1
No
ET 058
No
ET 059
No
ET 060
No
- 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.
Following this test, if the diagnostic tool has indicated

misfiring faults DF065 , DF059 , DF060 , DF061 , or
DF062 , refer to the appropriate fault finding procedure
for the symptom concerned.
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% - resulting in catalytic
converter damage. It causes the injection warning light to flash immediately.
- Pollutant misfiring - below 15% - causing the OBD
pollution limit to be exceeded. It causes the injection
warning light to come on if it is detected during three
consecutive journeys.
17B-46
PETROL INJECTION
Catalytic converter fault finding
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.
17B
III - REPAIR CONFIRMATION

If after the test, the diagnostic 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 remains at an average value.
2 - If it needs replacing
It rejects the oxygen and downstream oxygen sensor
PR099 starts to pulse. The voltage of the oxygen sensor fluctuates (the OBD warning light comes on after
three journeys).
WARNING
diagnostic tool. Switching off the ignition will lead to
17B-47
PETROL INJECTION
Oxygen sensor fault finding
Equipment required
17B
WARNING
diagnostic tool. Switching off the ignition will lead to
diagnostic tool
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.
I - POSSIBLE CAUSES OF FAULTS
V - REPAIR CONFIRMATION
If, after the test, the diagnostic tool has detected an
upstream oxygen sensor fault DF092: Upstream
oxygen sensor circuit refer to the fault finding procedure for this fault.
There are possible types of fault in the upstream oxygen sensor:

- mechanical damage to an electrical component
(breakage, cut in wire) which leads to an electrical
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-48
PETROL INJECTION
Speed limiter: Operating principle
Entry conditions:
- switch in speed limiter position,
- 19 mph (30 km/h) minimum, 125 mph (200 km/h)
maximum (guideline only),
- + , - or R buttons pressed.
Exit conditions:
- accelerator depressed firmly (beyond the safety resistance point),
- switch in the off position,
- 0 button depressed,
- injection computer intervention (fault or overspeed),
Note:
If the warning light on the instrument panel flashes,
it informs to the driver that the cruising speed cannot be maintained.
17B-49
17B
COOLING SYSTEM
General information
19A
When a faulty vehicle arrives, check:

IMPORTANT
The circuits are designed to be pressurised; take
care at high temperatures (risk of serious scalding).
Never remove the valve from the expansion bottle
while the engine is hot.
Similarly, take care when working under the bonnet,
as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine is
running.
- the condition and tension of the water pump drive

belt,
- that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
air.
Vehicles in the current range have cooling circuits with
the following basic specifications:
- Pressurised sealed circuit (expansion bottle valve),
Note:
Summary of expansion bottle valve ratings.
WARNING
Expansion bottle valve with:
The coolant helps to keep the engine running properly (heat exchange).
a yellow hand: 1.4 bar
The system does not operate using pure water.
a white hand: 1.6 bar

a grey hand: 1.8 bar
- circuit using type D coolant only.
WARNING
Drain with the engine warm.
Note:
Flushing and refilling should be carried out with a

warm or cold engine.
Ready-to-use coolant or antifreeze must be diluted

with distilled water in accordance with the guidelines marked on the container.
Never flush a hot engine (risk of serious thermal

shock).
WARNING
When carrying out a repair that requires a the circuit to be completely drained, 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 - 40 C 2 for very cold climates
Note:
Refer to the vehicle's maintenance service booklet
for information on cooling circuit service intervals.
For any further information, refer to the Workshop
Repair Manual of the vehicle concerned.
19A-1
COOLING SYSTEM
Specifications
19A
Grade and quantity of coolant

Engine
Suffix
Quantity
(litres)
Grade
730
K4J
6
732
760
761
6.5
722
5.3
728
6.5
GLACEOL RX
729
6.8
(type D).
732
7.5
770
K4M
K9K
F4R
771
6.5
776
F9Q
M9R
800
7.2
804
7.6
808
7.2
700
7.5
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
19A-2
Only use
coolant
fluid
COOLING SYSTEM
Checking
I - RECOMMENDATIONS FOR REPAIR
19A
II - CHECKING THE CIRCUIT SEALING
IMPORTANT
Note:

care at high temperatures (risk of serious scalding).
The expansion bottle valve must be replaced if

coolant is leaking from the valve.
Never remove the valve from the expansion

bottle while the engine is hot.
Checking the cooling system and the expansion

bottle valve
Similarly, take care when working under the bonnet, as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine
is 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
diagnostic and filling tool .
Note:
For any further information, refer to the Workshop Repair Manual of the vehicle concerned.
19A-3
COOLING SYSTEM
Diagram
19A
K4J, and 730 or 732 K4M, and 760 or 761
9
3
6
7
10
2
8
105003
(1)
Engine
(2)
Cooling radiator
(3)
Heating radiator
(4)
Expansion tank
(5)
Water pump
(6)
Thermostat
(7)
9 mm choke
(8)
16 mm choke
(9)
Bleed screws
(10)
Automatic gearbox coolant-oil

intercooler (if fitted to the vehicle)
Note:
The expansion bottle degassing valve rating is 1.4
bar .
19A-4
COOLING SYSTEM
Diagram
19A
K9K, and 722 or 728 or 729
3
9
1
7
8
4
6
10
11
110741
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
11 mm choke (K9K 722)
(8)
9 mm by-pass choke (K9K 728 /

729)
(9)
Bleed screws
(10)
Coolant-engine oil intercooler
(11)
Coolant-oil intercooler (K9K

729)
Note:
bar .
19A-5
COOLING SYSTEM
Diagram
19A
F9Q, and 800 or 808
9
3
9
5
4
6
10
8
2
102269
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
8 mm choke
(8)
9 mm choke
(9)
Bleed screws
(10)
Coolant-oil intercooler
Note:
bar .
19A-6
COOLING SYSTEM
Diagram
19A
F4R, and 770 or 771
9
3
9
10
4
5
7
6
11
102740
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
8.3 mm choke
(8)
16 mm choke
(9)
Bleed screws
(10)
Coolant-oil intercooler
(11)
Automatic gearbox coolant-oil

intercooler (if fitted to the vehicle)
Note:
bar .
19A-7
COOLING SYSTEM
Diagram
19A
F4R, and 776
9
3
12
11
4
6
10
7
2
13
106628
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
9 mm choke
(8)
16 mm choke
(9)
Bleed screws
(10)
Water-oil intercooler
(11)
Thermostat mounting
(12)
Turbocharger
(13)
Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-8
COOLING SYSTEM
Diagram
19A
F9Q, and 804
12 9
11
4
6
13
10
8
2
14
112266
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
8 mm choke
(8)
16 mm choke
(9)
Bleed screws
(10)
(11)
Cylinder head coolant outlet unit
(12)
Turbocharger
(13)
Exhaust gas cooler
(14)
Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEM
Diagram
19A
K9K, and 732
3
9
8
2
112268
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Bleed screws
(8)
(9)
Exhaust gas cooler
Note:
bar .
19A-10
COOLING SYSTEM
Diagram
19A
M9R, and 700
114452
(1)
Engine
(2)
Cooling radiator
(3)
Heater radiator
(4)
Expansion bottle
(5)
Water pump
(6)
Thermostat
(7)
Choke
(8)
Choke
(9)
Bleed screws
(10)
Water-oil heat exchanger
(11)
Note:
bar .
19A-11
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 pliers for cooling system hose clips
Mot. 1700
19A
When carrying out a repair that requires a complete

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
then measure the effective protection.
The parameters to be observed are:
- Protection down to - 25C 2 for cold and temperate climates,
- Protection down to - 40 C 2 for very cold climates.
Cooling system filling and diagnostic tool
Note:
IMPORTANT
Before carrying out any operation, protect electrical

equipment using plastic bags.

care at high temperatures (risk of serious burns).
Never remove the cap from the expansion bottle
Note:

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.

running.
WARNING
DRAINING
Use the following tools:
The coolant helps to keep the engine running properly (heat exchange).
- (Car. 1363) ,
The system does not operate using pure water.
- (Mot. 1202-01) ,
- (Mot. 1202-02) ,
WARNING
- (Mot. 1448) .
Drain the fluid with the engine warm.
Remove the expansion bottle cap.

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 cap orifice to remove as much water
as possible.
CLEANING
For cleaning (see 19A, Cooling, Cooling system:
cleaning).
FILLING
Use GLACEOL RX (TYPE D) coolant.
19A-12
COOLING SYSTEM
Cooling circuit: Draining - Refilling
Refill the cooling system using the cooling system
diagnostic and filling 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 cap.
Bleed the circuit (see 19A, Cooling system, Cooling circuit: Bleeding, page 19A-15) .
19A-13
19A
COOLING SYSTEM
Engine cooling circuit: Cleaning
IMPORTANT
care at high temperatures (risk of serious burns).
Do not remove the cap from the expansion bottle
running.
WARNING
Drain the fluid with the engine warm.
shock).
CLEANING THE COOLING SYSTEM
To clean the cooling system, fill with water 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.
Blast compressed air into the circuit through the expansion bottle cap orifice to remove as much water
as possible.
Connect the top and bottom hoses.
19A-14
19A
COOLING SYSTEM
Cooling circuit: Bleeding
BLEEDING
IMPORTANT
Do not open the bleed screw(s) while the engine
is running or hot.
Do not open the expansion bottle while the
engine is running or hot (above 50C ).
Adjust the level, if necessary.
Retighten the expansion bottle cap while the
engine is hot.
Using approved equipment, measure the degree
of coolant protection.
Check for any leaks.
Make sure the passenger compartment heating
is working properly.
K9K, and 722 or 728 or 729 or 732

Run the engine at 1500 rpm , rapidly varying the engine speed (until you reach maximum speed) 2 to 3
times approximately every 2 minutes until the engine cooling fan starts up for a second time.
F4R, and 770 or 771 or 776 F9Q, and 800 or 804

or 808 K4J, and 730 or 732 K4M, and 760 or
761
Run the engine at 2500 rpm , until the engine cooling fan has run three times (time required for automatic degassing).
19A-15
19A
COOLING SYSTEM
Cooling radiator: Removal - Refitting
19A

terminal.

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

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

- the front wheels,

Disconnect:
- the fog lights connector (if fitted to vehicle),
- the headlight washer pipes (if fitted).
Remove:
Tightening torquesm
- the bumper.
intercooler hose clip
bolts
5.5 Nm
4 Nm
110 Nm
REMOVAL
F4R, and 776 F9Q, and 800 or 804 or 808 K9K,

and 722 or 728 or 729 or 732
4
3
WARNING
102504

intercooler:
- risk of leaks and of coming loose if this procedure is not adhered to.
Remove:
- the clip (3) ,
- detach the hose using tool (Car. 1363) ,
- the mounting (4) .
- do not use degreaser, brake cleaner, or any

other product,
Disconnect the windscreen washer pipes.
- clean the bearing face on the intercooler and

- always replace the clip with a new one.
- replace the new 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,
19A-16
COOLING SYSTEM
19A

and 722 or 728 or 729 or 732
102365
Remove the cross member (5) .
Drain the cooling circuit through the radiator bottom

hose.
Disconnect:
- the radiator top hose,
- the expansion bottle hoses on the radiator,
102473
7
102474
Disconnect the intercooler inlet ducts (6) and outlet

ducts (7) .
19A-17
COOLING SYSTEM
19A
Tighten to torque:
Separate the condenser from the radiator.

WARNING
- the wheel mounting bolts ( 110 Nm ) .

piping.
Note
Remove the radiator.
Be sure to initialise the xenon bulb system (if fitted on vehicle; see 80C, Xenon bulbs, Xenon
Separate the fan unit from the radiator.
REFITTING
and 722 or 728 or 729 or 732
Tighten to torque the intercooler hose clip ( 5.5
Nm ) .
For refitting plastic clips, use:

- 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 unit (radiator,
condenser) are not damaged when moved.
- fill the cooling circuit (see 19A, Cooling, Draining
- filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ),
WARNING
19A-18
COOLING SYSTEM
19A
K9K, and 732

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Tightening torquesm
102504

mounting bolts
21 Nm

mounting bolts
44 Nm
wheel bolts
Disconnect the connectors (1) from the relay board,

Unclip the bonnet opening cable (2) ,
Remove:
- the clip (3) ,
110 Nm


- fitting ).
Remove:
- the front wheels,
102365
Remove:
- the front end panel bolts (5) ,
Drain the cooling system via the radiator bottom hose, using tool (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) .
19A-19
COOLING SYSTEM
19A
K9K, and 732
102473
109537
102474
112661
Disconnect the ducts (6) and (7) from the intercooler.

Disconnect:
- the cooling radiator top hose,
- the expansion bottle hoses (8) ,
- the fan unit resistor connector (9) .
- the fan unit connector
19A-20
COOLING SYSTEM
19A
K9K, and 732

Connect:
- the hoses onto the cooling radiator,
CA or CAREG
- the fan unit connectors;
Separate the condenser from the cooling radiator.

WARNING
Refit the intercooler.

piping.
Connect the intercooler ducts.

Refit the front end panel.
Tighten to torque:
Nm )

CONCERNED

Nm )
Remove the radiator assembly from the fan unit.
Clip the bonnet opening cable
Separate the cooling radiator from the fan unit.
Reconnect:
- the connectors to the relay board,
REFITTING
- the screen washer pipes.

CONCERNED
Fill with and bleed the coolant (see 37A, Cooling,

Position the fan unit on the cooling radiator.
Refit:
Refit the cooling radiator assembly and the fan unit.


- the front wheels,
CA or CAREG
Reposition the condenser on the cooling radiator.

WARNING
piping.
19A-21
COOLING SYSTEM
Water pump: Removal - Refitting
19A
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
REFITTING
Tightening torquesm
water pump mounting
bolts
9 Nm

mounting bolts
110 Nm
IMPORTANT
Wear goggles.
REMOVAL
Removal - Refitting .
Replace the water pump seal every time the water
pump is removed.
Remove:
WARNING

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

Remove:
Note:
Apply two drops of LOCTITE FRENETANCH to
the water pump mounting bolts.
Refit:
- the water pump,
- the water pump mounting bolts.
102422
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
19A-22
COOLING SYSTEM
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
102422
Tighten to torque and in order the water 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 front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheel
19A-23
19A
COOLING SYSTEM
19A
K4J, and 730 or 732 K4M, and 760 or 761
Tightening torquesm
water pump M8 mounting bolt
22 Nm
water pump M6 mounting bolts
10 Nm

mounting bolts
110 Nm
REMOVAL
Remove
14505

Remove:
- the engine undertray
- the timing tensioning roller,

- the water pump.
Remove:
REFITTING

IMPORTANT
Wear goggles.
WARNING
WARNING
squeezed out when parts are tightened. The product-fluid mix may cause damage to some components (engine, radiator, etc.).
19A-24
COOLING SYSTEM
K4J, and 730 or 732 K4M, and 760 or 761
10063
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mm

to 1 mm wide.
19A-25
19A
COOLING SYSTEM
19A
K4J, and 730 or 732 K4M, and 760 or 761

Refit:

8
14505
Note:
Apply one to two drops of LOCTITE FRENETANCH to the mounting bolts (1) and (4) of the
water pump.
Refit:
- the water pump,
Pretighten the water pump M6 mounting bolts to 8
Nm and the water pump M8 mounting bolts to 8
Nm .
- the water pump M8 mounting bolt ( 22 Nm ) ,
- the water pump M6 mounting bolts ( 10 Nm ) .
Refit:
Refit the front right-hand wheel
19A-26
COOLING SYSTEM
19A
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
water pump mounting
bolts
11 Nm

mounting bolts
110 Nm
REMOVAL

Remove:
102267


Remove the alternator upper mounting (1) .
Remove:
Undo the alternator lower mounting (2) .

Tilt the alternator forward.

102266
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
19A-27
COOLING SYSTEM
19A
K9K, and 722 or 728 or 729 or 732
3
5
102262
102262
Remove:
WARNING
- the water pump.

REFITTING
Note:
IMPORTANT
Wear goggles.
Refit:
- the water pump,
Clean the gasket faces using DECAPJOINT to dissolve any sealant still adhering.
pump is removed.
19A-28
- the water pump mounting bolts (1) to (5) .

COOLING SYSTEM
K9K, and 722 or 728 or 729 or 732
102266
Refit:
- the inner timing cover (5) ,
Timing belt ),
Refit:
Tighten to torque:
- the front right-hand wheel mounting bolts ( 110
Nm )
19A-29
19A
COOLING SYSTEM
19A
F4R, and 770 or 771 or 776
REFITTING
Tightening torquesm
water pump mounting
bolts
9 Nm

mounting bolts
110 Nm
IMPORTANT
Wear goggles.
REMOVAL
Removal - Refitting .
pump is removed.
Remove:
WARNING

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

Remove:
Note:
Refit:
- the water pump,
102422
Remove:
- the water pump.
19A-30
COOLING SYSTEM
F4R, and 770 or 771 or 776
5
3
102422

Refit:
Refit:
19A-31
19A
COOLING SYSTEM
19A
K9K, and 732

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Tightening torquesm
water pump mounting
bolts
bolts
11 Nm
130 Nm
102267
4 Nm
Loosen the alternator lower mounting bolt by three

turns.
Remove the alternator upper mounting bolt.
REMOVAL
Tilt the alternator against the radiator assembly.

terminal.
Remove:
Drain the cooling circuit via the radiator bottom hose,
using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.
1448) .
Remove:
- the accessories belt (see 11A, Top and Front of
Engine, Accessories belt ).
Timing belt
102266
Remove:
- the inner timing cover mounting bolts,
- the timing cover.
19A-32
COOLING SYSTEM
19A
K9K, and 732
REFITTING

CONCERNED
I - OPERATION FOR REFITTING PART

CONCERNED
WARNING
The water pump seal every time the water pump
is removed.
Note:
Apply one or two drops of LOCTITE FRENETANCH to the water pump mounting bolts.
102262
Remove:
- the water pump mounting bolts
- the water pump.
III - CLEANING
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
102262
- Clean the gasket faces with DECAPJOINT to

dissolve the part of the gasket still present.
Refit:
Apply the product to the part to be cleaned, wait

approximately 10 minutes, then remove residue
- the water pump,

19A-33
COOLING SYSTEM
K9K, and 732
102266
Refit:
- the inner timing cover,
- the alternator,
- the timing belt (see 11A, Top and front of engine:
Timing belt ),
- fill the cooling circuit (see 19A, Cooling, Draining
- Filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Bleeding the cooling circuit ),
Connect the battery starting with the positive terminal (see 80A Battery: Removal - Refitting ).
WARNING
Carry out the necessary programming.
Tighten to torque:
- the wheel mounting bolts ( 130 Nm )
- the battery cover mounting bolts ( 4 Nm )
19A-34
19A
COOLING SYSTEM
19A
M9R, and 700
REMOVAL

Mot. 1390

and refitting the
engine and gearbox
assembly

Tightening torquesm
water pump mounting
bolts
25 Nm
water pump pulley

mounting bolts
21 Nm

mounting bolts
21 Nm

mounting bolts
44 Nm
WARNING
When carrying out a repair that requires a complete 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 then measure the effective protection.
- protection down to - 25 C 2 for cold and temperate countries,
- protection down to - 40 C 2 for very cold
countries.
IMPORTANT
The circuits are designed to be pressurised, so
be careful at high temperatures (risk of serious
burns).
When working under the bonnet, be aware that
the radiator cooling fan(s) may start without warning.
Do not open the bleed screw(s) with the engine
running.
Remove:
19A-35
COOLING SYSTEM
19A
M9R, and 700
101212
114933
Remove:
- the right-hand side stiffener mounting bolts,
- the right-hand side stiffener (1) ,
- the rear mounting (see 19D, Suspended engine
mounting, Rear mounting: Removal - Refitting
).
112658

114855

19A-36
COOLING SYSTEM
19A
M9R, and 700
102504
102365
Remove:
Remove:
- the clip (6) ,
Remove the Cooling radiator - condenser intercooler assembly from its housing and move it
forwards.

Fit the (Mot. 1390) on two pads.
Drain the cooling system (see 19A, Cooling, Cooling system: Draining - Filling ).
Undo
- the right-hand suspended mounting support mounting bolts,
- the upper engine tie-bar mounting bolts.
Remove the upper engine tie-bar.
19A-37
COOLING SYSTEM
19A
M9R, and 700

CONCERNED
114858
Remove:
- the water pump pulley mounting bolts (11) ,
- the water pump pulley (12) .
114863
At the same time, turn the (Mot. 1390) forwards, lifting the right-hand suspended engine mounting (9)
and bring the compressor pulley (10) level.
19A-38
COOLING SYSTEM
19A
M9R, and 700

Tighten to torque the water pump pulley mounting
bolts ( 21 Nm ) .
Position
- the Engine - Gearbox assembly on the vehicle,
- the Cooling radiator - condenser - intercooler
assembly on the half sub-frame.
Refit:
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting ).
Tighten to torque:
Nm ) ,
114863

Nm ) .
Remove:
Clip:
- the water pump mounting bolts,
- the bonnet opening cable,
- the water pump (13) .

Refit the clips.
REFITTING

Refit:

CONCERNED
The water pump seal must be replaced.

engine, Accessories belt: Removal - Refitting )
WARNING
- the rear suspended engine mounting (see 19D,

Engine mounting, Rear suspended engine
mounting: Removal - Refitting ).
Clean the pump shaft cooling hole on the cylinder block.

Apply soapy water to the seal before refitting the water pump.
- the half sub-frame cross member side stiffener,

Refit the water pump.
Check that the water pump is supported by the cylinder block before tightening the bolts.

19A-39
COOLING SYSTEM
Plenum chamber: Removal - Refitting
19A
M9R, and 700
REMOVAL

Mot. 1202-01

system hose clips
(large model)
Mot. 1202-02

clips
Mot. 1448

Mot. 1700
Cooling circuit filling

and diagnostic tool

Remove the battery (see 80A, Battery, Battery: Removal - Refitting ).
Tightening torquesm
coolant outlet unit
cylinder head
11 Nm

bolts
21 Nm
wiring harness mounting nut
8 Nm
112659
WARNING
When carrying out a repair that requires a complete

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
then measure the effective protection.
Remove:
- protection down to -25C 2 for cold and temperate countries,
Unpick the wiring harness (4) from the battery - terminal.
- protection up to -40C 2 for countries with extremely cold climates.

Drain the cooling system via the radiator bottom
hose using the (Mot. 1202-01) or (Mot. 1202-02) or
(Mot. 1448) (see 19A, Cooling, Cooling system:
Draining - Filling).
IMPORTANT
The circuits are designed to be pressurised, so be
careful at high temperatures (risk of serious burns).
During an operation under the bonnet, be aware
that one (or several) of the radiator cooling fan(s)
may operate unexpectedly.
Do not open the bleed screw(s) with the engine running.
19A-40
COOLING SYSTEM
19A
M9R, and 700
114934
113291
Disconnect the coolant temperature sensor connector (5) .
Remove:
- the coolant outlet unit mounting bolts,
- the coolant outlet unit.

CONCERNED
REFITTING
replace the seal of the coolant outlet unit.
WARNING
The seal faces must be clean, dry and free from
grease (avoid finger marks).
II - REFITTING PART CONCERNED
Remove:
113293
Remove the cooling hose clips using the (Mot.

1202-01) or (Mot. 1202-02) or (Mot. 1448) on the
coolant outlet unit.
Disconnect the cooling hoses from the coolant outlet
unit.
Unpick the wiring harness on the coolant outlet unit.
19A-41
- the coolant outlet unit.

- the coolant outlet unit mounting bolts,
COOLING SYSTEM
M9R, and 700
113291
Tighten to torque and in order the coolant outlet

unit mounting bolts on the cylinder head ( 11 Nm
).
Connect the coolant outlet unit cooling hoses.
Refit the cooling hose clips using the (Mot. 1202-01)
or (Mot. 1202-02) or (Mot. 1448) on the coolant outlet unit.

Connect the coolant temperature sensor connector.
Refit the battery tray.
Remove:
- the wiring harness,
- the wiring harness mounting nut.
Tighten to torque:
- the wiring harness mounting nut ( 8 Nm ) .
Connect the injection computer connectors.
Clip on the battery - terminal wiring harness.
Refit the battery (see 80A, Battery, Battery: Removal - Refitting ).
Fill the cooling system using the (Mot. 1700) (see
19A, Cooling, Cooling system: Draining - Refilling ).
19A-42
19A
EXHAUST
General information
19B

F4R, and 776
Mot. 1199-01
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 and the
catalytic converter must be perfect.
109581
All seals removed must be replaced.

Take care not to damage the catalytic converter
during removal and refitting.
SPECIAL NOTES ON THE EXHAUST PIPE
1 - Exhaust pipe cutting line
The exhaust pipe is a single unit type.
When replacing one of the components, cut the exhaust pipe:
- correctly identify the area to be cut.
- use the cutting tool correctly (Mot. 1199-01) ,
109580
Before cutting the pipe between the catalytic converter

and the expansion chamber, remove the protective
plate.
- correctly position the After-Sales sleeve.

2 - Identifying the cut zone
Two punch marks on the exhaust pipe indicate the
area to be cut (see 19B, Exhaust, General information on exhausts ).
19B-1
EXHAUST
General information
19B
Cut zone 1
D
P1
P2
80 mm
100649
101504
Before cutting the pipe, mark the halfway point (D)

between marks (P1) and (P2) .
Cut zone 2
The distance between the two marks is 80 mm
3 - Using tool Mot. 1199-01
101503
102118
Position the tool on the pipe.

Tighten the two bolts on the cutting tool so that it 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
4 - Special notes on the replacement part
19B
Cut zone 1
60 mm
101960
WARNING
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 .
101501
Cut zone 2
5 - Fitting the After-Sales sleeve

Apply exhaust pipe mastic inside the sleeve.
To prevent any exhaust leaks, position the sleeve correctly on both lugs.
Place the sleeve on the worn section of the pipe. Adjust
the clip diameter by tightening slightly.
101500
6 - Special feature of cut zone 2

Remove the bolt securing the rubber mounting bush
(2) onto the body.
Lower the exhaust pipe.
Position tool (Mot. 1199-01) on the pipe.
Cut the exhaust pipe .
95478
Place the sleeve end on the worn section of the pipe.

Adjust the sleeve diameter by tightening gently.
19B-3
EXHAUST
General information
WARNING
Do not reuse a used bracket.
WARNING
Do not reuse an old sleeve.
The sleeve tightening nuts and bolts must be
positioned so that they cannot come into contact
with the underbody.
Tighten to torque the nut (1) on the exhaust sleeve
(25 Nm) .
When tightening to torque, a click indicates that the torque of (25 Nm) has been reached.
Check that:
- there is no contact with the underbody,
- the presence and correct positioning of all the exhaust pipe heat shields.
19B-4
19B
EXHAUST
Pipe assembly
19B
K4J, and 730 or 732
(1)
Cut zone 1
(2)
Cut zone 2
K4M, and 760 or 761
112063
112062
19B-5
EXHAUST
Pipe assembly
19B
(1)
Cut zone 1
(1)
Cut zone 1
(2)
Cut zone 2
(2)
Cut zone 2
F4R, and 770 or 771 or 776
112061
19B-6
EXHAUST
Pipe assembly
19B
K9K, and 722 or 728 or 729 or 732 F9Q, and 800 or 804 or 808
K9K, and 722
(1)
Cut zone 1
(2)
Cut zone 2
K9K, and 728 or 729 or 732
112060
112059
19B-7
EXHAUST
Pipe assembly
19B
(1)
Cut zone 1
(1)
Cut zone 1
(2)
Cut zone 2
(2)
Cut zone 2
F9Q, and 800 or 808
F9Q, and 804
2
2
112059
112058
19B-8
EXHAUST
Pipe assembly
(1)
Cut zone 1
(2)
Cut zone 2
19B-9
19B
EXHAUST
Catalytic pre-converter: Removal - Refitting
19B
F4R, and 776
Tightening torquesm
upstream stay mounting bolts (on the
engine)
38 Nm
catalytic converter
mounting bolt (on the
upstream stay)
8.5 Nm
upper bracket mounting bolt (on the exhaust

manifold)
8.5 Nm
upper bracket mounting bolt (on the catalytic

converter)
8.5 Nm
catalytic converter nuts

(on the turbocharger)
40 Nm
3
5
oxygen sensors
34 Nm
exhaust flange studs
8.5 Nm
4
21926
Disconnect the oxygen sensor connectors (2) .

Remove:
- the upper bracket (3) and upstream stays (4) ,
Remove the engine in order to remove the catalytic

pre-converter (see 10A, Engine and peripherals, Engine - gearbox ).
- the catalytic converter/gearbox stay mounting (5) ,

- the catalytic converter mounting nuts, (6) on the
turbocharger,
REMOVAL

Remove the oxygen sensor on the workbench.
REFITTING
Refit the oxygen sensors.
WARNING
Be sure to replace all the exhaust flange and turbocharger sealing joints.
Tighten to torque the upstream stay mounting
bolts (on the engine) ( 38 Nm ) .
Pretighten in order:
- the upper bracket mounting bolts,
- the nuts securing the catalytic converter to the turbocharger,
106246
Remove:
- the upstream catalytic converter stay mounting

bolt.
- the catalytic converter mounting bolt (on the

upstream stay) ( 8.5 Nm ) ,
- the heat shield.
19B-10
EXHAUST
F4R, and 776
- the upper bracket mounting bolt (on the exhaust manifold) ( 8.5 Nm ) ,
- the upper bracket mounting bolt (on the catalytic converter) ( 8.5 Nm ) ,
- the catalytic converter nuts (on the turbocharger) ( 40 Nm ) ,
- the exhaust flange studs ( 8.5 Nm ) .
19B-11
19B
EXHAUST
19B
F9Q, and 804

- the exhaust mounting bolts,
- the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal Refitting ).
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 bolts on
the engine
50 Nm
timing-end downstream
stay mounting nuts on
the catalytic pre-converter
30 Nm
outlet exhaust flange
studs
7 Nm
exhaust flange nuts

bolts
- the lower engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ).
111864
Remove:
- the catalytic pre-converter lower stay mounting
bolts (1)
- the catalytic pre-converter lower stay.
21 Nm
4 Nm
Remove:
- the upper engine tie-bar (see 19D, Engine mounting, Suspended engine mounting: Removal Refitting ).
Remove:
19B-12
EXHAUST
F9Q, and 804
3
2
111862
Remove:
- the catalytic pre-converter upper stay mounting
bolts (2) ,
- the catalytic pre-converter upper stay,
- the turbocharger and catalytic pre-converter mounting clip bolt (3) ,
- the catalytic pre-converter.
19B-13
19B
EXHAUST
19B
F9Q, and 804
REFITTING
and the catalytic pre-converter ( 20 Nm ) ,

- the catalytic pre-converter upstream stay
mounting nuts on the engine ( 30 Nm ) ,
WARNING
- the catalytic pre-converter upstream stay

mounting nuts on the catalytic pre-converter (
30 Nm ) ,
Always replace:
- the catalytic converter seal,
- the connector clip between the turbocharger
and the catalytic pre-converter.
- the catalytic pre-converter gearbox-side

downstream stay mounting bolts on the engine
( 50 Nm ) ,
On the workbench, refit the gearbox-side downstream stay to the catalytic pre-converter.
Tighten the gearbox-side downstream stay mounting bolts on the catalytic pre-converter so that they
make contact.
Fit the catalytic pre-converter to the engine.
Tighten the gearbox-side downstream stay mounting bolts on the engine so that they make contact.
Refit:
- the catalytic pre-converter gearbox-side

downstream stay mounting bolts on the catalytic pre-converter ( 50 Nm ) ,
- the catalytic pre-converter timing-end downstream stay mounting bolts on the engine ( 50
Nm ) ,
- the catalytic pre-converter timing-end downstream stay mounting nuts on the catalytic preconverter ( 30 Nm ) .
- the connector clip between the turbocharger and

the catalytic pre-converter,
Note:
- the catalytic pre-converter upstream stay.

- the catalytic pre-converter upstream stay mounting
nuts on the engine,
- the catalytic pre-converter upstream stay mounting
nuts on the catalytic pre-converter,
Loosen then tighten in order and until they make
contact:
Make sure there is no contact between the catalytic pre-converter and the turbocharger oil return
pipe.
Tighten to torque:
- the catalytic pre-converter outlet exhaust flange studs ( 7 Nm ) .
- the exhaust flange nuts ( 21 Nm ) ,
- 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.

WARNING
- the catalytic pre-converter timing-end downstream
stay mounting bolts on the engine,
- the catalytic pre-converter timing-end downstream

stay mounting nuts on the catalytic pre-converter,
WARNING
- the connector clip between the turbocharger and

the catalytic pre-converter.

Tighten to torque:
- the connector clip between the turbocharger
19B-14
tighten to torque the battery cover mounting bolts

( 4 Nm ) .
EXHAUST
Catalytic converter: Removal - Refitting
19B
Mot. 1495-01
22 mm socket for
Tightening torquesm
oxygen sensor
45 Nm
exhaust bracket studs
7 Nm
exhaust bracket nuts)
21 Nm
1
bolts
4 Nm
REMOVAL
101793

terminal.
Remove:
- the exhaust bracket mounting nuts (1) ,
F4R, and 770 or 771 K4J, and 730 or 732 K4M,

and 760 or 761
Remove the downstream oxygen sensor.
Cut the exhaust pipe (see 19B, Exhausts, General

information ).
19B-15
EXHAUST
REFITTING
WARNING
with the underbody.
Refit the downstream oxygen sensor.
Tighten to torque the oxygen sensor ( 45 Nm )
Refit and tighten to torque if necessary the exhaust
bracket studs ( 7 Nm ) .
Fit:
- the catalytic converter,
- the sleeve (see 19B, Exhausts, General information ).
WARNING
Always replace:
- the exhaust bracket seal.
- all the disconnected air inlet plastic pipes.
Tighten to torque the exhaust bracket nuts) ( 21
Nm )
Tighten the sleeve while easing the exhaust to ensure alignment.
Reconnect the oxygen sensor.
WARNING
( 4 Nm ) .
19B-16
19B
EXHAUST
19B
F9Q, and 800 or 808
Tightening torquesm
nuts mounting the catalytic converter onto the
turbocharger
30 Nm
catalytic converter stay

nut (timing end)
30 Nm

mounting bolt (timing
end)
44 Nm

mounting nut (flywheel
end)
21 Nm
exhaust bracket studs

(at the catalytic converter outlet)
7 Nm
exhaust bracket nuts (at

outlet)
21 Nm
exhaust pipe support

mounting bolt (on the
body)
21 Nm

bolts
4 Nm
101118
wheel bolts
Remove the nuts (1) from the exhaust bracket (at

the catalytic converter outlet).
Note:
Mark with a pen the position of the exhaust rubber mounting bush supports on the vehicle body.
110 Nm
REMOVAL

terminal.
Remove:
102116
Remove the mounting bolt (2) from the exhaust pipe

rubber mounting bush on the body.
19B-17
EXHAUST
19B
F9Q, and 800 or 808
102117
101120
Remove the (3) silencer rubber mounting bush bolt.
Remove:

vehicle.
- the catalytic converter stay mounting bolts (5) (timing end),

- the catalytic converter stay (timing end).
102479
Remove the catalytic converter stay mounting bolts

(4) (flywheel end).
19B-18
102313
Remove the engine tie-bar (6) .
EXHAUST
19B
F9Q, and 800 or 808

Refitting the stay at the timing end
101121
101120
Remove:
- the engine lifting bracket,
- the catalytic converter stay nut (timing end) ( 30

Nm ) (8) ,
- the nuts (7) securing the catalytic converter to the

turbocharger,
- the catalytic converter from underneath the vehicle.
REFITTING
WARNING
with the underbody.
The order for fitting catalytic converter stays must be
respected.
WARNING
The gaskets must always be replaced.
- the catalytic converter stay mounting bolts (timing
end),
- the stay mounting bolts (flywheel end),
- the catalytic converter nuts on the turbocharger,
Tighten to torque the nuts mounting the catalytic
converter onto the turbocharger ( 30 Nm ) .
19B-19
- the catalytic converter stay mounting bolt (timing end) ( 44 Nm ) (9) .
EXHAUST
19B
F9Q, and 800 or 808

Tighten to torque:
Refitting the stay at the timing end

10
102479
Tighten to torque and in order the catalytic converter stay mounting nut (flywheel end) ( 21 Nm )
(10) .
Note:
Make sure there is no contact between the catalytic conver ter and the turbocharger oil return
pipe.
Tighten to torque:
- the exhaust bracket studs (at the catalytic converter outlet) ( 7 Nm ) .
- the exhaust bracket nuts (at the catalytic converter outlet) ( 21 Nm ) ,
- the exhaust pipe support mounting bolt (on the
body) ( 21 Nm ) .
WARNING
19B-20
EXHAUST
19B
K9K, and 722 or 728 or 729 or 732
Tightening torquesm
turbocharger outlet
studs
7 Nm
catalytic converter
mounting nuts on the
turbocharger
26 Nm
upstream stay mounting bolts on the engine
44 Nm
d ownstream stay
gearbox
21 Nm
upstream stay mounting bolt on the catalytic

converter
25 Nm
d ownstream stay
catalytic converter
21 Nm
bolt securing the

exhaust pipe bracket
onto the body
21 Nm
catalytic converter outlet exhaust bracket

studs
7 Nm
2
3
102076
Remove:
- the exhaust pipe bracket mounting bolts (1) ,
- the catalytic converter stay mounting bolt (2) .
Loosen the other stay mountings on the gearbox.
21 Nm
ball joint bracket bolts

with their springs
21 Nm

bolts
4 Nm
Remove the stay (3) .
REMOVAL
terminal.
19B-21
EXHAUST
19B
K9K, and 722 or 728 or 729 or 732
102116
Remove the mounting bolt (4) from the exhaust pipe

rubber mounting bush on the body.
102077
Remove:
- the catalytic converter upstream stay mounting
bolts,
Note:
- the catalytic converter mounting nuts on the turbocharger (7) ,

102117
Remove the mounting bolt (5) from the silencer rubber mounting bush.
vehicle.
19B-22
EXHAUST
19B
K9K, and 722 or 728 or 729 or 732
REFITTING
WARNING
K9K, and 732
Always replace:
Tighten to torque the ball joint bracket bolts with

their springs ( 21 Nm ) .
- the catalytic converter seal,

- the turbocharger - catalytic converter bracket
studs.
Tighten to torque the turbocharger outlet studs ( 7

Nm ) .
Fit the catalytic converter.
- the upstream stay bolts on the engine,
WARNING
- the upstream stay bolts on the catalytic converter,
- the downstream stay bolts on the gearbox,

- the downstream stay bolts on the catalytic converter,
- the catalytic converter/turbocharger mounting nuts.
WARNING
Tighten to torque and in order

- the catalytic converter mounting nuts on the

turbocharger ( 26 Nm ) ,
- the upstream stay mounting bolts on the engine
( 44 Nm ) ,
- the downstream stay mounting bolts on the
gearbox ( 21 Nm ) ,
- the upstream stay mounting bolt on the catalytic converter ( 25 Nm ) ,
- the downstream stay mounting bolt on the catalytic converter ( 21 Nm ) ,
- the bolt securing the exhaust pipe bracket onto
the body ( 21 Nm ) ,
Note:
Make sure there is no contact between the catalytic conver ter and the turbocharger oil return
pipe.
K9K, and 722 or 728 or 729

Tighten to torque:
- the catalytic converter outlet exhaust bracket
studs ( 7 Nm ) ,
19B-23

( 4 Nm ) .
EXHAUST
19B
M9R, and 700
REMOVAL
Equipment required
roller-type stud removal tool

safety belt

Tightening torquesm
Remove:
14.5 Nm
catalytic converter
mounting clamp mounting bolts on the cylinder
block
21 Nm
catalytic converter
mounting nuts on the
turbocharger
21 Nm
catalytic converter halfclamp mounting bolts
21 Nm
stay mounting bolt on

8 Nm

the cylinder block
21 Nm

21 Nm
bolts of the ball-jointed

bracket with springs
21 Nm
silencer rubber mounting bush mounting bolt
21 Nm
exhaust pipe rubber

mounting bush mounting bolt
21 Nm

- the acoustic protection clips on the scuttle panel
partition,
- the acoustic protection.
114986
Remove:
- the nuts (1) mounting the catalytic converter to the
turbocharger,
IMPORTANT
19B-24
EXHAUST
19B
M9R, and 700
114771
Remove:
- the lower engine tie-bar (see 19D, Engine mounting, rear suspended engine mounting: Removal - Refitting ).
- the catalytic converter stay mounting bolt (2) ,
- the catalytic converter stay mounting nuts (3) ,
- the nuts (4) mounting the stay on the cylinder
block,
- the catalytic converter stay,
- the catalytic converter studs using a roller-type
stud removal tool .
19B-25
114991
Remove the bolts from the ball-jointed bracket (5)

with springs.
EXHAUST
19B
M9R, and 700

CONCERNED
102116
114980
Remove:
- the catalytic converter half-clamp mounting bolts
(8) ,
- the catalytic converter half-clamps (9) .
Remove the catalytic converter, timing end.
Fit the catalytic converter using a safety belt to the
lifting eye on the timing end.
102117
Note:
Remove:
- the exhaust pipe rubber mounting bush mounting
bolt (6) ,
- The silencer rubber mounting bush mounting bolt
(7) .
Detach the exhaust pipe.
19B-26
EXHAUST
19B
M9R, and 700
REFITTING
Remove the seal from the ball-jointed bracket.
Remove the turbocharger studs using a roller-type
stud removal tool .
- on the exhaust pipe,
- on the catalytic converter in case of reuse,
- the turbocharger,
Refit the new studs onto the turbocharger using a
roller-type stud removal tool .
Tighten to torque the studs on the turbocharger (
14.5 Nm ) .
Fit the new catalytic converter mounting clamps onto
the cylinder block.
114981
Remove:
- the catalytic converter mounting clamp mounting
bolts (10) ,
- the catalytic converter mounting clamps.
Remove the safety belt .
Move the engine towards the front of the vehicle.
114843
Remove the catalytic converter.
19B-27
Finger tighten the catalytic converter mounting

clamp mounting bolts on the cylinder block until contact is made.
Tighten to torque the catalytic converter mounting
clamp mounting bolts on the cylinder block ( 21
Nm ) .
EXHAUST
19B
M9R, and 700

- the stay mounting bolt on the catalytic converter ( 8 Nm ) ,

CONCERNED
- the stay mounting nuts on the cylinder block (

21 Nm ) ,
- the stay mounting nuts on the catalytic converter ( 21 Nm ) .
mounting, Rear suspended engine mounting:
Tighten to torque the lower engine tie-bar (see 19D,
Engine mounting, Rear suspended engine
mounting: Tightening torque ).
Refit the new seal to the ball-jointed bracket.
Fit the exhaust pipe.
114844
Move the engine towards the front of the vehicle.
Refit:
Fit:
- the exhaust pipe rubber mounting bush mounting

bolt, aligning the marks,
- the new seal between the turbocharger and the catalytic converter,
- the silencer rubber mounting bush mounting bolt,

aligning the marks,
- the ball-jointed bracket bolts with springs.
Refit the catalytic converter onto the turbocharger.
Tighten to torque:
Fit:
- the new catalytic converter nuts onto the turbocharger,
- the bolts of the ball-jointed bracket with springs

( 21 Nm ) ,
- the silencer rubber mounting bush mounting
bolt ( 21 Nm ) ,
- the new catalytic converter half-clamps.

Refit:
- the catalytic converter studs using a roller-type
stud removal tool ,
- 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 acoustic protection,
- the stay mounting nuts on the catalytic converter,
- the acoustic protection clips on the scuttle panel

partition,
- the stay mounting nuts on the cylinder block.

Tighten to torque:

- the catalytic converter mounting nuts on the

turbocharger ( 21 Nm ) ,
- the catalytic converter half-clamp mounting

bolts ( 21 Nm ) ,
19B-28
EXHAUST
Expansion chamber: Removal - Refitting
19B
REFITTING
Tightening torquesm
bolts securing the rubber mounting bush support on the expansion
chamber
8 Nm
bolts securing the rubber mounting bush support on the body
21 Nm
WARNING
Cut the new expansion chamber pipe (see 19B,
Exhaust, General Vehicle Information ).
Fit:
- the expansion chamber,
Tighten to torque:
REMOVAL
- the bolts securing the rubber mounting bush

support on the expansion chamber ( 8 Nm ) ,
Position the vehicle on a lift.

Vehicle Information ).

support on the body ( 21 Nm ) .
Tighten the sleeves, while easing the exhaust pipe
to ensure the correct alignment of the pipe .

WARNING
The sleeve tightening nuts and bolts assembly must be positioned so that it cannot come
into contact with the underbody.
101818
Remove:
- the bolts (1) securing the expansion chamber to the
rubber mounting bush support,
- the expansion chamber.
Note:
If the rubber mounting bushes are damaged,
mark the position of the support on the
bodywork, then replace the support / rubber
mounting bush assembly .
19B-29
EXHAUST
Silencer: Removal - Refitting
19B
REFITTING
Fit:
Tightening torquesm
bolts securing the rubber mounting bush on
the silencer
8 Nm
bolts securing the rubber mounting bush support on the body
21 Nm
- the silencer,
Tighten to torque:
- the bolts securing the rubber mounting bush on
the silencer ( 8 Nm ) ,
support on the body ( 21 Nm ) .
REMOVAL
Tighten the sleeve, while easing in the exhaust pipe

to ensure the correct alignment of the pipe.

information ).
WARNING
The sleeve tightening nut and bolts assembly
must be positioned so that it cannot come into
contact with the underbody.
101817
Remove:
- the silencer mounting bolts (1) on the rubber mounting bush support,
- the the silencer.
Note:
If the rubber mounting bushes are damaged:
- mark the position of the mounting on the vehicle
body,
- replace the support / rubber mounting bush
fitting assembly .
19B-30
EXHAUST
Particle filter: Function
19B
F9Q, and 804

The extent to which the particle filter is clogged depends on the user's driving style:
Equipment required
- during an average trip (combined cycle and motorway

of more than 15 minutes ), the particle filter automatically burns the particles without being noticed by the
customer (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 tapping circuit,
except at the level of the unions on the exhaust pipe
(only the supplier can guarantee pressure tapping circuit sealing),
- 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.
- if the operating temperature is not high enough to trigger spontaneous regeneration, clogging increases
until it exceeds 35 g ; 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 pollutant 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 continuously evaluates the level of clogging of the particle filter using the pressure
difference upstream and downstream of the particle filter. When it is clogged, the two temperature values inform the injection computer that the temperature
conditions are high enough (approximately 600C ) to
trigger regeneration.
This consists of burning the particles held in the particle filter: to do this, the injection switches to delayed
injection mode and the fuel not burned in the combustion chambers burns the residues contained in the
particle filter cells.
19B-31
EXHAUST
Particle filter: Removal - Refitting
19B
F9Q, and 804
Tightening torquesm
rubber mounting bush
support mounting nut on
the particle filter
25 Nm

between the connection
hose and the catalytic
pre-converter
21 Nm

nuts on the sub-frame
25 Nm
exhaust sleeve nut
25 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 onto 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.
Cut the exhaust pipe after the particle filter (see 19B,
Exhaust : repair precautions ) and (see 19B, Exhaust: General information ).
19B-32
EXHAUST
19B
F9Q, and 804
111881
Remove the heat shield (3) mounting clip then move

it aside slightly
Unpick the downstream pressure measurement tapping and also the downstream temperature sensor
cabling from the heat shield.
111885
Disconnect the upstream and downstream temperature sensor offset connectors (6) .
Unpick the upstream and downstream temperature
sensor offset connectors (6) .
Pass the downstream pressure measurement tapping into the engine compartment whilst leaving the
pressure sensor complete.
111885
Remove:
111882
Disconnect the particle filter pressure sensor connector (4) located in the engine compartment.
Remove the retaining clip (5) from the cabling on the
particle filter pressure sensor mounting.
19B-33
- the bolt (7) securing the filter particle pressure sensor mounting located in the engine compartment.
- the particle filter pressure sensor assembly (8) and
its mounting.
EXHAUST
19B
F9Q, and 804
107038
Remove:
REFITTING
- the nuts (9) on the exhaust flange between the connection hose and the catalytic pre-converter,
WARNING
- the sub-frame rubber mounting bush bolts (10) ,

- the particle filter.
Always replace:
Remove the particle filter assembly:
- the seal between the hose and particle filter,
- the rubber mounting bush,
- the seal between the hose and the catalytic preconverter,
- 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-34
- any adapter on the exhaust pipe that has been

loosened,
WARNING
Always clean the bearing surfaces of the connection hose - par ticle filter flanges thoroughly.
With particle filter 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 on their adapters on the exhaust pipe (see
19B, Exhaust, Particle filter temperature sensors: Removal - Refitting ).
adapter on the exhaust line (see 19B, Exhaust,
- the rubber mounting bush on the particle filter.
Torque tighten the rubber mounting bush support
mounting nut on the particle filter ( 25 Nm ) .
Place the pressure sensor and its mounting in the
engine compartment before fitting the particle filter.
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
Vehicle Information ) by applying sealing mastic for
the exhaust.
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-35
106673
WARNING
All the adapters on the exhaust pipe (12) must be
replaced.
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 this 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 onto 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-36
EXHAUST
F9Q, and 804
WARNING
Connect the battery, starting with the positive terminal. carry out the necessary programming (see
80A, Battery: Removal - Refitting ).
Use the diagnostic tool to clear any faults which may
be stored by the injection computer before restarting
the engine.
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.
- 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-37
19B
EXHAUST
Particle filter pressure sensor: Removal - Refitting
19B
F9Q, and 804

Tightening torquesm
21 Nm
upstream pressure
measurement tapping
on its union bolted onto
the exhaust pipe
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 and Refitting ).
19B-38
EXHAUST
19B
F9Q, and 804
3
2
4
6
106670
Remove the upstream pressure pipe (1) from its intermediary adapter (2) bolted to the exhaust pipe.
WARNING
111885
Remove:
- the mounting nut (3) from the particle filter pressure
sensor mounting (4) ,
- the particle filter pressure sensor:
When removing the pressure measurement tapping (1) from its adapter it is essential to open
the adapter (2) 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
assembly if necessary, this is supplied assembled by the Parts Department (see Particle
filter : repair precautions, Safety instructions
).
WARNING
The pressure measurement circuit must never be
opened except at the level of the adapters on the
exhaust pipe.
19B-39
EXHAUST
F9Q, and 804
REFITTING
106673
WARNING
Each exhaust pipe intermediary adapter (7) that
is removed must be replaced.
Coat the upstream pressure measurement tapping
threads with ANTI-SEIZE high temperature grease.
WARNING
the threading.
19B-40
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 ) with the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measurement tapping on its union bolted onto the exhaust pipe ( 21 Nm ) .
Refit the particle filter (see 19B, Exhaust, Particle
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).
Use the diagnostic tool to clear any faults which may
19B-41
be stored by the injection computer before restarting

the engine.
EXHAUST
Particle filter temperature sensors: Removal - Refitting
19B
F9Q, and 804

Tightening torquesm
Equipment required
diagnostic tool
Tightening torquesm
adapter, if it has been
replaced
44 Nm
upstream particle filter

temperature sensor.
30 Nm
adapter, if it has been

replaced
44 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-42
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.
106671
Remove the upstream particle filter temperature

sensor (1) from its adapter (2) bolted onto 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
Always replace any adapter (2) that has been

removed from the exhaust pipe.
Disconnect the downstream particle filter temperature sensor offset connector (3) .
Tighten to torque the adapter, if it has been replaced ( 44 Nm ) .

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:
- that there is no contact with the wiring harness,
19B-43
EXHAUST
19B
F9Q, and 804

2 - Refitting
WARNING
Always replace any adapter (3) that has been
removed from the exhaust pipe.
Tighten to torque the adapter, if it has been replaced ( 44 Nm ) .
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
Unpick 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.
Connect the battery, starting with the positive terminal
WARNING
Carry out the necessary programming (see section 80A, Battery: Removing - Refitting ).
Before restarting the engine, use the diagnostic
tool to clear any faults stored by the injection computer.
106671
Remove the downstream particle filter temperature

sensor (4) from its adapter (5) bolted onto 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-44
EXHAUST
Connecting hose: Removal - Refitting
19B
F9Q, and 804

Tightening torquesm
exhaust flange nuts
21 Nm
Tighten to torque the exhaust flange 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 for the exhaust flange between the connection hose and the particle filter,
- the connection hose.
REFITTING
WARNING
Always 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 hose connection flanges for the catalytic
pre-converter connection,
- 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-45
EXHAUST
19B
F9Q, and 804

Follow this procedure:
PROCEDURE FOR FORCED REGENERATION OF

THE PARTICLE FILTER USING THE CLIP
DIAGNOSTIC TOOL
- run command SC017 or VP040 ,

- during regeneration, the engine speed will be held
at 1500 rpm , and the engine noise changes (delayed injection),
Command SC017: REGENERATION OF THE

PARTICLE FILTER
- the exhaust fumes rise in temperature and burn the

soot retained in the particle filter,
Note:
- the command lasts for approximately 30 minutes ,
Only run this command under the following conditions:
- when the engine speed returns to idle speed the

command has terminated,
- fault DF308 Particle filter clogged , or DF312

Number of regenerations exceeded , or
DF383 Particle filter regeneration impossible
present,
- check the quantity of soot contained in the particle

filter PR383 < 10 .
Note:
- soot weight in the particle filter greater than

45 g .
Be prepared for strong odours and thick smoke

during particle filter regeneration.
Once forced regeneration of the particle filter is complete:
IMPORTANT
During the forced regeneration of the particle filter, the temperature in the exhaust pipe rises
significantly.
- deal with the present faults,

- clear the stored faults.
Try to carry out this procedure outside the workshop if possible or use an exhaust gas extractor
approved for high temperatures.
Allow the engine to cool down.

Replace the oil filter.
Top up the oil.
WARNING
Check the engine oil level before running the
command to avoid any engine racing.
Note:
The level should be between MIN and

MAX on the dipstick.
The level should be between MIN and

MAX on the dipstick.
To run this command, select the specific commands mode on the Clip tool, and select command
SC017 or VP040 .
Note:
If necessary, regeneration can be stopped by
pressing the engine start button twice in succession.
19B-46
EXHAUST
19B
F9Q
For the particle filter forced regeneration procedure,
see MR 366 or MR 372 Fault finding, 13B, Diesel
injection, Fault finding, Interpretation of commands, Particle filter regeneration .

Mot. 1329
Mot. 1018
Sump plug tool.
Note:
If required, the forced regeneration procedure
may be stopped by pressing the engine Start button twice in succession.
Equipment required
diagnostic tool
kit for particle filter
Note:
Be prepared for strong odours and thick smoke
during particle filter forced regeneration.
Tightening torquesm
engine drain plug
20 Nm
rubber mounting
bushes on the body
21 Nm

on the connector pipe
8 Nm

on the rear silencer
8 Nm
When particle filter forced regeneration is complete,

using the diagnostic tool:
- deal with the present faults,
- clear the stored faults.
IMPORTANT
Allow the engine to cool before draining the oil.
PROCEDURE FOR PARTICLE FILTER FORCED

REGENERATION USING THE CLIP DIAGNOSTIC
TOOL
Remove the oil filter using the (Mot. 1329) .

Coat the new oil filter sealing ring with engine oil.
Connect the diagnostic tool to the vehicle.
Tighten the oil filter until the seal makes contact with
the engine.
IMPORTANT
Tighten the new oil filter manually 3/4 of a turn.
During forced regeneration of the particle filter,

the temperature in the exhaust pipe rises significantly.
Wipe away any excess oil.

Remove the engine oil filler cap.
Be sure either to carry out the operation outside

the workshop, or to use the kit for particle filter
, approved for high temperatures, on the exhaust
gas extractors in the workshop.
Remove the sump drain plug using the (Mot. 1018)

or an 8 mm square male drain pipe union .
Allow all the engine oil to flow into a drain tray.
WARNING
To prevent engine racing, check the engine oil
level using the dipstick before running the forced
regeneration command.
The engine oil level must be between the
MIN and MAX marks on the dipstick.
19B-47
EXHAUST
19B
F9Q
For the connector pipe and rear silencer rubber
mounting bushes, tighten to torque:
Rubber-lipped seal
- the mounting bolt of the rubber mounting bushes

on the body ( 21 Nm ) ,
- the mounting bolts of the rubber mounting bush
on the connector pipe ( 8 Nm ) ,
- the mounting bolts of the rubber mounting bush
on the rear silencer ( 8 Nm ) ,
113765
Refit the drain plug with its new seal (no fitting direction).
Tighten to torque the engine drain plug ( 20 Nm ) .
Clean any traces of the drained oil from the sump.
Refill the engine oil.
Refit the filler plug.
Wait for 10 minutes .
Check the oil level using the dipstick.
Top up if necessary.
Note:
The engine oil level must be between the
MIN and MAX marks on the dipstick.
After any particle filter forced regeneration operation, always replace:
- the particle filter rubber mounting bush on the axle
sub-frame (see MR 364 or MR 370, 19B, Exhaust,
Particle filter: Removal - Refitting ),
- the particle filter pressure sensor with its upstream
and downstream pressure measurement tappings
(see MR 364 or MR 370, 19B, Exhaust, Particle
filter pressure sensor : Removal - Refitting ),
- the exhaust connector pipe rubber mounting bush
on the body,
- the rear silencer rubber mounting bush on the body.
19B-48
RESERVOIR
19C
Mot. 1311-08
DRAINING THE FUEL TANK
Union for measuring

fuel pressure
K4J, and 730 or 732 F4R, and 770 or 771 or 776
WARNING
During this operation, it is essential to:

close to the work area,
- guard against petrol splashes caused by the residual pressure in the pipes,
WARNING
The ignition must be switched off during this operation.
1
101496
Disconnect the fuel inlet union (1) .

Position and fit a (3) T (Mot. 1311-08) union.
Fit a pipe (2) long enough to carry the fuel into a container to the T -union outlet.
19C-1
RESERVOIR
19C
K4M, and 760 or 761
4
2
102502
101803
Place the electrical connector (4) to one side without

disconnecting it.
Disconnect the fuel inlet union (1) .

Position and fit a (3) T (Mot. 1311-08) union.
Fit a pipe (2) long enough to carry the fuel into a container to the T -union outlet.
Remove the protection and switching unit cover.
102503
Disconnect the brown connector (6) from the Protection and Switching Unit.
19C-2
RESERVOIR
12
102501
Connect terminal (5) of the brown connector to a +

battery supply to operate the fuel pump.
Let the petrol flow out until it comes intermittently.
Disconnect the + battery supply from terminal (5) .
Note:
It is also possible to use the pneumatic siphoning
Pump tool for draining the fuel tank (see catalogue entitled Equipment) , to be adapted on the
union at T (Mot. 1311-08) .
19C-3
19C
RESERVOIR
19C
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
Equipment required
petrol or diesel tank drain pneumatic siphoning
pump
IMPORTANT
close to the work area,
union,
DRAINING THE FUEL TANK
102460
Remove the carpet retaining clip.

Take out the carpet.
99641

terminal.
Note:
Since diesel vehicles are not fitted with an electrical fuel pump, the petrol or diesel tank drain
pneumatic siphoning pump tool must be used
to drain the tank.
102461
Lift up the cushion from the rear bench seat (see

Workshop repair Manual 365 Bodywork, 76A,
Rear seat mountings and runners, Complete
seat base ).
Remove:
- the closure panel mounting bolts (1) ,
- the closure panel,
- the inspection flap blanking cover (2) .
19C-4
RESERVOIR
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 K9K, and 722 or 728 or 729 or 732
102462
Disconnect:
- the fuel tank sender connector (3) ,
- the body height sensor connector (4) (if fitted),
- union (5) .
Make preparations for the fuel outflow.
Connect the rubber suction pipe of the petrol or diesel tank drain pneumatic siphoning pump to the
diesel fuel supply quick-release union, and the siphoning pump's backflow pipe to the container (5) .
Run the petrol or diesel tank drain pneumatic siphoning pump .
Let the fuel flow out until it comes intermittently.
Drain the tank.
WARNING
19C-5
19C
RESERVOIR
19C
F4R or K4J or K4M
3
1
11
9
2
12
13
10
7
5
5
2
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 leak prevention valve in case of vehicle roll-over
12
Anti-backflow pipe (degassing - filling)
13
Petrol suction assembly
19C-6
RESERVOIR
19C
F4R or K4J or K4M
3
4
10
13036
No.
Description
Connection to petrol vapour absorber
Overfill prevention ball
19C-7
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-8
RESERVOIR
19C
1
2
2
10
7
5
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 suction assembly
19C-9
RESERVOIR
19C
2
8
1
13036-1
No.
Description
Fresh air vent
Overfill prevention ball
19C-10
RESERVOIR
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 unleaded fuel has a leaktight cap.
19C-11
19C
RESERVOIR
Fuel tank: Removal - Refitting
Equipment required
19C
F4R or K4J or K4M

Remove the petrol vapour absorber (see 14A, Antipollution, Petrol vapour absorber ).
component jack
Unclip the petrol vapour absorber pipes.

Tightening torquesm
wheel bolt
fuel tank mounting
bolts
Disconnect the connectors on the Pump-SenderFilter assembly (see 19C, Fuel tank, Pump-Sender-Filter ).
110 Nm
21 Nm
4 Nm
IMPORTANT

- refrain from smoking or bringing red-hot objects
near the working area,
- watch out for fuel splashes when disconnecting
the union,
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Draining
the fuel tank ).
Remove the pump-sender-filter assembly (see
19C, Fuel tank, Pump-sender-filter ) for petrol engines or the sender (see 19C, Fuel tank, Sender )
for diesel engines.
102465
Remove:
- the mounting bolts (1) from the fuel tank and the
heat shield,

terminal.
- the heat shield mounting clips (2) ,
Remove:
- the heat shield (3) .

- the nuts mounting the exhaust clamp on the manifold,
- the bolt mounting the expansion chamber on the
body,
- the bolts connecting the silentbloc mounting to the
silencer,
- the exhaust pipe from the sub-frame and the rear
axle.
Disconnect the headlight height adjustment sensor
wiring (depending on vehicle equipment level).
Unclip the headlight height adjustment sensor linkage (depending on vehicle equipment level).
19C-12
RESERVOIR
19C
102467
Remove mounting clips (4) from the brake and fuel

pipes.
Unclip:
102466
Position the component jack under the tank.

Remove the fuel tank mounting bolts (6) .
Lower the fuel tank.
- the fuel pipe unions at the catalytic converter,

- the clips from the fuel pipes.
102459
5
102468
Remove the tank by turning it around the exhaust pipe.
Remove fuel tank filler neck hose connection clips

(5) .
Take care not to damage the brake pipes or the parking brake cable.
Move the hoses to one side.
19C-13
RESERVOIR
REFITTING
Reshape the heat shield.
Take care not to bring the heat shield into contact
with the fuel tank.
The tank hose securing clips must always be replaced.
Tighten to torque:
- the wheel bolt ( 110 Nm ) ,
- the fuel tank mounting ( 21 Nm ) .
Check that the fuel pipe unions click into place.
Refit the pump-sender-filter assembly (see 19C,
Fuel tank, Pump-sender-filter ) for petrol engines
or the sender (see 19C, Fuel tank, Sender ) for diesel engines.
WARNING
( 4 Nm ) .
19C-14
19C
RESERVOIR
Filler neck: Removal - Refitting
19C
Tightening torquesm
bolts
4 Nm
3
IMPORTANT
near the working area,
- watch out for fuel splashes when disconnecting
the union,
REMOVAL
Drain the fuel tank (see 19C, Fuel 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.
104559
Remove:
- the filler neck mounting bolts (4) ,
- the filler neck.
1
102468
REFITTING
Disconnect the anti-backflow pipe (1) .
Always replace the clips with new ones.
Remove filler pipe clips (2) .

WARNING
19C-15
RESERVOIR
Filler neck: Removal - Refitting
( 4 Nm ) .
19C-16
19C
RESERVOIR
Sender unit: Removal - Refitting
19C
F9Q or K9K or M9R

Mot. 1397
Universal spanner for

removing fuel sender
nut
Tightening torquesm
bolts
4 Nm
IMPORTANT
union,
102461
Remove:

REMOVAL
terminal.
Lift up the rear bench seat base (see MR 365 Bodywork, 76A, Rear seat runners and frames,
Complete seat base ).
Move the carpet to one side.
19C-17
- the blanking cover (2) on the inspection flap.
RESERVOIR
19C
F9Q or K9K or M9R
104546
Disconnect:
104547
Remove the nut from the sender using tool (Mot.

1397) (5) .
- electrical connectors (3) ,
Remove the sender unit, being careful with the float.
- quick-release union(s) (4) .

Prepare for fuel outflow.
Fit the correct blanking plugs into the unions (see
MR 364 Mgane, 13B, Injection: Cleanliness guidelines ).
19C-18
WARNING
Refit the sender nut as soon as the sender has
been removed to prevent any deformation of the
fuel tank.
RESERVOIR
F9Q or K9K or M9R
REFITTING
102470
Replace the O-ring seal.

Refit the sender unit by aligning mark (6) on the sender with mark (7) on the tank.
Position nut (9) .
Tighten the nut (9) until mark (8) on the nut is aligned
with mark (7) on the tank and mark (6) on the sender.
Connect the battery starting with the positive terminal (see MR 364 Mgane, 80A, Battery: Removal Refitting ).
( 4 Nm ) .
19C-19
19C
RESERVOIR
Pump-sender unit-filter: Removal - Refitting
19C
K4M F4R K4J

Mot. 1397
Universal spanner for

removing fuel sender
nut
Tightening torquesm
bolts
4 Nm
2
IMPORTANT
union,
102461
Remove:
REMOVAL

terminal.
- the blanking cover (2) on the inspection flap.
Lift up the rear bench seat base (see MR 365 Bodywork, 76A, Rear seat runners and frames,
Complete seat base ).
Move the carpet to one side.
104546
Disconnect:
- electrical connectors (3) ,
- quick-release union(s) (4) .
Prepare for fuel outflow.
19C-20
RESERVOIR
Pump-sender unit-filter: Removal - Refitting
19C
K4M F4R K4J
REFITTING
104547
Remove the nut from the pump/sender/filter assembly using tool (Mot. 1397) (5) .
Remove the pump/sender/filter assembly, being careful not to damage the float.
102470
Replace the O-ring seal.

Refit the pump/sender/filter assembly, aligning mark
(6) on the pump/sender/filter assembly with mark (7)
on the tank.
WARNING
Position the nut (9) .
Refit the pump/sender/filter assembly nut as

soon as the pump/sender/filter assembly has
been removed to prevent any deformation of the
fuel tank.
Tighten the nut (9) until the mark (8) on the nut is aligned with mark (7) on the tank and mark (6) on the
pump/sender/filter assembly.
Connect the battery starting with the positive terminal (see MR 364 Mechanical systems, 80A, Battery: Removal - Refitting ).
( 4 Nm ) .
19C-21
RESERVOIR
Petrol filter: General information
102299
The fuel filter is located in the fuel tank; it is built 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-22
19C
RESERVOIR
Fuel level sensor: Checking
19C
Checking the sender unit

Capacity
Resistance value
between terminals A1
and B2 () 10
Height H (mm) 6mm
Tank full
20
upper stop
Tank 3/4 full
95
150
Tank 1/2 full
170
111
Tank 1/4 full
245
72
Spare
290
40
Tank empty
320
lower stop
MEASURING 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-23
ENGINE MOUNTING
19D
K4J, and 730 or 732 K4M, and 760, and JR5
7
4
6
5
103235
Tightening torques (in Nm)

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
180
(7)
62
19D-1
ENGINE MOUNTING
19D
K9K, and 722 or 728
10
9
4
8
7
6
5
3
7
2
103236

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
62
(7)
21
(8)
62
(9)
180
(10)
62
19D-2
ENGINE MOUNTING
19D
F9Q, and 800 or 804 or 808
12
11
10
5
3
4
8
103237

(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
K4M, and 761
7
6
9
8
3
1
8
5
2
103274

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
180
(7)
62
(8)
21 for M8 bolts
62
bolts
(9)
for M10
62
19D-4
ENGINE MOUNTING
19D
F4R, and 770 or 771 or 776
12
7
11
10
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
(10)
62
(11)
180
(12)
62
19D-5
ENGINE MOUNTING
19D
F4R, and 770 or 771 or 776
12
11
9
10
5
3
13
4
1
103244

(1)
62
(2)
105
(3)
105
(4)
62
(5)
62
(6)
180
(7)
105
(8)
62
(9)
21
(10)
62
(11)
180
(12)
62
19D-6
ENGINE MOUNTING
19D
9
8
4
5
3
1
1
110743

(1)
62
(2)
105
(3)
62
(4)
105
(5)
62
(6)
62
(7)
62
(8)
62
(9)
62
19D-7
ENGINE MOUNTING
19D
K9K, and 732
113926
(1)
62
(2)
62
(3)
105
(4)
115
(5)
62
(6)
180
(7)
105
(8)
62
(9)
105
(10)
62
(11)
62
19D-8
ENGINE MOUNTING
Suspended engine mounting: Tightening torque
19D
K9K, and 732
113926
No.
Description
Tightening
torque
(Nm)
(1)
Bolt mounting the lower engine tie-bar on the sub-frame
105
(2)
Bolt mounting the lower engine tie-bar onto its support
180
(3)
62
(4)
Bolt mounting the upper engine tie-bar onto the bodywork
105
(5)
Bolt mounting the upper engine tie-bar onto the engine
115
(6)
Bolt mounting the right-hand suspended mounting support on the body
62
(7)
Bolt mounting the right-hand suspended mounting support on the engine
62
(8)
Bolt mounting the left-hand suspended mounting support onto the gearbox
62
(9)
Bolt mounting the left-hand suspended mounting support on the body
62
(10)
Left-hand rubber pad mounting nut on the gearbox mounting
62
(11)
Left-hand rubber pad mounting bolts on the body mounting
105
19D-9
ENGINE MOUNTING
19D
M9R, and 700
114630
No.
Description
Tightening torque (Nm)
(1)
Bolt mounting the lower engine tie-bar on the sub-frame
105
(2)
180
(3)
Lower engine tie-bar support mounting bolt
62
(4)
Bolt mounting the upper engine tie-bar onto the bodywork
105
(5)
Bolt mounting the upper engine tie-bar onto the engine
115
(6)
Bolt mounting the right-hand suspended mounting support on the body
62
(7)
Bolt mounting the right-hand suspended mounting support on the engine
62
(8)
Bolt mounting the left-hand suspended mounting support onto the gearbox
105
(9)
Bolt mounting the left-hand suspended mounting support on the body
62
(10)
Left-hand rubber pad mounting nut on the gearbox mounting
62
(11)
Left-hand rubber pad mounting bolts on the body mounting
62
19D-10
ENGINE MOUNTING
19D
106075
No.
Tightening torque (Nm)
(1)
62
(2)
105
(3)
105
(4)
62
(5)
62
(6)
180
(7)
105
(8)
62
(9)
62
(10)
21
(11)
105
(12)
180
(13)
62
19D-11
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting
19D
K9K, and 732

Mot. 1453
Multiple-adjusting
straps
Tightening torquesm
left-hand suspended
gearbox
62 Nm
left-hand suspended
body
62 Nm
left-hand rubber pad

body mounting
105 Nm
left-hand rubber pad

mounting nut on the
gearbox mounting
62 Nm
101822
Disconnect the engine management computer connectors (1) .

Unclip:
REMOVAL
- the battery negative terminal wiring harness,

- the wiring harness from the battery tray.

Remove:
Remove:
- the battery tray with the computer and its support.
- the scuttle panel grille (see MR365 Bodywork,

- the battery (see 80A, Battery: Removal - Refitting ).
102450

Mark the position of the suspended mounting on the
body.
19D-12
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting
19D
K9K, and 732

Tighten to torque the left-hand suspended mounting bolts on the body ( 62 Nm ) .

CONCERNED
Refit the left-hand rubber pad.

Refit the left-hand rubber pad mounting nut onto the
gearbox mounting and the left-hand rubber pad
mounting bolts onto the body mounting.
Tighten to torque:
- the left-hand rubber pad mounting bolts on the
body mounting ( 105 Nm ) ,
- the left-hand rubber pad mounting nut on the
gearbox mounting ( 62 Nm ) .
Refit:
- the battery tray with the engine management computer and its support,
- the battery tray mounting bolts.
112655
Remove:
Clip:
- the battery negative terminal wiring harness,
- the left-hand rubber pad mounting nut (3) on the

gearbox mounting,
- the left-hand rubber pad mounting bolts (4) on the
body mounting,
- the rubber pad,
- the bolts (5) mounting the left-hand suspended
mounting on the body,
- the left-hand suspended mounting on the body,
- the bolts (6) mounting the left-hand suspended
mounting on the gearbox.
- the gearbox left-hand suspended mounting.
REFITTING
CONCERNED
Refit the gearbox left-hand suspended mounting.
Refit the bolts mounting the left-hand suspended
mounting on the gearbox.
Tighten to torque the left-hand suspended mounting bolts on the gearbox ( 62 Nm ) .
Refit the left-hand suspended mounting on the body.
Refit the bolts mounting the left-hand suspended
mounting on the body,
19D-13
- the wiring harness onto the battery tray.

Connect the engine management computer connectors.
Refit:
- the scuttle panel grille (see MR 365, 55A, Exterior
protection, Scuttle panel grille ),
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting
19D
K9K, and 732

Mot. 1453
Multiple-adjusting
straps
Tightening torquesm
bolts mounting the
right-hand suspended
mounting on the body
62 Nm
bolts mounting the

right-hand suspended
mounting support on the
engine
62 Nm
upper engine tie-bar

engine
115 Nm
upper engine tie-bar

body
105 Nm
102450

Mark the position of the suspended mounting on the
body.
CONCERNED
REMOVAL
- Refitting ).
Remove the scuttle panel grille (see MR 365, Bodywork, 55A, Exterior protection, Scuttle panel
grille ).
113927
Remove:
- the upper engine tie-bar mounting bolt (2) on the
engine,
- the upper engine tie-bar mounting bolt (1) on the
body,
- the bolts (3) mounting the suspended mounting on
the body,
19D-14
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting
K9K, and 732
- the bolts (4) mounting the suspended mounting on
the engine,
- the suspended mounting.
REFITTING
CONCERNED
Refit:
- the right-hand suspended mounting support,
- the bolts mounting the right-hand suspended
mounting support on the body,
mounting on the engine,
- the upper engine tie-bar mounting bolt onto the body,
- the upper engine tie-bar mounting bolt onto the engine,
Tighten to torque:
mounting on the body ( 62 Nm )
mounting support on the engine ( 62 Nm )
- the upper engine tie-bar mounting bolt on the
engine ( 115 Nm )
- the upper engine tie-bar mounting bolt on the
body ( 105 Nm )
Remove the (Mot. 1453)
Refit the scuttle panel grille (see MR 365, Bodywork, 55A, Exterior protection, Scuttle panel
grille ).
Connect the battery (see 80A, Battery: Removal Refitting).
19D-15
19D
ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting
19D
K9K, and 732
REFITTING
Tightening torquesm
bolt mounting the
engine tie-bar on its
support
180 Nm
bolt mounting the

engine tie-bar on the
sub-frame
105 Nm
Refit:
- the bolt mounting the engine tie-bar on its support
- the bolt mounting the engine tie-bar on the sub-frame
Tighten to torque:
- the bolt mounting the engine tie-bar on its support ( 180 Nm ) ,
REMOVAL
- the bolt mounting the engine tie-bar on the subframe ( 105 Nm ) .


- Refitting ).
Remove the engine undertray

CONCERNED
112653
Remove:
- the bolt mounting the engine tie-bar on the sub-frame (1) ,
(2) .
19D-16

ENGINE MOUNTING
Rear suspended engine mounting: Removal - Refitting
19D
M9R, and 700
Tightening torquesm
bolt mounting the
engine tie-bar on its
support
180 Nm
bolt mounting the

engine tie-bar on the
sub-frame
105 Nm
REMOVAL
- Refitting ).
Remove the engine tie-bar.
- by pushing it back (1) to detach it from its support,
114632
- by pivoting it (2) to the right.

CONCERNED
REFITTING
Refit:
- the bolt mounting the engine tie-bar on the sub-frame
Tighten to torque:
- the bolt mounting the engine tie-bar on its support ( 180 Nm ) ,
- the bolt mounting the engine tie-bar on the subframe ( 105 Nm ) .
114650
Remove:
- the bolt mounting the engine tie-bar on the sub-frame,
- the bolt mounting the engine tie-bar on its support.
19D-17

MR364MEGANE1

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1

Engine and peripherals

ENGINE AND LOWER ENGINE ASSEMBLY

TOP AND FRONT OF ENGINE

All copyrights reserved by Renault.

Renault s.a.s. 2005

X84, and B84 or C84 or G84 or S84

All copyrights reserved by Renault.

Renault s.a.s. 2005

Mgane II - Section 1ContentsPage

ENGINE AND LOWER ENGINE ASSEMBLY

Oil consumption Check

Oil filter: Removal - Refitting

Exchanger: Removal Refitting

Oil pressure sensor:

Oil level sensor: Removal Refitting

Sump: Removal - Refitting

Oil pump: Removal Refitting

Engine speed and position

Engine oil: Draining Refilling

Timing belt: Removal Refitting

TOP AND FRONT OF ENGINE

Cylinder head gasket :

Tightening the cylinder head

Cylinder head: Removal Refitting

Air resonator: Removal Refitting

Air filter: Replacement

Air filter: Removal - Refitting

Air filter unit: Removal Refitting

Air flowmeter: Removal Refitting

Air inlet flap: Removal Refitting

Air inlet duct: Removal Refitting

Inlet manifold: Removal Refitting

Injector holder shim:

Manifolds: Removal Refitting

TOP AND FRONT OF ENGINE

Throttle valve: Removal Refitting

Throttle valve: Cleaning

Engine stop device

Injection warning light

Injection / air conditioning

High pressure pipe:

High pressure pipe:

Diesel injector: check

High pressure pump:

Diesel injector: Removal Refitting

Diesel fuel supply circuit

Petrol filter: General

High-pressure pipe between

Diesel filter: Removal Refitting

Injector rail: Removal Refitting

Injector rail - Injectors:

Rail pressure sensor

Electric fuel: Checking

Rail pressure sensor:

Fuel flow actuator: Removal Refitting

Leak flow from injectors:

Fuel pressure regulator:

Accelerometer: Removal Refitting

Venturi: Removal - Refitting

Diesel injection computer:

Heater plugs Removal Refitting

Intercooler: Removal Refitting