Mr395 Laguna Motor f9q en

1 Engine and peripherals
10A ENGINE AND CYLINDER BLOCK ASSEMBLY
11A TOP AND FRONT OF ENGINE
12A FUEL MIXTURE
12B TURBOCHARGING
13A FUEL SUPPLY
13B DIESEL INJECTION
13C PREHEATING
14A ANTIPOLLUTION
16A STARTING - CHARGING
17A IGNITION
17B PETROL INJECTION

X74
FEBRUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

19A COOLING
19B EXHAUST
19C TANK
19D ENGINE MOUNTING
X74
FEBRUARY 2009 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the technical All copyrights reserved by Renault.
specifications current when it was prepared.
The reproduction or translation in part of whole of the present document, as well as the use
The methods may be modified as a result of changes introduced by the manufacturer in the of the spare parts reference numbering system, are prohibited without the prior written
production of the various component units and accessories from which his vehicles are consent of Renault.
constructed."
© Renault s.a.s 2008

LAGUNA II Phase II and Phase I update -
LAGUNA II Phase II and Phase I update - Section 1 ContentsPage
Section 1
Contents
Page
ENGINE AND CYLINDER BLOCK

10A 11A TOP AND FRONT OF ENGINE
ASSEMBLY
Engine: Specifications 10A-1 Final compression pressure:
Check 11A-1
Crankshaft seal at timing end
Removal - Refitting 10A-16 Accessories belt: Removal -
Refitting 11A-4
Crankshaft seal at gearbox
end : Removal - Refitting 10A-25 Crankshaft accessories
pulley: Removal - Refitting 11A-16
Engine oil: Specifications 10A-35
Timing belt: Removal -
Engine oil: Draining - Refitting 11A-26
Refilling 10A-62
Timing chain: Removal -
Oil consumption Check 10A-77 Refitting 11A-131
Oil filter: Removal - Refitting 10A-78 Rocker cover: Removal -
Oil filter unit: Removal - Refitting 11A-142
Refitting 10A-85 Camshaft dephaser:
Exchanger: Removal - Function 11A-181
Oil pressure sensor: Description 11A-183
Removal - Refitting 10A-98 Camshaft: Removal -
Oil level sensor: Removal - Refitting 11A-185
Sump: Removal - Refitting 10A-114 Removal - Refitting 11A-224
Conrod bearing shell: Camshaft seal at timing end:

Removal - Refitting 10A-130 Removal - Refitting 11A-227
Oil pump: Removal - Cylinder head: Removal -

Refitting 10A-141 Refitting 11A-239
Multifunction support: Cylinder head: Removal -

Removal - Refitting 10A-154 Refitting 11A-245
Engine/gearbox assembly: Oil decanter: Removal -

Removal - Refitting 10A-162 Refitting 11A-288
Oil pressure: Check 10A-272

Contents
12A FUEL MIXTURE 12B TURBOCHARGING
Air inlet 12A-1 Turbocharging pressure

regulation valve 12B-55
Air intake: Description 12A-8
Intercooler: Removal -
Air resonator: Removal - Refitting 12B-56
Refitting 12A-15
Air filter: Replacement 12A-19
Air filter: Removal - Refitting 12A-21 13A FUEL SUPPLY

Air filter unit: Removal -
Refitting 12A-28 Petrol supply system:
Operating diagram 13A-1
Air flowmeter: Removal -
Refitting 12A-38 Petrol filter : Removal -
Refitting 13A-2
Engine damper flap:
Removal - Refitting 12A-41 Manual priming pump:
Removal - Refitting 13A-3
Air inlet flap: Removal -
Refitting 12A-43 Fuel filter: Removal -
Refitting 13A-5
Throttle valve: Removal -
Refitting 12A-47 Injector rail - Injectors:
Air inlet duct: Removal -
Refitting 12A-55 Fuel pressure: check 13A-18
Inlet manifold: Removal - Fuel flow: check 13A-20

Refitting 12A-59
Exhaust manifold - Intake

distributor: Removal -
13B DIESEL INJECTION
Refitting 12A-62
Inlet manifold: Removal - Diesel injection: Precautions

Refitting 12A-71 for repair 13B-1
Injector holder shim: Diesel injection: List and

Removal - Refitting 12A-84 location of components 13B-10
Exhaust manifold: Removal - Diesel injection computer:

Refitting 12A-87 Removal - Refitting 13B-28
Camshaft position sensor:

Removal - Refitting 13B-35
12B TURBOCHARGING Crankshaft position sensor:

Turbocharging: Precautions
High pressure pump:
for repair 12B-1
Turbocharger: Removal -
Fuel pressure regulator:
Refitting 12B-4
Turbocharger oil pipe:
Diesel return pipe: Removal -
Refitting 13B-66
Pressure regulator: Checking
Contents
13B DIESEL INJECTION 14A ANTIPOLLUTION
Diesel injector fuel return rail: Exhaust gas recirculation:

Removal - Refitting 13B-71 Operating diagram 14A-8
Injector rail protector: Fuel vapour recirculation

Removal - Refitting 13B-79 circuit: check 14A-11
High-pressure pipe between Fuel vapour canister:

the pump and rail: Removal - Removal - Refitting 14A-13
Refitting 13B-94
Fuel vapour
High-pressure pipe between canister:Checking 14A-14
the rail and injector: Removal
- Refitting 13B-106 Exhaust gas recirculation
unit: Removal - Refitting 14A-15
Injector rail: Removal -
Refitting 13B-116 Exhaust gas recirculation
solenoid valve: Removal -
Rail pressure sensor: Refitting 14A-18
Intercooler: Removal -
Oxygen sensor: Removal - Refitting 14A-29
Refitting 13B-136
Exhaust gas recirculation
Fuel temperature sensor: rigid pipe: Removal -
Removal - Refitting 13B-138 Refitting 14A-39
Diesel injector: Removal - Exhaust gas recirculation

Refitting 13B-141 solenoid valve: Cleaning 14A-43
13C PREHEATING 16A STARTING - CHARGING
Pre/postheating unit: Starting system:

Removal - Refitting 13C-1 Identification 16A-1
Heater plugs Removal - Alternator: Removal -

Refitting 13C-2 Refitting 16A-2
Starter: Removal - Refitting 16A-18
14A ANTIPOLLUTION
17A IGNITION
Oil vapour rebreathing
system: Descriptions 14A-1
Ignition: Specifications 17A-1
Oil vapour rebreathing
system: Operating diagram 14A-2 Coils Removal - Refitting 17A-2
Exhaust gas recirculation: Spark plugs: Removal -

Description 14A-4 Refitting 17A-10
Exhaust gas recirculation:

Function
Contents
17B PETROL INJECTION 19A COOLING
Fuel injection: List and Electric water pump:

location of components 17B-1 Removal - Refitting 19A-100
Oxygen sensors: Removal - Coolant temperature sensor:

Refitting 17B-18 Removal - Refitting 19A-102
Petrol injection computer:

Crankshaft position sensor: 19B EXHAUST

Exhaust: Parts and
consumables for the repair
work 19B-1
19A COOLING Exhaust: Precautions for
repair 19B-18
Engine cooling: Parts and
consumables for the repair Catalytic pre-converter:
work 19A-1 Removal - Refitting 19B-22
Engine cooling: Precautions Catalytic converter: Removal

for repair 19A-3 - Refitting 19B-47
Engine cooling circuit: Silencer: Removal - Refitting 19B-56

Specifications 19A-5
Particle filter: Function 19B-59
Engine cooling circuit: check 19A-6
Particle filter: Parts
Engine cooling circuit: description 19B-60
Operating diagram 19A-10
Exhaust gas temperature
Cooling circuit: Draining - sensor: Removal - Refitting 19B-64
Refilling 19A-22
Exhaust gas pressure
Cooling radiator: Removal - sensor: Removal - Refitting 19B-70
Refitting 19A-26
Particle filter: Removal -
Water pump: Removal - Refitting 19B-72
Refitting 19A-42
Particle filter pressure
Thermostat: Removal - sensor: Removal - Refitting 19B-103
Refitting 19A-58
Particle filter temperature
Plenum chamber: Removal - sensors: Removal - Refitting 19B-126
Refitting 19A-60
Connecting hose: Removal -
Engine cooling fan assembly: Refitting 19B-136
Particle filter: Cleaning 19B-142
Thermoplunger unit:
Water pump inlet pipe:

Expansion bottle: Removal -

Refitting 19A-98
Contents
19C TANK
Fuel tank: Operating diagram 19C-1
Fuel tank: Removal -

Refitting 19C-7
Filler neck: Removal -

Refitting 19C-11
Fuel tank: Draining 19C-13
Sender unit: Removal -

Refitting 19C-16
Pump-sender unit-filter:
Removal - Refitting 19C-20
Fuel level sensor: Distinctive 19C-24
19D ENGINE MOUNTING
Suspended engine
mounting: Tightening torque 19D-1
Left-hand suspended engine

mounting: Removal -
Refitting 19D-8
Right-hand suspended
engine mounting: Removal -
Refitting 19D-24
Lower engine tie-bar:

Removal - Refitting 19D-36
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine: Specifications 10A
F9Q
I - ENGINE IDENTIFICATION
124959
The engine can be identified by markings (1) located
on the cylinder block.
Details of markings
19858
The markings consist of:
- (2) : the engine type,
- (3) : the engine approval letter,
- (4) : the engine suffix,
- (5) : the factory where the engine is fitted,
- (6) : the engine production number.
10A-5
F9Q
II - TABLE OF ENGINE SPECIFICATIONS
Engine type Engine suffix Cubic capa- Bore (mm) Stroke (mm) Compres-
city(cc) sion ratio
200
204 18.4:1
260
264 16.9/1
650
664
18.4:1
670
674
718 19:1
732
18.4:1
733
738
740 19:1
748
F9Q 1870 80 93
750
752 18.4:1
754
758
16.9/1
759
760
762
772
774 18.4:1
790
796
800
803
16.9/1
804
10A-6
F9Q
Engine type Engine suffix Cubic capa- Bore (mm) Stroke (mm) Compres-
city(cc) sion ratio
808
18.4:1
812
816 16.9/1
F9Q 818 1870 80 93

18.4:1
820
870
16.9/1
872
10A-7
Crankshaft seal at gearbox end : Removal - Refitting 10A
F4R or F9Q or K4M or L7X, and DOCUMENT PHASE 2
II - OPERATION FOR REMOVAL OF PART
CONCERNED
105267
a Tighten the nut so that the claws grip the seal.
105259
a Ensure that you have the (Mot. 1579) available or
(see allocation table).
105268
a Turn the threaded rod so that the tool comes into
contact with the crankshaft, then continue to rotate it
105265 to remove the seal.
a Position the claws of the tool on the inner face of the
seal.
10A-26
Crankshaft seal at gearbox end : Removal - Refitting 10A
REFITTING
I - REFITTING PREPARATION OPERATION
a clean all of the joint faces.
Note:
Joint faces must be clean, dry and free from
grease (avoid finger marks).
WARNING
Touching the lip of the seal is strictly forbidden.
Any contact with it will result in the lip being per-
manently damaged, which will cause an oil leak.
II - REFITTING OPERATION FOR PART

CONCERNED
a Refit the seal using the adapted tool (see allocation

table).
III - FINAL OPERATION
1 - Manual gearbox
a Refit:
- the flywheel (see Section 02, Driveshaft, 20A,

Clutch, Flywheel: Removal - Refitting).
- the clutch (see Section 02, Driveshaft, 20A,

Clutch, Pressure plate - Disc: Removal - Refit-
ting),
- the gearbox (see Section 02, Driveshaft, 21A,

Gearbox, Gearbox: Removal - Refitting),
2 - Automatic gearbox
a Refit:
- the drive plate (see Section 02, Driveshaft, 23A,

Automatic transmission, Drive plate: Removal -
Refitting).
- The automatic transmission (see Section 02, Dri-

veshaft, 23A, Automatic transmission, Automa-
tic transmission: Removal - Refitting),
a Connect the battery (see 80A, Battery, Battery: Re-

moval - Refitting).
10A-27
Engine oil: Specifications 10A
I - OIL GRADE FOR VEHICLES (EXCEPT LOGAN-
SANDERO) WITH A FABRICATION DATE AFTER
08/10/2007:
1 - For countries in Europe (Germany, Andorra,

Austria, Belgium, Denmark, Spain, Estonia,
Finland, France, Great Britain, Greece, Hungary,
Ireland, Iceland, Italy, Latvia, Liechtenstein,
Lithuania, Luxembourg, Norway, Netherlands,
Poland, Portugal, Czech Republic, Slovakia,
Slovenia, Sweden, Switzerland, Croatia, Israel):
RENAULT recommends, for both filling and changing,

using engine oil which follows the recommendations
116205 below:
RENAULT recommends ELF.
Grades to use according to the external temperature (t)

Standard
if t greater than - if t greater than - if t greater than -
20°C 25°C 30°C
General (excluding special

cases):
- Naturally aspirated petrol, RN0700 10W40 or 5W30 5W30 or 5W40 0W30 or 0W40
or 5W40 or or 0W30 or
- Naturally aspirated E85.
0W30 or 0W40 0W40
- Diesel without particle filter, RN0710 5W40 or 0W40 5W40 or 0W40 0W40
- Renault spor t petrol,
- Turbocharged petrol
- Diesel equipped with parti- RN0720 5W30 or 5W40 5W30 or 5W40 0W30 or 0W40
cle filter, or 0W30 or or 0W30 or
0W40 0W40
Special cases (also see fol-

lowing page):
- CLIO III K4M with power RN0710 5W40 or 0W40 5W40 or 0W40 0W40
greater than 120hp (88 kW)
- G9T engine with particle fil- RN0710 5W40 or 0W40 5W40 or 0W40 0W40
ter.
- K9K engine without parti- RN0700 10W40 or 5W40 5W40 or 0W40 0W40
cle filter with Renault service or 0W40
interval every 12,000 miles
(20,000 km) or 1 year.
10A-35
- KANGOO II K9K without ACEA C3 or 5W30 or 0W30 5W30 or 0W30 0W30
particle filter with power RN720
greater than 100 hp (73kW)
and a fabrication date before
08/09/2008,
- LAGUNA III K9K with a
fabrication date before 28/05/
2008.
MASTER PROPULSION ACEA E7 10W30 5W30 NC
2 - For French overseas territories (Guadeloupe,

French Guiana, Martinique, Réunion):
a - For French Overseas Territories and vehicles

with a fabrication date after 23/06/08 (inclusive):

Standards
if t greater if t greater if t greater if t greater
than - 15˚C than - 20°C than - 25°C than - 30°C
RN0700 10W40 10W40 5W30 or 0W30 or

5W40 0W40
Naturally aspirated petrol
engine ACEA A3/B4 10W40 10W40 5W30 or 5W30 or
or ACEA A5/ 5W40 5W40
B5
Turbocharged or Renault RN0710 5W40 5W40 5W40 0W40

Sport petrol engine (except
turbocharged D4F) ACEA A3 5W40 5W40 5W40 0W40
RN0710 5W40 5W40 5W40 0W40
Turbocharged D4F ACEA A3/B4 5W40 5W40 5W40 0W40
ACEA A5/B5 5W30 5W30 5W30 0W30
Diesel engine without parti- RN0710 5W40 5W40 5W40 0W40

cle filter (except Espace IV
Diesel without particle filter ACEA A3/B4 10W40 or 10W40 or 5W40 or 0W30 or
and P9X engine) 10W50 10W50 5W50 0W40
Espace IV without particle fil- RN0710 5W40 5W40 5W40 0W40

ter
ACEA A3/B4 5W40 5W40 5W40 0W30 or
P9X engine 0W40
Diesel engine with particle fil- RN0720 5W30 or 5W30 or 5W30 or 0W30 or
ter (except G9T) 5W40 5W40 5W40 0W40
G9T with particle filter ACEA B4 5W40 5W40 5W40 0W40
10A-36
b - For French overseas territories and vehicles 3 - For Romania
with a fabrication date after 08/10/07 and before 23/
06/08 (not inclusive):
Refer to the recommendations for the French overseas
territories in the section entitled "Oil grade for vehicles
with a fabrication date between 01/01/2001 and 08/10/
2007 (not inclusive)".

Standards
Naturally aspirated petrol ACEA A3/B4 10W40 10W40 5W30 or 5W30 or

engine or ACEA A5/ 5W40 5W40
B5
Turbocharged or Renault ACEA A3 5W40 5W40 5W40 0W40

turbocharged D4F)
ACEA A3/B4 5W40 5W40 5W40 0W40

Turbocharged D4F
ACEA A5/B5 5W30 5W30 5W30 0W30 or
0W40
Diesel engine without parti- ACEA B2/ 15W40 or 10W40 or 5W40 or 0W40
cle filter (except Espace IV ACEA B3/ 15W50 10W50 5W50
Diesel without particle filter, ACEA B4
P9X engine, Trafic and Mas-
ter without particle filter)
Espace IV without particle fil- RN0710

ter 5W40 5W40 5W40 0W40
ACEA A3/B4
P9X engine
Trafic F9Q without particle fil- ACEA A3/B4 5W30 or 5W40

ter
Trafic without particle filter, RN0710 5W40 5W40 5W40 0W40

M9R, G9T and G9U
Master without particle filter
4 - For United Arab Emirates - Abu Dhabi, United

Arab Emirates - Dubai, Kuwait, Oman, Qatar,
Algeria, Tunisia, Russia, Ukraine, Turkey, Bulgaria
and vehicles with a fabrication date after 02/06/08
for Thalia, Symbol, after 15/07/08 for Kangoo II,
Mégane II, Scenic II, Clio III, Sandero, Logan, after
10A-37
29/09/08 for Master, Twingo II, Clio II, Trafic, Vel
Satis, Kangoo I, Modus, Espace IV, Laguna III:
For United Arab Emirates - Abu Dhabi, United Arab Emirates - Dubai, Kuwait, Oman, Qatar, Algeria, Tunisia:

Standards
ACEA A1/
ACEA A2/
ACEA A3/ 10W30 or 5W30 or
Naturally aspirated petrol 15W40 or 0W30 or
ACEA A5 10W40 or 5W40 or
engine 15W50 0W40
10W50 5W50
API SL/API
SM

turbocharged D4F)
ACEA A3/B4 5W40 5W40 5W40 0W40

Turbocharged D4F
ACEA A5/B5 5W30 5W30 5W30 0W30 or
0W40
ACEA B2/ 0W30 or

Diesel engine without parti-
ACEA B3/ 0W40
cle filter (except Espace IV 15W40 or 10W40 or 5W40 or
ACEA B4
Diesel without particle filter 15W50 10W50 5W50
and P9X engine) API CF 0W40
Espace IV without particle RN0710

filter 5W40 5W40 5W40 0W40
ACEA A3/B4
P9X engine
Diesel engine with particle RN0720 5W30 or 5W30 or 5W30 or 0W30 or

filter (except G9T) 5W40 5W40 5W40 0W40
For Russia, Ukraine:

Standards
ACEA A1/
ACEA A2/
engine 15W50 0W40
10W50 5W50
API SL/API
SM
10A-38
turbocharged D4F)
ACEA A3/B4 5W40 5W40 5W40 0W40

Turbocharged D4F
ACEA A5/B5 5W30 5W30 5W30 0W30 or
0W40
Diesel engine without parti- ACEA B2/ 0W30 or

cle filter (except Espace IV ACEA B3/ 0W40
15W40 or 10W40 or 5W40 or
15W50 10W50 5W50
ter without particle filter) API CF 0W40

ter 5W40 5W40 5W40 0W40
ACEA A3/B4
P9X engine
Trafic and Master without RN0710 5W40 5W40 5W40 0W40

particle filter
For Turkey:

Standards
ACEA A1/
ACEA A2/
engine 15W50 0W40
10W50 5W50
API SL/API
SM

turbocharged D4F)
ACEA A3/B4 5W40 5W40 5W40 0W40

Turbocharged D4F
ACEA A5/B5 5W30 5W30 5W30 0W30 or
0W40
Diesel engine without parti- RN0710 5W40 5W40 5W40 0W40

cle filter (except K9K engine
without particle filter, M9R
engine without particle filter,
Espace IV Diesel without
particle filter and P9X
engine)
10A-39
K9K engine without particle RN0710 5W40 5W40 5W40 0W40
filter, M9R engine without
particle filter ACEA A5/B5 5W30

ter 5W40 5W40 5W40 0W40
ACEA A3/B4
P9X engine
For Bulgaria:

Standards
Naturally aspirated petrol ACEA A3/B4 10W40 10W40 5W30 or 5W30 or

engine or ACEA A5/ 5W40 5W40
B5

turbocharged D4F)
ACEA A3/B4 5W40 5W40 5W40 0W40

Turbocharged D4F
ACEA A5/B5 5W30 5W30 5W30 0W30 or
0W40
Diesel engine without parti- ACEA B2/ 15W40 or 10W40 or 5W40 or 0W40
cle filter (except Espace IV ACEA B3/ 15W50 10W50 5W50
ter without particle filter)

ter 5W40 5W40 5W40 0W40
ACEA A3/B4
P9X engine
Trafic F9Q without particle fil- ACEA A3/B4 5W30 or 5W40

ter
Trafic without particle filter, RN0710 5W40 5W40 5W40 0W40

M9R, G9T and G9U
Master without particle filter
5 - For Albania, Argentina, Bermuda, Bosnia- Japan, Kosovo, Macedonia, Malta, Mexico, New
Herzegovina, Chile, Greek Cyprus, Turkish Cyprus, Caledonia, New Zealand, Serbia, Montenegro,
10A-40
Singapore, Taiwan, Province of China, Thailand
and vehicles with a fabrication date after 26/08/08.

Standards
RN0700 10W40 10W40 5W30 or 0W30 or

5W40 0W40
Naturally aspirated petrol
engine on LAGUNA, ACEA A1/ 15W40 or 10W30 or 5W30 or 0W30 or
MEGANE III and KANGOO II ACEA A2/ 15W50 10W40 or 5W40 or 0W40
ACEA A3/ 10W50 5W50
ACEA A5
RN0700 10W40 10W40 5W30 or 0W30 or

5W40 0W40
ACEA A1/ 15W40 or 10W30 or 5W30 or 0W30 or

ACEA A2/ 15W50 10W40 or 5W40 or 0W40
Other models with naturally
ACEA A3/ 10W50 5W50
aspirated petrol engine
ACEA A5
API SL/API 15W40 or 10W30 or 5W30 or 0W30 or

SM 15W50 10W40 or 5W40 or 0W40
10W50 5W50

turbocharged D4F engine) ACEA A3 5W40 5W40 5W40 0W40
RN0710 5W40 5W40 5W40 0W40
ACEA A3/B4 5W40 5W40 5W40 0W30 or

Turbocharged D4F engine
0W40
ACEA A5/B5 5W30 5W30 5W30 0W30
RN0710 5W40 5W40 5W40 0W40

Diesel engine without parti-
cle filter on LAGUNA,
ACEA B3/ 15W40 or 10W40 or 5W40 or 0W30 or
MEGANE III and KANGOO II
ACEA B4 15W50 10W50 5W50 0W40
Espace IV Diesel without RN0710 5W40 5W40 5W40 0W40

engine) ACEA A3/B4 5W40 5W40 5W40 0W40
RN0710 5W40 5W40 5W40 0W40
Other Diesel models without ACEA B3/ 15W40 or 10W40 or 5W40 or 0W30 or
a particle filter which are not ACEA B4 15W50 10W50 5W50 0W40
listed above
API CF 15W40 or 10W40 or 5W40 or 0W40
15W50 10W50 5W50
10A-41
6 - For other countries and other vehicles with a
fabrication date after 08/10/2007 which are not
listed above:

Standards
RN0700 10W40 10W40 5W30 or 0W30 or

5W40 0W40
ACEA A1/ 15W40 or 10W30 or 5W30 or 0W30 or

ACEA A2/ 15W50 10W40 or 5W40 or 0W40
All models with naturally
ACEA A3/ 10W50 5W50
aspirated petrol engine
ACEA A5
API SL/API 15W40 or 10W30 or 5W30 or 0W30 or

SM 15W50 10W40 or 5W40 or 0W40
10W50 5W50

turbocharged D4F engine) ACEA A3/B4 5W40 5W40 5W40 0W40
RN0710 5W40 5W40 5W40 0W40
ACEA A3/B4 5W40 5W40 5W40 0W30 or

Turbocharged D4F engine
0W40
ACEA A5/B5 5W30 5W30 5W30 0W30
RN0710 5W40 5W40 5W40 0W40
ACEA B3/ 15W40 or 10W40 or 5W40 or 0W30 or

All diesel engine models
ACEA B4 15W50 10W50 5W50 0W40
without a particle filter
API CF 15W40 or 10W40 or 5W40 or 0W40
15W50 10W50 5W50
Espace IV Diesel without RN0710 5W40 5W40 5W40 0W40

engine) ACEA A3/B4 5W40 5W40 5W40 0W40
II - OIL GRADE FOR VEHICLES (EXCEPT LOGAN- Luxembourg, Norway, Holland, Poland, Portugal,
SANDERO) WITH A MANUFACTURE DATE Czech Republic, Slovakia, Slovenia, Sweden,
BETWEEN 01/01/2001 AND 08/10/2007 (NOT
INCLUSIVE):
1 - For EUROPE (Germany, Andorra, Austria,

Belgium, Denmark, Spain, Estonia, Finland,
France, Great-Britain, Greece, Hungry, Ireland,
Iceland, Italy, Latvia, Liechtenstein, Lithuania,
10A-42
Switzerland, Croatia, Israel) and French overseas RENAULT recommends, for both filling and changing,
territories: using engine oil which follows the recommendations
below:
Instructions for tables:
Note:
- When the grades are specified in the table below,
RN standard oils are better grade oils than ACEA
only use one of them depending on the external tem-
standard oils. It is therefore possible to substitute
perature of the country (see graphs under the table to
the ACEA standard recommended oil by the RN
identify the operating temperatures of the grades),
standard but it is prohibited to substitute RN stan-
dard recommended oil by the ACEA standard (see - When the grades are not specified in the table (pre-
table of interchangeability for correspondences). sence of an "X" in the box), refer to the graphs under
the table to find the grade authorised according to the
fuel used.
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
C3G X X
D4D X X
TWINGO D4F X X
D7D X X
D7F X X
Naturally X X
aspirated
D4F
Turbochar- Only Only

ged D4F
5W40 or 5W30 or
TWINGO II 0W30 or 0W30 or
0W40 0W40
K4M X X
D7F X X
K9K X
10A-43
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
D4D X X
D4F X X
D7D X X
D7F X X
E7J X X
RENAULT Only
SPORT F4R
5W40 or
CLIO II 0W40
F8Q X X
F9Q X
K4J X X
K4M X X
K7J X X
K7M X X
K9K X
10A-44
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
Naturally X X
aspirated
D4F

ged D4F
5W40 or 5W30 or
0W30 or 0W30 or
0W40 0W40
K4J X X
K4M X X
M4R X X
RENAULT Only
SPORT F4R
5W40 or
0W40
CLIO III K9K without X

particle filter
with Renault
service every
12,000 miles
(20,000 km)
or 1 year or
every 18,000
(30,000 km)
or 2 years
K9K without Only 5W40

particle filter or 5W50 or
with Renault 0W30 or
Service 0W40
every 18,000
miles (30,000
km) or 1 year
K9K with par- Only

ticle filter
5W30 or
0W30
CLIO V6 L7X Only

5W40 or
0W40
10A-45
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
Naturally X X
aspirated
D4F

ged D4F
5W40 or 5W30 or
0W30 or 0W30 or
0W40 0W40
K4J X X
K4M X X
K9K without X
particle filter
with Renault
MODUS service every
12,000 miles
(20,000 km)
or 1 year or
every 18,000
(30,000 km)
or 2 years

Service 0W40
every 18,000
miles (30,000
km) or 1 year
K9K with par- Only

ticle filter
5W30 or
0W30
10A-46
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
E7F X X
F3R X X
F4P X X
F4R X X
F5R X X
MEGANE/
F7R X
SCENIC
F8Q X X
F9Q X
K4J X X
K4M X X
K7M X X
10A-47
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
Naturally X X
aspirated
F4R
Turbochar- Only
ged F4R (not
5W40 or
RENAULT
SPORT) 0W40
RENAULT Only
SPORT tur-
5W40 or
bocharged
F4R 0W40
F9Q without X
particle filter
with Renault
service every
12,000 miles
MEGANE II/ (20,000 km)
or 1 year or
SCENIC II every 18,000
(30,000 km)
or 2 years
F9Q without Only 5W40

Service 0W40
every 18,000
miles (30,000
km) or 1 year
F9Q with Only

particle filter
5W30 or
0W30
K4J X X
K4M X X
MEGANE II/ K9K without X

particle filter
SCENIC II
with Renault
service every
12,000 miles
(20,000 km)
or 1 year or
every 18,000
(30,000 km)
or 2 years
10A-48
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3

Service 0W40
every 18,000
miles (30,000
km) or 1 year
K9K with par- Only

ticle filter
5W30 or
0W30
M9R without X
particle filter
MEGANE II/ with Renault
Service
SCENIC II every 12,000
miles (20,000
km) or 1 year
M9R without Only 5W40

Service 0W40
every 18,000
miles (30,000
km) or 1 year
M9R with Only

particle filter
5W30 or
0W30
10A-49
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
F4P X X
Naturally X X
aspirated
F4R
Turbochar- Only
ged F4R (not
5W40 or
GT/CEL-
SIUM) 0W40
GT/CEL- Only
SIUM turbo-
5W40 or
charged F4R
0W40
F5R X X
F9Q without Only

particle filter
5W40 or
LAGUNA II 0W40 or
0W30
F9Q with Only

particle filter
5W30 or
0W30
G9T without X
particle filter
G9T with Only

particle filter
5W40 or
0W40
K4M X X
L7X X X
M9R without X
particle filter
LAGUNA II M9R with Only

particle filter
5W30 or
0W30
10A-50
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
G8T X X
J7R X X
J7T X X
J8S X X
SAFRANE L7X X X
N7Q X X
N7U X X
S8U X X
Z7X X X
Turbochar- Only
ged F4R
5W40 or
0W40
G9T without X
particle filter
G9T with Only

particle filter
5W40 or
0W40
P9X Only
VELSATIS
5W40 or
0W40 or
0W30
V4Y X X
M9R without X
particle filter
M9R with Only

particle filter
5W30 or
0W30
10A-51
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
F3R X X
F4R X X
F9Q X
G8T X X
G9T X
ESPACE J6R X X
(I-III) J7R X X
J7T X X
J8S X X
L7X X X
Z7W X X
Z7X X X
10A-52
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
Naturally X X
aspirated
F4R
Turbochar- Only
ged F4R
5W40 or
0W40
F9Q Only
5W40 or
0W40 or
0W30
G9T without Only

particle filter
5W40 or
0W40 or
0W30
ESPACE IV
G9T with Only
particle filter
5W40 or
0W40
M9R without X
particle filter
with Renault
Service
every 12,000
miles (20,000
km) or 1 year

Service 0W40
every 18,000
miles (30,000
km) or 1 year
M9R with Only

particle filter
5W30 or
0W30
P9X Only
ESPACE IV
5W40 or
0W40 or
0W30
V4Y X X
10A-53
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
F3R X X
Naturally X X
aspirated
F4R
Turbochar- X
ged F4R
AVANTIME
F9Q X
G8T X X
G9T X
L7X X X
Z7X X X
D4D X X
D4F X X
D7D X X
D7F X X
E7J X X
F8Q X X
F9Q X
KANGOO
K4M X X
K7J X X
K7M X X
K9K X
Electric Only
5W40 or
0W40
10A-54
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
F4R X X
F9Q X
M9R Only 5W40

or 5W50 or
0W30 or
0W40
TRAFIC II G9U without Only 5W40
0W30 or
0W40
G9U with Only

particle filter
5W30 or
0W30
F4R X X
F9Q X
G9T X
G9U without Only 5W40

0W30 or
0W40
G9U with Only

particle filter
5W30 or
MASTER 0W30
J5R X X
J7T X X
J8S X X
S8U X X
S9U X
S9W X
ZD3 X
10A-55
ACEA standard
Vehicle Engine
A3 A5 B3 B4 C3
D4D X X
K4M X X
LOGAN-
K7J X X
SANDERO
K7M X X
K9K X
Standard
Vehicle Engine
RN0710 RN0720 RN0700 ACEA C3 or
RN720
K9K Only 5W30

or 0W30

particle filter or 0W40
M9R with Only 5W30

0W30 or
0W40
K4M Only 10W40

LAGUNA III or 5W30 or
5W40 or
0W30 or
0W40
M4R Only 10W40

or 5W30 or
5W40 or
0W30 or
0W40
Turbochar- Only 5W40

ged F4R or 0W40
a - Petrol engine:
In order to find the oil grade for the external temperatu-
re, refer to the graph below:
10A-56
Note:
If an engine oil grade is not available or has been
discontinued, please refer to the Table of oil inter-
changeability section.
Note:
ACEA B1 standard oils should not be used for DIE-
SEL engines under any circumstances.
2 - For other countries:
a - Petrol engine:
RENAULT recommends, for both filling and changing

113996
the oil, that ACEA A1*, ACEA A3 or ACEA A5* stan-
dard engine oil is used, or if this is not available ACEA
* Except for turbocharged engines, F7P, F7R, RE-
A2, API SJ, API SL or API SM standard.
NAULT SPORT F4R, RENAULT SPORT turbocharged
F4R and RENAULT SPORT L7X. To find out which oil grade to choose, please refer to
the following graph:
b - DIESEL engine:
In order to find the oil grade for the external temperatu-
re, refer to the graph below:
113992
* Except for turbocharged engines, F7P, F7R, RE-

NAULT SPORT F4R, RENAULT SPORT turbocharged
115728 F4R and RENAULT SPORT L7X.
* Only with standards ACEA B4 or ACEA C3.
- Special cases:
• For RENAULT CLIO SPORT F4R, RENAULT CLIO

SPORT L7X RENAULT MEGANE II SPORT turbo-
charged F4R, turbocharged F4R engines, LAGUNA
GT/CELSIUM turbocharged F4R, and Electric KAN-
10A-57
GOO, only use ACEA A3 standard of 5W40 grade • F9Q engines fitted with particle filter, M9R engines
(or 0W40 grade, depending on the external tempe- fitted with particle filter, K9K engines fitted with parti-
rature). cle filter, G9U engines fitted with particle filter, only
use oil which is ACEA C3 standard and 5W30 gra-
• For turbocharged D4F engines, only use oil which is de (or 0W30 grade depending on the external tem-
ACEA A3 standard and 5W40 grade (or 0W40 or perature).
0W30 grade depending on the external temperatu-
re), or ACEA A5 standard and 5W30 grade (or • LAGUNA III 1.5 dCi without particle filter and LAGU-
0W40 or 0W30 grade depending on the external NA III 2.0 dCi without particle filter, use RN0710
temperature). standard oil and 5W40 grade (or 0W40 depending
on external temperature),
b - DIESEL engine: • LAGUNA III 2.0 dCi equipped with a particle filter,
only use oil which is RN0720 standard and grade
RENAULT recommends, for both filling and changing 5W40 or 5W30 (or 0W30 or 0W40 according to the
the oil, that ACEA B3, ACEA B4, ACEA C3* standard external temperature).
engine oil is used, or if this is not available ACEA B2 or
API CF standard.
3 - table of oil interchangeability:
* ACEA C3 standard engine oils can only be used in
the following special cases.
a - ACEA/RN standards
To find out which oil grade to choose, please refer to
the following graph:
Note:
RN standard oils are better grade oils than ACEA
standard oils. It is therefore possible to substitute
the ACEA standard recommended oil by the RN
standard but it is prohibited to substitute RN stan-
dard recommended oil by the ACEA standard
WARNING
The RN standard grades to use are the same as
those recommended initially in ACEA standard.
ACEA standard RN standard which

can replace ACEA
standard
115727 ACEA A3 on naturally RN0700

aspirated engine
* Only with ACEA standard.
ACEA A3 on turbo- RN0710
- Special cases: charged engine
• For G9T engines with particle filters, only use oil ACEA A5 RN0700
which is B4 standard and 5W40 grade (or 0W40
grade depending on the external temperature). ACEA B3 RN0710
• For P9X engines, LAGUNA II F9Q without particle ACEA B4 RN0710

filter, and ESPACE IV diesel without particle filter,
only use oil which is B4 standard and 5W40 grade ACEA C3 RN0720
(or 0W30 grade or 0W40 grade depending on the
external temperature). Example of use:
10A-58
The vehicle is a CLIO III K9K equipped with a particle III - OIL GRADE FOR VEHICLES (EXCEPT LOGAN-
filter, the oil recommendations are 5W30 or 0W30 in SANDERO) WITH A FABRICATION DATE BEFORE
ACEA C3 standard. I can therefore use RN0720 stan- 01/01/2001:
dard oil, with the same grades as are recommended for
ACEA C3 standard, that is 5W30 or 0W30 (depending
on the external temperature). Note:
b - ACEA standard: discontinued, please refer to the Table of oil inter-
changeability section.
Standard Minimum standard
with which it can be
replaced
Note:
ACEA A1* ACEA A3 or ACEA ACEA B1 standard oils should not be used for DIE-
A5* SEL engines under any circumstances.
ACEA A2 ACEA A3
Petrol
ACEA A3 - 1 - For EUROPE (Germany, Andorra, Austria,
Belgium, Denmark, Spain, Estonia, Finland,
ACEA A5* ACEA A3 France, Great-Britain, Greece, Hungry, Ireland,
Iceland, Italy, Latvia, Liechtenstein, Lithuania,
ACEA B1* ACEA B3 or ACEA Luxembourg, Norway, Holland, Poland, Portugal,
B5* Czech Republic, Slovakia, Slovenia, Sweden,
Switzerland, Croatia, Israel):
ACEA B2 ACEA B3
ACEA B3 ACEA B4
DIESEL a - Petrol engine:
ACEA B4 -
ACEA B5* ACEA B4 the oil that ACEA A2 or ACEA A1standard * oil is
used (oil enabling a reduction in fuel consumption).
ACEA C3 -
Oil grade depends on the exterior average temperature
* engine oil enabling a reduction in fuel consumption.
c - API standard:
Standard Minimum standard

with which it can be
replaced
API SH API SJ
API SJ API SL
Petrol
API SL API SM
API SM -
DIESEL API CF -
113992
* Except turbocharged engines, F7P and F7R.
10A-59
b - DIESEL engine:
the oil ACEA B2 standard oil.
113994
b - DIESEL engine:
113993 the oil API CF standard oil.
Note:
discontinued, please refer to the "Table of oil inter-
changeability" section.
Note:
ACEA B1 standard oils should not be used for DIE-
SEL engines under any circumstances.
2 - For other countries:
a - Petrol engine:
the oil API SH or API SJ standard oil.
113995
10A-60
3 - table of oil interchangeability: c - API standard:
a - CCMC standard:
Standard Minimum
standard
with which
Standard Minimum
it can be
standard
replaced
with which
it can be API SH API SJ
replaced
API SJ API SL
CCMC G4 ACEA A2 Petrol
Petrol API SL API SM
CCMC G5 ACEA A2
API SM -
DIESEL CCMC PD2 ACEA A2
DIESEL API CF -
b - ACEA standard:
Standard Minimum
standard
with which
it can be
replaced
ACEA A1* ACEA A3

or
ACEA A5*
Petrol
ACEA A2 ACEA A3
ACEA A3 -
ACEA A5* ACEA A3
ACEA B1* ACEA B3

or
ACEA B5*
ACEA B2 ACEA B3
DIESEL
ACEA B3 ACEA B4
ACEA B4 -
ACEA B5* ACEA B4
ACEA C3 -
* oil enabling a reduction in fuel consumption.
10A-61
Engine oil: Draining - Refilling 10A
F9Q
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
Essential equipment
a Remove the engine undertray.
oil recovery container
oil draining wrench
8 mm square drain plug socket
Tightening torquesm
engine oil drain plug 20 N.m
Average oil capacity (adjust

using dipstick) (litres)
Engine Oil c h a n ge Oil c h a n ge

without oil fil- plus oil filter
ter replace- replacement
ment
F9Q 4.5 4.6

without 19120
particle
filter a Place an oil recovery container under the engine
oil drain plug (2) .
F9Q with 4.7 4.8
a Remove the drain plug (2) using a oil draining
particle
wrench.
filter
a Allow the engine oil to flow into the oil recovery con-
tainer.
I - DRAINING:
113765
111274
a Fit a new seal to the drain plug (2) (no direction of fit-
a Remove the oil filler cap (1) fitted with the dipstick. ting).
10A-71
Engine oil: Draining - Refilling 10A
F9Q
a Refit the drain plug to the sump.
a Torque tighten the engine oil drain plug (20 N.m)
using a 8 mm square drain plug socket.
a Refit the engine undertray.
II - FILLING:
a
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.
Note:
Prevent oil outflow on the engine to avoid dama-
ging the surrounding components.
a Fill the engine with engine oil recommended by the

manufacturer (see 10A, Engine and cylinder block
assembly, Engine oil: Specifications, page 10A-
35) (Technical Note 6013A, 04, Lubricants).
Note:
When filling up the engine oil, always allow at
least 10 minutes for the oil to drain down before
checking with a dipstick.
a Check the oil level with the dipstick.

a Refit the filler cap fitted with the dipstick.
10A-72
Oil filter: Removal - Refitting 10A
F9Q, and 664 or 674 or 758 or 759, and DOCUMENT PHASE 2
REMOVAL
I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see 02A, Lif-
ting equipment, Vehicle: Towing and Lifting).
a Remove:
- the engine covers,
- the engine undertray.
a Drain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-62) .
II - REMOVING THE OIL FILTER

a From the cylinder head, fit the.
a Remove the oil filter.
REFITTING

a Lubricate the new oil filter seal.
II - REFITTING THE OIL FILTER

a Refit the oil filter.
a Tighten the oil filter until it makes contact.
a Tighten the oil filter 3/4 of a turn by hand.

a Top up the engine oil (see 10A, Engine and cylin-
der block assembly, Engine oil: Draining - Refil-
ling, page 10A-62) .
a Refit:
- the engine undertray,
- the engine covers.
10A-83
Exchanger: Removal - Refitting 10A
CONCERNED
Tightening torquesm
the oil - coolant exchan- 60 Nm

ger nipple
REMOVAL

ting equipment, Vehicle, Towing and lifting).
a Disconnect the battery (see 80A, Battery, Battery:
Removal - Refitting).
a Remove:
- the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
115619
10A-78) .
a Fit the hose clamps at (2) .
a Disconnect:
a Disconnect the hoses using the.
- the air conditioning compressor connector,
a Remove:
- the oil level sensor connector,
- the oil-coolant heat exchanger nipple,
- the oil pressure sensor connector,
- the oil - coolant heat exchanger.
- the alternator electrical connections.
REFITTING
I - REFITTING PREPARATIONS OPERATION

a Clean the sealing mating faces.
a Replace the oil cooler seal.
II - OPERATION FOR REFITTING PART

CONCERNED
a Refit:
- the oil cooler,
- the nipple.
a Torque tighten the oil - coolant exchanger nipple
(60 Nm)
a Connect the hoses using the.
115599 a Remove the hose clamps.

a Remove the mounting bolt (1) from the wiring har-
ness bracket. III - FINAL OPERATION.
a Move the wiring harnesses to one side. a Replace the wiring harnesses.
10A-94
Exchanger: Removal - Refitting 10A
a Refit the wiring harness bracket mounting bolt.
a Connect:
- the electrical connections to the alternator,
- the oil pressure sensor connector,
- the oil level sensor connector,
- the air conditioning compressor connector.
a Refit:
- the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
10A-78) ,
moval - Refitting).
10A-95
Oil pressure sensor: Removal - Refitting 10A
CONCERNED
Tightening torquesm
oil pressure sensor 30 Nm
REMOVAL

a Remove:
115619
a Disconnect the oil pressure sensor connector (2) .

a Remove the oil pressure sensor (3) using the.
REFITTING

a Degrease the pressure face of the oil pressure sen-
sor on the cylinder block.

CONCERNED
115599
a Refit the oil pressure sensor using the.
a Remove the mounting bolt (1) from the wiring har-
ness bracket. a Tighten to torque the oil pressure sensor (30 Nm).
a Remove the oil filter (see 10A, Engine and cylinder a Connect the oil pressure sensor connector.
block assembly, Oil filter: Removal - Refitting,
page 10A-78) .
a Refit the oil filter (see 10A, Engine and cylinder
page 10A-78) .
a Use the spanner to tighten the wiring harness brac-
ket mounting bolt.
a Refit:
10A-105
Oil level sensor: Removal - Refitting 10A
CONCERNED
Tightening torquesm
oil level sensor 25 Nm
REMOVAL

a Remove:
115619
a Disconnect the connector (2) from the oil level sen-

sor.
a Remove the oil level sensor (3) using the.
REFITTING
a Degrease the pressure face of the oil level sensor on

the cylinder block.
115599
a Remove the mounting bolt (1) from the wiring har- CONCERNED
ness bracket.
a Refit the oil level sensor using the.
a Use the spanner to tighten the wiring harness brac-

ket mounting bolt.
a Tighten to torque the oil level sensor (25 Nm)
a Connect the connector to the oil level sensor.
a Refit:
10A-113
Sump: Removal - Refitting 10A
F9Q, and DOCUMENT PHASE 2
REFITTING
Tightening torquesm a
lower cover mounting 15 Nm WARNING
bolts
The gasket faces must be clean, dry and free
from grease (avoid finger marks).
REMOVAL Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain
ting equipment, Two-post lift: Safety).
components (engine, radiator, etc.)
a Disconnect the battery, starting with the negative
terminal.
a Remove: Note:
- the engine undertray, There are two procedures for preparing the cylin-
der block sealing surface when refitting:
- the engine cover,
- the first procedure is used if the crankshaft clo-
- the dipstick.
sure panel has been sealed with RHODOR-
a Drain the engine oil. SEAL 5661 silicone,
a Disconnect the oil level sensor. - the second procedure is used if the crankshaft
closure panel has been fitted with a seal.
a Remove:
- the mounting bolts of the right-hand driveshaft flan-
ge on the relay bearing, I - PROCEDURE ONE
- the relay bearing mounting bolts on the lower co-
ver,
- the mounting bolts of the lower cover on the gear-
box ,
- the mounting bolts of the lower cover on the cylin-
der block,
- the lower cover.
15159
a Apply a bead of RHODORSEAL 5661 silicone:
- at (1) each side of bearing No.˚1,
- at (2) the joint between the cylinder block and the

crankshaft closure panel.
a Refit the lower cover with a new seal.
10A-116
Sump: Removal - Refitting 10A
F9Q, and DOCUMENT PHASE 2
II - PROCEDURE TWO
15195
15159 a Tighten to torque and in order:
a
- the lower cover mounting bolts (8) , (15) , (4) ,
Note: (19) , (11) and (12) (18 Nm),
Do not cut the two crankshaft closure panel seal - the lower cover mounting bolts (10) , (13) , (9) ,
tabs which sit higher than the cylinder block sea- (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18) , (3)
ling surface (4) . , (20) , (2) , (21) , (1) and (22) (15 Nm.).
a Tighten to torque and in order the lower cover
a Apply a bead of RHODORSEAL 5661 silicone at (3) mounting bolts (15 Nm).
, at the joint between the crankshaft closure panel
and the cylinder block. a Proceed in the reverse order to removal.
a Refit the lower cover with a new seal. a Top up the engine oil.
a Connect the battery, starting with the positive termi-
nal.
WARNING
Carry out the necessary programming (see 80A,
Battery, Battery: Removal - Refitting)
10A-117
Conrod bearing shell: Removal - Refitting 10A
F9Q
REMOVING - REFITTING
Essential special tooling
Mot. 1914 Tool for fitting G9 con rod I - REMOVAL PREPARATION OPERATION
bearing shells
Mot. 1920 Tool for fitting F9 / K9 con rod Towing and lifting) (02A, Lifting equipment).
bearing shells
Essential equipment a Drain the oil from the engine (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
indelible pencil Refilling, page 10A-62) .
diagnostic tool a Remove the oil filter (see 10A, Engine and cylinder
page 10A-78) .
Tightening torquesm
a Remove the lower engine tie-bar (see 19D, Engine
con rod cap bolts 25 N.m + 110˚ mounting, Lower engine tie-bar: Removal - Refit-
± 10˚ ting, page 19D-36) .
a Remove the sump (see 10A, Engine and cylinder

block assembly, Sump: Removal - Refitting,
IMPORTANT page 10A-114) .
To avoid all risk of damage to the systems, apply
a Remove the oil pump (see 10A, Engine and cylin-
the safety and cleanliness instructions and opera-
der block assembly, Oil pump: Removal - Refit-
tion recommendations before carrying out any
ting, page 10A-141) .
repair (see Vehicle: Precautions for repair) .
II - REMOVAL OPERATION FOR THE CON ROD

BEARING SHELLS NO.2
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
139306
a Use SURFACE CLEANER (see Vehicle: Parts

and ingredients for the repairwork) (04B, Consu-
mables - Products) to clean the big ends.
a Mark the position of the con rod cap in relation to the
con rod body using a indelible pencil.
10A-136
F9Q
139300 139310
a Remove: a Fit the tie rod of the tool (Mot. 1914) (1) on the con
rod body.
- the con rod bolts,
a Push the con rod upwards to release the con rod
- the con rod cap,
from the crankpin.
- the lower con rod bearing shell.
a Turn the crankshaft 90˚ clockwise (timing end).
Note:
If reusing the con rod bearing shells, mark the
position of the lower con rod bearing shell in rela-
tion to the con rod cap.

mables - products) to clean the bearing mating face
on the con rod cap.
10A-137
F9Q
139315
a
WARNING
Failure to observe the following procedure may
damage the piston base cooling jets.
Pull the con rod - piston assembly using the tie rod of
the tool (Mot. 1914), taking care not to allow the pis-
ton to touch the piston base cooling jets.
a Remove the upper con rod bearing shell.
Note:
If reusing the con rod bearing shells, mark the
position of the upper con rod bearing shell in
relation to the con rod body.

mables - products) to clean the bearing mating face
on the con rod body.
REFITTING
I - REFITTING OPERATION FOR THE CON ROD

BEARING SHELLS ON CYLINDER NO.2
a parts always to be replaced: con rod cap bolts
(10,03,02,10)
10A-138
F9Q
a Position the lower con rod bearing shell so that the
ends do not protrude beyond the con rod cap.
a Lubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.
133814
133815
a Screw the head of the tool (Mot. 1920) for F9Q engi-
nes onto the sleeve of the tool (Mot. 1914).
a Position the lower con rod bearing shell on the tool

(Mot. 1920).
Note:
The contact surface between the bearing shell
and the con rod must be dry and free of grease.
Fit the lower con rod bearing shell on the con rod
cap using the tool (Mot. 1920).
10A-139
F9Q
II - REMOVAL - REFITTING OPERATIONS FOR THE
CON ROD BEARING SHELLS ON CYLINDERS
NO.3, 1 AND 4
a Perform the same removal - refitting operations as

for the con rod bearing shells on cylinder no. 2.
Note:
For removing and refitting the con rod bearing
shells on cylinders no. 1 and no. 4, position the
pistons at Bottom Dead Centre before performing
the same removal and refitting operations as for
the con rod bearing shells on cylinder no. 2.
a parts always to be replaced: engine oil sump

seal (10,03,01,09)
139318
parts always to be replaced: Oil filter (10,05,05,
a Position the upper con rod bearing shell on the tool 03)
(Mot. 1920).
parts always to be replaced: Engine oil sump
a Fit the upper con rod bearing shell on the con rod
drain plug seal (10,03,01,04)
body using the tool (Mot. 1920).
a Position the lower con rod bearing shell so that the a Refit the oil pump (see 10A, Engine and cylinder
block assembly, Oil pump: Removal - Refitting,
end do not protrude beyond the con rod body.
page 10A-141) .
a Lubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil. a Refit the engine oil sump (see 10A, Engine and cy-
linder block assembly, Sump: Removal - Refit-
a Push the con rod - piston assembly back up into pla- ting, page 10A-114) .
ce.
a Refit the lower engine tie-bar (see 19D, Engine
a Turn the crankshaft 90˚ anticlockwise. mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-36) .
a Lubricate the crankpin with new engine oil.
a Pull the con rod - piston assembly to position the con a Refit the oil filter (see 10A, Engine and cylinder
rod on the crankshaft. block assembly, Oil filter: Removal - Refitting,
page 10A-78) .
a
a Disconnect the crankshaft position sensor to prevent
Note: the engine from starting.
Before refitting the con rod cap, ensure that there
a Fill up the engine oil (see 10A, Engine and cylinder
are no impurities (filings, cloth lint, etc.) on the
con rod body or cap surfaces. block assembly, Engine oil: Draining - Refilling,
page 10A-62) .
Refit: a Start the engine using the starter until the engine oil
- the con rod cap according to the mark made during warning light goes out.
removal,
a Connect the crankshaft position sensor.
- the new con rod bolts.
a Torque and angle tighten the con rod cap bolts (25
N.m + 110˚ ± 10˚). a Clear the present faults using the diagnostic tool.
10A-140
Oil pump: Removal - Refitting 10A
REFITTING
Tightening torquesm
oil pump mounting bolts 25 Nm
a Clean the sealing surfaces.
oil splash plate moun- 25 Nm
ting bolt II - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
REMOVAL
- the oil pump,
- the oil pump mounting bolts,
- the oil splash plate,
ting equipment, Vehicle: Towing and Lifting). - the oil splash plate mounting bolt.
a Tighten to torque:
Removal - Refitting). - the oil pump mounting bolts (25 Nm),
- the oil splash plate mounting bolt (25 Nm).
a Drain the engine oil (see 10A, Engine and cylinder III - FINAL OPERATION
a Refit the sump (see 10A, Engine and cylinder
page 10A-62) .
block assembly, Sump: Removal - Refitting,
a Remove the sump (see 10A, Engine and cylinder page 10A-114) .
block assembly, Sump: Removal - Refitting, a Top up the engine oil (see 10A, Engine and cylin-
page 10A-114) . der block assembly, Engine oil: Draining - Refil-
ling, page 10A-62) .
II - OPERATION FOR REMOVAL OF PART a Connect the battery (see 80A, Battery, Battery: Re-
CONCERNED moval - Refitting).
a Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has gone
out,
- leave the engine to idle,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
23224
a Remove:
- the oil splash plate mounting bolt (1) ,
- the oil splash plate ,
- the oil pump mounting bolts (2) ,
- the oil pump.
10A-141
Multifunction support: Removal - Refitting 10A
CONCERNED
Tightening torquesm
multifunction support 44 Nm
mounting bolts
air conditioning com- 25 Nm

pressor mounting bolts
REMOVAL

a Disconnect the battery (see 80A, Battery, Battery: 104337
a Remove:
a Remove the alternator (see 16A, Starting - Char-
ging, Alternator: Removal - Refitting, page 16A- - the multifunction support mounting bolts,
2) .
- the multifunction support.
a Disconnect:
- the air conditioning compressor connector, REFITTING
- the pressostat connector.
a Remove the air conditioning compressor mounting I - REFITTING OPERATION FOR PART
bolts. CONCERNED
a Attach the air conditioner compressor to the radiator a Refit:

cross member.
- the multifunction support,
- the multifunction support mounting bolts.

WARNING
Do not deform the air conditioning pipes. a Tighten to torque the multifunction support moun-
ting bolts (44 Nm)
II - FINAL OPERATION
a Refit:
- the air conditioning compressor,

- the air conditioning compressor mounting bolts.
a Tighten to torque the air conditioning compressor

mounting bolts (25 Nm).
a Connect:
- the air conditioning compressor connector,
- the pressostat connector.

a Remove the alternator (see 16A, Starting - Char-
ging, Alternator: Removal - Refitting, page 16A-
2) .
moval - Refitting).
10A-154
Engine/gearbox assembly: Removal - Refitting 10A
F9Q, and 674, and DOCUMENT PHASE 2
Essential special tooling Tightening torquesm
Tav. 476 Ball joint extractor. aluminium side mem- 44 Nm

ber mounting bolts on
Essential equipment the lower cross member
safety strap(s) aluminium side mem- 44 Nm

ber tie rod mounting
refrigerant charging station bolts
load balancer
REMOVAL
a Place the vehicle on a two-post lift (see 02A, Lifting
Tightening torquesm
equipment, Two-post lift: Safety).
suspended engine 21 Nm
mounting bolts on the
bodywork IMPORTANT
During this operation, secure the vehicle to the
suspended engine 62 Nm lift with a strap safety strap(s) to prevent it from
mounting bolts on the becoming unbalanced.
engine
a For information on the strap fitting procedure, (see
engine mounting upper 105 Nm
02A, Lifting equipment, Two-post lift: Safety).
tie rod mounting bolts
gearbox suspended 62 Nm
terminal.
mounting bolts
a Remove:
gearbox suspended 44 Nm
mounting nut - the engine cover,
engine tie-bar mounting 105 Nm - the battery,

bolt on the sub-frame
- the front wheels,
engine tie-bar mounting 180 Nm
bolt on engine - the engine undertray,
- the right-hand and left-hand wheel arch liners.

lower ball joint nut 110 Nm
a Drain:
track rod end nut 37 Nm
- the refrigerant circuit using a refrigerant charging
shock absorber lower 180 Nm
station,
end mounting bolts
- the coolant circuit via the radiator bottom hose
brake calliper guide pin 7 Nm using tool,and.
bolts
- the gearbox if necessary,
driveshaft gaiter moun- 30 Nm
ting bolts - the engine, if necessary.
stabiliser bar tie rod nuts 44 Nm

I - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
- the brake calliper,
- the ABS sensor.
a Attach the calliper to the vehicle.
10A-176
18613 22377
a Remove: a Remove:
- the lower ball joint. - the lower ball joint.
- the track rod end nut (1) , - the track rod end nut (3) ,
- the track rod end using tool (Tav. 476), - the track rod end using tool (Tav. 476),
- driveshaft gaiter mountings, - the mounting bolts (4) from the transmission relay
bearing flange bracket,
- the shock absorber lower end mounting bolts (2) ,
- the driveshaft relay bearing bracket,
- the « left-hand stub axle carrier and driveshaft
assembly » . - the shock absorber lower end mounting bolts (5) ,
- the « right-hand stub axle carrier and driveshaft
II - RIGHT-HAND SIDE OF THE VEHICLE assembly » .
a Remove:
- the brake calliper, Note:
- the ABS sensor. Check the condition of the lip seal contact sur-
face.
Always replace the differential output lip seal with
a new one whenever the driveshaft is removed
(see 21A, Manual gearbox, Differential output
seal).
10A-177
a Unclip the wiring harness on the upper cross mem-
ber.
a Disconnect:
- the headlight connectors,
- the bonnet contact connector (if fitted).
19129
a Disconnect the fog lights at (6) .
a Remove the front bumper (see 55A, Exterior pro-

tection, Front bumper: Remove and Refit).
111454
a Remove the headlight upper mounting bolts (10) .
18701
a Remove the relay plate at (7) .
a Unclip the fuse carrier (8) .
a Remove: 111455
- the battery tray mounting bolts (9) , a Remove the headlight lower mounting bolts (11) .
- the battery tray. a Unclip the headlight from its centring device (12) .
a Unclip the power steering reservoir a Remove the headlights.
10A-178
a Remove:
- the « air filter unit - air inlet sleeve assembly » ,
- the two lower radiator mountings,
- the radiator top hose,
- the connector on the fan unit,
- the hoses from the expansion bottle,
- the connector on the condenser,
- the air conditioning pipe mountings on the com-

pressor and the dehydration canister.
111845
a Remove:
Note:
- the upper cross member mounting bolts (13) , Plugs must be fitted to the pipes and the expan-
sion valve to prevent moisture from entering the
- the bonnet opening cable, system.
- the upper cross member.

a Remove the cooling assembly.
18985
111714
a Remove: a Disconnect:
- the injection computer mounting bolts (14) , - the fuel pipes (19) on the fuel filter,
- the wiring harness mounting bolt (15) , - the diesel return pipe union on the diesel tempera-
ture probe,
- the engine wiring harness connectors (16) ,
- the connectors (20) from the fuel filter.
- the earth wire nuts on the side member (17) ,
a Drain the brake fluid reservoir down to the clutch
- the computer mounting (18) . master cylinder pipe union using a syringe.
10A-179
a Disconnect the oxygen probe connector under the
vehicle.
a Remove:
- the exhaust downpipe mountings,
- the power steering intercooler mountings on the
lower cross member.
18655
a Remove:
- the clips on the clutch slave cylinder,
- the pipes on the clutch slave cylinder,
- the gearbox controls (21) .
111561
a Remove:
- the side members (24) ,
- the cross member (25) .
a Position the workshop hoist equipped with a load
balancer or a chain.
a Support the « engine and gearbox assembly » .
a Remove:
- the suspended engine mounting,
- the gearbox support pad,
18990-1 - the gearbox suspended engine mounting,

a Remove:
- the mounting bolt (22) ,
- the mounting bolt (23) ,
- the engine tie-bar.
a Drain the power steering reservoir.
a Remove:
- the return hose on the power assisted steering re-
servoir,
- the power assisted steering pipes on the steering
rack.
10A-180
- the engine tie-bar mounting bolt on engine (180
Nm),
- the lower ball joint nut (110 Nm),
- the track rod end nut (37 Nm),
- the shock absorber lower end mounting bolts

(180 Nm),
- the brake calliper guide pin bolts (7 Nm),
- the driveshaft gaiter mounting bolts (30 Nm),
- the stabiliser bar tie rod nuts (44 Nm),
- the aluminium side member mounting bolts on

the lower cross member (44 Nm),
18986
a Remove the lower cross member (26) . - the aluminium side member tie rod mounting
bolts (44 Nm).
WARNING a Add the brake fluid to the brake fluid reservoir.

The lower cross member (26) contributes to the a Perform the following operations:
rigidity of the engine compartment structure.
Before any operation on the lower cross member, - bleed the clutch system (see 37A, Mechanical
it is essential that the engine is supported at its component controls, Bleeding the clutch sys-
support points. tem:),
- top up the gearbox oil,

a Remove the « engine and gearbox » assembly.
- top up the engine oil if necessary,
WARNING - fill and bleed the cooling circuit (see 19A, Cooling,
Refit the lower cross member after having remo- Bleeding the cooling circuit),
ved the « engine and gearbox assembly » .
- fill the refrigerant circuit using a refrigerant char-
ging station.
REFITTING
a Remove the lower cross member. IMPORTANT
Depress the brake pedal several times to bring
a Position the « engine and gearbox » assembly in the
the pistons into contact with the brake pads and
vehicle.
discs.
a Refit the lower cross member.
a Proceed in the reverse order to removal.
WARNING
Ensure that the brake pipe and the ABS sensor
- the suspended engine mounting bolts on the wiring are properly fixed.
bodywork (21 Nm),
Do not twist the brake hose.
- the suspended engine mounting bolts on the
engine (62 Nm), a Connect the battery, starting with the positive termi-
nal.
- the engine mounting upper tie rod mounting
bolts (105 Nm),
- the gearbox suspended mounting bolts (62 WARNING
Nm), Carry out the necessary programming (see 80A,
Battery, Battery: Remove and Refit).
- the gearbox suspended mounting nut (44 Nm),
- the engine tie-bar mounting bolt on the sub-fra- a Adjust the headlights (see 80B, Headlights,
me (105 Nm), Halogen headlights: Adjustment).
10A-181
a If the vehicle is fitted with Xenon headlights, it is ne-
cessary to initialise the system and adjust the headli-
ghts (see 80C, Xenon bulbs, Xenon headlights:
Adjustment).
IMPORTANT
To prevent eye injuries do not look at a Xenon
bulb when lit (lit voltage: 20,000V).
10A-182
F9Q, and 755
REMOVAL
Tav. 476 Ball joint extractor. ting equipment, Two-post lift: Safety).
Essential equipment
Note:
safety strap(s) During this operation, secure the vehicle to the
lift with a safety strap(s), to prevent it from beco-
refrigerant charging station ming unbalanced.
load balancer For the strap fitting procedure (see 02A, Lifting
Tightening torquesm a Disconnect the battery, starting with the negative

terminal.
bolts mounting the sus- 21 Nm
a Remove:
pended engine moun-
ting on the body - the engine cover,
bolts mounting the sus- 62 Nm - the battery,

pended engine moun- - the front wheels,
ting on the engine
engine mounting upper 105 Nm
- the right-hand and left-hand wheel arch liners.
linkage mounting bolts
a Drain:
mounting bolts for the 62 Nm
- the refrigerant circuit using a refrigerant charging
gearbox suspended
station,
mounting
- the cooling system via the radiator bottom hose
mounting nut for the 44 Nm using the,and.
gearbox suspended
mounting - the gearbox, if necessary,
- the engine, if necessary.
bolt on the subframe
I - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
bolt on the engine
lower ball joint nut 110 Nm
- the ABS sensor.
track rod end nut 37 Nm
shock absorber base 180 Nm
mounting bolts
brake calliper guide pin 7 Nm

bolts
aluminium side mem- 44 Nm

ber mounting bolts on
the lower cross member
aluminium side mem- 44 Nm

ber tie rod mounting
bolts
10A-183
F9Q, and 755
18613 22377
a Remove: a Remove:
- the lower ball joint, - the lower ball joint,
- the track rod end nut (1) , - the track rod end nut (3) ,
- the track rod end using the (Tav. 476), - the track rod end using the (Tav. 476),
- the shock absorber base mounting bolts (2) . - the driveshaft relay bearing bracket mounting bolts
(4) ,
- the left-hand driveshaft-stub axle carrier assembly.
- the driveshaft relay bearing bracket,
II - RIGHT-HAND SIDE OF THE VEHICLE - the shock absorber base mounting bolts (5) .
a Remove: - the right-hand driveshaft-stub axle carrier assem-
bly.
- the ABS sensor.
Note:
Check the condition of the contact surface of the
lip seal.
Always replace the differential output lip seal with
a new one whenever the driveshaft is removed
(see 21A, Manual gearbox, Differential output
seal).
10A-184
F9Q, and 755
a Unclip the wiring harness on the upper cross mem-
ber.
a Disconnect:
- the headlight connectors,
- the bonnet switch connector (if fitted).
19129
a Disconnect the fog lights at (6) .
a Remove the front bumper (see 55A, Exterior pro-

tection, Front bumper: Removal - Refitting).
111454
a Remove the headlight upper mounting bolts (10) .
18701
a Remove the relay plate at (7) .
a Unclip the fuse carrier (8) .
a Remove: 111455
- the battery tray mounting bolts (9) , a Remove the headlight lower mounting bolt (11) .
- the battery tray. a Unclip the headlight from its centring device (12) .
a Unclip the power steering reservoir. a Remove the headlights.
10A-185
F9Q, and 755
a Remove:
- the air filter unit and air intake sleeve assembly,
- the lower radiator mountings,
- the radiator top hose,
- the connector on the fan unit,
- the hoses from the expansion bottle,
- the connector on the condenser,
- the air conditioning pipe mountings on the com-

pressor and the dehydration canister.
111845
a Remove:
Note:
- the upper cross member mounting bolts (13) , Plugs must be fitted to the pipes and the expan-
sion valve to prevent moisture from entering the
- the bonnet opening cable, system.
- the upper cross member.

a Remove the cooling assembly.
18985
111714
- the wiring harness mounting bolt (15) , - the diesel return pipe union on the diesel tempera-
ture probe,
- the engine wiring harness connectors (16) ,
- the fuel filter connectors (20) .
a Drain the brake fluid reservoir down to the clutch
- the computer mounting (18) . master cylinder pipe union using a syringe.
10A-186
F9Q, and 755
a Drain the power steering reservoir.
a Remove:
- the return hose on the power steering reservoir,
- the power assisted steering pipes on the steering

rack.
a Disconnect the oxygen probe connector under the

vehicle.
a Remove:
- the exhaust downpipe mountings,
- the power-assisted steering radiator mountings on

the lower cross member.
14829
a Disconnect the multifunction switch cable ball joint
(21) .
a Detach the sleeve stop at (22) .
a Disconnect the multifunction switch cable (22) .
Note:
Do not move the orange ring during this opera-
tion. It may break when removed or refitted. If
this happens, do not replace the control cable as
its absence will not affect the operation of the
system.
111561
a Remove:
- the side members (25) ,
- the cross member (26) .
a Position the workshop hoist equipped with a load

balancer or a chain.
a Support the « engine - gearbox » assembly.
18990-1 a Remove:
a Remove:
- the suspended engine mounting,
- the mounting bolt, (23)
- the mounting bolt, (24) - the gearbox support rubber pad,
- the engine tie-bar. - the suspended gearbox mounting,
10A-187
F9Q, and 755
- the engine tie-bar mounting bolt on the subfra-
me (105 Nm),
- the engine tie-bar mounting bolt on the engine

(180 Nm),
- the lower ball joint nut (110 Nm),
- the track rod end nut (37 Nm),
- the shock absorber base mounting bolts (180

Nm),
- the brake calliper guide pin bolts (7 Nm),
- the aluminium side member mounting bolts on

the lower cross member (44 Nm),
18986
- the aluminium side member tie rod mounting
a Remove the lower cross member (27) . bolts (44 Nm).
a Add the brake fluid to the brake fluid reservoir.

WARNING
a Perform the following operations:
The lower cross member (27) contributes to the
rigidity of the engine compartment structure. - bleed the clutch system (see 37A, Mechanical
Before any operation on the lower cross member, component controls, Bleeding the clutch sys-
it is essential that the engine is supported at its tem),
contact points.
- top up the gearbox oil,
a Remove the « engine - gearbox » assembly.
- fill up the engine oil if necessary,
- fill and bleed the cooling circuit (see 19A, Cooling,

WARNING
Bleeding the cooling circuit),
Refit the lower cross member after having remo-
ved the « engine - gearbox » assembly. - fill the refrigerant circuit using a refrigerant char-
ging station.
REFITTING
IMPORTANT
a Remove the lower cross member.
Depress the brake pedal several times to bring
a Position the « engine - gearbox » assembly in the the pistons into contact with the brake pads and
vehicle. discs.
a Refit the lower cross member.
a Proceed in the reverse order to removal. WARNING

Ensure that the brake hose and the ABS sensor
a Torque tighten:
wiring are properly fixed.
- the bolts mounting the suspended engine Do not twist the brake hose.
mounting on the body (21 Nm),
- the bolts mounting the suspended engine a Connect the battery, starting with the positive termi-
mounting on the engine (62 Nm), nal.
- the engine mounting upper linkage mounting

bolts (105 Nm), WARNING
- the mounting bolts for the gearbox suspended Carry out the necessary programming (see 80A,
mounting (62 Nm), Battery, Battery: Removal - Refitting).
- the mounting nut for the gearbox suspended a Adjust the headlight units (see 80B, Headlights,
mounting (44 Nm), Halogen headlights: Adjustment).
10A-188
F9Q, and 755
a If the vehicle is fitted with xenon headlights, it is ne-
cessary to initialise the system and adjust the beam
height (see 80C, Discharge bulbs, Xenon headli-
ghts: Adjustment).
IMPORTANT
Never light a bulb which is not fitted in its headli-
ght unit (can damage eyesight).
10A-189
Mot. 1390 Support for removing/refitting

the engine - gearbox assem-
bly.
REMOVAL

ting equipment, Vehicle: Towing and lifting).
IMPORTANT
During this operation, secure the vehicle to the
lift with a strap to prevent it from becoming unba-
lanced.
115592
a Unclip:
- the turbocharger regulation solenoid valve (3) .
- the Protection and Switching Unit (4) ,
- the cooling hose on the battery tray.
a Using the, remove:
- the power steering reservoir inlet hose clip,
- the power steering reservoir outlet hose clip,
a Remove:
- the power steering reservoir inlet hose,
- the power steering reservoir outlet hose,
a Disconnect the air flow sensor connector.

102885
a Drill into the bolt shaft of the tamperproof bolts (5)
a Remove:
using a 5 mm drill bit.
- the engine cover,
a Remove:
- the battery (see 80A, Battery, Battery: Removal -
Refitting), - the battery tray tamperproof bolts (5) using the,
- the automatic transmission computer connector (1) - the air duct mounting bolt (6) ,
,
- the air duct,
- the automatic transmission computer (2) .
- the battery tray,
- the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-28) ,
- the diesel filter protector,
10A-251
a Drain: a Unclip:
- the coolant circuit (see 62A, Air conditioning, Air - the power steering reservoir,
conditioning: Parts and consumables for repair
- the fan unit harness.
work),
a Remove:
- the transmission (see 23A, Automatic transmis-
sion, Automatic transmission oil: Draining - Re- - the headlights (see 80B, Headlights, Halogen
filling), headlights: Removal - Refitting),
- the engine, if necessary (see 10A, Engine and cy- - the power steering reservoir hose clips using the,
linder block assembly, Engine oil: Draining - - the power steering reservoir hoses,
Refilling, page 10A-62) ,
- the power steering reservoir,
- the intercooler hoses,
a Clean the cooling system (see Engine cooling cir-
cuit: Cleaning) . - the mountings securing the air conditioning pipe on
the compressor,
a Remove:
- the mountings securing the air conditioning pipe on
- the front wheels (see 35A, Wheels and tyres, the condenser,
Wheel: Removal - Refitting),
- the mounting securing the air conditioning pipe on
- the front wheel arch liners (see MR 396 Bo- the dehydration canister, coming from the com-
dywork, 55A, Exterior protection, Wheel arch pressor.
liner: Removal - Refitting),
a Disconnect:
- the left-hand driveshaft hub carrier (see 31A, Front - the air conditioning pipes from the compressor,
axle components, Front left-hand driveshaft
hub carrier: Removal - Refitting), - the air conditioning pipes from the condenser,
- the front left-hand driveshaft (see 29A, Drives- - the air conditioning pipe from the dehydration ca-
hafts, Front left-hand wheel driveshaft: Remo- nister, coming from the compressor.
val - Refitting),
- the right-hand driveshaft hub carrier (see 31A, WARNING
Front axle components, Front right-hand dri- Plugs must be fitted on the hoses to prevent
veshaft hub carrier: Removal - Refitting), moisture from entering the system.
- the front right-hand driveshaft (see 29A, Drives-
a Remove:
hafts, Front right-hand driveshaft: Removal -
Refitting), - the air conditioning pipe between the condenser
and the compressor,
- the front bumper (see MR 396, Bodywork, 55A,
Exterior protection, Front bumper: Removal - - the air conditioning pipe between the dehydration
Refitting). canister and the compressor.
a Disconnect:
- the fan unit connectors,
- the pressostat connector from the condenser.
a Drain the cooling system (see 19A, Cooling, Coo-
ling circuit: Draining - Refilling, page 19A-22) .
- the cooling radiator top hose clip,
- the passenger compartment heater hose clips.
a Remove:
- the cooling radiator top hose,
- the passenger compartment heater hoses.
10A-252
18985 111714
- the wiring harness mounting bolt (8) , - the diesel return pipe (14) ,
- the engine wiring harness connectors (9) , - the fuel filter connectors (15) .
a Unclip the gearbox harness connectors (11) . WARNING
Plugs must be fitted on the hoses to prevent
a Disconnect the gearbox harness connectors (11) .
moisture from entering the system.
a Remove:
- the injection computer with its mounting (12) ,
- the bolts mounting the heating element on the ra-
diator mounting cross member,
- the mountings securing the power-assisted stee-
ring radiator on the lower cross member,
- the radiator mounting cross member (see MR 396,
41A, Front lower structure, Radiator mounting
cross member: Removal - Refitting),
- the cooling assembly,
- the expansion bottle (see 19A, Cooling, Expan-
sion bottle: Removal - Refitting, page 19A-98) .
111562
a Disconnect:
- the multifunction switch cable ball joint (16) ,
10A-253
- the modular connector (17) by releasing the con-
nector slide,
- the connector between the vacuum pump and the

brake servo.
a Unclip the gearbox harness connectors.
a Disconnect:
- the gearbox harness connectors,
- the pre-postheating unit harness connector,
- the electric coolant pump connector.
a Remove:
- the electric coolant pump mounting,
- the power-assisted steering hose mountings.
a Remove:
- the electric coolant pump mounting, 113416

a Unclip the particle filter pressure sensor connector
- the power-assisted steering pipes. (19) located in the engine compartment.
a Disconnect the particle filter pressure sensor con-
nector (19) .
111725
a Disconnect the power-assisted steering pump pipe

(18) . 106688
a Remove the nut (20) .
WARNING
Plugs must be fitted on the hoses to prevent
moisture from entering the system.
a Remove the engine tie-bar (see 1 9 D , Engine

mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-36) .
10A-254
106689 106669
a Unclip the offset downstream temperature sensor a Remove:
connector (21) .
- the nuts (23) securing the rubber mounting to the
a Disconnect the offset downstream temperature sen- sub-frame,
sor connector (21) .
- the two exhaust pipe nuts (24) between the con-
necting hose and the catalytic pre-converter.
a Raise the particle filter to extract the rubber moun-
ting bush from the crimped studs on the sub-frame.
a Pull the exhaust pipe towards the rear of the vehicle.

CONCERNED
113415
a Unclip the offset upstream temperature sensor con-
nector (22) .
a Disconnect the offset upstream temperature sensor
22240
connector (22) .
a Mark the positions of the suspended engine moun-
tings on the body.
a Support the « engine - gearbox » assembly on the
marks (25) using the (Mot. 1390).
10A-255
a Remove: a Connect the particle filter pressure sensor connector
(19) .
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended a Clip on the particle filter pressure sensor connector
engine mounting: Removal - Refitting, page (19) located in the engine compartment.
19D-24) ,
a Refit the engine tie-bar (see 19D, Engine moun-
- the left-hand suspended engine mounting (see ting, Lower engine tie-bar: Removal - Refitting,
19D, Engine mounting, Left-hand suspended page 19D-36) .
engine mounting: Removal - Refitting, page
a Remove the power-assisted steering pipe plugs.
19D-8) .
a Connect the power-assisted steering pump pipe.
a Raise the vehicle, moving the engine towards the
front. a Refit:
a Remove the « engine - gearbox assembly » . - the power-assisted steering hose mountings,
- the electric coolant pump mounting.
REFITTING a Connect:
- the electric coolant pump connector,
I - REFITTING OPERATION FOR PART
CONCERNED - the pre-postheating unit harness connector,
a Position the « engine - gearbox » assembly. - the gearbox harness connectors.
a Refit: a Clip on the gearbox harness connectors.
- the right-hand suspended engine mounting (see a Connect:

19D, Engine mounting, Right-hand suspended - the connector between the vacuum pump and the
engine mounting: Removal - Refitting, page brake servo,
19D-24) ,
- the modular connector by releasing the connector
- the left-hand suspended engine mounting (see slide,
19D, Engine mounting, Left-hand suspended
engine mounting: Removal - Refitting, page - the multifunction switch cable ball joint.
19D-8) . a Remove the diesel pipe plugs.
a Connect:
- the fuel filter connectors,
a Raise the particle filter to refit the crimped studs rub-
ber mounting bush on the sub-frame. - the diesel return pipe,
a Refit the exhaust pipe. - the fuel pipes onto the fuel filter.
a Refit: a Refit:
- the nuts on the exhaust bracket between the con- - the expansion bottle (see 19A, Cooling, Expan-
necting hose and the catalytic pre-converter, sion bottle: Removal - Refitting, page 19A-98) ,
- the nuts securing the rubber mounting bush on the - the cooling assembly,
sub-frame. - the radiator mounting cross member (see MR 396,
41A, Front lower structure, Radiator mounting
a Connect the offset upstream temperature sensor
cross member: Removal - Refitting),
connector (22) .
a Clip on the offset upstream temperature sensor con-
nector (22) . - the mountings securing the power-assisted stee-
ring radiator on the lower cross member,
a Connect the offset downstream temperature sensor
connector (21) . - the bolts mounting the heating element on the ra-
diator mounting cross member,
a Clip on the offset downstream temperature sensor
connector (21) . - the injection computer with its mounting.
a Refit the nut (20) . a Connect the gearbox harness connectors.
10A-256
a Clip on the gearbox harness connectors. a Refit:
a Refit: - the front bumper (see MR 396, Bodywork, 55A,
Exterior protection, Front bumper: Removal -
- the earth wire nuts on the side member, Refitting),
- the engine wiring harness connectors, - the front right-hand driveshaft (see 29A, Drives-
- the wiring harness mounting bolt, hafts, Front right-hand driveshaft: Removal -
Refitting),
- the injection computer mounting bolts.
- the right-hand driveshaft hub carrier (see 31A,
a Refit: Front axle components, Front right-hand dri-
veshaft hub carrier: Removal - Refitting),
- the air conditioning pipes to the compressor,
- the front left-hand driveshaft (see 29A, Drives-
- the air conditioning pipes to the condenser, hafts, Front left-hand wheel driveshaft: Remo-
- the air conditioning pipe on the dehydration canis- val - Refitting),
ter coming from the compressor. - the left-hand driveshaft hub carrier (see 31A, Front
axle components, Front left-hand driveshaft
a Refit:
hub carrier: Removal - Refitting),
- the mounting securing the air conditioning pipe on
- the front wheel arch liners (see MR 396 Bo-
the dehydration canister, coming from the com-
dywork, 55A, Exterior protection, Wheel arch
pressor,
- the mountings securing the air conditioning pipe on
- the front wheels (see 35A, Wheels and tyres,
the condenser,
Wheel: Removal - Refitting).
- the mountings securing the air conditioning pipe on a Refill:
the compressor,
- the intercooler hoses,
- the engine, if necessary (see 10A, Engine and cy-
- the power steering reservoir, linder block assembly, Engine oil: Draining -
Refilling, page 10A-62) ,
- the power steering reservoir hoses,
- the transmission (see 23A, Automatic transmis-
- the power steering reservoir hose clips using the,
sion, Automatic transmission oil: Draining - Re-
- the headlights (see 80B, Headlights, Halogen filling),
headlights: Removal - Refitting). - the coolant circuit (see 62A, Air conditioning, Air
a Clip on: conditioning: Parts and consumables for repair
work).
- the fan unit harness,
a
Note:
a Refit:
The battery tray tamperproof bolts must be repla-
- the cooling radiator top hose, ced.
- the passenger compartment heater hoses. Refit:
a Using the, refit: - the diesel filter protector,
- the cooling radiator top hose clip, - the air filter unit (see 12A, Fuel mixture, Air filter
- the passenger compartment heater hose clips. unit: Removal - Refitting, page 12A-28) ,
a Fill the cooling system (see 19A, Cooling, Cooling - the battery tray,
circuit: Draining - Refilling, page 19A-22) . - the air duct,
a Connect: - the air duct mounting bolt,
- the fan unit connectors, - the battery tray tamperproof bolts.
- the pressostat connector from the condenser. a Connect the air flow sensor connector.
10A-257
a Refit:
- the power steering reservoir inlet hose,
- the power steering reservoir outlet hose,
a Using the, refit:
- the power steering reservoir inlet hose clip,
- the power steering reservoir outlet hose clip,
a Clip on:
- the cooling hose on the battery tray,
- the Protection and Switching Unit,
- the turbocharger regulation solenoid valve.
a Refit:
- the automatic transmission computer,
- the automatic transmission computer connector,
Refitting),
- the front engine cover.
a Bleed the cooling system (see Cooling circuit:
Bleeding) .
10A-258
Oil pressure: Check 10A
I - ESSENTIAL EQUIPMENT
a Long bush (22 mm).
II - CHECK
Towing and lifting) .
a Remove the front engine cover.
a Remove the oil pressure sensor (see 10A, Engine
and cylinder block assembly, Oil pressure sen-
sor: Removal - Refitting, page 10A-98) .
115619
a Connect the pressure gauge in place of the oil pres-
sure sensor (3) .
a Warm up the engine (approximately 80˚C).
a Measure the pressure which should be:
- at idle speed: 1.2 bar
- at 3000 rpm: 3.5 bar
III - REFITTING
87363 a Disconnect the pressure gauge.

a Attach the end piece (1) to the pressure gauge (2) a Refit the oil pressure sensor (see 10A, Engine and
from kit. cylinder block assembly, Oil pressure sensor:
Removal - Refitting, page 10A-98) .
a Refit the engine cover.
10A-279
Oil pressure: Check 10A
F9Q, and 750, and DOCUMENT PHASE 1 – K4M, and 710, and DOCUMENT PHASE 1 – F4P, and 770 or 771,
and DOCUMENT PHASE 1 – L7X, and 731, and DOCUMENT PHASE 1
a Warm up the engine (approximately 80˚C).
a Measure the pressure which should be:
Mot. 1495 22 mm oxygen sensor remo-
- for K4M and F4P engines:
val/refitting socket - 1/2"
square drive and a 24 mm • At idle: 1 bar,
Allen key.
• 3000 rpm: 3 bar.
Mot. 836-05 Oil pressure gauge kit. - for L7X engine:
Mot. 1437 Connection for oil pressure • At idle: 2 bar,

measurement. • 3000 rpm: 5 bar.
- for F9Q engine:
CHECKING
• 1000 rpm: 1.2 bar,
a Position the vehicle on a two-post lift (see MR 339, • 3000 rpm: 5 bar.
Mechanical, 02A, Lifting equipment, Underbody
lift).
a Remove the engine protector.
a Disconnect the engine oil pressure sensor connec-
tors.
a Remove the engine oil pressure sensor using the

(Mot. 1495).
87363
a Carry out the fitting procedure according to the engi-

ne and then connect the following components in
place of the engine oil pressure sensor:
- for K4M, F4P and F9Q engines: assemble the
adapter (1) and the pressure gauge (2) from kit
(Mot. 836-05),
- for L7X engine: assemble the adapter (Mot. 1437)
(3) and the pressure gauge (2) from kit (Mot. 836-
05).
10A-280
TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
CONCERNED
Tightening torquesm
fixed roller mounting bolt 30 Nm
tensioning roller moun- 25 Nm

ting bolt
front right-hand wheel 110 Nm
REMOVAL

a Put the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift).
a Remove:
- the front right-hand wheel,
- the engine undertray, 16152
a Turn the accessories belt auto tensioner clockwise
- the right-hand side protector.
using a 16 mm spanner.
a Remove:
- the accessories belt,
- the auto tensioner,
- the fixed roller.
WARNING
Do not run the engine without the accessories
belt to avoid damaging the crankshaft accesso-
ries pulley.
REFITTING

a
WARNING
The belt must be replaced with a new one if it
has been removed.
WARNING
When replacing the belt, always replace the ten-
sioning rollers and fixed rollers.
a Use a brush to remove any deposits from the

crankshaft pulley V-grooves.
11A-13
Accessories belt: Removal - Refitting 11A
CONCERNED
a Refit:
- the auto tensioner,
- the fixed roller.
- the fixed roller mounting bolt (30 Nm)
- the tensioning roller mounting bolt (25 Nm)
a Pivot the accessories belt auto tensioner clockwise.
a Refit the belt.

a Refit:
- the right-hand side protector,
a Tighten to torque the front right-hand wheel (110
Nm)
moval: Refitting).
11A-14
Crankshaft accessories pulley: Removal - Refitting 11A
F9Q, and 664 or 674 or 758, and DOCUMENT PHASE 2
CONCERNED
Tightening torquesm
a Refit the crankshaft accessories pulley.
crankshaft pulley moun- 40 Nm + a Lock the flywheel using a screwdriver.
ting bolt ±10˚
110˚±
a Tighten to torque the crankshaft pulley mounting
bolt (40 Nm + 110˚± ± 10˚)
REMOVAL
I - REMOVAL PREPARATION OPERATION a Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting,
a Position the vehicle on a two-post lift (see 02A, Lif- page 11A-4)
ting equipment, Underbody lift).
a Connect the battery (see 80A, Battery, Battery, Re-
a Disconnect the battery (see 80A, Battery, Battery, moval: Refitting).
Removal: Refitting).
a Remove the accessories belt (see 11A, Top and

front of engine, Accessories belt: Removal - Re-
fitting, page 11A-4)

CONCERNED
a Lock the flywheel using a screwdriver.
a Remove:
- the crankshaft accessories pulley mounting bolt,
- the crankshaft accessories pulley.
Note:
Never apply force or relative torque between the
pulley and the engine.
Do not heat sections of the part or the entire part
above 100˚C
REFITTING
I - OPERATION FOR REFITTING PART

CONCERNED
a Under no circumstances must the timing sprocket-

bolt contact surface be impacted.
Note:
Never press on the inertia ring and sprocket.
Do not exceed the maximum tightening torque
for the mounting bolt. It may crack or become
deformed.
11A-25
Timing belt: Removal - Refitting 11A
Mot. 1453 Multiple-adjusting engine

mounting support with retai-
ning straps.
Mot. 1453-01 Additional winder nut on

engine lift support Mot. 1453.
Mot. 1054 TDC setting pin.
Mot. 1543 Tool for pretensioning timing

belt.
Mot. 1705 Adapter for the timing belt

pretensioning tool. To be used 18676
with Mot.1543.
a Fit the (Mot. 1453) and the (Mot. 1453-01) with re-
Mot. 1505 Belt tension setting tool (fre- taining straps.
quency meter) a Remove the right-hand suspended engine moun-
ting.
Tightening torquesm
TDC pin plug 20 Nm

ting nut
crankshaft accessories 40 Nm + 110˚ ±

pulley mounting bolt 10˚
WARNING
Never turn the engine in the opposite direction to its
normal operating direction.
REMOVAL
15102
REMOVAL PREPARATION OPERATION
a Remove:
- the TDC setting pin plug (1) ,
- the flywheel guard cover plate.
a Remove:
- the accessories belt (see 11A, Cylinder head, Ac-

cessories belt: Removal - Refitting).
11A-93
OPERATION FOR REMOVAL OF PART Adjusting the timing
CONCERNED
104329
104739 a Rotate the crankshaft clockwise (timing end); bring
a Remove: the camshaft pulley marking to half a tooth before
the marking on the protection plate.
- the crankshaft accessories pulley, locking the
flywheel with a screwdriver,
- the timing cover mounting bolts (2) ,
- the timing cover.
104330
a As soon as the mark on the camshaft pulley is half a
tooth before the mark on the cover plate, press the
TDC setting pin (Mot. 1054) until the crankshaft is
correctly set.
11A-94
CONCERNED
104326
a Loosen the tensioning roller mounting nut (3) to re-
lax the tensioning roller. 104336
a Refit the tensioning roller, taking care to position it
a Remove the timing belt.
correctly on the locating pin (4) .
REFITTING

a
WARNING
Replace the timing belt, the tensioning roller, the
crankshaft accessories pulley and bolt.
11A-95
16187 104327
a Check that the TDC setting pin (Mot. 1054) is in pla- a Fit the new timing belt, aligning the marks on the belt
ce. with those on the crankshaft, camshaft and high-
pressure pump sprockets (count 28 belt tooth spa-
ces between the mark on the camshaft sprocket and
Note: the mark on the high-pressure pump sprocket).
The crankshaft groove (5) should be in the mid- a Press the tensioning roller against the belt by tighte-
dle of the two crankshaft closure cover ribs (6) . ning the bolt (8) on the tensioning roller support.
The crankshaft timing sprocket mark (7) should
be offset one tooth to the left of the vertical axis
of the engine. Note:
The bolt (8) is manufactured locally.
a Remove the TDC setting pin (Mot. 1054).

a Fit the crankshaft accessories pulley bolt.
11A-96
16563 104332
a Pretension the timing belt between the crankshaft ti-
ming sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of
(11 Nm).
104331
a Mount the timing belt pretensioning tool (Mot. 1543)
(9) fitted with the cover (Mot. 1705) on the cranks-
haft accessories pulley bolt.
11A-97
104333 105435
a Place the sensor of the tool onto the belt (Mot. 1505) a Remove the crankshaft accessories pulley bolt.
between the crankshaft sprocket and the tensioning
roller. III - FINAL OPERATION
a Tension the belt to obtain the recommended value a Refit the crankshaft accessories pulley, without se-
90 ± 3 Hz by turning the bolt (10) . parating its two constituent components.
a Tighten to torque the tensioning roller mounting a Tighten to torque and angle the crankshaft acces-
nut (10 Nm). sories pulley mounting bolt (40 Nm + 110˚ ± 10˚).
a Refit the TDC setting pin cap, applying a drop of
a Turn the crankshaft through two revolutions. RHODORSEAL 5661 onto the thread hole.
a Reposition the TDC setting pin (Mot. 1054). a Clip the flywheel guard flap.
a Position the timing at its setting point (start pressing a Refit:

on the pin half a tooth before alignment of the cams- - the right-hand suspended engine mounting (see
haft pulley mark and the cover plate mark, to avoid 19D, Engine mounting, Suspended engine
going into a camshaft balancing hole). mounting),
a Remove the TDC setting pin (Mot. 1054). - the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting).
a Tighten to torque the TDC pin plug (20 Nm).
a Remove the (Mot. 1453) and (Mot. 1453-01) with
a Apply a pretensioning force between the crankshaft the retaining belts.
timing sprocket and the tensioning roller using the
(Mot. 1543) and a torque wrench set to a torque of moval - Refitting).
11 Nm.
a Place the sensor of the (Mot. 1505) between the

crankshaft sprocket and the tensioning roller.
a Check that the tension value is 80 ± 5 Hz ; if not, rea-

djust.
a Tighten to torque the tensioning roller mounting

nut (45 Nm).
a Remove the (Mot. 1543).
11A-98
F9Q, and 650 or 670 or 750 or 752 or 754, and DOCUMENT PHASE 1
REMOVAL
Mot. 1054 TDC setting pin. I - REMOVAL PREPARATION OPERATION
Mot. 1543 Tool for pretensioning timing a For the preliminary stages of adjusting the timing
belt. (see MR 339 Mechanical, 11A, Top and front of
engine, Timing belt).
Mot. 1705 Adapter for the timing belt
a Remove the crankshaft accessories pulley by loc-
pretensioning tool. To be used
king the flywheel with a large screwdriver.
with Mot.1543.
Mot. 1715 Belt tension checking tool ADJUSTING THE TIMING

(frequency indicator).
Mot. 1505 Belt tension setting tool (fre-

quency meter)
Tightening torquesm

ting bolts
tensioning roller nut 45 Nm
TDC pin plug 25 Nm
IMPORTANT
Wear protective gloves during the operation.
15102
WARNING
a Remove the plug (1) from the TDC setting pin.
Never rotate the engine anti-clockwise (timing
end). a Fit the (Mot. 1054), without inserting it fully.
WARNING
ries pulley.
a Parts always to be replaced:
- the tensioning roller(s),
- the fixed roller(s),
- the crankshaft accessories pulley bolt,
- any removed belt.
a Repair consumables:
- silicone adhesive sealant.
11A-99
16188
a Rotate the crankshaft in a clockwise direction at the
timing end.
a Once the mark (2) on the camshaft pulley appears in
the window (3) of the timing cover, press on the
(Mot. 1054) until the crankshaft is set (the mark on
the camshaft pulley should be located in the centre
of the window).
11A-100
16151
a Remove the timing cover.
a Make a mark with an indelible pencil on the inner ti-
ming cover opposite the camshaft pulley mark.
11A-101
CONCERNED
16151-1
a Undo the tensioning roller nut (4) .
11A-102
CONCERNED
16153
a Remove the bolt (5) from the tensioning roller moun-
ting. 16153
a Refit the new "tensioning roller - mounting" assem-
a Remove the “tensioning roller - mounting” assembly.
bly.
a Check that the tensioning roller is correctly positio-
REFITTING ned on the pin (6) .
a Torque tighten the tensioning roller mounting
I - REFITTING PREPARATION OPERATION bolts (10 Nm).
a
ADJUSTING THE TIMING
WARNING
When replacing a timing belt, the timing belt,
fixed roller, tensioning roller and crankshaft
accessories pulley bolts must be replaced.
104330
a Check that the mark on the camshaft pulley lines up
with the mark on the inner timing cover.
11A-103
16563-1
16187
a Check that the (Mot. 1054) is correctly fitted.

a The crankshaft groove (7) should be in the middle of
the two crankshaft closure cover ribs (8) . The
crankshaft timing sprocket mark (9) should be set
one tooth to the left of the engine's vertical axis.
104331
a Fit the (Mot. 1543) equipped with the (Mot. 1705) on
the crankshaft accessories pulley.
104327
a Refit the new timing belt aligning the belt marks with
those of the sprockets.
a Set the tensioning roller tight against the timing belt
using the bolt (10) .
a Fit the old crankshaft accessories pulley bolt.
11A-104
16351-2
a Check that the bar (11) of the (Mot. 1543) is across
the entire width of the timing belt.
(11 Nm).
11A-105
104333 104333
a Position the sensor of the (Mot. 1715) o r (Mot.
1505) between the crankshaft timing sprocket and
the tensioning roller.
a Tension the timing belt using the bolt (13) until the
a Tension the timing belt using the bolt (12) until the tension value of 90 ± 3 Hz is reached.
tension value of 90 ± 3 Hz is reached.
a Torque tighten the tensioning roller nut (45 Nm).
a Remove the (Mot. 1543) and (Mot. 1705).
WARNING a Apply a drop of SILICONE ADHESIVE SEALANT to
Failure to observe the following procedure can the thread hole of the TDC pin plug.
lead to the destruction of the engine.
a Refit the TDC pin plug.
a Torque tighten the TDC pin plug (25 Nm).
a Fit the (Mot. 1054), without inserting it fully.
a Remove:
a Turn the crankshaft four times.
- the timing cover,
a Set the timing to its setting point (start pressing the - the timing cover bolts.
(Mot. 1054) half a tooth before alignment of the
camshaft pulley mark and the inner timing cover
mark, to prevent it entering a crankshaft balancing
hole). a Refit the accessories crankshaft pulley with a new
bolt.

a Check that the bar of the (Mot. 1543) is across the

entire width of the timing belt.

(11 Nm).
11A-106
11A-107
106874
a The tightening torque of the new crankshaft acces-
sories pulley bolt depends on the shape of the
crankshaft accessories pulley.
± 10˚.
- Pulley mark (1) 40 Nm +110˚±
± 10˚.
- Pulley mark (2) and (3) 40 Nm +100˚±
± 10˚.
a After having set the timing belt tension (see MR 339
Mechanical, 11A, Top and front of engine, Timi-
ng belt).
11A-108
REMOVAL
Mot. 1367-02 Engine stand.

Mot. 1054 TDC setting pin.
Mot. 1543 Tool for pretensioning timing ting Equipment, Vehicle: Towing and lifting).
belt.
Mot. 1705 Adapter for the timing belt Removal - Refitting).
pretensioning tool. To be used
with Mot.1543. a Remove:
Mot. 1715 Belt tension checking tool - the engine cover,

(frequency indicator). - the front right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting),
Mot. 1505 Belt tension setting tool (fre-
quency meter) - the front right-hand wheel arch liner (see MR 396
Bodywork, 55A, Exterior protection, Front
wheel arch liner: Removal - Refitting),
Tightening torquesm
ting bolts - the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting).
tensioning roller nut 45 Nm
a Unclip the diesel filter unit from its mounting.
TDC setting pin plug 25 Nm
a Unclip the diesel pipes.
a
a Move the « fuel pipes - diesel filter » assembly to
IMPORTANT one side.
Wear protective gloves during the operation.
a Remove:
- The crankshaft accessories pulley, locking the

WARNING flywheel using a large screwdriver,
Never rotate the engine anti-clockwise (timing
end). - the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Remo-
val - Refitting, page 19D-36) .
WARNING
ries pulley.
a Parts always to be replaced:
- the tensioning roller(s),
- the fixed roller(s),
- the crankshaft accessories pulley bolt,

- any removed belt.
a Consumables for repair:
- adhesive silicone seal (part no. 77 11 227 484), 19626
- degreaser (part no. 77 11 224 559). a Fit the (Mot. 1367-02).
11A-120
111729 16188
a Remove the right-hand suspended engine mounting a Rotate the crankshaft in a clockwise direction at the
(see 19D, Engine mounting, Right-hand suspen- timing end.
ded engine mounting: Removal - Refitting, page
a Bring the mark (2) of the camshaft pulley into the
19D-24) .
window (3) of the timing cover and push the (Mot.
1054) until the crankshaft is set (the camshaft pulley
ADJUSTING THE TIMING mark must be approximately in the centre of the win-
dow).
15102
a Remove the plug (1) from the TDC setting pin.
a Fit the (Mot. 1054) without inserting it fully.
11A-121
16151
a Remove:
- the timing cover bolts,
- the timing cover.
Note:
Make a mark with an indelible pencil on the inner
timing cover opposite the camshaft pulley mark.
11A-122
CONCERNED
16151-1
a Undo the tensioning roller nut (4) .
11A-123
16153 16153
a Remove the bolt (5) from the tensioning roller moun- a Check that the tensioning roller is correctly positio-
ting. ned on the pin (6) .
a Remove the “tensioning roller - mounting” assembly. a Torque tighten the tensioning roller mounting
bolts (10 Nm).
REFITTING
ADJUSTING THE TIMING

a
WARNING
When replacing a timing belt, the timing belt,
fixed roller, tensioning roller and crankshaft
accessories pulley bolts must be replaced.

CONCERNED
a Refit:
- the new “tensioning roller - mounting” assembly,
- the “tensioning roller - mounting” assembly bolts.
104330
a Check that the mark on the camshaft pulley lines up
with the mark on the inner timing cover.
11A-124
16187 104327
a Check that the (Mot. 1054) is correctly positioned. a Refit the new timing belt, aligning the timing belt
marks with the camshaft and crankshaft sprocket
a The crankshaft groove (7) should be in the middle of
marks.
the two crankshaft closure cover ribs (8) . The
crankshaft timing sprocket mark (9) should be set a Set the tensioning roller tight against the timing belt
one tooth to the left of the engine's vertical axis. using the bolt (10) .
a Fit the old crankshaft accessories pulley bolt.
11A-125
16563-1
104331
11A-126
16351-2
a Check that the bar (11) of the (Mot. 1543) is across
the entire width of the timing belt.
(11 Nm).
11A-127
104333 104333
a Tension the timing belt using the bolt (13) until the
a Tension the timing belt using the bolt (12) until the tension value of 90 ± 3 Hz is reached.
tension value of 90 ± 3 Hz is reached.
a Torque tighten the tensioning roller nut (45 Nm).
a Remove the (Mot. 1543) and (Mot. 1705).
WARNING a Apply a drop of SILICONE ADHESIVE SEALANT to
Failure to observe the following procedure can the thread hole of the TDC pin plug.
lead to the destruction of the engine.
a Refit the TDC pin plug.
a Torque tighten the TDC setting pin plug (25 Nm).
a Fit the (Mot. 1054) without inserting it fully.
a Remove:
a Turn the crankshaft four times.
- the timing cover,
a Set the timing to its setting point (start pressing the - the timing cover bolts.
(Mot. 1054) half a tooth before alignment of the
camshaft pulley mark and the inner timing cover
mark, to prevent it entering a crankshaft balancing
hole). a Refit the accessories crankshaft pulley with a new
bolt.

a Check that the bar of the (Mot. 1543) is across the

entire width of the timing belt.

(11 Nm).
11A-128
11A-129
106874
a The tightening torque of the new crankshaft acces-
sories pulley bolt depends on the shape of the
crankshaft accessories pulley.
± 10˚.
- Pulley mark (1) 40 Nm +110˚±
± 10˚.
± 10˚.
a Refit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand suspen-
ded engine mounting: Removal - Refitting, page
19D-24) .
a Remove the (Mot. 1367-02).
a Refit the rear suspended engine mounting (see 19D,
val - Refitting, page 19D-36) .
a Fit the « diesel filter - fuel pipes » assembly.
a Clip on the diesel pipes.
a Clip the diesel filter box onto its support.
a Refit:
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting),
- the front right-hand wheel arch liner (see MR 396
Bodywork, 55A, Exterior protection, Front
- the front right-hand wheel (see 35A, Wheels and
- the engine cover.
moval - Refitting).
11A-130
Rocker cover: Removal - Refitting 11A
Tightening torquesm
rocker cover outer bolts 12 Nm
rocker cover central bolt 15 Nm
REMOVAL

a Put the vehicle on a two-post lift (see 02A, Lifting
equipment, Underbody lift).
Removal - Refitting). a Disconnect:
a Remove the inlet duct (see 12A, Fuel mixture, Air - the camshaft sensor connector (3) ,
inlet duct: Removal - Refitting, page 12A-55)
- the injector connectors (4) .
a Move the wiring to one side.

CONCERNED
115589 115600
a Disconnect the rail pressure connector. a Remove:
a Remove: - the rocker cover bolts (5) ,
- the two diesel splash guard mounting bolts (1) , - the rocker cover (6) ,
- the diesel splash guard (2) . - the seal,
11A-169
Rocker cover: Removal - Refitting 11A
REFITTING a Connect the battery (see 80A, Battery, Battery: Re-

moval - Refitting).

a Always replace the rocker cover seal.
WARNING
Do not put oil on the cylinder head rocker cover.

CONCERNED
a Refit the rocker cover
115600
- the rocker cover outer bolts (12 Nm) (7) ,
- the rocker cover central bolt (15 Nm) (8) .

a Connect:
- the injector connectors,
- the camshaft sensor connector.
a Refit the diesel splash guard.
Note:
Check the position of the cable on either side of
the cover before tightening the diesel splash
guard bolts.
a Tighten the diesel splash guard mounting bolts with

a spanner.
a Connect the rail pressure connector.
a Refit the inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting, page 12A-55)
11A-170
Camshaft: Removal - Refitting 11A
F9Q
- the camshaft seal (see 11A, Top and front of en-
gine, Camshaft seal at timing end: Removal -
Tightening torquesm Refitting, page 11A-227) .
bolts of the camshaft 30 N.m

bearing cap cover
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see Engine: Precautions for repair) .
REMOVAL

Towing and lifting) (02A, Lifting equipment).
a Remove:
- the engine cover, 136226
- the vacuum pump (see Vacuum pump: Removal a Remove:
- Refitting) (37A, Mechanical component controls),
- the inner timing cover bolts (1) ,
- the engine undertray bolts, - the inner timing cover,
- the engine undertray, - the rocker cover (see 11A, Top and front of engi-
- the front right-hand wheel (see Wheel: Removal - ne, Rocker cover: Removal - Refitting, page
Refitting) (35A, Wheels and tyres), 11A-142) .
- the front right-hand wheel arch liner (see Front

wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-16) ,
- the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-36) ,
- the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
Refitting, page 13B-35) ,
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-24) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-26) ,
11A-220
F9Q
II - OPERATION FOR REMOVAL OF PART REFITTING
CONCERNED

a
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
a Use SUPER CLEANING AGENT FOR JOINT FA-

CES (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products) to
clean:
- the joint face of the camshaft bearing cap cover,
136227 - the cylinder head joint face.
a Remove:
- the bolts (2) of the camshaft bearing cap cover, and ingredients for the repairwork) (04B, Consu-
mables - Products) to degrease:
- the camshaft bearing cap cover.
- the joint face of the camshaft bearing cap cover,
- the cylinder head joint face.
a parts always to be replaced: Camshaft seal on ti-
ming end (10,02,02,02).
parts always to be replaced: camshaft timing
sprocket bolt (10,02,02,16).
136229
a Remove the camshaft (3) .
11A-221
F9Q
12515
a
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
16186-1
ture of sealant and fluid could damage certain
components (engine, radiator, etc.). a Torque tighten in order the bolts of the camshaft
bearing cap cover (30 N.m).
a Apply RESIN ADHESIVE (see Vehicle: Parts and
ingredients for the repairwork) (04B, Consuma-
bles - Products) using a stipple roller on the joint III - FINAL OPERATION
face of the camshaft bearing cap cover until the joint a Refit:
face is completely coated.
- the rocker cover (see 11A, Top and front of engi-
a Use a cloth to remove any RESIN ADHESIVE in the ne, Rocker cover: Removal - Refitting, page
camshaft bearing caps. 11A-142) ,
- the inner timing cover,
CONCERNED - a new camshaft seal on the timing end (see 11A,
Top and front of engine, Camshaft seal at timi-
a Refit the camshaft. ng end: Removal - Refitting, page 11A-227) .
a Apply a drop of FRENETANCHE (see Vehicle: - the timing belt (see 11A, Top and front of engine,
Parts and ingredients for the repairwork) (04B, Timing belt: Removal - Refitting, page 11A-26) ,
Consumables - Products) on the bolts of the cams-
haft bearing cap cover. - the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
a Refit the camshaft bearing cap cover. engine mounting: Removal - Refitting, page
19D-24) ,
- the camshaft position sensor (see 13B, Diesel in-
jection, Camshaft position sensor: Removal -
- the lower engine tie-bar (see 19D, Engine moun-
ting, Lower engine tie-bar: Removal - Refitting,
page 19D-36) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-16) ,
page 11A-4) ,
11A-222
F9Q
- the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the vacuum pump (see Vacuum pump: Removal
- Refitting) (37A, Mechanical component controls),
- the engine cover.
11A-223
Camshaft seal at timing end: Removal - Refitting 11A
Essential special tooling CONCERNED
Mot. 799-01 Timing gear wheel immobili-
ser.
Mot. 988-02 Camshaft oil seal fitting tool,

timing end (25 x 42 x 7 seal)
for F engine.
Tightening torquesm
camshaft pulley bolt 60 Nm

a Disconnect the battery (see 80A Battery, Battery:
Removal: Refitting).
a Remove:
16183-2
engine, Accessories belt: Removal - Refitting, a Lock the camshaft pulley using locking tool (Mot.
page 11A-4) 799-01) (1)
- the timing belt (see 11A, Top and front of engine, a Remove:
Timing belt: Removal - Refitting, page 11A-26) - the camshaft pulley bolt,
- the high-pressure pump (see 13B, Diesel injec- - the camshaft pulley,
tion, High pressure pump: Removal - Refitting,
page 13B-40) - the camshaft seal
WARNING
Do not damage the seal mating face when remo-
ving the camshaft seal.
REFITTING

a Always replace the camshaft pulley bolt.
11A-227
Camshaft seal at timing end: Removal - Refitting 11A
CONCERNED
16183
a Refit:
- the camshaft seal using the (Mot. 988-02) (2)
- the camshaft pulley.
a Lock the camshaft pulley using locking tool (Mot.
799-01)
a Tighten to torque the camshaft pulley bolt (60 Nm)

a Remove:
- the high-pressure pump (see 13B, Diesel injec-
tion, High pressure pump: Removal - Refitting,
page 13B-40)
Timing belt: Removal - Refitting, page 11A-26)
page 11A-4)
moval - Refitting).
11A-228
Cylinder head: Removal - Refitting 11A
F9Q, and 758 or 759, and DOCUMENT PHASE 2
a Drain the engine cooling system (see 19A, Cooling,
Essential special tooling Cooling circuit: Draining - Refilling, page 19A-22)
.
Mot. 1453 Multiple-adjusting engine
mounting support with retai-
ning straps.
WARNING
Mot. 1453-01 Additional winder nut on To prevent impurities from entering the circuit,
engine lift support Mot. 1453. place protective plugs on all fuel circuit compo-
nents exposed to the open air.
Mot. 1672 Lower engine support.
a It is essential to read the repair precautions (see

Essential equipment
13B, Diesel injection, Diesel injection: Precau-
cylinder head test tank tions for repair, page 13B-1) .
a Position the tool (Mot. 1453) fitted with the tool (Mot.
Tightening torquesm 1453-01).
cylinder head bolts (ini- 30 N.m a Remove:

tial torque)
- the battery tray (see Battery tray: Removal - Re-
cylinder head bolts 230˚ ± 6˚ fitting) (80A, Battery),
- the intake duct (see 12A, Fuel mixture, Air inlet

IMPORTANT duct: Removal - Refitting, page 12A-55) ,
Use the diagnostic tool before any operation is car- - the accessories belt (see 11A, Top and front of
ried out on the injection circuit to check: engine, Accessories belt: Removal - Refitting,
- that the rail is not under pressure, page 11A-4) ,
- that the fuel temperature is not too high. - the timing belt (see 11A, Top and front of engine,
Working on the circuit with the engine running is Timing belt: Removal - Refitting, page 11A-26) ,
strictly forbidden.
- the catalytic pre-converter (see 19B, Exhaust, Ca-
talytic pre-converter: Removal - Refitting, page
REMOVAL 19B-22) ,
- the starter (see 16A, Starting - Charging, Starter:

I - REMOVAL PREPARATION OPERATION Removal - Refitting, page 16A-18) ,
Towing and lifting) (02A, Lifting equipment). - the turbocharger oil pipe (see 12B, Turbochar-
ging, Turbocharger oil pipe: Removal - Refit-
a Remove:
ting, page 12B-41) ,
- the exhaust gas cooler (see 14A, Antipollution,
Intercooler: Removal - Refitting, page 14A-29) ,
a Remove the battery (see Battery: Removal - Refit-
ting) (80A, Battery). - the turbocharger (see 12B, Turbocharging, Tur-
bocharger: Removal - Refitting, page 12B-4) ,
- the water chamber (see 19A, Cooling, Plenum

chamber: Removal - Refitting, page 19A-60) .
a Position the (Mot. 1672).
a Remove the tool (Mot. 1453) fitted with the tool

(Mot. 1453-01).
11A-283
CONCERNED
111965
a Disconnect:
111888 - the camshaft sensor connector (7) ,
a Disconnect: - the injector connectors (8) ,
- the rail pressure sensor connector (1) , a Insert the blanking plugs.
a Move the electrical wiringto one side.
- the diesel pressure regulator connector (2) .
a Remove:
- the two bolts (3) of the diesel splash guard,
- the diesel splash guard (4) .
111889
a Disconnect:
- the diesel return temperature sensor connector,
- the high-pressure pump pressure regulator con-
nector,
- the heater plug connectors (9) ,
- the diesel return pipe (10) ,
- the diesel supply pipe.
111886
a Disconnect:
- the vacuum pipe from the vacuum pump (5) ,
- the exhaust gas recirculation unit connector (6) .
11A-284
a Apply the product to the section to be cleaned; wait
approximately ten minutes, then remove the residue
using a wooden spatula.
WARNING
Protect the oilway to prevent any foreign bodies
from entering the cylinder head oil supply pipes.
Failure to follow this instruction could lead to the
pipes becoming blocked, causing rapid camshaft
damage.
WARNING
Do not allow this product to drip onto the pain-
twork.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
102348 Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
a Remove:
would quickly result in engine damage.
- the rear bolts (11) of the high pressure pump,
- the cylinder head bolts, 2 - checking the gasket face
a Check for gasket face deformation using a ruler and

- the cylinder head.
a set of shims.
The maximum deformation is 0.05 mm.
REFITTING
WARNING
REFITTING PREPARATION OPERATION
No regrinding of the cylinder head is permitted.
a Test the cylinder head to detect any possible cracks

1 - Cleaning
using a cylinder head test tank.
a Clean the cylinder head. a If replacing the cylinder head, (see Cylinder
head:Stripping - Restoring) (Technical Note
6007A, 10A, Engine and peripherals).
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in I - OPERATION FOR REFITTING PART
a risk of leaks. CONCERNED
a Bring the pistons to mid-stroke position to prevent
any risk of contact with the valves when tightening
IMPORTANT the cylinder head.
Always wear protective gear (gloves, goggles a Degrease the joint faces using SURFACE CLEA-
and breathing masks). NER (see Vehicle: Parts and ingredients for the
repairwork) (04B, Consumables - Products).
a Clean the joint faces with SUPER CLEANER FOR
JOINT FACES (see Vehicle: Parts and ingre- a Refit:
dients for the repairwork) (04B, Consumables - - the cylinder head with a new cylinder head gasket,
Products) to dissolve any part of the seal still adhe-
ring to the sump and to the cylinder block. - new cylinder head bolts.
11A-285
a Refit the diesel splash guard.
Note:
Check the position of the cable on either side of
the cover before tightening the diesel splash
guard bolts.
a Tighten the diesel splash guard bolts with a spanner.

a Connect
- the diesel pressure regulator connector,
- the rail pressure sensor connector.
a Position the tool (Mot. 1453) fitted with the tool (Mot.
1453-01).
a Remove the tool (Mot. 1672)
16189 a Refit:
a Tighten to torque and in order the cylinder head - the water chamber (see 19A, Cooling, Plenum
bolts (initial torque) (30 N.m). chamber: Removal - Refitting, page 19A-60) ,
a Check that all the cylinder head bolts are correctly ti- - the turbocharger (see 12B, Turbocharging, Tur-
ghtened to 30 N.m. bocharger: Removal - Refitting, page 12B-4) ,
a Angle tighten in order the cylinder head bolts (230˚ - the exhaust gas cooler (see 14A, Antipollution,
± 6˚). Intercooler: Removal - Refitting, page 14A-29) ,
a Connect: - the turbocharger oil pipe (see 12B, Turbochar-
ging, Turbocharger oil pipe: Removal - Refit-
- the diesel supply pipe,
- the diesel return pipe,
- the heater plug connectors , Removal - Refitting, page 16A-18) ,
- the high-pressure pump pressure regulator con- - the catalytic pre-converter (see 19B, Exhaust, Ca-
nector, talytic pre-converter: Removal - Refitting, page
19B-22) ,
- the diesel return temperature sensor connector.
a Fit the electrical wiring. Timing belt: Removal - Refitting, page 11A-26) ,
WARNING engine, Accessories belt: Removal - Refitting,
Do not remove the blanking plugs from each page 11A-4) ,
component until the last moment. - the intake duct (see 12A, Fuel mixture, Air inlet
Also, do not remove the components from their duct: Removal - Refitting, page 12A-55) ,
packaging until they are to be fitted to the vehi-
- the battery tray (see Battery tray: Removal - Re-
cle.
fitting) (80A, Battery).
a Connect: a Remove the tool (Mot. 1453) fitted with the tool
(Mot. 1453-01).
- the injector connectors,
a Reprime the diesel circuit with the manual priming
- the camshaft sensor connector,
pump.
- the exhaust gas recirculation unit connector,
a Refit the battery (see Battery: Removal - Refitting)
- the vacuum pipe to the vacuum pump. (80A, Battery).
11A-286
a Fill and bleed the cooling system (see 19A, Coo-
ling, Cooling circuit: Draining - Refilling, page
19A-22) .
a Refit:
11A-287
Oil decanter: Removal - Refitting 11A
II - REMOVAL OPERATION FOR PART
CONCERNED
Tightening torquesm
oil decanter mounting 30 Nm

bolts
REMOVAL

115619
a Move the coolant pipes to one side (3) .
a Disconnect:
- the oil return pipes (4) ,
- the pipe (5) .
a Remove the decanter mounting bolts.
a Move aside the decanter mounting clip on the cylin-

der block using the.
111856
a Remove the oil decanter.
a Remove:
- the inlet manifold (1) (see 12A, Fuel mixture, Air REFITTING
inlet duct: Removal - Refitting, page 12A-55) ,
- the dipstick (2) . I - REFITTING OPERATION FOR PART
CONCERNED
a Refit:
- the decanter mounting clip on the decanter end

piece using the.
- the oil decanter, by moving aside the mounting clip

using the.
a Torque tighten the oil decanter mounting bolts (30

Nm).
a Connect:
- the pipe (5) ,
- the oil return pipes (4) .
11A-298
a Refit:
- the dipstick,
- the inlet manifold (1) (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting, page 12A-55) ,
moval - Refitting).
11A-299
a Remove:
Tightening torquesm - the front engine covers,

- the dipstick.
oil separator mounting 10 Nm
bolts
OPERATION FOR REMOVAL OF PART
CONCERNED
REMOVAL a Disconnect the oil vapour rebreathing pipe.

18297-1
a Remove: REFITTING
- the separator-cylinder block gas pipe (1) ,
- the separator-oil return pipe (2) , REFITTING PREPARATION OPERATION
- the oil separator mounting bolts, a It is essential to replace the seal between the retai-
ning ring and the oil separator.
- the oil separator.
a Lubricate the seal.
OPERATION FOR REFITTING PART CONCERNED

a Fit the oil separator.
11A-300
a Tighten to torque the oil separator mounting bolts
(10 Nm).
a Refit:
- the separator-oil return pipe,
- the separator-cylinder block gas pipe.
a Connect the oil vapour rebreathing pipe.
a Refit:
- the dipstick,
- the front engine covers.
moval - Refitting).
11A-301
FUEL MIXTURE
Air inlet 12A
B74 or K74, and F9Q, and 750
Diagram of the air inlet circuit
18950
(1) Intercooler
(2) Air filter unit
(3) Flowmeter
(4) Inlet manifold
(5) Turbocharger
(6) Air inlet
12A-1
FUEL MIXTURE
Air inlet 12A
Diagram of the air inlet circuit
18950
(1) Air inlet duct

(2) Air filter unit
(3) Throttle valve
(4) Turbocharger
(5) Intercooler
(6) Inlet manifold
12A-4
FUEL MIXTURE
Air intake: Description 12A
DIAGRAM OF THE AIR INLET CIRCUIT
18950
(1) Air filter unit air inlet pipe

(2) Air filter unit
(3) Flowmeter
(4) Air filter unit air outlet pipe
(5) Turbocharger
(6) Turbocharger air outlet pipe
(7) Intercooler air inlet pipe
(8) Intercooler
(9) Intercooler air outlet pipe
(10) Engine stop flap
(11) Inlet manifold
12A-11
FUEL MIXTURE
Air intake: Description 12A
DIAGRAM OF THE AIR INLET CIRCUIT
116100
(1) Air filter unit air inlet pipe

(2) Air filter unit
(3) Flowmeter
(4) Air filter unit air outlet pipe
(5) Turbocharger
(6) Turbocharger air outlet pipe
(7) Intercooler air inlet pipe
(8) Intercooler
(9) Intercooler air outlet pipe
(10) Damper flap
(11) Turbocharging pressure sensor
(12) Air inlet duct
(13) Inlet manifold
12A-13
FUEL MIXTURE
Air filter: Removal - Refitting 12A
F9Q or G9T, and DOCUMENT PHASE 2
a Tighten to torque the air pipe clip on the air filter
unit (5.5 Nm).
Tightening torquesm
a Connect the air flow sensor connector.
air pipe clip on the air fil- 5.5 Nm
ter unit
REMOVAL
115632
a Disconnect the air flowmeter connector (1) .

a Loosen the air pipe clip (2) on the air filter unit.
a Disconnect the air pipe from the air filter unit.
a Remove:
- the air filter cover mounting bolts (3) ,
- the air filter cover,
- the air filter.
REFITTING
a
WARNING
If the air filter is fitted incorrectly in the air filter
unit, unfiltered air may enter the engine.
a Refit:
- the air filter,
- the air filter unit cover,
- the mounting bolts from the air filter unit cover,
- Connect the air filter unit air pipe.
12A-25
FUEL MIXTURE
Air filter unit: Removal - Refitting 12A
CONCERNED
Tightening torquesm
the air pipe clip on the 5.5 Nm

air filter unit
REMOVAL
115633
a Remove the air filter unit by unclipping it from its lo-
cation.
111717
a Disconnect the air flowmeter connector (1) . REFITTING
a Loosen the air pipe clip (2) on the air filter unit.
a Disconnect the air pipe from the air filter unit. REFITTING OPERATION FOR PART CONCERNED
a Unclip the engine compartment connection unit from a Clip on the air filter unit.
the battery tray.
a Connect the air filter unit air pipe.
a Remove the air pipe retaining clip on the battery
a Refit the air pipe retaining clip on the battery tray.
tray.
a Clip on the battery tray engine compartment connec-
a Disconnect the air pipe from the air filter unit. tion unit.
a Connect the air filter unit air pipe.
a Tighten to torque the air pipe clip on the air filter
unit (5.5 Nm).
a Connect the air flowmeter connector.
12A-37
FUEL MIXTURE
Air flowmeter: Removal - Refitting 12A
CONCERNED
Tightening torquesm
air flowmeter bolts 4 Nm
air filter box air outlet 5.5 Nm

pipe clip
REMOVAL

115643
a Remove:
- the bolts from the air flowmeter (3) ,
- the air flowmeter,
- the seal,
REFITTING
119556 a It is essential to replace the air flowmeter seal.

a Disconnect the air flowmeter connector (1) .
a Loosen the air outlet pipe clip (2) on the air filter box.
CONCERNED
a Disconnect the air filter box outlet air pipe.
a Refit:
- the air flowmeter,
- the air flowmeter bolts.
a Torque tighten the air flowmeter bolts (4 Nm).

a Connect the air filter box outlet air pipe.
a Torque tighten the air filter box air outlet pipe clip
(5.5 Nm).
moval - Refitting).
12A-40
FUEL MIXTURE
Engine damper flap: Removal - Refitting 12A
CONCERNED
Tightening torquesm
engine damper flap 10 Nm

mounting bolts
air pipe mounting clip 5 Nm

bolt
REMOVAL

18298
a Disconnect the engine damper flap air pipe (3) .
a Remove:
- the engine damper flap mounting bolts,
- the engine damper flap.
REFITTING

a It is essential to replace the engine damper flap seal.

CONCERNED
a Refit the engine damper flap with its new seal.
a Torque tighten the engine damper flap mounting
19135-1
bolts (10 Nm).
a Undo the mounting clip (1) from the engine damper
flap air pipe (2) .
III - FINAL OPERATION.
a Connect the air pipe to the engine damper flap.
a Torque tighten the air pipe mounting clip bolt (5
Nm).
12A-41
FUEL MIXTURE
Air inlet flap: Removal - Refitting 12A
REFITTING
Tightening torquesm
damper valve mounting 8 Nm
a Replace the seal.
bolts

REMOVAL CONCERNED
a Refit the damper valve.
I - REMOVAL PREPARATION OPERATION a Screw in the damper valve mounting bolts by hand.
a Remove the front engine covers. a Tighten to torque the damper valve mounting
bolts (8 Nm).
Removal - Refitting). a Connect:
- the connector on the damper valve,
II - OPERATION FOR REMOVAL OF PART - the turbocharger pressure sensor connector.
CONCERNED
a Connect the air pipe.
a Refit the air pipe nut.
a Tighten:
- the air pipe nut,
- the air pipe clip.
a Refit the engine covers.
moval - Refitting)
a When replacing the damper valve, carry out the ne-
cessary programming (see MR 397, Fault finding,
13B, Diesel Injection, Fault finding - Replace-
ment of components).
115621
a Loosen the air pipe clip (1) .
a Remove the air pipe nut (2) .
a Disconnect the air pipe.
a Remove the air pipe.
a Disconnect:
- the damper valve connector (3) ,
- the turbocharger pressure sensor connector (4) .

a Remove:
- the three damper valve mounting bolts (5) ,
- the damper valve.
12A-45
FUEL MIXTURE
Air inlet duct: Removal - Refitting 12A
Tightening torquesm
inlet duct mounting bolts 25 Nm
inlet duct mounting nut 21 Nm

a Remove the front engine covers.

CONCERNED
115620
a Disconnect:
- the pressure sensor connector (4) ,
- the damper valve connector (5) ,
- the oil vapour rebreather pipe (6) :
on the oil decanter,
on the air hose from the air filter unit output.
a Remove:
- the inlet duct mountings (7) ,
- the inlet duct.
115621
a Remove the air duct mounting nut (1) . REFITTING
a Loosen the air inlet duct (2) .
a Disconnect the air pipe (3) .
a Replace the seals.

CONCERNED
a Refit:
- the inlet duct,
- the inlet duct mountings.
a Tighten to torque and in order:
- the inlet duct mounting bolts (25 Nm)
- the inlet duct mounting nut (21 Nm)
12A-55
FUEL MIXTURE
a Connect:
- the oil vapour rebreather pipe:
on the oil decanter,
on the air pipe from the air filter unit output,
- the connector on the damper valve,
- the pressure sensor connector,
a Connect the air pipe.
a Tighten the air inlet duct.
a Refit the air duct mounting nut.
a Tighten the air duct mounting nut.

moval - Refitting).
a Refit the front engine covers.
12A-56
FUEL MIXTURE
REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED

a Remove:
- the front engine covers,
Refitting).
19135-1
a Disconnect the turbocharger pressure sensor con-
nector (5) .
a Loosen:
- the inlet duct mounting clip (6) on the inlet manifold,
115592 - the inlet duct mounting clip (6) on the intercooler.
a Unclip: a Remove the inlet duct.
- the turbocharger regulation solenoid valve (1) ,
- the engine compartment connection unit (2) . REFITTING
a Disconnect the air flowmeter connector.
a Remove:
CONCERNED
- the battery tray mounting bolts (3) ,
a Refit the inlet duct.
- the air pipe mounting bolt (4) ,
a Tighten:
- the battery tray.
- the inlet duct mounting clip on the intercooler,
- the inlet duct mounting clip on the inlet manifold.
a Connect the turbocharger pressure sensor connec-
tor.
a Refit the battery tray.
a Tighten:
- the battery tray mounting bolts,
- the air pipe mounting bolt.
12A-57
FUEL MIXTURE
a Clip on:
- the engine compartment connection unit,
a Refit:
Refitting).
- the front engine covers.
12A-58
FUEL MIXTURE
Exhaust manifold - Intake distributor: Removal - Refitting 12A
Tightening torquesm
manifold mounting studs 8 Nm
manifold mounting nuts 27.5 Nm
damper unit mounting 8 Nm

bolts
REMOVAL
a Disconnect the battery, starting with the negative 18298
terminal. a Remove:
a Remove the turbocharger (see 12B, Turbochar- - the damper unit bolts,
ging, Turbocharger).
- the damper unit (3) .
a Remove:
- the exhaust gas recirculation solenoid valve pipe,
- the lifting eye.
18984
a Disconnect:
- the air inlet pipe from the damper,
- the exhaust gas recirculation solenoid valve con-
nector (1) .
a Remove the heating element unit mounting bolt (2) .
a Move the heating element unit to one side.
12A-62
FUEL MIXTURE
1217
a Remove the manifold mounting nuts.
REFITTING
a Replace the manifold gaskets.
a Refit the manifolds.
- the manifold mounting studs (8 Nm),
- the manifold mounting nuts (27.5 Nm),
- the damper unit mounting bolts (8 Nm).

nal.
WARNING
Battery: Removal - Refitting).
12A-63
FUEL MIXTURE

F9Q, and 664
Mot. 1567 Long nose pliers for EGR
duct clips. a Remove the exhaust gas recirculation unit (see 14A,
Antipollution, Exhaust gas recirculation unit:
Tightening torquesm
manifold studs 8 Nm
manifold mounting nut 28 Nm F9Q, and 674

a Remove the exhaust gas recirculation solenoid val-
engine damper flap 10 Nm
ve (see 14A, Antipollution, Exhaust gas recircu-
solenoid valve moun-
lation solenoid valve: Removal - Refitting, page
ting bolts
14A-18)
REMOVAL
a Remove:
- the catalytic converter (see 19B, Exhaust, Cataly-
a Position the vehicle on a two-post lift (see 02A, Lif- tic converter: Removal - Refitting, page 19B-47)
ting equipment, Vehicle, Lifting and Towing). ,
a Remove the engine covers. - the turbocharger (see 12B, Turbocharging, Tur-
a Disconnect the battery (see 80A, Battery, Battery: bocharger: Removal - Refitting, page 12B-4) .
CONCERNED
102486
a Disconnect the air pipes (2) on the vacuum canister
(3) .
111709 a Remove:
a Loosen the air inlet duct clip (1) . - the vacuum canister mounting bolts,
a Disconnect the air inlet duct from the manifold. - the vacuum canister (3) .
a Disconnect the engine damper flap solenoid valve
connector (4) .
a Remove:
- the engine stop solenoid valve mounting bolts,
12A-64
FUEL MIXTURE
- the engine stop solenoid valve (5) . - the exhaust gas recirculation pipe clips.
a Detach the air pipes from the inlet manifold.
F9Q, and 674
102478
a Remove the exhaust gas recirculation pipe (6) using
16181
the (Mot. 1567).
a For studs (9) removed when removing the manifold:
- apply FRENETANCHE at the top of the cylinder
head thread holes,
- wipe any run-off after refitting the studs.
Note:
This operation is only applicable to studs (9) .
a Refit all of the manifold studs removed.

a Tighten to torque the manifold studs (8 Nm).

CONCERNED
104423 a Refit:
a Remove the engine lifting eye (7) . - the manifolds,
a Remove: - the manifold mounting nuts,
- the manifold mounting nuts, - the engine lifting eye.
- the manifolds.
a Tighten to torque the manifold mounting nut (28
Nm).
REFITTING
F9Q, and 674
a Refit the exhaust gas recirculation pipe using the
a Replace the manifold gasket. (Mot. 1567).
Replace:
- the manifold gaskets,
12A-65
FUEL MIXTURE
a Attach the inlet manifold air pipes.
a Refit:
- the engine stop solenoid valve,
- the engine stop solenoid valve mounting bolts.
a Tighten to torque the engine damper flap solenoid

valve mounting bolts (10 Nm).
a Refit:
- the vacuum canister,
- the vacuum canister mounting bolt.
a Tighten the vacuum canister mounting bolt.
a Connect the engine damper flap solenoid valve con-

nector.
a Connect the air pipes onto the vacuum canister.
a Refit:
- the turbocharger (see 12B, Turbocharging, Tur-


tic converter: Removal - Refitting, page 19B-47)
.
F9Q, and 674
a Refit the exhaust gas recirculation solenoid valve

(see 14A, Antipollution, Exhaust gas recircula-
tion solenoid valve: Removal - Refitting, page
14A-18)
F9Q, and 664
a Refit the exhaust gas recirculation unit (see 14A,

Antipollution, Exhaust gas recirculation unit:
a Connect the air inlet duct.
a Tighten the air inlet duct clip.

moval - Refitting).
12A-66
FUEL MIXTURE

duct clips.
Tightening torquesm
manifold mounting studs 8 Nm
manifold mounting nuts 28 Nm
exhaust gas recircula- 25 Nm

tion pipe mounting bolts
on the exhaust gas
recirculation solenoid
valve

on the inlet manifold
111863
a Remove:
REMOVAL
- the clip (1) using the (Mot. 1567),
- the exhaust gas recirculation pipe mounting bolts
a Remove the engine covers. on the inlet manifold,
duct: Removal - Refitting, page 12A-55) ,
ting equipment, Vehicle, Lifting and Towing). - the injection rail protector (see 13B, Diesel injec-
tion, Injector rail protector: Removal - Refitting,
a Remove:
page 13B-79) .
- the pre-converter (see 19B, Exhaust, Catalytic
pre-converter: Removal - Refitting, page 19B-
22) ,
111861
a Remove:

(2) on the exhaust gas recirculation solenoid valve,
- the exhaust gas recirculation pipe,
12A-67
FUEL MIXTURE
- the exhaust gas recirculation solenoid valve (see - the turbocharger (see 12B, Turbocharging, Tur-
14A, Antipollution, Exhaust gas recirculation bocharger: Removal - Refitting, page 12B-4) .
solenoid valve: Removal - Refitting, page 14A-
18) ,
115729
a Disconnect the exhaust gas temperature sensor (3) .
a Detach the wiring harness from the exhaust gas

temperature sensor connector (4) .
111865
a Remove:
- the lifting eye mounting bolts (5) ,

12A-68
FUEL MIXTURE
CONCERNED

a In the event of replacing an exhaust manifold, refit
the exhaust gas temperature sensor on the work-
bench.
a Always replace:
- the manifold gaskets,
- the EGR solenoid valve seal,
- the EGR duct clip.
111872
16181
a For studs (9) removed when removing the mani-
folds:
- apply FRENETANCHE at the top of the cylinder
head thread holes,
- wipe any run-off after refitting the studs.
Note:
This operation is only applicable to studs (9) .
111873
a Refit all of the manifold studs removed.
a Remove:
a Tighten to torque the manifold mounting studs (8
- the manifold mounting nuts, Nm).
- the exhaust manifold (6) , II - REFITTING OPERATION FOR PART

CONCERNED
- the inlet manifold (7) .
a Offer up the manifold gasket.
a In the event of replacing an exhaust manifold, remo-
a Refit:
ve the exhaust gas temperature sensor (8) on the
workbench. - the manifolds,
12A-69
FUEL MIXTURE
- the manifold mounting nuts. a Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting).
a Tighten to torque the manifold mounting nuts (28
Nm).

a Refit:
- the turbocharger (see 12B, Turbocharging, Tur-
- the lifting eye mounting bolts.
a Attach the wiring harness of the exhaust gas tempe-
rature sensor.
a Connect the exhaust gas temperature sensor.
a Refit:
- the exhaust gas recirculation solenoid valve (see
14A, Antipollution, Exhaust gas recirculation
solenoid valve: Removal - Refitting, page 14A-
18) ,
- the exhaust gas recirculation pipe.
Finger tighten:
on the exhaust gas recirculation solenoid valve,
on the inlet manifold.
a Refit the clip using the (Mot. 1567).
- the exhaust gas recirculation pipe mounting
bolts on the exhaust gas recirculation solenoid
valve (25 Nm),
bolts on the inlet manifold (25 Nm).
a Refit:
- the injection rail protector (see 13B, Diesel injec-
page 13B-79) ,
duct: Removal - Refitting, page 12A-55) ,
Removal - Refitting, page 16A-18) ,
19B-22) .
12A-70
TURBOCHARGING
Turbocharging: Precautions for repair 12B
F4R or F9Q or G9T or M9R
III - APPLICATION CONDITIONS OF
INSTRUCTIONS
Essential equipment
The instructions below must be followed when repla-
parts washer cing a turbocharger due to mechanical damage:
- damage to the bearing system,
I - TURBOCHARGER: GENERAL INSTRUCTIONS - broken shaft or turbine wheel,
For the turbocharging pressure regulator check (see - compressor wheel rubbing against the turbocharger
Fault finding - Tests) (Technical Note 3419A, 12B, casing,
Turbocharging).
- broken or damaged compressor wheel,
- extensive clogging of the turbine wheel casing (hard
WARNING deposits).
The turbocharger pressure regulator rod must not FOR THE AIR CIRCUIT:
be adjusted.
- Consequences:
• swarf or metal objects in the turbocharger inlet and
II - TURBOCHARGER CIRCUIT DIAGRAM
outlet pipes,
• oil in the air circuit (collected in the intercooler).
- Risks (after replacing the turbocharger):
• metal objects sucked in by the compressor wheel
(destruction of the turbocharger).
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).
WARNING
Metal objects may enter the oil and air circuits as a
result of a broken turbocharger.
112666
Failure to follow the INSTRUCTIONS listed will lead
(1) Air filter unit to the turbocharger breaking again.
(2) Air flowmeter INSTRUCTIONS:
(3) Compressor wheel
- Drain the engine oil (see 10A, Engine and cylinder
(4) Intercooler block assembly, Engine oil: Draining - Refilling,
(5) Inlet manifold page 10A-62)
(6) Exhaust manifold - Replace the oil filter (see 10A, Engine and cylinder
(7) Turbine wheel block assembly, Oil filter: Removal - Refitting,
page 10A-78) .
(8) Bearing system (bearing +
wheel shaft) - Replace the seals and fittings,
(A) Air filter box air outlet pipe - Carry out the following only if the compressor wheel is
(B) Turbocharger air outlet pipe broken or rubbing against the turbocharger casing:
(C) Intercooler air outlet pipe • Drain the intercooler,
12B-1
TURBOCHARGING
• Clean the turbocharger air pipes. Check that there are no metal objects inside the air
flowmeter (2) .
Remove:
Note:
- the air pipe(between the air filter unit and the turbo-
When carrying out an operation on the air or lubri-
charger) (A) ,
cation circuit, it is necessary to plug the open holes
to prevent any risk of foreign bodies entering the - the air pipe (B) (between the turbocharger and the in-
system. tercooler).
IV - AIR CIRCUIT*: INSTRUCTIONS FOLLOWING

MECHANICAL DAMAGE TO THE TURBOCHARGER
Note:
(*) These instructions for the air circuit are only to
be followed in the case of:
- broken compressor wheel,
- compressor wheel rubbing against the turbochar-
ger casing.
Remove the intercooler if fitted to the vehicle (see 12B,

Turbocharging, Intercooler: Removal - Refitting,
page 12B-56) .
Turn the intercooler over and allow the oil inside to

drain out.
112772
For air pipes comprising several components:
- mark (10) the fitting position of each component,
- separate all the components.
110738
Note:
If the compressor wheel (9) is damaged, metal
objects are ejected inside the air pipes.
112770
12B-2
TURBOCHARGING
One by one, clean the pipes removed with the parts V - LUBRICATION CIRCUIT**: INSTRUCTIONS
washer : FOLLOWING MECHANICAL DAMAGE TO THE
TURBOCHARGER
- brush as much of the inside of the pipe as possible
(only use brushes with plastic bristles),
- wash plenty of cleaning product from the cleaning sta- Note:
tion through the pipe,
(**) These instructions relating to the lubrication cir-
- allow the cleaned pipe to drain by standing it upright, cuit must always be followed in all cases of mecha-
nical damage as listed above.
- ensure the cleaning product has drained out comple-
tely (check areas where liquid may be retained, e.g.
gaiters, resonators etc.). Drain the engine oil (see 10A, Engine and cylinder
page 10A-62) .
Replace the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting, page
10A-78) .
Only fill the engine with a suitable oil type (see 10A,
Engine and cylinder block assembly, Engine oil:
Specifications, page 10A-35) (Technical Note 6013A,
04A, Lubricants).
VI - GENERAL INSTRUCTIONS TO BE FOLLOWED

WHEN REMOVING A TURBOCHARGER
Always replace:
- the oil supply pipe:

• if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
• if the pipe is fitted with self-retaining seals.

112771
- the oil return pipe:
Dry the pipes one by one using a compressed air spray
gun. • if the pipe is blocked, even partially (due to scale,
carbonised oil etc.),
For pipes comprising several components:
- assemble the components, taking note of their correct • if the pipe is fitted with self-retaining seals.
fitting position (10) . - all seals that have been removed,
Refit: - all fittings that have been removed.
- the air pipe(between the air filter unit and the turbo-
charger) (A) ,
WARNING
- the air pipe (B) (between the turbocharger and the in-
tercooler). Failure to observe the following procedure may lead
to destruction of the turbocharger.
Refit the intercooler, if fitted to the vehicle (see 12B,
Turbocharging, Intercooler: Removal - Refitting, When starting the engine:
page 12B-56) .
- do not accelerate,
- allow the engine to run for 1 minute,the time taken for
the oil circuit pressure to increase (until the oil pressu-
re warning light on the instrument panel goes out),

- check the air circuit and the oil circuit for leaks.
12B-3
TURBOCHARGING
Turbocharger: Removal - Refitting 12B
F9Q, and 664 or 674
REMOVAL
Mot. 1566 Spanner for removing high I - REMOVAL PREPARATION OPERATION

pressure pipes.
Tightening torquesm a Remove the engine covers.

turbocharger mounting 8 Nm Removal - Refitting).
studs
a Remove:
turbocharger mounting 26 Nm
nuts
turbocharger supply 22.5 Nm tic converter: Removal - Refitting, page 19B-47)
pipe hollow mounting .
bolt
nut mounting the oil 22.5 Nm II - OPERATION FOR REMOVAL OF PART

supply pipe on the cylin- CONCERNED
der block
bolt mounting the oil 25 Nm

supply pipe on the cylin-
der block
turbocharger oil return 12 Nm

pipe mounting bolt
studs
turbocharger union end 26 Nm

piece
nuts
oil supply pipe moun- 22.5 Nm

ting nut, turbocharger
side
oil supply pipe moun- 22.5 Nm 104424

ting nut, cylinder block a Disconnect:
side
- the oil vapour rebreathing pipe (1) ,
oil supply pipe moun- 25 Nm
- the turbocharging pressure regulator pipe (2) .
ting bolt on the cylinder
block

pipe mounting bolt
12B-16
TURBOCHARGING
F9Q, and 664 or 674
1 - Oil supply pipe with hollow bolt union
(turbocharger side)
104421
a Disconnect the turbocharger air inlet and outlet pi-
pes (3) . 114207
a Remove:
Note: - the mounting bolt (4) from the oil supply pipe,
During factory fitting, two types of oil supply pipe - the hollow bolt (5) mounting the oil supply pipe
can be fitted to the turbocharger. union on the turbocharger.
The removal procedure for the turbocharger a Loosen the union (6) on the cylinder block.
depends on the type of pipe fitted. a Remove the oil supply pipe, passing it between the
wheels of the turbocharger.
a Remove:
- the oil return pipe mounting bolts,
- the oil return pipe,
- the turbocharger mounting nuts,
- the turbocharger.
12B-17
TURBOCHARGING
F9Q, and 664 or 674
2 - Oil supply pipe with nut union (turbocharger
side)
114467
a If the oil supply pipe is being replaced, remove the
104417 end piece from the oil supply union (9) . This stage
a Remove the bolt (7) mounting the oil supply pipe to prepares the turbocharger for the supply pipe to be
the cylinder block. refitted with a hollow bolt union.
a Unscrew the oil supply pipe unions on:
- the cylinder block, REFITTING
- the turbocharger (8) using the (Mot. 1566).
a Remove the turbocharger oil supply pipe.
a
a Remove:
Note:
- the oil return pipe mounting bolts,
During factory fitting, two types of oil supply pipe
- the oil return pipe,
can be fitted to the turbocharger.
- the turbocharger mounting nuts,
The refitting procedure for the turbocharger
- the turbocharger. depends on the type of pipe fitted.
Note: WARNING
In the Par ts Department, there is only one part Ensure that no foreign bodies enter the turbine or
number for the supply pipe. Only the oil supply compressor during the refitting operation.
pipe with the hollow bolt union is available.
Check that the turbocharger oil return pipe is not
completely or partially blocked by scale.
Check that there is no leak. If not, replace the
part.
12B-18
TURBOCHARGING
F9Q, and 664 or 674
a 2 - Oil supply pipe with nut union (turbocharger
side)
WARNING
Always replace:
- all O-rings and both copper seals of the turbo-
charger oil supply pipe,
- the exhaust bracket seal,
- any damaged heat shield.

(turbocharger side)
a Tighten to torque the turbocharger mounting
studs (8 Nm).
a Refit the turbocharger.
a Tighten to torque the turbocharger mounting nuts
(26 Nm).
a Position the oil supply pipe:
- finger tighten the nut mounting the oil supply union
on the cylinder block, 114467
- Finger tighten the supply pipe hollow mounting a Always replace the seal on the end piece of the
bolt, union (10) , if the end piece has been removed.
- Finger tighten the bolt mounting the oil supply pipe a Tighten to torque:
- the turbocharger mounting studs (8 Nm),
a Refit the oil return pipe.
- the turbocharger union end piece (26 Nm), if re-
a Tighten to torque: moved.
- the turbocharger supply pipe hollow mounting
bolt (22.5 Nm), a Refit the turbocharger.
- the nut mounting the oil supply pipe on the cy- a Tighten to torque the turbocharger mounting nuts
linder block (22.5 Nm), (26 Nm).
- the bolt mounting the oil supply pipe on the cy- a Position the oil supply pipe:
linder block (25 Nm)
- finger tighten the oil supply pipe mounting nuts,
- the turbocharger oil return pipe mounting bolt
(12 Nm). - Finger tighten the bolt mounting the oil supply pipe
a Refit the oil return pipe.
a Using the tool, tighten to torque the oil supply pipe

mounting nut, turbocharger side (22.5 Nm).
- the oil supply pipe mounting nut, cylinder block

side (22.5 Nm),
- the oil supply pipe mounting bolt on the cylin-

der block (25 Nm),
- the turbocharger oil return pipe mounting bolt

(12 Nm).
12B-19
TURBOCHARGING
F9Q, and 664 or 674
FINAL OPERATION
a Refit:
tic converter: Removal - Refitting, page 19B-47)
a Make sure that there is no contact with the underbo-
dy.
a Connect:
- the oil vapour rebreathing pipe,
- the turbocharging pressure regulator pipe,
- the turbocharger air inlet and outlet pipes.
moval - Refitting).
- start the engine,
out,
12B-20
TURBOCHARGING
Tightening torquesm
turbocharger mounting 8 N.m

studs
turbocharger mounting 37 N.m

nuts
turbocharger oil pipe 22.5 N.m

hollow bolt
oil pipe mounting bolts 25 N.m
oil pipe hollow bolt on 44 N.m

the cylinder block
turbocharger oil return 12 N.m

pipe mounting bolts
REMOVAL 115592
a Unclip:
- the engine compartment connection unit (1) ,
- the turbocharger regulation solenoid valve (2) .
ting Equipment, Vehicle: Towing and Lifting).
a Remove:
a Remove:
- the underbody protectors,
- the engine cover.
- the battery tray.
a Remove the battery (see 80A, Battery, Battery: Re-
moval - Refitting). a Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-28)
12B-21
TURBOCHARGING
111869 111865
a Disconnect: a Remove
- the oil vapour rebreathing pipe, - the turbocharger oil return pipe (8) .
- the turbocharger vacuum pipe (5) . - the turbocharger oil return pipe mounting bolts,
a Remove the air filter air outlet pipe (6) .
a Drain the cooling system (see 19A, Cooling, Coo- Removal - Refitting, page 16A-18)
111860
a Disconnect the turbocharger outlet air pipe (7) .
a Remove the catalytic pre-converter (see 19B, Ex-
haust, Catalytic pre-converter: Removal - Refit-
ting, page 19B-22) . 111866
a Using the, remove.
- the « hose - rigid pipe » assembly (10) between the

exhaust gas cooler (9) and the coolant outlet unit,
- the « hose - rigid pipe » assembly (11) between the
exhaust gas cooler (9) and the heater matrix hose.
12B-22
TURBOCHARGING
CONCERNED
111870
a Remove:
111867
- the hollow bolt mounting the oil pipe on the cylinder
a Remove the heat shield (12) .
block (13) ,
- the oil pipe mounting bolts (14) ,
- the hollow mounting bolt of the turbocharger oil
pipe (15) ,
- the oil pipe, from above.
temperature sensor connector.
a Disconnect:
- the turbocharger vacuum pipe,
- the turbocharger coolant top hose,
- the turbocharger coolant bottom hose.
12B-23
TURBOCHARGING
111871 112457
a Remove the turbocharger mounting nuts (16) .
112458
a Remove the turbocharger (17) .
12B-24
TURBOCHARGING
REFITTING - the coolant bottom hose,
- the coolant top hose.

a Clip on the exhaust gas temperature sensor har-
a
ness.
WARNING a Refit:
Ensure that no foreign bodies enter the turbine or - the new oil supply pipe, from above,
compressor during the refitting operation.
Check that the turbocharger oil return pipe is not - the new hollow bolt of the turbocharger oil pipe,
completely or partially blocked by scale. Check
that there are no leaks. If there are, replace the - the mounting bolts from the oil pipe,
part.
- the new hollow bolt of the oil pipe on the cylinder
a parts always to be replaced: turbocharger oil block.
supply pipe (10,09,03,01).
a Torque tighten:
parts always to be replaced: Turbocharger oil
supply pipe bolt (10,09,03,04). - the turbocharger oil pipe hollow bolt (22.5 N.m),
parts always to be replaced: turbocharger oil - the oil pipe mounting bolts (25 N.m),
pipe seal (10,09,03,05) (return pipe).
parts always to be replaced: seal between ex- - the oil pipe hollow bolt on the cylinder block (44
haust manifold and turbocharger (10,09,01,07) N.m).
parts always to be replaced: Turbocharger nut a Refit the heat shield.

(10,09,01,03).
part always to be replaced: O-ring of the air filter unit
air outlet pipe.
a Using the, refit:
Note:
- the « hose - rigid pipe » assembly between the ex-
The turbocharger - manifold gasket has a direc- haust gas cooler and the coolant outlet unit,
tion of fitting.
- the « hose - rigid pipe » assembly between the ex-
The tab of the gasket should be on the turbo-
haust gas cooler and the heater matrix hose.
charger side.
a Refit:
Note: - the turbocharger oil return pipe,

attach the turbocharger mounting studs (8
- the turbocharger oil return pipe mounting bolts.
N.m)
a Torque tighten the turbocharger oil return pipe
mounting bolts (12 N.m)
CONCERNED
a Refit:
a Refit:
- the turbocharger, Removal - Refitting, page 16A-18) ,
- the new turbocharger mounting nuts.
a Torque tighten the turbocharger mounting nuts talytic pre-converter: Removal - Refitting, page
(37 N.m). 19B-22)
a Connect:
a Refit the air filter unit (see 12A, Fuel mixture, Air fil-
- the turbocharger vacuum pipe, ter unit: Removal - Refitting, page 12A-28)
12B-25
TURBOCHARGING
a Refit:
- the battery tray,
- the air pipe mounting bolt.
a Clip:
- the turbocharger regulation solenoid valve,
- the engine compartment connection unit.
a Refit the battery (see 80A, Battery, Battery: Remo-
val - Refitting).
a Fill the cooling system (see 19A, Cooling, Cooling
system: Draining - Filling).
141130
a Bleed the cooling system (see 19A, Cooling, Coo-
a Refit the new O-ring of the air pipe. ling system: Bleed).
Note: - start the engine,
When refitting, be sure to correctly position the - check that the oil pressure warning light has gone
new O-ring of the air pipe in its groove (18) . out,
a Refit:
- the engine cover,
- the underbody protector.
111869
a Refit the air pipe.
Note:
Fit the air pipe straight onto the turbocharger,
without rotation.
12B-26
TURBOCHARGING
Turbocharger oil pipe: Removal - Refitting 12B
Tightening torquesm
hollow bolt mounting the 22.5 Nm

oil pipe on the turbo-
charger
hollow bolt mounting the 44 Nm

oil pipe on the cylinder
block
oil pipe mounting bolts 25 Nm
catalytic pre-converter 50 Nm
strut mounting bolt
catalytic pre-converter 30 Nm
strut mounting nuts
plenum chamber moun- 10 Nm

ting bolts
115592
a Unclip:
REMOVAL
- the engine compartment connection unit (1) ,
I - REMOVAL PREPARATION OPERATION - the turbocharger regulation solenoid valve (2) .
a Position the vehicle on a two-post lift (see 02A, Lif- a Remove:
moval - Refitting).
- the battery tray.
a Remove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-28) .
12B-41
TURBOCHARGING
111869
a Disconnect the oil vapour rebreathing pipe.
a Disconnect the turbocharger vacuum pipe (5) .
a Remove the air filter outlet air pipe.
111860
a Disconnect the turbocharger outlet air pipe (6) .
12B-42
TURBOCHARGING
- the hoses (10) and (11) from the plenum chamber
using the.
a Remove the mounting bolts (12) from the plenum
chamber.
a Move the plenum chamber to one side.

CONCERNED
115597
111864
a Remove:
- the mounting bolt (13) from the catalytic pre-con-
verter strut,
- the mounting nuts (14) from the catalytic pre-con-
verter strut,
- the catalytic pre-converter strut.
115729
a Disconnect:
- the exhaust gas recirculation solenoid valve con-

nector,
- the connector from the coolant temperature sensor
(7) ,
- the exhaust gas temperature sensor connector (8) .

temperature sensor connector (9) .
a Disconnect:
- the vacuum pipe from the vacuum pump,
12B-43
TURBOCHARGING
- the hollow bolt mounting the oil pipe on the cy-
linder block (44 Nm),
- the oil pipe mounting bolts (25 Nm).
a Refit:
- the catalytic pre-converter strut,
- the catalytic pre-converter strut mounting bolt,
- the catalytic pre-converter strut mounting nuts.
- the catalytic pre-converter strut mounting bolt
(50 Nm),
- the catalytic pre-converter strut mounting nuts
(30 Nm).
a Refit:
111870 - the plenum chamber with its new seal,
a Remove: - the plenum chamber mounting bolts.
- the hollow bolt (15) mounting the oil pipe on the cy- a Tighten to torque the plenum chamber mounting
linder block, bolts (10 Nm).
- the mounting bolts (16) from the oil pipe, a Connect the hoses onto the plenum chamber using
- the hollow mounting bolt (17) from the turbochar- the.
ger, a Connect the vacuum pipe to the vacuum pump.
- the oil pipe, from above. a Clip the exhaust gas temperature sensor harness
onto the turbocharger.
REFITTING a Connect:
- the exhaust gas temperature sensor connector,
- the coolant temperature sensor connector,
a Always replace:
- the EGR solenoid valve connector.
- the turbocharger oil pipe,
a Refit:
- the oil pipe hollow mounting bolts,
- the air filter outlet air pipe onto the turbocharger,
- the plenum chamber seal.
unit: Removal - Refitting, page 12A-28) .
CONCERNED a Connect:
a Refit the oil supply pipe. - the turbocharger air outlet pipe,
a Finger tighten the turbocharger oil supply pipe hol- - the oil vapour rebreathing pipe.
low bolt. a Refit:
a Finger tighten the oil supply pipe hollow bolt onto the - the battery tray,
cylinder block.
a Refit the oil supply pipe mounting bolts.
- the air duct mounting bolt.
a Clip on:
- the hollow bolt mounting the oil pipe on the tur-
bocharger (22.5 Nm), - the turbocharger pressure regulator solenoid valve,
12B-44
TURBOCHARGING
val - Refitting).
circuit: Draining - Refilling, page 19A-22) .
Bleeding) .
- start the engine,
out,
12B-45
TURBOCHARGING
Mot. 1566 Spanner for removing high a
pressure pipes.
Note:
During factory fitting, two types of oil supply pipe
Tightening torquesm can be fitted to the turbocharger.
turbocharger supply 22.5 Nm

pipe hollow mounting 1 - Oil supply pipe with hollow bolt union
bolt (turbocharger side)
nut mounting the oil 22.5 Nm

der block
bolt mounting the oil 25 Nm

der block
turbocharger union end 26 Nm

piece

ting nut, turbocharger
side

ting nut, cylinder block
side
nut mounting the oil 25 Nm

der block 114207
a Remove:
- the mounting bolt (1) from the oil supply pipe,
REMOVAL
- the hollow bolt (2) mounting the oil supply pipe
union on the turbocharger.
a Unscrew the oil supply pipe nut (3) from the cylinder
block.
a Remove the oil supply pipe, passing it between the
a Remove:
wheels of the turbocharger.
- the engine cover,
moval - Refitting).
12B-46
TURBOCHARGING
side)
114467
a If the oil supply pipe is being replaced, remove the

104417
end piece from the oil supply union (6) . This stage
a Remove the bolt (4) mounting the oil supply pipe to prepares the turbocharger for the supply pipe to be
the cylinder block. refitted with a hollow bolt union.
a Undo the oil supply pipe nuts on:
- the cylinder block, REFITTING
- the turbocharger (5) using the (Mot. 1566).
a Remove the turbocharger oil supply pipe.
a
Note:
In the Par ts Department, there is only one part WARNING
number for the supply pipe. Only the oil supply When refitting, carefully check that no foreign
pipe with the hollow bolt union is available. bodies have contaminated the turbocharger.
a Always replace:
- the turbocharger oil supply pipe (for the version
with the hollow bolt union on the turbocharger si-
de),
- the oil supply pipe seals (for the version with the
nut on the turbocharger side).

CONCERNED

(turbocharger side)
- finger tighten the nut mounting the oil supply pipe
on the cylinder block,
12B-47
TURBOCHARGING
- finger tighten the supply pipe hollow mounting bolt, - the nut mounting the oil supply pipe on the cy-
linder block (25 Nm).
- finger tighten the bolt mounting the oil supply pipe
- the turbocharger supply pipe hollow mounting moval - Refitting).
bolt (22.5 Nm),
- the nut mounting the oil supply pipe on the cy- - start the engine,
linder block (22.5 Nm),
- the bolt mounting the oil supply pipe on the cy- out,
linder block (25 Nm).
side) - switch off the ignition,
a Refit:
114467
a Always replace the seal on the end piece of the

union (7) , if the end piece has been removed.
a Tighten to torque the turbocharger union end pie-

ce (26 Nm).
- finger tighten the oil supply pipe mounting nuts,
- finger tighten the bolt mounting the oil supply pipe

a Using the (Mot. 1566), tighten to torque the oil sup-

ply pipe mounting nut, turbocharger side (22.5
Nm).
- the oil supply pipe mounting nut, cylinder block
side (22.5 Nm),
12B-48
TURBOCHARGING
Turbocharging pressure regulation valve 12B
WARNING Axis Description

If the turbocharger solenoid valve is removed, it is
essential to mark the supply and return pipes on X Time in seconds (s)
the solenoid valve.
Y Coolant temperature in degrees
Celsius (˚C)
18997
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 turbo-
charging pressure to be regulated.
The turbocharging pressure regulation valve is normal-

ly open. The engine operates as naturally aspirated.
The solenoid valve, normally closed, is supplied after

the engine is started following a delay which varies ac-
cording to the coolant temperature.
1218
12B-55
TURBOCHARGING
Intercooler: Removal - Refitting 12B

CONCERNED

a Remove:
Refitting),
- the headlights (see 80B, Headlights, Halogen
headlights: Removal - Refitting),
- the upper cross member (see MR 340-42B, Upper
front structure, Front upper cross member: Re-
moval - Refitting).
111844
111843
a Loosen:
- the air inlet duct clip on the intercooler (1) ,
- the air outlet duct clip on the intercooler (2) .
a Disconnect the air inlet and outlet from the intercoo-
ler.
12B-59
TURBOCHARGING
Intercooler: Removal - Refitting 12B
REFITTING

a
WARNING
Check that the intercooler is not full of oil.

CONCERNED
a Refit the intercooler.
a Clip on the intercooler.
a Refit:
- the guard,
- the condenser retaining clips.
a Connect the air inlet and outlet ducts on the inter-
115622 cooler.
a Remove the retaining clips from the condenser (3) . a Tighten:
a Remove the condenser. - the air inlet duct clip on the intercooler,
- the air outlet duct clip on the intercooler.

a Refit:
- the upper cross member (see MR 340-42B, Upper
front structure, Front upper cross member: Re-
moval - Refitting),
- the headlights (see 80B, Headlights, Halogen
headlights: Removal - Refitting),
Refitting).
moval - Refitting).
a Adjust the headlights (see 80B, Headlights,
Halogen headlights: Adjustment).
115591
a Remove the guard (4) .
a Unclip the intercooler (5) .
a Remove the intercooler.
12B-60
FUEL SUPPLY
Fuel filter: Removal - Refitting 13A
Tightening torquesm
fuel filter cover bolt 6 Nm
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for repair, page 13B-1) .
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
REMOVAL
23044
a Clean the fuel pipe unions (2) and (3) before discon-
necting the pipes (see 13B, Diesel injection, Diesel
a Remove the front engine cover. injection: Precautions for repair, page 13B-1) .
WARNING
Keep the pipe unions away from contaminated
areas.
a Disconnect:
- the connector (1) ,
- the high pressure pump supply pipe (2) ,
- the manual priming pump pipe (3) .
WARNING
To prevent impurities from entering the circuit,
plugs must be fitted to the openings of all the fuel
circuit components exposed to the open air.
a Fit blanking plugs to the fuel supply pipes and fuel fil-
ter.

CONCERNED
a Unclip the fuel filter from its mounting.
13A-8
FUEL SUPPLY
CONCERNED
WARNING
Do not remove the blanking plugs from each
component until the last moment.
Also, do not remove the components from their
cle.
a Fit:
- the new filter cartridge in the tank,
- the new seal on the cover,
- the new seal on the cover bolt.

a Align the marks made during the removal operation
on the fuel filter tank and cover.
19317
a Torque tighten the fuel filter cover bolt (6 Nm).
a Place a container under the drain plug (4) .
a Clip the fuel filter onto its mounting.
a Undo the plug (4) by one turn.
a Let the fuel flow into the container. III - FINAL OPERATION.
a Tighten the bolt (4) . a Connect:
a Mark the position of the cover in relation to the fuel - the high pressure pump fuel supply pipe to the fuel
filter tank. filter,
a Remove: - the manual priming pump pipe to the fuel filter,
- the cover bolt (5) with its seal, - the fuel filter connector.
- the fuel filter tank seal,
- the filter cartridge.
REFITTING
a parts always to be replaced: fuel filter seal (11,

03,01,07).
a parts always to be replaced: Fuel filter (11,03,01,

05).
a part always to be replaced: Cover bolt seal.
a Use cleaning cloths (see 13B, Diesel injection,

Diesel injection: Precautions for repair, page
13B-1) to clean:
- the fuel filter tank, 19317
- the fuel filter cover. a Open the air bleed screw (6) by one turn.
13A-9
FUEL SUPPLY
115627
a Prime the fuel circuit with the manual priming pump
(7) until fuel flows through the air bleed screw.
a Close the air bleed screw.
a Check that there are no fuel leaks.
a Start the engine.
a Check that there are no fuel leaks.
a Switch off the engine.
13A-10
DIESEL INJECTION
Diesel injection: Precautions for repair 13B
F5R or F9Q or G9T or G9U or M9R
I - RISKS RELATING TO CONTAMINATION 2 - Blanking plugs
The high-pressure direct injection system is highly sen- The blanking plugs are used to cap the fuel circuit once
sitive to contamination. The risks caused by contami- it is opened and to therefore prevent contaminants
nation are: from entering.
- damage to or destruction of the high pressure injec- A set of blanking plugs should be used once only and
tion system, used plugs must be discarded after use: once used,
the plugs are soiled and cleaning them is not sufficient
- a component seizing, to make them reusable.
- a component not being properly sealed. Unused plugs must also be discarded and must not be
used when carrying out work on an injection system.
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 F5R
few microns in size) have penetrated the system during
Part number for set of blanking plugs: 77 01 206 382.
dismantling.
The cleanliness principle must be applied from the filter

to the injectors.
What are the sources of contamination? F9Q or G9T or G9U or M9R

- metal or plastic swarf, Part number for set of blanking plugs: (see Vehicle:
- paint, Parts and ingredients for the repairwork) (04B, Con-
sumables - Products).
- fibres:
• cardboard,
• brushes,
Note:
• paper,
There is no specific set of blanking plugs for S9U
• clothing, and S9W engines. In order to comply with the
cleanliness recommendations, use plugs that are
• cloth,
compatible with the blanking plug sets for F9Q,
- foreign bodies such as hair, G9U, G9T or ZD3 engines.
- ambient air,
3 - Protective bags
- etc.
Use hermetically-resealable plastic bags, using adhe-
sive tape, for example, to store components which will
be refitted and reused. Stored parts will therefore be
WARNING
less subject to the risk of contamination.
Do not clean the engine with a high pressure clea-
ner to prevent damaging the connections. These are single-use bags: after use they must be dis-
carded.
1 - Cleaning cloths
4 - Cleaning products
Use lint-free cleaning cloths (see Vehicle: Parts and Two cleaning products can be used:
ingredients for the repairwork) (04B, Consumables -
Products). - an injector cleaner (see Vehicle: Parts and ingre-
dients for the repairwork) (04B, Consumables -
It is prohibited to use cloths or ordinary paper towels: Products),
these produce lint and lose fibres, which then contami-
nate the fuel circuit. - an aerosol spray brake cleaner (see Vehicle: Parts
Each cloth must only be used once. mables - Products).
13B-1
DIESEL INJECTION
To use the injector cleaner, be sure to have a clean Replace leaktight protective gloves (Nitrile type) when
brush in good condition (the brush must not lose any they are soiled or damaged.
bristles) as well as a clean container which has no im-
purities in it. All components removed from the injection system
must be stored in a hermetically sealed plastic bag
once they have been capped.
Note:
Reseal the bag hermetically, for example using adhesi-
Use a new injector cleaner each time work is car- ve tape, even if the bag must be opened shortly afte-
ried out (a used cleaning agent will contain impuri- rwards: ambient air can be a source of impurities.
ties).
After opening the fuel circuit, the use of brushes, clea-
ning agents, air blow guns, rifle-type brushes or stan-
II - ADVICE TO BE FOLLOWED BEFORE ANY dard cloths is strictly prohibited: these items are likely
OPERATION to allow impurities to enter the system.
1) Carry out the work in a clean working area and take When replacing a component with a new one or when
care to protect removed components from dust using refitting it after storing it in a plastic bag, do not unpack
plastic bags which are hermetically-resealable, for it until it is time to fit it on the vehicle.
example.
2) Always order the following from the Parts Depart- IV - CLEANING
ment before carrying out work:
- a new set of blanking plugs, specific to the engine, There are currently two procedures for cleaning the
fuel circuit before opening it in order to carry out work in
- enough lint-free cleaning cloths. the workshop.
- one of the two cleaning products for fuel pipe These procedures enable the fuel circuit to be cleaned
unions, to prevent contamination from entering: they both have
- the parts that are always to be replaced after each the same end result and neither is preferred over the
removal operation, mentioned in the operational pro- other.
cedures specific to the vehicle (see related Workshop
Repair Manual).
1 - Cleaning using injector cleaner
3) Wear safety goggles fitted with side shields to pre-
vent the cleaning product from splashing the eyes. Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
4) Wear leaktight protective gloves (Nitrile type) to the relevant Workshop Repair Manual).
avoid prolonged contact with the skin.
Protect sections which are sensitive to fuel leaks.
Note: Pour the injector cleaning agent into a container which

is free from impurities.
When using leather protective gloves, wear a pair of
leaktight protective gloves (Nitrile type) over the top.
5) Before carrying out work on the injection system, IMPORTANT

use plastic bags or clean rags, for example, to protect: Wear leaktight gloves (Nitrile type) for this opera-
tion.
- the accessories and timing belts,
- the electrical accessories (starter, alternator, power- Dip a clean brush, which is not shedding bristles, into
assisted steering pump, sensors and electrical con- the container of injector cleaning agent.
nectors),
- the flywheel face.
IMPORTANT
Wear goggles with side protectors for this opera-
III - INSTRUCTIONS TO BE FOLLOWED DURING
tion.
THE OPERATION
Wash your hands before and while carrying out the Clean the unions carefully using the brush and the in-
work. jector cleaning agent.
13B-2
DIESEL INJECTION
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Check that no
bristles from the brush have come away and that the
area is clean.
Wipe the sections that were cleaned with fresh clea-

ning cloths.
Open the circuit at the unions and immediately fit the

relevant blanking plugs.
WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with com-
pressed air. Use cleaning cloths only, if necessary.
2 - Using the brake cleaner
Clear the access to the unions that need opening, fol-

lowing the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
IMPORTANT
tion.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
Spray the brake cleaner 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). Check that no
bristles from the brush have come away and that the
area is clean.
Open the circuit at the unions and immediately fit the

relevant blanking plugs.
WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with com-
pressed air. Use cleaning cloths only, if necessary.
13B-3
DIESEL INJECTION
F9Q or G9T or G9U
13B-4
DIESEL INJECTION
Set of plugs:
13B-5
DIESEL INJECTION
16148
13B-6
DIESEL INJECTION
M9R
13B-7
DIESEL INJECTION
Set of plugs:
13B-8
DIESEL INJECTION
113737
13B-9
DIESEL INJECTION
Diesel injection: List and location of components 13B
111837
(1) Manual priming pump

(2) Turbocharging pressure regula-
tion solenoid valve
(3) Cylinder reference sensor
(4) Solenoid injector
(5) Engine damper flap vacuum
reserve
(6) Engine damper flap solenoid
valve
(7) Engine damper flap
(8) Engine damper flap control
diaphragm
(9) Injection computer
(10) Flowmeter with air temperature
sensor
(12) Fuel temperature sensor 16181
(13) Rail pressure sensor
(14) Fuel pressure regulator
(15) High pressure pump
(16) Diesel filter
13B-18
DIESEL INJECTION
18997 19135-1
(17) Turbocharger (10) Air flowmeter with air tempera-

(18) Catalytic converter ture sensor
(2) Turbocharging pressure regula- (11) Turbocharging pressure sensor

tion solenoid valve
18298
(7) Damper unit (engine damper

flap)
(5) Vacuum reserve
(8) Damper unit control diaphragm
19315 (6) Damper unit solenoid valve
(20) EGR solenoid valve
(19) Preheating unit
13B-19
DIESEL INJECTION
111715 102351
(1) Manual priming pump (14) Fuel pressure regulator

(16) Diesel filter
111859
(21) Injector rail

13B-20
DIESEL INJECTION
115586

(3) Solenoid injector
(4) Damper flap
(5) Turbocharging pressure regula-
tion solenoid valve
(6) Flowmeter with air temperature
sensor
(9) High pressure pump
(10) Diesel filter
16181
13B-21
DIESEL INJECTION
111864 19315
(11) Turbocharger (14) Preheating unit

(12) Catalytic pre-converter
115590
114987
(7) Air flowmeter with air tempera-
(13) Exhaust gas temperature sensor ture sensor
13B-22
DIESEL INJECTION
111859
(16) Injector rail

115620

(15) EGR unit
102351
111715

(12) Diesel filter
13B-23
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
- the air duct mounting bolt (4) ,
Tightening torquesm - the battery tray.
battery tray bolts 21 Nm

CONCERNED
REMOVAL

a Remove the engine covers.
a When reprogramming or replacing the computer,
save the data (see MR397 Fault finding, 13B, Die-
sel injection, Fault finding-Replacement of com-
ponents).
a Remove the battery.
115588
a Remove the guard (5) .
115592
a Unclip the engine compartment connection unit from
the battery tray (1) .
F9Q, and 758 or 759

a Unclip the turbocharger regulation solenoid valve (2)
.
115587
a Disconnect the three computer connectors (6) .

a Drill out the tamperproof bolts (3) using a ∅ 5mm
drill bit. a Remove:
a Remove: - the computer mounting bolts (7) ,

- the bolts (3) using the, - the computer.
13B-31
DIESEL INJECTION
Diesel injection computer: Removal - Refitting 13B
REFITTING

CONCERNED
a Refit the computer on its support.
a Tighten the computer mounting bolts.
a Connect the three computer connectors.
a Refit the guard.
a Refit the battery tray.
a Tighten to torque the battery tray bolts (21 Nm).
a Tighten the air duct mounting bolt.
a Clip on the engine compartment connection unit.
F9Q, and 758 or 759

a Clip on the turbocharger regulation solenoid valve.

moval - Refitting).
a When reprogramming or replacing the computer,
enter the data (see MR 397 Fault finding, 13B; Die-
sel injection, Fault finding-Replacement of com-
ponents).
13B-32
DIESEL INJECTION
High pressure pump: Removal - Refitting 13B
Respect the precautions for repair work (see 13B, Die-
Essential special tooling sel injection, Diesel injection: Precautions for re-
pair, page 13B-1) .
Mot. 1668 Locking high pressure pump
sprocket.
Mot. 1525 Extractor for timing gear with REMOVAL

tapered hub.
Mot. 1525-03 Adapter sockets for Mot.1525. I - REMOVAL PREPARATION OPERATION

(for 33-tooth pulley).
Essential equipment ting equipment, Vehicle: Towing and Lifting).
diagnostic tool a Disconnect the battery (see 80A, Battery, Battery:

Tightening torquesm a Remove:
high pressure pump 30 Nm - the accessories belt (see 11A, Top and front of
mounting bolts on the engine, Accessories belt: Removal - Refitting,
high pressure pump page 11A-4) ,
front support
high pressure pump pul- 70 Nm Timing belt: Removal - Refitting, page 11A-26) ,
ley nut
- the injector rail protector (see 13B, Diesel injec-
mounting bolts of the 20 Nm+ 80˚ tion, Injector rail protector: Removal - Refitting,
high pressure pump page 13B-79) .
front support on the
cylinder head
high pressure pump 30 Nm

rear pump support
IMPORTANT
Before carrying out any work on the injection sys-

tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
Loosening a high pressure pipe union when the
engine is running is strictly prohibited.
WARNING
Ensure that any high pressure pipe removed is 111725
replaced.
a Disconnect:
- the diesel fuel heater from the diesel filter,

WARNING
- the heater plugs,
Dismantling the interior of the high pressure pump
and the injectors is prohibited. - the pressure regulator (1) ,
13B-40
DIESEL INJECTION
CONCERNED
102351
a Disconnect the diesel supply (2) and return pipes (3)
. 111721
a Remove the bolts (4) mounting the high pressure
a Plug the openings.
pump to the high pressure pump rear support.
a Remove:
a Remove:
- the diesel pipe retaining clip from the front support
- the bolts mounting the high pressure pump front
of the high pressure pump,
support,
- the high pressure pipe between the pump and the
- the high pressure pump with the high pressure
rail (see 13B, Diesel injection, High-pressure
pump front support.
pipe between the pump and rail: Removal - Re-
fitting, page 13B-94) .
13B-41
DIESEL INJECTION
102893 102345
a Position the (Mot. 1668) (5) . a Remove:
a Remove the nut (6) from the high pressure pump - the mounting bolts (9) for the high pressure pump,
pulley.
- the high pressure pump.
REFITTING

CONCERNED
WARNING
a Refit the high pressure pump on the pump support.
- the high pressure pump mounting bolts on the

high pressure pump front support (30 Nm),
- the high pressure pump pulley nut (70 Nm) by

102894 immobilising the pulley with the (Mot. 1668).
a Put in place the pulley extractor (Mot. 1525) (7) with
a Push the centring ring onto the high pressure pump
jaws (Mot. 1525-03) on the pump pulley.
rear support.
a Extract the pulley by tightening the pulley extractor a Refit the « high pressure pump and front support »
thrust bolt (8) . assembly.
a Remove the (Mot. 1525), (Mot. 1525-03) and the a Finger tighten the mounting bolts of the front support
(Mot. 1668). of the pump until contact.
13B-42
DIESEL INJECTION
a Remove the blanking plugs from the openings.
a Refit:
- the pipe between the high pressure pump and the
rail (see 13B, Diesel injection, High-pressure
pipe between the pump and rail: Removal - Re-
fitting, page 13B-94) .
- the diesel pipe retaining clip from the front support
of the high pressure pump,
a Remove the blanking plugs from the openings.
a Connect:
- the diesel supply and return pipes,
- the pressure regulator,
- the heater plugs,
- the diesel fuel heater from the diesel filter.
a Refit:
111721
a Refit the high pressure pump mounting bolts on the Timing belt: Removal - Refitting, page 11A-26) ,
rear support.
a Finger tighten the bolts until contact. engine, Accessories belt: Removal - Refitting,
page 11A-4) .
a Prime the diesel circuit using the manual priming
pump.
moval - Refitting).
WARNING
Check that there are no diesel leaks:

- Run the engine at idle speed,
- Accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.
a Refit the injector rail protector (see 13B, Diesel in-

jection, Injector rail protector: Removal - Refit-
ting, page 13B-79) .
112337
- the mounting bolts of the high pressure pump

front support on the cylinder head (20 Nm+
80˚),

rear pump support (30 Nm) using the Crowfoot
13 socket.
13B-43
DIESEL INJECTION
Respect the repair precautions (see 13B, Diesel injec-
Essential special tooling tion, Diesel injection: Precautions for repair, page
13B-1) .
Mot. 1668 Locking high pressure pump
sprocket.
REMOVAL
Mot. 1525 Extractor for timing gear with
tapered hub.
Mot. 1525-03 Adapter sockets for Mot.1525.
(for 33-tooth pulley).
Essential equipment a Disconnect the battery (see 80A, Battery, Battery:

diagnostic tool a Remove:
Tightening torquesm engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
Timing belt: Removal - Refitting, page 11A-26) .
pump supports
high pressure pump pul- 50 Nm

ley nut
high pressure pump 20 Nm+80˚

front support mounting
bolts on the cylinder
head

rear pump support
IMPORTANT 111888
Before carrying out any work on the injection sys- a Remove the injector rail protector (see 13B, Diesel
tem, check using the diagnostic tool : injection, Injector rail protector: Removal - Refit-
a Disconnect:
engine is running is strictly prohibited. - the heater plugs,
- the pressure regulator (1) ,
WARNING
Ensure that any high pressure pipe removed is
replaced.
WARNING
Dismantling the interior of the high pressure pump
and the injectors is prohibited.
13B-48
DIESEL INJECTION
102351 102348
a Disconnect the diesel supply and return pipes (2) . a Remove the bolts (3) mounting the high pressure
a Plug the openings. pump to the high pressure pump rear support.
a Remove the pump-rail high pressure pipe (see 13B, a Remove:

Diesel injection, High-pressure pipe between the
pump and rail: Removal - Refitting, page 13B-94) - the bolts mounting the high pressure pump front
. support,
- the high pressure pump with the high pressure

II - OPERATION FOR REMOVAL OF PART pump front support.
CONCERNED
102893
a Position the (Mot. 1668) (4) .
a Remove the nut (5) from the high pressure pump

pulley.
13B-49
DIESEL INJECTION
REFITTING

CONCERNED
a
WARNING
a Refit the high pressure pump on the pump support.

pump supports (30 Nm),
- the high pressure pump pulley nut (50 Nm) by
immobilising the pulley with (Mot. 1668).
102894
a Fit the pulley extractor (Mot. 1525) with claws (Mot.

1525-03) (6) for pulleys with thirty-three teeth.
a Remove the pulley by tightening the pulley extractor

thrust bolt (7) .
a Remove (Mot. 1525), (Mot. 1525-03), and (Mot.

1668).
102349
a Push the ring (9) back as shown in the diagram.

a Refit the « high pressure pump - front support » as-
sembly.
a Refit the high pressure pump front support mounting
bolts.
a Finger tighten the pump front support mounting
bolts.
a Refit the high pressure pump mounting bolts on the
102345 rear support.
a Finger tighten the bolts.
a Remove:
- the high pressure pump mounting bolts (8) ,
- the high pressure pump front support mounting
- the high pressure pump. bolts on the cylinder head (20 Nm+80˚),
13B-50
DIESEL INJECTION
rear pump support (30 Nm).
a Remove the blanking plugs.
a Reconnect:
- the diesel supply and return pipes,
- the heater plugs,
- the pressure regulator,
a Refit:
- the pump-rail high pressure pipe (see 13B, Diesel
injection, High-pressure pipe between the
pump and rail: Removal - Refitting, page 13B-
94) ,
page 11A-4) ,
Timing belt: Removal - Refitting, page 11A-26) .
Note:
Refit the inlet duct without refitting the injector rail
protector or replacing the duct seal.
a Refit the air inlet duct (see 12A, Fuel mixture, Air
inlet duct: Removal - Refitting, page 12A-55) .
a Prime the diesel circuit using the manual priming
pump.
moval - Refitting).
WARNING
Check that there are no fuel leaks:

- Run the engine at idle speed,
- Accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.
a Remove the air inlet duct.

13B-51
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
the fuel pressure regula- 6 Nm

tor bolts

tion, Diesel injection: Precautions for repair, page
13B-1) .
WARNING
Once the warranty period for the high pressure
pump has expired, only the pressure regulator can
be replaced separately.
Whilst the warranty period for the high pressure
pump is still valid, the high pressure pump should
be replaced as a whole if the pressure regulator 111725
displays a fault.
a Disconnect the fuel pressure regulator connector (1)
.
REMOVAL

a Remove the engine cover.
a Use a compressed air blow gun to clear any impuri-
ties from the vicinity of the fuel pressure regulator.
a Clean the fuel pressure regulator (see 13B, Diesel
injection, Diesel injection: Precautions for re-
pair, page 13B-1) .
102351
a Remove:
- the bolts (2) for mounting the fuel pressure regula-

tor,
- the fuel pressure regulator (remove manually: do

not use a tool to lever it out).
a Fit the protective plug in the opening in the high
pressure pump.
13B-59
DIESEL INJECTION
Fuel pressure regulator: Removal - Refitting 13B
REFITTING a Check that there are no leaks from the diesel circuit
after any work is carried out:
I - REFITTING PREPARATION OPERATION - run the engine at idle speed,
a Do not remove the protective caps from each com- - accelerate several times at no load,
ponent until the last moment. - switch off the ignition,
a Clean the contact surface of the fuel pressure regu- - check that there is no diesel fuel escaping.
lator on the high pressure pump.
a Wipe the bearing face of the fuel pressure regulator
on the high pressure pump using new wipes (see
tions for repair, page 13B-1) .
a Prepare the new regulator:

- remove the protective plug,
- check the position of the seals,
- lubricate the O-rings with clean diesel fuel.
Note:
Lubrication is very important to avoid external
leaks.
a Remove the protective plug from the opening in the

high pressure pump.
a Rinse the fuel pressure regulator casing by running
the priming pump located next to the fuel filter.

CONCERNED
a Fit the new fuel pressure regulator by gently rotating

it clockwise and gently pushing it until it is comple-
tely in.
a Refit the fuel pressure regulator mounting bolts.

a Finger tighten the mounting bolts.
a Tighten to torque the fuel pressure regulator bolts
(6 Nm).
a Discard all the plugs after finishing the operation.
a Connect the fuel pressure regulator connector.

a Reprime the circuit using the manual priming pump.

moval - Refitting).
a Check, using the diagnostic tool, that there are no
stored faults. Clear the faults if necessary.
13B-60
DIESEL INJECTION
Diesel return pipe: Removal - Refitting 13B
a Clean the diesel return pipe (see 13B, Diesel injec-
tion, Diesel injection: Precautions for repair,
Essential equipment
page 13B-1) .
diagnostic tool
CONCERNED
IMPORTANT


13B-1) .
REMOVAL

Removal - Refitting). a Disconnect the diesel return pipe:
- from the injector rail (1) ,
F9Q, and 758 or 759
- from the high pressure pump (2) ,
a Remove the air inlet duct (see 12A, Fuel mixture, - from the diesel filter return pipe (3) .
Air inlet duct: Removal - Refitting, page 12A-55) .
111888
a Remove the injector rail protector (see 13B, Diesel

injection, Injector rail protector: Removal - Refit-
13B-68
DIESEL INJECTION
F9Q, and 664 or 674
110904
a Disconnect the diesel return pipe:
20347 - do not remove the clip (5) ,
a Disconnect the diesel temperature sensor connector - press the clip,
(4) .
- pull the diesel return pipe union upwards.
a Remove the diesel return pipe.
Note:
a Fit suitable blanking plugs on:
the diesel fuel temperature sensor is an integral
part of the fuel return pipe; these two compo- - the diesel return pipe,
nents cannot be removed separately.
- the fuel circuit openings.
WARNING
If the diesel fuel return pipe is to be reused, keep
it in a sealed plastic bag all the time it is discon-
nected.
13B-69
DIESEL INJECTION
REFITTING III - FINAL OPERATION
I - REFITTING PREPARATION OPERATION F9Q, and 758 or 759

a a Refit the air inlet duct (see 12A, Fuel mixture, Air
WARNING
Only remove the blanking plugs immediately Note:
before connecting the fuel circuit pipes. Refit the air inlet duct without refitting the injector
The plugs are single-use. Do not reuse them; rail protector or replacing the duct seal.
dispose of the whole set after use.
WARNING a Connect the battery (see 80A, Battery, Battery: Re-

Check the condition of the seals on the injector moval - Refitting).
diesel return unions.
If there is any damage, replace the whole fuel WARNING
return pipe.
II - REFITTING OPERATION FOR PART - run the engine at idle speed,

CONCERNED - accelerate several times at no load,
a Take the diesel fuel return pipe out of the plastic - switch off the ignition,
bag.
- check that there is no flow.
WARNING
If a diesel fuel return pipe is being replaced, only F9Q, and 758 or 759
remove the new one from its original packaging a Remove the air inlet duct.
when it is about to be refitted.
a Remove all the blanking plugs.

a Refit the diesel return pipe. a Refit the injector rail protector (see 13B, Diesel in-
a Connect the diesel return pipe: jection, Injector rail protector: Removal - Refit-
- to the injector rail,
- to the high pressure pump, F9Q, and 758 or 759
- to the diesel filter return pipe. a Refit the air inlet duct (see 12A, Fuel mixture, Air
F9Q, and 664 or 674
a Connect the diesel temperature sensor connector.
13B-70
DIESEL INJECTION
Injector rail protector: Removal - Refitting 13B
REFITTING
Tightening torquesm
injector rail protector 8 Nm CONCERNED
mounting bolts
a Refit the injector rail protector.
a Clip on the injector rail protector.
REMOVAL a Refit the injector rail protector mounting bolts.
a Tighten to torque the injector rail protector moun-
ting bolts (8 Nm).
a Connect the rail pressure sensor connector.
F9Q, and 758 or 759
F9Q, and 758 or 759
a Remove the air inlet duct (see 12A, Fuel mixture,
Air inlet duct: Removal - Refitting, page 12A-55) . a Refit the air inlet duct (see 12A, Fuel mixture, Air

CONCERNED
115589
a Disconnect the rail pressure sensor connector (1) .
a Remove the injector rail protector mounting bolts (2)

.
a Unclip the injector rail protector.
a Remove the injector rail protector.
13B-91
DIESEL INJECTION
High-pressure pipe between the pump and rail: Removal - Refitting 13B
Mot. 1566 Spanner for removing high

pressure pipes.
Tightening torquesm
« pump-injector » high 29 Nm
pressure pipe nuts on
the rail
« pump-rail » high pres- 25 Nm

sure pipe nuts on the
pump
IMPORTANT
111725
Use the diagnostic tool before any operation is car- a Disconnect the diesel return pipe union (1) from the
ried out on the injection circuit to check: high pressure pump.
- that the rail is not under pressure,
CONCERNED
Working on the circuit with the engine running is
a Loosen:
strictly forbidden.
- the high pressure pipe nut at the pump end using
Respect the repair precautions (see 13B, Diesel injec- the (Mot. 1566),
tion, Diesel injection: Precautions for repair, page - the high pressure pipe nut at the rail end using the
13B-1) (Mot. 1566).
a Move the nuts along the tube, keeping the olive in
REMOVAL contact with the taper.

F9Q, and 758 or 759


13B-97
DIESEL INJECTION
High-pressure pipe between the pump and rail: Removal - Refitting 13B
- the diesel fuel pressure sensor connector.
F9Q, and 758 or 759

Note:
Refit the air inlet duct without refitting the injector
rail protector or replacing the duct seal.

moval - Refitting).
WARNING
111838
a Plug the openings. - run the engine at idle speed,

REFITTING - switch off the ignition,
CONCERNED
F9Q, and 758 or 759
a Always replace any high pressure pipe or high pres-
sure pipe clip removed with a new one. a Remove the air inlet duct.
a Remove the blanking plugs
a Position:
- the high pressure pipe olive in the injector rail inlet
taper,
- the high pressure pipe olive in the high pressure
pump outlet.
F9Q, and 758 or 759
a Finger tighten the high pressure pipe nuts, starting
with the one located on the injector end.
a Slightly pretighten the high pressure pipe nuts.
a Using the (Mot. 1566), tighten to torque and in order
the « pump-injector » high pressure pipe nuts
on the rail (29 Nm). a Refit the engine cover.

the « pump-rail » high pressure pipe nuts on the
pump (25 Nm).
a Connect:
- the diesel return pipe union to the high pressure
pump,
13B-98
DIESEL INJECTION
High-pressure pipe between the rail and injector: Removal - Refitting 13B
Mot. 1566 Spanner for removing high

pressure pipes.
Tightening torquesm
injector rail mounting 25 Nm

nuts
« rail - injector » high 29 Nm

the rail
« rail - injector » high 25 Nm

the injectors
111725
a Disconnect the diesel return pipe union (1) from the
IMPORTANT
high pressure pump.
Use the diagnostic tool before any operation is car- a If all the pipes are to be replaced: loosen the injector
ried out on the injection circuit to check: rail mounting nuts by a few turns.
- that the rail is not under pressure,
Working on the circuit with the engine running is
strictly forbidden.

13B-1)
REMOVAL

F9Q, and 758 or 759


13B-113
DIESEL INJECTION
CONCERNED
111838
1327 a Remove the high pressure pipe.

a
The injector intermediate union (2) must be held REFITTING

using a spanner while the high pressure pipes
are loosened.
Do not damage the injector return nozzle. I - REFITTING OPERATION FOR PART
CONCERNED
a Undo:
- the high pressure pipe nut (3) at the injector end a Remove the blanking plugs
using the (Mot. 1566),
a Position:
- the high pressure pipe nut at the rail end using the
(Mot. 1566). - the high pressure pipe olive in the injector taper,
a Move the nuts along the tube, keeping the olive in
- the high pressure pipe olive in the injector rail out-
contact with the taper.
let.
a Manually tighten the high pressure pipe nuts, star-

ting with the one located on the injector end.
Note:
The « rail-injector » pipes can be fitted in any
order.
a If all the pipes are to be replaced: tighten to torque

the injector rail mounting nuts (25 Nm).

the « rail - injector » high pressure pipe nuts on
the rail (29 Nm).
13B-114
DIESEL INJECTION
moval - Refitting).
WARNING

- run the engine at idle speed,
F9Q, and 758 or 759


1327
a ting, page 13B-79) .
Note:
F9Q, and 758 or 759
The injector intermediate union (4) must be held
using a spanner while the high pressure pipes a Refit the air inlet duct (see 12A, Fuel mixture, Air
are loosened. inlet duct: Removal - Refitting, page 12A-55) .
Do not damage the injector return nozzle.

the « rail - injector » high pressure pipe nuts on a Refit the engine cover.
the injectors (25 Nm).
Note:
Tighten one pipe fully before moving on to the
next pipe.
a Connect the diesel return pipe union to the high
pressure pump.
F9Q, and 758 or 759

Note:
13B-115
DIESEL INJECTION
Injector rail: Removal - Refitting 13B
Tightening torquesm
injector rail mounting 25 Nm

nuts

rear support mounting
bolts on the cylinder
block

rear support
IMPORTANT
Use the diagnostic tool before any operation is car- 111838

ried out on the injection circuit to check: a Disconnect:
- that the rail is not under pressure, - the return pipe union (1) on the injector rail,
- that the fuel temperature is not too high. - the heater plug connectors.
Working on the circuit with the engine running is a Move the heater plug wiring harness to one side.
strictly forbidden.
Observe the repair precautions (see 13B, Diesel in-

jection, Diesel injection: Precautions for repair,
page 13B-1) l.
REMOVAL

F9Q, and 758 or 759


13B-124
DIESEL INJECTION
- the high pressure pipes between the rail and the in-
jectors (see 13B, Diesel injection, High-pressure
F9Q, and 664 pipe between the rail and injector: Removal -
Refitting, page 13B-106) .
111840
111724
a Disconnect the fuel temperature sensor connector
a Disconnect:
(2) .
- the oil vapour rebreathing pipe (4) ,
a Disconnect the fuel return pipe (3) on the high pres-
sure pump side. - the cylinder block outlet oil vapour rebreathing pipe
(5) ,
- the oil return pipe on the oil separator,
a Remove:
a Plug the openings. - the oil separator mounting bolts,
- the oil separator.
F9Q, and 664
a Move the diesel temperature sensor to one side.
Note:
The diesel temperature sensor is an integral part
of the diesel return pipe; these two components
are connected and cannot be removed separa-
tely.
a Remove:
- the high pressure pipe between the high pressure

pump and the rail (see 13B, Diesel injection,
High-pressure pipe between the pump and rail:
Removal - Refitting, page 13B-94) ,
13B-125
DIESEL INJECTION
CONCERNED

F9Q, and 664 CONCERNED
a Position the injector rail.
a Always replace any high pressure pipe or high pres-
sure pipe clip removed with a new one.
a Pretighten the injector rail mounting nuts, leaving
clearance between the nuts and the rail.
a Tighten to torque the injector rail mounting nuts
(25 Nm).
a Refit:
- the rear pump support,
- the rear pump support mounting bolts.
a Finger tighten until contact:
- the « rail-pump » pipe nuts on the pump and rail si-
des,
- the « injector -rail » pipe nuts on the injector and
rail sides.
111721
- the high pressure pump rear support mounting
a Remove: bolts on the cylinder block (44 Nm),
- the rear pump support mounting bolts (6) , rear support (30 Nm).
- the rear pump support.

a Refit:
- the oil separator,
- the oil separator mounting bolts,
- the oil return pipe on the oil separator,
- the cylinder block outlet oil vapour rebreathing pi-
pe,
- the oil vapour rebreathing pipe union connected to
the air inlet pipes.
a Fit the diesel fuel temperature sensor.
a Connect:
- the fuel return pipe on the high pressure pump si-
de,
- the fuel temperature sensor connector.
111859
a Fit the heater plug wiring harness.
a
a Connect:
- the injector rail mounting bolts (7) ; - the return pipe union to the injector rail,
- the injector rail. - the heater plug connectors.
13B-126
DIESEL INJECTION
F9Q, and 758 or 759

Note:

moval - Refitting).
WARNING

- check that there is no fuel escaping.
F9Q, and 758 or 759


F9Q, and 758 or 759

13B-127
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
Mot. 997-01 Tool for removing/refitting

injector holder fitted with
cable.
Essential equipment
diagnostic tool
Tightening torquesm
pressure sensor 80 Nm
111888
WARNING a Remove the injector rail protector (see 13B, Diesel

Once the warranty period for the injector rail has
expired, only the pressure sensor can be replaced
separately. a Clean the rail pressure sensor (see 13B, Diesel in-
During the injector rail warranty period, the injector jection, Diesel injection: Precautions for repair,
rail should be completely replaced if the pressure page 13B-1) .
sensor fails.
CONCERNED
IMPORTANT
a Remove the pressure sensor using the (Mot. 997-
01).
tem, check using the diagnostic tool : a Fit blanking plugs into the openings.
- that the fuel temperature is not too high. REFITTING
engine is running is strictly prohibited. I - REFITTING PREPARATION OPERATION
Read the repair precautions (see 13B, Diesel injec-
13B-1) .
REMOVAL

F9Q, and 758 or 759

112662
Air inlet duct: Removal - Refitting, page 12A-55) . a Check the condition of the lip seal (1) :
- if the lip seal is marked, the pressure sensor must

be replaced.
13B-132
DIESEL INJECTION
Rail pressure sensor: Removal - Refitting 13B
CONCERNED
a Tighten the pressure sensor by hand.
a Using the (Mot. 997-01), tighten to torque the pres-

sure sensor (80 Nm).
F9Q, and 758 or 759
Note:

moval - Refitting).
WARNING
Check that there are no diesel fuel leaks:

F9Q, and 758 or 759

F9Q, and 758 or 759
13B-133
DIESEL INJECTION
Fuel temperature sensor: Removal - Refitting 13B
Observe the repair precautions (see 13B, Diesel in-
jection, Diesel injection: Precautions for repair,
page 13B-1) .
WARNING
Obtain the special high pressure injection circuit
blanking plugs kit.
Always replace any high pressure pipe or high pres-
sure pipe clip removed with a new one.
REMOVAL


CONCERNED
a Remove the diesel return pipe (see 13B, Diesel in-
jection, Diesel return pipe: Removal - Refitting,
page 13B-66)
Note:
the diesel fuel temperature sensor is an integral
part of the fuel return pipe, these two compo-
nents cannot be removed separately.
REFITTING

CONCERNED
a Refit the diesel return pipe (see 13B, Diesel injec-
tion, Diesel return pipe: Removal - Refitting,
page 13B-66) .
13B-138
DIESEL INJECTION
Diesel injector: Removal - Refitting 13B

F9Q, and 758 or 759
Mot. 1817 Injector well cleaning kit
Essential equipment
diagnostic tool

Tightening torquesm injection, Injector rail protector: Removal - Refit-
injector clamp bolts 25 N.m
IMPORTANT

• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- Loosening a high pressure pipe union when the
IMPORTANT
Consult the safety and cleanliness advice and ope-
ration recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for repair, page 13B-1) .
111841
a Disconnect the injector connectors.
a Remove:
WARNING
- the diesel return pipe (see 13B, Diesel injection,
To prevent impurities from entering the circuit, place Diesel return pipe: Removal - Refitting, page
protective plugs on all fuel circuit components 13B-66) ,
exposed to the open air.
jector (see 13B, Diesel injection, High-pressure
pipe between the rail and injector: Removal -
Note: Refitting, page 13B-106) .
Injectors may be replaced individually. Only remove

the high pressure pipe concerned. II - OPERATION FOR REMOVAL OF PART
CONCERNED
a Put blanking plugs in the openings.
REMOVAL a Remove:
- the injector clamp bolt,
I - REMOVAL PREPARATION OPERATION - the injector with its clamp.
WARNING
a Disconnect the battery (see Battery : Removal -
Refitting) (80A, Battery). Make sure that you mark the injector positions.
13B-141
DIESEL INJECTION
a Remove the compression washer. II - REFITTING OPERATION FOR PART
CONCERNED
Note: a
If the compression washer is stuck at the bottom WARNING
of the well, use the (Mot. 1817) (see Injector
well cleaning tool: Use) (Technical Note 6040A,
13B, Diesel injection).
Also, do not remove the components from their
REFITTING cle.

a
IMPORTANT
tion.
WARNING
It is strictly forbidden to clean the injectors with:

- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
Cleaning parts
a Always clean the well of the removed injector (see
Injector well cleaning tool: Use) (Technical Note 1326
6040A, 13B, Diesel injection). a Replace the compression washer.
a If reusing the removed injector: a Refit the injector with its clamp.
- clean the diesel injector using a cloth soaked in IN-
JECTOR CLEANER or BRAKE CLEANER, a Torque tighten the injector clamp bolts (25 N.m).
- if necessary, leave the injector nozzle to soak in IN-

JECTOR CLEANER, WARNING
- wipe the injector with a new wipe, Avoid pressurising the high pressure pipes.
- (see Vehicle: Parts and ingredients for the re-
pairwork) (04B, Consumables - Products) or (see
tions for repair, page 13B-1) . a Refit:
a Always replace the compression washer.
jector (see 13B, Diesel injection, High-pressure
pipe between the rail and injector: Removal -
- the diesel return pipe (see 13B, Diesel injection,

Diesel return pipe: Removal - Refitting, page
13B-66) .
a Connect the injector connectors.
13B-142
DIESEL INJECTION
F9Q, and 758 or 759

Note:
a Connect the battery (see Battery : Removal - Refit-

ting) (80A, Battery).
a Check that there are no diesel leaks:
F9Q, and 758 or 759


F9Q, and 758 or 759

13B-143
PREHEATING
Pre/postheating unit: Removal - Refitting 13C
F9Q or G9T or M9R, and DOCUMENT PHASE 2
CONCERNED
Tightening torquesm
pre-postheating unit bolt 8 Nm
REMOVAL

19315
a Disconnect the pre/postheating unit connector (1) .
a Remove:
- the bolt (2) from the pre-postheating unit,
- the pre-postheating unit.
REFITTING
111404
a Remove:
- the front left-hand wheel (see 35A, Wheels and ty-
CONCERNED
res, Wheel: Removal - Refitting),
- the front left-hand wheel arch liner (see MR 396, a Refit the pre-postheating unit.
Bodywork, 55A, Exterior protection, Wheel arch
a Torque tighten the pre-postheating unit bolt (8
liner: Removal - Refitting).
Nm).
a Connect the pre-postheating unit connector.
a Refit:
- the front left-hand wheel arch liner (see MR 396,

Bodywork, 55A, Exterior protection, Wheel arch
- the front left-hand wheel (see 35A, Wheels and ty-

res, Wheel: Removal - Refitting).

moval - Refitting).
13C-1
PREHEATING
Heater plugs Removal - Refitting 13C
REFITTING
Tightening torquesm
heater plugs 15 Nm
a
WARNING
REMOVAL Ensure that no foreign bodies enter the cylinder
during this operation.
a Remove the engine covers. II - REFITTING OPERATION FOR PART

CONCERNED
Removal - Refitting). a Screw in the heater plugs by hand.
a Tighten to torque the heater plugs (15 Nm) using a
10 mm long socket.
F9Q, and 758 or 759
a connect the heater plug connectors.
F9Q, and 758 or 759


moval - Refitting).
111723


CONCERNED
a Disconnect the heater plug connectors.
a Clean around the plugs to prevent any impurities en-

tering the cylinders.
a Remove the plugs using a 10 mm long socket.
13C-2
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
I - THE CIRCUIT
23244
III - OPERATING PRINCIPLE
(1) Engine The solenoid valve is controlled by an opening cyclic
(2) Injection computer ratio signal issued by the injection computer. The ope-
(3) Inlet manifold ning cyclic ratio modulates the opening of the solenoid
valve, and consequently the quantity of exhaust gas di-
(4) Exhaust manifold rected back to the inlet manifold.
(5) Turbocharger
The computer runs a constant test to keep track of the
(6) Exhaust gas recirculation sole- position of the exhaust gas recirculation solenoid val-
noid valve ve.
(7) Air flowmeter
(8) Air inlet IV - OPERATING CONDITIONS
(9) Exhaust gas outlet The following parameters determine activation of the
(10) Intercooler inlet exhaust gas recirculation solenoid valve:
(11) Intercooler outlet - coolant temperature,
- air temperature,
II - PURPOSE OF THE EXHAUST GAS
- atmospheric pressure,
RECIRCULATION SYSTEM
- injection flow,
Exhaust gas recirculation is used to reduce the con-
centration of nitrogen oxides (NOx) in exhaust fumes. - engine speed.
Exhaust gas recirculation is cut off if:
The injection computer allows gas to pass by control-
ling a solenoid valve. - the battery voltage is below 9 V,
14A-6
ANTIPOLLUTION
Exhaust gas recirculation: Description 14A
- If the engine speed is above 2,950 rpm when the pe-
dal 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 7.2 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 according to the coo-
lant temperature mapping.
15761
Track Description
1 Solenoid valve supply (+ battery)
2 Sensor supply (+5V)
4 Sensor earth
5 Solenoid earth
6 Sensor output
103127
X Time in seconds
Y Coolant temperature in ˚C
The exhaust gas recirculation solenoid valve is no lon-

ger supplied if there is a fault on:
- the coolant temperature sensor,
- the air temperature sensor,
- the turbocharging pressure sensor,
- the atmospheric pressure sensor.
14A-7
ANTIPOLLUTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A
REFITTING
Mot. 1729 Pin wrench for removing the I - REFITTING PREPARATION OPERATION
EGR valve.
a Always replace the EGR solenoid valve seal.
Tightening torquesm II - REFITTING OPERATION FOR PART

CONCERNED
EGR solenoid valve 9 Nm a Refit the EGR solenoid valve with a new seal.
mounting bolts
a Finger tighten the EGR solenoid valve mounting
bolts.
REMOVAL a Tighten to torque the EGR solenoid valve moun-
ting bolts (9 Nm).
I - REMOVAL PREPARATION OPERATION a Connect the EGR solenoid valve connector.
Removal - Refitting). III - FINAL OPERATION
a Remove the engine cover. a Refit the engine damper flap (see 12A, Fuel mixtu-
re, Engine damper flap: Removal - Refitting, page
a Remove the engine damper flap (see 12A, Fuel 12A-41) .
mixture, Engine damper flap: Removal - Refit-
ting, page 12A-41) .
moval - Refitting).
CONCERNED a In the event of replacement of the EGR solenoid val-
ve, carry out the necessary programming (see MR
a Disconnect the exhaust gas recirculation solenoid 397 Fault finding, 13B, Diesel injection, Fault fin-
valve connector . ding - Replacement of components.
a Remove the EGR solenoid valve mounting bolts.
107634
a Remove the EGR solenoid valve using the (Mot.

1729) :
- position the lugs (1) of the (Mot. 1729) in the moun-

ting holes of the EGR solenoid valve,
- ensure that the lugs (1) are fully inserted,

- turn the tool in small stages to detach the EGR so-
lenoid valve from its housing.
14A-18
ANTIPOLLUTION
Tightening torquesm
EGR solenoid valve 25 Nm

mounting bolts

REMOVAL

a Remove:
- the inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting, page 12A-55) , 111964
- the injection rail protector (see 13B, Diesel injec-

page 13B-79) .

CONCERNED
a Disconnect the EGR solenoid valve connector.
113177
a Remove:
111861
a Remove the mounting bolts (1) from the EGR pipe. - the EGR solenoid valve mounting bolts (2) ,
- the EGR solenoid valve.
REFITTING
a Replace the EGR solenoid valve seals.
14A-22
ANTIPOLLUTION
112665
a the EGR solenoid valve cannot be removed.
Replace the assembly if necessary.

CONCERNED
a Refit:
- the EGR solenoid valve,
- the EGR solenoid valve mounting bolts.
- the EGR solenoid valve mounting bolts (25 Nm),
bolts (18 Nm).
a Connect the EGR solenoid valve connector.

a Remove:
- the injector rail protector (see 13B, Diesel injec-
page 13B-79) ,
- the inlet duct (see 12A, Fuel mixture, Air inlet
duct: Removal - Refitting, page 12A-55) .
moval - Refitting).
a If replacing the EGR solenoid valve, carry out the
necessary programming (see MR 397 Fault finding
- Replacement of components.
14A-23
ANTIPOLLUTION
Intercooler: Removal - Refitting 14A

duct clips.
Tightening torquesm
exhaust gas cooler bolts 25 Nm
bolts between the 25 Nm

exhaust gas cooler and
the exhaust manifold
heat shield bolts 9 Nm

pipe mounting bolts

115592
battery tray bolts 21 Nm a Unclip:
REMOVAL - the turbocharger regulation solenoid valve .
a Remove the bolt (1) from the air filter unit inlet air pi-
a Position the vehicle on a two-post lift (see 02A, Lif- pe.
a Drill the tamperproof bolt shafts (2) using a ∅ 5 mm
a Remove the battery (see 80A, Battery, Battery: Re- drill bit.
moval - Refitting).
a Remove:
- the bolts (2) using the,
- the battery tray,
- the air pipe between the air filter and the turbochar-
ger duct.
a Move the engine compartment connection unit to
one side.
14A-31
ANTIPOLLUTION
CONCERNED
111861
a Remove:
- the bolts (3) from the EGR pipe,
111865
talytic pre-converter: Removal - Refitting, page a Remove:
19B-22) . - the turbocharger oil return pipe bolts (6) ,
- the oil return pipe (7) from the turbocharger.
111863
a Remove:
111868
- the clip (4) from the exhaust gas cooler using the a Remove the starter motor (see 16A, Starting -
(Mot. 1567), Charging, Starter: Removal - Refitting, page 16A-
- the exhaust gas recirculation pipe (5) . 18) .
14A-32
ANTIPOLLUTION
116222
a Remove:
- the bolts (14) from the exhaust gas cooler,
- the exhaust gas cooler.
111866
- the « hose - rigid pipe assembly » (9) between the

exhaust gas cooler (8) and the plenum chamber,
- the « hose - rigid pipe assembly » (10) between

the exhaust gas cooler (8) and the heater matrix
hose.
116223
a Remove the bolts (13) between the exhaust gas
cooler and the exhaust manifold.
REFITTING

a
WARNING
Ensure that the water inlet and outlet hoses of
the exhaust gas cooler are correctly aligned so
that they are not kinked.
111867 a Always replace:
a Remove: - the seal between the EGR pipe and the EGR unit,
- the seal between the exhaust gas cooler and the
- the heat shield bolts (11) , manifold,
- the heat shield (12) . - the exhaust gas cooler clip,
14A-33
ANTIPOLLUTION
- the battery tray tamperproof bolts. II - FINAL OPERATION
a Refit:
I - REFITTING OPERATION FOR PART - the injector rail protector (see 13B, Diesel injec-
CONCERNED tion, Injector rail protector: Removal - Refitting,
page 13B-79) ,
a Refit:
- the air pipe between the air filter and the turbochar-
- the exhaust gas cooler, ger duct,
- the exhaust gas cooler bolts, - the battery tray,
- the bolts between the exhaust gas cooler and the - the battery tray bolts,
exhaust manifold. a Tighten to torque the battery tray bolts (21 Nm).
a Tighten to torque: a Refit the air filter unit air inlet pipe bolt.
a Tighten the air filter unit air inlet pipe bolt.
- the exhaust gas cooler bolts (25 Nm),
- the bolts between the exhaust gas cooler and
the exhaust manifold (25 Nm) a Clip on:
a Refit:
- the heat shield,
- the heat shield bolts. val - Refitting).
a Tighten to torque the heat shield bolts (9 Nm). a Fill the cooling system (see 19A, Cooling, Cooling
a Using the, refit:
a Bleed the cooling circuit (see Cooling circuit: Blee-
- the « hose - rigid pipe assembly » between the ex- ding) .
haust gas cooler and the plenum chamber, a Check that there are no leaks:
- the « hose - rigid pipe assembly » between the ex- - start the engine,
haust gas cooler and the heater matrix hose. - check that the oil pressure warning light has gone
out,
a Refit:
- the starter motor (see 16A, Starting - Charging,
Starter: Removal - Refitting, page 16A-18) , - accelerate several times at no load,
- the turbocharger oil return pipe,
- the turbocharger oil return pipe bolts.
a Tighten to torque the turbocharger oil return pipe

mounting bolts (12 Nm).
a Refit:
- the exhaust gas recirculation pipe,
- the exhaust gas cooler clip using the (Mot. 1567).
- the exhaust gas recirculation pipe mounting bolts.
a Tighten to torque the exhaust gas recirculation

pipe mounting bolts (25 Nm).
a Refit the catalytic pre-converter (see 19B, Exhaust,

Catalytic pre-converter: Removal - Refitting,
page 19B-22) .
14A-34
STARTING - CHARGING
Starting system: Identification 16A
M9R, and DOCUMENT PHASE 2 – L7X, and DOCUMENT PHASE 2 – G9T, and DOCUMENT PHASE 2 – F4R,
and DOCUMENT PHASE 2 – K4M, and DOCUMENT PHASE 2 – F9Q, and DOCUMENT PHASE 2
Engine Supplier pulley type
F4R
K4M VALEO Standard
L7X VALEO Standard
F9Q BOSCH Declutchable
G9T BOSCH Standard
M9R VALEO Declutchable
16A-1
STARTING - CHARGING
Alternator: Removal - Refitting 16A
Tightening torquesm
alternator mounting 25 Nm
bolts
accessories belt fixed 25 Nm

roller mounting bolt
REMOVAL

a Disconnect the battery (see 80A, Battery, Battery,

18432
a Remove the accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re- a Remove the alternator using a screwdriver.
fitting, page 11A-4) .
a Remove: REFITTING
- the accessories belt fixed roller bolt,
- the accessories belt fixed roller.

CONCERNED
a Disconnect the alternator electrical connections.
18987
a Refit the rings (2) using pliers or a vice to facilitate fit-
ting.
19703
a Remove the alternator mounting bolts (1) .
16A-2
STARTING - CHARGING
Alternator: Removal - Refitting 16A
CONCERNED
a Refit:
- the alternator,
- the alternator mounting bolts.
a Tighten to torque the alternator mounting bolts
(25 Nm).
a Connect the alternator electrical connections.

a Refit the accessories belt fixed roller.
Refit:
- the accessories belt fixed roller,
- the accessories belt fixed roller mounting bolt.
a Tighten to torque the accessories belt fixed roller
mounting bolt (25 Nm).
a Refit the accessories belt (see 11A, Top and front
of engine, Accessories belt: Removal - Refitting,
page 11A-4) .
a Connect the battery (see 80A, Battery, Battery, Re-
moval - Refitting).
16A-3
STARTING - CHARGING
Starter: Removal - Refitting 16A
F9Q, and 664 or 674
Tightening torquesm
starter mounting bolts 44 Nm
REMOVAL

terminal.
a Remove:
- the engine cover,
- the battery,
- the battery tray,

101120
a Remove:
- the catalytic converter strut (7) ,
- the catalytic converter (8) mounting plate on the
gearbox,
- the catalytic converter (9) (see 19B, Exhaust, Ca-
talytic converter: Removal - Refitting).
a Disconnect the starter motor electrical connections.
19135-1
a Remove:
- the union (1) from the oil decanter,
- the air hose (2) ,
- the clip (3) mounting the air inlet hose on the dam-
per unit,
18980
- the mounting nut (4) between the two air hoses. a Remove:
a Move the air hose (5) to one side slightly. - the starter mounting bolts (10) ,
a Move aside the turbocharger air hose (6) . - the starter.
16A-18
STARTING - CHARGING
F9Q, and 664 or 674
REFITTING
a Check that the centring dowel is in place.
a Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter: Removal - Refitting).
a Tighten to torque the starter mounting bolts (44
Nm).
nal.
WARNING
Battery, Battery: Removal - Refitting).
16A-19
STARTING - CHARGING
Tightening torquesm
starter mounting bolts 44 Nm

pipe mounting bolts
REMOVAL

ting Equipment, Vehicle: Towing and lifting).
moval - Refitting).
115592
a Unclip:
- the engine compartment connection unit (2) .
a Disconnect the air flowmeter connector.
a Remove:
- the battery tray,
- the air hose between the air filter and the turbo-
charger duct.
a Move the engine compartment connection unit to
one side.
a Remove the catalytic pre-converter (see 19B, Ex-
haust, Catalytic pre-converter: Removal - Refit-
16A-21
STARTING - CHARGING
CONCERNED
111860
a Loosen the air duct clip (5) between the turbochar-
ger and the air filter box.
a Disconnect the air duct between the turbocharger
and the air filter unit.
111868
a Disconnect the wiring harness from the starter.
a Remove the starter mounting bolts (7) .
a Remove the starter.
REFITTING

a Check that the centring dowel is in place.

CONCERNED
a Refit:
- the starter,
111865
- the starter mounting bolts.
a Remove:
a Torque tighten the starter mounting bolts (44 Nm)
a Connect the wiring harness.
- the turbocharger oil return pipe (6) .

a Replace the turbocharger oil return pipe seal.
a Refit:
- the turbocharger oil return pipe,
a Torque tighten the turbocharger oil return pipe
mounting bolts (12 Nm)
16A-22
STARTING - CHARGING
a Refit:
19B-22) ,
- the air hose between the air filter and turbocharger
duct,
- the battery tray,
- the air duct mounting bolt,
- the air duct clip between the turbocharger and the
air filter unit.
a Tighten with a spanner:
- the air duct clip between the turbocharger and the
air filter unit.
a Clip:
moval - Refitting).
16A-23
COOLING
Engine cooling: Parts and consumables for the repair work 19A
DOCUMENT PHASE 1
CONSUMABLES
Use GLACEOL RX (TYPE D) coolant.
Note:
Ready-to-use coolant or antifreeze must be diluted
with distilled water in accordance with the guideli-
nes marked on the container.
19A-1
COOLING
Engine cooling: Parts and consumables for the repair work 19A
F4R or F9Q or G9T or K4M or L7X or M9R, and DOCUMENT PHASE 2
CONSUMABLES
Use GLACEOL RX (TYPE D) coolant.
Note:
19A-2
COOLING
Engine cooling: Precautions for repair 19A
DOCUMENT PHASE 1
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drive
IMPORTANT
belt,
The circuits are designed to be pressurized; take
care at high temperatures (risk of serious burns), - that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
Never remove the valve from the expansion bottle air.
while the engine is hot.
Vehicles in the current range have cooling circuits with
Similarly, take care when working under the bonnet, the following basic characteristics:
as the radiator fan(s) may start up unexpectedly.
- Pressurized sealed circuit (expansion bottle valve),
Do not open the bleed valve(s) while the engine is
running.
Note:
Summary of expansion bottle valve ratings.
WARNING Expansion bottle valve with:
The coolant helps to keep the engine running pro-
perly (heat exchange). • a brown circle: 1.2 bar
The system does not operate using pure water. • a blue circle: 1.4 bar
• a yellow hand: 1.4 bar
• a white hand: 1.6 bar
WARNING • a grey hand: 1.8 bar
Drain the oil when the engine is warm.
- circuit using only type « D » coolant.
Flushing and refilling should be carried out with a
warm or cold engine.
Never flush a hot engine (risk of serious thermal Note:
shock). Ready-to-use coolant or antifreeze must be diluted
WARNING
When carrying out a repair that requires a complete
circuit drain, it is essential to flush the circuit with
clean water, blow compressed air through the cir-
cuit to eliminate water, fill and drain the circuit and
then measure the effective protection.
The parameters to be observed are:
- Protection down to - 25˚C ± 2 for cold and tempe-
rate climates,
- Protection down to - 40 ˚C ± 2 for very cold clima-
tes.
Note:
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-3
COOLING
Engine cooling: Precautions for repair 19A
IMPORTANT Note:
The circuits are designed to be pressurised, take Refer to the vehicle's Maintenance Booklet for infor-
care at high temperatures (risk of serious scalding). mation on cooling circuit service intervals.
Do not remove the expansion bottle cap when the For any further information, refer to the Workshop
engine is warm. Take care when working under the Repair Manual of the vehicle concerned.
bonnet as the engine cooling fan(s) may start to
operate without warning. When a faulty vehicle arrives, check:
Do not open the bleed screw(s) with the engine run- - the condition and tension of the coolant pump drive
ning. belt,
Only use GLACEOLE RX (TYPE D) coolant. - that the fan, the radiator and the radiator grille are not
obstructed by an object which may impede the flow of
air.
WARNING Vehicles in the current range have cooling circuits with
The coolant helps to keep the engine running pro- the following basic specifications:
perly (heat exchange).
- Pressurised sealed circuit (expansion bottle valve),
The system does not operate using pure water.
Note:
WARNING Summary of expansion bottle valve ratings.

Drain with the engine warm. Expansion bottle valve with:
Flushing and refilling should be carried out with a • a brown circle: 1.2 bar
warm or cold engine. • a blue circle: 1.4 bar
Never flush a hot engine (risk of serious thermal • a yellow marking: 1.4 bar
shock).
• a white marking: 1.6 bar
• a grey marking: 1.8 bar
WARNING - circuit using type « D » coolant only.
It is essential to replace the expansion bottle cap if
the coolant is leaking from the valve.
Note:
WARNING with distilled water in accordance with the guideli-
When carrying out a repair that requires a the cir-
cuit 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 protec-
tion.
The criteria to be met are:
- Protection down to -25˚C ± 2 for cold and tempe-
rate climates,
- Protection down to -40˚C ± 2 for very cold climates
19A-4
COOLING
Engine cooling circuit: Specifications 19A
Vehicles in the current range have cooling systems - circuit using type « D » liquid,
with the following basic specifications:
- passenger compartment heating systems equipped
- hermetically-sealed pressurised circuit (expansion with a « heater matrix » type radiator located under
chamber valve), the dashboard which helps to cool the engine.
Volume of coolant
Engine Suffix Quantity Grade

(litres)
F4R 714-715-784-786-787-886-887 6.5
F9Q 664-674-758-759 7
G9T 600-605-706-707 6.8 GLACEOL RX (type

D)
K4M 716 6.5 Only use coolant
L7X 733 7.2
M9R 740-760 7.5
Special notes: - protection down to - 40˚C ± 2 "extreme cold" coun-

tries.
- protection down to - 25˚C ± 2 for cold and temperate
countries,
Thermostat opening temperatures
Engine Suffix Start of End of opening

opening (˚C) (˚C)
F4R 714-715-784-786-787-886-887 89 99 ± 2
F9Q 664-674-758-759 89 99 ± 2
G9T 600-605-706-707 89 99 ± 2
K4M 716 89 99 ± 2
L7X 733 89 99 ± 2
M9R 740-760 89 99 ± 2
19A-5
COOLING
Engine cooling circuit: check 19A
DOCUMENT PHASE 1
Special tooling required
Mot. 1700 Cooling circuit filling and dia-

gnostic tool
I - RECOMMENDATIONS FOR REPAIR

a
IMPORTANT
The circuits are designed to be pressurized; take
care at high temperatures (risk of serious burns).
Never remove the valve from the expansion
bottle while the engine is hot.
Similarly, take care when working under the bon-
net, as the radiator fan(s) may start up unexpec-
tedly.
Do not open the bleed valve(s) while the engine
is running.
II - CHECKING THE CIRCUIT SEALING

a
Note:
The expansion bottle valve must be replaced if
coolant is leaking from the valve.
19A-6
COOLING
DOCUMENT PHASE 1
Checking the cooling circuit and the expansion
bottle valve
107138
a Check the cooling circuit and the expansion bottle
valve using the cooling circuit diagnostic and filling
tool (Mot. 1700). For guidance on the use of this tool
see TN 3857A, How to use the cooling circuit dia-
gnostic and filling tool.
Note:
For any further information, refer to the Works-
hop Repair Manual of the vehicle concerned.
19A-7
COOLING
DOCUMENT PHASE 2
1 - Checking the expansion bottle cap valve
Mot. 1700 Fault finding and filling-blee-

ding cooling system.
Ms. 554-07 Cooling system tester kit

(complete). Contains plugs
554-01, 554-04, 554-06
Ms. 554-06 Spare cap for testing expan-

sion bottle valves (2nd fitting).
Ms. 554-01 Spare expansion bottle adap-

ter cap.
IMPORTANT
When working in the engine compartment, take
care as the radiator fan(s) may start up unexpecte-
dly (risk of being cut).
To avoid any risk of serious burns when the engine
107138
is hot:
a Use the cooling system filling and diagnostic tool
- do not open the expansion bottle cap,
(Mot. 1700). Consult the procedure for using this
- do not drain the cooling system, tool (see 19A, Cooling, Engine cooling: Precau-
tions for repair, page 19A-3) (Technical Note
- do not open the bleed screw(s).
3857A, 19A, Cooling).
2 - Checking the sealing of the cooling circuit

Note:
a Use the cooling system filling and diagnostic tool
There are two procedures for checking the cooling (Mot. 1700). Consult the procedure for using this
system: tool (see 19A, Cooling, Engine cooling: Precau-
tions for repair, page 19A-3) (Technical Note
- The procedure using the (Mot. 1700),
3857A, 19A, Cooling).
- The procedure using the (Ms. 554-07).
a The expansion bottle cap valve rating is 1.4 bar. II - CHECKING THE COOLING CIRCUIT USING THE
(MS. 554-07)
I - CHECKING THE COOLING CIRCUIT USING THE a

(MOT. 1700).
WARNING
a If the coolant is leaking from the expansion bottle
cap, replace the valve.
WARNING
If the coolant is leaking from the expansion bottle
cap, replace the valve.
19A-8
COOLING
DOCUMENT PHASE 2
1 - Checking the expansion bottle cap valve a Gradually undo the union of the (Ms. 554-07) to de-
compress the cooling system and then remove the
adapter (Ms. 554-01) and refit the expansion bottle
cap.
97871
a Fit the test tool (Ms. 554-07) with the adapter (Ms.
554-06).
a Fit the expansion bottle cap onto the adapter (Ms.

554-06).
Note:
The pressure should not drop; if it does, look for
the leak.
a Pump with the (Ms. 554-07), the pressure should

stabilise at the expansion bottle cap valve rating with
a test tolerance of ± 0.1 bar.
2 - Checking the cooling circuit sealing
a Replace the expansion bottle cap with the adapter

(Ms. 554-01).
a Connect the adapter (Ms. 554-01) to the (Ms. 554-

07).
a Use the tool as a pump to pressurise the cooling

system.
a Stop pumping at 0.1 bar below the expansion bottle

cap valve rating.
Note:
The pressure should not drop; if it does, look for
the leak.
19A-9
COOLING
Engine cooling circuit: Operating diagram 19A
F9Q, and JR5 or PK6, and DOCUMENT PHASE 2
19508
(1) Engine
(2) Radiator
(3) Expansion bottle
(4) Heater matrix
(5) Thermostat
(6) Heating elements
(7) Coolant-oil exchanger
(8) Coolant pump
(9) Bleed screw
(10) 8 mm choke
(11) 3.5 mm choke
19A-15
COOLING
Cooling circuit: Draining - Refilling 19A
F4R or F9Q or G9T or K4M or M9R, and DOCUMENT PHASE 2
a Remove the cooling radiator bottom hose clip using
Essential special tooling the (Mot. 1202-01) or (Mot. 1202-02) o r (Mot.
1448).
Mot. 1202-01 Pliers for large hose clips.
a Open the cooling system by removing the cooling ra-
Mot. 1202-02 Pliers for small hose clips. diator bottom hose using the tool (Car. 1363).
Mot. 1448 Long nose pliers for hose a Use a compressed air nozzle to blow air into the
clips. system through the expansion bottle opening to re-
move as much coolant as possible.
Car. 1363 Set of trim removal levers.
Mot. 1700 Fault finding and filling-blee- II - CLEANING

ding cooling system. a Fill the cooling system with water through the expan-
sion bottle.
Ms. 554-07 Cooling system tester kit
(complete). Contains plugs a Let the water run until the water collected from the
554-01, 554-04, 554-06 cooling radiator bottom hose becomes clear.
a Disconnect the radiator top hose in order to clean
Essential equipment the cooling circuit correctly.
coolant draining tray a Use a compressed air nozzle to blow air into the
circuit through the expansion bottle opening to re-
compressed air nozzle move as much water as possible.
a Refit the removed hoses.
pedal press
a III - FILLING
IMPORTANT a
When working in the engine compartment, take
Note:
care as the radiator fan(s) may start up unexpec-
tedly (risk of being cut). There are two procedures for filling the cooling
system:
To avoid any risk of serious burns when the
engine is hot: - the method using the (Mot. 1700) tool is recom-
mended by Renault. It saves a considerable
- do not open the expansion bottle cap,
amount of time because it does not require the
- do not drain the cooling system, cooling system bleed screws to be opened,
- do not open the bleed screw(s). - the procedure without a special tool.
WARNING 1 - Filling procedure with the tool (Mot. 1700)

Before the operation, protect the electrical acces- a Fill the cooling system with the engine coolant re-
sories to prevent any risk of short circuiting and commended by the manufacturer (see Vehicle:
protect the belts to avoid damaging them. Parts and ingredients for the repairwork) (MR
395, 04B, Consumables - Products) using the (Mot.
1700). Consult the procedure for using this tool (see
I - DRAINING Cooling circuit Filling) (Technical Note 3857A,
a Position the vehicle on a two-post lift (see Vehicle: 19A, Cooling).
Towing and lifting) (MR 395, 02A, Lifting equip-
ment).
a Remove:
- the expansion bottle cap,
a Position the coolant draining tray under the vehi-
cle.
19A-24
COOLING
Cooling circuit: Draining - Refilling 19A
F4R or F9Q or G9T or K4M or M9R, and DOCUMENT PHASE 2
2 - Filling method without special tools
a F9Q
WARNING a Maintain the engine speed at 2500 rpm using a pe-

dal press, until the engine cooling fan starts for the
It is essential to open all of the bleed screws to
second time.
remove as much as air as possible in the cooling
system, Failure to perform this procedure may
prevent the cooling system from filling properly
and may damage the engine.
G9T
a Open all bleed screws (see 19A, Cooling, Engine
cooling circuit: Operating diagram, page 19A-10) a Maintain the engine speed at 2500 rpm using a pe-
. dal press for a minimum of 20 minutes and until the
engine cooling fan has started twice.
a Fill the cooling system with the engine coolant re-
commended by the manufacturer (see Vehicle:
Parts and ingredients for the repairwork) (MR
395, 04B, Consumables - Products) via the expan-
sion bottle until it overflows.
M9R
a Close all the bleed screws as soon as the coolant a Maintain the engine speed at 1500 rpm using a pe-
starts to flow in a continuous stream. dal press for a minimum of 20 minutes and until the
engine cooling fan has started twice.
a Pressurise the system using the (Ms. 554-07) to
check that there are no leaks (see 19A, Cooling,
Engine cooling circuit: check, page 19A-6) .
a Refit the expansion bottle cap. a Check that the heating is operating correctly.
a Let the engine cool until the temperature drops be-
a Clean any surfaces soiled by the coolant.
low 50˚C.
a Connect the heating elements (if fitted to the vehi-
IV - BLEEDING cle).
a a Adjust the coolant fluid level to the "Max" mark.

a Refit the expansion bottle cap.
WARNING
Do not open the bleed screw whilst the engine is
running; this would damage the engine. V - FINAL OPERATION.
a Remove the coolant recovery tray.
a Deactivate the air conditioning system so that the
engine cooling fan is not operating from the start of a Refit the engine undertray.
the operation.
a Disconnect the heating elements (if fitted to the vehi-

cle).
a Start the engine.
F4R or K4M
a Maintain the engine speed at 2500 rpm using a pe-

dal press, until the engine cooling fan starts for the
second time (time required for automatic degas-
sing).
19A-25
COOLING
Cooling radiator: Removal - Refitting 19A
a Bleed the cooling circuit via the lower hose on the ra-
WARNING
diator with the help of tooloror(see 19A, Cooling,
Do not damage the fins of the cooling unit (radiator, Cooling circuit: Draining-refilling).
condenser etc.).
a Remove:
When carrying out a repair that requires a complete
change, it is essential to flush the circuit with clean - the front bumper (see 55A, Exterior protection,
water, blow compressed air through the circuit to Front bumper: Removal - Refitting).
eliminate water, fill and drain the circuit and then - The headlights (see 80B, Headlights, Halogen
measure the effective protection. headlights: Removal - Refitting).
The parameters to be observed are:
- protection down to - 25˚C ± 2 for cold and tempe-
rate countries,
- protection down to - 40 ˚C ± 2 for very cold coun-
tries.
WARNING
Before disconnecting the battery:

- switch off all consumers,
111845
- wait for the engine cooling fan assembly to stop
a Remove the upper cross member mounting bolts.
- if the vehicle is equipped with Carminat, wait until
a Remove the upper cross member over the engine.
the system stops after switching off the + after
ignition (approximately 1 minute). a Remove the clamp of the cooling radiator top hose
using tooloror.
a Disconnect:
IMPORTANT - the fan assembly connectors,
The circuits are designed to be pressurised, and so - the radiator upper hose,
care must be taken at high temperatures, as there
is a risk of serious burns. a Separate the condenser from the « cooling system
exchanger » assembly.
Do not remove the cap from the expansion bottle
while the engine is hot. a Remove:
When carrying out a repair under the bonnet, guard - the intercooler (see 12B, Turbocharging, inter-
against inadvertently setting off the radiator fan(s). cooler: Removal - Refitting),
Do not open the bleed screw(s) while the engine is - the lower positioning pins of the radiator,
running. - the cooling system.
a Separate the fan assembly from the cooling radiator.
REMOVAL

terminal.
a Remove:
- the engine cover,
19A-26
COOLING
REFITTING
IMPORTANT
To prevent eye injuries do not look at a xenon
bulb when lit (lit voltage 20,000 V).
WARNING
You must initialise the xenon bulb system (if fit-
ted).
WARNING
Connect the battery, starting with the positive ter-
minal; Carry out the necessary programming.
a Fill and bleed the cooling circuit (see section 19A,

Cooling, Cooling circuit: Bleeding).
19A-27
COOLING
REMOVAL

a Remove:
moval - Refitting).
a Remove the fan unit (see 19A, Cooling, Engine
cooling fan assembly: Removal - Refitting, page
19A-71) .
115592
a Unclip:
a Remove:
- the battery tray,
- the cooling radiator top hose clip using the
- the cooling radiator top hose.
a Disconnect the pressostat connector from the con-
denser.
19A-30
COOLING
CONCERNED
115622
a Remove the condenser clips (5) .
115591
a Strap the condenser and the intercooler to the front
a Unclip:
end panel.
a Remove the lower cross member (see MR 396 Pa- - the intercooler from the radiator (6) ,
nelwork, 41A, Front lower structure, Mounting - the condenser from the radiator (7) .
cross member).
a Remove the cooling radiator.
REFITTING
I - OPERATION FOR REFITTING PART

CONCERNED
a Refit the cooling radiator.
a Clip on:
- the condenser to the radiator.
- the intercooler to the radiator.
a Refit the lower cross member (see MR 396 Pa-
nelwork, 41A, Front lower structure, Mounting
cross member).
a Refit the condenser clips.
a Remove the straps.
a Connect the pressostat connector to the condenser.
a Refit:
- the cooling radiator top hose clip using the
- the cooling radiator top hose,
19A-31
COOLING
- the battery tray,
a Clip on:
a Refit the fan unit (see 19A, Cooling, Engine coo-
ling fan assembly: Removal - Refitting, page
19A-71) .
Bleeding) .
a Refit:
Refitting).
19A-32
COOLING
Water pump: Removal - Refitting 19A
CONCERNED
Tightening torquesm
coolant pump mounting 9 Nm

bolts
REMOVAL

a Remove:
102422
a Remove:
a Remove:
engine, Accessories belt: Removal - Refitting, - the coolant pump mounting bolts (1) ,
page 11A-4) , - the coolant pump.
Timing belt: Removal - Refitting, page 11A-26) . REFITTING

a Clean the joint face.
Note:
Apply a drop of LOCTITE FRENETANCH to the
pump bolts.
19A-45
COOLING
Water pump: Removal - Refitting 19A
CONCERNED
102422
a Refit the coolant pump fitted with a new seal.
Refit:
- the coolant pump fitted with a new seal,
- the coolant pump mounting bolts.
a Torque tighten, gradually and in order, the coolant

pump mounting bolts (9 Nm).
a Refit:

Timing belt: Removal - Refitting, page 11A-26) ,

page 11A-4) .
a Refit:


Bleeding) .

moval - Refitting).
19A-46
COOLING
Plenum chamber: Removal - Refitting 19A
- the air duct between the air flowmeter and the tur-
bocharger.
Tightening torquesm
coolant outlet unit 10 Nm

mounting bolts
REMOVAL

a Remove:
moval - Refitting).
ling circuit: Draining - Refilling, page 19A-22) . 115621
a Remove the mounting bolt from the air ducts (5) .
a Disconnect the air inlet duct (6) .
a Remove the metal duct between the turbocharger
and the intercooler.
Note:
The mounting bolt for the metal duct and the air
inlet duct is the same.
115592
a Unclip:
a Remove:
- the battery tray,
19A-62
COOLING
Plenum chamber: Removal - Refitting 19A
II - OPERATION FOR REMOVAL OF PART III - FINAL OPERATION
CONCERNED
a Refit the metal duct between the turbocharger and
the intercooler.
a Connect the air inlet duct.
a Refit the air duct mounting bolt.
a Tighten the air duct mounting bolt with a spanner.
a Refit:
bocharger,
- the battery tray,
- the air duct retaining bolt.
a Use a spanner to tighten:
- the air duct retaining bolt.
115597 a Clip on:
a Disconnect the coolant temperature sensor electri- - the engine compartment connection unit,
cal connector (7) . - the turbocharger regulation solenoid valve.
a Remove: a Fill the cooling system (see 19A, Cooling, Cooling
- the coolant hoses (8) using the,
- the mounting bolts from the coolant outlet unit (9) , Bleeding) .
- the coolant outlet unit. a Refit:
REFITTING - the engine undertray.
I - REFITTING PREPARATION OPERATION Refitting).
a Replacer the coolant unit seal.
a Clean the cylinder head joint face.

CONCERNED
a Refit:
- the coolant outlet unit,
- the mounting bolts to the coolant outlet unit
a Tighten to torque the coolant outlet unit mounting

bolts (10 Nm).
a Refit the coolant hoses using the.
a Connect the coolant temperature sensor electrical

connector.
19A-63
COOLING
Engine cooling fan assembly: Removal - Refitting 19A
a Remove:
a Disconnect:
- the motor-driven fan assembly connector,
- the electrical resistance connector.
a Unclip the motor-driven fan assembly wiring harnes-
ses.
111561
a Remove:
- the tie-rod bolts (2) ,
- the tie-rod,
- the heating element mounting bolts.

CONCERNED
a Lower the vehicle to the correct height.
a Raise the fan so that the cooling radiator can be
unclipped.
a Move the hoses and the heating element to one si-
de.
115622 a Remove the motor-driven fan assembly from under-
a Remove the radiator pins (1) . neath the vehicle.
a Lift up the radiator using a wedge.

REFITTING

CONCERNED
a Refit the motor-driven fan assembly from under-
neath the vehicle.
a Clip the motor-driven fan assembly onto the radiator.
a Refit:
- the tie-rod,
- the tie-rod bolts,
19A-74
COOLING
Engine cooling fan assembly: Removal - Refitting 19A
- the heating element support mounting bolts.
- the tie-rod bolts,
- the heating element support mounting bolts.
a Remove the wedge.
a Clip on the radiator pins.
a Connect:
- the motor-driven fan assembly connector,
- the electrical resistance connector.
a Attach the motor-driven fan assembly wiring harnes-
ses.
a Refit:
moval - Refitting).
19A-75
COOLING
Water pump inlet pipe: Removal - Refitting 19A
Tightening torquesm
coolant pump inlet pipe 40 Nm

mounting bolt
REMOVAL

a Remove:
16185-1
a Drain the cooling system (see 19A, Cooling, Coo- a
Note:
OPERATION FOR REMOVAL OF PART The coolant pump pipe is fitted.

CONCERNED
REFITTING

a Replace the seal.

CONCERNED
a refit:
- the coolant pump inlet pipe,
- the mounting bolts to the coolant pump inlet pipe.
Fitting the pipe:

- turn the pipe a quarter of a turn (mounting brac-
ket horizontal).
- fit the pipe,
115619
- position the pipe,
a Disconnect the bottom hose between the coolant
Look at the timing end between the multifunction
pump inlet pipe and the cooling radiator (1) , using
support and the engine.
the.
a Remove: a Torque tighten the coolant pump inlet pipe moun-

ting bolt (40 Nm).
- the coolant pump inlet pipe mounting bolt (2) ,
a Connect the bottom hose between the coolant pump
- the coolant pump inlet pipe. inlet pipe and the cooling radiator, using the.
19A-85
COOLING
Water pump inlet pipe: Removal - Refitting 19A
FINAL OPERATION
Bleeding) .
moval - Refitting).
a refit:
19A-86
COOLING
Coolant temperature sensor: Removal - Refitting 19A

CONCERNED

a Remove:
moval - Refitting).
115597
a Disconnect the coolant temperature sensor connec-
tor.
a Remove:
- the coolant temperature sensor retaining clip (5) ,
- the coolant temperature sensor (6) .
REFITTING
115592
a Unclip:
a Replace the coolant temperature sensor O-ring.
a Disconnect the air flow sensor connector. CONCERNED
a Remove: a Refit:
- the battery tray mounting bolts (3) , - the coolant temperature sensor,
- the air duct mounting bolt (4) , - the coolant temperature sensor retaining clip.
- the battery tray, a Connect the coolant temperature sensor connector.
- the air duct between the air flowmeter and turbo-
charger. III - FINAL OPERATION
a Refit:
bocharger,
- the battery tray.
19A-104
COOLING
Coolant temperature sensor: Removal - Refitting 19A
a Use a spanner to tighten:
a Clip on:
circuit: Draining - Refilling, page 19A-22)
Bleeding)
a Refit:
Refitting).
19A-105
EXHAUST
Exhaust: Parts and consumables for the repair work 19B
DOCUMENT PHASE 2
F9Q, and 758 or 759
19B-8
EXHAUST
DOCUMENT PHASE 2
116146
19B-9
EXHAUST
DOCUMENT PHASE 2
F9Q, and 664 or 674
19B-10
EXHAUST
DOCUMENT PHASE 2
116144
19B-11
EXHAUST
Catalytic pre-converter: Removal - Refitting 19B
B74 or K74, and F9Q, and 758, and DOCUMENT PHASE 2
Tightening torquesm
connection clamp 18 Nm
nuts mounting the cata- 30 Nm

lytic pre-converter upper
stay on the cylinder
head
bolts mounting the cata- 50 Nm

lytic pre-converter lower
left-hand stay on the
cylinder block
bolts mounting the cata- 50 Nm 113406

lytic pre-converter lower a Remove:
left-hand stay on the
catalytic pre-converter - the nuts (1) on the exhaust bracket between the
flexible pipe and the catalytic pre-converter,
nuts mounting the cata- 30 Nm - the nuts (2) mounting the particle filter rubber
lytic pre-converter lower mounting bush on the sub-frame.
right-hand stay on the
cylinder block a Separate the flexible pipe from the catalytic pre-con-
verter:
nuts mounting the cata- 30 Nm
- raise the particle filter to extract the rubber moun-
lytic pre-converter lower
ting bush from the studs crimped on the sub-frame,
right-hand stay on the
catalytic pre-converter - pull the exhaust pipe towards the rear of the vehi-
cle, then lower it to extract the flexible pipe from the
exhaust bracket nuts 21 Nm catalytic pre-converter studs.
between the flexible
pipe and the catalytic
pre-converter
nuts mounting the parti- 25 Nm

cle filter rubber moun-
ting bush on the sub-
frame
REMOVAL

a Remove:


a Remove the rear suspended engine mounting (see
19D, Engine mounting, Lower engine tie-bar: Re-
moval - Refitting, page 19D-36)
19B-27
EXHAUST
CONCERNED
113409
a Remove:
- the nuts (3) mounting the catalytic pre-converter on
the catalytic pre-converter upper stay,
- the connection clamp (4) .
19B-28
EXHAUST
IMPORTANT
Catalytic converters contain ceramic fibres; these
are contained within a closed unit, and cannot
disperse. Cutting or drilling catalytic converters is
prohibited.
REFITTING

a
WARNING
Replace:
- the seal between the flexible pipe and the cata-
lytic pre-converter,
111864 - the connection clip,

WARNING
It is essential to carefully clean all the upstream
and downstream mating faces of the catalytic
pre-converter.
113410
a Remove:
- the bolt (5) mounting the catalytic pre-converter
lower right-hand stay on the cylinder block,
- the nuts (6) mounting the catalytic pre-converter on
the catalytic pre-converter lower right-hand stay,
- the catalytic pre-converter lower right-hand stay,
- the catalytic pre-converter lower left-hand stay
mounting bolts (7) ,
- the catalytic pre-converter lower left-hand stay,
- the catalytic pre-converter from underneath the ve-
hicle.
19B-29
EXHAUST
CONCERNED
113409
a Refit the nuts mounting the catalytic pre-converter
113410 upper stay on the cylinder head.
a Place the catalytic pre-converter and its new clamp
on the cylinder block: position the catalytic pre-con-
verter lower left-hand stay and manually tighten the
mounting bolts (allow the catalytic converter to move
freely).
a Position the catalytic pre-converter lower right-hand
stay and manually tighten the mounting bolts (8) (al-
low the catalytic converter to move freely).
a Pretighten the connection clip (leave the catalytic
converter free of movement).
WARNING
Do not re-use a used sleeve.
WARNING
Check that the catalytic pre-converter is not in
contact with the turbocharger oil return pipe.
19B-30
EXHAUST
- the nuts mounting the catalytic pre-converter
lower right-hand stay on the cylinder block (30
Nm) at (13) ,
lower right-hand stay on the catalytic pre-con-
verter (30 Nm) at (14) .

a Position the particle filter and the exhaust pipe in
their original positions.
a Refit:
- the nuts on the exhaust bracket between the flexi-
ble pipe and the catalytic pre-converter,
- the nuts mounting the particle filter rubber moun-
ting bush on the sub-frame.
- the exhaust bracket nuts between the flexible
113410 pipe and the catalytic pre-converter (21 Nm),
- the nuts mounting the particle filter rubber
mounting bush on the sub-frame (25 Nm),
a Refit the rear suspended engine mounting (see 19D,
val - Refitting, page 19D-36)
moval - Refitting).
a Refit:
dy.
WARNING
It is essential to check the alignment of the parti-
cle filter downstream pressure measurement
connection.
111864
- the connection clamp (18 Nm) at (9) ,

upper stay on the cylinder head (30 Nm) at (10) ,
- the bolts mounting the catalytic pre-converter

lower left-hand stay on the cylinder block (50
Nm) at (11) ,
- the bolts mounting the catalytic pre-converter

lower left-hand stay on the catalytic pre-con-
verter (50 Nm) at (12) ,
19B-31
EXHAUST
Catalytic converter: Removal - Refitting 19B
Tightening torquesm
nuts securing the cataly- 30 Nm

tic converter to the tur-
bocharger
catalytic converter ups- 30 Nm

tream stay nut
catalytic converter ups- 44 Nm

tream stay mounting
bolt
catalytic c o nverter 21 Nm
downstream stay moun-
ting bolts
catalytic converter out- 7 Nm

let exhaust flange studs
catalytic converter out- 21 Nm 101118

let exhaust flange nuts
a Remove the nuts (1) from the exhaust bracket (at
the catalytic converter outlet).
REMOVAL
terminal.
a Remove:
- the front right-hand wheel,
102479
a Remove the catalytic converter mounting bolts on
the downstream stay (2) .
19B-47
EXHAUST
REFITTING
a
WARNING
The gaskets must always be replaced with new
gaskets.
a Pretighten in order:
- the catalytic converter upstream stay mounting
bolts,
- the downstream stay mounting bolts,
- the catalytic converter nuts on the turbocharger,
Refit and tighten to torque the nuts securing the
catalytic converter to the turbocharger (30 Nm).
a Refit the catalytic converter stays observing the or-
der of fitting.
Refitting the upstream stay

101120
a Remove:

bolts (3) ,
- the catalytic converter upstream stay.
101120
a Tighten to torque and in order
- the catalytic converter upstream stay nut (30
Nm) (5) ,
bolt (44 Nm) (6) .
101121
a Remove:
- the nuts (4) securing the catalytic converter to the

turbocharger,
- the catalytic converter from underneath the vehicle.
19B-48
EXHAUST
Refitting the downstream stay
102479
a Tighten to torque the catalytic converter downs-
tream stay mounting bolts (21 Nm) (7) .
WARNING
Do not reuse an old sleeve.
The « sleeve bolt and tightening nut » assembly
must be positioned so that they cannot come into
contact with the underbody.
Any damaged heat shields must be replaced.

- the catalytic converter outlet exhaust flange
studs (7 Nm),
- the catalytic converter outlet exhaust flange
nuts (21 Nm).
a Make sure that all the exhaust pipe heat shields are
in place and properly secured.
nal.
WARNING
Battery, Battery: Removal - Refitting).
19B-49
EXHAUST
Silencer: Removal - Refitting 19B
Tightening torquesm
rubber mounting bush 21 Nm

body
REMOVAL
115379
a Remove:
- the silencer mounting nuts (2) ,
- the silencer.
Note:
If the rubber mounting bushes are damaged:
115378 - mark the position of the mounting on the vehicle
a Remove the silencer clip (1) . body,
a Place the exhaust pipe on the rear axle. - replace the « support/rubber mounting bush
fitting » assembly.
REFITTING
a Refit the exhaust silencer.
WARNING
Do not reuse a used clip.
a It is essential to replace the silencer clip.
a Tighten to torque the rubber mounting bush

mounting bolts on the body (21 Nm).
a Make sure that all the exhaust pipe heat shields are
in place and properly secured.
19B-56
EXHAUST
Silencer: Removal - Refitting 19B
dy.
WARNING
19B-57
EXHAUST
Particle filter: Function 19B
The particle filter load level depends on the user's dri-
ving style:
Essential equipment
- during an average trip (combined cycle and motorway
diagnostic tool of more than 15 minutes), the particle filter automati-
cally burns the particles without being noticed by the
customer (apart from some white smoke): this is
I - SAFETY ADVICE « spontaneous regeneration » ,
- if the operating temperature is not high enough to trig-
Owing to the high temperatures, safety precautions ger spontaneous regeneration, clogging increases
must be respected, and the pressure circuit must never until it exceeds 35 g ; an acceleration request to trig-
be opened and separated except at the exhaust pipe ger spontaneous regeneration is then sent to the dri-
unions (only the supplier can guarantee pressure cir- ver via an instrument panel warning light; the same
cuit sealing). happens if several attempts to regenerate have failed.
- if these conditions are still not met and clogging ex-
Moreover, incorrect positioning of the pressure pipes ceeds 45 g. « Static regeneration » , using the dia-
may result in their flexible parts being twisted: this can gnostic tool must be performed in the workshop (
cause low points, where water in the exhaust pipe can « SERVICE » warning light comes on and the
collect. There is then a risk of the pipe bursting due to « CHECK ANTIPOLLUTION» message appears:
expansion if the water freezes. (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 under the body on the cataly-

tic pre-converter outlet, limits the polluting emissions
by accumulating the unburnt particles from the exhaust
gases (loading or filtering phase), then these particles
are eliminated by combustion (regeneration phase).
The injection computer uses the sensors to measure

the temperature as well as the exhaust gas pressure
upstream and downstream of the particle filter.
The injection computer is constantly evaluating the de-

gree of clogging in the particle filter from the pressure
difference upstream and downstream of the particle fil-
ter. When it is clogged, the two temperature values in-
form the injection computer that the temperature
conditions are high enough (approximately 600˚C) to
trigger regeneration.
This consists of burning the particles held in the parti-

cle filter: to do this, the injection switches to « delayed
injection » mode and the fuel not burned in the com-
bustion chambers burns the residues contained in the
particle filter cells.
19B-59
EXHAUST
Particle filter: Parts description 19B
B74 or K74, and F9Q, and 758 or 759, and DOCUMENT PHASE 2
SYSTEM PRESENTATION
113405
(1) Particle filter pressure sensor

(located in the engine compart-
ment)
(2) Connecting hose
(3) Particle filter
(4) Temperature sensor upstream of
the particle filter
(5) Temperature sensor downs-
tream of the particle filter
(6) Upstream pressure measure-
ment tapping
(7) Downstream pressure measure-
ment tapping
(8) Rubber mounting bush
19B-60
EXHAUST
Exhaust gas temperature sensor: Removal - Refitting 19B
Tightening torquesm
exhaust gas tempera- 30 Nm

ture sensor
REMOVAL

a Remove:
- the air duct between the air filter unit and the turbo-
charger.
II - OPERATION FOR REMOVAL OF PART 114987

CONCERNED
19670
115729
a Disconnect the exhaust gas temperature sensor a Remove the temperature sensor (3) using a crow
connector (1) . foot de 11 mm spanner.
a Unclip:
- the strut connector, REFITTING
- the turbocharger wiring harness (2) .
OPERATION FOR REFITTING PART CONCERNED
a Refit the exhaust gas temperature sensor.
a Tighten to torque the exhaust gas temperature

sensor (30 Nm), using a crow foot de 11 mm span-
ner.
19B-64
EXHAUST
Exhaust gas temperature sensor: Removal - Refitting 19B
a Clip:
- the connector onto the strut,
- the wiring harness onto the turbocharger.
a Connect the exhaust gas temperature sensor con-
nector.
FINAL OPERATION
a Refit the air duct between the turbocharger and the
air unit.
moval - Refitting).
19B-65
EXHAUST
Particle filter: Removal - Refitting 19B
CONCERNED
Essential equipment
diagnostic tool
Tightening torquesm
nut mounting the rub- 25 Nm

ber mounting bush on
the particle filter
adapter bolted to the 44 Nm

exhaust pipe
downstream pressure 21 Nm
measurement connec-
tion on its adapter bol- 113406
ted onto the exhaust
a Remove:
pipe
- the nuts (1) securing the rubber mounting to the
exhaust bracket nuts 21 Nm sub-frame,
between the connecting
hose and the catalytic - the exhaust bracket nuts (2) between the connec-
pre-converter ting hose and the catalytic pre-converter.
nuts mounting the rub- 25 Nm

ber mounting bush on
the sub-frame
REMOVAL

ting equipment, Towing and lifting).
a Remove:
19B-72
EXHAUST
106673 113411
a Remove the downstream pressure measurement a Unclip the pressure measurement pipe downstream
connection (3) from its adapter (4) bolted onto the of the particle filter heat shield.
exhaust pipe.
a Pass the downstream pressure measurement pipe
into the engine compartment whilst leaving it joined
WARNING to the pressure sensor.
Always hold the adapter with a lock wrench when
removing the pressure measurement tapping.
Note:
The pressure measurement circuit must never be
opened except at the adapters on the exhaust
pipe.
113416
a Disconnect the particle filter pressure sensor con-
nector at (5) located in the engine compartment.
a Remove the mounting nut (6) from the particle filter
pressure sensor support located in the engine com-
partment.
a Remove the particle filter pressure sensor and its
support.
19B-73
EXHAUST
106688 106689
a Remove the clip nut (7) . a Disconnect the offset downstream temperature sen-
sor connector (8) .
a Unclip the offset downstream temperature sensor
connector.
Note:
To detach the connector:
- pull on the tab to release it,
- slide the connector over the clip on the electri-
cal connector side.
19B-74
EXHAUST
113415 113412
a Disconnect the upstream temperature sensor offset a Unpick the wire of the upstream temperature sensor
connector (9) . offset connector at (10) .
a Unclip the offset upstream temperature sensor con-
nector.
Note:
- pull on the tab to release it,
cal connector side.
110905
a Remove the connecting clip (11) between the rear

silencer and the particle filter.
a Remove the « particle filter-connecting hose-pres-

sure sensor-temperature sensor » assembly:
- raise the particle filter to extract the rubber moun-

ting bush from the studs crimped on the sub-frame,
- pull the exhaust pipe towards the rear of the vehi-

cle, then lower it to extract the flexible pipe from the
catalytic pre-converter studs.
19B-75
EXHAUST
a Remove the following from particle filter assembly: - the upstream and downstream temperature sen-
sors from their adapters on the exhaust pipe (see
- the nut mounting the rubber mounting bush on the 19B, Exhaust, Particle filter temperature sen-
particle filter,
sors),
- the rubber mounting bush,
- the rubber mounting bush,
- the upstream and downstream temperature sen-
- the nut mounting the rubber mounting bush on the
sors from their adapters on the exhaust pipe (see
particle filter.
19B, Exhaust, Particle filter temperature sen-
sors), a Torque tighten the nut mounting the rubber
mounting bush on the particle filter (25 Nm).
- the upstream pressure measurement connection
from its adapter on the exhaust pipe (see 19B Ex- a Refit the « particle filter-connecting hose-pressure
haust, Particle filter pressure sensor), sensor-temperature sensor » assembly:
- the connecting hose (see 19B, Exhaust, Connec-
ting hose).
WARNING
When fitting the particle filter, be sure to pass the
REFITTING downstream pressure measurement tapping
behind the par ticle filter heat shield.
I - REFITTING PREPARATION OPERATION a Refit the connecting clip between the rear silencer
a and the particle filter.
a Connect the offset downstream temperature sensor

WARNING
connector.
Always replace:
a Clip:
- the seal between the connecting hose and par-
- the wire of the upstream temperature sensor offset
ticle filter,
connector,
- the seal between the connecting hose and the
catalytic pre-converter, - the upstream temperature sensor offset connector.
- the connection clip between the rear silencer a Connect the offset upstream temperature sensor
and the particle filter, connector.
- any adapter on the exhaust pipe that has been a Clip the upstream temperature sensor offset con-
removed, nector.
a Refit:
- the clip nut,

WARNING
- the particle filter pressure sensor and its support,
The bearing faces on the « connecting hose-
catalytic pre-converter » bracket and on the - the mounting nut onto the particle filter pressure
« connecting hose-particle filter » bracket must sensor support located in the engine compartment.
be cleaned carefully.
a Lock the mounting nut on the particle filter pressure
sensor mounting located in the engine compart-
II - REFITTING OPERATION FOR PART ment.
CONCERNED
a Connect the particle filter pressure sensor connector
a With particle filter removed, refit: located in the engine compartment.
- the connecting hose with a new seal (see 19B, Ex- a Pass the downstream pressure measurement pipe
haust, Connecting hose), into the engine compartment whilst leaving it joined
to the pressure sensor.
- the upstream pressure measurement connection
on its adapter on the exhaust pipe (see 19B, Ex- a Clip the downstream pressure measurement con-
haust, Particle filter pressure sensor), nection onto the particle filter heat shield.
19B-76
EXHAUST
a Coat the thread of the downstream pressure measu-
rement connection with high-temperature ANTI-SEI-
ZE grease or copper-aluminium lubricant.
WARNING
Make sure that the grease does not run over the
threading.
WARNING
Always replace any adapter removed from the
exhaust pipe.
114244
a Position the rigid part of the downstream pressure - the downstream pressure measurement con-
±
measurement pipe then turn it so that it is parallel (± nection on its adapter bolted onto the exhaust
3˚)) with the exhaust pipe longitudinal axis. pipe (21 Nm).
a Cut a rectangular piece of cardboard (from packa-
a Without tightening, fit the downstream pressure
ging from a spare part, for example) with a width of
measurement connection to its adapter bolted onto
25 mm and a length of 50 mm.
the exhaust pipe.
a Torque tighten:
- the adapter bolted to the exhaust pipe (44 Nm)

only if it is replaced,
19B-77
EXHAUST
a Torque tighten:
- the exhaust bracket nuts between the connec-

ting hose and the catalytic pre-converter (21
Nm),
- the nuts mounting the rubber mounting bush

on the sub-frame (25 Nm).
WARNING
Make sure, after tightening the pressure measu-
rement pipes, that this pressure measurement
line assembly has no low points (siphon) suscep-
tible 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,
106688 - at the level of the retaining clips, activate the

pressure measurement pipes on the heat shield
a Place the width of the rectangular cardboard
(turn the pipe in the clip so as to avoid the low
between the exhaust pipe tube (12) and the downs-
points).
tream pressure measurement connection (13) and
check that there is a distance of 25 mm between the
parts. a Make sure that there is no contact with the underbo-
dy.
a
Note:
WARNING
If the distance is less than 25 mm, the downs-
tream pressure measurement connection may be
damaged by the exhaust pipe. To obtain the
dimension, pivot the downstream pressure
measurement connection in relation to its retai- III - FINAL OPERATION.
ning clips on the heat shield: if that does not
work, undo the downstream pressure measure- a Connect the battery (see 80A, Battery, Battery: Re-
ment connection and gently move it upwards. moval - Refitting).
a Refit: a Refit:
- the nuts on the exhaust bracket between the flexi- - the engine undertray,
ble pipe and the catalytic pre-converter,
- the nuts securing the rubber mounting bush on the - the engine covers.
sub-frame.
a Before restarting the engine, use the diagnostic
tool to clear any faults stored by the injection com-
puter.
WARNING
With the engine running, carry out a leak test and
use a leak detector to run a 5 minute check for
leaks around the adapters on the exhaust pipe
a To reinitialise the particle filter parameters see MR

397 Fault finding.
19B-78
EXHAUST
Particle filter pressure sensor: Removal - Refitting 19B
Essential equipment Tightening torquesm

diagnostic tool adapter bolted to the 44 Nm
exhaust pipe
upstream pressure 21 Nm
measurement tapping
on its adapter bolted to
the exhaust pipe
113405
a Remove:
(1) Particle filter pressure sensor - the engine covers,
(2) Upstream pressure measure-
ment tapping end piece
(3) Downstream pressure measure- a Disconnect the battery (see 80A, Battery, Battery:
ment tapping end piece Removal - Refitting).
a Remove the particle filter (see 19B, Exhaust, Parti-
cle filter).
REMOVAL

19B-103
EXHAUST
CONCERNED
114216
a Remove the particle filter pressure sensor mounting
106670 nut (6) from its mounting.
a Remove the upstream pressure measurement tap-
ping (4) from its intermediate adapter (5) bolted to
the exhaust pipe. WARNING
Never separate the pressure tappings from the
particle filter pressure sensor. Replace the
WARNING « sensor-pipe-end piece » assembly if neces-
Always hold the adapter (5) with a lock wrench sar y, supplied as a single unit by the Parts
when removing the pressure measurement tap- Department (see 19B, Exhaust, Particle filter).
ping.
REFITTING
Note:
The pressure measurement circuit must never be I - REFITTING PREPARATION OPERATION
opened except at the adapters on the exhaust a Coat the thread of the downstream pressure measu-
pipe. rement tapping with ANTI-SEIZE OR COPPER-
ALUMINUM LUBRICANT.
WARNING
Make sure that the grease is not expelled from
the threading.
WARNING
Always replace any adapter removed from the
exhaust pipe.
19B-104
EXHAUST
CONCERNED
114244
a Fit the rigid part of the upstream pressure tapping III - FINAL OPERATION
then position it so that it is parallel (± 3˚) with the ex-
a Refit the particle filter (see 19B, Exhaust, Particle
haust pipe longitudinal axis.
filter).
a Refit the upstream pressure measurement tapping
from its intermediate adapter bolted to the exhaust
Note:
pipe.
Make sure, after tightening the pressure measu-
a Tighten to torque: rement tappings, that the pressure measure-
ment tapping line assembly has no low points
(siphon) susceptible to water accumulation.
only if it has been replaced,
To do this:
- the upstream pressure measurement tapping
on its adapter bolted to the exhaust pipe (21 - check that the rigid sections of the pressure
Nm). pipes are correctly positioned in relation to the
exhaust pipe longitudinal axis,
a Refit:
- manipulate the pressure measurement tappings
- the particle filter pressure sensor and its support, at the retaining clips on the heat shield (turn the
pipe in the clip so as to avoid low points).
- the mounting nut on the particle filter pressure sen-
sor mounting located in the engine compartment. a Connect the battery (see 80A, Battery, Battery: Re-
moval - Refitting).
a Lock the mounting nut on the particle filter pressure
a Refit:
sensor mounting located in the engine compart-
ment. - the engine undertray,
19B-105
EXHAUST
a Before restarting the engine, use the diagnostic
tool to clear any faults stored by the injection com-
puter.
19B-106
EXHAUST
Particle filter temperature sensors: Removal - Refitting 19B
Tightening torquesm
Essential equipment
adapter bolted to the 44 Nm
diagnostic tool exhaust pipe
particle filter downs- 30 Nm

Tightening torquesm tream temperature sen-
sor on its adapter bolted
adapter bolted to the 44 Nm to the exhaust pipe
exhaust pipe
particle filter upstream 30 Nm

tempera t u r e sensor
from its adapter bolted
to the exhaust pipe
113405
19B-126
EXHAUST
REFITTING THE PARTICLE FILTER

(1) Temperature sensor upstream of UPSTREAM TEMPERATURE SENSOR
the particle filter
a Coat the thread of the upstream particle filter tempe-
(2) Temperature sensor downs- rature sensor with COPPER-ALUMINIUM LUBRI-
tream of the particle filter CANT OR ANTI-SEIZE high temperature grease.
REMOVING THE PARTICLE FILTER WARNING

UPSTREAM TEMPERATURE SENSOR Make sure that the grease is not expelled from
a Position the vehicle on a two-post lift (see 02A, Lif- the threading.
a Remove:
WARNING
- the engine covers, Always replace any adapter removed from the
- the engine undertray. exhaust pipe.
a Disconnect the battery (see 80A, Battery, Battery: a Refit the upstream particle filter temperature sensor
Removal - Refitting). to its adapter bolted to the exhaust pipe.
a Remove the particle filter (see 19B, Exhaust, Parti- a Tighten to torque:
cle filter).
only if it is replaced,
- the particle filter upstream temperature sensor
from its adapter bolted to the exhaust pipe (30
Nm).
a Check:
- that there is no contact with the electrical wiring
harness,
- the electrical wiring harness for wear.
a Replace if necessary.
filter).
113404
a Remove the particle filter upstream temperature moval - Refitting).
sensor (3) from its adapter (4) bolted to the exhaust
a Refit:
pipe.
WARNING - the engine covers.
Always hold the adapter with a lock wrench when a Before restarting the engine, use the diagnostic
removing the particle filter temperature sensor. tool to clear any faults stored by the injection com-
puter.
REMOVING THE PARTICLE FILTER

DOWNSTREAM TEMPERATURE SENSOR
a Remove:
19B-127
EXHAUST
106689
a Disconnect and unclip the particle filter downstream
106688 temperature sensor offset connector (6) .
a Remove the clip nut (5) .
Note:
- pull on the clip tab to release it,
cal connector side.
a Remove the particle filter downstream temperature

sensor from its adapter bolted to the exhaust pipe.
Note:
Always hold the adapter with a lock wrench when
removing the particle filter temperature sensor.
19B-128
EXHAUST
Connecting hose: Removal - Refitting 19B
REFITTING
Tightening torquesm
exhaust bracket nuts 21 Nm
a
between the connecting
hose and the particle fil- WARNING
ter
You must carefully clean the exhaust bracket
mating faces between the connecting hose and
the catalytic pre-converter together with the
REMOVAL
exhaust bracket mating faces between the con-
necting hose and the particle filter.
All the seals must be replaced.
a Remove: CONCERNED
- the engine covers, a Refit:
- the engine undertray. - the connecting hose with a new seal,
a Disconnect the battery (see 80A, Battery, Battery: - the nuts from the exhaust bracket between the con-
Removal - Refitting). necting hose and the particle filter.
a Remove the particle filter (see 19B, Exhaust, Parti- a Tighten to torque the exhaust bracket nuts
cle filter). between the connecting hose and the particle fil-
ter (21 Nm).
CONCERNED III - FINAL OPERATION
filter).
moval - Refitting).
a Refit:
113406
a Remove:
- the nuts (1) from the exhaust bracket between the
connecting hose and the particle filter,
- the connecting hose.
19B-136
EXHAUST
Particle filter: Cleaning 19B
F9Q, and 758 or 759 – G9T, and 600
I - INSTRUCTIONS FOR CARRYING OUT FORCED
Essential special tooling REGENERATION OF THE PARTICLE FILTER
Mot. 1281-01 Oil filter removing tool, 96 mm
diameter. Precautions to be taken during forced regeneration
of the particle filter
Essential equipment a There are currently two additional kits for extracting
exhaust gases in the workshop (see 2005 garage
kit for particle filter equipment catalogue), both of which are approved
for the high temperatures produced during particle
kit for twin exhaust
filter forced regeneration.
diagnostic tool These two approved kits for particle filter regenera-
tion are:
Tightening torquesm - the kit for particle filter to be fitted to vehicles

equipped with a single exhaust pipe on the silen-
engine drain plug 20 Nm cer,
- the kit for twin exhaust to be fitted to vehicles
equipped with a twin exhaust pipe on the silencer,
Note: IMPORTANT
Forced regeneration can only be carried out after During the particle filter forced regeneration, the
the « SERVICE » warning light has come on with temperature of the exhaust pipe rises signifi-
the message «REGENERATE PARTICLE cantly.
FILTER » or the orange « CHECK EMISSIONS »
One of these approved kits must always be used
warning light (see Driver's Handbook for vehicle
due to the high temperatures during forced rege-
concerned).
neration, whether it is carried out in the workshop
with an exhaust gas extractor or outside the
workshop.
Ensure that the kit used does not touch the rear
bumper during the particle filter forced regenera-
tion.
19B-144
EXHAUST
F9Q, and 758 or 759 – G9T, and 600
Twin exhaust pipe kit special features II - PROCEDURE FOR PARTICLE FILTER FORCED
REGENERATION USING THE CLIP DIAGNOSTIC
TOOL
a Connect the diagnostic tool to the vehicle.
IMPORTANT
During the particle filter forced regeneration, the
temperature of the exhaust pipe rises signifi-
cantly.
One of these approved kits must always be used
due to the high temperatures during forced rege-
neration, whether it is carried out in the workshop
with an exhaust gas extractor or outside the
workshop.
Ensure that the kit used does not touch the rear
bumper during the particle filter forced regenera-
tion.
116224
WARNING
a
To prevent engine racing, check the engine oil
Note: level using the dipstick before running the forced
regeneration command.
When using a kit for twin exhaust (1) on a sin-
gle exhaust pipe, ensure that: The engine oil level must be between the
« MIN » and « MAX » marks on the dipstick.
- an exhaust gas extractor is fitted on openings
(2) and (3) if the forced regeneration is being a For the particle filter forced regeneration procedure,
carried out in the workshop, see MR 397 Fault finding, 13B, Diesel injection,
Fault finding - Interpretation of commands, Parti-
- openings (2) and (3) are positioned so that hot
cle filter regeneration.
exhaust gases are not directed towards another
vehicle or person if the operation is being car-
ried out outside the workshop. Note:
If required, the forced regeneration procedure
may be stopped by pressing the engine Start but-
ton twice in succession.
Note:
Be prepared for strong odours and thick smoke
during particle filter forced regeneration.
a When particle filter forced regeneration is complete,

using the diagnostic tool:
- deal with the present faults,
- clear the stored faults.
19B-145
EXHAUST
F9Q, and 758 or 759 – G9T, and 600
a Position the vehicle on a two-post lift (see MR 395 Copper seal
Mechanical, 02A, Lifting equipment, Towing and
lifting).
IMPORTANT
Allow the engine to cool before draining the oil.
a Remove the oil filter using thefor F9Q engines and

the (Mot. 1281-01) for G9T engines.
a Coat the new oil filter sealing ring with engine oil.
a Tighten the oil filter until the seal makes contact with
the engine.
a Tighten the new oil filter manually 3/4 of a turn.
a Wipe away any excess oil.
a Remove: 113764
a Position the groove of the sump plug sealing washer
- the engine oil filler cap, facing the drain plug (for copper seals).
- the engine undertray, a Tighten to torque the engine drain plug (20 Nm).
a Clean any traces of the drained oil from the sump.
- the sump drain plug using theor an 8 mm square
male drain adapter.
a Refill the engine oil.
a Allow all the engine oil to flow into a drain tray.
a Refit the filler cap.
a Wait for 10 minutes.
Rubber-lipped seal
a Check the oil level using the dipstick.
a Top up, if necessary.
Note:
The engine oil level must be between the
« MIN » and « MAX » marks on the dipstick.
113765
a Refit the new seal (no direction of fitting for rubber-

lipped seals).
19B-146
TANK
Fuel tank: Operating diagram 19C
18572
(1) Fuel tank

(2) Tank mounting hole
(3) Filler neck
(4) Filler neck mounting clip
(5) Filler plug
(6) Fuel supply pipe
(7) Fuel return pipe
(8) Fuel tank venting valve and
vehicle roll-over leak prevention
valve
(9) Anti-splashback pipe (degas-
sing - filling)
(10) Fuel sender
19C-1
TANK
19C-2
TANK
13036-1
(11) Breather
(12) Overfill prevention ball
(13) Filling anti-splashback pipe
(14) Opening for air outlet during fil-
ling
(15) Fuel filling opening
(16) Fuel tank venting valve and
vehicle roll-over leak prevention
valve
(X1) Volume of air allowing fuel
expansion
(X2) Usable fuel volume
FUNCTION OF THE VALVES:
1 - Overfill prevention valve:

The ball (12) acts as an overfill valve.
When refilling the fuel tank, the ball (12) rests in its sea-
ting, thus retaining a certain volume of air in the tank.
As the tank gradually fills, the air in the tank is driven
out through the air outlet hole (14) .
When the fuel level reaches the air outlet hole (14) , the
air in the tank can no longer escape and the fuel rises
in the filler neck up to the filling nozzle.
When the filling nozzle clicks three times, the tank is
full.
Note:
When the tank is full, a sufficient volume of air must
remain in the tank to allow the fuel contained within
it to expand, but without increasing the pressure in
the tank.
2 - Vehicle roll-over leak prevention valve:

In the event of a vehicle roll, the ball (12) plugs the ven-
ting valve hole (11) , thus preventing the tank from
emptying.
19C-3
TANK
Fuel tank: Removal - Refitting 19C
DOCUMENT PHASE 2
Essential equipment
component jack
Tightening torquesm
fuel tank mounting bolts 21 Nm
filler neck mounting bolt 21 N.m
rear axle mounting bolts 80 N.m
WARNING
During this operation, be sure to:

- refrain from smoking or bringing red hot objects
near the working area,
- beware of fuel splashes when disconnecting the 104545
union, a Partially remove the blanking cover (1) from the ins-
pection flap.
- protect sensitive areas from fuel outflow.
REMOVAL

a Lift up:
- the rear bench seat base (see MR 396, 76A, Rear
seat frames and runners, Rear seat base: Re-
moval - Refitting),
- the carpet under the rear seat base.
a Drain the fuel tank (see 19C, Fuel tank, Fuel tank:
Draining).
19C-7
TANK
DOCUMENT PHASE 2
18577 18582
a Disconnect: a Remove the exhaust silencer mounting clip (5) .
- the fuel sender connector (2) , a Position the exhaust pipe resting on the rear axle.
- the fuel supply quick-release union (3) , a Remove the heat shield (6) .
- the fuel return quick-release union (4) . a Remove:
- the rear right-hand wheel (see 35A, Wheel and ty-
Note: res, Wheel: Removal - Refitting).
Make provisions for the flow of fuel from the fuel - the rear right-hand wheel arch liner (see MR 396,
supply and return pipes. Bodywork, 55A, Exterior protection, Exterior
wheel arch liner: Removal - Refitting).
a Fit the protective plugs to the unions using the ap-
propriate plug weld kit (part no. 77 01 206 804).
19C-8
TANK
DOCUMENT PHASE 2
18392 18580
a Remove: a Disconnect the anti-splashback pipe (10) .
- the mounting clips (7) of the brake pipes, a Remove:
- the heat shield (8) . - the filler neck mounting bolt (11) ,
a Detach the brake pipes from the acoustic bar. - the filler neck clip (12) .
a Disconnect the body height sensor (depending on a Disconnect the filler neck from the fuel tank.
vehicle equipment level).
a Unclip the tyre pressure monitoring system harness II - OPERATION FOR REMOVAL OF PART
from the acoustic bar. CONCERNED
a Remove the acoustic bar connecting the mounting a Fit the component jack under the fuel tank.
points of the rear axle by removing and refitting the
rear axle mounting bolts (9) one at a time.
19C-9
TANK
DOCUMENT PHASE 2
a Refit:
- the new clip (12) of the filler neck,
- the filler neck mounting bolt (11) .
a Torque tighten the filler neck mounting bolt (21

N.m).
a Refit the anti-splashback pipe (10) .
a Refit the acoustic bar connecting the mounting
points of the rear axle by removing and refitting the
rear axle mounting bolts (9) one at a time.
a Torque tighten the rear axle mounting bolts (80
N.m).
a Clip the tyre pressure monitoring system harness

onto the acoustic bar.
a Connect the body height sensor (depending on the
vehicle equipment level).
a Refit:
18579
a Remove: - the heat shield (8) ,

- the brake pipe clips (7) .
- the mounting bolts (13) from the fuel tank,
a Refit:
- the fuel tank by turning it around the exhaust pipe
(this operation requires two people). - the rear right-hand wheel arch liner (see MR 396,
Bodywork, 55A, Exterior protection, Exterior
REFITTING
- the rear right-hand wheel (see 35A, Wheel and ty-
res, Wheel: Removal - Refitting).
a Refit:
a
- the heat shield (6) ,
Note:
- the new clamp (5) of the exhaust silencer,
Always replace:
- the filler neck mounting clip on the fuel tank,
a Remove the protective plugs.
- the exhaust silencer mounting clip.
a Connect:
II - REFITTING OPERATION FOR PART - the fuel return quick-release union (4) ,
CONCERNED - the fuel supply quick-release union (3) ,
a Refit: - the fuel sender connector (2) .
- the fuel tank by turning it around the exhaust pipe a Refit the blanking cover (1) of the exhaust flap.
(this operation requires two people),
a Fit:
- the fuel tank mounting bolts (13) .
- the carpet under the rear bench seat base.
a Torque tighten the fuel tank mounting bolts (21
Nm). - the rear bench seat base (see MR 396, 76A, Rear
seat frames and runners, Rear bench seat ba-
se: Removal - Refitting).
a Fit the filler neck on the fuel tank. moval - Refitting).
19C-10
TANK
Filler neck: Removal - Refitting 19C
DOCUMENT PHASE 2
CONCERNED
Tightening torquesm
filler neck mounting bolt 21 Nm
WARNING
During this operation, it is essential to:

- beware of fuel splashes when disconnecting the
union,
REMOVAL

ting equipment, Two-post lift: Safety). 18580
a Drain the fuel tank (see 19C, Tank, Fuel tank). a Disconnect the anti-splashback pipe (1) .
Draining).
a Disconnect the battery (see 80A, Battery, Battery: a Remove the filler pipe clip (2) .
a Remove filler neck mounting bolts (3) .
a Remove:
- the rear right-hand wheel (see 35A, Wheels and
- the rear right-hand wheel arch liner (see MR 396,
wheel arch liner: Removal - Refitting).
18581
a Remove:
- the mounting bolts (5) ,
- the filler neck (4) .
19C-11
TANK
Filler neck: Removal - Refitting 19C
DOCUMENT PHASE 2
REFITTING

a
Note:
Always replace the filler pipe clip with a new one.

CONCERNED
a Refit:
- the filler neck (4) ,
- the mounting bolts (5) .
a Refit the filler neck mounting bolt (3) .
a Fit the new filler pipe clip (2) .
a Tighten to torque the filler neck mounting bolt (21
Nm) (3) .
a Connect the anti-splashback pipe (1) .

a Refit:
- the rear right-hand wheel arch liner (see MR 396,
- the rear right-hand wheel (see 35A, Wheels and
tyres, Wheel: Removal - Refitting).
moval - Refitting).
19C-12
TANK
Fuel tank: Draining 19C
Essential equipment
pneumatic transfer pump for fuels
WARNING
During this operation, it is essential to:

union,
I - DRAINING
104545
a Partially remove the inspection flap cover (1) .
99641
a Lift up:
seat frames and runners, Rear seat cushion:
Removal - Refitting),
19C-13
TANK
Fuel tank: Draining 19C
moval - Refitting).
18577
a Disconnect the fuel supply quick-release union (2) .

a
Note:
Make provisions for the flow of fuel from the fuel
supply pipe.
a Fit the protective plugs into the union with the appro-
priate plug kit (see 13B, Diesel Injection, Diesel in-
jection: Precautions during repair).
a Connect the aspiration hose of the pneumatic
transfer pump for fuels to the quick-release union
(2) (fuel sender side) and the splashback pipe of the
pneumatic transfer pump for fuels into a contai-
ner.
a Run the pneumatic transfer pump for fuels.
a Let the fuel flow out until it flows intermittently into

the container.
II - REFITTING
a Disconnect the aspiration hose of the pneumatic
transfer pump for fuels from the quick-release
union (fuel sender side).
a Connect the fuel supply quick-release union (2) to
the fuel sender.
a Refit the inspection flap cover (1) .
a Fit:
19C-14
TANK
Sender unit: Removal - Refitting 19C
Mot. 1397 Universal petrol tank gauge

nut wrench.
WARNING
During this operation, be sure to:

union,
REMOVAL
I - REMOVAL PREPARATION OPERATION 18577

a Disconnect:
Removal - Refitting). - the fuel sender connector (2) ,
a Lift up: - the fuel supply quick-release union (3) ,
- the rear bench seat base (see MR 396, 76A, Rear - the fuel return quick-release union (4) .
se: Removal - Refitting),
Note:
Make provisions for the flow of fuel from the fuel
supply and return pipes.
a Fit protective plugs to the unions from the appropria-

te plug kit (see 13B, Diesel injection, Diesel injec-
tion: Precautions for repair).
104545
a Partially remove the blanking cover (1) from the ins-
pection flap.
a Drain the tank (see 19C, Tank, Fuel tank: Draining,
page 19C-13) .
19C-16
TANK
II - REMOVAL OPERATION FOR PART II - REFITTING OPERATION FOR PART
CONCERNED CONCERNED
104547
102470
a Remove the mounting nut from the fuel sender using
the (Mot. 1397) (5) . a Refit the fuel sender by aligning the mark (6) on the
sender with the mark (7) on the tank.
a Remove the fuel sender, being careful not to dama-
ge the float. a Position the fuel sender mounting nut (9) .
a
a Using the (Mot. 1397) (5) , tighten the nut (9) until
WARNING the mark (8) on the nut is aligned with the mark (7)
Refit the sender nut as soon as the sender has on the tank and the mark (6) on the fuel sender.
been removed to prevent any deformation of the
fuel tank.

REFITTING
a Connect:
- the fuel return quick-release union (4) ,
a
- the fuel supply quick-release union (2) ,
Note:
Always replace the fuel sender O-ring seal. - the fuel sender connector (3) .
a Refit the inspection flap blanking cover (1) .
a Fit:


moval - Refitting).
19C-17
TANK
Mot. 1397 Universal petrol tank gauge

nut wrench.
Tightening torquesm
battery cover mounting 4 Nm

bolts
IMPORTANT
During this operation:

union,
18577
a Disconnect:
REMOVAL - the electrical connector (3) ,

terminal. - quick-release union(s) (2) .
a Lift up the rear bench seat base. a Prepare for fuel outflow.
a Move the carpet to one side.
a Fit the correct blanking plugs into the unions (Part
number: 77 01 206 804).
104545
a Remove the inspection flap cover (1) .
104547
a Remove the mounting nut from the sender unit using

tool (Mot. 1397) (4)
19C-18
TANK
a Remove the sender unit, being careful with the float.
WARNING
Refit the sender nut as soon as the sender has
been removed to prevent any deformation of the
fuel tank.
REFITTING
a Replace the O-ring seal.
108884
a Refit the sender by aligning mark (5) on the sender
with mark (6) on the tank.
a Position the nut (8) .
a Tighten the nut (8) until mark (7) on the nut is aligned
with mark (6) on the tank and mark (5) on the sen-
der.
nal (see MR for the vehicle concerned, 80A, Bat-
tery, Special notes
a Tighten to torque the battery cover mounting bolts
(4 Nm).
19C-19
TANK
Fuel level sensor: Distinctive 19C
I - SENDER UNIT: CONNECTION
For the pump-sender unit connection (see Electrical
wiring diagram NT, Laguna II, Component 199).
II - CHECKING THE SENDER UNIT

Remove the pump-sender unit (see 19C, Tank, Pump-
sender unit: Removal - Refitting).
Value Capacity Height H

across the ( i nm m ±5
two termi- mm)
nals (in Ω ±
10
20 Full tank Upper stop
87 Tank 3/4 full 133
290 Reserve 25
320 Tank empty Lower stop
Check that the resistance varies when the float is mo-

ved.
III - MEASURING HEIGHT H

Place the sender unit on a flat surface.
H is the height between the sender unit float pivot and
the flat surface.
Refit the pump-sender unit (see 19C, Tank, Pump-
sender unit: Removal - Refitting).
19C-24
ENGINE MOUNTING
Suspended engine mounting: Tightening torque 19D
111726
Tightening torques (in Nm)
(A) 21
(B) 62
(C) 105
(D) 44
(E) 110
(F) 190
(G) 62
(H) * 105
(I) 105
(J) 44
* Tighten to torque and in order the bolts (H) : (1) , (2)

and (3) .
19D-1
ENGINE MOUNTING
Left-hand suspended engine mounting: Removal - Refitting 19D
Tightening torquesm
suspended mounting 105 Nm

lower mounting bolts

upper mounting bolt
rubber pad mounting 105 Nm

bolts
rubber pad mounting
bolt
115592
REMOVAL a Unclip:
- the connection unit (2) .
a Position the vehicle on a two-post lift (see 02A, Lif- a Disconnect the air flow sensor connector.
a Remove:
a Remove: - the battery tray mounting bolts (3) ,
- the front engine cover,
- the battery tray,
- the air duct between the air flow sensor and the tur-
bocharger,
- the left-hand wheel arch liner.
a Remove the battery (see 80A, Battery, Battery: Re- unit: Removal - Refitting, page 12A-28) .
moval - Refitting).
105432
a Position the (Mot. 1672).
19D-12
ENGINE MOUNTING
CONCERNED
115593
a Remove:
115595
- the power-assisted steering pipe mounting bolts (8)
a Remove:
,
- the rubber pad mounting bolts (5) ,
- the suspended mounting lower mounting bolts (9) ,
- the suspended mounting rubber pad mounting bolt
- the suspended mounting.
(6) ,
- the rubber pad,
- the upper mounting bolt (7) from the suspended
mounting.
19D-13
ENGINE MOUNTING
REFITTING - the rubber pad mounting bolts (12) ,
- the suspended mounting rubber pad mounting bolt

I - OPERATION FOR REFITTING PART (13) .
CONCERNED a Tighten to torque and in order:
- the suspended mounting lower mounting bolts

(105 Nm),
- the suspended mounting upper mounting bolt

(105 Nm),
- the rubber pad mounting bolts (105 Nm),
- the suspended mounting rubber pad mounting

bolt (44 Nm).
a Refit the power-assisted steering pipe mounting

bolt.
a Tighten the power-assisted steering pipe mounting

bolts with a spanner.
a Refit the air duct mounting bolt.

a Tighten the air duct mounting bolt with a spanner.
115593
a Refit:
- the air duct between the air flow sensor and the tur-
bocharger,
- the battery tray.
Use a spanner to tighten:

Clip on:
- the air flow sensor connector,
115595 a Remove the (Mot. 1672).

a Refit: a Refit:
- the suspended mounting, - the engine covers,
- the suspended mounting lower mounting bolts (10) - the engine undertray,
,
- the left-hand wheel arch liner,
- the suspended mounting upper mounting bolt (11) ,
- the rubber pad, Refitting).
19D-14
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
Tightening torquesm
bolts
rubber pad bolts on the 21 Nm

body
upper engine tie-bar 105 Nm

mounting bolts
REMOVAL

115596
Removal - Refitting). a Remove:
a Remove: - the upper engine tie-bar mounting bolts (1) ,

- the engine cover, - the upper engine tie-bar.
- the engine undertray. - the suspended mounting bolts (2) .
105432
a Fit the (Mot. 1672).
a Mark the position of the suspended engine mounting
on the body.
115594
a Remove:
- the rubber pad mounting bolts on the body (3) ,
- the right-hand suspended engine mounting.
19D-28
ENGINE MOUNTING
Right-hand suspended engine mounting: Removal - Refitting 19D
REFITTING

CONCERNED
a Refit:
- the right-hand suspended engine mounting,
- the suspended mounting bolts,
- the rubber pad bolts on the body,
- the upper engine tie-bar.
- the upper engine tie-bar mounting bolts.
- the suspended mounting bolts (62 Nm),
- the rubber pad bolts on the body (21 Nm),
- the upper engine tie-bar mounting bolts (105
Nm).
a Refit:
moval - Refitting).
19D-29
ENGINE MOUNTING
Lower engine tie-bar: Removal - Refitting 19D
CONCERNED
Tightening torquesm
engine tie-bar support 62 Nm

mounting bolt
anti-slide rod mounting 62 Nm

bolts

bolt on the engine and
transmission assembly

bolt on the sub-frame
REMOVAL

113414
Removal - Refitting). a Remove:
a Remove: - the mounting bolts from the engine tie-bar (1) ,
- the engine cover, - the engine tie-bar,
- the engine undertray. - the anti-slide rod mounting bolts (2) ,

- the anti-slide rod.
113413
a Remove:
- the engine tie-bar support mounting bolts (3) ,
- the engine tie-bar support,
19D-39
ENGINE MOUNTING
Lower engine tie-bar: Removal - Refitting 19D
REFITTING

CONCERNED
a Refit the engine tie-bar support.
Refit:
- the engine tie-bar support,
- the engine tie-bar support mounting bolt.
a tighten to torque the engine tie-bar support moun-
ting bolt (62 Nm).
a Refit:
- the anti-slide rod,
- the anti-slide rod mounting bolts,
- the engine tie-bar,
- the engine tie-bar mounting bolt on the engine and
transmission assembly,
- the bolt mounting the engine tie-bar on the sub-fra-
me.
- the anti-slide rod mounting bolts (62 Nm),
- the engine tie-bar mounting bolt on the engine
and transmission assembly (190 Nm),
- the engine tie-bar mounting bolt on the sub-fra-
me (110 Nm).
a Refit:
moval - Refitting).
19D-40

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Mr395 Laguna Motor f9q en

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1 Engine and peripherals

10A ENGINE AND CYLINDER BLOCK ASSEMBLY

11A TOP AND FRONT OF ENGINE

12A FUEL MIXTURE

13A FUEL SUPPLY

13B DIESEL INJECTION

16A STARTING - CHARGING

17B PETROL INJECTION

FEBRUARY 2009 Edition Anglaise

© Renault s.a.s 2008

19D ENGINE MOUNTING

FEBRUARY 2009 Edition Anglaise

© Renault s.a.s 2008

ENGINE AND CYLINDER BLOCK

Conrod bearing shell: Camshaft seal at timing end:

Oil pump: Removal - Cylinder head: Removal -

Multifunction support: Cylinder head: Removal -

Engine/gearbox assembly: Oil decanter: Removal -

Oil pressure: Check 10A-272

12A FUEL MIXTURE 12B TURBOCHARGING

Air inlet 12A-1 Turbocharging pressure

Air filter: Replacement 12A-19

Air filter: Removal - Refitting 12A-21 13A FUEL SUPPLY

Inlet manifold: Removal - Fuel flow: check 13A-20

Exhaust manifold - Intake

Inlet manifold: Removal - Diesel injection: Precautions

Injector holder shim: Diesel injection: List and

Exhaust manifold: Removal - Diesel injection computer:

Camshaft position sensor:

12B TURBOCHARGING Crankshaft position sensor:

13B DIESEL INJECTION 14A ANTIPOLLUTION

Diesel injector fuel return rail: Exhaust gas recirculation:

Injector rail protector: Fuel vapour recirculation

High-pressure pipe between Fuel vapour canister:

Diesel injector: Removal - Exhaust gas recirculation

13C PREHEATING 16A STARTING - CHARGING

Pre/postheating unit: Starting system:

Heater plugs Removal - Alternator: Removal -

Starter: Removal - Refitting 16A-18

Exhaust gas recirculation: Spark plugs: Removal -

Exhaust gas recirculation:

17B PETROL INJECTION 19A COOLING

Fuel injection: List and Electric water pump:

Oxygen sensors: Removal - Coolant temperature sensor:

Petrol injection computer:

Crankshaft position sensor: 19B EXHAUST

Engine cooling: Precautions Catalytic converter: Removal

Engine cooling circuit: Silencer: Removal - Refitting 19B-56

Water pump inlet pipe:

Expansion bottle: Removal -

Fuel tank: Operating diagram 19C-1

Fuel tank: Removal -

Filler neck: Removal -

Fuel tank: Draining 19C-13

Sender unit: Removal -

Fuel level sensor: Distinctive 19C-24

19D ENGINE MOUNTING

Left-hand suspended engine

Lower engine tie-bar:

F9Q 818 1870 80 93

I - REFITTING PREPARATION OPERATION

a clean all of the joint faces.

II - REFITTING OPERATION FOR PART