Citroen C-Elysee - Peugeot 301 (2012-2017) Service Manual

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TECHNICAL NOTE : ADDITIVES FOR PARTICLE FILTER
This document describes the after-sales maintenance operations that follow from the changes in the particle
filter additives.
CAUTION : This document concerns filling of the rigid reservoir only. The additive must be used only on the
vehicles that have a particle filter.
1. The new 3rd generation particle filter additives

Suppliers and brands :
 RHODIA : EOLYS POWERFLEX
 INFINEUM : F7995
2. Previous type of additive

Additive DPX 42 is still available and must be used for all servicing on vehicles that have DPX 42.
The EOLYS 176 additive is replaced by the INFINEUM F7995 additive. When current stocks are exhausted,
only the new product will be supplied.
3. Compatibility between additives

Additive DPX42 cannot be mixed with any other additive.
Additives EOLYS POWERFLEX and INFINEUM F7995 cannot be mixed with each other.
N.B. : The different generations of additive do not affect the calibrations of the engine management ECU.
CAUTION : It is not permissible to mix additives INFINEUM F7995 and Rhodia EOLYS POWERFLEX with
each other.
4. Filling or topping up with additive
Conversion chart for filling or topping-up operations

Additive present in the vehicle Colour of clickfit on filler interface Additive to be used in all operations
DPX 42 Click-fit neither blue nor green DPX 42
EOLYS 176 Green clickfit EOLYS 176 - INFINEUM F7995
INFINEUM F7995 Green clickfit INFINEUM F7995
EOLYS POWERFLEX Blue clickfit EOLYS POWERFLEX
Page 1 of 24
TECHNICAL NOTE : ANCILLARY DRIVE BELT
1. Flexible ancillary drive belt
ESSENTIAL : Before removal and for any future reuse of the removed belt, the engine must be at ambient
temperature (below 30°C) ; In all other cases : Replace the flexible ancillary drive belt .
CAUTION : Mark the direction of rotation of the ancillary drive belt before removing it.
CAUTION : If re-using the existing accessories drive belt, refit it in the correct fitting direction.
CAUTION : Check that the rollers turn freely (no play and no tightness).
2. Visual check
Check that the timing belt is free of cracks and traces of oil.
Check the absence of oil leaks (crankshaft and camshaft sealing rings).
Check the absence of coolant fluid leaks (Coolant pump).
Check that the track of the engine speed sensor target is not distorted or scratched.
N.B. : Replace any defective parts.
3. Petrol engines
3.1. 384F engine
Page 2 of 24
Figure : B1BB1E8D
all models.
(1) Air conditioning compressor (according to equipment).
3.2. TU1/TU3/TU5/ET3 engines
Page 3 of 24
Figure : B1BB1E9D
Without power steering and without air conditioning.
Figure : B1BB1EAD
Without air conditioning / With driven power steering pump.

Page 4 of 24
Figure : B1BB1EBD
With air conditioning and without power steering.
Figure : B1BB1ECD
With air conditioning / With driven power steering pump (Manual tension roller).
Page 5 of 24
Figure : B1BB1EDD
With air conditioning / With driven power steering pump (Dynamic roller tensioner ).
Figure : B1BB1EED
With air conditioning / Power steering electric pump assembly (Dynamic roller tensioner ).
3.3. EB0/EB2 engines
Page 6 of 24
Figure : B1BB1LTD
With air conditioning.
Figure : B1BB1LUD
Without air conditioning.

Page 7 of 24
3.4. EP3/EP6 engines
Figure : B1BB1EFD
all models.
3.5. EC5 engine
Page 8 of 24
Figure : B1BB1LVD
Figure : B1BB1LWD

Page 9 of 24
3.6. EW7/EW10/EW12 engines
Figure : B1BB1EGD

Page 10 of 24
Figure : B1BB1EHD
With air conditioning / With driven power steering pump.
Figure : B1BB1EID
With air conditioning / Power steering electric pump assembly .

(1) : Air conditioning compressor (according to equipment).
3.7. 4A92 engine
Page 11 of 24
Figure : B1BB1IZD
all models.
3.8. 4B11 / 4B12 engines
Page 12 of 24
Figure : B1BB1EJD
all models.
3.9. ES9 engine
Figure : B1BB1EKD
Page 13 of 24
all models.
4. diesel engines
4.1. DV4/DV6 engine
Figure : B1BB1ELD

Page 14 of 24
Figure : B1BB1EMD
Figure : B1BB1END

Page 15 of 24
Figure : B1BB1EOD
Figure : B1BB1EPD
With air conditioning/Power steering electric pump assembly / Stop and start.
Page 16 of 24
4.2. DW8/DW10/DW12 engines
Figure : B1BB1EQD
Figure : B1BB1ESD
Page 17 of 24
Figure : B1BB1ETD
Figure : B1BB1EUD
Page 18 of 24
Figure : B1BB1EVD
Figure : B1BB1EWD
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Figure : B1BB1EXD
With air conditioning / Power steering electric pump assembly / Hybrid.
Figure : B1BB1T6D
Page 20 of 24

4.3. DT17/DT20 engines
Figure : B1BB1EYD
all models.
4.4. 4N13 engine
Page 21 of 24
Figure : B1BB1J0D
all models.
4.5. P22DTE engine
Page 22 of 24
Figure : B1BB1EZD

Page 23 of 24
Figure : B1BB1F0D

4.6. F30DT engine
Figure : B1BB1F1D
Page 24 of 24
all models.
Page 1 of 24
TECHNICAL NOTE : ANCILLARY DRIVE BELT
1. Flexible ancillary drive belt
ESSENTIAL : Before removal and for any future reuse of the removed belt, the engine must be at ambient
temperature (below 30°C) ; In all other cases : Replace the flexible ancillary drive belt .
CAUTION : Mark the direction of rotation of the ancillary drive belt before removing it.
CAUTION : If re-using the existing accessories drive belt, refit it in the correct fitting direction.
CAUTION : Check that the rollers turn freely (no play and no tightness).
2. Visual check
Check the absence of coolant fluid leaks (Coolant pump).
Check that the track of the engine speed sensor target is not distorted or scratched.
3. Petrol engines
3.1. 384F engine
Page 2 of 24
Figure : B1BB1E8D
all models.
3.2. TU1/TU3/TU5/ET3 engines
Page 3 of 24
Figure : B1BB1E9D
Figure : B1BB1EAD

Page 4 of 24
Figure : B1BB1EBD
Figure : B1BB1ECD
With air conditioning / With driven power steering pump (Manual tension roller).
Page 5 of 24
Figure : B1BB1EDD
With air conditioning / With driven power steering pump (Dynamic roller tensioner ).
Figure : B1BB1EED
With air conditioning / Power steering electric pump assembly (Dynamic roller tensioner ).
3.3. EB0/EB2 engines
Page 6 of 24
Figure : B1BB1LTD
Figure : B1BB1LUD

Page 7 of 24
3.4. EP3/EP6 engines
Figure : B1BB1EFD
all models.
3.5. EC5 engine
Page 8 of 24
Figure : B1BB1LVD
Figure : B1BB1LWD

Page 9 of 24
3.6. EW7/EW10/EW12 engines
Figure : B1BB1EGD

Page 10 of 24
Figure : B1BB1EHD
Figure : B1BB1EID

(1) : Air conditioning compressor (according to equipment).
3.7. 4A92 engine
Page 11 of 24
Figure : B1BB1IZD
all models.
3.8. 4B11 / 4B12 engines
Page 12 of 24
Figure : B1BB1EJD
all models.
3.9. ES9 engine
Figure : B1BB1EKD
Page 13 of 24
all models.
4. diesel engines
4.1. DV4/DV6 engine
Figure : B1BB1ELD

Page 14 of 24
Figure : B1BB1EMD
Figure : B1BB1END

Page 15 of 24
Figure : B1BB1EOD
Figure : B1BB1EPD
With air conditioning/Power steering electric pump assembly / Stop and start.
Page 16 of 24
4.2. DW8/DW10/DW12 engines
Figure : B1BB1EQD
Figure : B1BB1ESD
Page 17 of 24
Figure : B1BB1ETD
Figure : B1BB1EUD
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Figure : B1BB1EVD
Figure : B1BB1EWD
Page 19 of 24
Figure : B1BB1EXD
With air conditioning / Power steering electric pump assembly / Hybrid.
Figure : B1BB1T6D
Page 20 of 24

4.3. DT17/DT20 engines
Figure : B1BB1EYD
all models.
4.4. 4N13 engine
Page 21 of 24
Figure : B1BB1J0D
all models.
4.5. P22DTE engine
Page 22 of 24
Figure : B1BB1EZD

Page 23 of 24
Figure : B1BB1F0D

4.6. F30DT engine
Figure : B1BB1F1D
Page 24 of 24
all models.
Page 1 of 4
CHECK : FUEL ADDITIVE CIRCUIT
ESSENTIAL : Observe the safety and cleanliness recommendations .
1. Tooling
Equipment : Diagnostic station.
tool Reference Designation

[01101] Manual vacuum pump DA16 with adaptors
Figure : E5AB16GT
[0188-T] plugs kit
Figure : E5AB06IT
2. Schematic diagram : Fuel additive circuit

Page 2 of 4
Figure : B1KD00SD
(1) Additive injector (Fuel pump gauge module ).

(2) Anti-return valve (According to equipment).
(3) Additive supply pipe.
(4) Additive pump (Additive tank).
CAUTION : Some vehicles are not fitted with a non-return valve from the additive injector.
N.B. : The additive injector fitted with a non-return valve should open at a pressure lower than 400 mbars
(According to equipment).
3. Check
ESSENTIAL : Respect the safety and cleanliness requirements relating to the particle filter .
3.1. ADDITIVE PUMP AUDIBLE TEST

Carry out the "actuating the additive pump" actuator test (According to specification) ; Using a diagnostic tool.
N.B. : This is an audible test to ensure that the additive pump is controlled.
Check Noise and sensation of vibration when the No noise or sensation of vibration when the
additive pump is operating additive pump is operating
Finding The additive pump is controlled The additive pump is faulty or the power supply is
cut
Action Continue the checking Repair the additive pump or restore the power
Page 3 of 4
supply
Continue the checking
3.2. Checking the additive circuit, the additive supply pipe and the additive injector
ESSENTIAL : For all work on the additive circuit, wear safety goggles and hydrocarbon resistant gloves.
Figure : B1KD01ID
CAUTION : Visually check the condition of the additive supply pipe (3), looking for traces of additive leaks.
Replace the additive supply pipe (3) (if necessary).
Plug the additive pump ; Using tool [0188-T].

Connect the tool [01101] to the additive supply pipe (3) (Additive tank end) ; Using a click-on pipe that
guarantees the assembly is leak free.
Activate, using pressure, the manual pump [01101].
Check Pressure lower than or equal to 400 mbars Pressure higher than 400 mbars
Observation The additive injector and the additive supply pipe are not The additive injector is jammed
blocked or
The additive supply tube is
blocked
Action Condition correct Condition not correct
End of check Continue the checking
4. Repriming the additive supply tube

Page 4 of 4
CAUTION : In all cases, Always fill the additive supplied pipe (3).
Remove tools [01101] and [0188-T].

Couple the additive supply tube (3) to the fuel pump gauge module (5) and to the additive pump (4).
Carry out the actuator test "filling of the pipe: additive pump - additive injector" (According to specification) ;
Using a diagnostic tool.
Page 1 of 10
CHECK : HIGH PRESSURE FUEL CIRCUIT
1. Tooling

[1613-A] (kit dummy high pressure fuel injection rail
1613)
Figure : E5AB08XT
[1613-B] (kit fuel decompression container

1613)
Figure : E5AB08YT
[1613-C] (kit dummy flow electrovalve

1613)
Page 2 of 10
Figure : E5AB08ZT
[1613-D] (kit fuel pressure display

1613)
Figure : E5AB090T
[1613-E1] high pressure fuel pipe

(kit 1613)
Figure : E5AB091T
[1613-F] (kit containers for return of diesel injector

1613) leaks
Page 3 of 10
Figure : E5AD012T
[1613-G] (kit container for measuring the high pressure

1613) fuel injection pump return flow
Figure : E5AB092T
[1613-H] (kit union for return of leaks on diesel

1613) injector (DELPHI injection)
Figure : E5AB093T
[1613-J] (kit union for return of leaks on diesel

1613) injector (BOSCH/SIEMENS injection)
Page 4 of 10
Figure : E5AB094T
[1613-K] (kit plugs kit

1613)
Figure : E5AD011T
[1613-N] (kit union for return of leaks on diesel

1613) injector (engine DV6C Euro 5 ) (SIEMENS
injection)
Figure : E5AB0N1T
[1613-Q] (kit union for return of leaks on diesel

1613/2) injector (engine DV Euro 5 ) (BOSCH
injection)
Page 5 of 10
Figure : E5AB0XGT
2. Identification
Engine code Factory symbol Injection system

DW10 RHL SIEMENS
RHR SIEMENS
RHS BOSCH
RHZ BOSCH
RHX BOSCH
RHV BOSCH/SIEMENS
RHY BOSCH/SIEMENS
RHS SIEMENS
DW12 4HY BOSCH
4HW BOSCH
4HX BOSCH
4HZ BOSCH
DV4 8HX BOSCH/SIEMENS
8HV DELPHI
8HY BOSCH
8HZ BOSCH
8HU BOSCH
8HS BOSCH
8HR BOSCH
8HP BOSCH
DV6 9HX BOSCH
9HZ BOSCH
9HY BOSCH
9HV BOSCH
9HT BOSCH
9HW BOSCH
Page 6 of 10
9HX BOSCH
9HT BOSCH
9HU BOSCH
9HS BOSCH
9HR SIEMENS
9HL SIEMENS
9HE BOSCH
9HJ BOSCH
9HK BOSCH
9HF BOSCH
9HP BOSCH
9HG SIEMENS
9HN BOSCH
F28 SOFIM 8140.43S BOSCH
8140.23 BOSCH
8140.43N BOSCH
DT17 UHZ SIEMENS
3. Preliminary checks
ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel
injection (HDi) engines.
3.1. Electrical circuit

Check :
 The battery charge
 The fault codes using the diagnostic tool
 The fuel high pressure value using the diagnostic tool : Measure parameters
3.2. High pressure environment

Check :
 The quantity of fuel in the tank : 15 litres minimum
 Fuel quality (if in doubt over the fuel quality, use an auxiliary tank with a filter, filled with fuel which you
know where it came from)
 The low pressure fuel supply circuit (see the relevant operation)
3.3. Engine operation

Check the camshaft drive (timing belt).
Check the components that could cause lack of engine power :
 Obstructed exhaust
 Clogged air filter
 Clogged fuel filter
Page 7 of 10
4. Injection system BOSCH

4.1. Checking the pressure sensor on the fuel high pressure common injection rail,
DW10/DW12 engines (absence of engine starting)
Disconnect the connector of the fuel high pressure sensor.
Operate the starter :
 The engine starts : Replace the fuel high pressure sensor
 The engine will not start : Continue the checking
4.2. Checking the diesel injectors
CAUTION : Do not uncouple the rubber pipes from the diesel injector leak return unions.
Uncouple the diesel injector leak return unions.

Fit the unions of tools [1613-J / 1613-Q] on the diesel injectors (depending on the version).
Couple the containers of tools [1613-F] on the unions of tools [1613-J / 1613-Q] (depending on the version).
Attach the container carrier bar [1613-F] to the engine bonnet.
 The engine starts : Allow the engine to idle for 2 minutes
 The engine will not start : Operate the starter motor for 15 seconds
CAUTION : The volume of fuel returning to the diesel injectors is a few millilitres, the volume of fuel returning
to the diesel injectors increases as a function of the condition of the engine (wear).
Replace any diesel injectors that have a fuel return flow greater than that for the other injectors.
N.B. : After replacing one or more diesel injectors, do a diesel injectors check.
The functioning of the diesel injectors is correct, Continue the checking.

4.3. Checking the high pressure fuel pump
Disconnect the connector from the camshaft position sensor.
CAUTION : Before slackening, clean the high pressure unions (See the corresponding operation).
Remove the high pressure pipe linking the high pressure fuel pump to the high pressure fuel common injection
rail.
Depending on the type of high pressure fuel pump, connect tool [1613-A] with the aid of either tool [1613-E1]
or the fuel high pressure pipe already removed.
Couple the container of tool [1613-B] on tool [1613-A].
Connect tool [1613-D] on tool [1613-A].
Fuel pressure control, Using tool [1613-D] :
 Press the test button
 The display on tool [1613-D] indicates the battery charge
 The display on tool [1613-D] indicates the last fuel pressure value tested (for 5 seconds)
 Press the test button and action the starter at the same time
 When the "stop" message appears on the display of the tool [1613-D], stop the action on the starter
 The display on the tool [1613-D] indicates the maximum fuel pressure value (for 5 seconds)
Page 8 of 10
 The display on the tool [1613-D] indicates the residual pressure value
N.B. : The display of tool [1613-D] flashes if the fuel pressure value is higher than 50 bars.
The fuel pressure is higher than 300 bars : Do the preliminary checks once again.
The fuel pressure is lower than 300 bars : Continue the checking.
CAUTION : Open the fuel decompression screw ["a"] before uncoupling tool [1613-A].
4.4. Checking the fuel pressure regulator (If available in replacement parts)
Replace the fuel pressure regulator with a new regulator.
Check the high pressure fuel pump.
The fuel pressure is higher than 300 bars : The original fuel pressure regulator is defective.
The fuel pressure is lower than 300 bars : Replace the high pressure fuel pump.
CAUTION : Replace the high pressure fuel pipe that was removed.
N.B. : If replacing the fuel high pressure pump, do not lose the new regulator.
5. Injection system SIEMENS

5.1. Checking the pressure sensor on the fuel high pressure common injection rail,
DW10/DW12 SOFIM engines (absence of engine starting)
Disconnect the connector of the fuel high pressure sensor.
 The engine starts : Replace the fuel high pressure sensor
 The engine will not start : Continue the checking

Fit the unions of tools [1613-J / 1613-N] on the diesel injectors (depending on the version).
Couple the containers of tools [1613-F] on the unions of tools [1613-J / 1613-N] (depending on the version).
Attach the container carrier bar [1613-F] to the engine bonnet.
 The engine starts : Allow the engine to idle for 2 minutes
CAUTION : The volume of fuel returning to the diesel injectors is a few millilitres, the volume of fuel returning
to the diesel injectors increases as a function of the condition of the engine (wear).
Replace any diesel injectors that have a fuel return flow greater than that for the other injectors.
Page 9 of 10
The functioning of the diesel injectors is correct : Continue the checking.

rail.
Couple the container of tool [2] on tool [1613-A].
Fuel pressure control Using tool [1613-D] :
6. Injection system DELPHI

6.1. Hydraulic balance
Unplug :
 The diesel injectors
 The flow electrovalve
Connect tool [1613-C] in place of the flow electrovalve.

Check the pressure value in parameter measures using the diagnostic tool.
The fuel pressure is higher than 1050 bars : Redo the fuel supply check.
The fuel pressure is lower than 1050 bars : Continue the checking.

Couple in their place the unions of tools (1613-H).
Page 10 of 10
Couple the containers of tools [1613-F] on the diesel injector leak return unions.
Attach the container carrier bar to the engine bonnet.
Method of operation :
 The engine starts : Using the diagnostic tool, start the leak detection test (1 single cycle)
CAUTION : With the engine running, the maximum volume should not be greater than 37 ml With the engine
not running, the return should be less than 10 cm in the connecting pipes.
Replace any diesel injectors that have a fuel return flow greater than 37 ml, or more than 10 cm (engine not
running).
The functioning of the diesel injectors is correct, Continue the checking.

rail.
Couple the container of tool [1613-B] on tool [1613-A].
Fuel pressure control Using tool [1613-D] :
Page 1 of 3
CHECK : LOW PRESSURE FUEL SUPPLY CIRCUIT (BOSCH INJECTION)
1. Tooling

[1604-A] [/]pressure gauge for checking the
[4073- turbocharging pressure
T.A]
Figure : E5AB0VKT
[1604-C] Ø 10 mm union for low pressure plug

[4215-T]
Figure : E5AB0VLT
[1604-G] Extension
[4251-T]
Page 2 of 3
Figure : E5AB0VMT
2. Check
CAUTION : Respect the safety and cleanliness recommendations that are specific to high pressure
diesel injection (HDi) engines .
Figure : B1HDZL9D
Remove the engine style cover (according to equipment).
CAUTION : Before uncoupling, clean all the unions on the low pressure circuit (if necessary).
Uncouple the union of the fuel low pressure pipe (at "a") ; Using a flat screwdriver.
Page 3 of 3
CAUTION : Check the cleanliness of the tools [1604-A / 4073-T.A], [1604-C / 4215-T], [1604-G / 4251-T].
N.B. : An extension [1604-G / 4251-T] may be used in order to obtain a reading from the passenger
compartment (at "e").
Connect with a by-pass circuit tools 1604-A / 4073-T.A and 1604-C / 4215-T between the fuel high pressure
pump and the fuel filter (at the fuel filter outlet) (at "c", "d").
Secure the tool [1604-A / 4073-T.A] so that it is immobilised during taking of measurements.
Prime the circuit using the manual priming pump, so as not to falsify the measure (at "b").
Switch on the ignition.
Check the low-pressure fuel pressure values .
3. Refitting
Remove the tools [1604-A / 4073-T.A], [1604-C / 4215-T], [1604-G / 4251-T].
Connect the union to the low-pressure fuel pipe (at "a").
Refit the engine style cover (according to equipment).
Operate the manual priming pump 120 for seconds to prime the fuel circuit (at "b").
4. Checking the sealing of the circuit

Start the engine.
Allow the engine to idle for 2 minutes.
Check that there are no leaks.
Check that there are no air bubbles in the return circuit .
Page 1 of 9
CHECK : VACUUM CIRCUIT
1. Tooling

[DA16] Manual pressure-vacuum pump with
adaptors
Figure : E5AB0HWT
2. Vacuum circuit
2.1. Versions DV6C, DV6D, DV6E and DV6UC
Page 2 of 9
Figure : B1HDZ9KD
(1) Vacuum pump .

(2) Control capsule - Turbocharger wastegate valve.
(3) Turbocharging pressure regulation control electrovalve .
(4) Control capsule - Control circuit for the exhaust gas cooler by-pass flap.
(5) Electrovalve controlling the EGR exchanger by-pass.
2.2. DV4C version
Page 3 of 9
Figure : B1HDZEAD
(1) Vacuum pump .

(4) Control capsule - Control circuit for the exhaust gas cooler by-pass flap.
(5) Electrovalve controlling the EGR exchanger by-pass.
2.3. Versions DV6CM, DV6DM, DV6DUM and DV6EM
Page 4 of 9
Figure : B1HDZFYD
(1) Vacuum pump .

3. Vacuum source checks (Vacuum pump )

Check the effectiveness of the vacuum pump (1).
N.B. : If the values are not correct : Replace the component that is faulty.
Page 5 of 9
Figure : B1HDZEBD
Uncouple the vacuum pipe (at "a").

Connect the tool [DA16] to the vacuum pump (1) (at "a").
Start the engine.
Wait 30 seconds.
N.B. : The vacuum value should be 0,8 ± 0,1 bar at idling speed.
Stop the engine.

Remove the tool [DA16].
Couple the vacuum pipe (at "a").
4. Check : Turbocharging pressure regulation control circuit

4.1. Using the diagnostic equipment
Start the engine (for one minute).
N.B. : The engine must be switched on in order to create the air vacuum in the circuit (The check is carried
out with the engine off).
Lift and support the vehicle.

Remove the under engine protection .
Carry out : An actuator test (Turbocharger pressure regulation electrovalve) ; Using the diagnostic equipment.
Check the movement of the control rod on the turbocharger .
If the control rod does not move : Check the following points :
 The sealing of the vacuum circuit (Porous pipes, cracked pipes)
 Vacuum circuit not obstructed (Pipes blocked, kinked)
Page 6 of 9
Carry out all the following checks ; Using tool [DA16].

4.2. Check : Control capsule - Turbocharger wastegate valve (DV6C, DV6CM version)
Figure : B1HDZIXD
Uncouple the vacuum pipe (at "b").

Connect the tool [DA16] on the turbocharger wastegate valve (2) (at "b") on the turbocharger (6).
Apply a vacuum of approximately 0,8 bar.
N.B. : The control rod "c" on the turbocharger should move 12 ± 2 mm.
CAUTION : If the control rod "c" does not move ; Replace the turbocharger (6) (see the relevant operation) If
not : Carry out the following check.

Connect the negative pressure pipe (at "b").
Refit the under-engine protection .
4.3. Check : Control capsule - Turbocharger wastegate valve (Versions DV4C, DV6UC,
DV6UDM, DV6D, DV6DM, DV6E and DV6EM)
Page 7 of 9
Figure : B1HDZIYD
Remove : The turbocharger upper heat shield (6).

Uncouple the vacuum pipe (at "b").
Connect the tool [DA16] on the turbocharger wastegate valve (2) (at "b") on the turbocharger (6).
N.B. : The control rod "c" on the turbocharger should move 6 ± 1 mm.
CAUTION : If the control rod "c" does not move ; Replace the turbocharger (6) (see the relevant operation) If
not : Carry out the following check.

Connect the negative pressure pipe (at "b").
Refit : The turbocharger upper heat shield (6).
4.4. Check : Turbocharging pressure regulation control electrovalve
Connect the tool [DA16] to the turbocharging pressure regulation control electrovalve (3) outlet (at "d").
Start the engine (for one minute).
N.B. : The engine must be switched on in order to create the air vacuum in the circuit. The check is carried
out with the engine off.
Carry out : An actuator test (Turbocharging pressure regulation control electrovalve ) ; Using the diagnostic
equipment.
Check the fluctuation of the vacuum on the tool [DA16] (10 fluctuations of approximately 0,4 ± 0,1 bar).
N.B. : If the vacuum does not fluctuate, check the electrical connection of the turbocharging pressure
Page 8 of 9
regulation control electrovalve (3) using the diagnostic tool; otherwise replace the turbocharging pressure
regulation control electrovalve (3).

Connect the negative pressure pipe (at "d").
5. Check : Exhaust gas recycling control circuit (Except DV6CM, DV6DM, DV6UDM
and DV6EM engines)
5.1. Using the diagnostic equipment
Check : The exhaust gas recycling control circuit ; Using the diagnostic equipment.
Check that the exhaust gas recycling valve clicks audibly on its seat.
If the clicking is not audible ; Check the following points :
 The sealing of the vacuum circuit (Porous pipes, cracked pipes)
 That the vacuum circuit is not blocked (Pipes blocked, kinked)
Carry out all the following checks ; Using tool [DA16].

5.2. Using the manual pressure-vacuum pump [DA16]
Figure : B1HDZIZD
Remove the air filter housing .

Uncouple the vacuum pipe (at "e").
Connect tool [DA16] to the control diaphragm (4) of the EGR module (at "e").
N.B. : When the vacuum is suddenly released, the rod of the control diaphragm must return to its initial
Page 9 of 9
position.

Connect the negative pressure pipe (at "e").
Raise the vehicle.
Remove and move aside : The acoustic shield .
Connect the tool [DA16] to the outlet of the exhaust gas recycling regulation electrovalve (5) (at "f").
Lower the vehicle.
Start the engine (For 1 minute(s)).
N.B. : The engine must be switched on in order to create the air vacuum in the circuit (The check is carried
out with the engine off).
Carry out : An actuator test (Exhaust gas recycling solenoid valve ) ; Using the diagnostic equipment.
Check the fluctuation of the vacuum on the tool [DA16] (10 fluctuations of approximately 0,4 ± 0,1 bar).
N.B. : If the vacuum does not switch, check the electrical connection of the exhaust gas recycling control
solenoid valve (5) ; Using the diagnostic equipment.

Connect the negative pressure pipe (at "f").
Refit :
 The air filter casing
 The acoustic shield
Page 1 of 4
CHECK : OIL PRESSURE
1. Tooling

[1503-AY] Oil pressure gauge
Figure : E5AD01TT
[1503-B] Pressure take-off hose
Figure : E5AB046T
[1503-J] engine oil pressure union

Page 2 of 4
Figure : E5AD01PT
2. Check
CAUTION : Adhere to the tightening torques .
Check the oil level.
CAUTION : Oil pressure is checked with the engine hot after checking the oil level.
Figure : B1BD03PD
Remove the air deflector (2) and air inlet neck (1) assembly (according to equipment).
Page 3 of 4
Figure : B1FD02ND
Protect the area with absorbent paper or a clean rag.

Remove the filter element protection cover (3).
Unclip the filter element from the protection cover (3).
Refit the filter element on the oil filter support .
Page 4 of 4
Figure : B1FD03OD
Fit :
 The union [1503-J] on the oil filter support ; Tighten to the specified torque
 The hose [1503-B] onto the union [1503-J]
 The pressure gauge [1503-AY] onto the hose [1503-B]
Start the engine.

Measure the oil pressures.
Compare the readings on the oil pressure gauge with those in the table .
N.B. : Only carry out work on the engine if the values read are lower than those in the table.
Remove the tools [1503-AY], [1503-B], [1503-J].

Unclip the filter element from the tool [1503-J].
Refit :
 The filter element on the protective cover of the filter element (3)
 The filter element protective cover (3) ; Tighten to the specified torque
 The air deflector (2) and air inlet duct (1) assembly
Top up the engine oil.

Page 1 of 8
CHECK : SETTING THE VALVE TIMING
1. Tooling

[0194-C] [/] flywheel stop
Figure : E5AB08ST
[0194-B] Camshaft probe
Figure : E5AB08RT
[0194-A] [/] crankshaft setting rod

Page 2 of 8
Figure : E5AB08QT
[0194-A] High pressure fuel pump drive pulley

immobilising rod
Figure : E5AB08QT
[0194-T] plugs kit
Figure : E5AB05LT
2. Removing
ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure
Put the vehicle on a hoist.

Disconnect the battery.
Page 3 of 8
Remove the engine style cover .
Figure : B1BD01LD
Uncouple and move aside the pipes (1) (at "a") ; Close using tool [0194-T].
Remove :
 The front right wheel
 The front right mud guard
 The accessories drive belt
Page 4 of 8
Figure : B1ED05VD
Turn the engine until the pin [0194-C] engages in the engine flywheel.
Lock the flywheel ; Using tool [0194-C].
Figure : B1EP1UND
Page 5 of 8
Move aside the electrical harness (5).

Remove :
 The top timing cover (4)
 The (6) bolt
 The cover of the pulley (2)
 The pulley (2)
N.B. : To make it easier to remove the lower timing cover (3) ; Move the accessories drive belt dynamic
tensioner roller.
Remove the lower timing cover (3).

Refit bolt (6).
Remove the tool [0194-C].
3. Check
3.1. Visual check
CAUTION : Carry out the checks below.
Check the absence of coolant fluid leaks (coolant pump).
Check that the track of the engine speed sensor target is not damaged or scratched.
Replace any defective parts.
3.2. Checking the valve timing
Page 6 of 8
Figure : B1ED05XD
CAUTION : The magnetic track should carry no sign of damage and should not be approached by any other
magnetic source ; Otherwise, replace the crankshaft pulley.
Turn the crankshaft through 6 revolutions clockwise using the screw (6).
CAUTION : Never turn back.
Peg :
 The crankshaft ; Using tool [0194-A]
 The camshaft ; Using the pin [0194-B] (oil the peg)
 The high pressure fuel pump drive pulley ; Using tool [0194-A] (oil the peg)
CAUTION : If it is impossible to peg the camshaft, check that the offset between the camshaft pulley hole
and the pegging hole is not greater than 1 mm ; If this is not the case, repeat the cambelt fitting procedure.
Figure : B1EP1UQD
Check the positioning of the index (7).
N.B. : The dynamic roller tensioner index (7) must be centred in the gap ( as "b").
CAUTION : If it does, repeat the timing belt tensioning operation.
Remove the tools [0194B], [0194-A], [0194-A].
4. Refitting
Page 7 of 8
Figure : B1EP1URD
Refit the tool [0194-C].

Remove bolts (6).
N.B. : To make it easier to refit the lower timing cover (3) ; Move the accessories drive belt dynamic
tensioner roller.
Refit :
 The lower timing cover (3)
 The pulley (2)
Fit the bolt (6) (new) ; Tighten to the specified torque.

Refit :
 The electrical harness (5)
N.B. : Use new plastic tie wraps .
Refit the ancillary belt .

Remove the tool [0194-T].
Connect the fuel supply and return pipes (1) ( as "a").
Refit :
 The engine cover
Page 8 of 8

CAUTION : Perform the operations to be carried out following reconnection of the battery.
Reconnect the battery.

Operate the manual priming pump several times to prime the fuel circuit.
Page 1 of 5
CHECKING AND ADJUSTING VALUES : DV4C - DV6DTED - DV6DBM - DV6ETED ENGINE

TYPE
1. Foreword
1.1. Units of pressure
1/ Units of pressure in bars.
N.B. : One bar has the advantage of being close to the average atmospheric pressure at sea level.
2/ Unit of pressure in millimetres of mercury (symbol: mmHg) or Torr (symbol: Torr).

This unit of measurement of pressure was origially defined as the pressure exerted at 0°C by a 1 millimetre
column of mercury, later indexed to the atmospheric pressure.
The pressure values indicated in the tables below are the values read on the pressure gauge (Relative
pressure).
N.B. : Relative pressure is equal to absolute pressure minus atmospheric pressure.
1.2. Units of tension

The SEEM unit measures by deflection of the static tension of the belt, by deforming a portion of its length.
2. General engine information

2.1. DV4C engine
Type of engine DV4C

Engine legislative type 8HR
Cubic capacity 1398 cc
Fuel Diesel
Maximum power 50 kW
Engine speed at maximum power 4000 rpm
Maximum torque 16 daNm
Engine speed at maximum torque 1750 rpm
2.2. dv6c engine
Type of engine DV6CU

Engine legislative type 9HM
Fuel Diesel
Maximum power 66 kW
Page 2 of 5
2.3. DV6D engine
Type of engine DV6DTED DV6DTED

Engine legislative type 9HP 9HF
Fuel Diesel
Maximum power 68 kW 66 kW
Engine speed at maximum power 4000 rpm 4000 rpm
Maximum torque 23 daNm 21,5 daNm
Engine speed at maximum torque 1750 rpm 1500 rpm
Type of engine DV6DBM DV6DUM DV6DTEDM

Engine legislative type 9HE 9HH 9HJ
Fuel Diesel
Maximum torque 21,5 daNm 18 daNm 23 daNm
Engine speed at maximum torque 1750 rpm 1500 rpm 1750 rpm
2.4. DV6E engine
Type of engine DV6ETED DV6ETEDM

Engine legislative type 9HN 9HK
Cubic capacity 1560 cc 1560 cc
Fuel Diesel Diesel
Maximum torque 18,5 daNm 18,5 daNm
3. Oil capacity
Oil capacity without replacement of the filter cartridge 3,25 litres

Oil capacity with replacement of the filter cartridge 3,75 litres
Capacity between minimum and maximum on the oil gauge 1,5 litre
Oil change interval : Refer to the maintenance schedule.
CAUTION : Check the oil level systematically using the manual oil dipstick.
Page 3 of 5
4. Oil pressure
N.B. : Check the oil level with the engine cold.
CAUTION : The oil pressure check is carried out with the engine warm (Oil temperature : 110 °C).
Engine speed Minimum oil pressure

1000 rpm 1,3 bar
4000 rpm 3,5 bars
CAUTION : Carry out work on the engine if the oil pressure values are below those in the table.
5. Ancillary drive belt
With and without air conditioning By dynamic roller tensioner
6. timing belt
Belt tension By mechanical tensioner roller
7. Cylinder head bolts
Figure : B1BB0VTD
Page 4 of 5
N.B. : Do not use cylinder head bolts that are longer than "A" mm, use new bolts.
Designation "A"
Maximum length under heads of the screws 149 mm
8. Pressure, engine end of compression

Measure the pressure at the end of compression, in order, on cylinders 1, 2, 3 and 4.
N.B. : The difference in pressure between 2 cylinders must not exceed 5 bars.
CAUTION : Always search for the origins of fault(s), where the values measured are found to be significantly
out.
9. Boost pressure
Engine speed Boost pressure

2500 rpm 0,2 bar
4000 rpm 0,6 bar
10. Air supply circuit

10.1. Vacuum pump
Engine speed Negative pressure

Idling 0,9 ± 0,1 bar
10.2. Turbocharger wastegate valve

Turbocharger - make MHI (According to equipment).
Pressure regulation valve Movement of the regulation valve rod

150 Mbar 2 mm
200 Mbar 4 mm
250 Mbar 6 mm
Greater than 250 mbar Maximum
11. Low pressure fuel supply circuit
Reference values Vacuum measured by the Vacuum measured by the

Engine idling or under starter motor for less pressure gauge [4073-T.A] pressure gauge [1604-A]
than 15 seconds (If the engine does not start)
Vacuum values to identify an air leak on the D < 7,5 cmHg D < 100 Mbar
low-pressure circuit
Normal vacuum values 7,5 cmHg < D < 22,5 cmHg 100 Mbar < D < 300 Mbar
Page 5 of 5
Vacuum values to identify a block on the low- D > 22,5 cmHg D > 300 Mbar
pressure circuit
(Diesel filter clogged)
Page 1 of 5

TYPE
1. Foreword

pressure).


2.1. DV4C engine
Type of engine DV4C

Fuel Diesel
Maximum power 50 kW
2.2. dv6c engine

Fuel Diesel
Maximum power 66 kW
Page 2 of 5
2.3. DV6D engine

Fuel Diesel

Fuel Diesel
2.4. DV6E engine

Fuel Diesel Diesel
3. Oil capacity

Page 3 of 5
4. Oil pressure

1000 rpm 1,3 bar
4000 rpm 3,5 bars
6. timing belt
Figure : B1BB0VTD
Page 4 of 5
Designation "A"

out.
9. Boost pressure

2500 rpm 0,2 bar
4000 rpm 0,6 bar

10.1. Vacuum pump



150 Mbar 2 mm
200 Mbar 4 mm
250 Mbar 6 mm

Page 5 of 5
pressure circuit
Page 1 of 3
CLEANING : UNIONS ON THE FUEL HIGH PRESSURE COMMON INJECTION RAIL (HDI)
1. Tooling
Equipment :
 Degreasing product SODIMAC N°35
 Cleaning tray
 Brush
 Vacuum extractor
 Round end-piece
2. Preliminary operations
Disconnect the ancillaries battery.

Remove the air cleaner unit .
Protect the alternator.
3. Method of operation
3.1. CONTINENTAL / SIEMENS assembly
Page 2 of 3
Figure : B1BK3XLD
CAUTION : Follow the recommendations for cleaning the repair zones (at "a") (See common operations).
3.2. BOSCH assembly

Page 3 of 3
Figure : B1HK100CD
CAUTION : Follow the recommendations for cleaning the repair zones (at "a") (See common operations).
3.3. Common operations

Clean the repair areas (at "a") :
 Pour the degreaser into the cleaning tray
 Dip the brush in the degreaser
 Clean the zones "a" while using the suction device at the same time ; Using the vacuum cleaner and
the round end piece
Clean the vacuum cleaner and the round adaptor after use.
Remove the alternator protector.
Refit the air cleaner unit .
CAUTION : Perform the operations that are required following a reconnection of the ancillaries battery .
Reconnect the ancillaries battery.

Page 1 of 5
DISMANTLING - RE-ASSEMBLY : ADDITIVE TANK
CAUTION : Observe the safety and cleanliness recommendations .
1. Tooling
Equipment : Component lift.
Unclip the connectors Reference Designation

[0194-T] Set of plugs
Figure : E5AB05LT
2. Removing
Page 2 of 5
Figure : B1KG0IKD
Remove :
 The left hand rear wheel
 The left-hand rear mud guard
Uncouple the exhaust line (2).

Remove the exhaust fixings (1).
Move the exhaust line (2) aside.
Remove the heat shield (3).
Unclip and move aside the fuel supply and return pipes (at "a").
Page 3 of 5
Figure : B1HG3VWD
Remove the bolt (4).

Move the filler neck (5) away from the wing .
Figure : B1HG3VXD
Page 4 of 5
Position a component lift under the fuel tank ( 6).

Remove the nuts (7).
Lower the fuel tank (6) slightly.
Figure : B1KG0ILD
CAUTION : Plug the openings ; Using the tools [0194-T].
Disconnect the connector (at "b").

Uncouple pipe and move it aside (at "c").
Remove :
 The nuts (8)
 The additive reservoir (9)
3. Refitting
CAUTION : Adhere to the tightening torques.
Tightening torques :
 Exhaust
 Fuel system
 Road wheels
Refit :
 The additive reservoir (9)
 The nuts (8)
Remove the tools [0194-T].

Page 5 of 5
Couple the piping (at "c").

Connect the connector (at "b").
Put fuel tank (6) into place ; Using a component lift.
Position the filler neck (5) inside the wing .
Clip the fuel supply and return pipes (at "a").
Refit :
 The nuts (7)
 The (4) bolt
 The heat shield (3)
 The exhaust pipe (2)
 The hangers (1)
Couple the exhaust line (2).

Refit :
CAUTION : Perform the operations that are required following a reconnection of the ancillaries battery.

Page 1 of 5
DISMANTLING - RE-ASSEMBLY : COOLING FAN
1. Tooling

[0165-2] Cable pliers for flexible clips
Figure : E5AI007T
2. Removing
Place the vehicle on a two-post ramp.
Disconnect the ancillaries battery .
Remove :
 The protective panel under the engine (according to equipment)
Drain the cooling system.

Page 2 of 5
Figure : B1GG18ED
Remove :
 The flexible clip (1) ; Using tool [0165-2]
 The bottom hose (2) of the radiator
Figure : B1GG0EOD
Page 3 of 5
Unclip the electrical harness (at "a").

Disconnect the electrical harness connectors (at "b", "c", "d").
Figure : B1GG18FD
Remove the bolts (4).

Lift the cooling fan (3) to disengage the fixing tabs from their housings (at "e", "f").
CAUTION : Do not damage the cooling radiator fins.
Remove the cooling fan assembly from under the vehicle.

Page 4 of 5
Figure : B1GG18GD
Remove :
 The (5) bolt
 The cooling fan electric control unit (6)
3. Refitting
Refit :
 The cooling fan electric control unit (6) on the cooling fan (3)
 The (5) bolt
Reintroduce the fixing tabs of the cooling fan (3) into their housings (at "e", "f").
Refit the bolts (4).
Connect the electrical harness connectors (at "b", "c", "d").
Clip the electrical harness (at "a").
Refit :
Fill and bleed the engine cooling circuit.

Refit :
Page 5 of 5

Start the engine ; Wait for the fan assembly (3) to cut in then cut out.
Stop the engine.
Page 1 of 2
DISMANTLING - RE-ASSEMBLY : CYLINDER REFERENCE SENSOR
2. Removing
Figure : B1HG3Z9D

Disconnect the connector ( as "a").
Remove :
 The (2) bolt
 Cylinder reference sensor (1)
3. Refitting
CAUTION : Replace the sensor seal.

Page 2 of 2
Refit :
 Cylinder reference sensor (1) (equipped with a new seal)
 The (2) bolt
Connect the connector ( as "a").


Page 1 of 14
DISMANTLING - RE-ASSEMBLY : ENGINE AND GEARBOX ASSEMBLY
1. Tooling
Equipment : 1 Belt.

[0004] lifting bench
Figure : E5AB05KT
[0005-C] set of retaining supports (right)
[0005-E] Rod/power train connecting tool
[0005-G] set of retaining supports (Adjustable

supports)
Figure : E5AB1CXT
Page 2 of 14
Figure : E5AB05LT
[0216-G1] Tool for detaching ball-joints Ø 10 mm
[0216-G2] Tool for detaching ball-joints Ø 13 mm
Figure : E5AB0EST
Figure : E5AI007T
2. Removing
ESSENTIAL : Observe the safety and cleanliness instructions which are specific to high-pressure
diesel injection engines (H.D.I.) .

Strap the vehicle onto the lift.
Page 3 of 14

Figure : B1BG3JHD
CAUTION : Plug the fuel supply and return pipes ; Using tool [0194-T].
Uncouple and move aside the fuel supply and return pipes (at "a").
Unclip the fuel pipes attaching to the upper timing cover.
CAUTION : Cover the openings of the air inlet circuit .
Remove :
 The air inlet neck (4)
 The service battery (2)
 The ancillaries battery tray
 The service battery tray support
 The engine fuse box cover (3)
 The air filter housing (1)
Uncouple the air ducts (5).

Page 4 of 14
Figure : B1BG3JID
Remove the nut (6).

Move aside the harness (7).
Detach and move aside the electrical harnesses (at "b", "c).
Disconnect the connectors (at "d").
Remove :
 The gearbox earth cable
Drain :
 The cooling system
 The gearbox
Page 5 of 14
Figure : B1BG3JJD
Detach and move aside :

 The vacuum pipe (at "e")
 The click-fit pipes of the heater assembly (8)
Detach the vacuum pipe (at "f").

Remove the fan .
Page 6 of 14
Figure : B1BG3JKD
Uncouple :
 The ball-joints (9) on the gear control cables ; Using tool [0216-G1]
 The push rod (11) ; Using tool [0216-G2]
Release the gear control cables assembly by pressing on the catch (10) (In the direction of the arrow ).
Move aside the gearbox controls .
Page 7 of 14
Figure : B1BG3JLD
Unclip the pipe (12) (at "g").

Remove :
 The drive shafts (13)
 The front subframe
2.1. Vehicles with air-conditioning

Page 8 of 14
Figure : C5HG1K2D
Remove the accessories drive belt .

Disconnect the air conditioning compressor (15) connector (at "h").
Unclip and move aside the electrical harnesses attached to the air conditioning compressor (15).
CAUTION : Make sure you don’t bend the air-conditioning pipes.

Move aside and secure the air conditioning compressor (15) (Without opening the refrigerant circuit).
2.2. Removing (continued)
Page 9 of 14
Figure : B1BG3JMD
N.B. : (16) bleed screw(s) .

Move aside the hydraulic clutch control slave cylinder (17).
Page 10 of 14
Figure : B1BG3JND
Install the lifting table [0004] with the supports [0005-C], [0005-E], [0005-G] under the engine-gearbox
assembly .
Position the tools [0005-G], [0005-C], [0005-E] (at "j", "k").
Figure : B1BG3JOD
Fit the tool [0005-C] ; Fit a shim (at "l").

Fix the tools [0005-G], [0005-C] to the lifting table [0004].
Raise the lifting table [0004] slightly to place the engine-gearbox assembly under stress.
N.B. : Make marks on the ground to reference the position of the power train.
Page 11 of 14
Figure : B1BG3JQD
Uncouple and move aside the hose (12).

Remove :
 The bolts (20)
 The bolts (22)
 The engine mountings (19), (21)
Page 12 of 14
Figure : B1BG3JRD
CAUTION : Check that the power train will not make contact with the bodywork.
Remove the engine-gearbox assembly from the underneath of the vehicle (Carefully).
3. Refitting
Tightening torque :
 Front suspension
 Engine-gearbox assembly mounting
 Exhaust system
 Steering
 Electrical equipment
CAUTION : Check that the power train will not make contact with the bodywork.
Position the engine-gearbox assembly (Carefully).

Refit :
 The engine mountings (19) et (21)
 The bolts (22)
 The bolts (20)
 The bolts (23)
Page 13 of 14
Remove the tools [0005-G], [0005-C].

Remove the shim (at "l").
Lower and remove the bench [0004].
Connect the hose (12).
Refit :
 The hydraulic clutch control slave cylinder (17)
 The bolts (18)
Bleed the clutch hydraulic circuit (if necessary) ; Using the bleed screw (16).
3.1. Vehicles with air-conditioning
Refit :
 The air-conditioning compressor (15)
 The bolts (14)
Connect the connectors of the air conditioning compressor (15) (at "h").

3.2. Refitting (continued)
Refit :
 The front subframe
 The drive shafts (13)
Reclip the pipe (12) (at "g").

Lock the gear control cables assembly on the support .
Couple up :
 The ball-joints (9) on the gear control cables
 The push rod (11)
Refit the cooling fan .

Position and couple up :
 The click-fit pipes of the heater assembly (8)
 The vacuum pipe (at "e")
Attach the vacuum pipe (at "f").

Refill :
 The cooling system
 The gearbox
Refit :
 The gearbox earth cable
Put the electrical harness in place (7).

Clip the electric harnesses (at "b", "c").
Connect the connectors (at "d").
Refit :
 The nut (6)
 The engine fuse box cover (3)
Page 14 of 14
 The air filter housing (1)

 The service battery tray support
 The service battery (2)
Clip the fuel pipes attaching to the upper timing cover.

Remove the closers [0194-T].
Connect the fuel supply and return pipes (at "a").
CAUTION : Remove the plugs from the openings of the air intake circuit.
Couple the air ducts (5).

Remove the strap .

Refit :
 The vehicle to its wheels
4. Checks
Read the fault codes ; Using the diagnostic equipment.
Verify :
 There is no noise
 The circuits are free from leaks
Carry out :
 A road test
 A reading of the auto-diagnostic memories
Page 1 of 4
DISMANTLING - RE-ASSEMBLY : ENGINE COOLING RADIATOR
1. Tooling

Figure : E5AI007T
2. Removing
Place the vehicle on a 2-post lift.
Remove :
 The air inlet neck
 The front bumper
 The cooling fan
CAUTION : Do not damage the fins of the engine cooling radiator ; Protect with thick cardboard.
Page 2 of 4
Figure : B1GG18HD
Separate the release cable from the engine cover.

Remove :
 The bolts (1)
 The upper crossmember (2)
Page 3 of 4
Figure : B1GG18ID

 The pipe (3)
 The pipe (4) ; Using tool [0165-2]
Uncouple the engine cooling radiator lower hose .

Remove the engine cooling radiator (5).
3. Refitting
Figure : B1GG18JD
CAUTION : Check the presence of the centring rubbers (6) (RH and LH).
Page 4 of 4
Figure : B1GG18KD
CAUTION : Check the presence of the centring rubbers (7) on the upper crossmember (2).
Couple the bottom hose of the engine cooling radiator.

Reposition the engine cooling radiator (5).
Couple up :
 The pipe (3)
Refit :
 The bolts (1)
 The cooling fan
Fill in the coolant circuit and bleed it..

4. Check
Start the engine.
Check the sealing of the cooling system.
Refit :
Page 1 of 4
DISMANTLING - RE-ASSEMBLY : ENGINE ECU
CAUTION : Before adding or replacing any parts, ensure that the customer has not lost their confidential
card (according to equipment).
1. Removing
Figure : B1HG3S7D
Unclip the cover (1) of the engine ECU (at "a") ; In the direction of the arrow "b".
Remove the cover (1) of the engine ECU .
Page 2 of 4
Figure : B1HG3S8D

Disconnect the 3 connectors (at "c").
Release the engine management ECU (2) and its mounting(In the direction of the arrow ).
Figure : B1HG3S9D
Page 3 of 4
Remove the mountings (3).

Remove the engine management ECU (2) from its mounting (4).
2. Refitting
Refit the engine ECU (2) on its support (4).
Refit : The mountings (3).
Connect the connectors (at "c").
Refit : The engine management ECU (2) and its mounting (4) .
Refit the cover (1) on the engine management ECU (2).
3. Operations to be carried out after the ECU has been replaced
CAUTION : Always carry out the following operations after replacing an ECU.
3.1. Programming the engine management ECU
CAUTION : Swapping an engine management ECU between two vehicles means that it will be impossible to
start the vehicles.
When replacing an injection engine management ECU, the engine immobiliser system must be programmed.
Requirements for initialising the immobiliser system :
 Be in possession of the access code to the built-in systems interface (written on the customer’s
confidential card) (According to equipment)
 Be in possession of a new engine management ECU
 Use the diagnostic tool
 Carry out a programming procedure of the engine management ECU
 Download the engine management ECU (If necessary)
Carry out : Learning- engine immobiliser system.

3.2. Configuring the engine management ECU
Parameters which can be configured :
 Cooling system ( electric cooling fan unit)
 Air conditioning pressure sensor
 gearbox
 Petrol injector
 additional heating
 control units
 Calibration identification no.
Carry out : Configuring the engine management ECU.

3.3. Engine management ECU downloading
The engine management ECU software is updated by downloading (ECU fitted with a flash EPROM).
Page 4 of 4
N.B. : This operation is performed using diagnostic equipment.
Carry out : Engine management ECU downloading (If necessary).
4. Procedures for returning under warranty

Disconnecting the engine management ECU results in it being locked automatically.
CAUTION : If a part is returned under warranty, return the engine management ECU with the access code.
Page 1 of 3
DISMANTLING - RE-ASSEMBLY : FUEL FILLER CAP
1. Tooling

[1350-ZZ] Stripping tool
Figure : E5AG02MT
2. Removing
Remove the left-hand rear mud guard .
Page 2 of 3
Figure : C4CG0QQD
Open the fuel filler flap (2).

Remove the fuel flap cover (1) (In the direction of the arrow ).
Figure : C4CG0QRD
Page 3 of 3
Disengage the fuel flap opening control cable (3) (After having made the 1/4 turn) (Anti-clockwise).
Figure : C4CG0QSD
Remove the reservoir cap (4).

Detach the fuel flap (2) (at "a") ; Using tool [1350-ZZ] (By the wheel arch).
Remove the fuel flap (2).
3. Refitting
Proceed in the reverse order to removal.
Check the operation of the opening of the fuel filler flap from the passenger compartment.
Page 1 of 4
DISMANTLING - RE-ASSEMBLY : FUEL PUMP-GAUGE ASSEMBLY
1. Tooling

Figure : E5AB05LT
[1607] Gauge securing ring removal-refitting

spanner
Figure : E5AB09OT
2. Additional operations
Wait 30 seconds after switching off the engine before disconnecting the fuel pipes.
Remove the cushion of the rear bench seat .
3. Removing
Page 2 of 4
Figure : B1HG3T0D
Remove the blanking piece (1).
CAUTION : Before uncoupling them, clean the click-on connectors (2).
Disconnect the connectors (at "a", "c") (according to equipment).

Unclip the electrical harness (at "b") (according to equipment).
CAUTION : Plug the click-fit unions (2) ; Using tool [0194-T].
Uncouple the click-fit unions (2) (according to equipment).

Page 3 of 4
Figure : B1HG3T1D
CAUTION : On removal, protect the fuel gauge well surround with absorbent paper ; Place a tray under the
fuel gauge well immediately.
CAUTION : Following removal of the fuel pump and gauge assembly (4) : Immediately screw the ring nut (3)
back on the tank to avoid any distortion of the fuel gauge well (Risk of fuel leak).
Remove :
 The ring/nut (3) ; Using tool [1607]
 The fuel pump and gauge assembly (4), taking care not to damage or distort the float arm (5)
 The seal (6)
Refit the retaining ring (3) on the fuel tank .
4. Refitting
CAUTION : Always replace the seal (6).
CAUTION : Take care not to damage the seal (6) and the float arm (5).
Unscrew the ring-nut (3).

Refit :
 The seal (6) (new)
 The fuel pump and gauge assembly (4), taking care not to damage or distort the float arm (5)
Page 4 of 4
Figure : B1HG3T2D
Refit the ring nut (3) : Tighten with the aid of the tool [1607].
N.B. : Align the arrow "d" on the ring nut (3) with the mark "e" on the fuel tank .
Connect the connectors at "a" and "c" (according to equipment).

Clip the electrical harness (at "b") (according to equipment).
Couple the click-fit unions (2) (according to equipment).
Operate the manual priming pump for 120 seconds to prime the fuel circuit.

Check the operation of the fuel gauge on the instrument panel .
5. Checking for leaks

Start the engine.
Check there are no leaks.
Check that there are no air bubbles in the return circuit .
Refit :
 The blank (1)
 The rear benchseat base
Stop the engine.

Page 1 of 5
DISMANTLING - RE-ASSEMBLY : FUEL TANK
1. Tooling
Tool Reference Designation

Figure : E5AB05LT
2. Removing
Drain the fuel tank .
Raise the rear seat cushion .
CAUTION : Plug the openings ; Using the tools [0194-T].

Page 2 of 5
Figure : B1HG3VUD
Remove the protector (1).

Unclip the connector (at "a").
Disconnect the connectors (at "b").
Uncouple and move aside the fuel piping (at "c").
Page 3 of 5
Figure : B1HG3ZFD
Remove :
 The rear suspension springs
 The left-hand rear damper

 The bump stop
 The stabiliser bar
Uncouple the exhaust line (2).

Remove the exhaust line (2) flexible mountings .
Move the exhaust line (2) aside.
Remove the heat shield (3).
Figure : B1HG3VWD

Move the filler neck (5) away from the wing .
Page 4 of 5
Figure : B1HG3VXD
Position a component lift under the fuel tank ((6)).

Lower the fuel tank (6) slightly.
Unclip the fuel tank (6) pipes .
Remove the tank (6).
3. Refitting
 Exhaust
 Fuel system
 Road wheels
Put fuel tank (6) into place ; Using a component lift (Guide the filler neck (5) between the rear suspension
crossmember and the vehicle floor).
Clip the fuel tank pipes (6).
Refit the fuel tank (6).
Position the filler neck (5) inside the wing .
Refit :
 The nuts (7)
 The (4) bolt
 The exhaust pipe (2)
 The exhaust line (2) flexible mountings
Page 5 of 5
Couple the exhaust line (2).

Refit :
 The stabiliser bar
 The bump stop
 The left-hand rear damper
 The rear suspension springs

Couple up the fuel pipes (at "c").

Clip connector in place (at "a").
Connect the connectors (at "b").
Clip connector in place (at "a").
Refit the protector (1).
Fill the fuel tank .
Operate the manual priming pump 120 for seconds to prime the fuel circuit.

Page 1 of 6
DISMANTLING - RE-ASSEMBLY : OPENING CONTROL OF THE FUEL FLAP
1. Tooling

[1350-ZZ] Stripping tools
Figure : E5AG02MT
2. Removing
Remove (On the driver’s side) :
 The rear mud guard
 The boot side trim
 The rear seat cushion
 The rear wheelarch trim
 The centre pillar lower trim

Page 2 of 6
Figure : C4CG0RUD
N.B. : By the wheel arch.
Disengage the fuel flap opening control cable (1) (After having made the 1/4 turn) (Anti-clockwise).
Figure : C4CG0RVD
Page 3 of 6
Unclip ; Using tool [1350-ZZ] :

 The fastening ties (at "b")
 The grommet (at "a")
Disengage the fuel flap opening control cable (1).
Figure : C4CG0RWD
Release the floor carpet .

Unclip the fuel flap opening control cable (1) (at "c") ; Using tool [1350-ZZ].
Disengage the fuel flap opening control cable (1).
Page 4 of 6
Figure : C4CG0RXD
Remove :
 The securing bolt (2)
 The trim (3)
Page 5 of 6
Figure : C4CG0RYD
Unclip and detach ; Using tool [1350-ZZ] :

 The outer cable stop (4)
 The cable end piece (5)
Remove the fuel flap opening control cable (1).

Page 6 of 6
3. Refitting
Proceed in the reverse order to removal.

Check the operation of the equipment.
Page 1 of 21
DISMANTLING - RE-ASSEMBLY : PEDAL BRACKET
1. Tooling

[0818] Tool for unclipping the connection between
the pedal bracket ball joint / Brake servo
Figure : E5AG03KT
[0818 - Z] Tool for unclipping the connection between

the pedal bracket ball joint / Brake servo
(Improvement of the tool [0818] ; Addition of
a handle)
Figure : E5AB15ET
Page 2 of 21
Figure : B3FG2F7D
CAUTION : Place the front wheels in the straight ahead position. Lock the steering wheel in this position.
Disconnect the connector (at "a").

Remove :
 The nuts (1), (2)
 The accelerator pedal (3)
 The nut (5)
 The (4) bolt (Move aside the clip (6))
Slide the steering column (7) in the direction of the arrow "b" in order to uncouple the steering column (7) from
the power steering valve .
Page 3 of 21
Figure : B3FG2F8D
Unplug :
 The connector (at "c")
 The connector (at "d")
Unclip the electrical harness (at "e").

Remove the stoplamp switch (8).
2.1. Unclipping the cylindrical connection between the master cylinder/pedal bracket
(Vehicle with manual gearbox)
Page 4 of 21
Figure : B2BG03ID
CAUTION : Do not break the lugs on the end of the rod (9) of the clutch hydraulic control master cylinder.
Gently separate the lugs on the rod (9) of the clutch hydraulic control master cylinder.
Unclip the rod (9) from the hydraulic clutch master cylinder (at "f").
2.2. Unclipping the master cylinder/pedal bracket joint connection (Vehicle with manual
gearbox)
N.B. : First assembly.

Page 5 of 21
Figure : B2BG03JD
Carry out the following operations simultaneously :

 Pinch together the lugs of the locking clip (10) ; With a 10 mm ring spanner
 Separate the rod (9) of the hydraulic clutch control master cylinder from the pedal bracket ; Using a
plastic pallet
Page 6 of 21
Figure : B2BG03KD
Release the locking clip (10) from the pedal bracket ; Using a plastic pallet.
N.B. : Second assembly.
Figure : B2BG03LD
Press on the locking clip (10).

Disconnect the rod (9) of the hydraulic clutch control master cylinder from the pedal bracket ; Using a plastic
pallet.
2.3. Unclipping the yoke connection from the braking system
Page 7 of 21
Figure : B3FG0X0D
Remove the clip with a blue ring (11).

Turn the shaft (12) one quarter of a turn clockwise and remove it.
2.4. Unclipping the ball joint connection from the braking system
Figure : B3FG260T
CAUTION : Do not damage the bellows of the brake servo.
Move aside the tabs (at "g") ; Using tool [0818 / 0818-Z] (from below).
Hold tool [0818 / 0818-Z] in place, pull gently on the brake pedal and disconnect the rod of the brake servo
from the brake pedal.
Remove :
 The nuts (13)
 The pedal gear
Page 8 of 21
3. Work on the brake pedal only

3.1. Removing the brake pedal
Disconnect the brake servo connection from the brake pedal.
Figure : B3FG0X3D
Remove :
 The nut (14)
 The shaft (15) of the brake pedal
 The brake pedal
3.2. Refitting the brake pedal

Page 9 of 21
Figure : B3FG0X5D
Check that the white shouldered rings (16) are present and complete.
Lubricate the rotation shaft with silicone-free grease that is compatible with plastic.
Refit :
 The brake pedal
 The shaft (15) of the brake pedal
 A nut 14 (new)
Check that the rod of the brake servo is correctly positioned in the fixing shaft of the brake pedal.
Reconnect the connection between the brake servo at the brake pedal .
4. Work on the clutch assistance spring

4.1. Removing the clutch assistance spring
Page 10 of 21
Figure : B3FG0X6D
N.B. : Mark the direction of fitting of the clutch servo spring (17). Mark them (if necessary).
Pass a cable tie between the legs of the coils of the clutch assistance spring (17).
Press the clutch pedal down half way.
Tighten the cable tie.
Remove the clutch assistance spring (17).
4.2. Refitting the clutch assistance spring
Lubricate the retention pins of the clutch assistance spring (17) with silicone-free grease (Pedal side and pedal
bracket side).
Refitting the clutch assistance spring (17).
Cut the cable tie.
Check the position and retention of the clutch assistance spring (17) on the pedal bracket.
Press the clutch pedal several times.
5. Work on the clutch pedal only

5.1. Removing the clutch pedal only
Remove :
 The clutch master cylinder/pedal connection
 The clutch pedal assistance spring

Page 11 of 21
Figure : B3FG0X7D
N.B. : Identify the fitting direction of the shaft (19) of the clutch pedal.
Remove :
 The nut (18)
 The shaft (19) of the clutch pedal
 The clutch pedal
5.2. Refitting the clutch pedal only

Page 12 of 21
Figure : B2BG03QD
Check that the white shouldered rings (20) are present and complete.
Lubricate the rotation shaft with silicone-free grease that is compatible with plastic.
Refit :
 The clutch pedal
 The shaft (19) of the clutch pedal
 The nut (18) (new)
Refit :
 The clutch pedal assistance spring (17)
 The clutch master cylinder/pedal connection (There are 2 assembly possibilities)
N.B. : Check that the master cylinder is still complete before refitting.
6. Work on the accelerator pedal only

6.1. Removing the accelerator pedal only
Unclip the harnesses next to the accelerator pedal.
Page 13 of 21
Figure : B3FG2FFD
Remove :
 The nuts (1) (2)
 The accelerator pedal
6.2. Refitting the accelerator pedal only
N.B. : When replacing a complete pedal bracket do not carry out this stage.
Page 14 of 21
Figure : B3FG2FGD
Refit :
 The accelerator pedal
 The new nuts (1), (2) In the order shown
Clip the electric harnesses next to the accelerator pedal.
7. Refitting the complete pedal bracket
Refit :
 The clutch switch (new) (if necessary)
 The pedal covers
Page 15 of 21
Figure : B2BG03RD
CAUTION : Follow the tightening sequence.
Fit the nuts (13) (new).

7.1. Clipping the connection of the brake system yoke
CAUTION : Check the direction of assembly from right to left.
Take a clip with a blue ring (11) (new).

Lubricate the clip.
Pass the shaft (12) through the brake servo yoke and the brake pedal.
Turn a quarter turn anticlockwise to lock the clip on the yoke.
N.B. : Check that the blue ring (11) protrudes.

Page 16 of 21
Figure : B3FG0XCD
CAUTION : Check that the brake pedal is locked on to the rod of the brake servo.
7.2. Clipping the ball joint connection of the braking system

Page 17 of 21
Figure : B3FG0XDD
CAUTION : Position the brake servo rod in the clipping system of the brake pedal.
Couple the rod of the brake servo to the brake pedal by pressing on the brake pedal.
CAUTION : Check that the brake pedal is locked on to the rod of the brake servo (Gently pull and push on
the pedal).
Clip the electric harnesses next to the pedal bracket.

7.3. Clipping the cylindrical connection between the master cylinder/pedal bracket (On
vehicles fitted with a manual gearbox)
Reconnect the connector (at "d").
CAUTION : Check that removing the master cylinder has caused no break or damage to the head of the
master cylinder (Lugs or petals).
Lightly grease the link between the hydraulic clutch control master cylinder and the pedal gear ; Using G7
grease.
Check of a master cylinder with cylindrical clipping system.
Figure : B2BY08DD
N.B. : If one or more lugs (22) or the U bracket (21) is broken, replace the master cylinder.
Page 18 of 21
Figure : B2BY06DD
N.B. : If the eye "h" of the rod (9) is worn, replace the master cylinder.
N.B. : If no anomalies are observed, reclip the master cylinder.

Page 19 of 21
Figure : B2BG03SD
Clip the rod (9) of the hydraulic clutch master cylinder (at "f").
Check the clipping of the rod (9) of the hydraulic clutch control master cylinder (at "f") (Pull-push).
7.4. Clipping the ball joint connection between the master cylinder/pedal bracket (On
vehicles fitted with a manual gearbox)
N.B. : Check of a master cylinder with ball joint clipping system.
Figure : B2BG03TD
N.B. : If the eye "j" of the rod (9) is worn, replace the master cylinder.
First assembly.
Page 20 of 21
Figure : B2BG03UD
Second assembly.
Figure : B2BG03VD
N.B. : Check that the locking clip (10) on the new hydraulic clutch control master cylinder is in the position
Page 21 of 21
above.
Figure : B2BG03WD
Clip the rod (9) of the hydraulic clutch master cylinder (at "k").
Check the clipping of the rod (9) of the hydraulic clutch control master cylinder (at "k") (Pull-push).
7.5. Refitting the complete pedal bracket (continued)
Refit the stop lamp switch (8).
Clip the electrical harness (at "e").
Connect the connectors (at "c", "d").
Refit :
 The accelerator pedal (3)
 The new nuts (1), (2)
Connect the connector (at "a").

Couple the steering column (7) to the tail of the power steering valve.
Refit :
 The (4) bolt
 The nut (5)

Page 1 of 4
DISMANTLING - RE-ASSEMBLY : TURBOCHARGER AIR COOLER
1. Removing
Remove the front bumper .
Figure : B1HG3YOD
Loosen the clips (1).

Remove the air unions (2).
Page 2 of 4
Figure : B1HG3YPD

Remove :
 The bolts (3)
 The turbocharging air cooler (5)
2. Refitting

Page 3 of 4
Figure : B1HG3YQD
Figure : B1HG3YRD
Page 4 of 4
Refit :
 The turbocharging air cooler (5)
 The bolts (3)
 The air unions (2)
Tighten the clips (1).

Position the bonnet release cable.
Refit the front bumper .

Page 1 of 5
DISMANTLING - RE-ASSEMBLY : COOLING FAN
1. Tooling

Figure : E5AI007T
2. Removing
Remove :

Page 2 of 5
Figure : B1GG18ED
Remove :
Figure : B1GG0EOD
Page 3 of 5
Unclip the electrical harness (at "a").

Disconnect the electrical harness connectors (at "b", "c", "d").
Figure : B1GG18FD

Lift the cooling fan (3) to disengage the fixing tabs from their housings (at "e", "f").
CAUTION : Do not damage the cooling radiator fins.
Remove the cooling fan assembly from under the vehicle.

Page 4 of 5
Figure : B1GG18GD
Remove :
 The (5) bolt
 The cooling fan electric control unit (6)
3. Refitting
Refit :
 The cooling fan electric control unit (6) on the cooling fan (3)
 The (5) bolt
Reintroduce the fixing tabs of the cooling fan (3) into their housings (at "e", "f").
Connect the electrical harness connectors (at "b", "c", "d").
Clip the electrical harness (at "a").
Refit :

Refit :
Page 5 of 5

Start the engine ; Wait for the fan assembly (3) to cut in then cut out.
Stop the engine.
Page 1 of 2
DISMANTLING - RE-ASSEMBLY : CYLINDER REFERENCE SENSOR
2. Removing
Figure : B1HG3Z9D

Remove :
 The (2) bolt
 Cylinder reference sensor (1)
3. Refitting
CAUTION : Replace the sensor seal.

Page 2 of 2
Refit :
 Cylinder reference sensor (1) (equipped with a new seal)
 The (2) bolt


Page 1 of 4
DISMANTLING - RE-ASSEMBLY : ENGINE COOLING RADIATOR
1. Tooling

Figure : E5AI007T
2. Removing
Remove :
 The cooling fan
CAUTION : Do not damage the fins of the engine cooling radiator ; Protect with thick cardboard.
Page 2 of 4
Figure : B1GG18HD

Remove :
 The bolts (1)
Page 3 of 4
Figure : B1GG18ID

 The pipe (3)
Uncouple the engine cooling radiator lower hose .

Remove the engine cooling radiator (5).
3. Refitting
Figure : B1GG18JD
Page 4 of 4
Figure : B1GG18KD
Couple the bottom hose of the engine cooling radiator.

Reposition the engine cooling radiator (5).
Couple up :
 The pipe (3)
Refit :
 The bolts (1)
 The cooling fan
Fill in the coolant circuit and bleed it..

4. Check
Start the engine.
Check the sealing of the cooling system.
Refit :
Page 1 of 6
DRAIN AND REFILL - REFILLING - BLEEDING : COOLING SYSTEM
CAUTION : Refer to the vehicle’s servicing schedule for the coolant checking interval.
Check the pH of the coolant ; Using reactive strips.
N.B. : The pH value of the coolant should be between 7 and 8.
Replace the coolant if the pH value is out of tolerance.
1. Tooling

[01102] Tool for filling the cooling system by vacuum
Figure : E5AB1CNT
[0173] Bayonet filling cylinder
Figure : E5AB1JNT
[0173-B] Adaptor / extension for bayonet filling

cylinder [0173]
Page 2 of 6
Figure : E5AI009T
[0173-C] blocking rod for filling cylinder
Figure : E5AI006T
[0173-2] Screw-fit filling cylinder (without extension)
Figure : E5AB1JOT

Page 3 of 6
Figure : E5AB0GVT
2. Draining the cooling system
CAUTION : The draining operation is carried out with the engine cold.

Remove :
 The de-aeration chamber plug (Carefully)
N.B. : Place a clean tray underneath the engine to recover the coolant.
Figure : B1GI00MD
Page 4 of 6
Uncouple the pipe (1) (at "a") ; Using tool [0165-2].

Open the bleed screws located on the coolant outlet housing and the heater pipe.
Allow the coolant to run out.
Drain the cylinder block (if necessary).
CAUTION : If the tool for filling the cooling system by vacuum [01102] is used, measure the quantity of
coolant drained.
3. Filling the cooling system
CAUTION : If the cooling system is contaminated, rinse with clean water.
CAUTION : Always use new coolant.
CAUTION : Each filling operation must always be followed by a cooling system degas operation.
3.1. Filling the cooling system by gravity

Connect the hose (1) (at "a") ; Using tool [0165-2].
N.B. : Refit new clips .
Figure : B1GI09DD
"A" : Fitting with filling cylinder offset ; Using the tools [0173], [0173-B], [0173-C].
"B" : Fitting with filling cylinder direct ; Using tool [0173-2].
Fit the filling cylinder , blank and adaptor assembly on the expansion chamber (according to assembly).
Page 5 of 6
Open the rod on the filling cylinder .

Slowly fill the cooling system with clean coolant.
Close the bleed screw when the fluid is flowing freely without any air bubbles.
N.B. : The filling cylinder should be filled to the 1 litre mark for correct bleeding of the heater matrix.
3.2. Filling using the tool for filling the cooling system by vacuum
Close the bleed screw .

Put the equipment for filling by vacuum [01102] in place on the expansion bottle .
CAUTION : To avoid entry of air into the circuit, provide for 20 % additional coolant.
Prepare a receptacle of coolant containing the quantity of fluid drained + 20 %.
N.B. : The receptacle must be positioned slightly lower than the equipment for filling by vacuum.
Figure : B1GI09CD
Place the cooling circuit under a vacuum to reach -0,9 bar (diagram "C") :
 Wait 10 seconds and check that the value obtained does not drop
 Fill the cooling circuit completely and wait for the return to 0 bar (diagram "D")
Page 6 of 6
N.B. : The quantity of coolant filled should correspond to the quantity of fluid drained.
Repeat the operation until the cooling system is full (if necessary).
CAUTION : Remove the equipment for filling by vacuum [01102] and rinse the assembly with clean water.
4. Degassing and checking the cooling system

Fit the charging cylinder , closer and adaptor assembly on the expansion bottle, in the case of draining using
the tool for filling by vacuum [01102].
Start the engine.
N.B. : The air conditioning control should not operate during this phase.
4.1. Toutes motorisations sauf norme de dépollution EURO 6

Keep the engine speed at 1500 - 2000 rpm, up to the second cooling cycle (cooling fan(s) cutting in and out).
CAUTION : Check that there are no coolant leaks.
4.2. Diesel engine Euro 6

The cutting in of the fan assembly for 10 seconds indicates the switch to after sales degas mode.
Accelerate to an engine speed above 2300 rpm for more than 10 seconds to switch to degas mode.
Maintain the engine speed at 2500 rpm until the fan assembly cuts in again.
4.3. Degassing and checking the cooling system (continued)
CAUTION : Check that the level of coolant in the filling cylinder is sufficient.
Stop the engine.
ESSENTIAL : Do not remove the filling cylinder while the engine is hot.
Leave the engine to cool.

Blank the filling cylinder using the blocking rod .
Remove the filling cylinder , plug and adapter assembly.
Check the coolant level when cold.
Top up the coolant to the "max" level (Cold).
CAUTION : Do not fill the system past the max mark.
Refit and tighten the cap on the header tank .
CAUTION : Check that the cooling system filler cap is locked (For bayonet cap).
Refit :
Page 1 of 6
DRAIN AND REFILL - REFILLING - BLEEDING : COOLING SYSTEM
CAUTION : Refer to the vehicle’s servicing schedule for the coolant checking interval.
Check the pH of the coolant ; Using reactive strips.
N.B. : The pH value of the coolant should be between 7 and 8.
Replace the coolant if the pH value is out of tolerance.
1. Tooling

[01102] Tool for filling the cooling system by vacuum
Figure : E5AB1CNT
[0173] Bayonet filling cylinder
Figure : E5AB1JNT
[0173-B] Adaptor / extension for bayonet filling

cylinder [0173]
Page 2 of 6
Figure : E5AI009T
[0173-C] blocking rod for filling cylinder
Figure : E5AI006T
[0173-2] Screw-fit filling cylinder (without extension)
Figure : E5AB1JOT

Page 3 of 6
Figure : E5AB0GVT
2. Draining the cooling system
CAUTION : The draining operation is carried out with the engine cold.

Remove :
 The de-aeration chamber plug (Carefully)
N.B. : Place a clean tray underneath the engine to recover the coolant.
Figure : B1GI00MD
Page 4 of 6
Uncouple the pipe (1) (at "a") ; Using tool [0165-2].

Open the bleed screws located on the coolant outlet housing and the heater pipe.
Allow the coolant to run out.
Drain the cylinder block (if necessary).
CAUTION : If the tool for filling the cooling system by vacuum [01102] is used, measure the quantity of
coolant drained.
3. Filling the cooling system
CAUTION : If the cooling system is contaminated, rinse with clean water.
CAUTION : Each filling operation must always be followed by a cooling system degas operation.
3.1. Filling the cooling system by gravity

Figure : B1GI09DD
"A" : Fitting with filling cylinder offset ; Using the tools [0173], [0173-B], [0173-C].
"B" : Fitting with filling cylinder direct ; Using tool [0173-2].
Fit the filling cylinder , blank and adaptor assembly on the expansion chamber (according to assembly).
Page 5 of 6

Slowly fill the cooling system with clean coolant.
Close the bleed screw when the fluid is flowing freely without any air bubbles.
N.B. : The filling cylinder should be filled to the 1 litre mark for correct bleeding of the heater matrix.
3.2. Filling using the tool for filling the cooling system by vacuum
Close the bleed screw .

Put the equipment for filling by vacuum [01102] in place on the expansion bottle .
CAUTION : To avoid entry of air into the circuit, provide for 20 % additional coolant.
Prepare a receptacle of coolant containing the quantity of fluid drained + 20 %.
N.B. : The receptacle must be positioned slightly lower than the equipment for filling by vacuum.
Figure : B1GI09CD
Place the cooling circuit under a vacuum to reach -0,9 bar (diagram "C") :
 Wait 10 seconds and check that the value obtained does not drop
 Fill the cooling circuit completely and wait for the return to 0 bar (diagram "D")
Page 6 of 6
N.B. : The quantity of coolant filled should correspond to the quantity of fluid drained.
Repeat the operation until the cooling system is full (if necessary).
CAUTION : Remove the equipment for filling by vacuum [01102] and rinse the assembly with clean water.
4. Degassing and checking the cooling system

Fit the charging cylinder , closer and adaptor assembly on the expansion bottle, in the case of draining using
the tool for filling by vacuum [01102].
Start the engine.
N.B. : The air conditioning control should not operate during this phase.
4.1. Toutes motorisations sauf norme de dépollution EURO 6

Keep the engine speed at 1500 - 2000 rpm, up to the second cooling cycle (cooling fan(s) cutting in and out).
CAUTION : Check that there are no coolant leaks.
4.2. Diesel engine Euro 6

The cutting in of the fan assembly for 10 seconds indicates the switch to after sales degas mode.
Accelerate to an engine speed above 2300 rpm for more than 10 seconds to switch to degas mode.
Maintain the engine speed at 2500 rpm until the fan assembly cuts in again.
4.3. Degassing and checking the cooling system (continued)
CAUTION : Check that the level of coolant in the filling cylinder is sufficient.
Stop the engine.
ESSENTIAL : Do not remove the filling cylinder while the engine is hot.
Leave the engine to cool.

Blank the filling cylinder using the blocking rod .
Remove the filling cylinder , plug and adapter assembly.
Check the coolant level when cold.
Top up the coolant to the "max" level (Cold).
CAUTION : Do not fill the system past the max mark.
Refit and tighten the cap on the header tank .
CAUTION : Check that the cooling system filler cap is locked (For bayonet cap).
Refit :
Page 1 of 5

TYPE
1. Foreword

pressure).


2.1. DV4C engine
Type of engine DV4C

Fuel Diesel
Maximum power 50 kW
2.2. dv6c engine

Fuel Diesel
Maximum power 66 kW
Page 2 of 5
2.3. DV6D engine

Fuel Diesel

Fuel Diesel
2.4. DV6E engine

Fuel Diesel Diesel
3. Oil capacity

Page 3 of 5
4. Oil pressure

1000 rpm 1,3 bar
4000 rpm 3,5 bars
6. timing belt
Figure : B1BB0VTD
Page 4 of 5
Designation "A"

out.
9. Boost pressure

2500 rpm 0,2 bar
4000 rpm 0,6 bar

10.1. Vacuum pump



150 Mbar 2 mm
200 Mbar 4 mm
250 Mbar 6 mm

Page 5 of 5
pressure circuit
Page 1 of 7
CHECK : PRESSURE, ENGINE END OF COMPRESSION
1. Tooling
Equipment :
 Compression tester ; Type MULLER 203 102-100
 Leakage tester ; Type FACOM 910.A
 Diesel engine adaptor ; Type FACOM 910.A6

Figure : E5AB0B8T
[0194-G] Dummy plug
Figure : E5AD01CT
[0194-W] flywheel stop

Page 2 of 7
Figure : E5AB0B7T
Ensure that the speed of engine rotation, driven by the starter, is correct (Minimal value : 250 rpm).
Check the engine oil level.
Check the condition of the air filter.
3. Removing
N.B. : Checking is carried out with the engine cold.

Remove - Isolate the pre-heat plugs supply wire .
Disconnect the connector of the diesel injectors.
4. Measuring the pressures at the end of compression

Page 3 of 7
Figure : B1BD036D
Remove the glow plugs (Cylinder by cylinder).

Fit the tool [0194-G]to cylinder N° 1 ; Tighten to 1 daN.m.
Connect the compressiometer to the tool [0194-G].
Operate the starter for 10 seconds.
Note down the value of the pressure in cylinder N° 1.
Apply the same method for cylinders no.2, no.3 and no.4 ; Using the tools [0194-G] and the compression
gauge.
N.B. : The maximum difference between any 2 cylinders should be 5 bars.
CAUTION : If the pressure values are low, check the condition of the air filter and the head gasket before
planning an engine overhaul.
5. Additional check : Compression loss measurement
CAUTION : Checking is carried out with the engine cold.
Place the vehicle on a lift.

Remove :
 The protective panel under the engine
 The lower torque reaction link (If necessary)
Page 4 of 7
Figure : B1CG02GD
Remove the upper timing cover .

Set the timing belt .
N.B. : Pin the camshaft pulley ; Using tool [0194-B].
Determine which cylinder is at end-of-compression phase ; Using the tools :

 [0194-G]
 Leakage tester
 Diesel engine adaptor
Page 5 of 7
Figure : B1BM0KAD
Draw some lines (at "a") on the casing and the pulley to know Top Dead Centre (TDC).
Figure : B1BD024D
Insert the flywheel stop [0194-W] (At "b" and "c").

Page 6 of 7
Tighten the bolt (1) .

Read the loss of compression ; Using the tools :
 [0194-G]
 Leakage tester
 Diesel engine adaptor
N.B. : (average value = 20%).
Connect :
 The diesel engine adaptor on the tool [0194-G]
 The leakage tester on the diesel engine adaptor
Connect the compressed air to the leakage tester and apply pressure (See instructions for use).
N.B. : A considerable compression leak results in noise, or causes air bubbles to rise in the cooling system .
If the value is incorrect, faulty parts can be located by locating the noise made by the passage of air.
Use the leakage tester and an autoscope (type FACOM DM.77) to determine the origin of the leak.
Determining the origin of the compression losses

Diagnostic Check the condition of the following components
Air leak : Air inlet manifold Inlet valves
Air leak : Exhaust manifold / Exhaust system Exhaust valves
Air leak : Oil filler cap / Oil gauge well pistons / Piston rings
Air bubbles : Cooling system Cylinder head gasket / Cylinder head
Carry out the same operation for the 3 other cylinders, each time rotating the crankshaft halfway by using the
pulley/casing identification marks.
N.B. : The order of ignition of the cylinders is 1 - 3 - 4 - 2.
6. Refitting
Remove :
 The compression gauge
 The tool [0194-G]
 The leakage tester
 The diesel engine adaptor
 The tool [0194-W]
 The tool [0194-B]
Reconnect the connectors of the injectors.
CAUTION : Ensure that the glow plugs are in good condition ; Replace any defective parts.
Refit :
Page 7 of 7
 The pre-heater plugs (/)

 The supply wire of the glow plugs
 The top timing cover
 The lower torque reaction link (If necessary)

Clear the faults in the memory ; Using the diagnostic equipment.
Page 1 of 1
FORCED REGENERATION : PARTICLE FILTER (TECHNICAL NOTE)
ESSENTIAL : Observe the safety and cleanliness recommendations.
ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust line.
1. Tooling
Diagnostic tool.
2. Forced regeneration of the particle emission filter
injection (HDi) engines.
ESSENTIAL : Where the recommended installation is not available, carry out the forced regeneration of the
particle filter outside the workshop, on an area of hard standing and remote from any inflammable materials.
Make the work area secure. Ensure that no one passes or stands behind the vehicle during the forced
regeneration. Put the vehicle in the "high" position (vehicle with hydraulic suspension). Check that there are
no aerosols or inflammable products inside the boot. Wear heat-resistant gloves. Connect the vehicle to an
approved gas extractor for this type of operation.
CAUTION : Check that the level of fuel in the tank is sufficient (minimum 20 litres).
CAUTION : Check the following fluid levels : Engine oil ; Coolant.
CAUTION : Check : The tightness of the turbocharging hoses (Risk of uncoupling).
ESSENTIAL : Remove the under-engine protection.
Start the engine and allow it to warm up (65°C minimum).

Connect the diagnostic tool on the vehicle’s central socket.
Carry out :
 Fault reading (Engine ECU)
 Fault clearing
Trigger the particle emission filter forced regeneration cycle ; Using the diagnostic equipment.
After the regeneration cycle : Allow the engine to run at idle, with the bonnet open, to help the cooling.
Stop the engine.
ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust line. Wear heat-resistant
gloves.

Page 1 of 1
FORCED REGENERATION : PARTICLE FILTER
WITH PARTICLE EMISSION FILTER
1. Tooling
Diagnostic tool.
2. Forced regeneration of the particle emission filter
injection (HDi) engines .
ESSENTIAL : Where the recommended installation is not available, carry out the forced regeneration of the
particle filter outside the workshop, on an area of hard standing and remote from any inflammable materials.
Make the work area secure. Ensure that no one passes or stands behind the vehicle during the forced
regeneration. Put the vehicle in the "high" position (vehicle with hydraulic suspension). Check that there are no
aerosols or inflammable products inside the boot. Wear heat-resistant gloves. Connect the vehicle to an
approved gas extractor for this type of operation.
CAUTION : Check that the level of fuel in the tank is sufficient (minimum 20 litres).
CAUTION : Check the following levels : Engine oil ; Coolant.
CAUTION : Check : The tightness of the turbocharging hoses (Risk of uncoupling).
ESSENTIAL : Remove the under-engine protection.
Start the engine and allow it to warm up (65°C minimum).

Connect the diagnostic tool on the vehicle’s central socket.
Carry out :
 Fault reading (Engine ECU )
 Fault clearing
Trigger the particle emission filter forced regeneration cycle ; Using the diagnostic equipment.
After the regeneration cycle : Allow the engine to run at idle, with the bonnet open, to help the cooling.
Stop the engine.
ESSENTIAL : Wait at least one hour before carrying out any work on the exhaust line. Wear heat-resistant
gloves.

Page 1 of 2
MODIFICATION : TURBOCHARGER LUBRICATION PIPE BANJO BOLT
Engines concerned :
 DV4 engines all types
 DV6 engines all types
Application : Immediate.
1. Modification
Replacement of the lower banjo bolt on the turbocharger lubricating pipe with a banjo bolt that has a
removable, larger-capacity, strainer filter.
1.1. Previous assembly
Figure : B1HT00PD
"a" Integral strainer filter.

(1) Turbocharger lubricating pipe.
(2) Banjo bolt with integral strainer filter.
(3) Seals.
1.2. New assembly
Page 2 of 2
Figure : B1HT00QD
(4) Banjo bolt .

(5) Seals.
(6) Removable strainer filter.
2. Repair
2.1. Previous assembly
If removing the turbocharger, replace the old banjo bolt (2) with the new banjo bolt (4) fitted with the removable
strainer filter (6).
Refit :
 The banjo bolt (4) fitted with the strainer filter (6)
 The seals (5) (new)
2.2. New assembly

If removing the turbocharger, check the condition of the strainer filter (6).
If the removable strainer filter (6) is clogged, replace the assembly of bolt (4) and removable strainer filter (6).
Refit :
 The banjo bolt (4) fitted with the strainer filter (6)
 The seals (5) (new)
3. Replacement Parts
From now on the Replacement Parts Department supplies only new parts.
Page 1 of 5
PROHIBITED OPERATIONS : DIRECT INJECTION SYSTEM (HDI)
1. Protection
CAUTION : Always plug the apertures straightaway after opening up the fuel circuit ; Using the specific
plugs kit.
2. Cleaning
CAUTION : The use of a "high pressure" cleaner is prohibited.
CAUTION : Do not use compressed air.
3. Fuel supply system

Recommended fuel : Diesel.
CAUTION : Do not use fuel other than diesel (Risk of destruction of the injection system and of the engine).
CAUTION : The addition of additives such as fuel circuit cleaner/remetalliser, is prohibited.
4. Electrical circuit
Exchanging an engine management ECU between two vehicles makes it impossible to start the vehicles.
CAUTION : Do not supply a diesel injector with 12 volts.
5. high pressure fuel pump

Page 2 of 5
Figure : B1BK3YMD
Do not separate the following components from the fuel high pressure pump (1) :
 High pressure outlet union (at "a") (malfunction)
 Sealing ring (at "b") (replacement parts not available)
5.2. BOSCH assembly

Page 3 of 5
Figure : B1BK3YND
Do not separate the ring seal from the high pressure fuel pump (1) (at "b") (No replacement parts).
6. Diesel injector
CAUTION : Cleaning operations using diesel and ultrasound are prohibited.

Page 4 of 5
Figure : B1BK3YPD
Do not separate the diesel injector body (2) from the following components :
 High pressure union (at "d") (malfunction)
 Diesel injector (at "e") (replacement parts not available)
 Electromagnetic element (at "c") (replacement parts not available)
Calamine cleaning on the injector nose is prohibited.

6.2. BOSCH assembly

Page 5 of 5
Figure : B1BK3YQD

Page 1 of 3
PROHIBITED OPERATIONS : HDI DIRECT INJECTION SYSTEM BOSCH
1. Protection
plugs kit.
2. Cleaning

CAUTION : Do not use fuel other than diesel (Risk of destruction of the injection system and of the engine).
CAUTION : The addition of additives such as fuel circuit cleaner/remetalliser, is prohibited.
Exchanging an engine management ECU between two vehicles makes it impossible to start the vehicles.

Page 2 of 3
Figure : B1BK3YND
Do not separate the ring seal from the high pressure fuel pump (1) (at "b") (No replacement parts).
6. Diesel injector

Page 3 of 3
Figure : B1BK3YQD

Page 1 of 3
PROHIBITED OPERATIONS : HDI DIRECT INJECTION SYSTEM CONTINENTAL-SIEMENS
1. Protection
plugs kit.
2. Cleaning

CAUTION : Do not use fuel other than diesel (Risk of destruction of the injection system and of the engine.
CAUTION : The addition of additives, such as fuel circuit cleaners/remetallisers, is forbidden.
Switching an injection ECU from one vehicle to another will make it impossible to start either vehicle.

Page 2 of 3
Figure : B1BK3XMD
Do not separate the following components from the fuel high pressure pump (1) :
 High pressure outlet union "a" (malfunction)
 Sealing ring "b" (replacement parts not available)
6. Diesel injector

Page 3 of 3
Figure : B1BK3XND
 Electromagnetic element "c" (replacement parts not available)
 High pressure union "d" (malfunction)
 Diesel injector "e" (replacement parts not available)

Page 1 of 4
PROHIBITED OPERATIONS : HDI DIRECT INJECTION SYSTEM DENSO
1. Protection
plugs kit.
2. Cleaning

CAUTION : Do not use fuel other than diesel (Risk of destruction of the injection system and of the engine.
CAUTION : The addition of additives, such as fuel circuit cleaners/remetallisers, is forbidden.
Switching an injection ECU from one vehicle to another will make it impossible to start either vehicle.
5. Fuel high pressure pump

Page 2 of 4
Figure : B1BK3YJD
Do not separate the following components from the high pressure fuel pump (1) :
 The high pressure outlet unions "a" and "c" (malfunction)
 The fuel supply union "b" (Malfunction)
 The fuel temperature sensor "d" (replacement parts not available)
6. Fuel high pressure common injection rail

Page 3 of 4
Figure : B1BK3YKD
Do not separate the following components from the fuel high pressure common injection rail (2) :
 The pressure sensor "e" (replacement parts not available)
 The pressure regulator "f" (replacement parts not available)
7. Diesel injector

Page 4 of 4
Figure : B1BK3YLD
Do not separate the following components from the diesel injector carrier (3) :
 Electromagnetic element "g" (replacement parts not available)
 Diesel injector "h" (replacement parts not available)
CAUTION : Calamine cleaning on the injector nose is prohibited.

Page 1 of 1
PROHIBITED OPERATIONS : PETROL DIRECT INJECTION SYSTEM THP
1. Cleaning
The use of a "high pressure" cleaner is prohibited.
Do not use compressed air.

Recommended fuel : Unleaded petrol.
Swapping of engine ECUs between two vehicles makes it impossible to start either vehicle.
It is forbidden to supply either one or all of the injectors with 12 volts.
Figure : B1BK3XBD
Heating unit (1) :

 Fuel high pressure regulation electrovalve (2) ; (No replacement parts)
 Oil excess pressure valve (3) ; (No replacement parts)
Page 1 of 4
REMOVAL - REFITTING : HIGH PRESSURE FUEL INJECTION COMMON RAIL
ESSENTIAL : Observe the safety and cleanliness instructions .
1. Parts which must always be replaced
Description Quantity
Fuel high pressure pipes 4
2. Tooling
Equipment : Approved leak detector.
Tool Reference Description

Figure : E5AB05LT
[1603] Tightening kit
Figure : E5AB0A3T
3. Removal
Page 2 of 4
Put the vehicle on a two post lift.

Remove the under-engine protection (according to equipment).
Take down :
 The engine style cover (according to equipment)
 The air cleaner housing
 The inlet air metering unit
 The complete fuel filter with its mounting
 The exhaust gas recycling module
 The air inlet pipe
Figure : B1HG1N0D
CAUTION : Clean the unions (1), (3) of the high pressure fuel pipes (2) prior to slackening (if necessary).
Slacken :
 The high pressure fuel pipe (2) unions (3)
 The high pressure fuel pipe (2) unions (1) ; Apply a counter-torque (at "a")
CAUTION : Blank all of the open high pressure fuel circuit openings ; Using the plugs [0194-T].
Remove the fuel high pressure pipes (2).

Page 3 of 4
Figure : B1HG12UD
Uncouple and move aside the hose (6).

Move the fuel high pressure common injection rail (4) aside.
Disconnect the fuel high pressure sensor (at "b").
Remove the fuel high pressure common injection rail (4).
4. Refitting
CAUTION : Observe the tightening torque values .
Present the fuel high pressure common injection rail (4).

Connect the fuel high pressure sensor (at "b").
Fit :
 The fuel high pressure common injection rail (4)
 The screws (5) (without tightening)
N.B. : Refitting the bolts (5) should allow the fuel high pressure common injection rail (4) a vertical freedom
of movement for tightening the unions (1), (3) of the high pressure fuel pipes (2).
CAUTION : Replace the high pressure fuel pipes (2) that have been removed.
Remove the tools[0194-T].

Page 4 of 4
Pre-assemble the following components in order to adjust their position :

 The connectors (3) on the fuel high pressure injection common rail (4)
 The union (1) on the diesel injector
 The union (3) on the high pressure fuel pump
Pre-tighten ; Using the tools [1603] :

 The high pressure fuel pipe (2) unions (3) ; Apply a counter-torque (at "a") (according to equipment)
Tighten ; Using the tools [1603] :

 The high pressure fuel pipe (2) unions (3) ; Apply a counter-torque (at "a") (according to equipment)
Tighten screws (5).

Fit :
 The complete fuel filter with its mounting
 The air cleaner housing
Fill and bleed the cooling system.

5. Leakage check
CAUTION : Spray the leak detector product on the diesel injector unions (1), (3) and on the fuel high
pressure common injection rail (4).

Spray the leak detector product on the fuel high pressure unions (1) and (3).
Allow the product to dry.
Start the engine.
Check that there are no fuel leaks.
Accelerate the engine to 3500 r.p.m.
Return the vehicle to its wheels.
Carry out a road test.
Switch off the engine.
Replace the faulty parts if necessary.
Refit the under-engine protection (according to equipment).
Page 1 of 10
REMOVAL - REFITTING : HIGH PRESSURE FUEL REGULATOR ON HIGH PRESSURE

FUEL PUMP
CAUTION : Before removing any high pressure fuel sensor or actuator, carry out the diagnostics using the
specific tools.
1. Tooling
Equipment :
 Degreasing product (type SODIMAC)
 Cleaning tray
 Brush
 Vacuum extractor
 Round end-piece

Figure : E5AB05LT
[1603-3] Torque wrench adjustable from 5 to 25 Nm
Figure : E5AB0PGT
Page 2 of 10
2. Location
2.1. BOSCH high pressure fuel pump
Figure : B1HG3ZTD
The fuel high pressure regulator is fixed on the fuel high pressure pump (1a) ; At the rear right of the engine (at
"a").
2.2. CONTINENTAL/SIEMENS high pressure fuel pump
Page 3 of 10
Figure : B1HG3ZUD
The fuel high pressure regulator is fixed on the fuel high pressure pump (1b) ; At the rear right of the engine (at
"a").
3. BOSCH high pressure fuel pump

3.1. Removal

Move aside the engine rear acoustic shield .
Page 4 of 10
Figure : B1HG3ZVD
Figure : B1HG3ZWD
"A" Direction of fitting marking.

Page 5 of 10
Mark the position "A" of the fuel high pressure regulator in relation to the fuel high-pressure pump.
Figure : B1HG3ZXD
CAUTION : Protect the surrounding area from any spray of fuel.
CAUTION : Do not use a cutting or abrasive tool ; The seal faces should not show any traces of impacts or
scratches.
CAUTION : Do not use the connector for leverage.
CAUTION : To prevent any risk of contaminating the fuel circuit, remove high-pressure fuel regulator (2a)
only once the new part is available.
Slacken screws (3) by a few turns.

Clean then vacuum the area surrounding the fuel high-pressure regulator (2a).
Remove fuel high-pressure regulator (2a) by hand, unscrewing by half-turns from right-to-left while pulling.
3.2. Refitting
CAUTION : Use a mirror to check that no contaminants are present in fuel high-pressure regulator housing
Page 6 of 10
(2a) ; Clean and vacuum if necessary.
CAUTION : Clean the gasket faces with an approved descaling product ; Do not use a cutting or abrasive
tool ; The seal faces should not show any traces of impacts or scratches.
CAUTION : Fit the new fuel high pressure regulator (2a) immediately, so as to avoid any risk of
contamination of the fuel circuit.
Figure : B1HG3ZYD
Lubricate the ring and the seals with vaseline (or similar).
CAUTION : Do not apply pressure to the connector.
Insert the fuel high pressure regulator (2a), rotating it carefully.


3.3. Learning
CAUTION : Following replacement of the fuel high pressure regulator (2a), perform its initialisation using the
diagnostic tool.
Use the diagnostic tool.

From the "spare parts" menu select the "high pressure fuel pump change" function and follow the programming
Page 7 of 10
procedure.
3.4. Checking
Start the engine, at the same time operating the fuel circuit priming pump.
N.B. : Operation requiring two people.

Stop the engine.
Refit :
 The engine rear acoustic shield
4. CONTINENTAL/SIEMENS high pressure fuel pump

4.1. Removal

Figure : B1HG3ZZD
CAUTION : Before uncoupling, clean all the unions on the low pressure circuit .
Page 8 of 10
Uncouple the fuel supply pipe (4) and move it aside.

Figure : B1HG400D
CAUTION : Protect the surrounding area from any spray of fuel.
scratches.
CAUTION : Do not use the connector for leverage.
CAUTION : To prevent any risk of contaminating the fuel circuit, remove high-pressure fuel regulator (2b)
only once the new part is available.
Slacken screws (3) by a few turns.

Clean then vacuum the area surrounding the fuel high-pressure regulator (2b).
Remove fuel high-pressure regulator (2b) by hand, unscrewing by half-turns from right-to-left while pulling.
4.2. Refitting

Page 9 of 10
CAUTION : Use a mirror to check that no contaminants are present in fuel high-pressure regulator housing
(2b) ; Clean and vacuum if necessary.
CAUTION : Fit the new fuel high pressure regulator (2b) immediately, so as to avoid any risk of
contamination of the fuel circuit.
Figure : B1HG401D
Lubricate the ring and the seals with vaseline (or similar).
CAUTION : Do not apply pressure to the connector.
Insert the fuel high pressure regulator (2b), rotating it carefully.

Connect the fuel supply pipe (4).

4.3. Learning
CAUTION : Following replacement of the fuel high pressure regulator (2b), perform its initialisation using the
diagnostic tool.
Page 10 of 10
Use the diagnostic tool.

From the "spare parts" menu select the "high pressure fuel pump change" function and follow the
programming procedure.
4.4. Checking
Start the engine, at the same time operating the fuel circuit priming pump.
N.B. : Operation requiring two people.

Stop the engine.
Refit :
Page 1 of 5
REMOVAL / REFITTING : COOLANT OUTLET HOUSING
ESSENTIAL : Ensure that the precautions relating to safety and cleanliness are adhered to .
1. Tooling
Tool Part number Description

[0165-2] Pliers for removing elastic clips
Figure : E5AI00HT
Figure : E5AB05LT
2. Removing
Put the vehicle on a two post lift.

Remove the protective plate from under the engine.
Remove :
Page 2 of 5

 The battery cover
 The engine management ECU cover
 The air inlet duct
 The air sleeve
Move aside the assembly of support and engine ECU .

Remove :
 The battery
 The battery tray (if necessary)
 The air filter casing (if necessary)
Figure : B1GG0ODD
Disconnect and move aside the union (1).

Disconnect and move aside the connectors (At "b").
Unclip the electrical harness support (3) (from below) (at "d") ; Using a small flat screwdriver.
Move aside the electrical harness (3) support .
Unclip the electrical harness (at "a", "c").
Page 3 of 5
Figure : B1GG0OGD
CAUTION : Do not use sharp tools or a hammer for any part removal-refitting operation. If the part is
dropped or receives a sharp knock, it must be replaced.
CAUTION : Plug the openings ; Using the tool [0194-T].

 The cooling hoses (4), (9) ; Using the tool [0165-2]
 The cooling hoses (6), (7)
 The screws (8)
 The thermostat (5)
3. Refitting

Page 4 of 5
Figure : B1GG0OJD
Fit the coolant outlet elbow (5) with a new joint.
CAUTION : Take care with the positioning of the seal in its location.
Refit and tighten the 4 screws (8).

Remove the tools[0194-T].
Recouple :
 The cooling hoses (6), (7)
 The cooling hoses (4), (9) ; Using the tool [0165-2]
Refit the electrical harness support (3) (at "d").

Clip the electrical harness (3) (At a", "c",).
Refit bolt (2).
Connect the union (1).
Fit :
 The air filter casing (if necessary)
 The battery tray (if necessary)
 The battery
Reposition the engine ECU assembly and its mounting .

Fit :
 The air sleeve
 The engine management ECU cover
 The battery cover
Page 5 of 5

Refit the protective panel under the engine.
Page 1 of 13
REMOVAL - REFITTING : CYLINDER HEAD ON THE VEHICLE
Cylinder head gasket 1
2. Tooling
Equipment :
 Dial gauge of FACOM type
 Magnetic dial gauge mounting of type FACOM 812.2
 Set of shims
 Rule for checking flatness
 Approved cleaning product
 Grease index "G12"

[0185] Cylinder head bolt socket
Figure : E5AG07DT
[0188-L] cylinder head releasing levers

Page 2 of 13
Figure : E5AB0AUT
3. Removal

Take down :
 The engine cover (according to equipment)
 The air filter housing
 The fuel filter
 The fuel filter support
 The glow plugs
 The fuel injectors
 The timing belt
 The catalytic converter and particle filter assembly
 The turbocharger
 The exhaust manifold
 The alternator and its support (On the left-hand side)
 The camshaft housing
 The thermostat

Page 3 of 13
Figure : B1DG0ACD
Take down :
 The upper fixing bolt (1) from the high-pressure fuel pump rear mounting
 The upper fixing bolt (2) from the high-pressure fuel pump front mounting
3.2. BOSCH assembly

Page 4 of 13
Figure : B1DG0H4D
Take down :
3.3. Common operations

Page 5 of 13
Figure : B1DG0ADD
CAUTION : Observe the slackening order .
Loosen the cylinder head screws (In the order shown) ; Using the tool [0185].
Remove the cylinder head bolts .
Detach the cylinder head ; Using the tools [0188-L].
Remove the cylinder head.
4. Check
CAUTION : Clean the gasket faces with an approved descaling product. Do not use a cutting or abrasive
tool ; The joint faces must not have any trace of knocks or scores.
4.1. Checking the flatness

Page 6 of 13
Figure : B1DG0PTD
Check the flatness of the cylinder head joint face ; Using a set of shims and a rule.
N.B. : Maximum permissible bow = 0,05 mm.
4.2. Checking valve protrusion

Page 7 of 13
Figure : B1DG0Q1D
Fit a dial gauge with a magnetic mounting on the cylinder head seal face.
Place the end of the dial gauge on the cylinder head joint face .
Set the dial gauge to zero.
Place the end of the dial gauge on the checking points (at "a").
Calculate the average of the 4 values measured.
Check the pocketing of the valves in relation to the cylinder head face :
 Exhaust valves : 0,6 mm
 Inlet valves : 0,7 mm
N.B. : If the value measured does not correspond to the values indicated, investigate the origin of the fault
(measurement error, handling error etc.).
Replace any defective parts (if necessary).

4.3. Checking the protrusion of the pistons
CAUTION : Remove the crankshaft immobilisation and locking tool.

Page 8 of 13
Figure : B1DG0Q2D
Fit a dial gauge with a magnetic mounting on the seal face of the cylinder block.
Place the end of the dial gauge on the upper surface of the cylinder block.
Set the dial gauge to zero.
Place the end of the dial gauge on one of the checking points (at "b").
Turn the crankshaft to the top dead centre of the piston without going beyond it.
Read the value .
Place the end of the dial gauge on one of the checking points (at "c").
Read the value .
Calculate the average of the 2 values measured.
CAUTION : The highest mean value determines the thickness of the cylinder head seal to be fitted.
Proceed in the same way for the other pistons.
N.B. : Max. height difference between pistons : 0,10 mm If the value measured does not correspond to the
values indicated, investigate the origin of the fault (measurement error, handling error etc.).
Replace any defective parts (if necessary).

4.4. Checking cylinder head bolts before re-use
Page 9 of 13
Figure : B1DP1ZZD
CAUTION : The dimension "A" must be less than 149 mm.
4.5. Choice of cylinder head gasket

Page 10 of 13
Figure : B1DG0EWD
"d" supplier identification.

"e" Thickness identification .
Piston protrusion (mm) Thickness No. of holes at "e"

0,685 to 0,734 1,35 mm (1)
0,533 to 0,634 1,25 mm (1 + 2)
0,635 to 0,684 1,30 mm (1 + 2 + 3)
0,735 to 0,784 1,40 mm (1 + 2 + 3 + 4)
0,785 to 0,886 1,45 mm (1 + 2 + 3 + 4 + 5)
5. Refitting
tool. The joint faces must not have any trace of knocks or scores.
Pass a tap into the cylinder head securing holes .
CAUTION : Refit the crankshaft pulley pin .

Page 11 of 13
Figure : B1DG0EXD
Check the presence of the centring pins (at "f").

Check that the crankshaft setting rod engages freely in its location.
CAUTION : Check the positioning of the gasket when refitting the cylinder head. Coat the threads and the
contact area under the bolt head with "G12" grease (Refer to the products catalogue).
Fit a new cylinder head gasket of a thickness determined in advance (observing the direction of fitting).
Refit the cylinder head.
Brush the threads of the cylinder head bolts.
Page 12 of 13
Figure : B1DP1Z3D
Fit the cylinder head bolts coated with "G12" on the threads and under the bolt heads.
Figure : B1DG0AJD
CAUTION : Follow the tightening sequence .

Page 13 of 13
Tighten the cylinder head bolts in the order indicated ; Using the tool [0185].
Fit :
 The exhaust manifold
 The thermostat
 The camshaft housing
 The alternator and its support
 The catalytic converter and particle filter assembly
 The timing belt
 The fuel injectors
 The glow plugs
 The fuel filter

Start the engine.
Check the absence of leaks.
Switch off the engine.
Fit :
 The engine undershield
Page 1 of 9
REMOVING - REFITTING : (BOSCH) HIGH PRESSURE FUEL PUMP
Designation Quantity
High pressure fuel supply pipe 1
2. Tooling
Equipment : Approved leak detector.

[0194-X] High-pressure pump pinion extractor
Figure : E5AB0APT
[0194-J] High-pressure pump pinion rotation stop
Figure : E5AB0AJT
[0194-A] High pressure pump lock pin

Page 2 of 9
Figure : E5AB08QT
[0194-T] The plugs kit
Figure : E5AB05LT
3. Removing

Remove :
 The air filter box
 The fuel filter complete
 The timing belt
Page 3 of 9
Figure : B1HG146D
Remove the tool [0194-A].

Immobilise the high pressure fuel pump pulley (1) (at "a") ; Using tool [0194-J].
Remove the nut (2).
Figure : B1HG147D
Page 4 of 9
Position the tool [0194-X] in the grooves of the high pressure fuel pump pulley (1) (at "b").
Manoeuvre the tool [0194-X] by hand clockwise until it is in place.
Tighten the bolt "c" of the tool [0194-X] to extract the pulley (1) from the shaft of the high pressure fuel pump.
Remove the tools [0194-X], [0194-J].
Figure : B1HG1IMD
Disconnect the connectors (at "d").
CAUTION : Before uncoupling, clean all the unions on the low pressure circuit (if necessary).
Uncouple and plug the fuel pipes (3), (4).
CAUTION : Clean the high pressure unions (6) before slackening.
CAUTION : Blank all the apertures of the fuel high pressure circuit ; Using the plugs [0194-T].
Slacken the unions of the high pressure fuel supply pipe (6).
Remove the fuel high pressure supply pipe (5).
Page 5 of 9
Figure : B1HG1CQD
Release and move aside the electrical harness (at "e").

Remove the bolts (7), (9).
Move aside the support (8) of the EGR by-pass butterfly control solenoid valve (10).
Figure : B1HG1IOD
Page 6 of 9
Remove :
 The bolts (11), (13), (14)
 The rear mounting (12) of the high pressure fuel pump
Figure : B1HG1IPD
Remove :
 The bolts (16)
 The fuel high pressure pump (15)
4. Refitting

Page 7 of 9
Figure : B1HG1IQD
Check the presence of the pin (17) on the shaft of the high pressure fuel pump (15).
Place the high pressure fuel pump (15) on its front mounting .
Refit :
 The bolts (16)
 The rear mounting (12) of the high pressure fuel pump (15)
 The bolts (11), (13), (14) ; (without tightening)
Tighten in the sequence :

 The (14) bolt
 The (13) bolt
 The (11) bolt
Refit :
 The support (8) of the EGR by-pass butterfly control electrovalve (10)
 The bolts (7, (9)
Clip the electrical harness (at "e").
CAUTION : Always replace the high pressure fuel pipes .
Remove the plugs [0194-T].

Refit the high pressure fuel supply pipe (5) (new).
Pre-tighten the high pressure fuel pipe (5) unions (6).
Tighten the high pressure fuel pipe (5) unions (6).
Couple up the fuel pipes (3), (4).
Connect the connectors (at "d").
Page 8 of 9
Refit the pulley (1) of the high pressure fuel pump (15).
Place tool [0194-J] in the mounting of the high pressure fuel pump .
Fit and tighten the nut (2).
Remove the tool [0194-J].
Figure : B1HG14DD
N.B. : When the timing is set : Pin the high pressure fuel pump (15) ; Using the pin [0194-A].
Refit :
 The timing belt
 The fuel filter complete
Reprime the fuel circuit ; Using a pump (Check through the hose that there are no air bubbles in the fuel
circuit).
CAUTION : Spray the leak detector product on the diesel injector unions and on the fuel high pressure
Page 9 of 9
common injection rail .

Spray the leak detector product on the high pressure fuel unions.
Allow the product to dry.
Start the engine.
Accelerate the engine to 3500 r.p.m.
Carry out a road test.
Stop the engine.
Replace any defective parts.
Page 1 of 4
REMOVING - REFITTING : ADDITIVE PUMP
1. Tooling

[0188-T] plugs kit
Figure : E5AB06IT
2. Removing
ESSENTIAL : Before carrying out any work, put on protective goggles and gloves which are resistant to
hydrocarbons.

Remove the protector under the body (At the rear right) (If necessary).
Page 2 of 4
Figure : B1KH00MD
CAUTION : Plug the openings ; Using tool [0188-T].
Disconnect :
 The connector (at "a")
 The tube (1)
Unclip the 3 fixings (3) (A quarter turn) ; By means of a screwdriver.

Remove : The lower housing (2) with the flexible reservoir.
Page 3 of 4
Figure : B1KH00ND
Detach the flexible reservoir (5) from the lower housing (2).
Uncouple and close the pipe (4).
Figure : B1KG07OD
Page 4 of 4
Remove the additive pump (6) from the lower housing (2).
3. Refitting
Refit the additive pump (6) in the lower housing (2).
Figure : B1KH00OD
Remove the blanking piece of the pipe (4).

Couple the pipe (4) to the flexible reservoir (5).
CAUTION : The flexible reservoir (5) must not protrude sideways from the lower housing (2) : Risk of
damage (On reassembly) .
Fit the flexible reservoir (5) in the lower housing (2).

Refit : The lower housing (2).
Clip the 3 fixings (3) (A quarter turn) .
Re-connect the connector ( as "a") .
Connect the pipe (1).
Refit the underbody protection (At the rear right) (If necessary).
CAUTION : Reset the additive counters to zero ; Using the diagnostic equipment.
Carry out the actuator test "filling of the pipe: additive pump - additive injector" ; Using a diagnostic tool.
Page 1 of 8
REMOVING - REFITTING : AIR FILTER UNIT
1. Filter element
1.1. Removing
Remove the engine cover (according to equipment).
Figure : B1HG1WPD
Remove :
 The 3 bolts (2)
 The retention clip (at "a")
 The air filter cover (1)
Page 2 of 8
Figure : B1HG1WSD
Remove the filter element (at "b").

1.2. Refitting
Refit :
 Filter element (at "b")
 The 3 bolts (2)
2. Air filter unit

2.1. Removing
Remove the engine cover (according to equipment).
Page 3 of 8
Figure : B1HG1WVD
Remove :
 The 3 bolts (2)
Remove the 2 fixing screws : Remote brake fluid reservoir (according to equipment).

Move aside the offset brake fluid reservoir (according to equipment).
Disconnect the connector (at "c").
Page 4 of 8
Figure : B1HG1WYD
Disconnect and move aside the connectors at "d".

Remove the bolt (3) from the air duct (4).
Uncouple the air duct (4) ( as "e").
CAUTION : Plug the turbocharger inlet.
Remove :
 The air duct (4)
Page 5 of 8
Figure : B1HG0Y2D
CAUTION : Uncouple and unclip the vacuum pipe (7) from the vacuum pump (6) ( as "f", "g", "h") (There is a
risk of the end piece breaking).
Uncouple the vacuum pump (6) ( as "f").

Release the vacuum pump (7) and move it aside ( as "g", "h") (according to equipment).
Page 6 of 8
Figure : B1HG0Y7D
Move the heat shield (8) aside ( as "j", "k").

Remove the mountings (10) (Recover the rubber bushes).
Release the air flow sensor and air filter housing assembly (9) and move it aside (following the arrow ).
Remove the air flow sensor and air filter housing assembly (9) (Recover the rubber bushes).
N.B. : Refit the offset brake fluid reservoir (according to equipment).
2.2. Refitting

Page 7 of 8
Figure : B1HG0Y4D
CAUTION : Before refitting : Check that the rubber bushes are present ( as "l", "n") ; Check that the pipe is
present ( as "m").
Figure : B1HG0YAD
Page 8 of 8
Move aside the offset brake fluid reservoir (according to equipment).

Reposition the air flow sensor and air filter housing assembly (9) (at "n") on the supports (11), (12) ( as "p",
"q").
Refit :
 The air flow sensor and air filter housing assembly (9)
 The mountings (10)
 The acoustic shield (8) ( as "j", "k")
Attach the vacuum pipe (7) ( as "g", "h") (according to equipment).

Couple up the vacuum pump (6) ( as "f").
Refit :
 The filter element ( as "b")
 The 3 bolts (2)
 The retention clip ( as "a")
Connect the connector ( as "c").
N.B. : Remove the blanking pieces on the turbocharger at the last moment.
Refit :
 The air duct (4); Couple up the air duct (4) ( as "e")
 The securing bolt (3)
 The offset brake fluid reservoir (according to equipment)
 The 2 securing bolts : Remote brake fluid reservoir (according to equipment)
Connect the connectors ( as "d").

Refit the engine cover (according to equipment).

Page 1 of 3
REMOVING - REFITTING : AIR INLET FLOW METER
Air inlet flow meter seal 1
2. Location
Figure : B1HG3X8D
The air flow meter (1) is located on the turbocharger air inlet duct.
3. Removing
Page 2 of 3
Figure : B1HG3X9D

Remove the air inlet duct (2).
Figure : B1HG3TOD
Page 3 of 3
Remove :
 The 2 bolts (3)
 The air flow meter(1)
4. Refitting
Figure : B1HG3TPD
CAUTION : Lubricate the seal (4).
Refit :
 Seal (4) (new)
 The air flow meter(1)
 The 2 bolts (3)
 The air inlet duct (2)
Reconnect the connector (at "a").
CAUTION : Delete the fault codes.

Page 1 of 5
REMOVING - REFITTING : AIR INLET PIPE
Seals (Air inlet pipe) 2
2. Location
Figure : B1HG3SVD
(1) Air inlet pipe.
3. Removing

Page 2 of 5
Figure : B1HG3STD

Uncouple connection (at "b").
Remove :
Page 3 of 5
Figure : B1HG3SUD
Disconnect and move aside the connector (at "c").

Remove :
 The bolts (3)
 The stud (2)
 The air inlet pipe (1)
Page 4 of 5
Figure : B1HG1FDD
Remove :
 The (5) bolt
 The turbocharging pressure sensor (4)
4. Refitting
CAUTION : At refitting, all the removed seals must be replaced with new seals.
Page 5 of 5
Figure : B1HG1FID
Always replace the seals (6), (7) ; Lightly lubricate the seals ; With engine oil .
Refit :
 The turbocharging pressure sensor (4)
 The (5) bolt
 The air inlet pipe (1)
 The stud (2)
 The bolts (3)
Reconnect the connector (at "c").

Refit :
Couple the union (at "b").

5. Checking
Start the engine.
Check the sealing of the assembly.
Page 1 of 5
REMOVING - REFITTING : CAMSHAFT POSITION SENSOR
1. Location
Figure : B1HG2CRD
(1) Camshaft position sensor.

(2a) The inlet air bypass unit (previous fitting).
(2b) The inlet air bypass unit (new fitting).
N.B. : The camshaft position sensor (1) is located under the air intake by-pass valve (2).
2. Removing

Remove :
 The inlet air bypass unit (2)
Page 2 of 5
Figure : B1HG10ND
Disconnect the connectors (at "a", "b").

Unclip the electrical harnesses (4) from the support (3).
Figure : B1HG1ISD
Page 3 of 5
Remove :
 The particle filter pressure sensor
 The 2 bolts (5)
 The electrical harnesses (4) support (3)
Figure : B1HG1ITD
Remove :
 The auxiliary equipment drive belt
 The dynamic roller tensioner (9)
 The alternator (8)
 The dipstick guide fixing bolt (7)
 The alternator (8) support (6)
Page 4 of 5
Figure : B1HG1IWD
Remove :
 The (10) bolt
 The camshaft position sensor (1)
3. Refitting
Refit :
 The (10) bolt
Move aside the electrical harness .

Refit :
 The alternator (8) support (6)
 The dipstick guide fixing bolt (7)
 The alternator (8)
 The auxiliary equipment drive belt
 The electrical harnesses (4) support (3)
 The 2 bolts (5)
 The particle filter pressure sensor
Clip the electrical harnesses (4) on the support (3).

Reconnect the connectors (at "a", "b").
Page 5 of 5
Refit :
 The inlet air bypass unit (2)
4. Checking
Start the engine.
Check the operation of the camshaft position sensor (1) ; Using the diagnostic equipment.
Page 1 of 9
REMOVING - REFITTING : CLUTCH MECHANISM
CAUTION : In order to improve the centering of the friction plate and to eliminate engine jerks, vibrations
and noise, compress the clutch mechanism when tightening the fixing bolts ; Using tool [0217].
CAUTION : Always replace the clutch bearing when replacing the clutch mechanism or the clutch disc.
1. Tooling

[0217] Clutch mechanism compression tool
[0217-A] Clutch mechanism compressor
[0217- Retaining rod (Ø 8 mm)

B2Z]
[0217-Cx] Clutch centring drift (According to

gearbox (see table below))
Figure : E5AG04PT
Clutch centring drift

Engine types [0217-C1] [0217-C2] [0217-C3Z] [0217-C4] [0217-C5Z] [0217-C6Z] [0217-C7]
DV4 BE MA/MAP
DV4 C MA/MAP
DV6 MCM BE MCP
DV6UC BE
DV6DU (M) BE
DV6C (M) MCP/ML MCP/MCM BE
DV6D (M) BE/MCP MCP
DV6E (M) BE
DW10 ML/BE MCP MCP
DW12 ML W6MBA
4B12 W5MBA
EB0 MA
EB2 MA/MAP
Page 2 of 9
EB2M MA/MAP
EC5 MA BE
EP3 - EP3C BE/MA/MAP
EP6 - EP6C (M) BE/MA/MCM/ MCP
EP6CDTR MCM
EP6DTS MCM
EP6CDT MCP MCM/MCP
EP6CDTX MCM
ES9 ML
ET3 MA/MAP
EW10 BE/MCP
EW12 BE
EW6 BE
EW7 BE
TU1 MA
TU3 MA/MAP
TU5 MA/MAP BE
SOFIM MLGU5 M40
PUMA MLGU5/MLGU6
1,3 DTE MTM/MTA
2. Removing
Remove the gearbox.
Page 3 of 9
Figure : B2BG01DD
Fit the tool [0217-CX].
Figure : B2BG08ED
Remove the 3 bolts (1) (Every second bolt).

Position the tools [0217-A] and [0217-B2Z] on the clutch mechanism (2).
CAUTION : Some engine flywheels have open threads. Do not let the threads of the 3 retaining rods
protrude when tightening; Risk of distortion of the secondary engine flywheel.
Screw in the 3 retaining rods [0217-B2Z] in place of the fixing screws (1) ; Do not let the threads protrude.
CAUTION : On compression of the clutch mechanism ; Do not go beyond the point of resistance when
tightening the central bolt of the tool [0217-A]. The tightening must not exceed 10 turns clockwise.
Compress the clutch mechanism (2) with the central bolt of tool [0217-A] (at "a").
Finish removing the remaining bolts (1).
Release the clutch mechanism (2) by moving the central bolt of the tool [0217-A] (at "a").
Remove tools [0217-A] and [0217-B2Z].
Remove :
 The clutch mechanism (2)
 The clutch disc
3. Preparation for removal

3.1. Checking - Cleaning
Page 4 of 9
Visually check :
 The flywheel face for damage or scores
 The flywheel for wear
 The condition of the starter ring gear
If there is oil in the clutch mechanism (2) :

 Check the condition of the crankshaft ring seal
 Check the condition of the input shaft ring seal
CAUTION : Do not reuse a clutch disc the hub of which bears traces of corrosion or grease.
Remove corrosion and grease from the following parts ; Using a degreaser Index "N1" :
 The clutch housing
 The primary shaft
 The clutch bearing guide (according to equipment)
 The clutch fork (according to equipment)
N.B. : In the case of significant corrosion, use a metal brush without damaging the parts.
3.2. Greasing
CAUTION : The greasing stage must be observed strictly.
Figure : B2BG08FD
Page 5 of 9
CAUTION : Protect the interior of the clutch housing from splashes of grease.
Vehicles equipped with a gearbox that has a mechanical clutch bearing Spray a little grease MOLYCOTE G-
RAPID PLUS (aerosol) on the splines of the primary shaft and on the clutch bearing guide tube (at "b"
and "c").
Vehicles equipped with a gearbox that has a hydraulic clutch bearing : Grease the splines of the primary
shaft with MOLYCOTE G-RAPID PLUS (at "c").
CAUTION : Do not soil the lining of the clutch disc ; Risk of slipping.
Put the clutch disc (3) in place on the grooved shaft and carry out several translational movements to distribute
the grease.
Remove the clutch disc .
Figure : B2BG08GD
CAUTION : An excess of grease will contaminate the clutch friction plate and cause noise in neutral, slipping
or juddering of the clutch.
"d" : Traces of grease present on a clutch disc contaminated as a result of a surplus of grease.
"e" : Traces of greases present on a clutch housing contaminated as a result of a surplus of grease.
CAUTION : Clean off all traces of grease which may splash onto the friction plate during rotation.
Remove the surplus grease on the top of the grooves and the end of the input shaft using a cloth.
N.B. : The film of grease applied to the rotating components must be as thin as possible to avoid splashes.
Page 6 of 9
4. Refitting
CAUTION : Observe the tightening torque values.
Figure : B2BG08HD
CAUTION : When refitting, place the face of the clutch disc, where the N° PSA 96 XXX XXX 80 is marked,
gearbox end.
Refit the clutch disc (3).

Centre the clutch disc (3) ; Using tool [0217-CX].
Page 7 of 9
Figure : B2BM01JD
CAUTION : The clutch mechanism and disc are paired at the factory and cannot be replaced separately.
CAUTION : Any fitting of a clutch mechanism with automatic free play adjustment (whether new or re-used)
must compulsorily be performed using the compression tool [0217].
Refit the clutch mechanism (2).
N.B. : Do not remove the tool [0217-CX].

Page 8 of 9
Figure : B2BG08ID
CAUTION : No resetting of the clutch wear adjustment is permitted.
Tighten the 3 bolts (1) by hand.
Page 9 of 9
Figure : B2BG08JD
Gradually compress the clutch mechanism (2) until it is in contact with the primary engine flywheel (at "f").
Check that there is no friction :
 Apply slight force to the clutch disc (3) to check the rotation ; Using a thin, flat screwdriver
 If rotation is difficult or impossible, continue the clutch mechanism compression operation very gradually
until it rotates (1/8 th turn on the bolt of the tool [0217-B2Z])
If it is not possible to check that there is no friction (clutch disc inaccessible), tighten the central bolt of the tool
[0217-B2Z] by another two turns to maximum.
Tighten the 3 bolts (1) to the specified torque.
Unscrew the centre bolt of the tool [0217-A] (at "a") by several turns to detension the clutch mechanism (2).
Remove tools [0217-A], [0217-B2Z] and [0217-CX].
Refit and tighten the remaining 3 bolts (1).
Refit the gearbox.
Page 1 of 6
REMOVING - REFITTING : COOLANT INLET MANIFOLD
1. Tooling

Figure : E5AI007T
2. Removing
Remove the under engine protection (according to equipment).
Remove :

Remove :
 The service battery
Remove :
Page 2 of 6
Figure : B1GG0H1D

Uncouple the hose (1) from the coolant outlet housing (at "b").
Figure : B1GG0H2D
Page 3 of 6
Remove :
 The nuts (2)
 The acoustic shield support (3)
 The nut (4)
 The nut (5)
Disconnect the connector (at "e").

Unclip the harness (at "c", "d", "f").
Figure : B1GG0H3D

Move aside the electrovalve support (7) with the electrovalve .
Page 4 of 6
Figure : B1GG0J8D
Remove the collar (10) ; Using tool [0165-2].

Uncouple the pipe (9).
Move aside the coolant inlet manifold (11) from the EGR valve (at "g").
Move aside the coolant inlet manifold (11) from the cylinder block (at "h").
Remove the coolant inlet manifold (11) (From below).
3. Refitting
3.1. Preparation
Page 5 of 6
Figure : B1GG0J9D
Refit the seals (13), (14), (15) (new).

Lubricate the seals (13), (14), (15) ; With engine oil .
3.2. Refitting
 Engine
 Wheel
CAUTION : Take care with the positioning of the fuel bleed pipe.
Refit the water inlet manifold (11) (From below).

Position the coolant inlet manifold (11) on the cylinder block (at "h").
Position the coolant inlet manifold (11) on the EGR valve (at "g").
Refit bolt (12).
Refit the clip (10) ; Using tool [0165-2].
Position the electrovalve support (7) with the electrovalve.
Position the electrical harness (6).
Clip the harness (at "c", "d", "f").
Connect the connector (at "e").
Refit :
 The nut (5)
 The nut (4)
Page 6 of 6

 The nuts (2)
Couple the hose (1) to the coolant outlet housing (at "b").

Refit :
Refit :
Put the engine ECU and support assembly in place.

Refit :
4. Check
Start the engine.
Keep the engine speed at 2000 rpm, up to the first cooling cycle.
Stop the engine.
5. Refitting (continued)
Page 1 of 2
REMOVING - REFITTING : COOLANT PUMP
Coolant pump seal 1
2. Removing
Place the vehicle on a two-post lift.

Drain the engine cooling circuit.
Remove :
 The ancillary drive belt
 The timing belt
Figure : B1GM0APD
Page 2 of 2
Remove :
 The coolant pump (2) bolts (1) (In the order shown)
 Coolant pump (2)
 The seal
3. Refitting
CAUTION : Replace systematically the water pump seal.
CAUTION : The seal faces should not show any traces of impacts or scratches.
Fit :
 Coolant pump (2) (equipped with a new seal)
 The coolant pump (2) bolts (1)
 The timing belt
 The ancillary drive belt

Page 1 of 3
REMOVING - REFITTING : ELECTRICALLY-CONTROLLED EXHAUST GAS RECYCLING

VALVE
1. Precaution
Figure : B1KG0C8D
(1) EGR module .

(1a) heat exchanger.
(1b) support .
(2) Electrically-controlled exhaust gas recycling valve.
CAUTION : Do not separate the heat exchanger (1a) from the support (1b).
N.B. : The exhaust gas recycling module is assembled at the factory with the aid of a template. Assembling it
without using a template would create positioning tensions on the cylinder head, adversely affecting the
fixings and the sealings of the module (1).
2. Removing
Remove :
Page 2 of 3

Uncouple : The vacuum pipe of the vacuum pump.
Figure : B1KG0CBD
scratches.
Disconnect and move aside the connector ( as "a").

Lever with a screwdriver ( as "b" et "c").
Remove : The electric EGR valve (2).
3. Refitting
Page 3 of 3
Figure : B1KG0CED
Replace the seal ( as "d").

Refit :
 The electric EGR valve (2)
 The bolts (3)

Refit :
Couple up : The vacuum pipe of the vacuum pump.

Initialise the electric EGR valve (2) ; Using the diagnostic equipment.
Page 1 of 11
REMOVING - REFITTING : ENGINE RING SEALS
N.B. : The sealing rings provide the seal on the crankshaft on the oil pump side and on the flywheel side, as
well as on the end of the camshaft on the timing pinion side ; The sealing rings consist of a preformed Teflon
lip.
N.B. : When the engine is started, the oil pressure exerts a force on the lip which makes contact leaving a
film of oil on the shaft thus creating sealing.
CAUTION : Check the absence of any mark on the bearings of the sealing ring.
CAUTION : If the lip is deformed, replace the sealing ring.
N.B. : The seal must remain on its support during fitting ; If handling, put the ring back on its support and
leave the assembly in position for 30 minutes before refitting.

1.1. Camshaft oil seal
Camshaft pulley screw 1
Camshaft oil seal 1
1.2. Oil pump ring seal
Oil pump ring seal 1
1.3. Crankshaft ring seal
Flywheel bolts 6
Crankshaft ring seal (on the gearbox side) 1
2. Tooling

Camshaft ring seal fitting drift
[0194-K]
Page 2 of 11
Figure : E5AG063T
Crankshaft ring seal fitting drift (Timing gear

[0194-L] side)
Figure : E5AG064T
Crankshaft ring seal fitting drift (Flywheel

[0194-M] side)
Figure : E5AG065T
[0132-AA] Immobilisation tool

Page 3 of 11
Figure : E5AB08VT
4. Camshaft oil seal
4.1. Removing
Remove the timing belt .
Page 4 of 11
Figure : B1BG16ED
CAUTION : Remove the camshaft setting peg .
Immobilise the camshaft pulley (1) ; Using tool [0132-AA].

Remove :
 The (2) bolt
 The camshaft pulley (1)
Figure : B1BG16FD
CAUTION : Check the absence of any mark on the bearings of the sealing ring (3).
Drill a hole 3,5 mm in diameter in the ring seal (3) (at "a").

Screw a bolt into the hole (at "a").
Remove the seal/screw assembly using pliers.
4.2. Refitting

Page 5 of 11
Figure : B1BG16GD
CAUTION : Always replace the ring seal (3).
CAUTION : Wipe away all the oil in the sealing ring housing and make sure that there are no marks on the
sealing ring.
Fit the sleeve equipped with its sealing ring (3) (new) onto the camshaft.
Fit the tool [0194-K].
Tighten the bolt of the tool [0194-K] until the surface of the tool comes into contact with the surface of the
camshaft carrier .
Remove the tool [0194-K].
CAUTION : Systematically replace the screw (2).
Refit :
 The (2) bolt (new) ; Using tool [0132-AA]
 The timing belt
5. Oil pump ring seal

5.1. Removing
Remove :
 The timing belt
 The crankshaft pulley
 The crankshaft pulley cotter pin
Page 6 of 11
Figure : B1BG16HD
Drill a hole 3,5 mm in diameter in the ring seal (4) (at "b").

Screw a bolt into the hole (at "b").
5.2. Refitting

Page 7 of 11
Figure : B1BG16ID
sealing ring.
Position the sleeve fitted with its new ring seal (4) on the crankshaft .
Put the tool [0194-L] and the crankshaft pulley bolt in place.
Tighten the crankshaft pulley bolt until the surface of the tool [0194-L] comes into contact with the surface of
the oil pump .
Remove the tool [0194-L].
Refit :
 The timing belt
6. Crankshaft seal ring

6.1. Removing
Remove :
 The gearbox
 The clutch mechanism
Page 8 of 11
Figure : B1CG02QD
Remove :
 The bolts (5)
 The flywheel (6)
Figure : B1BG16JD
Page 9 of 11
Drill a hole 3,5 mm in diameter in the ring seal (7) (at "c").

Screw a bolt into the hole (at "c").
6.2. Refitting
Figure : B1BG0PUD
Put the lower part of the tool [0194-M] in place on the flywheel .
sealing ring.
Page 10 of 11
Figure : B1BG16LD
Fit the sleeve equipped with its sealing ring (7) (new) onto the lower part of the tool [0194-M].
Tighten the bolt of the tool [0194-M] until the surface of the tool comes into contact with the surface of the
cylinder block .
Remove the tool [0194-M].
Page 11 of 11
Figure : B1CP0M2D
CAUTION : Always replace the bolts (5).
Refit :
 The bolts (5)
CAUTION : Observe the order of tightening of the bolts (5).
Check that the 3 clutch centring pins are present (at "d") (Manual gearbox ).
Refit :
 The gearbox
Refit the engine style cover .

Page 1 of 6
REMOVING - REFITTING : EXHAUST GAS PRESSURE SENSOR PRESSURE TAKE-OFF
1. Tooling

[0188-T] plugs kit HDI
Figure : E5AB06IT
[4145-T] pliers for removing "clic" clips
Figure : E5AB08PT
2. Removing
ESSENTIAL : Engine hot : Wait at least one hour before carrying out any work on the exhaust line.
Lift and support the vehicle with the wheels free.

Page 2 of 6
Figure : B1KG069D

Unclip the support ("b").
Move aside the exhaust gas pressure sensor (2).
CAUTION : Note the position of the pipes (3) on the exhaust gas pressure sensor (2).
Remove the "clic" clips (at "c") ; Using tool [4145-T].

Disconnect the pipes (3) from the exhaust gas differential pressure sensor (2).
Blank off the pipes (3) ; Using the set of plugs [0188-T].
Remove the exhaust gas pressure sensor (2).
Page 3 of 6
Figure : B1KG06AD
Move aside the electrical harness "e" from the location (at "d").
Remove :
 The (4) bolt
 The securing clip 6
 The pipe (5) (From below the vehicle)
Page 4 of 6
Figure : B1KG06BD
Remove :
 The pipe (9)
 The pressure take-off pipe (7) (upstream)
 The pressure take-off pipe (8) (downstream)
Page 5 of 6
Figure : B1KG06CD
Remove the "clic" clips (10) ; Using tool [4145-T].
CAUTION : Note the orientation and pairing of the flexible pressure take-off pipes (3) on the pipes (7), (8)
before disconnecting them.
Disconnect the flexible pressure take-off pipes (3) from the metal pressure take-off pipes (7), (8) (Metal pipes).
Plug the pressure take-off pipes and the pressure take-off ducts of the pre-catalyst/particle emission filter
assembly ; Using the set of plugs [0188-T].
3. Refitting
CAUTION : Replace the removed clic clips with new ones.
Remove the plugs [0188-T] from the pressure take-off pipes and from the pressure take-off ducts of the pre-
catalyst/particle emission filter assembly.
CAUTION : Connect the flexible pressure take-off pipes (3) onto the pipes (7), (8) in the orientation and
pairing noted when they were removed.
Refit :
 The 2 new "click-on" clips (10) ; Using tool [4145-T]
 The pressure take-off pipe (8) (downstream)
 The pressure take-off pipe (7) (upstream)
Tighten unions (9) and (5).

Refit :
 The securing clip 6
 The (4) bolt
 The electrical harness "e" (at "d")
Reposition the pipes (3) on the support "b" without straining them before connecting them to the exhaust gas
pressure sensor (2).
Connect the pipes (3) to the exhaust gas pressure sensor (2) in the places noted when they were removed.
Refit :
 The 2 new "click-on" clips (at "c") ; Using tool [4145-T]
 The exhaust gas pressure sensor (2)
Clip the support "b".

Refit bolt (1).
Reconnect the connector (at "a").
4. Check
Start the engine.
Check that there are no exhaust gas leaks.
Page 6 of 6
Stop the engine.
5. Additional operation
Page 1 of 4
REMOVING - REFITTING : EXHAUST MANIFOLD
Exhaust manifold fixing nuts 10
The exhaust manifold gasket 1
2. Removing
Remove :
 The particle filter/catalytic converter assembly
Figure : B1JG04JD
Remove :
 The dipstick guide
 The mounting nuts (3)
Page 2 of 4
Pull away the heat shield (2) (at "a").
Figure : B1JG08TD
Remove :
 The fixing nuts (4) of the exhaust manifold (5)
 The 8 spacers
 The exhaust manifold (5)
Page 3 of 4
Figure : B1JG04LD
N.B. : The exhaust manifold seal (6) is solid with the heat shield (2).
Remove :
 The 10 studs (7)
 The heat shield (2) (including the seal (6))
3. Refitting
CAUTION : Clean the sealing faces with the approved product ; Do not use a cutting or abrasive tool ; The
seal faces should not show any traces of impacts or scratches.
CAUTION : Always replace the 10 exhaust manifold (5) fixing nuts (4) and seal.
Refit :
 The heat shield (2) (new)
 The 10 studs (7)
 The exhaust manifold (5)
Page 4 of 4
Figure : B1JP0A5D
Refit :
 The 8 spacers
 The 10 mounting nuts (4) (Tighten in the sequence indicated)
 The mounting nuts (3)
 The dipstick guide
 The particle filter/catalytic converter assembly

Page 1 of 10
REMOVING - REFITTING : EXHAUST SYSTEM
1. Tooling
tool Reference Description

[0162] Pipe cutting grips for one-part exhaust
system
Figure : E5AG02NT
[0193-B] Pliers for removing exhaust clips
Figure : E5AG06ZT
2. Precautions to be taken
Page 2 of 10
Figure : B1JG05SD
The exhaust line must never be suspended, without support, from the hose (front).
The front flexible pipe should be protected against any external mechanical interference.
The front flexible pipe should not come into contact with any corrosive products.
Do not deform the front hose by more than 20° angular ("X"), 20 mm axial and 25 mm torsion ("Y").
The front hose cannot withstand any deformation ("X" and "Y") when it is in place.
CAUTION : Failure to observe these precautions results in a reduction of the service life of the front hose.
The uncoupling or removal of the exhaust line is essential for operations requiring lifting of the power train.
3. Exhaust rear silencer

3.1. Removing
Page 3 of 10
Figure : B1JM022D
N.B. : A factory fitted exhaust system is single part; the cutting zone is located at "a" (marked by 4 punch
marks at 90°).
N.B. : The cutting zone of the exhaust pipe is close to the rear crossmember and marked by 4 circular
indentations "a".
N.B. : Make a mark "b" on the exhaust pipe (on the catalytic converter end) to the dimension "A" = 40 mm.
N.B. : The mark "b" is for positioning the sleeve when refitting.
Page 4 of 10
Figure : B1JG0Q9D
"B" Rear left exhaust flexible mounting .

"C" Rear right exhaust flexible mounting .
Support the exhaust silencer ; Using a component lift.
Remove the nuts (1), (2) from the exhaust flexible mountings.
Page 5 of 10
Figure : B1JG0QAD
Cut off the exhaust pipe (at "a") ; Using tool [0162].

Suspend the intermediate pipe from the body.
Remove the exhaust rear silencer .
3.2. Refitting
Figure : B1JG0QBD
CAUTION : Replace the faulty exhaust flexible mountings.
Refit the rear exhaust silencer.

Fit the sleeve (3) appropriate to the diameter of the exhaust pipe.
So that the exhaust system is not stressed when the vehicle operates, fit the silencers so that the hangers are
offset by dimension .
Fit the nuts (1), (2) (Exhaust hangers).
Orient the sleeve (3) (In accordance with the illustration above).
CAUTION : So that the exhaust system is not stressed when the vehicle operates, fit the silencers so that
the hangers are offset by dimension "D" = 12 mm (Towards the front of the vehicle).
Tighten the 2 nuts (4).

4. Intermediate exhaust line

Page 6 of 10
Figure : B1JM022D
N.B. : A factory fitted exhaust system is single part; the cutting zone is located at "a" (marked by 4 punch
marks at 90°).
N.B. : The cutting zone of the exhaust pipe is close to the rear crossmember and marked by 4 circular
indentations "a".
N.B. : Make a mark "b" on the exhaust pipe (on the catalytic converter end) to the dimension "A" = 40 mm.
N.B. : The mark "b" is for positioning the sleeve when refitting.
Page 7 of 10
Figure : B1JG0Q9D
"B" Rear left exhaust flexible mounting .

"C" Rear right exhaust flexible mounting .
Support the exhaust silencer ; Using a component lift.
Remove the nuts (1), (2) from the exhaust flexible mountings.
Page 8 of 10
Figure : B1JG0QAD
Cut off the exhaust pipe (at "a") ; Using tool [0162].

Suspend the intermediate pipe from the body.
Remove the exhaust rear silencer .
Figure : B1JG0QDD
Remove the collar (5) ; Using tool [0193-B].

Page 9 of 10
Figure : B1JG0QED
CAUTION : Support the exhaust line ; Using a component lift.
Remove the nut (6) (Exhaust front hangers).
5. Refitting

Page 10 of 10
Figure : B1JG0QBD
CAUTION : Support the exhaust line ; Using a component lift.
Refit :
 The intermediate pipe
 The fixing (6) (Exhaust front hangers)
 The sleeve (3) appropriate to the diameter of the exhaust pipe
So that the exhaust system is not stressed when the vehicle operates, fit the silencers so that the hangers are
offset by dimension .
Fit the nuts (1), (2) (Exhaust hangers).
Orient the sleeve (3) (In accordance with the illustration above).
CAUTION : So that the exhaust system is not stressed when the vehicle operates, fit the silencers so that
the hangers are offset by dimension "D" = 12 mm (Towards the front of the vehicle).
Tighten the 2 nuts (4).

Refit the clip (5) ; Using tool [0193-B].
Page 1 of 8
REMOVING - REFITTING : FUEL FILTER
1. Tooling
Equipment :
 Degreasing product (Type SODIMAC)
 Cleaning tray
 Brush

Figure : E5AB05LT
[1520-B] plugs for click-fit unions

[5705-T]
Figure : E5AB0VRT
2. Removing
Page 2 of 8

Remove :
2.1. Fuel filter
Figure : B1HG1NXD
Place the tray underneath the fuel bleed pipe outlet (When coupling the tool , protect yourself using a cloth to
prevent any splashes of fuel).
Disconnect and move aside the connector ( as "b") (Water in diesel fuel detector) (according to equipment).
N.B. : The water in diesel detector acts as a lock for the water bleed screw (2) on the fuel filter.
Unlock : The water bleed screw (2) (Clockwise) ; Raise the water bleed screw (2) fully (In the direction of the
arrow ( as "c")).
Allow the liquid to flow out.
Disconnect and move aside the connector ( as "a") (Fuel filter heater).
Clean the unions (1), (3a), (3b) ; Using the degreasing product, the brush and the cleaning tray.
Uncouple the connectors (1), (3a), (3b).
Page 3 of 8
Figure : B1HG14SD
CAUTION : Plug the openings when a union is uncoupled ; Using the tools [1520-B / 5705-T].
CAUTION : Close the pipes on the fuel filter ; Using the tools [0194-T].
Slacken the bolts (4) (captive screws).
CAUTION : With great care, vertically disengage the fuel filter (5) from the fuel filter support (Risk of
damage).
Remove the fuel filter (5).

2.2. Fuel filter element
Page 4 of 8
Figure : B1HG1NZD
CAUTION : The water in diesel fuel detector, the priming pump and the diesel fuel heater are integral with
the cover (5a) of the fuel filter (5). If there is any anomaly, replace the fuel filter (5) cover (5a) in its entirety.
Check that the centring ring is present( as "d").
CAUTION : Place the cover (5a) of the fuel filter (5) upside down, in a spot that is secure and clean.
Remove :
 The bolts (6)
 The filter element (5b) from the cover (5a) of the fuel filter (5) (Fuel filter heater)
3. Refitting
CAUTION : Open the bag containing the fuel filter (5) just prior to refitting.
3.1. Fuel filter element

Page 5 of 8
Figure : B1HG1O2D
N.B. : Check the condition of the seal ( as "e") ; If there is any anomaly, replace the fuel filter (5) cover (5a) in
its entirety.
Unlock : The water bleed screw (2) (High position).

Refit the seal ( as "g") (New).
CAUTION : Be careful when positioning of the cover (5a) of the fuel filter (5) (Locating lugs ( as "f")).
Position the cover (5a) of the fuel filter (5) on the filter element (5b) (Locating lugs ( as "f")).
Refit the screws (6) without tightening.
Push the water bleed screw (2) fully ; Lock : The water bleed screw (2) (Anti-clockwise).
Retighten the bolts (6) to the correct torque.
3.2. Fuel filter
Page 6 of 8
Figure : B1HG1O5D
Check that the centring ring is present( as "d").
CAUTION : Very carefully, vertically position the fuel filter (5) in the slot "h" in the support (7) of the fuel filter
(5) (Risk of damage).
Fit the fuel filter assembly (5) onto the support (7) ( as "h") (Carefully).
Remove the tools [0194-T], [1520-B / 5705-T].
Couple the click-fit unions (1), (3a), (3b).
Connect :
 The connectors ( as "a") (Fuel filter heater)
 The connectors ( as "b") (Water in diesel fuel detector) (According to equipment)
Refit :
4. Priming and bleeding the fuel circuit

Page 7 of 8
Figure : B1HG42ID
Operate the manual priming pump (8) several times to prime the fuel circuit.

Start the engine.
6. Bleed during service (Presence of water)

Place the tray underneath the fuel bleed pipe outlet (When coupling the tool , protect yourself using a cloth to
prevent any splashes of fuel).
Page 8 of 8
Figure : B1HG42JD
Disconnect and move aside the connector ( as "b") (Water in diesel fuel detector) (according to equipment).
Unlock : The water bleed screw (2) (Clockwise) ; Raise the water bleed screw (2) fully (In the direction of the
arrow ( as "c")).
Leave the fuel to flow into the tray.
Push the water bleed screw (2) fully ; Lock : The water bleed screw (2) (Anti-clockwise).
Connect - Release : The connector ( as "b") (Water in diesel fuel detector) (according to equipment).
Operate the manual priming pump (8) several times to prime the fuel circuit.
Remove the tray from underneath the engine.
Page 1 of 5
REMOVING - REFITTING : FUEL TEMPERATURE SENSOR
1. Tooling

Figure : E5AB05LT
Low pressure fuel pipe clip on fuel filter support 1
3. Location
Page 2 of 5
Figure : B1CG02ED
(1) Fuel temperature sensor.

(2) Low pressure fuel pipe .
4. Removing
Remove :
 The inlet air bypass unit (according to equipment)
Page 3 of 5
Figure : B1HG2CJD
Disconnect and move aside the connector (at "a").

Uncouple and close ; Using the closers [0194-T] :
 The pipe (at "b")
 The pipe (at "d")
Unclip the low pressure fuel pipe (2) (at "c").

Page 4 of 5
Figure : B1HG1MHD
Remove the clip (4) from the mounting (5).

Carefully release the union of the low pressure fuel pipe (2) between the mounting (5) and the air inlet pipe
(3) (at "e").
Remove the fuel low pressure pipe (2) and fuel temperature sensor (1) assembly.
5. Refitting
Refit the fuel low pressure pipe (2) and fuel temperature sensor (1) assembly.
Carefully pass the union of the low pressure fuel pipe (2) between the mounting (5) and the air inlet pipe (3) (at
"e").
Refit the clip (4) (new).
Couple up :
 The pipe (at "d")
 The pipe (at "b")
Clip the low pressure fuel pipe (2) (at "c") (replace if necessary).

Refit :
 The inlet air bypass unit (according to equipment)
Page 5 of 5

Page 1 of 4
REMOVING - REFITTING : INLET AIR METERING UNIT
1. Tooling

[0194-T] plugs kit
Figure : E5AB05LT
2. Location
Page 2 of 4
Figure : B1HG120D
(1) Inlet air metering unit .
3. Removing
Figure : B1HG2CCD

Disconnect, blank off and move aside : The fuel supply pipes (2), (3) ; Using the tools [0194-T].
Loosen the clips (4) and (5).
N.B. : Identify the position of the air duct (6).
Remove the air conduit (6).

Page 3 of 4
Figure : B1HG2CDD

Remove :
 The (7) bolt
 The bolts (8)
 The inlet air metering unit (1)
4. Refitting

Page 4 of 4
Figure : B1HG2CED

(9) Air inlet pipe.
(10) Fuel filter support.
(11) Seal .
CAUTION : Always replace the seal (11) ; Put a little oil on the seal faces (with engine oil).
Refit :
 Seal (11) (new)
 The bolts (8)
 The (7) bolt

Refit the air duct (6).
N.B. : Ensure the the air duct (6) is positioned correctly.
Tighten hose clips (4) and (5).

Couple up : The fuel supply pipes (2), (3).
Page 1 of 5
REMOVING - REFITTING : PARTICLE FILTER
1. Precautions to be taken
ESSENTIAL : Before carrying out any work on the exhaust system, wait for it to cool down.
Figure : B1JG036D
Respect the precautions to be taken before repair :

 The front flexible pipe should be protected against any external mechanical interference
 The front flexible pipe should not come into contact with any corrosive products
 Do not deform the front flexible hose by more than 20° angular (X), 20 mm axial and 25 mm in shear
(Y)
 Do not deform the front flexible hose by more than 3° angular (X), 0 mm axial and 3 mm in shear (Y)
(Front flexible pipe in place)
CAUTION : Failure to observe these precautions results in a reduction of the service life of the front hose ;
The uncoupling or removal of the exhaust line is essential for operations requiring lifting of the power train.
2. Removing
Page 2 of 5
ESSENTIAL : Engine hot : Wait at least one hour before carrying out any work on the exhaust line.

Raise the vehicle.
Figure : B1KG030D
Remove the under engine protection (According to equipment).

Move the front bumper deflector aside (According to equipment).
Unscrew the bolt (1) to the maximum.
Remove and move aside the pressure take-off pipe (2).
Page 3 of 5
Figure : B1KG035D
Remove the exhaust clamp (5).

Unscrew the bolt (3) to the maximum.
Open out the collar (4) as fully as possible.
Remove the particulate emission filter (6) (In the direction of the arrow ) ; Retrieve the steel joint.
3. Refitting
CAUTION : Use all the components contained in the particle filter replacement kit.
Page 4 of 5
Figure : B1KG036D
N.B. : A shim is delivered with the flexible exhaust pipe and particle emission filter alignment kit.
Open out the collar (4) as fully as possible (Upwards).

Refit the particle emission filter (6) on the exhaust catalytic converter (7) (In the direction of the arrow ).
Insert the exhaust hose positioning shim (at "a").
Refit the clip (4).
Remove the block (at "a").
Refit :
 The exhaust clip (5)
 The pressure take-off pipe (2)
 The (1) bolt
4. Check
Start the engine.
Check that there are no leaks of exhaust gas.
Refit :
 The front bumper deflector (According to equipment)
 The protective panel under the engine (According to equipment)
Page 5 of 5
Check that the pressure sensors are working correctly (measuring of parameters using a diagnostic tool).
6. Instructions for returning the particle filter (used)
Figure : B1JM00SD
Block the openings of the used particulate emission filter (6) with the caps and plugs taken from the new
particulate emission filter .
Put the used particle filter (6) in the bag of the new particle filter.
Place this in the original packaging.
Page 1 of 3
REMOVING - REFITTING : PRESSURE SENSOR / INLET AIR TEMPERATURE
1. Location
Figure : B1HG3TLD
(1) Inlet air pressure and temperature sensor.
2. Removing
Remove the rear sound deadening screen from the engine and move it aside.
Page 2 of 3
Figure : B1HG3TMD
Remove :
 The bolts (3)
 The engine rear acoustic shield support (2)
Page 3 of 3
Figure : B1HG18OD

Remove :
 The bolt (4)
 The inlet air pressure/temperature sensor (1)
3. Refitting
Refit :
 The inlet air pressure/temperature sensor (1)
 The bolt (4)

Refit :
 The bolts (3)

Page 1 of 4
REMOVING - REFITTING : TURBO AIR COOLER BY-PASS UNIT
1. Removing
Release the harness (according to equipment).
1.1. "A" assembly
Figure : B1HG43KD
Uncouple the air unions (2).

Page 2 of 4
Figure : B1HG43LD
Remove :
 The (4) bolt
 The 2 bolts (5)
 The turbo air cooler air bypass unit (3)
1.2. "B" assembly

Page 3 of 4
Figure : B1HG43MD

Page 4 of 4
Figure : B1HG43OD
Remove :
 The (4) bolt
 The 2 bolts (5)
2. Refitting
Refit :
 The 2 bolts (5)
 The (4) bolt
 The air hoses (2) ; Tighten the clips (1)
 The electrical harness (according to equipment)

Page 1 of 7
REMOVING - REFITTING : TURBOCHARGER (MHI)
1. Removing
Place the vehicle on a ramp.
Remove :
 The catalytic converter
Figure : B1BG17AD
CAUTION : Protect the engine cooling radiator to prevent damage to the fins.
CAUTION : Plug the turbocharger inlet and outlet openings.
Disconnect the connector at "a".

Remove :
 The (5) bolt
 The turbocharger air inlet sleeve (4)
Page 2 of 7
 The bolts (6)

 The clip (1)
 The turbocharger outlet expansion chamber (2) ; Retrieve the seal
Figure : B1HG1I8D
Uncouple the vacuum pipe (8) (at "c").

Disconnect the connector at "b".
CAUTION : Keep the filling cylinder full.
Remove :
 The banjo bolt (7) from the turbocharger lubrication inlet pipe (12)
 The copper seals
 The turbocharger lubrication pipe (12)
Remove the collar (10).

Page 3 of 7
Figure : B1HG1IED
Uncouple the lubrication return pipe (9) (at "d").

Remove :
 The nuts (14)
 The turbocharger (13) ; Retrieve the seal
CAUTION : Protect : The exhaust manifold ; Using the closer .

Page 4 of 7
Figure : B1HG1IAD
CAUTION : Mark the orientation of the lubrication return pipe (9).
Remove (on the work bench) :

 The bolts (15)
 The lubrication return pipe (9)
2. Check
Examine the engine air filtering system.
Check :
 The air hoses
 The condition and the correct positioning of the vacuum pipe (8) of the turbocharger
Check the absence of foreign bodies in the following components :

 Induction circuit
 Exhaust gas manifold (Risk of destruction of the turbocharger (13) when operating)
Clean the surface of the turbocharger exhaust manifold (13).

Check that the oil circuit unions are clean.
CAUTION : Use the recommended bolts and nuts (heat resistant).
Replace :
 The turbocharger (13) fixing nuts (14)
 The banjo bolts (7), (11)
 The 4 copper seals of the turbocharger (13) lubrication banjo bolts (7),(11)
Page 5 of 7
 The catalytic converter clips
3. Refitting
CAUTION : When refitting : Remove the plugs on the turbocharger (13) at the last moment.
CAUTION : Clean the gasket faces with an approved descaling product. Do not use abrasives or sharp tools
on the joint faces. The gasket faces must not have any traces of knocks or scores.
Figure : B1HG1IBD
CAUTION : Test fit the components of the turbocharger (13), in order to adjust their position (Before final
tightening).
CAUTION : Always replace : The nuts (14).
CAUTION : Always replace : The banjo bolts (7), (11).
Refit : New seals (16), (17), (18), (19).

Page 6 of 7
Refit (on the work bench) :

 The bolts (15)
Couple up : The turbocharger (13) on the exhaust manifold .

Fit the nuts (14) (without tightening).
Position :
 The lubrication tube assembly (12)
 The banjo bolts (7), (11) (new)
 The copper seals (18), (19) (new)
Tighten the nuts (14) to the specified torque.
CAUTION : When refitting, lubricate the end of the lubrication return pipe (9) using engine oil.
Couple up : The lubrication return pipe (9) (at "d").

Refit the clip (10).
Figure : B1HG1IHD
Tightening procedure : Lubrication pipe (12) upper union :

 Position the lug "e" of the lubrication pipe (12) (As indicated above)
 Tighten to the specified torque : The upper bolt (7)
Tightening procedure : Lubrication pipe (12) lower union :

 Put a "A" = 10 mm diameter pin in place horizontally (As indicated above)
 Tighten the lower bolt (11), retaining the union with the pin
Remove the "A" = 10 mm diameter pin.

Page 7 of 7
Connect the connector at "b".

Couple up : The vacuum pipe (8) (at "c").
Remove the turbocharger inlet and outlet plugs.
Refit :
 The turbocharger (13) outlet expansion chamber (2) ; (new seal)
 The clip (1)
 The bolts (6)
 The turbocharger (13) air inlet sleeve (4)
 The (5) bolt
Connect the connector at "a".

Refit :
4. Precautions to be taken before starting the vehicle

Turn the engine over with the starter motor for 15 seconds.
Reconnect : The diesel injector connectors .
Let the engine run at idle for 30 seconds before increasing the load.
After switching on, check the sealing of the various unions.
Refit :
Page 1 of 4
REMOVING - REFITTING : TURBOCHARGER PRESSURE REGULATION ELECTROVALVE
1. Tooling
tool REFERENCE Designation

[0172-Z] Pliers for removal/refitting Clic clips
Figure : E5AI00DT
2. Location
Page 2 of 4
Figure : B1HG2CKD
(1) Turbocharger pressure regulation electrovalve (Variable geometry turbocharger electrovalve).
3. Removing
Remove :
 The battery style cover (if necessary)
 The engine ECU cover (if necessary)
 The air inlet housing and its duct
Figure : B1HG2CLD

Unlock the clip (4).
Page 3 of 4
Figure : B1HG195D
Disconnect the connector ( as "d").
CAUTION : On each removal : Mark the order of the vacuum pipes being removed.
Vacuum pipe "a" : Remove the "CLIC" clip ; Using tool [0172-Z].
Uncouple : The vacuum pipes "a","b","c".
Unscrew nut (6).
Remove :
 The nut (5)
 The turbocharger pressure regulation solenoid valve (1)
4. Refitting
Refit : The turbocharger pressure regulation solenoid valve (1).

Tighten the nut (6) (by hand).
Refit the nut (5).
Tighten the nuts (6), (5).
CAUTION : When refitting : Do not reverse the vacuum pipes .

Page 4 of 4
Figure : B1HG0UMD
Couple up : The vacuum pipes "a","b","c" :

 Sleeve "a" without marking : Vacuum inlet
 Sleeve "b" with marking : White spot : Turbocharger control solenoid valve
 Sleeve "c" with marking : breather
Vacuum pipe "a" : Refit the clip "CLIC" ; Using tool [0172-Z].
Connect the connector ( as "d").
Lock : The clip (4).
Refit :
 The (3) bolt
 The air inlet housing and its duct
 The engine ECU cover (if necessary)
 The battery style cover (if necessary)
Page 1 of 4
REMOVING - REFITTING : WATER TEMPERATURE SENSOR
Coolant temperature sensor seal 1
2. Tooling

Figure : E5AB06IT
3. Removing
Place the vehicle on a lift.
Remove the protective plate from under the engine.
Remove :
 The ancillaries battery cover (according to equipment)
 The engine ECU cover (according to equipment)
 The air inlet housing
 The air sleeve
Move the engine management ECU aside.

Remove :
 The ancillaries battery
Page 2 of 4
Figure : B1GG0P8D
CAUTION : Do not use cutting tools or hammers in any operation to remove-refit components. If a
component is dropped on a hard surface or suffers a serious impact, it should be replaced.

Remove :
 The clip (1)
 The coolant temperature sensor (2)
 Seal
Plug the coolant outlet housing ; Using the set of plugs [0188-T].
4. Refitting
Page 3 of 4
Figure : B1GG0PBD
CAUTION : Replace the seal (3) with a new seal that you have already lubricated.
CAUTION : Take care with the positioning of the seal (3) on the temperature sensor (2).
Remove tool [0188-T].

Refit :
 The coolant temperature sensor (2) complete with a new seal (3)
 The clip (1)

Refit :
 The ancillaries battery
 The engine management ECU
 The air sleeve
 The air inlet housing
 The engine ECU cover
 The ancillaries battery cover (according to equipment)

Page 4 of 4
5. Checks
Start the engine.
Refit the protective panel under the engine.
Page 1 of 8
REMOVING - REFITTING : ANCILLARY DRIVE BELT
1. Tooling

[01099] Accessory drive belt dynamic roller tensioner
compression tool
[01099-A] Offset adaptor
[01099- Dynamic tensioner roller adaptor (8,7 mm)

B1]
[01099- Dynamic tensioner roller adaptor (10 mm)

B2]
[01099-C] Double hexagonal end piece
Figure : E5AB1I0T [01099-D] Hexagonal adaptor
[0194-E3] Dynamic tensioner compression lever
Figure : E5AB09IT
[0194-F] [/] setting rod for dynamic roller tensioner

Page 2 of 8
Figure : E5AB09KT
[0188-Z] Dynamic roller tensioner compression lever
Figure : E5AB0G3T
2. Location
2.1. Markings on dynamic roller tensioner
Page 3 of 8
Figure : B1BG0WCD
"a" Setting hole.

"b" Maximum elongation mark.
"c" Zero extension mark.
"d" Belt extension checking mark (fixed on engine ).
This marking system permits checking of the extension of the ancillary drive belt.
N.B. : A coming together of the references "b" and "d" means that replacement of the ancillary drive belt is
necessary.
2.2. Vehicle without air conditioning

Page 4 of 8
Figure : B1BG13OD
CAUTION : Mark the direction of fitting of the ancillary drive belt if it is to be reused.
(1) Dynamic roller tensioner .

"a" Setting hole.
"e" Manoeuvring square.
2.3. Vehicle with air conditioning
Page 5 of 8
Figure : B1BG0WED
CAUTION : Mark the direction of fitting of the ancillary drive belt if it is to be reused.
(1) Dynamic roller tensioner .

"a" Setting hole.
"e" Manoeuvring square.
3. Removing
3.1. Method of use of the tools [01099]
Page 6 of 8
Figure : B1BG4H8D
Position the tool [01099-B2] (at "e").
Figure : B1BG4HAT
Place the tools [01099-A], [01099-D] in place on the tool [01099-B2].

Compress the dynamic tensioner roller (1) clockwise (following the arrow "f") ; Using tool [0188-Z] (The tool
[0188-Z] can be replaced with the standard tools).
Page 7 of 8
Figure : B1BG4H9D
Pin the dynamic roller tensioner (1) ; Using the pin [0194-F] (at "a").
Remove the accessories drive belt .
3.2. Method of use of the tools [0194-E3]
Page 8 of 8
Figure : B1BG13ND
Position the tool [0194-E3] (at "e").

Compress the dynamic roller tensioner (1) by pressing at "e" (clockwise) ; Using tool [0194-E3].
Gently bring the belt elongation checking mark "d" to its movement stop.
N.B. : The pin [0194-F] goes underneath the tool [0194-E3] for positioning at "a".
Peg ; Using the pin [0194-F] (at "a").
4. Refitting
CAUTION : Re-used belt : Observe the fitting direction of the belt.
Refit the ancillary belt .
CAUTION : Ensure that the accessories drive belt is correctly positioned in the grooves of the various
pulleys.
Compress the dynamic roller tensioner (1) (clockwise) ; Using the tool [0194-E3] or [01099], [0188-Z].
Remove the tool [0194-F].
Slacken the ancillary drive belt dynamic roller tensioner .
Remove the tool [0194-E3] or [01099], [0188-Z].

Page 1 of 7
REMOVING - REFITTING : CAMSHAFT HOUSING
Camshaft carrier oil ducts seal 5
2. Tooling

[0194-B] Setting pin for camshaft pulley
Figure : E5AB08WT
[1617-J] The plugs kit HDI
Figure : E5AG03LT
3. Removing
Page 2 of 7

Remove :
 The air mixer unit
 The air admission bypass valve
 The timing belt
CAUTION : Fit the upper right side engine mounting.
Remove the exhauster .
Figure : B1DG0X4D
N.B. : Pin the camshaft pulley (1) ; Using tool [0194-B].
Remove the cylinder head cover .

Page 3 of 7
Figure : B1DG0X5D
Remove :
 The alternator
 The alternator bracket
CAUTION : Observe the slackening order.
Remove the camshaft carrier (3) fixing bolts (2) (In the order shown).
Page 4 of 7
Figure : B1DG0X6D
N.B. : Remove the camshaft housing (3), using the separation zones (at "a").
4. Refitting
CAUTION : Always replace seals which have been removed.
N.B. : Check the sealing of the camshaft bearing cap covers. Reseal the camshaft bearing cap covers with
an approved product (if necessary).
CAUTION : Clean the joint faces ; Using an index D2 cleaning product ; Do not use a cutting or abrasive
Page 5 of 7
Figure : B1DG0X7D
CAUTION : Always replace the seals (5).
Figure : B1DG0X8D
Page 6 of 7
CAUTION : Check the presence of the centring pins (7).
Check the condition of the roller valve rockers and of the hydraulic cam followers.
Remove :
 The roller valve rockers (6)
 The hydraulic followers (8)
Lubricate (With engine oil) :

Refit (Observe their original location) :

CAUTION : The positioning operation must not take longer than 5 minutes.
Apply a bead of sealing paste (index "E10") (at "b").
Figure : B1DG0X9D
CAUTION : The crankshaft pin must be in place.
Position the camshaft carrier (3) on the centring pins (7).

Fit the camshaft housing (3).
CAUTION : Observe the order of tightening of the camshaft carrier (3) fixing bolts (2).
Page 7 of 7
Method of tightening for the bolts (2) of the camshaft housing (3) (In the order shown) :
 Pre-tightening to torque of the bolts (2)
 Tighten the bolts (2) to the specified torque
Lubricate the camshaft using engine oil.

Refit :
 The alternator bracket
 The alternator
 The cylinder head cover
CAUTION : Remove the tool [0194-B] from the camshaft pulley (1).
Refit :
 The vacuum pump
 The timing belt

Page 1 of 8
REMOVING - REFITTING : CAMSHAFT
Camshaft oil seal 1
Cylinder head cover gasket 1
2. Tooling

[0194-N] Camshaft carrier positioning tool
Figure : E5AB08UT
Figure : E5AB08VT
[0194-B] Setting pin for camshaft pulley

Page 2 of 8
Figure : E5AB08WT
3. Removing

Remove :
 The timing belt
CAUTION : Fit the upper right side engine mounting.
Remove the exhauster .

Page 3 of 8
Figure : B1DG0XAD
CAUTION : Remove the camshaft rod [0194-B].

Remove :
 The (2) bolt
Page 4 of 8
Figure : B1DG0XBD
Remove the bolt (4) from the camshaft position sensor (5).
Push back the camshaft position sensor (5).
Remove the cylinder head cover (3).
Figure : B1DG0XCD
Page 5 of 8
CAUTION : The joint faces of the camshaft upper main bearing cap casing (6) must not bear any signs of
knocks or scratches.
CAUTION : Proceed bolt by bolt in the order shown.
Remove :
 The bolts (7) of the camshaft upper main bearing cap casing (6) (In the order shown)
 The camshaft upper main bearing cap casting (6)
 The camshaft (8)
4. Refitting
CAUTION : Clean the sealing faces with the approved product "D2". Do not use a cutting or abrasive tool.
The seal faces should not show any traces of impacts or scratches.
Figure : B1DG0XDD
CAUTION : The crankshaft pin must be in place.
Remove :
Page 6 of 8

Lubricate (With engine oil) :

Check the condition of the roller cam followers (9) and of the hydraulic tappets (10).
Refit (Observe their original location) :
Apply a bead of sealing paste "E10" at "a" on the edge of the joint faces.
CAUTION : The positioning operation must not take longer than 5 minutes.
Figure : B1DG0XED
CAUTION : When refitting, place the camshaft pulley notch (1) at the top (In accordance with the illustration
above).
CAUTION : Place the tool [0194-N] (at "b") to centre the camshaft upper main bearing cap casing.
Refit :
 The camshaft (8)
 The camshaft upper main bearing cap casting (6) ; Using the tools [0194-N]
Page 7 of 8
Figure : B1DG0G3D
CAUTION : Observe the order of tightening of the camshaft upper main bearing cap casing (6) fixing bolts
(7).
Tightening method for the screws (7) (In the order shown) :
 Remove the tools [0194-N]
 Tightening of screws (7)
CAUTION : Fit a new camshaft sealing ring.
Lubricate the camshaft (8) using engine oil.

Fit the cylinder head cover (3) (with a new seal ).
Position the camshaft position sensor (5).
Refit bolt (4) to the camshaft position sensor (5).
Refit :
 The new bolt (2) (without tightening)

Tighten the bolt (2).
Remove the tool [0132-AA].
Remove the right-hand upper engine mounting .
Refit :
 The vacuum pump
 The timing belt
Page 8 of 8


Page 1 of 6
REMOVING - REFITTING : COOLANT INLET MANIFOLD
1. Tooling

Figure : E5AI007T
2. Removing
Remove :

Remove :
Remove :
Page 2 of 6
Figure : B1GG0H1D

Uncouple the hose (1) from the coolant outlet housing (at "b").
Figure : B1GG0H2D
Page 3 of 6
Remove :
 The nuts (2)
 The nut (4)
 The nut (5)
Disconnect the connector (at "e").

Unclip the harness (at "c", "d", "f").
Figure : B1GG0H3D

Move aside the electrovalve support (7) with the electrovalve .
Page 4 of 6
Figure : B1GG0J8D
Remove the collar (10) ; Using tool [0165-2].

Move aside the coolant inlet manifold (11) from the EGR valve (at "g").
Move aside the coolant inlet manifold (11) from the cylinder block (at "h").
Remove the coolant inlet manifold (11) (From below).
3. Refitting
3.1. Preparation
Page 5 of 6
Figure : B1GG0J9D
Refit the seals (13), (14), (15) (new).

Lubricate the seals (13), (14), (15) ; With engine oil .
3.2. Refitting
 Engine
 Wheel
CAUTION : Take care with the positioning of the fuel bleed pipe.
Refit the water inlet manifold (11) (From below).

Position the coolant inlet manifold (11) on the cylinder block (at "h").
Position the coolant inlet manifold (11) on the EGR valve (at "g").
Refit bolt (12).
Refit the clip (10) ; Using tool [0165-2].
Position the electrovalve support (7) with the electrovalve.
Position the electrical harness (6).
Clip the harness (at "c", "d", "f").
Connect the connector (at "e").
Refit :
 The nut (5)
 The nut (4)
Page 6 of 6

 The nuts (2)
Couple the hose (1) to the coolant outlet housing (at "b").

Refit :
Refit :
Put the engine ECU and support assembly in place.

Refit :
4. Check
Start the engine.
Keep the engine speed at 2000 rpm, up to the first cooling cycle.
Stop the engine.
Page 1 of 10
REMOVING - REFITTING : CYLINDER HEAD COVER
1. Tooling
Equipment ; Adjustable mirror.

[1617-J] The plugs kit HDI
Figure : E5AG03LT
2. Removing
Remove (depending on the proximity of the operation zone) :

 The battery style cover (according to equipment)
 The battery
 The battery tray (according to equipment)
Remove :
 The air filter casing
Page 2 of 10
Figure : B1DG0WWD
N.B. : Since the screw (1) fixing the electrical harness support is positioned between the engine and the
bulkhead, use a mirror to make the operation easier.

Disconnect injectors ( as "b").
Unclip clip (2).
Move aside the harness (3) ( as "c").
Unclip the harness (3) ( as "a").
Page 3 of 10
Figure : B1DG0WXD
Release the harness support (4) (from below) (at "d") ; Using a small flat screwdriver.
Lift and move aside the harness support (4).
Page 4 of 10
Figure : B1DG0WYD
Remove :
 The clip (8)
 The (7) bolt
CAUTION : Plug the openings ; Using tool [1617-J].

Page 5 of 10
Uncouple :
 The fuel return pipe (5) (at "f")
 The fuel return pipe (6) (at "h")
Unclip :
 The fuel return pipe (5) (at "e")
 The fuel return pipe (6) (at "g")
Release :
 The fuel return pipe (5)
 The fuel return pipe (6)
Figure : B1DG0GJD
Remove :
 The bolts (9)
Page 6 of 10
Figure : B1DG0GKD
Remove :
 The clip (11)
 The bolts (12)
Figure : B1DG0GLD
Page 7 of 10
Remove :
 The bolts (13)
 The cylinder head cover (14)
3. Refitting
Figure : B1DG0GMD
Fit a seal (15) (new) on the cylinder head cover (14).

Fit the cylinder head cover (14).
Page 8 of 10
Figure : B1DG0GND
CAUTION : Observe the order of tightening of the bolts (12), (13).
Tightening method for the screws (13) (In the order shown) :
 Tightening of screws (13)
Refit :
 The bolts (12)
 The clip (11)
Page 9 of 10
Figure : B1DG0GOD
Check that the seal (16) is positioned correctly on the upper timing cover (10).
Refit :
 The bolts (9)
Remove the tool [1617-J].

Couple up :
 The fuel return pipe (5) (at "f")
 The fuel return pipe (6) (at "h")
Clip in place :
 The fuel return pipe (5) (at "e")
 The fuel return pipe (6) (at "g")
Refit :
 The (7) bolt
 The clip (8)
 The harness bracket (4)
Lock the harness bracket (4) (at "d").

Reposition the electrical harness (3) (at "c").
Put the harness (3) in place and clip it (at "a").
Clip the clip (2).
Connect the injectors (at "b").
Refit :
 The (1) bolt ; Use a mirror to make the operation easier
Page 10 of 10

Refit (depending on the proximity of the operation zone) :

 The battery tray (according to equipment)
 The battery
 The battery style cover (according to equipment)
4. Check
Start the engine.
Page 1 of 9
REMOVING - REFITTING : EGR MODULE ASSEMBLY
1. Tooling

[0165-2] Pliers for removing elastic clips
Figure : E5AI00HT
2. Precaution
Page 2 of 9
Figure : B1KG0C8D
(1) EGR module assembly.

(1a) Heat exchanger.
(1b) Bracket .
(2) Electrically-controlled exhaust gas recycling valve.
CAUTION : Do not separate the heat exchanger (1a) from the support (1b).
N.B. : The exhaust gas recycling module is assembled at the factory with the aid of a template. Assembling it
without using a template would create positioning tensions on the cylinder head, adversely affecting the
fixings and the sealings of the module.
3. Removing
Remove :
 The engine style cover(According to equipment)
 The exhaust front flexible pipe (according to equipment)
Remove (depending on the proximity of the operation zone) :

 The battery style cover (According to equipment)
 The battery
 The battery tray (According to equipment)
Uncouple the vacuum pump unions and move them aside.

Remove and move aside : The engine rear acoustic shield.
Page 3 of 9
Figure : B1BG2OED

Move aside the pre-heat plugs supply harness (5).
Remove :
 The 2 bolts (3)
 The air filter housing support (4)
Page 4 of 9
Figure : B1BG0SYD
Uncouple :
 The pipe (7)
 The pipe (8)
Page 5 of 9
Figure : B1BG2OFD
Disconnect the connectors (at "b", "c").

Unfasten and move aside : The electric harness transition duct (9) (at "d").
Figure : B1KG0DOD
Page 6 of 9
Remove the bolt (15) (From below).

Uncouple the pipe (at "f") ; Using tool [0165-2].
Release and move aside the electrical harness (at "e").
Remove :
 The bolts (13)
 The nut (14)
 The bolts (11)
 The EGR module assembly (1) (Carefully)
Retrieve : The seals .
Figure : B1KG0DRD
Remove (On the bench) :

 The (19) bolt
 The coolant manifold (18)
 The bolts (16)
 The exhaust gas recycling pipe (17) (Retrieve : The seals )
Page 7 of 9
Figure : B1KG0DSD
Remove (On the bench) :

 The bolts (21)
 The water outlet (20) (recover the seals)
4. Refitting
4.1. Preparation
Clean the seal faces of the EGR module, using a special degreaser index "N1".
Page 8 of 9
Figure : B1KG0DTD
CAUTION : When positioning the seal faces (23), (26), pay particular attention to the retaining studs (risk of
leaks).
Refit : The seals (22), (23), (24), (25), (26) (new).

Lubricate : The seals (24), (25) ; With engine oil .
4.2. Subsequent operations
Refit (On the bench) :

 The water outlet (20)
 The bolts (21)
 The exhaust gas recycling pipe (17)
 The bolts (16)
 The coolant manifold (18)
 The bolt (19)
Refit :
 The EGR module assembly (1) (Carefully)
 The bolts (11)
 The nut (14)
 The bolts (13)
Clip in place : The electrical harness (at "e").

Recouple the connection hose (at "f") ; Using tool [0165-2].
Page 9 of 9
Refit bolt (15) (From below).

Clip in place : The electric harness transition duct (9) (at "d").
Refit bolt (10).
Connect the connectors (at "b", "c").
Couple up :
 The pipe (8)
 The pipe (7)
Refit :
 The air filter housing support (4)
 The 2 bolts (3)
Refit :
 The pre-heat plugs supply harness (5)
 The bolts (6)

Couple the vacuum pump unions.
Refit (depending on the proximity of the operation zone) :
 The battery tray (According to equipment)
 The battery
 The battery style cover (According to equipment)
Refit :
 The exhaust front flexible pipe (according to equipment)
 The engine style cover(According to equipment)
5. Checking
Start the engine.
Refit :
Page 1 of 3
REMOVING - REFITTING : ENGINE OIL TEMPERATURE AND LEVEL SENSOR
1. Location
Figure : B1BM0F0D
(1) Engine oil temperature and level sensor (Oil level sensor).
2. Removing
Lift and support the vehicle.
Remove the front right-hand wheel.
Page 2 of 3
Figure : B1FG02DD
Remove :
 The (4) bolt
 The nut (3)
Page 3 of 3
Figure : B1FG028D

Remove the engine oil temperature and level sensor (1).
3. Refitting
Refit the engine oil temperature and level sensor (1).

Refit :
 The nut (3)
 The (4) bolt

Page 1 of 11
REMOVING - REFITTING : ENGINE RING SEALS
N.B. : The sealing rings provide the seal on the crankshaft on the oil pump side and on the flywheel side, as
well as on the end of the camshaft on the timing pinion side ; The sealing rings consist of a preformed Teflon
lip.
N.B. : When the engine is started, the oil pressure exerts a force on the lip which makes contact leaving a
film of oil on the shaft thus creating sealing.
CAUTION : Check the absence of any mark on the bearings of the sealing ring.
CAUTION : If the lip is deformed, replace the sealing ring.
N.B. : The seal must remain on its support during fitting ; If handling, put the ring back on its support and
leave the assembly in position for 30 minutes before refitting.

1.1. Camshaft oil seal
Camshaft pulley screw 1
Camshaft oil seal 1
1.2. Oil pump ring seal
Oil pump ring seal 1
1.3. Crankshaft ring seal
Flywheel bolts 6
Crankshaft ring seal (on the gearbox side) 1
2. Tooling

Camshaft ring seal fitting drift
[0194-K]
Page 2 of 11
Figure : E5AG063T
Crankshaft ring seal fitting drift (Timing gear

[0194-L] side)
Figure : E5AG064T
Crankshaft ring seal fitting drift (Flywheel

[0194-M] side)
Figure : E5AG065T

Page 3 of 11
Figure : E5AB08VT
4. Camshaft oil seal
4.1. Removing
Page 4 of 11
Figure : B1BG16ED
CAUTION : Remove the camshaft setting peg .

Remove :
 The (2) bolt
Figure : B1BG16FD
Drill a hole 3,5 mm in diameter in the ring seal (3) (at "a").

Screw a bolt into the hole (at "a").
4.2. Refitting

Page 5 of 11
Figure : B1BG16GD
sealing ring.
Fit the sleeve equipped with its sealing ring (3) (new) onto the camshaft.
Fit the tool [0194-K].
Tighten the bolt of the tool [0194-K] until the surface of the tool comes into contact with the surface of the
camshaft carrier .
Remove the tool [0194-K].
CAUTION : Systematically replace the screw (2).
Refit :
 The (2) bolt (new) ; Using tool [0132-AA]
 The timing belt
5. Oil pump ring seal

5.1. Removing
Remove :
 The timing belt
Page 6 of 11
Figure : B1BG16HD
Drill a hole 3,5 mm in diameter in the ring seal (4) (at "b").

Screw a bolt into the hole (at "b").
5.2. Refitting

Page 7 of 11
Figure : B1BG16ID
sealing ring.
Position the sleeve fitted with its new ring seal (4) on the crankshaft .
Put the tool [0194-L] and the crankshaft pulley bolt in place.
Tighten the crankshaft pulley bolt until the surface of the tool [0194-L] comes into contact with the surface of
the oil pump .
Remove the tool [0194-L].
Refit :
 The timing belt
6. Crankshaft seal ring

6.1. Removing
Remove :
 The gearbox
Page 8 of 11
Figure : B1CG02QD
Remove :
 The bolts (5)
Figure : B1BG16JD
Page 9 of 11
Drill a hole 3,5 mm in diameter in the ring seal (7) (at "c").

Screw a bolt into the hole (at "c").
6.2. Refitting
Figure : B1BG0PUD
Put the lower part of the tool [0194-M] in place on the flywheel .
sealing ring.
Page 10 of 11
Figure : B1BG16LD
Fit the sleeve equipped with its sealing ring (7) (new) onto the lower part of the tool [0194-M].
Tighten the bolt of the tool [0194-M] until the surface of the tool comes into contact with the surface of the
cylinder block .
Remove the tool [0194-M].
Page 11 of 11
Figure : B1CP0M2D
CAUTION : Always replace the bolts (5).
Refit :
 The bolts (5)
CAUTION : Observe the order of tightening of the bolts (5).
Check that the 3 clutch centring pins are present (at "d") (Manual gearbox ).
Refit :
 The gearbox
Refit the engine style cover .

Page 1 of 4
REMOVING - REFITTING : INLET AIR METERING UNIT
1. Tooling

[0194-T] plugs kit
Figure : E5AB05LT
2. Location
Page 2 of 4
Figure : B1HG120D
3. Removing
Figure : B1HG2CCD

Disconnect, blank off and move aside : The fuel supply pipes (2), (3) ; Using the tools [0194-T].
Loosen the clips (4) and (5).
N.B. : Identify the position of the air duct (6).

Page 3 of 4
Figure : B1HG2CDD

Remove :
 The (7) bolt
 The bolts (8)
4. Refitting

Page 4 of 4
Figure : B1HG2CED

(9) Air inlet pipe.
(10) Fuel filter support.
(11) Seal .
CAUTION : Always replace the seal (11) ; Put a little oil on the seal faces (with engine oil).
Refit :
 Seal (11) (new)
 The bolts (8)
 The (7) bolt

N.B. : Ensure the the air duct (6) is positioned correctly.
Tighten hose clips (4) and (5).

Couple up : The fuel supply pipes (2), (3).
Page 1 of 5
REMOVING - REFITTING : OIL FILTER
CAUTION : The oil filter must be replaced after the engine has been drained.
1. Removing
Drain the engine oil circuit.
Figure : B1FG0CAD
Remove the air deflector (2) and air inlet neck (1) assembly (according to equipment).
Page 2 of 5
Figure : B1FG0CBD
Protect the area with absorbent paper or a clean rag.
N.B. : Move the electrical harnesses and the hoses aside (if necessary).
Remove the filter element protection cover (3).

Page 3 of 5
Figure : B1FG0CYD
Separate the filter element (4) from the cover (3).

Remove the seal (5).
2. Refitting
CAUTION : Always replace the filter element and its seal.
2.1. Preparation of the component

Page 4 of 5
Figure : B1FG0CDD
Replace the seal (5) on the cover (3).

Lubricate the seal (5) ; With engine oil .
CAUTION : Ensure that the seal (5) is not twisted or damaged.
Refit the seal (5) (at "a").

Page 5 of 5
Figure : B1FG0CYD
N.B. : Check that the seal is in the correct position by passing your finger all around the seal.
Refit the new filter element (4) on the cover (3).

2.2. Refitting (Continued)
CAUTION : Never use force in tightening the cover (3) (Risk of damaging the seal).
CAUTION : Clean any drips of oil.
Refit :
 The filter element protective cover (3)
 The air deflector (2) and air inlet duct (1) assembly (according to equipment)
Fill the engine oil and check the level.

Page 1 of 8
REMOVING - REFITTING : OIL PUMP
Crankshaft ring seal (oil pump side ) 1
Seal (Oil pump strainer) 1
Oil pump seal 1
2. Removing
2.1. Preliminary operations
Remove :
 The dipstick
Uncouple the exhaust line in order to avoid damage to the front rubber tube (at the flexible tube).
2.2. Oil sump
Drain the engine oil.
Page 2 of 8
Figure : B1FG03ID
Remove the 15 fixing screws (1).

Unscrew the 2 nuts (2).
N.B. : Partially undo the 2 studs (3) in order to separate the oil sump.
Separate the oil sump.

Remove :
 The 2 nuts (2)
 The oil sump
 The 2 studs (3)
2.3. oil pump

Page 3 of 8
Figure : B1FG03LD
Remove :
 The 3 bolts (4)
 The oil pump strainer (6)
 The dipstick guide tube (5)
Page 4 of 8
Figure : B1FG03MD
N.B. : Take care not to deform the target (9) when removing the crankshaft gear (8).
Remove :
 The (7) bolt
 The crankshaft gear (8) (Carefully)
N.B. : Retrieve the key.
Figure : B1FG03PD
Remove the 8 bolts (10).

Separate the oil pump (11) (at "a") ; Using a flat screwdriver.
Remove :
 The oil pump (11)
 The sealing ring (12)
3. Refitting
tool. The gasket faces must not have any traces of knocks or scores.
3.1. oil pump

Page 5 of 8
Figure : B1FG03SD
Check the presence of the centring pins (at "a").

Apply a bead of sealing compound (index "E10") (at "b").
Figure : B1FG03TD
Page 6 of 8
N.B. : On refitting, all removed seals must be replaced with new seals.
Check that the seal (13) is correctly positioned (at "c").
CAUTION : Replace the seal (12) of the crankshaft (oil pump side ).
Refit :
 The sealing ring (12) (new)
 The oil pump (11)
 The 8 screws (10) pre-coated with thread locking product, index "E3"
N.B. : Check that the track of the engine speed sensor target (9) is not damaged or scratched.
Refit :
 The cotter
 The crankshaft gear (8) (Carefully)
 The (7) bolt
N.B. : Check that the seal (14) is correctly positioned (at "d").
Refit :
 The dipstick guide tube (5)
 The oil pump strainer (6)
 The 3 bolts (4)
3.2. Oil sump

Page 7 of 8
Figure : B1FG03WD
N.B. : Apply a bead of sealing compound (index "E10") (at "e").
Figure : B1FG03ZD
Refit the 2 studs (3).

Tighten the studs (3).
Page 8 of 8
Refit :
 The oil sump
 The 2 nuts (2)
 The 15 securing bolts (1)
 The dipstick
 The timing belt
Couple the exhaust line at the rubber tube.

Fill or top up.

Start the engine.
Refit :
Stop the engine.

Page 1 of 12
REMOVING - REFITTING : TIMING BELT
1. Tools
Equipment ; A trolley jack.

[0194-A] crankshaft setting rod
High pressure fuel pump drive pulley

immobilising rod
Figure : E5AB08QT
Figure : E5AB08RT
[0194-C] flywheel stop

Page 2 of 12
Figure : E5AB08ST
[0194-T] plugs kit
Figure : E5AB05LT
2. Removing

Page 3 of 12
Figure : B1BG0QBD
Uncouple and move aside the fuel supply and return pipes( as "a").
Plug the fuel supply and return pipes ; Using tool [0194-T].
Remove :
 The air hoses (1)
Page 4 of 12
Figure : B1ED04YD
Uncouple the exhaust line in order to avoid damage to the front rubber tube (At the hose) (if necessary).
Rotate the engine until the tool [0194-C] locks the flywheel.
Page 5 of 12
Figure : B1EP1UFD
Release and move aside the electrical harness (3).

Disconnect the connector of the engine speed sensor.
Unclip the electrical harness next to the timing covers.
Remove :
 The accessories drive belt (/)
 The (4) bolt
 The pulley (5)
N.B. : To make it easier to remove the lower timing cover (6) ; Move the accessories drive belt dynamic
tensioner roller.
Remove the lower timing cover (6).

Refit bolt (4).
Page 6 of 12
Figure : B1CG02MD
CAUTION : The crankshaft pulley magnetic track must not bear any signs of damage and must be kept
away from all magnetic sources ; Otherwise, replace the crankshaft pulley.
Remove :
 The engine speed sensor (8)
 The offset prevention angle bracket (7)
Turn the crankshaft by means of the screw (4) to bring the camshaft to its pegging point.
Peg :
 The camshaft ; Using the pin [0194-B] (oil the peg)
 The high pressure fuel pump drive pulley ; Using the pin [0194-A] (oil the peg)
 The crankshaft ; Using the pin [0194-A]
Page 7 of 12
Figure : B1BG05DD
Place a trolley jack fitted with a soft pad under the engine oil sump .
N.B. : The trolley jack must be able to support the engine-gearbox assembly.
Remove :
 The 2 bolts (11)
 The 3 bolts (9)
 All of the flexible engine mountings (10)
Page 8 of 12
Figure : B1EG0DBD
Remove the intermediate engine mounting (13).
CAUTION : Support the dynamic roller tensioner ; Using a 6 -sided wrench ( as "b").
Slacken the bolt (14).

Slacken the timing belt (12) by pivoting the dynamic roller tensioner clockwise.
Remove the timing belt (12) starting with the coolant pump pulley .
3. Check
CAUTION : Just prior to refitting, carry out the checks below.
Check that the coolant pump rollers and pulley are turning freely (without excess play and without tightness).
Check the absence of coolant fluid leaks (coolant pump).
Check that the engine speed sensor target track (8) is not damaged or scratched.
4. Refitting
Tightening torque :
 Power unit suspension
Page 9 of 12
 Exhaust system
 engine
Figure : B1EG0GSD
Check the tightening of the guide roller (16).

Fit the timing belt (12) on the crankshaft pulley .
The bolt with the washer "c" :
 The tensioning roller (16)
 The high pressure fuel pump pulley (19)
 The coolant pump pulley (17)
Refit :
 The offset prevention angle bracket (7)
 The engine speed sensor (8)
4.1. Adjusting the timing belt tension

Page 10 of 12
Figure : B1EM09DD
Bring the index "d" to the centre of the gap "e" by turning the tensioner anticlockwise ; Using a 6 -sided
wrench.
CAUTION : The dynamic roller tensioner index "d" must be centred in the gap "e".
Remove the pegs [0194-B], [0194-A], [0194-A].

Refit :
 The intermediate engine mounting (13)
 All of the flexible engine mountings (10)
 The 3 bolts (9)
Remove the trolley jack.
CAUTION : Do not turn the engine anti clockwise.
Turn the crankshaft by 6 rotations clockwise.

Fit the crankshaft setting rod ; Using the pin [0194-A].
Check the positioning of the index ( as "d").
N.B. : The dynamic roller tensioner index "d" must be centred in the gap "e".
CAUTION : If it does, repeat the timing belt tensioning operation.
Pin the camshaft pulley ; Using the pin [0194-B].

Peg the fuel high pressure pump drive pulley ; Using the pin [0194-A].
Page 11 of 12
CAUTION : If it is impossible to peg the camshaft, check that the offset between the camshaft pulley hole
and the pegging hole is not greater than 1 mm. In the event of an incorrect measurement, start the
procedure again.
Remove the pegs [0194-B], [0194-A], [0194-A].

4.2. Subsequent operations
Figure : B1EP1USD
Refit the tool [0194-C].

Remove bolts (4).
N.B. : To make it easier to refit the lower timing cover (6) ; Move the accessories drive belt dynamic
tensioner roller.
Refit :
 The lower timing cover (6)
 The pulley (5)
 The (4) bolt (new)

Couple the exhaust line at the rubber tube (if necessary).
Reconnect the engine speed sensor (8) connector .
Refit :
 The accessories drive belt (/)
Page 12 of 12
N.B. : Use new plastic clips.
Secure the electrical harness attaching to the timing covers.

Clip the electrical harness (3).
Connect the fuel supply and return pipes ( as "a").
Refit :
 The air hoses (1)

5. Check
Start the engine.
Page 1 of 4
REMOVING - REFITTING : TURBO AIR COOLER BY-PASS UNIT
1. Removing
Release the harness (according to equipment).
1.1. "A" assembly
Figure : B1HG43KD

Page 2 of 4
Figure : B1HG43LD
Remove :
 The (4) bolt
 The 2 bolts (5)
1.2. "B" assembly

Page 3 of 4
Figure : B1HG43MD

Page 4 of 4
Figure : B1HG43OD
Remove :
 The (4) bolt
 The 2 bolts (5)
2. Refitting
Refit :
 The 2 bolts (5)
 The (4) bolt
 The air hoses (2) ; Tighten the clips (1)
 The electrical harness (according to equipment)

Page 1 of 7
REMOVING - REFITTING : TURBOCHARGER (MHI)
1. Removing
Place the vehicle on a ramp.
Remove :
Figure : B1BG17AD
CAUTION : Protect the engine cooling radiator to prevent damage to the fins.
Disconnect the connector at "a".

Remove :
 The (5) bolt
 The turbocharger air inlet sleeve (4)
Page 2 of 7
 The bolts (6)

 The clip (1)
 The turbocharger outlet expansion chamber (2) ; Retrieve the seal
Figure : B1HG1I8D
Uncouple the vacuum pipe (8) (at "c").

Disconnect the connector at "b".
CAUTION : Keep the filling cylinder full.
Remove :
 The turbocharger lubrication pipe (12)

Page 3 of 7
Figure : B1HG1IED
Uncouple the lubrication return pipe (9) (at "d").

Remove :
 The nuts (14)
 The turbocharger (13) ; Retrieve the seal
CAUTION : Protect : The exhaust manifold ; Using the closer .

Page 4 of 7
Figure : B1HG1IAD
Remove (on the work bench) :

 The bolts (15)
2. Check
Examine the engine air filtering system.
Check :
 The air hoses
 The condition and the correct positioning of the vacuum pipe (8) of the turbocharger
Check the absence of foreign bodies in the following components :

 Induction circuit
 Exhaust gas manifold (Risk of destruction of the turbocharger (13) when operating)
Clean the surface of the turbocharger exhaust manifold (13).

Check that the oil circuit unions are clean.
CAUTION : Use the recommended bolts and nuts (heat resistant).
Replace :
 The turbocharger (13) fixing nuts (14)
 The banjo bolts (7), (11)
 The 4 copper seals of the turbocharger (13) lubrication banjo bolts (7),(11)
Page 5 of 7
 The catalytic converter clips
3. Refitting
CAUTION : When refitting : Remove the plugs on the turbocharger (13) at the last moment.
CAUTION : Clean the gasket faces with an approved descaling product. Do not use abrasives or sharp tools
on the joint faces. The gasket faces must not have any traces of knocks or scores.
Figure : B1HG1IBD
CAUTION : Test fit the components of the turbocharger (13), in order to adjust their position (Before final
tightening).
CAUTION : Always replace : The nuts (14).
CAUTION : Always replace : The banjo bolts (7), (11).
Refit : New seals (16), (17), (18), (19).

Page 6 of 7
Refit (on the work bench) :

 The bolts (15)
Couple up : The turbocharger (13) on the exhaust manifold .

Fit the nuts (14) (without tightening).
Position :
 The lubrication tube assembly (12)
 The banjo bolts (7), (11) (new)
 The copper seals (18), (19) (new)
Tighten the nuts (14) to the specified torque.
CAUTION : When refitting, lubricate the end of the lubrication return pipe (9) using engine oil.
Couple up : The lubrication return pipe (9) (at "d").

Refit the clip (10).
Figure : B1HG1IHD
Tightening procedure : Lubrication pipe (12) upper union :

 Position the lug "e" of the lubrication pipe (12) (As indicated above)
 Tighten to the specified torque : The upper bolt (7)
Tightening procedure : Lubrication pipe (12) lower union :

 Put a "A" = 10 mm diameter pin in place horizontally (As indicated above)
 Tighten the lower bolt (11), retaining the union with the pin
Remove the "A" = 10 mm diameter pin.

Page 7 of 7
Connect the connector at "b".

Couple up : The vacuum pipe (8) (at "c").
Remove the turbocharger inlet and outlet plugs.
Refit :
 The turbocharger (13) outlet expansion chamber (2) ; (new seal)
 The clip (1)
 The bolts (6)
 The turbocharger (13) air inlet sleeve (4)
 The (5) bolt
Connect the connector at "a".

Refit :
4. Precautions to be taken before starting the vehicle

Turn the engine over with the starter motor for 15 seconds.
Reconnect : The diesel injector connectors .
Let the engine run at idle for 30 seconds before increasing the load.
After switching on, check the sealing of the various unions.
Refit :
Page 1 of 4
REPLACEMENT : FLEXIBLE ADDITIVE RESERVOIR
1. Tooling

[0188-T] plugs kit
Figure : E5AB06IT
2. Removing
ESSENTIAL : Before carrying out any work, put on protective goggles and gloves which are resistant to
hydrocarbons.

Page 2 of 4
Figure : B1KH00ED
CAUTION : Plug the openings ; Using tool [0188-T].

Release the fixings (2) by a quarter turn ; By means of a screwdriver .
Slightly move aside : The heat shield (1).
Remove : The lower housing (3) with the flexible reservoir .
Page 3 of 4
Figure : B1KH00HD
Detach the flexible reservoir (6) from the lower housing (3).
Uncouple and close the pipe (5).
3. Refitting
Page 4 of 4
Figure : B1KH00KD
Couple the pipe (5) to the flexible reservoir (6).

Reinsert the flexible reservoir (6) in the lower housing (3).
CAUTION : The flexible reservoir (6) must not protrude sideways from the lower housing (3) : Risk of
damage (On reassembly) .
Refit : The lower housing (3).

Turn the fasteners (2) a quarter turn.
Connect the pipe (4).
CAUTION : Reset the additive counters to zero ; Using the diagnostic equipment.
Perform the actuator test "refilling the pipe: additive pump - additive injector" ; Using a diagnostic tool.
Page 1 of 5
TECHNICAL NOTE : ENGINE OIL CAPACITIES
CAUTION : Always check the oil level using the dipstick.
N.B. : Values given as an indication.
1. Petrol engines
1.1. Engines types EW
Engine type EW7A - EW7J4 - EW10J4 - EW10D - EW10J4S

EW10A EW12J4 - EW12A
Oil capacity without replacement of the filter 4,75 litres 4 litres 5 litres
cartridge
Oil capacity with replacement of the filter 5 litres 4,25 litres 5,25 litres
cartridge
Capacity between minimum and maximum on 1,7 litre 1,7 litre 1,5 litre
the oil gauge
1.2. Engines types EP
Engine type EP3 - EP3C - EP6 - EP6C - EP6CB - EP6CM - EP6DT - EP6DTS -
EP6CDT - EP6CDTM - EP6CDTMD - EP6CDTX
Oil capacity without replacement of 4 litres
the filter cartridge
Oil capacity with replacement of the 4,25 litres
filter cartridge
Capacity between minimum and 1,2 litre
maximum on the oil gauge
1.3. 4A92 - 4B11 - 4B12 engines
4A92 4B11 4B12

Oil capacity without replacement of the filter cartridge 4 litres 4,25 litres
Oil capacity with replacement of the filter cartridge 4,2 litres 4,3 litres 4,5 litres
Capacity between minimum and maximum on the oil gauge -
1.4. Engines types EB
Engine type EB0 - EB2 - EB2M

Oil capacity without replacement of the filter cartridge 3 litres
Page 2 of 5
Capacity between minimum and maximum on the oil gauge 1 litre
1.5. Engines types EC5
Engine type EC 5M FF EC 5M
1.6. 384F engine
Engine type 384F

Oil capacity with replacement of the filter cartridge 3 litres
1.7. Engines types ES9
Engine type ES9J4S ES9A - ES9J4 ES9A

Engine legislative type XFX XFV - XFU - XFW XFX
Oil capacity without replacement of the filter cartridge 5 litres 4,5 litres 4,25 litres
Oil capacity with replacement of the filter cartridge 5,25 litres 4,75 litres 4,5 litres
Capacity between minimum and maximum on the oil gauge 2 litres
1.8. ET3J4 engine
Engine type ET3J4

1.9. Engines types TU
Engine type TU1 - TU3 TU5 - TU9M

Oil capacity without replacement of the filter cartridge 2,75 litres 3 litres
Oil capacity with replacement of the filter cartridge 3 litres 3,25 litres
Capacity between minimum and maximum on the oil gauge 1,5 litre 1,5 litre
2. Diesel engines
2.1. Engines types DV
Engine type DV4TD - DV4C - DV6A - DV6AU - DV6B - DV6BU - DV6TED4 DV6UTED4
DV4TED - DV6C - DV6CM - DV6DTED - DV6DBM -
DV6ETED - DV6ETEDM
Page 3 of 5
Oil capacity without 3,25 litres 3,25 litres 4,75 litres

replacement of the filter
cartridge
Oil capacity with replacement 3,75 litres 3,75 litres 5 litres
of the filter cartridge
Capacity between minimum 1,8 litre 1,5 litre 1,5 litre
and maximum on the oil
gauge
2.2. Engines types DW10
Engine type DW10TD - DW10BTED4 -

DW10ATED4 DW10UTED4
Oil capacity with replacement of the filter cartridge 4,75 litres 5, 25 litres
Capacity between minimum and maximum on the oil 1,4 litre 2 litres
gauge
Engine type DW10CTED4 DW10CTED4

RPO number To 11918 From 11919
Colour : dipstick Handle : Yellow Handle : Orange
Engine type DW10CTED4
Engine legislative type RHD-RHE-RHH
Oil capacity without replacement of the filter cartridge 5,25 litres 4,75 litres
Oil capacity with replacement of the filter cartridge 5,5 litres 5 litres
Capacity between minimum and maximum on the oil gauge 1,7 litre 1 litre
Engine type DW10CD - DW10CE DW10DTED4

Engine legislative type AHZ - AHY RHB
2.3. Engines types DW12
Engine type DW12C - DW12BTED4 - DW12UTED - DW12TED4

DW12MTED4
Oil capacity without replacement of the filter 5 litres 4,5 litres
cartridge
Oil capacity with replacement of the filter cartridge 5,25 litres 4,75 litres
Capacity between minimum and maximum on the 1,7 litre
oil gauge
2.4. F30DTE engine

Page 4 of 5
Engine type F30DTE

EURO 4 EURO 5
Oil capacity with replacement of the filter cartridge 8,6 litres 9 litres
Capacity between minimum and maximum on the oil gauge 1 litre 1 litre
2.5. DT17ted4 engine
Engine type DT17TED4

Designation By gravity By suction
2.6. Engines types F28
Engine type F28D - F28DT - F28DTCR - F28DTSE

Designation 8140.63 - 8140.43- 8140.23 - 8140.43 S
Oil capacity without replacement of the filter cartridge 6 litres 7 litres
Capacity between minimum and maximum on the oil gauge - -
2.7. 4N13 engine
Engine type 4N13

2.8. DW8 engine
Engine type DW8

Designation Without air conditioning With air conditioning
2.9. DT20C engine
Engine type DT20C

Designation By gravity By suction
Page 5 of 5
2.10. 2,3 SOFIM engine
Engine type 2,3 SOFIM

2.11. PUMA 2.2 DTE engine
Engine type PUMA 2.2 DTE

EURO 4 EURO 5
Engine legislative type 4HV 4HU 4HM 4HG 4HH 4HJ
Oil capacity with replacement of the filter cartridge 6 litres 6,2 litres
2.12. F13DTE engine
Engine type F13DTE

Page 1 of 5
TECHNICAL NOTE : GENERAL ENGINE INFORMATION
1. Engine code
Figure : E1AB07LD
(1) : First 2 characters of the engine code.
First 2 characters engine Commercial designation

CF- 384F 1,0 l 12V
ZM- EB0 1.0 i VTI
HF- TU1 1,1 l
HM- EB2 1.2 i 16v VTI
KF- TU3 1,4 l
K6-
KF- ET3 1.4 16V
NF- TU5 1.6 16V
N6-
NF- EC5 1.6 l 16V
NK- 4A92 1,6 l 16V
AF- 4B11 2,0 l 16V
SF- 4B12 2,4 l 16V
8F- EP3 1.4 VTi 16V
Page 2 of 5
5F- EP6 1.6 VTi 16V

1.6 THP 16V
6F- EW7 1,8 l 16V
RF- EW10 2,0 l 16V
3F- EW12 2,2 l 16V
XF- ES9 V6 3,0 l 24V
8H- DV4 1,4 l HDi
9H- DV6 1,6 l HDi
6H- 4N13 1,8 l HDI
RH- DW10 2.0 HDi 16v
4H- DW12 2.2 HDi 16v
P22DTE 2.2 HDI (Puma) engine type
F1- F30DT 3.0 HDi (Sofim engine type)
UH- DT17 2.7 HDi 24v
X8- DT20 3.0 HDi 24v
2. petrol engines
384F EB0 TU1 TU3

Engine legislative type CFA ZMZ HFX/ HFV KFX KFV K6D/ K6F K6E KFT KFW KFS
Capacity (cc) 998 999 1124 1360
Bore (mm) 71 71 72 75
Travel (mm) 84 84 69 77
Maximum power : (KW EEC) 50 50 44 55 54 53 54 55
Engine speed at max. power (r.p.m.) 6000 6000 5500 5400 5300 5400 5200 5500
Maximum torque : (daNm EEC) 9,3 9,5 9,4 11,1 11,8 12
Engine speed at max. torque (r.p.m.) 3600 3000 3300 3400 3300 3400 3300 3400 2800
ET3 EB2 EB2 m TU5

Engine legislative type KFU HMZ HMY NFR NFZ N6A NFV NFV NFU NFS
Cubic capacity ( cc) 1360 1199 1587
Bore (mm) 75 75 78
Travel (mm) 77 90,5 77
Maximum power : (KW EEC) 65 60 52 66 65 78 70 80 90
Engine speed at max. power (r.p.m.) 5250 5750 5500 5800 5600 5700 5800 6500
Maximum torque : (daNm EEC) 13,3 11,8 11 13,2 13,5 14,2 13,5 14,7 14,3
Engine speed at max. torque (r.p.m.) 3250 2750 3000 2500 3000 4000 3000 4000 3750
4A92 4B11 4B12 EP3/ EP3C

Engine legislative type NKZ AFZ AFY SFZ/ SFY 8FS/ 8FP 8FR
Cubic capacity ( cc) 1590 1998 2359 1397
Bore (mm) 75 86 88 77
Page 3 of 5
Travel (mm) 90 86 97 75
Maximum power : (KW EEC) 86 108 113 125 70 72
Engine speed at max. power (r.p.m.) 6000
Maximum torque : (daNm EEC) 15,4 19,9 19,8 23,2 13,6
Engine speed at max. torque (r.p.m.) 4000 4200 4250 4100 4000
EP6/ EP6C EP6DT/ EP6CDT EP6DTS

Engine legislative type 5FK 5FP/ 5FW/ 5FS/ 5FT 5FX/ 5FN/ 5F4/ 5FV/ 5FM 5FY 5FF 5FD
5FJ 5FL 5FE 5FR
Capacity (cc) 1598
Bore (mm) 77
Travel (mm) 85
Maximum power : (KW EEC) 72 84 88 103 110 115 120 128 149 152
Engine speed at max. power 6000 5200 6000 5800 6000
(r.p.m.)
Maximum torque : (daNm 15,2 16 24 27,5
EEC)
Engine speed at max. torque 3500 4250 1400 1600 2000
(r.p.m.)
EP6CDTS EP6CDTX EW7A EW10A

Engine legislative type 5FU 5FU 6FZ 6FY RFN RFH RFJ
Capacity (cc) 1598 1749 1749 1997
Bore (mm) 77 82,7 82,7 85
Travel (mm) 85 81,4 81,4 88
Engine speed at max. power (r.p.m.) 6000 5800 5500 6000
Maximum torque : (daNm EEC) 25,5 27,5 16 17 19 18 20
Engine speed at max. torque (r.p.m.) 1600 1700 4000 3750 4100 4000
EW12J4 ES9 EC5

Engine legislative type 3FZ XFW XFV NFP
Capacity (cc) 2230 2946 1587
Bore (mm) 86 87 78,5
Travel (mm) 96 82,6 82
Maximum power : (KW EEC) 116 150 155 85
Engine speed at max. power (r.p.m.) 5650 6000 6000
Maximum torque : (daNm EEC) 21,7 28,5 29 15
Engine speed at max. torque (r.p.m.) 3900 3750 4000
3. diesel engines
DV4 DV6
Page 4 of 5
Engine legislative type 8HT 8HX 8HS/ 8HP/ 8HR 8HZ 8HY 9HW 9HN/ 9HK 9HT BHZ BHY
Capacity (cc) 1398 1560
Bore (mm) 73 75
Travel (mm) 82 88,3
Engine speed at max. power (r.p.m.) 4000 4000 3750
Maximum torque : (daNm EEC) 13 15 16 16 20 17,5 18,5 30 25,4
DV6 DW8
Engine legislative type 9HH/ 9HF/ 9HU 9HX/ 9HP/ 9HY/ 9HL 9HR 9HG WJZ/
9HM 9HE 9HV 9HJ 9HZ WJY
Bore (mm) 75 82,2
Travel (mm) 88,3 88
Engine speed at max. power 4000 4600
(r.p.m.)
Maximum torque : (daNm 18 21,5 18 21,5 23 24 27 25,4 12,5
EEC)
Engine speed at max. torque 1500 1750 1500 1750 2500
(r.p.m.)
DW10
Engine legislative type RHV RHY AHY RHS/ RHM RHT RHG/ RHK RHL AHZ RHJ RHR/ RHD
Capacity (cc) 1997
Bore (mm) 85
Travel (mm) 88
Maximum power : (KW EEC) 62 66 72 79 80 88 93 94 100 100
Engine speed at max. power (r.p.m.) 4000
Maximum torque : (daNm EEC) 19,2 20,5 26 25 27 30 32 32 27 32
Engine speed at max. torque (r.p.m.) 1900 1500 1750 2000
DW10 DW12
Engine legislative type RHF RHE RHH RHC 4HW 4HN/ 4HK 4HP 4HR 4HT
Bore (mm) 85 85
Travel (mm) 88 96
Maximum power : (KW EEC) 103 110 120 94 115 120 120 125
Engine speed at max. power (r.p.m.) 4000 3750 3850 3750 4000
Maximum torque : (daNm EEC) 32 34 30 31,4 38 37 40 37
DW12 DT17 DT20 P22DTE

Page 5 of 5
Engine legislative type 4HS 4HL UHZ X8Y X8Z 4HV/ A 4HU/ B 4HM
Capacity (cc) 2179 2720 2993 2993 2198
Bore (mm) 85 81 84 86
Travel (mm) 96 88 90 94,6
Maximum power : (KW EEC) 125 150 177 175 74 88 95
Engine speed at max. power (r.p.m.) 4000 3500 4000 3800 2900 3500
Maximum torque : (daNm EEC) 40 45 44 50 45 25 32
F30DT 4N13
Engine legislative type F1CE0481D 6HZ
Bore (mm) 88 83
Travel (mm) 94 83,1
Maximum power : (KW EEC) 115 110
Engine speed at max. power (r.p.m.) 3500 4000
Maximum torque : (daNm EEC) 40 30
Engine speed at max. torque (r.p.m.) 1700 2000
4. Electric motors
ION/C-Zero Partner/Berlingo
Venturi
Engine legislative type ZKZ -
Engine type Triple-phase synchro motor
Maximum power : (KW EEC) 49 42
Continuous power 35 -
Engine speed at max. power (r.p.m.) 2500 to 8000 rpm -
Maximum torque : (daNm EEC) 18
Engine speed at max. torque (r.p.m.) 0 to 2000 rpm -
Page 1 of 3
TIGHTENING TORQUES : COMPONENTS OF THE FUEL CIRCUIT DV6D - DV6DM
1. Fuel main tank
Figure : B1HB18WD
Reference Designation Tightening torque

(1) bolts (Fuel filler neck) 1 daNm
Page 2 of 3
Figure : B1HB18XD

(2) bolts (Fuel main tank) 1,5 daNm
(3) Nuts (Fuel main tank) 1,5 daNm
2. Fuel additive tank (engine version DV6DTED)

Page 3 of 3
Figure : B1HB18YD

(1) bolts (Additive tank / Fuel tank) 0,4 daNm
Page 1 of 32
TIGHTENING TORQUES : DV4C, DV6C, DV6DTED, DV6ETED, DV6UC ENGINES (EURO 5)
1. Cylinder head
1.1. Tightening torques
Figure : B1BB0PMD
Reference Designation Stage Tightening torque

(1) bolts (Cylinder head) (*) Pre-tighten 2 daNm
Tightening 4 daNm
Angular tightening 260°
(2) bolts (Rear upper timing cover ) (*) Tightening 1 daNm
(3) bolts (Oil trap) (*) Pre-tighten 0,5 daNm
Tightening 1,3 daNm
(4) bolts (Camshaft bearings covers) (*) Pre-tighten 0,3 daNm
Tightening 1 daNm
(5) bolts ( vacuum pump) Pre-tighten 0,5 daNm
Tightening 1,8 daNm
(6) bolts ( vacuum pump) Pre-tighten 0,5 daNm
Tightening 2 daNm
(7) bolts ( lifting bracket ) Tightening 2 daNm
Page 2 of 32
(8) nuts (Exhaust manifold heat shield) Tightening 0,8 daNm

(9) nuts (Exhaust manifold) Tightening 2,5 daNm
(10) studs (Exhaust manifold) Tightening 1 daNm
(11) Pre-heater plugs Tightening 0,6 daNm
(*) Follow the tightening sequence
1.2. Order of tightening of the 10 cylinder head bolts (1)
Figure : B1BB1MHD
1.3. Sequence of tightening of screws (2) and (3)

Page 3 of 32
Figure : B1BB0MID
(2) : bolts (Rear upper timing cover ).

(3) : bolts (Oil trap).
1.4. Order of tightening of the camshaft main bearing cap casing bolts (4)
Page 4 of 32
Figure : B1BB1MID
2. Cylinder block
Page 5 of 32
Figure : B1BB0MJD
Reference Designation Stage Tightening

torque
(1) Caps (Cylinder block ) Tightening 3,2 daNm
(2) bolts (Conrods) Pre-tighten 0,5 daNm
Tightening 1 daNm
Angular 130°
tightening
(3) bolts (Double damped flywheel) (according to equipment) (*) Pre-tighten 2,5 daNm
Slackening -
Pre-tighten 0,8 daNm
Tightening 3 daNm
Angular 90°
tightening
bolts (Engine flywheel) (according to equipment) (*) Pre-tighten 2,5 daNm
Slackening -
Angular 75°
tightening
(4) bolts (Crankshaft main bearing cap casing) (*) Pre-tighten 0,6 daNm
Tightening 0,8 daNm
(5) bolts (Crankshaft main bearing cap casing) (*) Pre-tighten 0,6 daNm
Tightening 0,8 daNm
Page 6 of 32
(6) bolts (Bearing caps) (*) Pre-tighten 1 daNm

Angular 180°
slackening
Tightening 3 daNm
Angular 140°
tightening
(7) bolts (Accessories drive pulley) Pre-tighten 3,5 daNm
Angular 190°
tightening
(8) studs (Catalytic converter/particle filter assembly) (according to Tightening 0,6 daNm
equipment)
2.2. Order of tightening of the flywheel bolts (3)
Figure : B1BB1MLD
2.3. Order of tightening of the crankshaft bearing cap and bearing cap housing bolts (4), (5),
(6)
Page 7 of 32
Figure : B1DB01BD
(4) : bolts (Crankshaft main bearing cap casing) ( bolts M6 ).

(5) : bolts (Crankshaft main bearing cap casing) ( bolts M6 ).
(6) : bolts (Bearing caps) ( bolts M9 ).
Tightening procedure :
 Pre-tightening of the 10 bolts (6) to 1 m.daN (from 1 to 10)
 Pre-tightening of the 14 bolts (5) to 0,6 m.daN (from 11 to 24)
 Tightening of the 2 bolts (4) to 0,8 m.daN (inside the flywheel bell housing)
 Slackening of the bolts (6) by 180°
 Tightening of the 10 bolts (6) to 3 m.daN (from 1 to 10)
 Angular tighten the screws (6) to 140 ° (from 1 to 10)
 Tightening of the 14 bolts (5) to 0,8 m.daN (from 11 to 24)
3. Lubrication
Page 8 of 32
Figure : B1FB00ZD

(1) bolts (Oil pump assembly ) (*) Pre-tighten 0,5 daNm
Tightening 0,9 daNm
(2) Oil level sensor Tightening 3 daNm
(3) bolts (Turbocharger lubricating pipe) Tightening 3 daNm
(4) bolts (Turbocharger lubrication return pipe) Tightening 0,8 daNm
(5) collars (Turbocharger lubrication return pipe) Tightening 0,3 daNm
(6) Oil filter cover Tightening 2,5 daNm
(7) bolts (Oil filter support) Tightening 1 daNm
(8) bolts (Turbocharger electrovalve support) Tightening 1 daNm
(9) bolts ( sump) Tightening 1,2 daNm
(10) bolts ( coolant/oil heat exchanger) Tightening 1 daNm
(11) drain plug Tightening 3,4 daNm
(12) Oil pressure switch Tightening 3,2 daNm
(13) bolts (Dipstick guide tube) Tightening 0,8 daNm
(14) studs ( sump) Tightening 0,8 daNm
(15) bolts (Oil suction strainer) Tightening 1 daNm
(16) bolts (Piston skirt spray jets) Tightening 2 daNm
(17) bolts (Oil filler return tube) Tightening 1 daNm
3.2. sump - Except DV6UC engine

Page 9 of 32
Figure : B1FA00WD
(9a) : nut( sump).

(9b) : bolts ( sump).
(14) : studs ( sump).
3.3. sump - DV6UC engine
Page 10 of 32
Figure : B1BB1DCD
Lower oil sump :

 (9a) : nuts (x2)
 (9b) : bolts (x15)
 (14a) : studs (x2)
Upper oil sump :

 (9c) : bolts (x7)
 (9d) : nuts (x2)
 (14b) : studs (x2)
3.4. Sequence of tightening the bolts - Oil pump assembly (1)

Page 11 of 32
Figure : B1FB010D
4. Timing gear
Page 12 of 32
Figure : B1EB00ED
Reference Fixings Tightening procedure

(1) bolts (Camshaft pulley ) Pre-tighten to 2 daNm
Angular tightening to 50°
(2) bolts (Camshaft bearing caps) Pre-tighten to 0,3 daNm
Tightening to 1 m.daN
(3) nut(Timing belt roller bearing ) Tightening to 3,7 m.daN
(4) Stud (Timing belt roller bearing ) Tightening to 0,6 m.daN
(5) bolts (Shift prevention bracket) Tightening to 0,6 m.daN
(6) bolts (Engine speed sensor ) Tightening to 0,8 m.daN
(7) bolts (Timing belt tensioner roller) Tightening to 3 m.daN
(8) bolts (Lower timing cover) Tightening to 0,5 m.daN
(9) bolts (Upper timing cover ) Tightening to 0,4 m.daN
(10) bolts (Camshaft position sensor) Tightening to 0,8 m.daN
4.2. Order of tightening of the camshaft main bearing cap casing bolts (2)
Page 13 of 32
Figure : B1BB1MMD
5. Turbocharging circuit
5.1. Engines DV6 euro 5 - Engines DV4 euro 5 (STOP AND START version)
Page 14 of 32
Figure : B1BB0THD

(1) bolts (Inlet air metering unit ) Tightening 0,8 daNm
(2) bolts (Inlet air pressure and temperature sensor) Tightening 0,8 daNm
(3) bolts (Air filter chamber) Tightening 0,8 daNm
(4) bolts (Air filter cover) Tightening 0,5 daNm
(5) bolts (Air filter unit mounting) Tightening 0,8 daNm
(6) bolts (Air flow meter ) Tightening 0,3 daNm
(7) bolts (Turbocharger inlet duct) Tightening 0,7 daNm
(8) nut(Variable geometry turbocharger control solenoid valve) Tightening 0,8 daNm
(9) nut( turbocharger) Tightening 2,6 daNm
(10) bolts (Turbocharger air cooler) Tightening 0,8 daNm
(11) collars (Hoses ) Tightening 0,3 daNm
(12) bolts (Turbo air cooler by-pass unit) Tightening 0,8 daNm
(13) bolts (Turbocharger noise attenuator ) Tightening 0,7 daNm
(14) bolts (Air inlet manifold) Tightening 0,8 daNm
5.2. DV4 EURO 5 engine (Without stop and start)

Page 15 of 32
Figure : B1BB0TID

(1) bolts (Inlet air metering unit ) Tightening 0,8 daNm
(2a) bolts (Inlet air pressure sensor) Tightening 0,8 daNm
(2b) bolts (Inlet air temperature sensor) Tightening 0,8 daNm
(3) bolts (Air filter chamber) Tightening 0,8 daNm
(4) bolts (Air filter cover) Tightening 0,5 daNm
(5) bolts (Air filter unit mounting) Tightening 0,8 daNm
(6) bolts (Air flow meter ) Tightening 0,3 daNm
(7) bolts (Turbocharger inlet duct) Tightening 0,7 daNm
(8) nut(Variable geometry turbocharger control solenoid valve) Tightening 0,8 daNm
(9) nut( turbocharger) Tightening 2,6 daNm
(13) bolts (Turbocharger noise attenuator ) Tightening 0,7 daNm
(14) bolts (Air inlet manifold) Tightening 0,8 daNm
(16) bolts (Vacuum circuit) Tightening 0,8 daNm
6. Exhaust gas recirculation circuit

Page 16 of 32
Figure : B1KB006D

(1) bolts (EGR exchanger module) Tightening 0,8 daNm
(2) bolts (EGR pipe) Tightening 0,8 daNm
(3) nut(EGR exchanger module) Tightening 0,8 daNm
(4) bolts (EGR exchanger module) Tightening 2 daNm
(5) nut(EGR (exhaust gas recycling) electrovalve) Tightening 0,8 daNm
(6) bolts (EGR electrovalve support) Tightening 0,8 daNm
(7) bolts (Coolant inlet manifold) Tightening 2 daNm
(8) bolts (Coolant pipe) Tightening 0,8 daNm
(9) bolts (Vacuum pipe support) Tightening 0,8 daNm
7. Engine cooling system

Page 17 of 32
Figure : B1GB00DD

(1) bolts (Coolant outlet housing) (*) Pre-tighten 0,3 daNm
Tightening 0,8 daNm
(2) bolts (Coolant pump) (*) Pre-tighten 0,5 daNm
Tightening 0,9 daNm
(3) bolts (Coolant inlet manifold) Tightening 2 daNm
(4) bolts (Coolant pipe) Tightening 0,8 daNm
7.2. Order of tightening of the 4 coolant outlet housing fixing bolts (1)
Page 18 of 32
Figure : B1BB1MJD
7.3. Order of tightening of the coolant pump fixing bolts (2)

Page 19 of 32
Figure : B1BB1MKD
8. Injection system
8.1. injection CONTINENTAL (engine DV6C )
Figure : B1BB1MFD

torque
(1) Connections (Diesel injector ) Pre-tighten 2 daNm
Tightening 2,5 daNm
(2) Connections (Fuel high pressure pipes / Fuel high pressure Pre-tighten 2 daNm
common injection rail ) Tightening 2,5 daNm
(3) Union (High-pressure fuel pipe / Fuel high pressure pump) Pre-tighten 2 daNm
Tightening 2,5 daNm
(4) bolts (Fuel high pressure pump rear bracket) Tightening 1 daNm
(6) bolts (Diesel injector fixing flange) Pre-tighten 0,7 daNm
Angular 80°
tightening
(7) bolts (Fuel high pressure pump front bracket) Tightening 2 daNm
(8) bolts (Fuel injection pump / Bracket ) Tightening 2 daNm
Page 20 of 32
(9) Fuel injection pump pulley nut Tightening 5 daNm

(11) bolts (Fuel high pressure common injection rail / Engine block) Tightening 2 daNm
(12) Fuel high pressure sensor Tightening 4,5 daNm
(13) bolts (Fuel pressure regulator / Fuel high pressure pump) Pre-tighten 0,3 daNm
Tightening 0,7 daNm
8.2. BOSCH injection (DV EURO5 engines) (All types except for DV6C)
Figure : B1BB1MGD

torque
(1) Connections (Diesel injector ) Pre-tighten 2 daNm
Tightening 2,5 daNm
(2) Connections (Fuel high pressure pipes / Fuel high pressure Pre-tighten 2 daNm
common injection rail ) Tightening 2,5 daNm
(3) Union (High-pressure fuel pipe / Fuel high pressure pump) Pre-tighten 2 daNm
Tightening 2,5 daNm
(6) bolts (Diesel injector fixing flange) Pre-tighten 0,7 daNm
Angular 80°
tightening
(7) bolts (Fuel high pressure pump front bracket) Tightening 2 daNm
Page 21 of 32
(8) bolts (Fuel injection pump / Bracket ) Tightening 2 daNm

(9) Fuel injection pump pulley nut Tightening 5 daNm
(11) bolts (Fuel high pressure common injection rail / Engine block) Tightening 2 daNm
(12) Fuel high pressure sensor Tightening 4,5 daNm
(13) bolts (Fuel pressure regulator / Fuel high pressure pump) Pre-tighten 0,3 daNm
Tightening 0,7 daNm
8.3. Fuel filter
Figure : B1BB0PPD

(13) bolts (Fuel filter cover) Tightening 0,3 daNm
(14) bolts (Fuel filter ) Tightening 0,8 daNm
(15) bolts (Fuel filter support) Tightening 0,8 daNm
9. Engine equipment - Without stop and start

9.1. Alternator - Without stop and start
Page 22 of 32
Figure : D1CB004D

(1) bolts (Multifunction support) Tightening 2 daNm
(2) bolts (Alternator ) Tightening 4,9 daNm
(3) nut(Alternator power circuit ) Tightening 1,6 daNm
9.2. Version with air conditioning

Page 23 of 32
Figure : C5HB00OD

(5) bolts (Air conditioning compressor support) Tightening 2 daNm
(7) bolts ( air conditioning compressor) Tightening 2,4 daNm
(8) studs (Air conditioning compressor support) Tightening 0,6 daNm
9.3. Version without air conditioning

Page 24 of 32
Figure : B1BB0TKD

(5) bolts (Support for auxiliary equipment) Tightening 2 daNm
9.4. Dynamic roller tensioner - Electric power steering - Without stop and start
Page 25 of 32
Figure : B1BB0MKD

(1) bolts (Alternator upper support) Tightening 2 daNm
(9) bolts (Dynamic roller tensioner ) Tightening 2 daNm
9.5. Dynamic roller tensioner - Hydraulic power steering - Without stop and start
Page 26 of 32
Figure : B1BB1DJD

(3) nut (Alternator power circuit ) Tightening 1,6 daNm
(10) bolts (Roller tensioner) Tightening 4,5 daNm
(11) bolts (Automatic roller tensioner ) Tightening 3 daNm
(12) bolts (Automatic roller tensioner ) Tightening 2,1 daNm
10. Engine equipment - STOP AND START version

10.1. Reversible alternator - STOP AND START version
Page 27 of 32
Figure : B1BB1DLD

(1) bolts (Multifunction support) Tightening 2 daNm
(2) bolts (Reversible alternator) Tightening 4,3 daNm
(3) nut(Alternator power circuit ) Tightening 1,6 daNm
(6) nuts (Air conditioning compressor support) Tightening 2 daNm
10.2. Version with air conditioning - STOP AND START version

Page 28 of 32
Figure : B1BB1DMD

(6) nuts (Air conditioning compressor support) Tightening 2 daNm
(7) bolts ( air conditioning compressor) Tightening 2,4 daNm
10.3. Version without air conditioning - STOP AND START version

Page 29 of 32
Figure : B1BB1DND

(13) bolts (Ancillary drive belt roller pulley support) Tightening 2 daNm
10.4. Dynamic tensioner rollers - STOP AND START version

Page 30 of 32
Figure : B1BB1DOD

(9) bolts (Upper dynamic tensioner roller) Tightening 2 daNm
(14) bolts (Lower dynamic tensioner roller) Tightening 2 daNm
11. Starter
CAUTION : (*) Follow the tightening sequence.

Page 31 of 32
Figure : D1BB00HD
Reference Fixings Tightening procedure

(1) bolts - Starter (*) Tightening to 2 m.daN
(2) nut- Starter supply cable Tightening to 1 m.daN
(3) nut- Starter energising cable Tightening to 0,5 m.daN
11.2. Sequence of tightening the bolts (1)

(1) bolts - Starter .
Page 32 of 32
Figure : D1BB00KD
Tighten the bolts (1) in the sequence indicated.

Page 1 of 7
TIGHTENING TORQUES : ENGINE ASSEMBLY MOUNTINGS - GEARBOX
1. RH engine support
Figure : B1BB0HJD
Reference Designation Tightening torques

(1) bolts (Upper right-hand flexible engine mounting) 6 daNm
(2) bolts (Right side upper engine mounting) 6 daNm
(3) bolts (Right-hand intermediate engine mounting ) 5,5 daNm
2. Reaction rod
2.1. BE gearbox
Page 2 of 7
Figure : B1BB0T8D

(1) bolts (Reaction link yoke / gearbox) 6 daNm
(3) bolts (Reaction rod / Front subframe) 4 daNm
(4) Bolt-nut assembly (Reaction rod / Reaction link yoke) 4 daNm
2.2. MCM - MCP gearbox

Page 3 of 7
Figure : B1BB1K5D
Type MCM MCP type

Reference Designation Tightening torques Tightening torques
(6) bolts (Reaction link yoke / gearbox) 6 daNm 6 daNm
(7) bolts (Reaction rod / Front subframe) 4 daNm 6 daNm
(8) bolts (Reaction rod / Reaction link yoke) 4 daNm 4 daNm
3. Impacter (according to equipment)
Page 4 of 7
Figure : B1BB0TAD

(1) Screws on gearbox housing 4 daNm
(2) Nuts (Impacter / gearbox) 4 daNm
4. gearbox mounting
4.1. BE gearbox
Page 5 of 7
Figure : B1BB0TBD

(1) bolts (Flexible bush / gearbox) 6 daNm
(2) bolts (Upper flexible mounting / Body) 5,5 daNm
(3) bolts (Lh intermediate support / Gearbox casing) 6 daNm
4.2. MCM - MCP gearbox

Page 6 of 7
Figure : B1BB0TCD

(4) bolts (Upper flexible mounting / Body) 5,5 daNm
(5) bolts (Flexible bush / Gearbox support on gearbox) 6 daNm
(6) bolts (Lh intermediate support / Gearbox casing) 6 daNm
5. Driveshaft bearing
Page 7 of 7
Figure : B1BB1QBD

(1) bolts (Right-hand driveshaft bearing / Cylinder block ) 5.3 daNm
(2) Nuts (Driveshaft bearing bolt) 3 daNm
Page 1 of 4
TIGHTENING TORQUES : EXHAUST SYSTEM
1. Exhaust system
N.B. : The factory fit rear exhaust line is monoblock.
1.1. Original fit
Figure : B1JB093D
"a" Cutting zone (marked by burrs).

(1) nut- Intermediate mounting Tightening to 0,8
m.daN
(2) nuts - Rear support Tightening to 0,8
m.daN
(3) nuts - Front support Tightening to 0,8
m.daN
(4) Clip - Catalytic converter and particle filter (according to equipment) / Front Tightening to 2,5
pipe m.daN
1.2. Service fit

Page 2 of 4
Figure : B1JB078D
45 mm diameter.

(5) Connecting sleeve TORCA Tightening to 3,5 m.daN
Connecting sleeve CAILLAU Tightening to 2,1 m.daN
2. Catalytic converter and particle filter

Page 3 of 4
Figure : B1KB00DD

(4) Clip - front pipe / Catalytic converter and particle filter (according to Tightening to 2,5
equipment) m.daN
(6) Oxygen sensor (according to equipment) Tightening to 5
m.daN
(7) Clip - catalytic converter/ turbocharger Tightening to 2,5
m.daN
(8) bolts - Front catalytic converter heat shield Tightening to 0,8
m.daN
(9a) nuts - Exhaust catalytic converter / Cylinder block Tightening to 2,5
m.daN
(9b) studs - Exhaust catalytic converter / Cylinder block Tightening to 0,6
m.daN
(10) Clip - catalytic converter/ Particle filter (according to equipment) Tightening to 2,3
m.daN
(11) Particle filter inlet exhaust pressure pipe (according to equipment) Tightening to 2
m.daN
(12) Particle filter outlet exhaust pressure pipe (according to equipment) Tightening to 2
m.daN
(13) bolts - Retaining bracket / Exhaust gas pressure sensor pressure take- Tightening to 0,3
offs (according to equipment) m.daN
(14) Exhaust gas temperature sensor Tightening to 3
m.daN
(15) bolts - Connector support / Particle filter exhaust differential pressure Tightening to 0,8
Page 4 of 4
sensor (according to equipment) m.daN

(16) bolts - Particle filter exhaust differential pressure sensor (according to Tightening to 0,8
equipment) m.daN
Page 1 of 3
ADJUSTMENT : GEARBOX CONTROLS
CAUTION : An incorrect adjustment may make it difficult to engage gears.
1. Tooling

[0317-AU] Gear selection lever positioning gauge
Figure : E5AB0IVT
2. Preliminary operation
Remove the central console .
Remove the gear lever knob.
3. Adjustment
Page 2 of 3
Figure : B2CF04VD
Uncouple : The ball-joints (3).

Unlock : The gear engagement and selection control cables from the gear controls unit :
 Push the cylinders (1) in the direction of the arrow "a"
 Push the locking keys (2)
Page 3 of 3
Figure : B2CF04WD
Immobilise the gear lever ; Using tool [0317-AU].

Couple the ball-joints (3) on the gear lever.
Lock the locking keys (2).
Remove the tool [0317-AU].
Check all gear changes.
Refit the gear lever knob.
Refit the central console .
Page 1 of 3
ADJUSTMENT : GEARBOX CONTROLS
CAUTION : An incorrect adjustment may make it difficult to engage gears.
1. Tooling

[0317-AU] Gear selection lever positioning gauge
Figure : E5AB0IVT
Remove the central console .
Remove the gear lever knob.
3. Adjustment
Page 2 of 3
Figure : B2CF04VD
Uncouple : The ball-joints (3).

Unlock : The gear engagement and selection control cables from the gear controls unit :
 Push the cylinders (1) in the direction of the arrow "a"
 Push the locking keys (2)
Page 3 of 3
Figure : B2CF04WD
Immobilise the gear lever ; Using tool [0317-AU].

Couple the ball-joints (3) on the gear lever.
Lock the locking keys (2).
Remove the tool [0317-AU].
Check all gear changes.
Refit the gear lever knob.
Refit the central console .
Page 1 of 9
REMOVING - REFITTING : CLUTCH MECHANISM
CAUTION : In order to improve the centering of the friction plate and to eliminate engine jerks, vibrations
and noise, compress the clutch mechanism when tightening the fixing bolts ; Using tool [0217].
CAUTION : Always replace the clutch bearing when replacing the clutch mechanism or the clutch disc.
1. Tooling

[0217] Clutch mechanism compression tool
[0217-A] Clutch mechanism compressor
[0217- Retaining rod (Ø 8 mm)

B2Z]
[0217-Cx] Clutch centring drift (According to

gearbox (see table below))
Figure : E5AG04PT
Clutch centring drift

Engine types [0217-C1] [0217-C2] [0217-C3Z] [0217-C4] [0217-C5Z] [0217-C6Z] [0217-C7]
DV4 BE MA/MAP
DV4 C MA/MAP
DV6 MCM BE MCP
DV6UC BE
DV6DU (M) BE
DV6C (M) MCP/ML MCP/MCM BE
DV6D (M) BE/MCP MCP
DV6E (M) BE
DW10 ML/BE MCP MCP
DW12 ML W6MBA
4B12 W5MBA
EB0 MA
EB2 MA/MAP
Page 2 of 9
EB2M MA/MAP
EC5 MA BE
EP3 - EP3C BE/MA/MAP
EP6 - EP6C (M) BE/MA/MCM/ MCP
EP6CDTR MCM
EP6DTS MCM
EP6CDT MCP MCM/MCP
EP6CDTX MCM
ES9 ML
ET3 MA/MAP
EW10 BE/MCP
EW12 BE
EW6 BE
EW7 BE
TU1 MA
TU3 MA/MAP
TU5 MA/MAP BE
SOFIM MLGU5 M40
PUMA MLGU5/MLGU6
1,3 DTE MTM/MTA
2. Removing
Remove the gearbox.
Page 3 of 9
Figure : B2BG01DD
Fit the tool [0217-CX].
Figure : B2BG08ED
Remove the 3 bolts (1) (Every second bolt).

CAUTION : Some engine flywheels have open threads. Do not let the threads of the 3 retaining rods
protrude when tightening; Risk of distortion of the secondary engine flywheel.
CAUTION : On compression of the clutch mechanism ; Do not go beyond the point of resistance when
tightening the central bolt of the tool [0217-A]. The tightening must not exceed 10 turns clockwise.
Compress the clutch mechanism (2) with the central bolt of tool [0217-A] (at "a").
Finish removing the remaining bolts (1).
Release the clutch mechanism (2) by moving the central bolt of the tool [0217-A] (at "a").
Remove tools [0217-A] and [0217-B2Z].
Remove :
 The clutch disc
3. Preparation for removal

3.1. Checking - Cleaning
Page 4 of 9
Visually check :
 The flywheel face for damage or scores
 The flywheel for wear
 The condition of the starter ring gear
If there is oil in the clutch mechanism (2) :

 Check the condition of the crankshaft ring seal
 Check the condition of the input shaft ring seal
CAUTION : Do not reuse a clutch disc the hub of which bears traces of corrosion or grease.
Remove corrosion and grease from the following parts ; Using a degreaser Index "N1" :
 The clutch housing
 The primary shaft
 The clutch bearing guide (according to equipment)
 The clutch fork (according to equipment)
N.B. : In the case of significant corrosion, use a metal brush without damaging the parts.
3.2. Greasing
CAUTION : The greasing stage must be observed strictly.
Figure : B2BG08FD
Page 5 of 9
CAUTION : Protect the interior of the clutch housing from splashes of grease.
Vehicles equipped with a gearbox that has a mechanical clutch bearing Spray a little grease MOLYCOTE G-
RAPID PLUS (aerosol) on the splines of the primary shaft and on the clutch bearing guide tube (at "b"
and "c").
Vehicles equipped with a gearbox that has a hydraulic clutch bearing : Grease the splines of the primary
shaft with MOLYCOTE G-RAPID PLUS (at "c").
CAUTION : Do not soil the lining of the clutch disc ; Risk of slipping.
Put the clutch disc (3) in place on the grooved shaft and carry out several translational movements to distribute
the grease.
Remove the clutch disc .
Figure : B2BG08GD
CAUTION : An excess of grease will contaminate the clutch friction plate and cause noise in neutral, slipping
or juddering of the clutch.
"d" : Traces of grease present on a clutch disc contaminated as a result of a surplus of grease.
"e" : Traces of greases present on a clutch housing contaminated as a result of a surplus of grease.
CAUTION : Clean off all traces of grease which may splash onto the friction plate during rotation.
Remove the surplus grease on the top of the grooves and the end of the input shaft using a cloth.
N.B. : The film of grease applied to the rotating components must be as thin as possible to avoid splashes.
Page 6 of 9
4. Refitting
CAUTION : Observe the tightening torque values.
Figure : B2BG08HD
CAUTION : When refitting, place the face of the clutch disc, where the N° PSA 96 XXX XXX 80 is marked,
gearbox end.
Refit the clutch disc (3).

Centre the clutch disc (3) ; Using tool [0217-CX].
Page 7 of 9
Figure : B2BM01JD
CAUTION : The clutch mechanism and disc are paired at the factory and cannot be replaced separately.
CAUTION : Any fitting of a clutch mechanism with automatic free play adjustment (whether new or re-used)
must compulsorily be performed using the compression tool [0217].
Refit the clutch mechanism (2).
N.B. : Do not remove the tool [0217-CX].

Page 8 of 9
Figure : B2BG08ID
CAUTION : No resetting of the clutch wear adjustment is permitted.
Tighten the 3 bolts (1) by hand.
Page 9 of 9
Figure : B2BG08JD
Gradually compress the clutch mechanism (2) until it is in contact with the primary engine flywheel (at "f").
Check that there is no friction :
 Apply slight force to the clutch disc (3) to check the rotation ; Using a thin, flat screwdriver
 If rotation is difficult or impossible, continue the clutch mechanism compression operation very gradually
until it rotates (1/8 th turn on the bolt of the tool [0217-B2Z])
If it is not possible to check that there is no friction (clutch disc inaccessible), tighten the central bolt of the tool
[0217-B2Z] by another two turns to maximum.
Tighten the 3 bolts (1) to the specified torque.
Unscrew the centre bolt of the tool [0217-A] (at "a") by several turns to detension the clutch mechanism (2).
Remove tools [0217-A], [0217-B2Z] and [0217-CX].
Refit and tighten the remaining 3 bolts (1).
Refit the gearbox.
Page 1 of 26
DISMANTLING : MANUAL GEARBOX
1. Tooling
Presentation : Tooling .
2. Removing
Page 2 of 26
Figure : B2CM0LXD
Remove the reverse gear switch (1).

Page 3 of 26
Figure : B2CM0XGD
Remove :
 The vent plug (2)
 The speedometer drive pinion and support (3) (according to equipment)
 The RH driveshaft seal (4)
 The drain cap (5)
 The left-hand driveshaft seal (6)
 The top-up plug (7)
Page 4 of 26
Figure : B2CM0XHD
Remove :
 The clutch thrust bearing (8)
 The clutch fork (9)
 The clutch fork ball joint
2.1. 5th speed gear

Page 5 of 26
Figure : B2CG043D
Remove :
 The bolts (11)
 The casing (10)
Figure : B2CG04ID
Page 6 of 26
Engage 5th gear.

Remove the split pin (15) ; Using a pin punch .
Move the control to the neutral position.
N.B. : The fork must remain in position.
Engage a different gear to lock the forks in rotation.

Remove :
 The circlip (14)
 The nuts (12), (13)
Page 7 of 26
Figure : B2CM0MXD
Fit the tool [3].

Extract the hub ; Using tool [3].
Page 8 of 26
Figure : B2CG04JD
Mark the position of the hub (16) in relation to the synchronizer (17).
Remove the hub-synchroniser assembly (16), (17) together with the fork (18).
Figure : B2CG04KD
Page 9 of 26
Remove :
 The 5th speed driving gear (19)
 The thrust washer (20)
 The spacer (21)
2.2. gearbox casing
Figure : B2CG04LD
Remove :
 The output shaft bearing stop bolts (24)
 The fork shaft stop plate (22)
 The retaining screw (25) of the reverse inverter drive pin
 The bolts (23)
Page 10 of 26
Figure : B2CG04MD
Remove :
 The circlip (26) (using 2 sharp points if necessary, lift the shaft to help it to disengage)
 The gearbox casing (27)
N.B. : Use a mallet to free the casing from the centring rings.
2.3. Primary and secondary shafts

Page 11 of 26
Figure : B2CG04ND
Remove the oil filler tube (28).
Figure : B2CG04OD
Remove the reverse shaft and sliding gear (30).

Page 12 of 26
Rotate and remove the 5th gear shaft (29).
Figure : B2CG04PD
Remove the fork pin (31) by pulling upwards.
Figure : B2CG04QD
Page 13 of 26
Pivot the fork (32).

Disengage the clutch casing shafts by a few millimetres (towards the top).
Tilt the right hand part of the fork downwards.
Remove the fork (32).
Figure : B2CG04RD
Remove the primary shaft (34) and secondary shaft (33) assembly.
Page 14 of 26
Figure : B2CG04SD
Remove :
 The stop guide (36)
 The adjusting shim (38)
 The bearing outer race (37)
2.4. differential box

Page 15 of 26
Figure : B2CG04TD
Remove :
 The bolts (39)
 The final drive extension (40)
Retrieve :
 The speedometer drive gear (42)
 The O-ring (41)
 The positioning shim (43) (if fitted)
Remove :
 The bolts (44)
 The bolts (45)
Page 16 of 26
Figure : B2CG04UD
N.B. : The differential casing (46) has notches "a" and "b" to facilitate removal.
Place a screwdriver in the notches "a" and "b" and lever up.
Figure : B2CG04VD
Page 17 of 26
Remove :
 The differential housing (46)
 The differential housing (47) fitted with its bearing outer races
3. Gear selector
N.B. : Some BE4/5 gearboxes have a 5th gear/reverse gear change prohibition system.
3.1. Composition of the device
Figure : B2CG04WD
(48) : Prohibition pin.

(49) : Prohibition support retained by 2 screws in the gearbox casing.
CAUTION : The pin (48) when fitted on must project beyond the clutch housing joint face ("X" = 8 ± 0,5
mm ). The use of tool [5] guarantees this insertion dimension.
Page 18 of 26
Figure : B2CG04XD
N.B. : Gearboxes that do not have a 5th gear/reverse gear change prohibition have conventional double
shafts (51) and (52) on the gear engagement shaft (50).
3.2. Removing
Page 19 of 26
Figure : B2CG04YD
Remove :
 The reverse gear fork shaft (55)
 Reverse gear fork (58)
 The locking finger (54) and its spring (53)
 The magnetic plate (57)
 The output shaft bush (56)
Page 20 of 26
Figure : B2CG04ZD
Drive out the fixing pin (59) ; Using a pin punch .

Remove :
 Gear selection lever (60)
 The spring (61)
 The washer (62)
 The seal (63)
Page 21 of 26
 The gear selection shaft (64)
3.3. Gearboxes with a 5th gear/reverse gear change prohibition system
Figure : B2CG050D
Place tool [5] in the groove of the pin (48).

Immobilise the claws of tool [5] in the groove of the pin (48) (at "c").
Page 22 of 26
Figure : B2CM0NUD
Position tool [5] respecting the stacking of the components "A".

Turn the nut of tool [5] clockwise at "d" to extract the pin (48).
3.4. Gearboxes without a 5th gear/reverse gear change prohibition system
Page 23 of 26
Figure : B2CG051D
Position the gear engagement shaft (50) against the housing.

Drive out the pins (51), (52) (Drift out the pins in turn).
Figure : B2CG052D
Remove :
 The cassette assembly (65)
 Seal (67)
 The gear selection spring bracket (66)
N.B. : The cassette assembly cannot be disassembled.
3.5. Gearbox with upstream balls fitting

Page 24 of 26
Figure : B2CG055D
Remove :
 The pin (71) ; Using a pin punch
 Seal (72)
 The protector (69)
Page 25 of 26
Figure : B2CG056D
Check the condition of the bearing (73) (replace if necessary).

Remove the bearing (73) ; Using the tools [18], [19].
Figure : B2CG2XLD
Page 26 of 26
CAUTION : Replace the clutch casing if the ball socket is damaged (at "e").
Page 1 of 13
REPLACEMENT : DRIVESHAFT GAITERS
1. Tooling

[0316-A] inertia extractor
Figure : E5AB0NET
[4083-T] Stub axle removal threaded sleeve

[0410-A]
Figure : E5AB0IBT
[0409] Pliers for fitting driveshaft gaiter clips

Page 2 of 13
Figure : E5AB0ICT
[0412] hose clip pliers OETIKER
Figure : E5AH00BT
[0413] Pliers for wing clips
Figure : E5AH00CT
2. Identification
Page 3 of 13
Figure : B2FH00SD
The drive shafts are identified by a label stuck to the shaft (at "a") containing : The supplier reference.
List of suppliers :
 GKN
 PSA
 NTN
N.B. : The ABS crowns are discontinued (the function fulfilled by the crowns is transferred to the front wheel
bearings).
Remove the drive shafts.

Support the drive shaft in a vice fitted with soft jaws.
N.B. : Before removal : Mark the positions of the driveshaft gaiters.
4. Replacement : Wheel end gaiter
CAUTION : Always replace the clips and circlips that have been removed.
4.1. PSA and NTN driveshafts

Page 4 of 13
Figure : B2FH002D
Remove the clips (1) and (2) ; Using a hacksaw.
N.B. : Mark the gaiter position on driveshafts not having position grooves at "a".
Figure : B2FH02QD
Page 5 of 13
Remove the housing (3) ; Using the tools [0316-A], [4083-T / 0410-A].
Figure : B2FH004D
Remove :
 The stop ring (4)
 The drive shaft gaiter (5)
Refit :
 The drive shaft gaiter (5) (new)
 The stop ring (4) (new)
Page 6 of 13
Figure : B2FH005D
Fit a clip (6) on the stop ring to facilitate force-fitting of the housing (3).
Figure : B2FH02RD
Refit the housing (3) to the shaft ; Using the tools [0316-A], [4083-T / 0410-A].
Page 7 of 13

Fill the gaiter with all the grease available in the repair kit.
Refit the gaiter (5) on the housing (3).
CAUTION : Pay attention to the location of the gaiter on the shaft: gaiter lip in the groove "a" or on the mark
made when removing.
Refit and tighten the clips (1) and (2) .

4.2. Driveshaft GKN
N.B. : The driveshaft bowl on the wheel side cannot be removed ; The replacing of a wheel-end driveshaft
gaiter necessitates the removal of the gearbox-end gaiter.
Figure : B2FH00QD
Remove :
 The drive shaft gaiter (on the gearbox side)
 The clips (7), (8)
Refit the driveshaft gaiter (9) on the driveshaft.

Refit :
 The collars (7) and (8)
 The drive shaft gaiter (on the gearbox side)

Page 8 of 13
5. Replacement : Gearbox end gaiter
CAUTION : Always replace the clips and circlips that have been removed.
5.1. GKN and NTN driveshafts
Figure : B2FH011D
Remove the clips (10), (13).

Move aside the driveshaft gaiter (11).
Remove vertically the spider ecu(12).
Remove as much grease as possible from inside the gaiter .
Page 9 of 13
Figure : B2FH012D
Remove the excess grease from the gaiter and on the tripod.
Remove circlip (14).
Figure : B2FH013D
Page 10 of 13
Remove the tripod (15) ; Using a hammer and a pin punch.

Remove the driveshaft gaiter (11).
Refit the driveshaft gaiter (11) on the driveshaft (new).
Refit :
 The tripod (15)
 The circlip (14)
Refit :
 The tripod housing (12)
 The collars (10) and (13)
5.2. Driveshaft PSA
N.B. : At the gearbox end, as the spider cannot be removed, replacement of the gaiter is only possible
following removal of the seal at the wheel end.
Figure : B2FH011D
Remove :
 The drive shaft gaiter (/) (road wheel side)
 The clips (10), (13)
Take as much grease as possible off the driveshaft seal ; Do not use solvents.
Fit the new gaiter (11) on the drive shaft.
Spread the grease between the gaiter and the tripod.
Page 11 of 13
Refit :
 The clips (10), (13)
 The drive shaft gaiter (road wheel side)
6. Clips
Figure : B2FH015D
Position the driveshaft gaiter (18) (Observe the marks made during the dismantling operation).
Refit the new clips (16) and (17) ; Using the special tool (According to the clips) :
 CLIC clips ; Using tool [0409]
 OETIKER clips ; Using tool [0412]
Page 12 of 13
Figure : B2FH00BD
Tighten the wing clips ; Using the tools [0413] or [0409].
Figure : B2FH00CD
Tighten the clips : Until there is contact "A" = 0 mm.

Page 13 of 13
Figure : B2FH00DD
After tightening : Check the space "B" = 0,5 to 1 mm.
Refit the drive shafts.
Page 1 of 8
DISMANTLING - RE-ASSEMBLY : DRIVESHAFTS
1. Tooling

BE4/MA gearbox
[0317-U / 7114- Fitting drift for the final drive output lip
T.X] seal (right side)
Figure : E5AB0YZT
BE4/MA gearbox
[0317-T / 7114- Fitting drift for the final drive output lip
T.W] seal (left side)
Figure : E5AB0YYT
[0622] pivot ball-joint uncoupling lever

Page 2 of 8
Figure : E5AG08MT
[0709] ball-joint extractor
Figure : E5AB0Z7T
[6310-T] hub immobilising tool
Figure : E5AB0P0T
2. Removing
Lift and support the vehicle with the wheels free.
Drain gearbox.
Engine flywheel retaining pin (With a new seal).
2.1. Left and right hand drive shafts
Remove the front wheels.
Page 3 of 8
Figure : B3FG0NJD
Unlock the transmission nut (1).

Fit the tool [6310-T].
Remove :
 The drive shaft nut (1)
 The tool [6310-T]
Page 4 of 8
Figure : B2FG09MD
Remove the nut (2).

Move aside the rod (3) of the anti-roll bar .
Remove the nut (4).
Uncouple the steering ball joint ; Using tool [0709].
Remove the bolt (5) fixing the suspension arm ball-joint on the pivot.
Page 5 of 8
Figure : B2FG09ND
Uncouple the front suspension arm from the pivot using tool [0622], taking care not to damage the ball-joint
gaiter with the chain of tool [0622].
N.B. : Recover the pivot ball-joint cover.
2.2. L.H. driveshaft
CAUTION : Take care not to twist the brake hose .
N.B. : In order not to damage the LH driveshaft gaiter, disengage the pivot and swivel the damper body by a
quarter turn.
Disengage the LH driveshaft from the wheel hub.

Remove the L.H. driveshaft.
2.3. Right hand drive shaft
CAUTION : Take care not to twist the brake hose .
N.B. : In order not to damage the RH driveshaft gaiter, disengage the pivot and swivel the damper body by a
quarter turn.
Disengage the RH driveshaft from the wheel hub.

Page 6 of 8
Figure : B2FG09OD
Depending on engine type :

 Unscrew the nuts (7)
 Turn the bolts (6) a half turn to detach their from the bearing housing
Remove the right-hand drive shaft.
3. Checking
Check :
 The absence of play in the driveshaft joints
 The condition of the gaiters
 The condition of the driveshaft support bearing
Overhaul the driveshafts (if necessary).
4. Refitting
Tightening torque :
 Driveshafts
 Road wheels
 Front suspension
 Steering
CAUTION : Always fit new Nylstop nuts.

Page 7 of 8
N.B. : BE4/MA gearbox : Always replace the driveshaft seals during each operation ; Using tools [0317-U /
7114-T.X] and [0317-T / 7114-T.W].
Put grease in the gap between the lips of the drive shaft seal.
4.1. Right hand drive shaft
Engage the driveshaft in the differential.
Figure : B2FG09PD
Position the eccentric heads of the bolts (6) hard against the outer bearing cage.
Tighten the nuts (7).
Insert the drive shaft splines in the differential and in the wheel hub.
4.2. L.H. driveshaft
Engage :
 The driveshaft in the differential
 The driveshaft splines in the wheel hub
4.3. Left and right hand drive shafts
CAUTION : Refit the pivot ball-joint cover.
Couple the pivot lower ball-joint ; Using tool [0622].

Refit the fixing bolt (5) (Hub carrier ball joint on suspension arm ).
Couple up the steering ball-joint.
Refit the nut (4).
Reconnect anti-roll bar link rod (3).
Page 8 of 8
Refit :
 The nut (2)
 The drive shaft nut (1) ; Using tool [6310-T]

Peen the driveshaft nut (1).
Refit the front wheels.
Fill gearbox with oil and ensure correct level.
Page 1 of 23
REFITTING : MANUAL GEARBOX
CAUTION : Comply with the conditions for cleaning and reassembling the gearbox .
1. Tooling
Presentation : Tooling .
2. Refitting : Differential housing
Figure : B2CM0N5D
Check :
 That the centring pins are present (3)
 That the seal face is clean
Coat the joint face with a thin, even layer of sealing paste E10 (See recommended consumables procedure :
Mechanical).
Fit the differential (2) into the housing together with the bearing outer races (1).
Page 2 of 23
Figure : B2CM0N9D
Refit the differential housing (4).
Figure : B2CM0NAD
Refit the bolts (5), (6) (without tightening them).

Page 3 of 23
2.1. Extension adjustment
Figure : B2CM0NCD
"X" = Extension shoulder.

Measure dimension "X".
2.2. First assembly
Extension shoulder : "X" = 10 mm.
Page 4 of 23
Figure : B2CM0NED
Refit :
 The extension (9) equipped with an O-ring seal (8) (new)
 The bolts (10)
2.3. Second assembly

Extension shoulder "X" = 8,65 mm.
Page 5 of 23
Figure : B2CM0NFD
Position :
 The bearing adjustment shim [7] on the bearing outer race
 The extension without O-ring
Progressively tighten the extension screws while turning the differential, to obtain a tightness in rotation in
order to position the cage and bearings correctly.
Remove :
 The differential housing extension
Page 6 of 23
Figure : B2CM0NGD
Using a depth gauge [8], measure the distance "Y" between the joint face and the external bush of the
bearing.
Calculate the thickness of the positioning shim.
Y - X + 0,1 mm = Thickness of the positioning shim.
Page 7 of 23
Figure : B2CM0NKD
Refit :
 The positioning shim (15)
 The extension (12) fitted with a new O-ring (13)
 The bolts (11)
Figure : B2CM0NAD
Tighten :
 The bolts (6)
 The bolts (5)
N.B. : This order of operations ensures correct alignment of the joint faces.
3. Re-assembling : clutch housing
CAUTION : Systematically replace the seals and pins.
3.1. Gearbox with upstream detent device fitting

Page 8 of 23
Figure : B2CM0NMD
Refit :
 The bearing (16) (new) ; Using a bronze drift
 Seal (17) (new)
 The pin (20) (new)
 The cap (19) (new)
Page 9 of 23
Figure : B2CG2XKD
CAUTION : Replace the clutch casing if the ball socket is damaged (at "a").
3.2. Unclip the gear selector and gearchange control ball joints
Page 10 of 23
Figure : B2CM0NQD
Refit :
 The bracket (23)
 The seal (24) (new)
3.3. Gearboxes with a 5th gear/reverse gear change prohibition system
Figure : B2CM0NSD
CAUTION : Follow the order indicated.
Remove the threaded rod [15b].

Position :
 The pin (26)
 The tool [15c]
Tighten the 4 bolts (15a) to 1,5 m.daN .

Fit the threaded rod [15b].
Fully do up the threaded rod at "[15b]".
CAUTION : Place the tool correctly, as this guarantees the positioning of the pin (26).
3.4. Gearboxes without a 5th gear/reverse gear change prohibition system

Page 11 of 23
Figure : B2CM0NTD
Refit the pins (28) and (27).
Figure : B2CM0NVD
Refit :
Page 12 of 23
 The output shaft bush (31)

 The magnet (32)
 The spring (34)
 The locking finger (35)
 Reverse gear fork (33)
 The fork shaft (30)
 The selection shaft (29)
Page 13 of 23
Figure : B2CM0NXD
Refit :
 The O-ring (39) (new)
 The washer (40)
 The spring (36)
 The selection lever (38)
 The pin (37)
Page 14 of 23
4. Refitting
4.1. Primary and secondary shafts
Adjust the play of the primary shaft .
Figure : B2CM0NZD
Page 15 of 23
Couple the primary shaft (42) and the secondary shaft (41) with the 1st/2nd fork (43).
Position the gears in the gearbox casing.
Figure : B2CM0P0D
CAUTION : Position the fork (44) on the gearchange lever (46).
CAUTION : Put the fork (45) the right way round.
Refit :
 The fork (44)
 The fork shaft (45)
Page 16 of 23
Figure : B2CM0P1D
CAUTION : Check the position of the fork shaft on the gearchange lever.
Refit the 5th gear fork shaft (47).
Figure : B2CM0P2D
Page 17 of 23
CAUTION : Check the position of the pin (49) in its housing.
Fit the reverse shaft and gear (48).
N.B. : The tooth entry must point downwards (at "a").
Figure : B2CM0P3D
Position the oil duct (50).

4.2. gearbox casing
Page 18 of 23
Figure : B2CM0P4D
CAUTION : Check the fitting of the oil filler tube in hole on the housing (at "b").
Coat the clutch housing mating surface with sealing compound E10 (See recommended consumables
procedure : Mechanical).
Refit the gearbox casing (51).
Page 19 of 23
Figure : B2CM0P5D
Refit :
 The bolts (53)
 The (55) bolt (New washer)
 The fork shaft stop plate (52) (Flat part in the groove of the shaft) (at "c")
 The stop plate retention bolt
 The ring (new) (56) in the bearing groove
 The bolts (54)
Page 20 of 23
Figure : B2CG0IOD
Refit :
 The spacer washer (61) (Shoulder bearing side)
 The 5th speed gear thrust collar (59)
 The 5th speed driving gear (60)
 The hub-synchroniser assembly (58), (57)
Page 21 of 23
Figure : B2CM0P8D
Engage 3rd or 4th gear ; Using the gear engagement selector.

Engage 5th gear.
Remove the primary shaft nut.
Coat the threads of the secondary shaft with product E6 (See recommended consumables procedure :
Mechanical).
Remove :
 The 5th gear hub-synchroniser
 The fork of the fifth
Refit the 5th gear hub-synchroniser assembly.
N.B. : Respect the marks made when re-assembling (as per arrows).

Page 22 of 23
Figure : B2CM0PAD
Press the locking ball into its housing at "d", by pushing the hub-synchroniser assembly.
Figure : B2CM0PBD
Engage 3rd or 4th gear ; Using the gear engagement selector.

Page 23 of 23
Engage 5th gear.

Coat the threads of the primary shaft with product E6 (See recommended consumables procedure :
Mechanical).
Assembly the fork and its shaft using a pin (63) (new).
Figure : B2CM0PCD
Coat the 5th gear casing with seal paste E10 (See recommended consumables procedure : Mechanical).
Page 1 of 30
REMOVING - REFITTING : HYDRAULIC CLUTCH CONTROL
ESSENTIAL : Whenever you send any components of the hydraulic clutch control to the guarantee return
centre, plug the openings of the components removed, so as to aid the analysis (Use the plugs that are on
the new components). There are 2 systems for linking the clutch pedal transmitter: cylindrical link ; ball-joint
link.
Remove parts as necessary for removing the component(s) of the hydraulic clutch control.
2. Drain : Clutch control circuit
CAUTION : Mark the level of brake fluid in the reservoir before carrying out the operation.
There is more than one bleed system :

 Single-clip bleed system
 Double-clip bleed system
 Screw bleed system
2.1. Single-clip bleed system

Page 2 of 30
Figure : B2BG07HD
CAUTION : When reconnecting and disconnecting it, handle the hydraulic pipe (3) keeping it straight and do
not lever it to prevent any break.
CAUTION : The use of pliers and screwdrivers to act as a lever on the clip is prohibited, risk of loss of the
clutch function.
Remove the protection cap (1) from the bleed orifice .

Store the protection cap in a clean place.
Connect a transparent tube onto the bleed orifice .
CAUTION : The end of the transparent pipe must be submerged into the brake fluid.
N.B. : The press on the clip (2) may require considerable force.
Press on the clip (2) and pull on the hydraulic pipe (3) over approximately 5 mm to free the bleed aperture (In
the direction of the arrow "a").
Allow the brake fluid to flow out by gravity.
Push down on the hydraulic pipe (3) to block the bleed aperture (In the opposite direction to the arrow "a").
Refit the brake fluid reservoir cap .
Uncouple the transparent pipe.
Refit the protection cap on the bleed aperture .
2.2. Double-clip bleed system
Page 3 of 30
Figure : B2BG07ID
Remove the protection cap from the bleed orifice (7).

Couple a transparent pipe onto the bleed orifice (7).
Clamp the clip (5).
CAUTION : The clip (5) must always remain clipped in position on the hydraulic clutch slave cylinder during
the bleed.
Unclip the clip (6).

Pull on the hydraulic pipe (4) to free the bleed aperture (7) (following the arrow "b").
Clamp the clip (6).
Push down on the hydraulic pipe (4) to block the bleed aperture (7) (In the opposite direction to the arrow).
Unclip the clip (5) (without removing it).
Refit the protection cap on the bleed aperture (7).
2.3. Screw bleed system (Quarter turn system)
Page 4 of 30
Figure : B2BG07JD
Remove the bleed screw (8) protection cap.

Couple a transparent tube on the bleed screw (8).
Rotate the bleed screw (8) a quarter turn (Clockwise).

Close the bleed screw (8) (Anti-clockwise).
Refit the protection cap on the bleed screw (8).
2.4. Screw bleed system (6-sided screw system)
Page 5 of 30
Figure : B2BG07KD
Remove the bleed screw (9) protection cap.

Couple a transparent tube on the bleed screw (9).
Turn the bleed screw (9) (Anti-clockwise).

Close the bleed screw (9) (Clockwise).
Refit the protection cap on the bleed screw (9).
3. Hydraulic control master cylinder with cylindrical link on the clutch pedal
3.1. Removing
CAUTION : When reconnecting and disconnecting it, handle the hydraulic pipe keeping it straight and do not
lever it to prevent any break.
CAUTION : Do not break the lugs on the head of the rod on the hydraulic clutch control master cylinder.
Page 6 of 30
Figure : B2BG07LD
Unclip the rod (10) from the hydraulic clutch master cylinder (at "c").
Figure : B2BG07MD
CAUTION : Prepare for the flow of brake fluid. Use a cloth.

Page 7 of 30
Uncouple the supply pipe (11) (at "d").

Plug the opening of the brake fluid reservoir (at "d") ; With a clean cap.
Uncouple the hydraulic pipe (13) (at "e").
Unlock the hydraulic clutch control master cylinder (14) (Rotate an eighth turn clockwise).
Remove the hydraulic clutch control master cylinder (14).
3.2. Refitting
CAUTION : When coupling it, handle the hydraulic pipe (13) keeping it straight and not levering it to prevent
any break.
Lightly lubricate the connection between the rod (10) of the hydraulic clutch master cylinder (14) and the pedal
bracket ; Using G7 grease.
Refit the hydraulic clutch control master cylinder (14).
Lock the hydraulic clutch control master cylinder (14) (Rotate an eighth turn anti-clockwise).
Clamp the clip (12).
Couple up :
 The hydraulic pipe (13) (at "e")
 The supply pipe (11) (at "d")
Figure : B2BG07ND
Clip the rod (10) of the hydraulic clutch master cylinder (14) (at "c").
Check the clipping of the rod (10) of the hydraulic clutch control master cylinder (14) (at "c") (Pull-push).
4. Hydraulic control master cylinder with ball-joint link on the clutch pedal
Page 8 of 30
4.1. Removing
CAUTION : When reconnecting and disconnecting it, handle the hydraulic pipe (13) keeping it straight and
do not lever it to prevent any break.
CAUTION : Do not break the lugs on the head of the rod on the hydraulic clutch control master cylinder (14).
Figure : B2BG07OD
Carry out the following operations simultaneously :

 Pinch together the lugs of the locking clip (16) ; Using a ring spanner no. 10
 Move aside the rod (15) from the pedal gear ; Using a plastic pallet
Page 9 of 30
Figure : B2BG07PD
Release the locking clip (16) from the pedal bracket ; Using a plastic pallet.
Figure : B2BG07QD
Page 10 of 30
Press on the locking clip (16).

Disconnect the rod (15) of the hydraulic clutch control master cylinder from the pedal bracket ; Using a plastic
pallet.
Figure : B2BG07MD
Uncouple the supply pipe (11) (at "d").

Plug the opening of the brake fluid reservoir (at "d") ; With a clean cap.
N.B. : Third assembly.

Page 11 of 30
Figure : B2BG07RD
Disconnect the connector (at "f").

Uncouple the supply pipe (17) from the brake fluid reservoir.
Plug the opening of the brake fluid reservoir ; With a clean cap.
Uncouple the hydraulic pipe (19) (at "g").
Page 12 of 30
Figure : B2BG07SD
Unclip the hydraulic clutch control master cylinder (20) ; Using tool [G-0350-C] (at "h").
Move the hydraulic clutch control master cylinder (20) rod away from the pedal bracket.
Remove the clutch pedal support and hydraulic clutch control master cylinder assembly .
Page 13 of 30
Figure : B2BG07UD
CAUTION : Mark the direction of fitting of the clip (22) ; During removal.
4.2. Refitting
CAUTION : When coupling it, handle the hydraulic pipe keeping it straight and not levering it to prevent any
break.
Refit the hydraulic clutch control master cylinder (20).

Lock the hydraulic clutch control master cylinder (20) (Rotate an eighth turn anti-clockwise).
Figure : B2BG07VD
N.B. : Check that the locking clip (16) of the new clutch hydraulic master cylinder (14) is in the position
above.

Page 14 of 30
Figure : B2BG07WD
N.B. : Check that the locking clip (16) of the new clutch hydraulic master cylinder (14) is in the position
above.

Couple up :
 The hydraulic pipe (13) (at "e")
 The supply pipe (11) (at "d")
Clip :
 The locking clip (16) on the pedal bracket
 The rod (15) of the clutch hydraulic master cylinder (14) onto the locking clip (16)
Page 15 of 30
Figure : B2BG07XD
Check the clipping of the rod (15) of the hydraulic clutch control master cylinder (14) (at "j") (Pull-push).
Refit the hydraulic clutch control master cylinder (20) on the clutch pedal support.
Refit the clutch pedal support and hydraulic clutch control master cylinder assembly .
Fit the nuts (21).
Couple up :
 The hydraulic pipe (19) (at "g")
 The supply pipe (17)

Connect the connector (at "f").
5. Hydraulic clutch control slave cylinder (Bleed system with clip)

5.1. Removing the single-clip bleed system
Page 16 of 30
Figure : B2BG07YD
Press on the clip (2) and uncouple the hydraulic pipe (3)(In the direction of the arrow "a").
Remove :
 The bolts (23)
5.2. Removing the double-clip bleed system

Page 17 of 30
Figure : B2BG07ZD
Unclip the clips (5), (6) (Without removing).

Uncouple the hydraulic pipe (4).
Remove :
 The bolts (25)
5.3. Refitting the single-clip bleed system
any break.
Lightly lubricate the connection between the rod of the hydraulic clutch slave cylinder (26) and the clutch fork ;
Using G12 grease.
Refit :
 The bolts (23) (New bolts)
Connect the hydraulic pipe (3).

Page 18 of 30
Figure : B2BG00VD
Check the positioning of the rod of the hydraulic clutch control slave cylinder in the clutch fork.
5.4. Refitting the double-clip bleed system
any break.
Using G12 grease.
Refit :
Refit the clips (5), (6).

Connect the hydraulic pipe (4).
Page 19 of 30
Figure : B2BG00VD
6. Hydraulic clutch control slave cylinder (Screw bleed system)

6.1. Removing
Page 20 of 30
Figure : B2BG080D
CAUTION : Prepare for the flow of brake fluid .Use a cloth.
Unclip the clip (27) (Without removing).

Uncouple the hydraulic pipe (28) (at "k").
Remove :
 The bolts (29)
6.2. Refitting
any break.
Using G12 grease.
Refit :

Connect the hydraulic pipe (28) (at "k").
Page 21 of 30
Figure : B2BG00XD
7. Fitting with hydraulic stop

7.1. Removing
Page 22 of 30
Figure : B2BG081D

Uncouple the hydraulic pipe (33) (at "l").
Remove :
 The clip (31)
 The bleed union (34)
 The gearbox
Page 23 of 30
Figure : B2BG082D
Remove :
 The bolts (36)
 The hydraulic stop (35)
7.2. Refitting
any break.
Refit :
 The hydraulic stop (35)
 The bolts (36)
 The gearbox
 The bleed union (34)
 The clip (31)

Connect the hydraulic pipe (33) (at "l").
8. Hydraulic clutch pipe
Page 24 of 30
N.B. : There are 3 connection systems between the hydraulic pipe and the hydraulic clutch slave cylinder
(14).
8.1. Removing : Hydraulic clutch control master cylinder end
N.B. : First assembly - Second assembly.
Figure : B2BG084D


Page 25 of 30
Figure : B2BG085D

Uncouple the hydraulic pipe (19) (at "g").
8.2. Removing : Hydraulic clutch control slave cylinder end (Single-clip bleed system)
Page 26 of 30
Figure : B2BG086D
Press on the clip (2) and uncouple the hydraulic pipe (3)(In the direction of the arrow "a").
8.3. Removing : Hydraulic clutch control slave cylinder end (Double-clip bleed system)
Page 27 of 30
Figure : B2BG087D
Unclip the clips (5), (6) (Without removing).

Uncouple the hydraulic pipe (4).
8.4. Removing : Hydraulic clutch control slave cylinder end (Screw bleed system)
Page 28 of 30
Figure : B2BG088D

Uncouple the hydraulic pipe (28) (at "k").
8.5. Removing : Hydraulic stop bleed union end
Page 29 of 30
Figure : B2BG089D

Uncouple the hydraulic pipe (33) (at "l").
8.6. Refitting
CAUTION : When coupling it, handle the hydraulic pipe keeping it straight and not levering it to prevent any
break.
On the bleed union for hydraulic stop (34) :

 Connect the hydraulic pipe (33) (at "l")
 Clamp the clip (32)
Hydraulic clutch control slave cylinder end (30) (Screw bleed system) :
 Connect the hydraulic pipe (28) (at "k")
Hydraulic clutch control slave cylinder (24) side (Single-clip bleed system) : Connect the hydraulic pipe (3).
Hydraulic clutch control slave cylinder end (26) (Double-clip bleed system) :
 Connect the hydraulic pipe (4)
Hydraulic clutch control master cylinder end (14) ; First assembly - Second assembly :
 Connect the hydraulic pipe (13) (at "e")
Hydraulic clutch control master cylinder end ; Third assembly :

 Connect the hydraulic pipe (19) (at "g")
Page 30 of 30
Bleed the clutch hydraulic control.
Refit the parts that were removed for removal of the component(s) of the hydraulic clutch control.
CAUTION : Check that the bleed opening is correctly closed by operating the clutch pedal several times and
checking that there are no leaks or seeping (risk of vehicle fire in the event of a leak).
Page 1 of 5
CHECK - ADJUSTMENT : SET OF PRIMARY SHAFT BEARINGS
1. Recommended tools
Presentation : Recommended tools .
2. Removing
2.1. Bearing outer cage (gearbox casing side)
Figure : B2CM0M3D
Remove bearing outer race (1) ; Using tool [2] and press .
2.2. Bearing outer cage (clutch bell housing side)
Page 2 of 5
Figure : B2CM0M4D
Remove :
 Bearing outer race (2)
Measure the thickness of the adjustment shims (3).
3. Refitting
3.1. Bearing outer cage (gearbox casing side)
Page 3 of 5
Figure : B2CM0M5D
Refit bearing outer race (1) (new) ; Using tools [2], [9] and press .
3.2. Bearing outer cage (clutch bell housing side)
Figure : B2CM0M4D
Page 4 of 5
CAUTION : Replace the adjustment shim (3) with a shim 0,20mm less thick than the one removed.
Refit :
 The bearing guide
 The outer race (2) of the input shaft bearing
Figure : B2CM0M6D
Refit :
 The primary shaft (5)
 The bolts (4) (one screw out of two) ; Tighten to 1,25 daN.m
Rotate the input shaft (5) by a few revolutions.
4. Adjustment
Page 5 of 5
Figure : B2CM0M7D
Fit the input shaft nut with the abutment face outward (7).
Gently tighten the nut (7).
Place the dial gauge [14] on the supports [11], [12] and [13].
Position the sensor on the nut (7).
Push the primary shaft downwards.
Set the dial gauge [14] to zero.
Push the primary shaft upwards.
Read the value :
 The clearance should be between 0,05 and 0,15 mm
 If the value read on the dial gauge is not correct, repeat the setting
Remove :
 The dial gauge [14] on the supports [11], [12] and [13]
 The nut (7)
 The bolts (4)
 The primary shaft (5)
Page 1 of 17
STRIPPING - RE-ASSEMBLING : COMPONENTS INTERNAL TO THE GEARBOX
CAUTION : Comply with the conditions for cleaning and reassembling the gearbox .
CAUTION : Mark the positions of the components prior to removal.
1. Tooling
The recommended tools should be used .
2. Stripping : input shaft
Figure : B2CG27AD
CAUTION : The flat surface "a" of tool must be directed to the gear side so as not to press on the teeth.
Protect the end of the primary shaft with its nut (1).
Take weight under the 3rd gear pinion (3) and remove the rear bearing (2) ; Using the tool type FACOM U53T
and a press.
Page 2 of 17
Figure : B2CM0L2D
Remove :
 The 4th speed driving gear (6) and its thrust ring (5)
 The 3rd/4th gear synchroniser (4a) and its hub (4b) (Mark the position of the hub in relation to the
synchronizer )
 The 3rd speed driving gear (3)
Page 3 of 17
Figure : B2CG27CD
Remove the front bearing (7) ; Using the tool type FACOM U53T and a press.
3. Stripping : output shaft
Figure : B2CG27DD
Page 4 of 17
Use the 4th gear pinion (10) for support.

Remove : The 5th gear driven pinion (8) and the bearing (9) ; Using the tool type FACOM U53T and a press.
Figure : B2CM0L5D
Remove :
 The 4th gear and 3rd gear driven pinion (10)
 The 2nd gear driven pinion (12) and its thrust ring (11)
Page 5 of 17
Figure : B2CM0L6D
CAUTION : Mark the position of the hub in relation to the synchronizer .
Remove : The 2nd/1st gear synchroniser (13b) and its hub (13a).
Figure : B2CM0L7D
Page 6 of 17
Remove :
 The 1st speed driven gear (14)
 The needle thrust bearing (15)
Figure : B2CM0L8D
Remove the locking ring (16) ; Using circlip pliers (If necessary with a set of gauges).
Page 7 of 17
Figure : B2CG27FD
Protect the end of the secondary shaft with its nut (17).
Remove the bearing (18) ; Using the tool type FACOM U53T and a press.
4. Stripping : differential box

Page 8 of 17
Figure : B2CG27GD
Remove the bearings (19) ; Using an extractor type FACOM U53T + 53K and tool [0317-JZ / 4508-T.J].
Figure : B2CM0LBD
CAUTION : Do not separate the planet gears from their thrust washers and the sun wheels from their friction
washers.
Remove :
 The stop pin (24)
 The planet wheels shaft (25)
 The satellites (23) complete with their thrust cups (22)
 The sun wheels (21) (On the side opposite the crown wheel)
 The planet gear centring ring (20) (On the side opposite the crown wheel)
Page 9 of 17
Figure : B2CM0LCD
Remove :
 The fixing screws of the differential gearwheel
 Differential crown wheel (26)
5. Re-assembling : differential box

Page 10 of 17
Figure : B2CG27ID
Refit : The bearings (19) (new) ; By means of tool [0317-D / 7101-T.D] and a press.
Figure : B2CM0LBD
Refit :
Page 11 of 17
 The planet gear centring ring (20), On the side opposite the crown wheel
 The sun wheels (21)
 The planet gears (23) and their cup washers (22) by pivoting them
 The planet gear pin (25)
 The shaft stop pins (24) (new)
Figure : B2CM0LCD
Fit the crown wheel (26).
N.B. : Always replace : The fixing screws of the differential gearwheel.
Tightening method for the screws :

 Tightening in a cross pattern
 Tightening to the prescribed torque
6. Re-assembling : output shaft

Always replace :
 The bearings
 The circlips
 The nut (17)
Use components that are clean and free from defects.

Check the condition of the shaft bearing faces, there should not be any signs of impacts or scratches.
Oil the components as you fit them.
Match up the marks made during removal.
Page 12 of 17
Figure : B2CG27LD
Fit the new bearing (18) ; By means of tool [0317-E / 7101-T.E] and a press.
Page 13 of 17
Figure : B2CG27MP
A : With needle thrust bearing.

B : Without needle thrust bearing.
Refit :
 The bearing locking ring (16) (new)
 The needle thrust bearing (15) (according to the assembly operations)
 The 1st speed driven gear (14)
 The reverse gear synchroniser (13) and its hub (keep to the marks made at the time of removal)
 The 2nd gear driven pinion (11) and its thrust ring (12)
 The 4th gear and 3rd gear driven pinion (10)
N.B. : The tooth entries of the reverse gear synchroniser are oriented towards the 2nd gear pinion.
Page 14 of 17
Figure : B2CG27QD
Refit the bearing (9), groove uppermost (new) ; By means of tool [0317-F / 7101-T.F] and a press.
Figure : B2CM0LHD
Refit the 5th speed driven gear (8) ; Using a press.

Page 15 of 17
N.B. : The collar of the pinion must be towards the bearing.
7. Re-assembling : input shaft

Always replace :
 The bearings
 The nut (1)
Use components that are clean and free from defects.

Check the condition of the shaft bearing faces, there should not be any signs of impacts or scratches.
Oil the components as you fit them.
Match up the marks made during removal.
Figure : B2CG27SD
Refit the front bearing (7) (new) ; Using the extractor tools FACOM U53T, [0317-F / 7101-T.F] and a press.
Page 16 of 17
Figure : B2CM0LKD
Refit :
 The 3rd speed driving gear (3)
 The 3rd/4th gear synchroniser with its hub (4) (keep to the marks made at the time of removal)
 The 4th speed driving gear (6) and its thrust ring (5)
Page 17 of 17
Figure : B2CG27UD
Refit the rear bearing (2) (new) ; Using the extractor tools FACOM U53T, [0317-F / 7101-T.F] and a press.
Page 1 of 2
TIGHTENING TORQUES : DRIVESHAFTS
1. Recommendation
CAUTION : Tighten the driveshaft nuts ; With the help of a torque spanner.
2. Tightening torques : Drive shaft bearing nut
Drive shaftnut Drive shaft bearing

vehicles Tightening torques Angular tightening Tightening
ION 16 da.Nm - -
107 21,6 da.Nm - -
1007 24,5 da.Nm - 1 da.Nm
206
206+
207 24,5 da.Nm - 2 da.Nm
206 (M24X150) 32,5 da.Nm - 1 da.Nm
207 i (Iran) 32,5 da.Nm - 1 da.Nm
207 (Asean) 30 da.Nm - 1 da.Nm
207 (M24X150) 31 da.Nm - 2 da.Nm
405 (Iran) 32,5 da.Nm - 2 da.Nm
208 24,5 da.Nm (30 mm spanner) - 2 da.Nm
32,5 da.Nm (35 mm spanner)
2008 24,5 da.Nm (30 mm spanner) - 2 da.Nm
31,2 da.Nm (35 mm spanner)
301 24,5 da.Nm - 2 da.Nm
301 (China) 24,5 daNm - 2 daNm
307 32,5 da.Nm - 1 da.Nm
307 (China) 31 da.Nm - 1 da.Nm
308 32,5 da.Nm - 2 da.Nm
308(T9) 28,5 da.Nm - 2 da.Nm
308 (Russia) 32,5 da.Nm - 2 da.Nm
308 (China) 31,2 da.Nm - 1 da.Nm
RCZ 32,5 da.Nm - 2 da.Nm
3008
3008 (China)
5008
408 (China) 32,5 da.Nm - 1 da.Nm (engine TU )
32,5 da.Nm - 2 da.Nm (engine EW )
Page 2 of 2
408 (Russia) 32,5 da.Nm - 2 da.Nm

408 (Asean) 32,5 da.Nm - 2 da.Nm
(R.H.D.)
Partner 31,2 da.Nm - 2 da.Nm
408 (Mercosur) 30,5 da.Nm - 2 da.Nm
508
508 (China) 34,5 da.Nm - 2 da.Nm
407
807
EXPERT
Bipper 7 da.Nm 55° 2 da.Nm
BOXER 15 da.Nm 35°
3. Tightening torques : 4 wheel drive transmission
- Transverse driveshaft nut Longitudinal bearing Longitudinal driveshaft nuts on rear axle
(Front / Rear) bolt controlled clutch
vehicles Tightening torques
4007 16 da.Nm 4 da.Nm 5,4 da.Nm
4008 14,4 da.Nm (Nut with pin) 4 da.Nm 5,4 da.Nm
27 da.Nm (Nut without pin)
4. Tightening torques : Hybrid vehicles
- Front driveshaft nut Rear driveshaft nut Front driveshaft bearing Rear driveshaft bearing
vehicles Tightening torques
3008 32,5 da.Nm 34,5 da.Nm 2 da.Nm 1 da.Nm
508 31,2 da.Nm 31,2 da.Nm 2 da.Nm 1 da.Nm
Page 1 of 2
TIGHTENING TORQUES : WHEELS (TECHNICAL NOTE)
1. recommendations
CAUTION : The use of impact wrenches to refit the wheel bolts and wheel anti-theft bolts is strictly
prohibited.
CAUTION : The wheels are always tightened with dry bolts.
CAUTION : When installing a new steel wheel for the first time : Always double tighten the wheel, to avoid
any risk of slackening.
N.B. : Double tightening consists of tightening to the specified torque followed by slackening then
retightening to the specified torque.
Ensure that the anti-theft wrench is positioned correctly on refitting.
CAUTION : Tighten the wheel bolts using a torque wrench.
2. Tightening torques : Wheels
N.B. : A double tightening is a tightening to the torque followed by unscrewing then a tightening to the torque.
Vehicles Steel rims Aluminium rims

ION 10 daNm 10 daNm
106 9 daNm 10 daNm
107 10 daNm 10 daNm
1007 9 daNm 10 daNm
205 9 daNm 10 daNm
206 10 daNm 10 daNm
206+ 9 daNm 10 daNm
207 10 daNm 10 daNm
207 restyled 10 daNm 10 daNm
208 10 daNm 10 daNm
2008 10 daNm 10 daNm
301 10 daNm 10 daNm
306 9 daNm 10 daNm
307 9 daNm 10 daNm
308 10 daNm 10 daNm
308 (Russia) 10 daNm 10 daNm
308 (T9) 10 daNm 10 daNm
Page 2 of 2
RCZ - 10 daNm
405 9 daNm 10 daNm
406 9 daNm 10 daNm
407 9 daNm 10 daNm
408 (Russia) 10 daNm 10 daNm
508 10 daNm 10 daNm
605 9 daNm 10 daNm
607 9 daNm 10 daNm
806 9 daNm 9 daNm
807 10 daNm 10 daNm
Bipper 9 daNm 10 daNm
Partner (M49) - (M59) 9 daNm 9 daNm
Partner (B9) 10 daNm 10 daNm
EXPERT 10 daNm 9 daNm
BOXER (15 inches wheels) 16 daNm 16 daNm
BOXER (16 inches wheels) 18 daNm 18 daNm
3. Wheel valve
3.1. Vehicles not equipped with tyre under-inflation detection system
Always replace the wheel valves when changing the tyres.
3.2. Vehicles fitted with a tyre under-inflation detection system
Observe the tightening torque of the wheel valve nuts : Tighten to 0,8 daN.m.
12/11/2015 Page 1 of 4
REMOVING - REFITTING : PIVOT BALL-JOINT
1. Tooling

[0621-3B] Centring punch
Figure : E5AB17JT
2. Removing
CAUTION : Check the condition of the wishbone following removal of the rivets ; If the surface is marked or
if the paint is peeling, apply black anti-corrosion paint ; If there is any significant damage on removal of the
rivets, replace the wishbone.
N.B. : The possibility of right/left mixing of a riveted wishbone assembly and a bolt/nut wishbone assembly is
permitted.
Remove the front suspension lower arm .
Copyright 2004 - Mitchell Repair Information Company, LLC - All Rights Reserved.
12/11/2015 Page 2 of 4
Figure : B3CG0CCD
CAUTION : The rivet heads are punched on the wishbone side.
Punch the centre of the 3 rivets ; Using tool [0621-3B].

Position the centring barrel on the rivet head .
12/11/2015 Page 3 of 4
Figure : B3CP0BAD
CAUTION : Drilling must be carried out in the centreline of the rivet.
Pre-drill the head of the 3 rivets to a depth "X" between 8 and 10 mm using a 3 or 4 mm diameter drill bit.
Figure : B3CG0CDD
CAUTION : Drilling must be carried out in the centreline of the rivet. Drill the head for Y = 5 mm maximum to
avoid damaging the wishbone (at "a").
Drill the head of the 3 rivets using a 10 mm drill bit.
12/11/2015 Page 4 of 4
Figure : B3CG0CED
CAUTION : The chisel must not come into contact with the wishbone .
Drive out the 3 rivet heads ; Using a chisel .

Position the chisel on the rivet head (at "b").
Drive out the ball joint from the wishbone .
3. Refitting
CAUTION : Check the condition of the wishbone following removal of the rivets ; If the surface is marked or
if the paint is peeling, apply black anti-corrosion paint ; If there is any significant damage on removal of the
rivets, replace the wishbone.
Fit the ball joint supplied in the kit .

Use the bolts/nuts supplied in the kit .
Fit the bolts on the wishbone side and the nuts on the ball joint side.
Refit the front suspension lower arm .
12/11/2015 Page 1 of 3
DISMANTLING - RE-ASSEMBLY : REAR SUSPENSION SPRING
1. Tooling

[0920-A] spring compressor
Figure : E5AG051T
[0920-M5] Jaws
Figure : E5AG052T
N.B. : Check the presence and condition of the rubber protectors on the fixed and sliding cups of the spring
compressor .
2. Removing
12/11/2015 Page 2 of 3
Figure : B3BG0K6D
"a" = Reference for positioning the spring when refitting.

Position the spring compressor [0920-A] fitted with its cups [0920-M5].
Compress the suspension spring .
Remove the compression tool [0920-A] , [0920-M5] and the suspension spring .
Decompress the suspension spring.
Remove the spring .
CAUTION : Do not put a suspension spring in direct contact with any metallic object or tool.
CAUTION : Check the condition of the suspension spring (absence of signs of impact, scratches or
corrosion spots) ; The paint coating on the suspension spring should not be damaged, leaving the metal
bare.
3. Refitting
CAUTION : Position the colour mark towards the bottom (at "a").
Position the suspension spring in the compression tool [0920-A], [0920-M5].

Compress the suspension spring .
Fit the compression tool [0920-A] , [0920-M5] and the suspension spring on the rear crossmember .
Decompress the suspension spring.
12/11/2015 Page 3 of 3
Figure : B3BG0AFD
CAUTION : Check that the angle between the centreline "A" and the end of the lower coil of the spring is
between 55° and 80°.
12/11/2015 Page 1 of 8
DISMANTLING - RE-ASSEMBLY : REAR SUSPENSION FLEXIBLE MOUNTINGS
1. Tooling

[0316-A] inertia extractor
Figure : E5AB19NT
[0551-A] bolts
Figure : E5AB17YT
[0558-A] flexible mounting removal button
12/11/2015 Page 2 of 8
Figure : E5AB17ZT
[0558-B] Flexible mounting refitting shim
Figure : E5AB180T
[0551-E] Flexible mounting removal bell
Figure : E5AB181T
Remove the rear suspension .
3. Removing
12/11/2015 Page 3 of 8
Figure : B3DG0O8D
Detach the handbrake cable (at "a").

Unclip the clip (at "b").
Figure : B3DG0O9D
12/11/2015 Page 4 of 8
Release the brake hose from its mounting (at "c").

Unclip the connector (at "d").
Detach the sensor harness (at "e").
Remove :
 The nut (1)
 The (3) bolt
 The yoke (2)
Figure : B3DG0OAD
Make a hole in the rear suspension flexible mounting (4) (at "f") ; Using a 6 mm diameter drill bit.
12/11/2015 Page 5 of 8
Figure : B3DG0OBD
Put the inertia extractor [0316-A] and the tool [0558-A] in place on the hub of the rear suspension flexible
mounting (4).
Extract the rear suspension flexible mounting (4).
Remove tools [0316-A] and [0558-A].
4. Refitting
ESSENTIAL : Adhere to the tightening torques .
CAUTION : It is essential to replace the bolt (3) and the nut (1).
CAUTION : Observe the positioning of the rear suspension flexible mounting (4).
12/11/2015 Page 6 of 8
Figure : B3DG0OCD
CAUTION : Make a mark (at "g") the length of the rear suspension flexible mounting (4) on the axis of the
shoulder (at "h").
Figure : B3DG0LAD
12/11/2015 Page 7 of 8
Fit the tools [0551-A], [0558-B], [0558-A] on the hub of the rear suspension flexible mounting (4).
Pre-coat the rear suspension flexible mounting (4) with grease used for fitting the tyres.
Figure : B3DG0OED
Position all the tools [0551-A], [0558-B], [0558-A], [0551-E] and the rear suspension flexible mounting (4) in
the suspension arm.
CAUTION : Align the mark (at "g") on the rear suspension flexible mounting (4) and the recess (at "j") on the
suspension arm.
Tighten the nut of the tool [0551-A] to insert the rear axle flexible mounting (4) into the suspension arm by 30
mm.
N.B. : Remove the tool [558-A].
Position all the tools [0551-A], [0558-B], [0551-E] on the hub of the rear suspension flexible mounting (4).
Again tighten the nut of the tool [0551-A] until the rear suspension flexible mounting (4) is correctly in place.
Remove all the tools [0551-A], [0558-B], [0551-E].
Refit :
 The yoke (2)
 The bolt (3) (new)
 The new nut (1) (Without tightening it)
 Refit the rear axle
Tighten the nut (1).

Clip :
 The clip (at "b")
 The handbrake cable (at "a")
12/11/2015 Page 8 of 8
 The sensor harness (at "e")

 The connector (at "d")
Insert the brake hose into its mounting (at "c").
12/11/2015 Page 1 of 4
ADJUSTMENT : SETTING THE REFERENCE HEIGHT
1. Tooling

[0916-A] Suspension compressors
Figure : E5AF02ZT
[0916-C] shackles
Figure : E5AB0WCT
[0916-B] Safety straps
12/11/2015 Page 2 of 4
Figure : E5AB0WBT
[0102-M] Set of 2 slings
Figure : E5AF02VT
2. Setting the reference height
CAUTION : Front and rear suspension geometry checks and front suspension geometry adjustment must be
performed with the suspension accurately compressed to the reference height, in a suspension checking
bay.
Verify :
 That the tyres and the inflation pressures are correct
 That front wheels are in the straight ahead position
2.1. Front suspension (H1)

Remove the under engine protection (If necessary).
12/11/2015 Page 3 of 4
Figure : B3BF03SD
Engage the straps [0916-B] fitted with their shackles [0916-C] on the subframe extensions.
Fit the suspension compressor [0916-A].
Select the most suitable notches ("a") to pull on the straps as nearly vertically as possible.
Compress the suspension to obtain the front body height "H1" on the right-hand side and on the left-hand
side .
CAUTION : Take the height of the turntables into account when measuring the reference height "H1".
2.2. Rear suspension (H2)
12/11/2015 Page 4 of 4
Figure : B3BF03VD
Engage the straps [0916-B] fitted with their shackles [0916-C] around the fixings securing the shock absorber
on the body .
Engage the slings [0102-M] in the shackles [0916-C].
Fit the suspension compressor [0916-A].
Select the most suitable notches "a" to pull on the slings as nearly vertically as possible.
Compress the suspension to obtain the rear body height "H2" on the right-hand side and on the left-hand
side .
CAUTION : Take the height of the turntables into account when measuring the reference height "H2".
Verify that the height "H1" measured at the front has not changed.

Citroen C-Elysee - Peugeot 301 (2012-2017) Service Manual

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Page 1 of 1

TECHNICAL NOTE : ADDITIVES FOR PARTICLE FILTER

1. The new 3rd generation particle filter additives

2. Previous type of additive

3. Compatibility between additives

4. Filling or topping up with additive

Conversion chart for filling or topping-up operations

TECHNICAL NOTE : ANCILLARY DRIVE BELT

1. Flexible ancillary drive belt

N.B. : Replace any defective parts.

Without power steering and without air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning and without power steering.

With air conditioning.

Without air conditioning.

3.4. EP3/EP6 engines

Without air conditioning.

With air conditioning.

3.6. EW7/EW10/EW12 engines

Without air conditioning / With driven power steering pump.

With air conditioning / With driven power steering pump.

With air conditioning / Power steering electric pump assembly .

Without air conditioning.

With air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning / With driven power steering pump.

4.2. DW8/DW10/DW12 engines

Without power steering and without air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning and without power steering.

With air conditioning / With driven power steering pump.

With air conditioning / Power steering electric pump assembly .

With air conditioning / Power steering electric pump assembly .

With air conditioning / Power steering electric pump assembly / Hybrid.

With air conditioning / Power steering electric pump assembly .

Without air conditioning.

With air conditioning.

TECHNICAL NOTE : ANCILLARY DRIVE BELT

1. Flexible ancillary drive belt

N.B. : Replace any defective parts.

Without power steering and without air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning and without power steering.

With air conditioning.

Without air conditioning.

3.4. EP3/EP6 engines

Without air conditioning.

With air conditioning.

3.6. EW7/EW10/EW12 engines

Without air conditioning / With driven power steering pump.

With air conditioning / With driven power steering pump.

With air conditioning / Power steering electric pump assembly .

Without air conditioning.

With air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning / With driven power steering pump.

4.2. DW8/DW10/DW12 engines

Without power steering and without air conditioning.

Without air conditioning / With driven power steering pump.

With air conditioning and without power steering.

With air conditioning / With driven power steering pump.

With air conditioning / Power steering electric pump assembly .