Renault 2009 X79 Specifications

© Renault s.a.s 2007"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it wa

10A-4ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - RefittingK9K10Aa Screw on the nut until the cover touches the spacer.a

11A-17TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (

11A-18TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11AII - REMOVAL OPERATIONa Loosen the nut (3) of the timing tensioning roller.a Remove

11A-19TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Position the RENAULT badge (7) engraved on thestem of each camshaft sprocket vert

11A-20TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Position the adjustable index (11) opposite the mark(12) , by turning the eccentr

11A-21TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Use a screwdriver (15) to check that the flywheeldoes not turn (clockwise at the

11A-22TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Check that the adjustable index (17) is opposite the notch (18) , if this is not

11A-23TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa - Lower timing cover with a timing flapa Refit the lower timing cover flap, check

11A-24TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11A1 - Adjusting the timingaa Position the camshaft grooves horizontally and be-low th

11A-25TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Fit:- the (23) onto the ends of the camshafts,- an M6 bolt (24) to hold the.a Ref

11A-26TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Position the RENAULT badge (27) etched on thestem of each camshaft sprocket verti

10A-5ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - RefittingK4M or K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Positio

11A-27TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Refit a new timing fixed roller.a Torque tighten the timing fixed roller bolt (50

11A-28TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Ac - Lower timing cover with a timing flapa Remove the timing flap from the lower ti

11A-29TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11A5 - Checking the timinga Ensure that the index and the notch on the timingtensionin

11A-30TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK4M11Aa Refit:- the right-hand suspended engine mounting (see19D, Engine mounting, Right-

11A-31TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-po

11A-32TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Mark the position of the suspended engine mountingin relation to the bod

11A-33TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Unclip the three tabs (4) .a Remove the lower timing cover.a Remove:- th

11A-34TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Turn the crankshaft to position the camshaft pulleyhole (7) almost oppos

11A-35TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Remove:- the bolt (11) from the crankshaft accessories pul-ley, locking

11A-36TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611AIII - REFITTING OPERATIONa Refit:- the crankshaft timing sprocket,-a new t

10A-6ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - RefittingK4M or K9K10Aa Extract the crankshaft seal at the gearbox end

11A-37TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Fit the new timing belt, starting with the crankshaftsprocket, aligning

11A-38TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Rotate the crankshaft clockwise through two revolu-tions (timing end).a

11A-39TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611A1 - First positiona Loosen the tensioning roller bolt by no more thanone t

11A-40TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611A2 - Second positiona Loosen the tensioning roller bolt by one turn, holdin

11A-41TOP AND FRONT OF ENGINETiming belt: Removal - RefittingK9K, and 79611Aa Refit the lower timing cover, positioning the tab (28)in the opening (29

11A-42TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift

11A-43TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK4M11AII - REMOVAL OPERATIONa Remove the rocker cover bolts.a Remove the rocker cover ve

11A-44TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK4M11AREFITTINGI - REFITTING PREPARATION OPERATIONaa Clean the gasket face of the rocker

11A-45TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK4M11Aa Use a cloth to remove any RESIN GLUE in the bear-ing channels (2) on the rocker

11A-46TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK4M11AII - REFITTING OPERATIONa Refit the rocker cover.a Tighten to torque and in order:

10A-7ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - RefittingK4M or K9K10Aa Mount theon the crankshaft, securing it using b

11A-47TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK9K11AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air filter unit (see 12A, Fue

11A-48TOP AND FRONT OF ENGINERocker cover: Removal - RefittingK9K11AIII - FINAL OPERATIONa Connect the oil vapour rebreathing pipe.a Refit the air fil

11A-49TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see

11A-50TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK4M11AII - REMOVAL OPERATIONa Remove:- the inlet camshaft (1) ,- the exhaust camshaft (2) .1

11A-51TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK4M11Aa Remove:- the valve rockers (3) ;- the hydraulic tappets (4) .REFITTINGI - REFITTING

11A-52TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK4M11Aa Refit the new camshaft dowel (precoated section (7)on the camshaft side).a Torque ti

11A-53TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK9K11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see

11A-54TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK9K11AII - OPERATION FOR REMOVAL OF PART CONCERNEDa Mark the position of the camshaft bearin

11A-55TOP AND FRONT OF ENGINECamshaft: Removal - RefittingK9K11Aa Apply four beads (6) of RESIN ADHESIVE (see Ve-hicle: Parts and consumables for the

11A-56TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a t

10A-8ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - RefittingK4M or K9K10Aa Remove the nut, the cover, the protector and th

11A-57TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK4M11AII - REMOVAL OPERATIONaa Always remove the end piece (4) of the tool.

11A-58TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK4M11Aa Remove the camshaft seal by turning the bolt (9)clockwise.a Repeat

11A-59TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK4M11Aa Fit the protector fitted with a new seal (13) on the in-let and exh

11A-60TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK4M11AIII - FINAL OPERATIONa Refit:- the inlet camshaft pulley with a new n

11A-61TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the front engine cov

11A-62TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11A- the camshaft pulley.aa Remove the camshaft seal (5) making sure tha

11A-63TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11Aa Separate the claws by turning the bolt (10) clockwiseusing an open-

11A-64TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11AII - REFITTING OPERATION FOR PART CONCERNEDa Screw the stud (12) of t

11A-65TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11Aa Screw on the collar nut until the cover touches thecylinder head.2

11A-66TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11Aa Position the bell (20) fitted with the spacer on thecamshaft seal s

10A-9ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-p

11A-67TOP AND FRONT OF ENGINECamshaft seal, timing end: Removal - RefittingK9K11AIII - FINAL OPERATIONa Set the camshaft pulley hub using the tool (Mo

11A-68TOP AND FRONT OF ENGINEOil decanter: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove:- the air resonator (see 12A, Fue

11A-69TOP AND FRONT OF ENGINEOil decanter: Removal - RefittingK4M11AREFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: oil dec

11A-70TOP AND FRONT OF ENGINEOil decanter: Removal - RefittingK4M11Aa Torque tighten in order the new oil separator bolts(15 N.m).III - FINAL OPERATIO

12A-1FUEL MIXTUREAir inlet: DescriptionK4M12ADiagram of the air inlet circuit102071 (1) Air inlet trunking (2) Air resonator (3) Air filter unit (4)

12A-2FUEL MIXTUREAir resonator: Removal - RefittingK4M12AREMOVALREMOVAL OPERATION FOR PART CONCERNEDa Remove:- the elastic mounting (1) from the air r

12A-3FUEL MIXTUREAir filter: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air resonator (see 12A, Fuel mixture,Air re

12A-4FUEL MIXTUREAir filter: Removal - RefittingK9K12AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air filter unit (see 12A, Fuel mixture,Air

12A-5FUEL MIXTUREAir filter: Removal - RefittingK9K12AII - REFITTING OPERATION FOR PART CONCERNEDa Refit the air filter in the air filter unit cover.a

12A-6FUEL MIXTUREAir filter unit: Removal - RefittingK9K12AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the engine cover.a Disconnect:- the air in

10A-10ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10Aa Remove the power-assisted steering low pressurepipe bolt (2) on the fr

12A-7FUEL MIXTUREAir filter unit: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal - Re

12A-8FUEL MIXTUREAir filter unit: Removal - RefittingK4M12Aa Unclip:- the coolant pipes at (6) ,- the breather (7) .a Remove the coolant pipes mountin

12A-9FUEL MIXTUREAir filter unit: Removal - RefittingK4M12A- the plastic rivets and clips every time they are re-moved.II - REFITTING OPERATIONa Refit

12A-10FUEL MIXTUREAir flowmeter: Removal - RefittingK9K, and 79612AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the engine cover.a Disconnect the

12A-11FUEL MIXTUREThrottle valve: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal - Re

12A-12FUEL MIXTUREInlet distributor: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the accelerator cable on the thrott

12A-13FUEL MIXTUREInlet distributor: Removal - RefittingK4M12AaUse SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum

12A-14FUEL MIXTUREInjector holder shim: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Remova

12A-15FUEL MIXTUREInjector holder shim: Removal - RefittingK4M12AREFITTINGI - REFITTING PREPARATION OPERATIONa The injector holder shim seal must alwa

12A-16FUEL MIXTUREExhaust manifold: Removal - RefittingK9K12AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Ve

10A-11ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10Aa Remove:- the bracket bolts (12) ,- one by one, the front axle subframe

12A-17FUEL MIXTUREExhaust manifold: Removal - RefittingK9K12AIII - FINAL OPERATIONa Refit:- the turbocharger (see 12B, Turbocharging, Tur-bocharger: R

12A-18FUEL MIXTUREExhaust manifold: Removal - RefittingK4M12AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Ve

12A-19FUEL MIXTUREExhaust manifold: Removal - RefittingK4M12Aa Remove the stay (4) between the exhaust manifoldand the cylinder block.II - REMOVAL OPE

12A-20FUEL MIXTUREExhaust manifold: Removal - RefittingK4M12AII - REFITTING OPERATION FOR PART CONCERNEDa Refit the exhaust manifold.a Tighten to torq

12A-21FUEL MIXTUREExhaust manifold: Removal - RefittingK4M12AIII - FINAL OPERATIONa Refit the stay between the exhaust manifold and thecylinder block.

12B-1TURBOCHARGINGTurbocharger: Removal - RefittingK9K12BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicl

12B-2TURBOCHARGINGTurbocharger: Removal - RefittingK9K12BII - REMOVAL OPERATIONa Remove (see 12B, Turbocharging, Turbocharger oil pipe: Removal - Refi

12B-3TURBOCHARGINGTurbocharger: Removal - RefittingK9K12Ba Use an open wrench to fit the new turbocharger nutswithout tightening them (the turbocharge

12B-4TURBOCHARGINGTurbocharger oil pipe: Removal - RefittingK9K12BREMOVING THE TURBOCHARGER OIL SUPPLY PIPEI - REMOVAL PREPARATION OPERATIONa Disconne

12B-5TURBOCHARGINGTurbocharger oil pipe: Removal - RefittingK9K12Ba Remove:-the turbocharger oil supply pipe hollow boltfrom theturbocharger,- the tur

10A-12ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10AII - REMOVAL OPERATIONa Remove the power-assisted steering pump supportb

12B-6TURBOCHARGINGTurbocharger oil pipe: Removal - RefittingK9K12B- the turbocharger oil supply pipe nut on the cyl-inder head (shouldered nut 35 N.m

12B-7TURBOCHARGINGTurbocharger oil pipe: Removal - RefittingK9K12Ba Extract the turbocharger oil return pipe from the cyl-inder block.a Remove the tur

12B-8TURBOCHARGINGIntercooler: Removal - RefittingK9K12BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle

12B-9TURBOCHARGINGIntercooler: Removal - RefittingK9K12Ba Push the « radiator - fan » assembly in the directionof the arrow (4) in order to remove the

13A-1FUEL SUPPLYFuel circuit: Operating diagramK4M13AOperating diagram of the fuel supply circuit ( « pump - sender - fuel filter » assembly)The fuel

13A-2FUEL SUPPLYFuel circuit: Operating diagramK4M13AOperating diagram of the fuel supply circuit (external filter)The fuel supply circuit does not ha

13A-3FUEL SUPPLYManual priming pump: Removal - RefittingK9K13AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see V

13A-4FUEL SUPPLYManual priming pump: Removal - RefittingK9K13AII - OPERATION FOR REMOVAL OF PART CONCERNEDa Disconnect the fuel supply pipe at the fue

13A-5FUEL SUPPLYDiesel filter: Removal - RefittingK9K13AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a lift (see Vehicle: Towinga

13A-6FUEL SUPPLYDiesel filter: Removal - RefittingK9K13AII - REMOVAL OPERATIONMAHLE type filtera Remove:- the diesel filter protection plate nuts (2)

10A-13ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10Aa Clean the cylinder block joint face using SUPERCLEANING AGENT FOR JOI

13A-7FUEL SUPPLYDiesel filter: Removal - RefittingK9K13Aa Disconnect:- the fuel inlet pipe union (7) ,- the fuel outlet pipe union (8) ,- the fuel ret

13A-8FUEL SUPPLYDiesel filter: Removal - RefittingK9K13APriming the supply circuita Prime the fuel system with the manual priming pump(11) (automatic

13A-9FUEL SUPPLYFuel pressure: CheckK4M13ACHECKa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a S

13A-10FUEL SUPPLYFuel pressure: CheckK4M13Aa Connect:- the « T » union (Mot. 1311-08) (6) to the fuel tankoutlet pipe,- the pipe (5) fitted with a pr

13A-11FUEL SUPPLYFuel flow: CheckK4M13ACHECKa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Swit

13A-12FUEL SUPPLYFuel flow: CheckK4M13Aa Connect:- the « T » union (Mot. 1311-08) (6) to the fuel tankoutlet pipe,-the pipe (5) contained in the test

13A-13FUEL SUPPLYFuel flow: CheckK4M13Aa Connect the connector terminal (13) to the + BAT-TERY to operate the fuel pump.a Note the time taken for the

13B-1DIESEL INJECTIONDiesel injection: List and location of componentsK9K, and 79613B123977No. Description1 High pressure pump2 Injection computer3 In

13B-2DIESEL INJECTIONDiesel injection: List and location of componentsK9K, and 79613BHigh-pressure pump (1) .Injection computer (2) .Injector rail pre

13B-3DIESEL INJECTIONDiesel injection: List and location of componentsK9K, and 79613BAir flowmeter with integrated temperature sensor (12) ,Turbocharg

© Renault s.a.s 2007"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it wa

10A-14ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10AII - REFITTING OPERATIONa20170Note:When refitting the sump, ensure that:-

13B-4DIESEL INJECTIONDiesel injection: List and location of componentsK9K, and 79613BPre-postheating unit (17) .Accelerator pedal potentiometer (19) .

13B-5DIESEL INJECTIONDiesel injection computer: Removal - RefittingK9K13BThere are two ways to do this (see Fault finding - Re-placement of components

13B-6DIESEL INJECTIONDiesel injection computer: Removal - RefittingK9K13BREFITTINGI - REFITTING OPERATIONa Fit the injection computer on its mounting

13B-7DIESEL INJECTIONCamshaft position sensor: Removal - RefittingK9K13BREMOVALOPERATION FOR REMOVAL OF PART CONCERNEDa Disconnect the connector (1) f

13B-8DIESEL INJECTIONCrankshaft position sensor: Removal - RefittingK9K, and 79613BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a

13B-9DIESEL INJECTIONHigh pressure pump: Removal - RefittingK9K, and 79613BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-pos

13B-10DIESEL INJECTIONHigh pressure pump: Removal - RefittingK9K, and 79613Ba Disconnect:- the heater plugs (3) ,- the injectors (4) ,- the connectors

13B-11DIESEL INJECTIONHigh pressure pump: Removal - RefittingK9K, and 79613Ba Remove the high pressure pipe (13) between the in-jector rail and the hi

13B-12DIESEL INJECTIONHigh pressure pump: Removal - RefittingK9K, and 79613Ba Position the (16) fitted with the.II - REMOVAL OPERATIONa Remove:- the h

13B-13DIESEL INJECTIONHigh pressure pump: Removal - RefittingK9K, and 79613Ba Torque tighten in order the high pressure pumpbolts (23 N.m).a Torque ti

10A-15ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10Aa Refit the oil sump fitted with a new seal.a Tighten until contact:- th

13B-14DIESEL INJECTIONFlow actuator: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal -

13B-15DIESEL INJECTIONFlow actuator: Removal - RefittingK9K13Ba Disconnect:- the injector rail pressure sensor,- the accelerometer .a Unclamp the engi

13B-16DIESEL INJECTIONVenturi: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal - Re-fi

13B-17DIESEL INJECTIONVenturi: Removal - RefittingK9K13Ba Disconnect the return pipe (4) connecting the injec-tor to the high pressure pump.II - REMOV

13B-18DIESEL INJECTIONHigh pressure pipe: CheckK9K13BaCHECKa Remove the front engine cover.a Prime the fuel circuit using the manual priming pump(1) u

13B-19DIESEL INJECTIONHigh pressure pipe between pump and rail: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the batt

13B-20DIESEL INJECTIONHigh pressure pipe between pump and rail: Removal - RefittingK9K13B- the injectors.a Disconnect:- the high pressure pump connect

13B-21DIESEL INJECTIONHigh pressure pipe between pump and rail: Removal - RefittingK9K13Ba Slightly pretighten the high pressure pipe nuts.a Torque ti

13B-22DIESEL INJECTIONHigh pressure pipe between rail and injector: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the

13B-23DIESEL INJECTIONHigh pressure pipe between rail and injector: Removal - RefittingK9K13Ba Disconnect the following connectors (2) :- the heater p

10A-16ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK9K10Aa One by one, remove the threaded rods of the (Tav.1747) and replace the

13B-24DIESEL INJECTIONHigh pressure pipe between rail and injector: Removal - RefittingK9K13Baa If replacing the four high pressure pipes:- loosen the

13B-25DIESEL INJECTIONInjector rail: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal -

13B-26DIESEL INJECTIONInjector rail: Removal - RefittingK9K13Ba Disconnect:- the heater plugs (3) ,- the injectors (4) ,- the connectors on the high p

13B-27DIESEL INJECTIONInjector rail: Removal - RefittingK9K13B-the high pressure pipes between the injector railand the injectors (see 13B, Diesel inj

13B-28DIESEL INJECTIONFuel temperature sensor: Removal - RefittingK9K13BREMOVALaI - REMOVAL PREPARATION OPERATIONa Remove the front engine cover.a Dis

13B-29DIESEL INJECTIONFuel temperature sensor: Removal - RefittingK9K13BREFITTINGI - REFITTING PREPARATION OPERATIONa Lubricate the O-ring with lubric

13B-30DIESEL INJECTIONInjector leak flow: CheckK9K13BPARTS AND CONSUMABLES FOR THE REPAIRConsumables:- cleaning cloths (see Vehicle: Parts and consum-

13B-31DIESEL INJECTIONInjector leak flow: CheckK9K13Ba Connect four of the transparent pipes (3) of theontothe diesel injector return.a Insert these p

13B-32DIESEL INJECTIONDiesel injector: Removal - RefittingK9K13BInjectors may be replaced individually.REMOVALI - REMOVAL PREPARATION OPERATIONa Disco

13B-33DIESEL INJECTIONDiesel injector: Removal - RefittingK9K13Ba Disconnect:- the heater plugs (3) ,- the injectors (4) ,- the connectors (5) on the

10A-17ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-

13B-34DIESEL INJECTIONDiesel injector: Removal - RefittingK9K13BII - OPERATION FOR REMOVAL OF PART CONCERNEDa Loosen the injector clamp bolt (11) .a R

13B-35DIESEL INJECTIONDiesel injector: Removal - RefittingK9K13BREFITTINGI - REFITTING PREPARATION OPERATIONa Always replace the heat protection washe

13B-36DIESEL INJECTIONDiesel injector: Removal - RefittingK9K13Ba Program the alphanumeric code (C2I) (13) for thereplaced injector(s) using the Diagn

13B-37DIESEL INJECTIONAccelerometer: Removal - RefittingK9K13BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal -

13B-38DIESEL INJECTIONAccelerometer: Removal - RefittingK9K13BII - OPERATION FOR REMOVAL OF PART CONCERNEDa Remove the accelerometer using.REFITTINGI

13C-1PREHEATINGPre-postheating unit: Removal - RefittingK9K13CREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal -

13C-2PREHEATINGHeater plugs: Removal - RefittingK9K13CREMOVALI - REMOVAL PREPARATION STAGEa Remove the front engine cover.II - REMOVAL OPERATIONa Disc

13C-3PREHEATINGHeater plugs: Removal - RefittingK9K13Ca Unscrew the heater plugs using a 10 mm long sock-et connected to a universal joint or a hinged

14A-1ANTIPOLLUTIONExhaust gas recirculation: List and location of componentsK9K14A112326 (1) Exhaust gas recirculation sole-noid valve (2) Intercoole

14A-2ANTIPOLLUTIONFuel vapour absorber: Removal - RefittingK4M14AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a lift (see Vehicle

10A-18ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10Aa Remove the cooling pipe support bolt (2) on thesump.a Remove the front

14A-3ANTIPOLLUTIONFuel vapour absorber: Removal - RefittingK4M14AREFITTINGI - REFITTING PREPARATION OPERATIONa Remove the blanking plugs.II - REFITTIN

14A-4ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - RefittingK9K, and 79614AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air

14A-5ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - RefittingK9K, and 79614AaREFITTINGI - REFITTING PREPARATION OPERATIONa parts alw

14A-6ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - RefittingK9K, and 79614Aa Torque tighten the exhaust gas recirculation sole-noid

14A-7ANTIPOLLUTIONExhaust gas cooler: Removal - RefittingK9K, and 79614AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post l

14A-8ANTIPOLLUTIONExhaust gas cooler: Removal - RefittingK9K, and 79614A- the joint face of the exhaust gas cooler mountingon the gearbox end,- the jo

14A-9ANTIPOLLUTIONExhaust gas recirculation assembly: Removal - RefittingK9K, and 79614AI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a t

14A-10ANTIPOLLUTIONExhaust gas recirculation assembly: Removal - RefittingK9K, and 79614Aa Position the (Ms. 583) or the hose clamps on thecoolant inl

14A-11ANTIPOLLUTIONExhaust gas recirculation assembly: Removal - RefittingK9K, and 79614Aa Use GREY ABRASIVE PADS (see Vehicle: Partsand consumables

14A-12ANTIPOLLUTIONExhaust gas recirculation rigid pipe: Removal - RefittingK9K, and 79614AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehi

10A-19ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10Aa Remove:- the bracket bolts (11) ,- one by one, the front axle subframe

14A-13ANTIPOLLUTIONExhaust gas recirculation rigid pipe: Removal - RefittingK9K, and 79614Aa Clean using ABRASIVE PADS :- the joint face of the exhaus

16A-1STARTING - CHARGINGAlternator: Removal - RefittingK9K16AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal -

16A-2STARTING - CHARGINGAlternator: Removal - RefittingK9K16AII - REFITTING OPERATIONa Refit:- the alternator with its lower bolt,- the alternator upp

16A-3STARTING - CHARGINGAlternator: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING16AREMOVALI - REMOVAL PREPARATION OPERATI

16A-4STARTING - CHARGINGAlternator: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING16AII - REMOVAL OPERATIONa Remove:- the a

16A-5STARTING - CHARGINGAlternator: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING16A-the front bumper (see Front bumper: R

16A-6STARTING - CHARGINGAlternator: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION16AREMOVALI - REMOVAL PREPARATION OPERATIONa Position th

16A-7STARTING - CHARGINGAlternator: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION16AREFITTINGI - REFITTING PREPARATION OPERATIONa Push th

16A-8STARTING - CHARGINGStarter: Removal - RefittingK9K16AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal - Re-

16A-9STARTING - CHARGINGStarter: Removal - RefittingK9K16AIII - FINAL OPERATIONa Clip:- the engine wiring,- the intercooler duct on the fan assembly.a

10A-20ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10AII - REMOVAL OPERATIONa Remove:- the sump bolt from the multifunction su

16A-10STARTING - CHARGINGStarter: Removal - RefittingK4M16AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehi

16A-11STARTING - CHARGINGStarter: Removal - RefittingK4M16AII - REMOVAL OPERATIONa Remove:- the nut (5) on the starter solenoid lead,- the nut (6) on

16A-12STARTING - CHARGINGAlternator pulley: Removal - RefittingK4M16AI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see V

16A-13STARTING - CHARGINGAlternator pulley: Removal - RefittingK4M16AMot. 1732a Position the hexagonal socket (1) or the splinedsocket (2) from the ki

16A-14STARTING - CHARGINGAlternator pulley: Removal - RefittingK4M16AaLoosen the alternator pulley using a pneumatic orelectric wrench.aRemove:- the t

16A-15STARTING - CHARGINGAlternator pulley: Removal - RefittingK4M16AIV - REFITTING OPERATION FOR THE ALTERNATOR PULLEYa Tighten the new alternator pu

16A-16STARTING - CHARGINGAlternator pulley: Removal - RefittingK4M16Aa Immobilise the alternator rotor using the spanner (7).a Torque tighten the alte

16A-17STARTING - CHARGINGAlternator pulley: Removal - RefittingK9K16AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Re

16A-18STARTING - CHARGINGAlternator pulley: Removal - RefittingK9K16Aa Fit:- the splined socket (4) of thein the free wheel pulley(5) ,- the end piece

17A-1IGNITIONCoils: Removal - RefittingK4M17AREMOVALREMOVAL OPERATIONa Disconnect the connectors (1) from the ignition coils.a Remove:- the ignition c

10A-21ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10Aa Apply:-four beads (13) of SILICONE ADHESIVE SEAL-ANT (see Vehicle: Pa

17A-2IGNITIONCoils: Removal - RefittingK4M17Aa When refitting the ignition harness, it is essential toapply a bead of FLUOSTAR 2L 2 mm in diameteraro

17B-1PETROL INJECTIONPetrol injection: List and location of componentsK4M17B116656 (1) Air pressure sensor (2) Idle speed stepper motor (3) Air tem

17B-2PETROL INJECTIONPetrol injection: List and location of componentsK4M17B (4) Throttle position potentiometer (5) Ignition coil116635 (6) Throttle

17B-3PETROL INJECTIONPetrol injection: List and location of componentsK4M17B116648 (11) Crankshaft position sensor101498 (12) Coolant temperature se

17B-4PETROL INJECTIONOxygen sensors: Removal - RefittingK4M17BREMOVALI - REMOVAL PREPARATION OPERATION1 - Upstream oxygen sensora Remove:- the air res

17B-5PETROL INJECTIONOxygen sensors: Removal - RefittingK4M17B2 - Downstream oxygen sensora Unclip the wiring from the downstream oxygen sen-sor at (6

17B-6PETROL INJECTIONThrottle valve potentiometer: Removal -RefittingK4M17BREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air resonator (see 12A

17B-7PETROL INJECTIONPetrol injection computer: Removal - RefittingK4M17BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery

17B-8PETROL INJECTIONPetrol injection computer: Removal - RefittingK4M17BREFITTINGI - REFITTING OPERATIONa Refit the injection computer.a Torque tight

17B-9PETROL INJECTIONCrankshaft position sensor: Removal - RefittingK4M17BREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air resonator (see 12A,

10A-22ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10Aa Refit the oil sump fitted with a new seal.a Tighten until contact:- th

17B-10PETROL INJECTIONInjector rail - Injectors: Removal - RefittingK4M17BREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Batter

17B-11PETROL INJECTIONInjector rail - Injectors: Removal - RefittingK4M17BII - REMOVAL OPERATIONa Disconnect the injector connectors (4) .a Remove:- t

19A-1COOLINGEngine cooling system: Operating diagramK9K, and 79619A133248 (1) Engine (2) Cooling radiator (3) Heater radiator (4) Expansion bottle (5)

19A-2COOLINGEngine cooling system: Specifications19AVehicles in the current range have cooling systems with the following basic specifications:- herme

19A-3COOLINGEngine cooling system: Check19AExpansion bottle cap valve rating:I - CHECKING THE COOLING SYSTEM USING THE TOOL (MOT. 1700)a1 - Checking t

19A-4COOLINGEngine cooling system: Check19A1 - Checking the expansion bottle cap valvea Fit onto the tester, the adapter (Ms. 554-06).a Fit the expans

19A-5COOLINGEngine cooling circuit: List and location of componentsK4M19AI - LIST OF COMPONENTSThe engine cooling system is composed of:- an engine co

19A-6COOLINGCooling system: Draining - Refilling19AI - DRAININGa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Liftin

19A-7COOLINGCooling system: Draining - Refilling19Aa Open the bleed screw (2) .a Open the bleed screws (4) and (5) .a Fill the cooling system with eng

19A-8COOLINGCooling system: Draining - Refilling19Aa Pressurise the system using the toolto check thatthere are no leaks (see 19A, Cooling, Engine coo

10A-23ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - RefittingK4M10Aa Refit the front bumper (see Front bumper assem-bly: Exploded view) and

19A-9COOLINGCooling radiator: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a lift (see Vehicle: Towingan

19A-10COOLINGCooling radiator: Removal - RefittingK4M19Aa Remove the condenser bolts (2) .a Remove the cooling radiator hose clips (3) using thetool (

19A-11COOLINGCooling radiator: Removal - RefittingK9K19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a lift (see Vehicle: Towinga

19A-12COOLINGCooling radiator: Removal - RefittingK9K19Aa Remove the condenser bolts (2) .a Remove the cooling radiator hose clips (3) using thetool (

19A-13COOLINGCoolant pump: Removal - RefittingK9K, and 79619AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Ve

19A-14COOLINGCoolant pump: Removal - RefittingK9K, and 79619Aa Remove:- the inner timing cover bolts (2) ,- the inner timing cover.II - REMOVAL OPERAT

19A-15COOLINGCoolant pump: Removal - RefittingK9K, and 79619AII - REFITTING OPERATIONa Refit:- the coolant pump fitted with a new seal,- the coolant p

19A-16COOLINGCoolant pump: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Tow

19A-17COOLINGCoolant pump: Removal - RefittingK4M19AREFITTINGI - REFITTING PREPARATION OPERATIONaa Use SUPER CLEANING AGENT FOR JOINT FA-CES (see Veh

19A-18COOLINGCoolant pump: Removal - RefittingK4M19AII - REFITTING OPERATIONa Apply one to two drops of FRENETANCHE (seeVehicle: Parts and consumabl

DUSTER - Chapitre 1ContentsPagesDUSTER - Chapitre 1ContentsPages10AENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting

10A-24ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle

19A-19COOLINGThermostat: Removal - RefittingK9K19Aa The thermostat is integral with the coolant outletunit. The coolant outlet unit must be replaced t

19A-20COOLINGThermostat: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towin

19A-21COOLINGThermostat: Removal - RefittingK4M19A- the thermostat cover.a Remove:- the thermostat (4) ,- the thermostat seal (5) .REFITTINGI - REFITT

19A-22COOLINGWater chamber: Removal - RefittingK9K, and 79619AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see V

19A-23COOLINGWater chamber: Removal - RefittingK9K, and 79619Aa Disconnect the EGR assembly outlet pipe at (6) .a Move the EGR assembly outlet pipe as

19A-24COOLINGWater chamber: Removal - RefittingK9K, and 79619AII - REFITTING OPERATIONa Refit:-a new water chamber seal in the water chamberhousing,-

19A-25COOLINGWater chamber: Removal - RefittingK4M19AREMOVALI - OPERATION FOR REMOVAL OF PART CONCERNEDa Position the vehicle on a two-post lift (see

19A-26COOLINGWater chamber: Removal - RefittingK4M19Aa Screw on the water chamber bolts without tighteningthem.a Torque tighten in order:- the coolant

19A-27COOLINGEngine cooling fan assembly: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Remo

19A-28COOLINGEngine cooling fan assembly: Removal - RefittingK4M19Aa Disconnect the cooling fan assembly connector (5) .a Unclip the engine cooling fa

10A-25ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10Aa Remove the catalytic converter upstream stay (3) .aUndo the b

19A-29COOLINGEngine cooling fan assembly: Removal - RefittingK4M19Aa Unclip the « condenser - expansion valve » connect-ing pipe at (9) .a Pull the fa

19A-30COOLINGEngine cooling fan assembly: Removal - RefittingK9K19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (

19A-31COOLINGEngine cooling fan assembly: Removal - RefittingK9K19AII - REMOVAL OPERATIONa Unclip the following from the support (4) :- the intercoole

19A-32COOLINGEngine cooling fan assembly: Removal - RefittingK9K19Aa Disconnect:- the engine cooling fan assembly connector (9) ,- the engine cooling

19A-33COOLINGEngine cooling fan assembly: Removal - RefittingK9K19AREFITTINGI - REFITTING PREPARATION OPERATIONIn the event of replacementa Refit on t

19A-34COOLINGCoolant pump inlet pipe: Removal - RefittingK9K, and 79619AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post l

19A-35COOLINGCoolant pump inlet pipe: Removal - RefittingK9K, and 79619Aa Use SURFACE CLEANER (see ) (04B, Consuma-bles - Products) to clean and degr

19A-36COOLINGCoolant pump inlet pipe: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see

19A-37COOLINGCoolant pump inlet pipe: Removal - RefittingK4M19Aa Refit the injector rail protector.a Fill the cooling system (see 19A, Cooling, Coolin

19A-38COOLINGExpansion bottle: Removal - Refitting19AREMOVALREMOVAL OPERATIONa Remove the expansion bottle nuts (1) .a Move aside the expansion bottle

10A-26ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10AII - REMOVAL OPERATION FOR THE CON ROD BEARING SHELLS NO.2a Use

19A-39COOLINGExpansion bottle: Removal - Refitting19A- the expansion bottle bottom hose.a Refit the following using the tool (Mot. 1448) or « CLIC » c

19A-40COOLINGCoolant temperature sensor: Removal - RefittingK9K19AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (s

19A-41COOLINGCoolant temperature sensor: Removal - RefittingK9K19AII - REMOVAL OPERATIONa Disconnect the coolant temperature sensor connec-tor (6) .a

19A-42COOLINGCoolant temperature sensor: Removal - RefittingK9K19Aa Perform the following operations:- top up the cooling system,- bleed the cooling s

19A-43COOLINGCoolant temperature sensor: Removal - RefittingK4M19AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the air resonator (see 12A, Fuel mi

19A-44COOLINGCoolant temperature sensor: Removal - RefittingK4M19AIII - FINAL OPERATIONa Refit the air resonator (see 12A, Fuel mixture, Airresonator:

19B-1EXHAUSTExhaust: List and location of components19B

19B-2EXHAUSTExhaust: List and location of components19BK4M144569

19B-3EXHAUSTExhaust: List and location of components19B (A) Area to be cut A (B) Area to be cut B (1) Exhaust system sealing ring (2) Catalytic con

19B-4EXHAUSTExhaust: List and location of components19BK9K144609

10A-27ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10Aa Fit the tie rod of the toolon the con rod body.a Push the con

19B-5EXHAUSTExhaust: List and location of components19B (A) Area to be cut A (B) Area to be cut B (1) Exhaust system sealing ring (2) Intermediate

19B-6EXHAUSTExhaust: Precautions for the repair19BI - PARTS AND CONSUMABLES FOR THE REPAIR1 - Parts always to be replaced:- the exhaust sleeve (if fit

19B-7EXHAUSTExhaust: Precautions for the repair19BBefore cutting the exhaust system, draw a line (D) be-tween the two marks (P1) and (P2) .The distanc

19B-8EXHAUSTExhaust: Precautions for the repair19BExhaust sleeve with 1 boltExhaust sleeve with 2 boltsFit the exhaust sleeve onto the part of the exh

19B-9EXHAUSTExhaust: Precautions for the repair19BNote:If there are leaks from the EXHAUST SLEEVESWITH 1 BOLT, apply EXHAUST MASTIC to thesleeve (se

19B-10EXHAUSTCatalytic converter: Removal - RefittingK9K, and 79619BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift

19B-11EXHAUSTCatalytic converter: Removal - RefittingK9K, and 79619Ba Remove the bolt from the downstream strut on thecatalytic converter (2) .a Loose

19B-12EXHAUSTCatalytic converter: Removal - RefittingK9K, and 79619BREFITTINGI - REFITTING PREPARATION OPERATIONaa Use ABRASIVE PADS (see Vehicle: Pa

19B-13EXHAUSTCatalytic converter: Removal - RefittingK9K, and 79619Ba Check that there are no leaks and deal with them ifnecessary.

19B-14EXHAUSTCatalytic converter: Removal - RefittingK4M, and 4X2 TRANSMISSION19BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a t

10A-28ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10AaFit the head of the toolwith the marking " K9K INF "

19B-15EXHAUSTCatalytic converter: Removal - RefittingK4M, and 4X2 TRANSMISSION19Ba Remove:- the exhaust flange bolts (2) ,- the catalytic converter,-

19B-16EXHAUSTCatalytic converter: Removal - RefittingK4M, and 4X2 TRANSMISSION19Ba Check that there are no leaks and deal with them ifnecessary.

19B-17EXHAUSTExpansion chamber: Removal - RefittingK4M, and 4X2 TRANSMISSION19BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two

19B-18EXHAUSTIntermediate pipe: Removal - RefittingK9K19BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicl

19B-19EXHAUSTIntermediate pipe: Removal - RefittingK9K19BREFITTINGI - REFITTING OPERATIONa Refit the intermediate pipe.a Refit the exhaust sleeves (se

19B-20EXHAUSTSilencer: Removal - Refitting4X2 TRANSMISSION19BREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Ve

19C-1TANKFuel tank: Draining19CDRAININGI - DRAINING PREPARATION OPERATIONa Disconnect the battery (see Battery: Removal - Re-fitting) (80A, Battery).I

19C-2TANKFuel tank: Draining19Ca Remove:- the front right-hand wheel arch liner bolts (4) ,- the clip of the wheel arch liner (5) ,- the diesel filter

19C-3TANKFuel tank: Removal - Refitting4X2 TRANSMISSION19CThis method describes the removal - refitting pro-cedure for the plastic tankREMOVALI - REMO

19C-4TANKFuel tank: Removal - Refitting4X2 TRANSMISSION19Ca Remove the body earth cable at (2) . a Remove the oxygen sensor connector by sliding itfro

10A-29ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10Aa Remove the tool head with the marking " K9K INF "an

19C-5TANKFuel tank: Removal - Refitting4X2 TRANSMISSION19Ca Remove the catalytic converter mountings (6) on theexhaust manifold.a Detach the exhaust l

19C-6TANKFuel tank: Removal - Refitting4X2 TRANSMISSION19CII - OPERATION FOR REMOVAL OF PART CONCERNEDa Remove the bolts (9) from the filler neck.a Di

19C-7TANKFuel tank: Removal - Refitting4X2 TRANSMISSION19Ca Refit the fuel tank.a Refit the fuel tank bolts.a Torque tighten the fuel tank bolts (21 N

19C-8TANKFuel level sensor module: Removal - RefittingK4M or K9K19CREMOVALI - REMOVAL PREPARATION OPERATIONa Disconnect the battery (see Battery: Remo

19C-9TANKFuel level sensor module: Removal - RefittingK4M or K9K19Ca Disconnect:- the connector (3) ,- union (4) .a Remove the nut from the fuel level

19C-10TANKFuel level sensor module: Removal - RefittingK4M or K9K19CII - REFITTING OPERATIONa Position:- the new seal (6) in the neck correctly,- the

19D-1ENGINE MOUNTINGSuspended engine mounting: Tightening torqueK9K19D103236No. Description Tightening torque(N.m) (1) Right-hand suspended mounting

19D-2ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting19DREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two

19D-3ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting19D- the bolts (3) from the left-hand rubber pad mount-ing on the body,- t

19D-4ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - RefittingK9K19DREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the front engine c

10A-30ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10Aa Apply SILICONE ADHESIVE SEALANT (see Vehi-cle: Parts and con

19D-5ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - RefittingK9K19DII - REMOVAL OPERATIONa Mark the position of the right-hand suspend

19D-6ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - RefittingK4M19DREMOVALI - REMOVAL PREPARATION OPERATIONa Remove the front engine c

19D-7ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - RefittingK4M19DII - FINAL OPERATIONa Remove the engine support tool (Mot. 1453).a

19D-8ENGINE MOUNTINGLower engine tie-bar: Removal - Refitting19DREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see

10A-31ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - RefittingK9K10Aa Disconnect the crankshaft position sensor (4) to pre-vent the

10A-32ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - RefillingK4M or K9K10ADRAININGI - AVERAGE CAPACITY OF ENGINE OILa 4.7 litres (without o

10A-33ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - RefillingK4M or K9K10Aa Remove the drain plug (2) using theor a oil changewrench.a Let

ContentsThrottle valve: Removal - Refitting 12A-11Inlet distributor: Removal - Refitting 12A-12Injector holder shim: Removal - Refitting 12A-14Exhaust ma

10A-34ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - RefittingK9K10AREMOVALOPERATION FOR REMOVAL OF PART CONCERNEDa Position the (Mot. 1329)

10A-35ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-p

10A-36ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - RefittingK4M10Aa Top up the engine oil level to the dipstick if neces-sary (see 10A, Eng

10A-37ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - RefittingK9K, and 79610AaREMOVALREMOVAL PREPARATION OPERATIONa Position

10A-38ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - RefittingK9K, and 79610Aa Disconnect the air outlet duct (7) on the inte

10A-39ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - RefittingK9K, and 79610Aa Remove:- the bolt (12) from the oil-coolant he

10A-40ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - RefittingK9K, and 79610Aa Refit new seals (14) and (15) on the oil-water

10A-41ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - RefittingK9K, and 79610Aa Connect the air outlet duct to the intercooler

10A-42ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure sensor: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle o

10A-43ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure sensor: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle o

ContentsExhaust gas recirculation solenoid valve: Removal - Refitting 14A-4Exhaust gas cooler: Removal - Refitting 14A-7Exhaust gas recirculation assemb

10A-44ENGINE AND CYLINDER BLOCK ASSEMBLYOil pump: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-pos

10A-45ENGINE AND CYLINDER BLOCK ASSEMBLYOil pump: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-pos

10A-46ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: CheckK4M or K9K10AOil pressure tables:End pieces to be used:I - REMOVAL PREPARATION OPERATIONaII

10A-47ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: CheckK4M or K9K10Aa Top up the engine oil level if necessary (see Engineoil: Specifications) .a

10A-48ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING10AREMOVALI -

10A-49ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING10AREFITTINGI

10A-50ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION10AREMOVALI - REMOVAL PREPARA

10A-51ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION10AREFITTINGI - REFITTING OPE

10A-52ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle

10A-53ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK9K10AREFITTINGREFITTING OPERATIONa Refit the multifunction support.

ContentsIntermediate pipe: Removal - Refitting 19B-18Silencer: Removal - Refitting 19B-2019C TANKFuel tank: Draining 19C-1Fuel tank: Removal - Refitting

10A-54ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONaa Position the ve

10A-55ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Disconnect the accelerator cable on the throttlevalve at

10A-56ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10A- the cooling system (see 19A, Cooling, Coolingsystem: Dr

10A-57ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Remove:- the power-assisted steering low pressure pipe (

10A-58ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Remove the power-assisted steering low pressurepipe bolt

10A-59ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Move aside the clips (27) of the coolant hoses on thewat

10A-60ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Unclip:- the gear control cables on the gearbox at (31)

10A-61ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Remove:- the bolts (33) from the exhaust flange,- the ex

10A-62ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Remove the nut (35) on the rubber pad support ofthe left

10A-63ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK4M10Aa Remove the (Mot. 1390) from the engine - gearboxassembly

10A-1ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the

10A-64ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610AREMOVALI - REMOVAL PREPARATION OPERATIONaa Positi

10A-65ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Remove the engine wiring bolt (1) on the batter

10A-66ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610A- the cooling system (see 19A, Cooling, Coolings

10A-67ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Unclip:- the turbocharger control solenoid valv

10A-68ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Remove the power-assisted steering high pressur

10A-69ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Remove:- the power-assisted steering high press

10A-70ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610A- the steering box heat shield,- the steering box

10A-71ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aaa Disconnect the clutch control pipe on the clut

10A-72ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610AII - REMOVAL OPERATIONaa Position the (Mot. 1390)

10A-73ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Lift the vehicle to remove the engine - gearbox

10A-2ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - RefittingK9K10Aa Separate the jaws by screwing the nutof the tool (6)

10A-74ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - RefittingK9K, and 79610Aa Check that there are no leaks.

10A-75ENGINE AND CYLINDER BLOCK ASSEMBLYFlywheel: Removal - RefittingK4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove:- the gearbox (see Manual

10A-76ENGINE AND CYLINDER BLOCK ASSEMBLYFlywheel: Removal - RefittingK4M10Aa Screw in the new flywheel bolts without tighteningthem.a Lock the engine

10A-77ENGINE AND CYLINDER BLOCK ASSEMBLYFlywheel: Removal - RefittingK9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Remove:- the manual gearbox (see

11A-1TOP AND FRONT OF ENGINEPressure at end of compression: CheckK4M11ACHECKI - PREPARATION OPERATION FOR CHECKa Remove:- the coils (see 17A, Ignition

11A-2TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK9K, and STANDARD HEATING RECIRCULATION11AREMOVALI - REMOVAL PREPARATION OPERATIONa P

11A-3TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK9K, and STANDARD HEATING RECIRCULATION11AREFITTINGI - REFITTING PREPARATION OPERATIO

11A-4TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK9K, and AIR CONDITIONING11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the ve

11A-5TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK9K, and AIR CONDITIONING11AII - REFITTING OPERATION FOR PART CONCERNEDa Rotate the t

11A-6TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING11AaREMOVALI - REMOVAL PREPARAT

10A-3ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - RefittingK9K10Aa Screw the threaded rod (10) of theinto the crank-shaf

11A-7TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING11Aa Torque tighten:- the autom

11A-8TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION11AREMOVALI - REMOVAL PREPARATION OPERATIONa P

11A-9TOP AND FRONT OF ENGINEAccessories belt: Removal - RefittingK4M, and STANDARD HEATING RECIRCULATION11Aa Refit the front right-hand wheel (see Whe

11A-10TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK9K11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on

11A-11TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK9K11AREFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be

11A-12TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK9K11Aa Turn the crankshaft clockwise (timing end) smoothlyusing the bo

11A-13TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK4M11AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on

11A-14TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK4M11Aa Turn the crankshaft in its operating direction (clock-wise at t

11A-15TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK4M11Aa Position the setting tool.a Secure theto the ends of the camsha

11A-16TOP AND FRONT OF ENGINECrankshaft accessories pulley: Removal - RefittingK4M11A- the air resonator (see 12A, Fuel mixture, Air res-onator: Remov