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Logan X90, Assembly

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10A

-

5

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

REMOVAL

Place the vehicle on a two-post lift.

Essential special tooling

Mot. 1202-01

Clip pliers for cooling
system hose clips
(large model)

Mot. 1202-02

Clip pliers for cooling
system hose clips
(small model)

Mot. 1448

Remote operation
pliers for cooling sys-
tem hose clips

Mot. 1453

Multiple-adjusting
engine mounting sup-
port with retaining
straps

Mot. 1159-03

Engine mounting on
right-hand side mem-
ber for operations not
requiring removal of
the engine

Mot. 1390

Support  for removing
and refitting the engine
and gearbox assembly

Tav. 1747

Threaded rods for
removing the sub-
frame

Essential equipment

filling station

Tightening torques

m

gearbox rubber moun-
ting mounting bolts

10.5 daNm

gearbox cover moun-
ting nut on the gearbox
rubber mounting

6.2 daNm

sub-fra m e   m o u n t i n g
bolts

10.5 daNm

sub-frame  tie-rod upper
mounting bolts

2.1 daNm

sub-frame tie-rod lower
mounting bolts

6.2 daNm

steering rack mounting
bolts

10.5 daNm

shock absorber base
bolts

10,5 daNm

brake calliper mounting
bolts 

10.5 daNm

track rod end nuts

3.7 daNm

engine tie-bar mounting
bolts

10.5 daNm

wheel bolts

10.5 daNm

Note:

The « engine and gearbox » assembly can be
removed by removing the « engine and gearbox/
driveshafts/half-axles/sub-frame » assembly.

IMPORTANT

During this operation, use a strap to secure the
vehicle to the lift to prevent it from becoming
unbalanced.

For the strap fitting procedure, (see 02A, Lifting
equipment, Underbody lift).

Tightening torques

m

Summary of Contents for X90

Page 1: ...re constructed All copyrights reserved by Renault The reproduction or translation in part of whole of the present document as well as the use of the spare parts reference numbering system are prohibited without the prior written consent of Renault APRIL 2004 Edition Anglaise X90 1 Engine and lower engine assembly 10A ENGINE AND LOWER ENGINE ASSEMBLY 11A TOP AND FRONT OF ENGINE 12A FUEL MIXTURE 13A...

Page 2: ...ced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed All copyrights reserved by Renault The reproduction or translation in part of whole of the present document as well as the use of the spare parts reference numbering system are prohibited without the prior written consent of Renault APRIL 2004 Edition Anglaise X90 19D EN...

Page 3: ...ter Replacement 12A 9 Air filter unit 12A 11 Inlet manifold 12A 13 Exhaust manifold 12A 19 Throttle valve 12A 23 Throttle body Connection 12A 25 13A FUEL SUPPLY Petrol supply circuit 13A 1 Injector rail Injectors 13A 2 Fuel pressure regulator Checking 13A 6 Electric fuel Checking 13A 7 14A ANTIPOLLUTION Petrol vapour rebreathing Operation 14A 1 Fuel vapour rebreathing Checking 14A 2 Fuel vapour ca...

Page 4: ...en driving 17B 32 Combustion misfire fault finding 17B 33 Catalytic converter fault finding 17B 34 Oxygen sensor fault finding 17B 35 19A COOLING SYSTEM General information 19A 1 Specifications 19A 2 Checking 19A 3 Diagram 19A 4 Bleeding and filling the cooling circuit 19A 6 Bleeding the cooling circuit 19A 8 Cooling radiator 19A 9 Water pump 19A 14 Thermostat 19A 18 Engine cooling fan assembly 19...

Page 5: ...0 and K7J and 710 10A REPLACING THE OIL FILTER Remove the oil filter using tool Mot 1329 Coat the sealing ring of the new oil filter with engine oil Tighten the oil filter by hand Essential special tooling Mot 1329 Oil filter cover 76 mm diameter 109223 ...

Page 6: ...0 and K7M and 710 10A REPLACING THE OIL FILTER Remove the oil filter using tool Mot 1329 Coat the sealing ring of the new oil filter with engine oil Tighten the oil filter by hand Essential special tooling Mot 1329 Oil filter cover 76 mm diameter 109223 ...

Page 7: ...proximately 1240 miles 2000 km in the vehicle without letting the oil level reach the MIN mark 3 Topping up Turn the engine off Wait 2 minutes for all the oil to flow into the oil sump Carry out a visual inspection using the dipstick Top up to the MAX mark Note the quantity of oil added and the mileage cove red since the last top up to maximum level 4 Measurement of the oil consumption Oil consump...

Page 8: ...ong dowel of 22 mm The oil pressure check must be carried out with the en gine warm approximately 80 C II USE Connect the pressure gauge in place of the oil pressure switch III ENGINE MANAGEMENT K7J K7M engine Idling 1 bar 3000 rpm 3 bar Torque tighten the oil switch 3 5 daNm Special tooling required Mot 36 05 Oil pressure gauge kit 87363 K7J engine K7M engine C E F H F E G D C B A ...

Page 9: ... frame Essential equipment filling station Tightening torquesm gearbox rubber moun ting mounting bolts 10 5 daNm gearbox cover moun ting nut on the gearbox rubber mounting 6 2 daNm sub frame mounting bolts 10 5 daNm sub frame tie rod upper mounting bolts 2 1 daNm sub frame tie rod lower mounting bolts 6 2 daNm steering rack mounting bolts 10 5 daNm shock absorber base bolts 10 5 daNm brake callipe...

Page 10: ...e gearbox assembly L90 and K7J and 710 10A Disconnect the battery starting with the negative ter minal Remove fuse and relay cover 1 the fuse holders and relays from their supports 2 battery mounting clamp 3 the battery 107846 107845 3 1 2 109184 ...

Page 11: ...ry the air suction sleeve on the body the front wheels the engine undertray the bumper mounting bolts under the sub frame Drain the engine oil if necessary the gearbox oil if necessary the cooling circuit via the bottom hose using tool Mot 1202 01 tool Mot 1202 02 or tool Mot 1448 Disconnect fan assembly connector 6 Unclip the electrical harness from fan assembly 7 108564 108562 4 4 5 DIRECTION MA...

Page 12: ...power assisted steering pipe mounting bolts from the top of sub frame 11 on the multifunction support on the rear of the cylinder block Disconnect the low pressure hose on the power assisted stee ring pump and drain the circuit the high pressure pipe from the power assisted steering pump the high pressure pipe from the steering rack Remove the power assisted steering high pressure pipe DIRECTION A...

Page 13: ...ct the air conditioning pipe unions on the air conditioning compressor Disconnect connectors 14 of the fan assembly Disconnect connector 15 of the power assisted steering pressure switch DIRECTION MANUELLE and AIR CONDITIONING 109396 108107 WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to pre vent moisture from getting into the circuit 12 13 DIREC...

Page 14: ...igh pressure pipe from the steering rack Remove the power assisted steering high pressure pipe Disconnect connector 17 of the refrigerant pressu re sensor Drain the air conditioning circuit using the filling sta tion Disconnect the air conditioning pipe unions on the air conditioning compressor Disconnect ball joint 18 of the throttle valve control cable cable sleeve stop 19 of the throttle valve ...

Page 15: ... servo pipe from the inlet manifold petrol vapour rebreather pipe 20 from the inlet manifold the fuel supply pipe 21 from the injection rail Disconnect cooling hoses 22 Remove cooling hoses 23 from their support 107357 IMPORTANT Be careful of petrol splashing out when discon necting the fuel supply union Wear gloves during the operation 21 20 108565 109493 22 22 22 23 ...

Page 16: ...he earth strap on the gearbox Remove brake callipers 25 and attach them to the shock absorbers track rod ends 26 bolts 27 from the shock absorber bases upper mounting bolts 28 of the sub frame tie rods the two mounting bolts from the steering rack Attach the steering rack to the body 107934 24 107935 99070 26 25 27 28 ...

Page 17: ...h fork 29 the clutch control cable from sleeve stop 30 Remove rubber protection 31 from the gear lever Remove mounting bolt 32 from the gear lever fork Attach the gearbox control linkage to the body Remove the engine tie bar Remove the catalytic converter see 19B Exhaust Catalytic converter 109494 109213 30 29 31 109214 108648 32 ...

Page 18: ... mounting bolts the suspended mounting from engine 33 Put a shim under the engine on the right hand side of the sub frame put a rubber shim under multifunction support 34 fit tool Mot 1159 03 to the rear of engine 35 lower the engine to fix it in place on the right hand side of the sub frame Fit engine support tool Mot 1453 with the retaining belt by taking the flywheel end lifting eye as an an ch...

Page 19: ...m under gearbox 38 lower the gearbox to fix it in place on the left hand side of the sub frame Place tool Mot 1390 under the sub frame Lower the vehicle down onto the four pads of tool Mot 1390 Adjust the pad position to ensure the sub frame is stable on tool Mot 1390 Bring the pads into contact with the underside of the sub frame in 39 Lift the vehicle to separate engine and gearbox dri veshafts ...

Page 20: ...mounting bolts 6 2 daNm the steering rack mounting bolts 10 5 daNm the shock absorber base bolts 10 5 daNm the brake calliper mounting bolts 10 5 daNm the track rod end nuts 3 7 daNm the engine tie bar mounting bolts 10 5 daNm the wheel bolts 10 5 daNm Refit the catalytic converter see 19B Exhaust Ca talytic converter Perform the following operations top up the engine oil if necessary top up the g...

Page 21: ...rcuit by turning the steering wheel fully in one direction then the other with the engine running Fill up the air conditioning circuit with filling station Proceed in the reverse order to removal DIRECTION ASSISTEE and AIR CONDITIONING WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Remove and Refit ...

Page 22: ...b frame Essential equipment filling station Tightening torquesm gearbox rubber moun ting mounting bolts 10 5 daNm gearbox cover moun ting nut on the gearbox rubber mounting 6 2 daNm sub frame mounting bolts 10 5 daNm sub frame tie rod upper mounting bolts 2 1 daNm sub frame tie rod lower mounting bolts 6 2 daNm steering rack mounting bolts 10 5 daNm shock absorber base bolts 10 5 daNm brake callip...

Page 23: ...e gearbox assembly L90 and K7M and 710 10A Disconnect the battery starting with the negative ter minal Remove fuse and relay cover 1 the fuse holders and relays from their supports 2 battery mounting clamp 3 the battery 107846 107845 3 1 2 109184 ...

Page 24: ...ry the air suction sleeve on the body the front wheels the engine undertray the bumper mounting bolts under the sub frame Drain the engine oil if necessary the gearbox oil if necessary the cooling circuit via the bottom hose using tool Mot 1202 01 tool Mot 1202 02 or tool Mot 1448 Disconnect fan assembly connector 6 Unclip the electrical harness from fan assembly 7 108564 108562 4 4 5 DIRECTION MA...

Page 25: ... power assisted steering pipe mounting bolts from the top of sub frame 11 on the multifunction support on the rear of the cylinder block Disconnect the low pressure hose on the power assisted stee ring pump and drain the circuit the high pressure pipe from the power assisted steering pump the high pressure pipe from the steering rack Remove the power assisted steering high pressure pipe DIRECTION ...

Page 26: ...onnect the air conditioning pipe unions on the air conditioning compressor Disconnect fan assembly connectors 14 Disconnect connector 15 of the power assisted steering pressure switch DIRECTION MANUELLE and AIR CONDITIONING 109396 108107 WARNING Protective plugs must be inserted into the pipe and air conditioning compressor openings to pre vent moisture from getting into the circuit 12 13 DIRECTIO...

Page 27: ...e high pressure pipe from the steering rack Remove the power assisted steering high pressure pipe Disconnect connector 17 of the refrigerant pressu re sensor Drain the air conditioning circuit using filling station Disconnect the air conditioning pipe unions on the air conditioning compressor Disconnect ball joint 18 of the throttle valve control cable cable sleeve stop 19 of the throttle valve co...

Page 28: ... servo pipe from the inlet manifold petrol vapour rebreather pipe 20 from the inlet manifold fuel supply pipe 21 from the injection rail Disconnect the cooling hoses 22 Remove cooling hoses 23 from their support 107357 IMPORTANT Be careful of petrol splashing out when discon necting the fuel supply union Wear gloves during the operation 21 20 108565 109493 22 22 22 23 ...

Page 29: ...the earth strap on the gearbox Remove brake callipers 25 and attach them to the shock absorbers track rod ends 26 bolts 27 of the shock absorber bases upper mounting bolts 28 of the sub frame tie rods the two mounting bolts from the steering rack Attach the steering rack to the body 107934 24 107935 99070 26 27 25 28 ...

Page 30: ...h fork 29 the clutch control cable from sleeve stop 30 Remove rubber protection 31 from the gear lever Remove mounting bolt 32 from the gear lever fork Attach the gearbox control linkage to the body Remove the engine tie bar Remove the catalytic converter see 19B Exhaust Catalytic converter 109494 109213 30 29 31 109214 108648 32 ...

Page 31: ...ounting bolts the suspended mounting from engine 33 Put a shim under the engine on the right hand side of the sub frame put a rubber shim under multifunction support 34 fit tool Mot 1159 03 to the rear of the engine 35 lower the engine to fix it in place on the right hand side of the sub frame Fit engine support tool Mot 1453 with the retaining belt by taking the flywheel end lifting eye as an an ...

Page 32: ...shim under gearbox 38 lower the gearbox to fix it in place on the left hand side of the sub frame Place tool Mot 1390 under the sub frame Lower the vehicle onto the four pads of tool Mot 1390 Adjust the pad position to ensure the sub frame is stable on tool Mot 1390 Bring the pads into contact with the underside of the sub frame in 39 Lift the vehicle to separate the engine and gear box driveshaft...

Page 33: ...mounting bolts 6 2 daNm the steering rack mounting bolts 10 5 daNm the shock absorber base bolts 10 5 daNm the brake calliper mounting bolts 10 5 daNm the track rod end nuts 3 7 daNm the engine tie bar mounting bolts 10 5 daNm the wheel bolts 10 5 daNm Refit the catalytic converter see 19B Exhaust Ca talytic converter Perform the following operations top up the engine oil if necessary top up the g...

Page 34: ...rcuit by turning the steering wheel fully in one direction then the other with the engine running Fill up the air conditioning circuit with filling station Proceed in the reverse order to removal DIRECTION ASSISTEE and AIR CONDITIONING WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Remove and Refit ...

Page 35: ...eering rack Attach the steering rack to the body Remove mounting bolt 1 of the power assisted steering pipe on the top of the sub frame Essential special tooling Tav 1747 Threaded rods for removing the sub frame Tightening torquesm sump mounting bolts 1 4 daNm engine to gearbox cou pling bolts 4 4 daNm sub frame mounting bolts 10 5 daNm steering rack mounting bolts 10 5 daNm sub frame tie rod uppe...

Page 36: ...t a time then replace them by the threaded rods of tool Tav 1747 Lower the sub frame by at least 120 mm by progres sively unscrewing the nuts of tool Tav 1747 107934 107924 IMPORTANT Make sure the threaded rod of tool Tav 1747 is sufficiently screwed into the threaded hole and that the nut of the tool is properly resting on the sub frame 2 3 3 108645 108644 ...

Page 37: ...D LOWER ENGINE ASSEMBLY Sump L90 and K7J and 710 10A Remove coupling bolts 4 of the engine and gearbox the sump mounting bolts the sump REFITTING 107936 WARNING Replace the sump gasket the sub frame mounting bolts 4 4 ...

Page 38: ... a diameter of 7 mm at the intersection of the crankshaft closing panel and the cylinder block 20166 20167 Note The gasket faces must be clean dry and free from grease avoid finger marks 6 5 5 Note Excess sealant could be squeezed out when the parts are tightened The sealing compound fluid mixture can cause damage to certain compo nents engine radiator etc ...

Page 39: ...s 4 4 daNm Torque tighten the sub frame mounting bolts 10 5 daNm the steering rack mounting bolts 10 5 daNm the sub frame tie rod upper mounting bolts 2 1 daNm the sub frame tie rod lower mounting bolts 6 2 daNm the engine tie bar mounting bolts 10 5 daNm the wheel bolts 10 5 daNm Refit the catalytic converter see 19B Exhaust Ca talytic converter Proceed in the reverse order to removal Top up the ...

Page 40: ...wo mounting bolts from the steering rack Attach the steering rack to the body Remove mounting bolt 2 of the sub frame tie rods Essential special tooling Tav 1747 Threaded rods for removing the sub frame Tightening torquesm sump mounting bolts 1 4 daNm engine to gearbox cou pling bolts 4 4 daNm sub frame mounting bolts 10 5 daNm steering rack mounting bolts 10 5 daNm sub frame tie rod upper mountin...

Page 41: ...em by one of the threaded rods of tool Tav 1747 Lower the sub frame by at least 120 mm by progres sively unscrewing the nuts of tool Tav 1747 107924 IMPORTANT Make sure the threaded rod of tool Tav 1747 is sufficiently screwed into the threaded hole and that the nut of the tool is properly resting on the sub frame 3 3 108645 108644 ...

Page 42: ...LOWER ENGINE ASSEMBLY Sump L90 and K7M and 710 10A Remove the coupling bolts 4 of the engine and gearbox the sump mounting bolts the sump REFITTING 107936 WARNING Replace the sump gasket the sub frame mounting bolts 4 4 ...

Page 43: ... a diameter of 7 mm at the intersection of the crankshaft closing panel and the cylinder block 20166 20167 Note The gasket faces must be clean dry and free from grease avoid finger marks 5 6 5 Note Excess sealant could be squeezed out when the parts are tightened The sealing compound fluid mixture can cause damage to certain compo nents engine radiator etc ...

Page 44: ...s 4 4 daNm Torque tighten the sub frame mounting bolts 10 5 daNm the steering rack mounting bolts 10 5 daNm the sub frame tie rod upper mounting bolts 2 1 daNm the sub frame tie rod lower mounting bolts 6 2 daNm the engine tie bar mounting bolts 10 5 daNm the wheel bolts 10 5 daNm Refit the catalytic converter see 19B Exhaust Ca talytic converter Proceed in the reverse order to removal Top up the ...

Page 45: ...a two post lift Remove the sump see 10A Engine and periphe rals Sump Remove the mounting 1 bolts of the oil pump the oil pump REFITTING Tighten to torque the oil pump mounting bolts 2 5 daNm Refit the sump see 10A Engine and peripherals Sump Tightening torquesm oil pump mounting bolts 2 5 daNm 108646 1 ...

Page 46: ...a two post lift Remove the sump see 10A Engine and periphe rals Sump Remove the mounting 1 bolts of the oil pump the oil pump REFITTING Tighten to torque the oil pump mounting bolts 2 5 daNm Refit the sump see 10A Engine and peripherals Sump Tightening torquesm oil pump mounting bolts 2 5 daNm 108646 1 ...

Page 47: ...er assisted steering pump to the sub frame Remove the mounting 1 bolts of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the multifunction support mounting bolts 4 4 daNm the power assisted steering pump mounting bolts 2 1 daNm Refit the alternator see 16A Starting Charge Al ternator Proceed in the reverse order to removal Tightening...

Page 48: ...ditioning compressor Attach the air conditioning compressor to the sub frame Remove the mounting 3 bolts of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the multifunction support mounting bolts 4 4 daNm the air conditioning compressor mounting bolts 2 1 daNm Refit the air conditioning compressor belt see 11A Top and front of engine...

Page 49: ...rnator see 16A Starting Charge Alter nator Remove the mounting bolts 1 and 2 of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the M10 mounting bolts of the multifunction support 4 4 daNm 1 Tightening torquesm M10 mounting bolts of the multifunction sup port 4 4 daNm M8 mounting bolts of the multifunction support 2 1 daNm 109224 1092...

Page 50: ...ifunction support L90 and K7J and 710 and DIRECTION ASSISTEE and AIR CONDITIONING 10A the M8 mounting bolts of the multifunction sup port 2 1 daNm 2 Refit the alternator see 16A Starting Charge Al ternator Proceed in the reverse order to removal ...

Page 51: ...er assisted steering pump to the sub frame Remove the mounting 1 bolts of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the multifunction support mounting bolts 4 4 daNm the power assisted steering pump mounting bolts 2 1 daNm Refit the alternator see 16A Starting Charge Al ternator Proceed in the reverse order to removal Tightening...

Page 52: ...ioning com pressor Attach the air conditioning compressor to the sub frame Remove the mounting 3 bolts of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the multifunction support mounting bolts 4 4 daNm the air conditioning compressor mounting bolts 2 1 daNm Refit the air conditioning compressor belt see 11A Top and front of engine A...

Page 53: ...ternator see 16A Starting Charge Alternator Remove the mounting bolts 1 and 2 of the multifunction support the multifunction support REFITTING Position the multifunction support Torque tighten the five M10 mounting bolts of the multifunction support 4 4 daNm 1 Tightening torquesm M10 mounting bolts of the multifunction sup port 4 4 daNm M8 mounting bolts of the multifunction support 2 1 daNm 10922...

Page 54: ...function support L90 and K7M and 710 and DIRECTION ASSISTEE and AIR CONDITIONING 10A the two M8 mounting bolts of the multifunction support 2 1 daNm 2 Refit the alternator see 16A Starting Charge Al ternator Proceed in the reverse order to removal ...

Page 55: ... the alternator mounting screw 1 the alternator mounting bolt 2 Remove the accessories belt REFITTING Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm alternator mounting bolt 2 1 daNm alternator mounting bolt 4 4 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tio...

Page 56: ...n the engine through three revolutions to position the belt correctly Check the belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Torque tighten the alternator mounting bolt 2 1 daNm the alternator mounting bolt 4 4 daNm Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 16300 3 Crankshaft 4 Alternator 5 Measuring point ...

Page 57: ...I REMOVING THE ALTERNATOR BELT Slacken the alternator mounting screw 1 the alternator mounting bolt 2 Remove the alternator belt REFITTING I REFITTING THE ALTERNATOR BELT Refit the alternator belt Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm alternator mounting screw 2 1 daNm alternator mounting ...

Page 58: ...belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Torque tighten the alternator mounting screw 2 1 daNm the alternator mounting bolt 4 4 daNm II REFITTING THE AIR CONDITIONING COMPRESSOR BELT Air conditioning compressor belt fitting tool 6 Clip the belt fitting tool on the crankshaft pulley as shown in the diagram 16300 3 Crankshaft 4 Alternator 5 Me...

Page 59: ...n sup port Rotate the crankshaft clockwise until the belt is in place on the crankshaft pulley Turn the crankshaft through two revolutions to cor rectly position the air conditioning compressor belt Torque tighten the wheel bolts 10 5 daNm 109638 109639 7 109640 Note The air conditioning compressor belt fitting tool is single use and must be discarded after use 109641 WARNING Connect the battery s...

Page 60: ...e the accessories belt REFITTING Torque tighten the tension wheel mounting bolt 2 1 daNm the pulley mounting bolt 2 1 daNm Tightening torquesm tension wheel mounting bolt 2 1 daNm pulley mounting bolt 2 1 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tion 14494 3 2 1 WARNING Replace any belt that has been removed WARNING When replacing the belt be sure to repl...

Page 61: ...urn the engine through three revolutions to position the belt correctly Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 106001 WARNING Make sure that the inner tooth on all the pulleys remains free 109238 WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Remove and Refit ...

Page 62: ... belt REFITTING Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm tension wheel mounting bolts 2 1 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tion 109235 1 WARNING Replace any belt that has been removed WARNING The tension wheel must be replaced when the belt i...

Page 63: ...ester Use Turn the engine through three revolutions to position the belt correctly Check the belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Remove the bolt 7 Torque tighten the tension wheel mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 105999 WARNING Make sure that the outer tooth on all ...

Page 64: ...s II REMOVING THE ALTERNATOR BELT Slacken the alternator mounting screw 1 the alternator mounting bolt 2 Remove the alternator belt REFITTING I REFITTING THE ALTERNATOR BELT Refit the alternator belt Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm alternator mounting screw 2 1 daNm alternator mounti...

Page 65: ...belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Torque tighten the alternator mounting screw 2 1 daNm the alternator mounting bolt 4 4 daNm II REFITTING THE AIR CONDITIONING COMPRESSOR BELT Air conditioning compressor belt fitting tool 6 Clip the belt fitting tool on the crankshaft pulley as shown in the diagram 16300 3 Crankshaft 4 Alternator 5 Me...

Page 66: ... support Rotate the crankshaft clockwise until the belt is in place on the crankshaft pulley Turn the crankshaft through two revolutions to cor rectly position the air conditioning compressor belt Torque tighten the wheel bolts 10 5 daNm 109638 109639 7 109640 Note The air conditioning compressor belt fitting tool is single use and must be discarded after being used 109641 WARNING Connect the batt...

Page 67: ... belt REFITTING Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm tension wheel mounting bolts 2 1 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tion 109235 1 WARNING Replace any belt that has been removed WARNING The tension wheel must be replaced when the belt i...

Page 68: ...ster Use Turn the engine through three revolutions to position the belt correctly Check the belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Remove the bolt 7 Torque tighten the tension wheel mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 105999 WARNING Make sure that the outer tooth on all t...

Page 69: ...accessories belt REFITTING Torque tighten the tension wheel mounting bolt 2 1 daNm the idler pulley mounting bolt 2 1 daNm Tightening torquesm tension wheel mounting bolt 2 1 daNm idler pulley mounting bolt 2 1 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tion 14494 3 2 1 WARNING Replace any belt that has been removed WARNING When replacing the belt be sure t...

Page 70: ...urn the engine through three revolutions to position the belt correctly Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 106001 WARNING Make sure that the inner tooth on all the pulleys remains free 109238 WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Remove and Refit ...

Page 71: ...he alternator mounting screw 1 the alternator mounting bolt 2 Remove the accessories belt REFITTING Essential special tooling Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Tightening torquesm alternator mounting bolt 2 1 daNm alternator mounting bolt 4 4 daNm wheel bolts 10 5 daNm WARNING Never run the engine against its operating direc tion ...

Page 72: ...rn the engine through three revolutions to position the belt correctly Check the belt tension using tool Mot 1505 or Mot 1715 If the belt tension is outside tolerance readjust it Torque tighten the alternator mounting bolt 2 1 daNm the alternator mounting bolt 4 4 daNm Proceed in the reverse order to removal Torque tighten the wheel bolts 10 5 daNm 16300 3 Crankshaft 4 Alternator 5 Measuring point...

Page 73: ...gine mounting sup port with retaining straps Mot 1489 Top dead centre loca ting pin Mot 1501 Timing belt prestres sing tool Mot 1135 01 Timing gear belt ten sioner tool Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Essential equipment low torque wrench Tightening torquesm the tension wheel moun ting nut 5 daNm crankshaft pulley moun ting bolt...

Page 74: ...11A 20 TOP AND FRONT OF ENGINE Timing belt L90 and K7J and 710 11A Remove TDC pin plug 2 Remove lower timing cover 3 upper timing cover 4 107359 2 107498 107499 3 3 4 4 4 ...

Page 75: ...tooth before the vertical axle of the sproc ket low point 6 Insert TDC setting rod Mot 1489 Turn the crankshaft clockwise by pushing on TDC setting rod Mot 1489 until the crankshaft times Remove tension wheel mounting nut 7 the timing belt the tension wheel REFITTING Refit the tension wheel 107497 5 6 107494 WARNING Replace any belt that has been removed WARNING The tension wheel must be replaced ...

Page 76: ...ft pulley water pump pulley PROCEDURE FOR TENSIONING TIMING BELT Make the tension wheel push onto the timing belt Lightly tighten the tension wheel mounting nut Remove TDC setting rod Mot 1489 Fit timing belt pretensioning torque tool Mot 1501 on camshaft sprocket 10 Apply pretensioning torque to the timing belt section 11 with a low torque wrench adjusted to torque 1 daNm Remove the tool Mot 1501...

Page 77: ...ocket Apply pretensioning torque to the timing belt section with a low torque wrench adjusted to torque 1 daNm Remove the tool Mot 1501 Check using tool Mot 1505 or Mot 1715 that the timing belt tension is 165 Hz 10 If the tension value is outside tolerances adjust it by starting the tensioning process from the beginning Angle tighten to torque the crankshaft pulley mounting bolt 3 daNm 80 5 by bl...

Page 78: ...g engine mounting sup port with retaining straps Mot 1489 Top dead centre loca ting pin Mot 1501 Timing belt prestres sing tool Mot 1135 01 Timing gear belt ten sioner tool Mot 1505 Belt tension setting tool frequency meter Mot 1715 Belt tension setting tool frequency meter Essential equipment low torque wrench Tightening torquesm the tension wheel moun ting nut 5 daNm crankshaft pulley moun ting ...

Page 79: ...11A 25 TOP AND FRONT OF ENGINE Timing belt L90 and K7M and 710 11A Remove the TDC pin plug 2 Remove the lower timing cover 3 the upper timing cover 4 107359 2 107498 107499 3 3 4 4 4 ...

Page 80: ...tooth before the vertical axle of the sproc ket low point 6 Insert TDC setting rod Mot 1489 Turn the crankshaft clockwise by pushing on TDC setting rod Mot 1489 until the crankshaft times Remove tension wheel mounting nut 7 the timing belt the tension wheel REFITTING Refit the tension wheel 107497 6 5 107494 WARNING Replace any belt that has been removed WARNING The tension wheel must be replaced ...

Page 81: ...amshaft pulley water pump pulley PROCEDURE FOR TENSIONING TIMING BELT Make the tension wheel push onto the timing belt Lightly tighten the tension wheel mounting nut Remove TDC setting rod Mot 1489 Fit timing belt pretensioning torque tool Mot 1501 on camshaft sprocket 10 Apply pretensioning torque to the timing belt section 11 with a low torque wrench adjusted to torque 1 daNm Remove tool Mot 150...

Page 82: ...t Apply pretensioning torque to the timing belt section with a low torque wrench adjusted to torque 1 daNm Remove tool Mot 1501 Check using tool Mot 1715 or Mot 1489 that the timing belt tension is 165 Hz 20 If the tension value is outside tolerances adjust it by starting the tensioning process from the beginning Angle tighten to torque the crankshaft pulley mounting bolt 3 daNm 80 5 by blocking t...

Page 83: ...ng belt Drain the cooling circuit via the bottom hose using tool Mot 1202 01 tool Mot 1202 02 or tool Mot 1448 Essential special tooling Mot 1672 Lower engine support Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1202 02 Clip pliers for cooling system hose clips small model Mot 1448 Remote operation pliers for cooling sys tem hose clips Essential equipment cylinder head tes...

Page 84: ...tor 4 of the ignition coil Remove the ignition spark plug leads Remove the inlet manifold reinforcement stay loca ted between cylinder block and inlet manifold 5 Disconnect fuel supply pipe 6 on the injection rail 108423 107361 2 2 3 107358 Note The ignition spark plug leads are marked on the ignition coil cylinder number 1 engine flywheel end 107486 IMPORTANT Be careful of petrol splashing out wh...

Page 85: ...or 10 from the supply air depression sen sor connector 11 from the coolant temperature sen sor pipe 12 from the brake servo on the inlet manifold petrol vapour rebreather pipe 13 from the inlet manifold Disconnect ball joint 14 from the throttle valve control cable cable sleeve stop 15 from the throttle valve control cable Disconnect the three cooling hoses 16 with tool Mot 1202 01 tool Mot 1202 0...

Page 86: ...ing eye Remove retaining bolt 18 from the dipstick guide tu be Unhook electrical harness 19 Remove the exhaust manifold see 12A Burnt mix ture Exhaust manifold Remove the rocker cover mounting bolts the rocker cover Remove the cylinder head mounting bolts the cylinder head inlet manifold assembly the cylinder head gasket 109493 109216 17 19 18 10016 10015 ...

Page 87: ...s 220 10 IMPORTANT Do not scratch the aluminium gasket faces Wear goggles Wear gloves during the operation Clean the gasket faces with DECAPJOINT to dissolve any seals which are still cemented Apply the product to the section to be cleaned Wait approximately ten minutes then remove the residue using a wooden spatula WARNING Do not allow this product to drip onto the pain twork Clean the cylinder h...

Page 88: ...lt the accessories belt see 11A top and front of en gine Accessories belt the exhaust manifold see 11A Top and front of engine Exhaust manifold Torque tighten the multifunction support moun ting bolts 2 1 daNm Proceed in the reverse order to removal Fill up and bleed the cooling circuit see 19A Coo ling Draining Filling the cooling circuit 10016 DIRECTION ASSISTEE and AIR CONDITIONING WARNING Conn...

Page 89: ...ng belt Drain the cooling circuit via the bottom hose using tool Mot 1202 01 tool Mot 1202 02 or tool Mot 1448 Essential special tooling Mot 1672 Lower engine support Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1202 02 Clip pliers for cooling system hose clips small model Mot 1448 Remote operation pliers for cooling sys tem hose clips Essential equipment cylinder head tes...

Page 90: ...r 4 of the ignition coil Remove the ignition spark plug leads Remove the inlet manifold reinforcement stay loca ted between the cylinder block and inlet manifold 5 Disconnect fuel supply pipe 6 on the injection rail 108423 107361 2 2 3 107358 Note The ignition spark plug leads are marked on the ignition coil cylinder number 1 engine flywheel end 107486 IMPORTANT Be careful of petrol splashing out ...

Page 91: ...or 10 from the supply air depression sen sor connector 11 from the coolant temperature sen sor pipe 12 from the brake servo on the inlet manifold petrol vapour rebreather pipe 13 from the inlet manifold Disconnect ball joint 14 from the throttle valve control cable cable sleeve stop 15 from the throttle valve control cable Disconnect the three cooling hoses 16 with tool Mot 1202 01 tool Mot 1202 0...

Page 92: ...eye Remove retaining bolt 18 from the dipstick guide tu be Unhook the electrical harness 19 Remove the exhaust manifold see 12A Burnt mix ture Exhaust manifold Remove the rocker cover mounting bolts the rocker cover Remove the ten cylinder head mounting bolts the cylinder head inlet manifold assembly the cylinder head gasket 109493 109216 17 18 19 10016 10015 ...

Page 93: ...220 10 IMPORTANT Do not scratch the aluminium sealing surfaces Wear goggles Wear gloves during the operation Clean the gasket faces with DECAPJOINT to dissolve any seals which are still cemented Apply the product to the section to be cleaned Wait approximately ten minutes then remove the residue using a wooden spatula WARNING Do not allow this product to drip onto the pain twork Clean the cylinder...

Page 94: ...belt the accessories belt see 11A top and front of en gine Accessories belt the exhaust manifold see 11A Top and front of engine Exhaust manifold Torque tighten the multifunction support moun ting bolts 2 1 daNm Proceed in the reverse order to removal Fill up and bleed the cooling circuit see 19A Coo ling Draining Filling the cooling circuit 10016 DIRECTION ASSISTEE and AIR CONDITIONING WARNING Co...

Page 95: ...m 14 5 maxi mum 100 0 97 λ 1 03 Super unleaded Octane rating 95 LS0C Without OBD Temperatures in C 1 40 10 25 50 80 110 120 Negative temperature coefficient air temperature sensor resistance in Ω 49930 6790 9540 10440 2050 123 810 47 309 17 135 8 105 7 Negative temperature coefficient coo lant temperature sensor resistance in Ω 75780 6970 12460 1121 2250 112 810 38 280 9 114 3 87 2 Description Bra...

Page 96: ... C signal Track resistance 1200 240 Ω Pinking sensor JCAE Piezoelectric type sensor Tightening torque 20 Nm Engine speed and position sensor SIEMENS Integrated connector Resistance 200 to 270 Ω Upstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust gas temperature rises above 650 C Heating resistor 3 3 Ω at 20 C 4 track connector A heating resistor supply B heating resis...

Page 97: ...ance 26 4 Ω at 20 C 2 track connector 1 supply 2 earthing Coolant temperature sensor SYLEA Negative temperature coefficient thermistor see pre vious table Air temperature sensor DAV IATS 04 Negative temperature coefficient thermistor see pre vious table Spark plugs CHAMPION RYCLC87 Gap 0 95 0 05 mm Torque 25 to 30 Nm SAGEM RFN58LZ Refrigerant pressure sensor TEXAS INSTRUMENT 3 track connector A ea...

Page 98: ...14 5 maxi mum 100 0 97 λ 1 03 Super unleaded Octane rating 95 LS0D Without OBD Temperatures in C 1 40 10 25 50 80 110 120 Negative temperature coefficient air temperature sensor resistance in Ω 49930 6790 9540 10440 2050 123 810 47 309 17 135 8 105 7 Negative temperature coefficient coo lant temperature sensor resistance in Ω 75780 6970 12460 1121 2250 112 810 38 280 9 114 3 87 2 Description Brand...

Page 99: ...C signal Track resistance 1200 240 Ω Pinking sensor JCAE Piezoelectric type sensor Tightening torque 20 Nm Engine speed and position sensor SIEMENS Integrated connector Resistance 200 to 270 Ω Upstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust gas temperature rises above 650 C Heating resistor 3 3 Ω at 20 C 4 track connector A heating resistor supply B heating resist...

Page 100: ...sistance 26 4 Ω at 20 C 2 track connector 1 supply 2 earthing Coolant temperature sensor SYLEA Negative temperature coefficient thermistor see pre vious table Air temperature sensor DAV IATS 04 Negative temperature coefficient thermistor see pre vious table Spark plugs CHAMPION RYCLC87 Gap 0 95 0 05 mm Torque 25 to 30 Nm SAGEM RFN58LZ Refrigerant pressure sensor TEXAS INSTRUMENT 3 track connector ...

Page 101: ...12A 7 FUEL MIXTURE Air inlet K7J and 710 12A 1202 1 3 2 1 Air filter unit 2 Throttle valve 3 intake manifold ...

Page 102: ...12A 8 FUEL MIXTURE Air inlet K7M and 710 12A 1202 1 3 2 1 Air filter unit 2 Throttle valve 3 intake manifold ...

Page 103: ...lter Replacement K7J and 710 12A REMOVAL Remove the air filter unit cover mounting bolts Unfasten the cover mounting clips Remove the air filter unit cover the air filter REFITTING Proceed in the reverse order to removal 107574 ...

Page 104: ...lter Replacement K7M and 710 12A REMOVAL Remove the air filter unit cover mounting bolts Unfasten the cover mounting clips Remove the air filter unit cover the air filter REFITTING Proceed in the reverse order to removal 107574 ...

Page 105: ...nit K7J and 710 12A REMOVAL Remove the air filter unit mounting bolts 1 Disconnect the oil vapour rebreather pipe 2 the air inlet sleeve Remove the air filter unit REFITTING Proceed in the reverse order to removal 108423 107361 1 1 2 ...

Page 106: ...nit K7M and 710 12A REMOVAL Remove the air filter unit mounting bolts 1 Disconnect the oil vapour rebreather pipe 2 the air inlet sleeve Remove the air filter unit REFITTING Proceed in the reverse order to removal 108423 107361 1 1 2 ...

Page 107: ...l vapour rebreather pipe 2 the air inlet sleeve Remove the air filter unit Unclip the ball joints 3 Disconnect the temperature sensor 4 the pressure sensor 5 the brake servo pipe from the inlet manifold pipe 6 from the inlet manifold the petrol vapour rebreathing pipe from the inlet manifold Tightening torquesm inlet manifold mounting bolts 2 5 daNm inlet manifold mounting nuts 2 5 daNm 108423 107...

Page 108: ...e 8 from the injection rail Disconnect the injector connectors 107357 DIRECTION MANUELLE WARNING Before starting work protect the alternator with plastic bags IMPORTANT Wear gloves during the operation DIRECTION ASSISTEE IMPORTANT Wear gloves during the operation 8 7 IMPORTANT During this operation be sure to refrain from smoking or bringing very hot objects near the working area beware of fuel sp...

Page 109: ...been removed Refit the inlet manifold starting with the centre lower mounting nut 13 Torque tighten the inlet manifold mounting bolts 2 5 daNm the inlet manifold mounting nuts 2 5 daNm Proceed in the reverse order to removal 107486 107777 Note In order to completely remove the bottom centre mounting nut remove the outer nuts remove the manifold from the cylinder head 9 12 12 11 11 10 12 12 107777 ...

Page 110: ...l vapour rebreather pipe 2 the air inlet sleeve Remove the air filter unit Unclip the ball joints 3 Disconnect the temperature sensor 4 the pressure sensor 5 the brake servo pipe from the inlet manifold pipe 6 from the inlet manifold the petrol vapour rebreathing pipe from the inlet manifold Tightening torquesm inlet manifold mounting bolts 2 5 daNm inlet manifold mounting nuts 2 5 daNm 108423 107...

Page 111: ...pipe 8 from the injection rail Disconnect the injector connectors 107357 DIRECTION MANUELLE WARNING Before starting work protect the alternator with plastic bags IMPORTANT Wear gloves during the operation DIRECTION ASSISTEE IMPORTANT Wear gloves during the operation 8 7 IMPORTANT During this operation be sure to refrain from smoking or bringing hot objects near the working area beware of fuel spla...

Page 112: ...been removed Refit the inlet manifold starting with the centre lower mounting nut 13 Torque tighten the inlet manifold mounting bolts 2 5 daNm the inlet manifold mounting nuts 2 5 daNm Proceed in the reverse order to removal 107486 107777 Note In order to completely remove the bottom centre mounting nut remove the outer nuts remove the manifold from the cylinder head 12 12 11 11 10 9 12 12 107777 ...

Page 113: ...t manifold cylinder head mountings the exhaust manifold REFITTING Always replace all seals that have been removed Refit the new seal on the exhaust manifold Tightening torquesm exhaust manifold moun ting nuts 2 5 daNm exhaust downpipe mounting studs 0 7 daNm exhaust downpipe mounting nuts 2 1 daNm 108425 1 1 108427 109399 WARNING You must replace the exhaust bushing betw een the exhaust manifold a...

Page 114: ...2A Torque tighten in order the exhaust manifold mounting nuts 2 5 daNm Torque tighten the exhaust downpipe mounting studs 0 7 daNm if studs removed the exhaust downpipe mounting nuts 2 1 daNm Proceed in the reverse order to removal 108427 6 3 1 5 4 2 7 ...

Page 115: ...t manifold cylinder head mountings the exhaust manifold REFITTING Always replace all seals that have been removed Refit the new seal on the exhaust manifold Tightening torquesm exhaust manifold moun ting nuts 2 5 daNm exhaust downpipe mounting studs 0 7 daNm exhaust downpipe mounting nuts 2 1 daNm 108425 1 1 108427 109399 WARNING You must replace the exhaust bushing betw een the exhaust manifold a...

Page 116: ...2A Torque tighten in order the exhaust manifold mounting nuts 2 5 daNm Torque tighten the exhaust downpipe mounting studs 0 7 daNm if studs removed the exhaust downpipe mounting nuts 2 1 daNm Proceed in the reverse order to removal 108427 6 3 1 5 4 2 7 ...

Page 117: ...2 the air inlet sleeve Remove the air filter box Unclip the ball joint 3 Disconnect the throttle position sensor connector 4 the idling speed stepper motor connector 5 Remove the throttle valve by tilting it REFITTING Always replace all seals that have been removed Proceed in the reverse order to removal 108423 107361 1 1 2 107356 107357 3 5 4 ...

Page 118: ...pe 2 the air inlet sleeve Remove the air filter box Unclip the ball joint 3 Disconnect the throttle position sensor connector 4 the idling stepper motor connector 5 Remove the throttle valve by tilting it REFITTING Always replace all seals that have been removed Proceed in the reverse order to removal 108423 107361 1 1 2 107356 107357 3 4 5 ...

Page 119: ...12A 25 FUEL MIXTURE Throttle body Connection K7M and 710 12A To connect the throttle valve see Technical Note Wi ring Diagrams Components 222 and 649 109393 C A A D ...

Page 120: ...12A 26 FUEL MIXTURE Throttle body Connection K7J and 710 12A For information on connecting the throttle valve see Technical Note Wiring diagrams Components 222 and 649 109393 A A C D ...

Page 121: ...he fuel pressure does not vary with engine load The circuit comprises a petrol pump gauge filter supply unit fitted with a fuel filter 1 a pump 2 and a pressure regulator 3 all located in the tank a single pipe 4 coming from the tank a rail 5 without a return pipe and without a supply pressure regulator a fuel vapour recirculation tank 6 19310 3 4 5 6 2 1 ...

Page 122: ...sconnect the injector connectors the throttle position sensor connector 3 Disconnect the fuel inlet pipe 4 on the injector rail Disconnect the fuel inlet pipe 4 on the injector rail Tightening torquesm injection rail mounting bolts 0 7 daNm 108423 107361 1 1 2 107357 DIRECTION MANUELLE IMPORTANT Wear gloves during the operation WARNING Before the operation protect the alternator with plastic bags ...

Page 123: ... of the fuel unions when con necting Torque tighten the injection rail mounting bolts 0 7 daNm Proceed in the reverse order to removal IMPORTANT During this operation it is essential to refrain from smoking or bringing incandescent objects close to the work area beware of fuel splashes when disconnecting the union protect sensitive areas from fuel outflow 101473 5 WARNING Connect the battery start...

Page 124: ...sconnect the injector connectors the throttle position sensor connector 3 Disconnect the fuel inlet pipe 4 on theinjection rail Disconnect the fuel inlet pipe 4 on theinjection rail Tightening torquesm injection rail mounting bolts 0 7 daNm 108423 107361 1 1 2 107357 DIRECTION MANUELLE IMPORTANT Wear gloves during the operation WARNING Before the operation protect the alternator with plastic bags ...

Page 125: ...ck of the fuel unions when con necting Torque tighten the injection rail mounting bolts 0 7 daNm Proceed in the reverse order to removal IMPORTANT During this operation it is essential to refrain from smoking or bringing incandescent objects close to the work area beware of fuel splashes when disconnecting the union protect sensitive areas from fuel leakage 101473 5 WARNING Connect the battery sta...

Page 126: ...p Determine the pressure the pressure must be constant approximately 3 5 bar It may take a few seconds to obtain a correct pres sure reading Essential special tooling Mot 1311 08 Union for measuring fuel pressure Mot 1311 01 Fuel pressure pres sure gauges and soc ket unions IMPORTANT During this operation be sure to refrain from smoking or bringing hot objects near the working area beware of fuel ...

Page 127: ...rol supply pipe to the T union 3 Essential special tooling Mot 1311 08 Union for measuring fuel pressure Mot 1311 01 Fuel pressure pres sure gauges and soc ket unions IMPORTANT During this operation be sure to refrain from smoking or bringing very hot objects close to the working area beware of fuel splashes when disconnecting the union protect sensitive areas from fuel outflow 108650 IMPORTANT We...

Page 128: ...nnect the engine passenger compartment electric wiring harness connector 5 Connect the connector terminal 5 to battery feed Note the time taken for the measuring cylinder to fill up 109174 IMPORTANT This procedure must be carried out with the igni tion off 109171 2 5 109172 Note The minimum pump flow is 60 l h 8 1 5 ...

Page 129: ...val ve is integrated in the fuel vapour absorber The principle behind the solenoid valve is to open a passage of variable size according to the opening cy clic ratio signal sent by the injection computer The variation in the passage opened for fuel vapour in the solenoid valve results from the balance between the magnetic field created by the supply to the winding and the return spring force attem...

Page 130: ...C the engine is not at idling speed a given load threshold is reached the throttle potentiometer is not in the no load position During on board diagnostic fault finding fuel va pour absorber bleeding is not authorised It is possible to display the opening cyclic ratio of the fuel vapour absorber bleed solenoid valve using the diagnostic tool by referring to parameter PR023 canister bleed solenoid ...

Page 131: ...om underneath the fuel vapour absorber Disconnect pipes 1 from the fuel vapour absorber without re moving the bumper the solenoid valve connector Unclip breather pipe 2 Remove fuel vapour absorber mounting nuts 3 the fuel vapour absorber REFITTING Proceed in the reverse order to removal Torque tighten the fuel vapour absorber mounting nuts 21 Nm Tightening torquesm fuel vapour absorber mounting nu...

Page 132: ...e solenoid valve outlet The vacuum pressure should not vary by more than 10 mbar over 30 seconds Does the pressure vary Yes the solenoid valve is faulty replace the fuel vapour absorber the solenoid valve is integrated in the fuel vapour absorber No there is an electrical fault check the circuit If not under the conditions required for bleeding see 14A Antipollution Fuel vapour rebrea thing the va...

Page 133: ...he engine is run ning it indicates a battery charge fault II IDENTIFICATION III CHECKING Alternator minimum guaranteed flows under 13 5 V af ter 15 minutes of heating with the engine running and electrical consumers switched on Engine Alternator Current strength K7J 710 DM K7M 710 DM MELCO A001TA3792 70 A K7J 710 PAS K7M 710 PAS VALEO SG7 S013 75 A K7J 710 MS AC K7M 710 MS AC MELCO A002TC0391 110 ...

Page 134: ...g bolt 2 the alternator REFITTING Proceed in the reverse order to removal Refit the accessories belt s see 11A Top and front of engine Accessories belt Torque tighten the alternator mounting bolt 2 1 daNm the alternator mounting bolt 4 4 daNm Tightening torquesm alternator mounting bolt 2 1 daNm alternator mounting bolt 4 4 daNm 109237 1 2 WARNING Replace any belt that has been removed WARNING Whe...

Page 135: ...g bolt 2 the alternator REFITTING Proceed in the reverse order to removal Refit the accessories belt s see 11A Top and front of engine Accessories belt Torque tighten the alternator mounting bolt 2 1 daNm the alternator mounting bolt 4 4 daNm Tightening torquesm alternator mounting bolt 2 1 daNm alternator mounting bolt 4 4 daNm 109237 2 1 WARNING Replace any belt that has been removed WARNING Whe...

Page 136: ...lt Remove power assisted steering pump mounting bolt 1 power assisted steering pump mounting bolts 2 by pulling them through the holes in the pulley the power assisted steering pump from the multi function support without opening the circuit Tightening torquesm alternator mounting bolts 2 1 daNm power assisted steering pump mounting bolts 2 1 daNm 109225 109235 1 3 3 2 ...

Page 137: ... Refit the alternator Tighten to torque the alternator mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the power assisted steering pump mounting bolts 2 1 daNm Remove the accessories belt see 11A Top and front of engine Accessories belt 109217 WARNING Replace any belt that has been removed WARNING When replacing the belt be sure to replace the tension wheels and idle...

Page 138: ...lt Remove power assisted steering pump mounting bolt 1 power assisted steering pump mounting bolts 2 by pulling them through the holes in the pulley the power assisted steering pump from the multi function support without opening the circuit Tightening torquesm alternator mounting bolts 2 1 daNm power assisted steering pump mounting bolts 2 1 daNm 109225 109235 1 3 3 2 ...

Page 139: ...it the alternator Tighten to torque the alternator mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the power assisted steering pump mounting bolts 2 1 daNm Remove the accessories belt see 11A Top and front of engine Accessories belt 109217 WARNING Replace any belt that has been removed WARNING When replacing the belt be sure to replace the tension wheels and idler pu...

Page 140: ...nnector 1 Remove power assisted steering mounting bolt 2 power assisted steering pump mounting bolts 3 by pulling them through the holes in the pulley the power assisted steering pump from the multi function support without opening the circuit Place the power assisted steering pump to one side Tightening torquesm alternator mounting bolts 2 1 daNm air conditioning com pressor mounting bolts 2 1 da...

Page 141: ...ounting bolts 6 the alternator REFITTING Refit the alternator Tighten to torque the alternator mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the air conditioning compressor mounting bolts 2 1 daNm the power assisted steering pump mounting bolts 2 1 daNm Refit the accessories belt see 11A Top and front of engine Accessories belt the front bumper see 55A Exterior pro...

Page 142: ...con nector 1 Remove power assisted steering pump mounting bolt 2 power assisted steering pump mounting bolts 3 by pulling them through the holes in the pulley the power assisted steering pump from the multi function support without opening the circuit Place the power assisted steering pump to one side Tightening torquesm alternator mounting bolts 2 1 daNm air conditioning com pressor mounting bolt...

Page 143: ...mounting bolts 6 the alternator REFITTING Refit the alternator Tighten to torque the alternator mounting bolts 2 1 daNm Proceed in the reverse order to removal Torque tighten the air conditioning compressor mounting bolts 2 1 daNm the power assisted steering pump mounting bolts 2 1 daNm Refit the accessories belt see 11A Top and front of engine Accessories belt the front bumper see 55A Exterior pr...

Page 144: ...16A 12 STARTING LOAD Starter Identification K7J or K7M and 710 16A Engine Starter K7J MITSUBISHI M000T45171ZT K7M ...

Page 145: ...ver by unclipping it in the direction of 1 the expansion bottle mounting bolts the expansion bottle without opening the circuit Place the expansion bottle to one side Remove gearbox control linkage mounting bolt 2 Tightening torquesm starter mounting bolts 4 4 daNm 107847 1 109214 WARNING The linkage is fitted with a spacer do not lose the spacer when removing bolt 2 2 ...

Page 146: ...or wires Remove the starter motor mounting bolts 4 the starter REFITTING Tighten to torque the starter mounting bolts 4 4 daNm Proceed in the reverse order to removal 107486 109220 3 109215 WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Battery Remove and refit 4 4 ...

Page 147: ...er by unclipping it in the direction of 1 the expansion bottle mounting bolts the expansion bottle without opening the circuit Place the expansion bottle to one side Remove gearbox control linkage mounting bolt 2 Tightening torquesm starter mounting bolts 4 4 daNm 107847 1 1 109214 WARNING The linkage is fitted with a spacer do not lose the spacer when removing bolt 2 2 ...

Page 148: ...or leads Remove the starter motor mounting bolts 4 the starter REFITTING Tighten to torque the starter mounting bolts 4 4 daNm Proceed in the reverse order to removal 107486 109220 3 109215 WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Battery Remove and refit 4 4 ...

Page 149: ...J and 710 17A REMOVAL Disconnect the spark plug leads ignition coil unit connector 1 Remove the ignition coil unit mounting bolts the ignition coil unit Tightening torquesm ignition coil unit moun ting bolts 1 5 daNm 107358 1 ...

Page 150: ...tial to apply a bead of GRAISSE FLUOREE part num ber 82 00 168 855 with a diameter of 2 mm around the inner edge of the high voltage caps Proceed in the reverse order to removal Torque tighten the ignition coil unit mounting bolts 1 5 daNm 106640 WARNING Any damaged spark plug leads must be replaced ...

Page 151: ...M and 710 17A REMOVAL Disconnect the spark plug leads ignition coil unit connector 1 Remove the ignition coil unit mounting bolts the ignition coil unit Tightening torquesm ignition coil unit moun ting bolts 1 5 daNm 107358 1 ...

Page 152: ...tial to apply a bead of GRAISSE FLUOREE part num ber 82 00 168 855 with a diameter of 2 mm around the inner edge of the high voltage caps Proceed in the reverse order to removal Torque tighten the ignition coil unit mounting bolts 1 5 daNm 106640 WARNING Any damaged spark plug leads must be replaced ...

Page 153: ...ark plug leads it is essential to apply a bead of FLUORINE GREASE part number 82 00 168 855 with a diameter of 2 mm around the inner edge of the high voltage covers 107358 Engines Brand Type K7M CHAMPION RYCLC87 SAGEM RFN58LZ K7J CHAMPION RYCLC87 SAGEM RFN58LZ Flat skirt with seal Gap 0 95 0 05 mm Tightening spark plugs 2 5 to 3 daNm 106640 ...

Page 154: ...6 5 4 3 2 1 1 Ignition coil unit 2 Air filter 3 Throttle valve 4 Air temperature sensor 5 Air pressure sensor 6 Injection computer 7 Oil pressure sensor 8 Upstream oxygen sensor 9 Coolant temperature sensor 10 Engine position and speed sen sor 108562 6 Injection computer 11 6 12 ...

Page 155: ...mp relay 12 Injection locking relay 107357 14 Throttle position potentiometer 13 Idle speed regulator 15 Injectors 108426 13 15 14 15 8 109211 8 Upstream oxygen sensor 7 Oil pressure sensor 9 Coolant temperature sensor 10 Engine position and speed sen sor 107356 7 9 10 4 5 ...

Page 156: ...J and 710 17B 5 Air pressure sensor 4 Air temperature sensor 107358 1 Ignition coil unit 109219 16 Pinking sensor 1 16 DIRECTION ASSISTEE 109397 17 Power assisted steering pres sure switch AIR CONDITIONING 108107 18 Air conditioning pressostat 17 18 ...

Page 157: ...6 5 4 3 2 1 1 Ignition coil unit 2 Air filter 3 Throttle valve 4 Air temperature sensor 5 Air pressure sensor 6 Injection computer 7 Oil pressure sensor 8 Upstream oxygen sensor 9 Coolant temperature sensor 10 Engine position and speed sen sor 108562 6 Injection computer 11 6 12 ...

Page 158: ...mp relay 12 Injection locking relay 107357 14 Throttle position potentiometer 13 Idle speed regulator 15 Injectors 108426 13 14 15 15 8 109211 8 Upstream oxygen sensor 7 Oil pressure sensor 9 Coolant temperature sensor 10 Engine position and speed sen sor 107356 10 9 7 4 5 ...

Page 159: ...M and 710 17B 5 Air pressure sensor 4 Air temperature sensor 107358 1 Ignition coil unit 109219 16 Pinking sensor 1 16 DIRECTION ASSISTEE 109397 17 Power assisted steering pres sure switch AIR CONDITIONING 108107 18 Air conditioning pressostat 17 18 ...

Page 160: ...from its support by sliding it in the direction of the arrow Disconnect the upstream oxygen sensor connector Remove oxygen sensor using the tool Mot 1495 Essential special tooling Mot 1495 22 mm oxygen sensor removal refitting soc ket 1 2 square drive and a 24 mm Allen key Tightening torquesm oxygen sensors 4 5 daNm heat shield mounting nuts 2 5 daNm 108426 107925 ...

Page 161: ... oxygen sensor connector from its support by sliding it in the direction of the ar row Disconnect the connector of the downstream lamb da sensor Remove the lambda sensor REFITTING Proceed in the reverse order to removal Torque tighten the oxygen sensors 4 5 daNm using the tool Mot 1495 the heat shield mounting nuts 2 5 daNm 108424 ...

Page 162: ...from its support by sliding it in the direction of the arrow Disconnect the upstream oxygen sensor connector Remove oxygen sensor using the tool Mot 1495 Essential special tooling Mot 1495 22 mm oxygen sensor removal refitting soc ket 1 2 square drive and a 24 mm Allen key Tightening torquesm oxygen sensors 4 5 daNm heat shield mounting nuts 2 5 daNm 108426 107925 ...

Page 163: ...m oxygen sensor connector from its support by sliding it in the direction of the ar row Disconnect the connector of the downstream lamb da sensor Remove the lambda sensor REFITTING Proceed in the reverse order to removal Torque tighten the oxygen sensors 4 5 daNm using the tool Mot 1495 the heat shield mounting nuts 2 5 daNm 108424 ...

Page 164: ...ar between 3 500 and 3 000 rpm for at least 2 seconds make a second deceleration with injection cut off in second third fourth or fifth gear between 2 400 and 2 000 rpm for at least 3 seconds Using the diagnostic tool check that this program ming is properly done ET060 Flywheel signal with engine running Read the fault codes Repair if necessary Clear the fault codes Check that the vehicle is worki...

Page 165: ...ar between 3 500 and 3 000 rpm for at least 2 seconds make a second deceleration with injection cut off in second third fourth or fifth gear between 2 400 and 2 000 rpm for at least 3 seconds Using the diagnostic tool check that this program ming is properly done ET060 Flywheel signal with engine running Read the fault codes Repair if necessary Clear the fault codes Check that the vehicle is worki...

Page 166: ...he mounting 1 bolt of the battery the battery the computer cover by unclipping the 2 Remove the computer protector mounting bolts the computer protector Essential equipment diagnostic tool Tightening torquesm computer mounting nuts 0 8 daNm computer protector mounting bolts 0 8 daNm battery mounting clamp bolts 1 2 daNm 107847 1 2 108564 ...

Page 167: ...er Switch off the ignition Initialise the computer start the engine switch the engine off wait 30 seconds Switch on the ignition again and carry out the following stages using the diagnostic tool use command VP001 Write VIN perform a road test then check with the diagnos tic tool 108562 108563 3 4 WARNING Connect the battery starting with the positive ter minal carry out thenecessary programming s...

Page 168: ...ssible 2 Programming Perform flywheel target programming during a road test a deceleration with injection cut off in second third fourth or fifth gear between 3 500 and 3 000 rpm for at least 2 seconds make a second deceleration with injection cut off in second third fourth or fifth gear between 2 400 and 2 000 rpm for at least 3 seconds Using the diagnostic tool check that this program ming is pr...

Page 169: ...he mounting 1 bolt of the battery the battery the computer cover by unclipping the 2 Remove the computer protector mounting bolts the computer protector Essential equipment diagnostic tool Tightening torquesm computer mounting nuts 0 8 daNm computer protector mounting bolts 0 8 daNm battery mounting clamp bolts 1 2 daNm 107847 1 2 108564 ...

Page 170: ...er Switch off the ignition Initialise the computer start the engine switch the engine off wait 30 seconds Switch on the ignition again and carry out the following stages using the diagnostic tool use command VP001 Write VIN perform a road test then check with the diagnos tic tool 108562 108563 3 4 WARNING Connect the battery starting with the positive ter minal carry out thenecessary programming s...

Page 171: ...ble 2 Programming Perform flywheel target programming during a road test a deceleration with injection cut off in second third fourth or fifth gear between 3 500 and 3 000 rpm for at least 2 seconds make a second deceleration with injection cut off in second third fourth or fifth gear between 2 400 and 2 000 rpm for at least 3 seconds Using the diagnostic tool check that this program ming is prope...

Page 172: ...9 PETROL INJECTION Computer Connection K7J and 710 17B To connect the injection computer see wiring dia gram suited to the vehicle subject to fault finding com ponent 120 109395 75 61 15 31 1 16 90 60 30 76 ...

Page 173: ...0 PETROL INJECTION Computer Connection K7M and 710 17B To connect the injection computer see wiring dia gram suited to the vehicle subject to fault finding com ponent 120 109395 75 61 15 31 1 16 90 60 30 76 ...

Page 174: ...arried out by software using the TDC sensor Idle speed corrected according to air conditioning electrical consumers in operation Fuel vapour absorber bleed solenoid valve controlled by the opening cyclic ratio OCR according to engine speed and operating conditions Use on some models of two oxygen sensors positio ned upstream and downstream of the catalytic conver ter Automatic configuration in air...

Page 175: ...ed out by software using the TDC sensor Idle speed corrected according to air conditioning electrical consumers in operation Fuel vapour absorber bleed solenoid valve controlled by the opening cyclic ratio OCR according to engine speed and operating conditions Use on some models of two oxygen sensors positio ned upstream and downstream of the catalytic conver ter Automatic configuration in air con...

Page 176: ...is continuously lit for 3 seconds then goes out 3 Vehicles with engine immobiliser function activated When switching on the ignition the computer does not recognise the code and stops the engine from starting The injection warning light is lit 3 seconds then goes out Before switching on the ignition the red immobiliser warning light flashes When switching on the ignition it flashes more rapidly If...

Page 177: ...HE STATUS OF THE COMPUTER CODED OR UNCODED Using the diagnostic tool it is possible to check the status of the injection computer Connect the diagnostic tool to the diagnostic soc ket Select and confirm the vehicle type Select and confirm petrol injection Choose the status option if status ET099 immobiliser code programmed is inactive this indicates that the injection computer has not been coded i...

Page 178: ...injection computer which then authorises the re quest for cold air if necessary II COMPRESSOR OPERATION PROGRAMMING During certain operating phases the injection computer disables the operation of the compressor Injection computer programming If the engine speed is too low operation of the com pressor is not authorised If the load exerted on the engine is too great rapid ac celeration driving up a...

Page 179: ...1 Disconnect the oil vapour rebreather pipe 2 the air inlet sleeve Remove the air filter unit Unclip ball joint 3 Disconnect potentiometer connector 4 the idling speed stepper motor connector 5 Remove the throttle valve by tilting it potentiometer mounting bolts 4 the potentiometer 108423 107361 1 1 2 107356 107357 3 5 4 ...

Page 180: ...17B 27 PETROL INJECTION Throttle body potentiometer K7J or K7M and 710 17B REFITTING Always replace all seals that have been removed Proceed in the reverse order to removal ...

Page 181: ...eering pump The idle speed can be approximately 100 rpm faster on some versions II ELCTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE The purpose of this correction is to compensate for the drop in voltage due to a power consumer being swit ched on when the battery is not sufficiently charged To do this the idle speed is increased allowing the rota tion of the alternator ...

Page 182: ...nge 600 mV 100 When decelerating the voltage should be less than 200 mV The voltage read on the control unit at idling speed should be ignored IV RICHNESS CORRECTION The value read on the fault finding tool for parameter PR035 RICHNESS CORRECTION VALUE repre sents the average of the richness corrections applied by the computer depending on the richness of the fuel mixture as determined by the oxyg...

Page 183: ...es the following accor ding to the coolant temperature the injection system the fan assembly relay the coolant temperature warning light The warning li ght is controlled by the injection computer if the coo lant temperature exceeds 120 C The fan assembly is activated at low speed if the coo lant temperature exceeds 100 C or in the event of coo lant temperature sensor failure and is stopped when th...

Page 184: ...t air coolant temperature conditions speed condition range of values engine conditions manifold pressure speed range of values and stability delay since start The OBD management program supplements the ma nagement of conventional electrical breakdowns To meet this standard the requirements are lighting up of the OBD warning light or for some faults causing to it flash storing OBD faults IMPLICATIO...

Page 185: ...ures are in progress the canister bleed is closed and the richness adaptives are locked at their last value II TEST PROCEDURE Rectify the electrical faults Erase all faults Carry out all injection programming if necessary III COMPLETE O B D INITIALISATION BY COMMAND MODE Clearing the fault memory Erasing programming for work on a component which could have disturbed the programming idle speed re g...

Page 186: ...lution threshold to be exceeded These cause the OBD warning light to illuminate if they are detected during three consecutive journeys I DETECTION CONDITIONS Before starting check that programming has been per formed The conditions prior to switching on the ignition and the current conditions must also be satisfied Make sure status ET014 Cylinder 1 recognition DONE ET202 OBD fault finding misfirin...

Page 187: ...h 70 km per hour When the conditions for starting fault finding are met richness excitation peaks are applied which has the effect of sending bursts of oxygen into the catalytic converter If the cata lytic converter is in good condition it absorbs the oxy gen and the downstream oxygen sensor value will remain at its average value If it is in poor condition it rejects the oxygen and the lambda sens...

Page 188: ...ed no electrical faults detected programming and cylinder recognition done no oxygen sensor fault finding performed since the ignition was switched on water temperatureover 75 C II FAULT DETECTION Fault finding is performed while the vehicle is being driven in one gear travelling at a steady speed and for the minimum period of time specified in the following table For this test the computer inhibi...

Page 189: ...t to be completely drained it is essential to flush the circuit using clean water blow compressed air into it to remove as much water as possible fill and bleed the circuit then measure the effective protection of the circuit i e protection down to 25 C 2 C for cold and tempe rate countries protection down to 40 C 2 C for very cold coun tries IMPORTANT The circuits are designed to be pressurised s...

Page 190: ...ate countries Protection down to 40 C 2 for very cold countries II THERMOSTAT All engines The rating of the expansion bottle degas sing valve with a yellow hand symbol is 1 4 bar Engine Quantity litres Grade K7J 710 Approximately 5 45 GLACEOL RX TYPE D Use coolant only K7M 710 Engine Start of opening C End of opening C K7J 710 89 99 2 K7M 710 89 99 2 ...

Page 191: ... bottle valve onto the cap of tool Ms 554 06 Use tool Ms 554 07 to check the valve rating Essential special tooling Ms 554 01 Plug spare to test expansion bottle val ves Ms 554 07 Equipment for chec king coolant circuit and expansion bottle valve Ms 554 06 Plug spare to test expansion bottle val ves 97871 Note The required pressure is 0 1 bar below the valve rating The pressure should not drop if ...

Page 192: ...SYSTEM Diagram K7J and 710 19A 109415 6 5 4 3 2 1 7 1 Engine 2 Water pump 3 Thermostat 4 Bleed screw 5 Heater radiator 6 Cooling radiator 7 Expansion bottle Note The expansion bottle degassing valve rating is 1 4 bar ...

Page 193: ...SYSTEM Diagram K7M and 710 19A 109415 7 6 5 4 3 2 1 1 Engine 2 Water pump 3 Thermostat 4 Bleed screw 5 Heater radiator 6 Cooling radiator 7 Expansion bottle Note The expansion bottle degassing valve rating is 1 4 bar ...

Page 194: ...nto the circuit through the ex pansion bottle valve aperture to remove as much wa ter as possible Refit the lower hose and its clip FILLING Bleed screw 1 must be opened Essential special tooling Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1448 Remote operation pliers for cooling sys tem hose clips WARNING Drain the oil when the engine is warm Flush and refill with oil wit...

Page 195: ... engine at 2500 rpm until the cooling fan s has have run three times time required for automa tic degassing If necessary top up the coolant level in the expan sion chamber IMPORTANT Do not open the bleed screw s while the engine is running or hot Never open the expansion bottle while the engine is hot over 50 C or running Top up if necessary Retighten the expansion bottle cap while the engine is h...

Page 196: ... the coolant level in the expan sion chamber IMPORTANT Do not open the bleed screw s while the engine is running or hot Never open the expansion bottle while the engine is hot over 50 C or running Top up if necessary Retighten the expansion bottle cap while the engine is hot Using approved equipment measure the degree of coolant protection Check for any leaks Make sure the passenger compartment he...

Page 197: ...the lower radiator hose using tool Mot 1202 01 or Mot 1448 see 19A Cooling Draining Filling the cooling circuit Remove bolts 1 Partially remove the front wheel arch liners Remove bolts 2 Remove bolts 3 Essential special tooling Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1448 Remote operation pliers for cooling sys tem hose clips 108633 1 108630 108629 2 3 3 ...

Page 198: ...ring pipe from the fan assembly Remove the power assisted steering fluid reservoir from its mountings without opening the circuit Secure the power assisted steering fluid reservoir to the engine Disconnect fan assembly connectors 5 the upper radiator hose using tool Mot 1202 01 or Mot 1448 Unclip the fan assembly the electric wiring harness air conditioning pipe 6 Remove bracket 7 for the power as...

Page 199: ...er to the upper cross member Remove radiator mounting nuts 10 Remove the upper radiator mounting brackets the fan assembly the radiator REFITTING Proceed in the reverse order to removal Fill and bleed the cooling circuit see 19A Cooling Draining Filling the cooling circuit 108104 108106 108107 8 8 9 9 108430 WARNING Ensure that the fins of the cooling radiator and the condenser are not damaged as ...

Page 200: ...hout opening the circuit Attach the power assisted steering fluid reservoir to the engine Remove bracket 1 for the power assisted steering fluid reservoir Disconnect the upper radiator hose using tool Mot 1202 01 or Mot 1448 fan assembly connector 2 Remove radiator mounting bolts 3 through the ra diator grille without removing the bumper Remove the radiator Essential special tooling Mot 1202 01 Cl...

Page 201: ...nd 710 and BASIC HEATING 19A REFITTING Proceed in the reverse order to removal Fill and bleed the cooling circuit see 19A Cooling Draining Filling the cooling circuit WARNING Ensure that the fins of the cooling radiator are not damaged as it is removed ...

Page 202: ...tooling Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1448 Remote operation pliers for cooling sys tem hose clips Tightening torquesm water pump M8 bolt 2 2 daNm water pump M6 bolts 1 daNm 109240 IMPORTANT Do not scratch the aluminium sealing surfaces Wear goggles Wear gloves during the operation Clean the sealing surfaces with DECAJOINT to dissolve off any part of the seal...

Page 203: ...hten in order the water pump M8 bolt 2 2 daNm 1 the water pump M6 bolts 1 daNm Remove the timing belt see 11A Top and front of engine Timing belt Fill up and bleed the cooling circuit see 19A Coo ling Draining Filling the cooling circuit 109240 1 3 4 5 6 7 8 2 ...

Page 204: ...oling Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1448 Remote operation pliers for cooling sys tem hose clips Tightening torquesm water pump M8 bolt 2 2 daNm water pump M6 bolts 1 daNm 109240 IMPORTANT Do not scratch the aluminium sealing surfaces Wear goggles Wear gloves during the operation Clean the sealing surfaces with DECAJOINT to dissolve off any part of the seal s...

Page 205: ...hten in order the water pump M8 bolt 2 2 daNm 1 the water pump M6 bolts 1 daNm Remove the timing belt see 11A Top and front of engine Timing belt Fill up and bleed the cooling circuit see 19A Coo ling Draining Filling the cooling circuit 109240 5 4 3 1 2 8 7 6 ...

Page 206: ...ve the mounting bolts from the thermostat support unit the thermostat support unit the thermostat REFITTING The thermostat support unit seal must always be re placed Proceed in the reverse order to removal Torque tighten the thermostat support unit moun ting bolts 1 daNm Essential special tooling Mot 1202 01 Clip pliers for cooling system hose clips large model Mot 1448 Remote operation pliers for...

Page 207: ...fitted to the vehicle the mounting clip for the wiring harness on the fan assembly REFITTING Proceed in the reverse order to removal Torque tighten the fan assembly mounting bolts 0 4 daNm CHECKING OPERATION OF THE FAN ASSEMBLY Start the engine Disconnect the coolant temperature sensor see 17B Petrol injection Location of components Check operation of the fan assembly Reconnect the coolant tempera...

Page 208: ...ip the following from the fan assembly the electric wiring harness air conditioning pipe 2 Remove the fan assembly IF REPLACING Remove the retaining clip for the hose connecting the power assisted steering to the fan assembly if fitted to the vehicle the fan assembly resistor the mounting clip for the wiring harness on the fan assembly REFITTING Proceed in the reverse order to removal Essential eq...

Page 209: ...connect the coolant temperature sensor see 17B Petrol injection Location of components Check operation of the fan assembly Reconnect the coolant temperature sensor connec tor Turn the engine off Use the diagnostic tool to clear fault code DF004 coolant temperature sensor circuit read the fault codes carry out any necessary repairs clear the fault codes ...

Page 210: ...ition the after sales sleeve correctly 2 Illustration of the area to be cut Two marks on the exhaust pipe define the area to be cut see 19A Exhaust Pipe assembly Cut zone 1 Cut zone 2 Before cutting the pipe mark the midpoint between the two marks The distance between the two marks is X2 80 mm WARNING All damaged heat shields must be replaced The seal between the exhaust manifold gasket face and t...

Page 211: ...ectly on the two lugs 3 and apply some exhaust MASTIC see 04B Consumable products Conditio ning to the inside of the sleeve slide on the sleeve fully positioning it on the lugs 3 on the old part of the pipe adjust the sleeve diameter by tightening gently mount the new component fully onto the lugs 3 Torque tighten the sleeve tightening nut 2 5 daNm 102118 95478 3 100649 WARNING Make sure that the ...

Page 212: ...19B 3 EXHAUST Pipe assembly K7J and 710 19B 109861 1 Cut zone 1 2 Cut zone 2 1 2 ...

Page 213: ...19B 4 EXHAUST Pipe assembly K7M and 710 19B 109861 1 Cut zone 1 2 Cut zone 2 2 1 ...

Page 214: ...ot 1199 01 between the two cutting points 1 Essential special tooling Mot 1199 01 Exhaust pipe cutter Mot 1495 22 mm oxygen sensor removal refitting soc ket 1 2 square drive and a 24 mm Allen key Tightening torquesm oxygen sensor 4 5 daNm catalytic converter mounting nuts 2 1 daNm IMPORTANT Catalytic converters contain ceramic fibres these are contained within a closed unit and cannot be dispersed...

Page 215: ... oxygen sensor Tighten to torque the oxygen sensor 4 5 daNm using tool Mot 1495 Mount the catalytic converter the sleeve see 19A Exhaust General informa tion Torque tighten the catalytic converter mounting nuts 2 1 daNm Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned Proceed in the reverse order to removal 107926 109399 WARNING Be sure to replace the sealing ring be...

Page 216: ...st pipe using tool Mot 1199 01 between the two cutting points 1 Essential special tooling Mot 1199 01 Exhaust pipe cutter Mot 1495 22 mm oxygen sensor removal refitting soc ket 1 2 square drive and a 24 mm Allen key Tightening torquesm oxygen sensor 4 5 daNm catalytic converter mounting nuts 2 1 daNm IMPORTANT Catalytic converters contain ceramic fibres these are contained within a closed unit and...

Page 217: ...e oxygen sensor Tighten to torque the oxygen sensor 4 5 daNm using tool Mot 1495 Fit the catalytic converter the sleeve see 19A Exhaust General informa tion Torque tighten the catalytic converter mounting nuts 2 1 daNm Tighten the sleeve while supporting the exhaust pipe to ensure they are aligned Proceed in the reverse order to removal 107926 109399 WARNING Be sure to replace the sealing ring bet...

Page 218: ...199 01 to cut the exhaust pipe in the centre of area to be cut 2 Remove the expansion chamber REFITTING Mount the expansion chamber the sleeves see 19B Exhaust Vehicle Specifi cation Tighten the sleeve while supporting the exhaust pipe to ensure correct alignment Proceed in the reverse order to removal Essential special tooling Mot 1199 01 Exhaust pipe cutter 108351 14747 1 108927 2 ...

Page 219: ...ipe in the centre of area to be cut 1 Remove the silencer REFITTING Mount the silencer the sleeve see 19B Exhausts Vehicle specifi cation Tighten the sleeve while supporting the exhaust pipe to ensure correct alignment Proceed in the reverse order to removal Essential special tooling Mot 1199 01 Exhaust pipe cutter 108927 1 ...

Page 220: ...al special tooling Mot 1311 08 Union for measuring fuel pressure Mot 1311 01 Fuel pressure pres sure gauges and soc ket unions IMPORTANT During this operation be sure to refrain from smoking or bringing hot objects close to the work area beware of fuel splashes when disconnecting the union protect sensitive areas from fuel outflow 108650 IMPORTANT Wear gloves during the operation 1 109173 IMPORTAN...

Page 221: ...10 19C Disconnect engine passenger compartment wiring harness 4 Connect connector terminal 5 to battery feed to operate the fuel pump Allow the fuel to run out until the flow is intermittent Disconnect the battery feed from terminal 5 109171 109172 4 5 1 8 ...

Page 222: ...e fuel tank see 19C Fuel tank Draining the fuel tank Disconnect the battery starting with the negative ter minal Open the two rear doors Remove the seat base from the rear bench seat Tightening torquesm fuel tank mounting bolts to torque 2 1 daNm catalytic converter mounting nuts 2 1 daNm 108525 108524 ...

Page 223: ...oor panel providing access to the pump gauge filter assembly Disconnect the fuel pump connector Remove the filler neck mounting bolts 1 Remove body earth cable 2 Remove heat shield attachment pins the heat shield Remove the engine undertray 109177 108652 1 109185 109183 2 3 3 ...

Page 224: ... on the left hand si de Attach the front section of the exhaust line assembly to the front lower arm on the left hand side Disconnect the fuel pipes coming from the fuel tank Unclip the cables connecting the parking brake to the fuel tank the body Remove the fuel tank mounting bolts the fluid reservoir 108424 107926 108650 IMPORTANT During this operation be sure to refrain from smoking or bringing...

Page 225: ...mbly Torque tighten the catalytic converter mounting nuts 2 1 daNm Proceed in the reverse order to removal 109399 WARNING It is essential to replace the sealing ring between the exhaust manifold and the catalytic converter WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 80A Battery Battery Remove and Refit ...

Page 226: ...oors Remove the seat base from the rear bench seat Essential special tooling Mot 1397 Universal spanner for removing fuel gauge nut IMPORTANT During this operation be sure to refrain from smoking or bringing hot objects close to the work area beware of fuel splashes when disconnecting the union protect sensitive areas from fuel outflow 108525 108524 ...

Page 227: ...sembly Remove the locking ring from the pump gauge filter assembly using tool Mot 1397 Allow the fuel in the pump gauge filter assembly to run out Remove the pump gauge filter assembly being ca reful not to damage the float 109177 109176 WARNING If several hours are to pass between the pump gauge filter assembly being removed and refitted tighten the locking ring on the fuel tank to prevent any da...

Page 228: ... in the reverse order to removal 109180 WARNING Make sure that the seal is positioned correctly when the pump gauge filter assembly is refitted 1 109179 WARNING The pump gauge filter assembly index and loc king ring index must be between the two mar kings on either side of the fuel tank index WARNING Connect the battery starting with the positive ter minal carry out the necessary programming see 8...

Page 229: ...ng diagrams compo nent 199 II CHECKING THE GAUGE SENDER UNIT Remove the pump gauge filter assembly see 19C Fuel tank Pump gauge filter Measuring the height H place the pump gauge filter assembly on a work sur face measure height H between the float pivot and the work surface Refit the pump gauge filter assembly see 19C Fuel tank Pump gauge filter 108538 Height H mm Value across terminals A1 and B1...

Page 230: ...19D 1 ENGINE MOUNTING Suspended engine mounting K7J and 710 19D 109231 3 3 4 2 2 2 1 1 Reference Tightening torque in daNm 1 10 5 2 6 2 3 6 2 4 10 5 ...

Page 231: ...19D 2 ENGINE MOUNTING Suspended engine mounting K7M and 710 19D 109231 2 1 1 2 2 3 3 4 Reference Tightening torque in daNm 1 10 5 2 6 2 3 6 2 4 10 5 ...

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