1. 0 General vehicle information01A VEHICLE MECHANICAL SPECIFICATIONS01C VEHICLE BODYWORK SPECIFICATIONS02A LIFTING EQUIPMENTX79NOVEMBER 2009 EDITION ANGLAISE"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".All rights reserved by Renault.Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault. Renault s.a.s 200703B COLLISION04B CONSUMABLES - PRODUCTS

2. DUSTER - Chapitre 0ContentsPagesDUSTER - Chapitre 0ContentsPages01A VEHICLE MECHANICAL SPECIFICATIONSVehicle: Specifications 01A-101C VEHICLE BODYWORK SPECIFICATIONSVehicle: Identification 01C-1Vehicle panel gaps:Adjustment value 01C-202A LIFTING EQUIPMENTVehicle: Towing and lifting 02A-103B COLLISIONVehicle involved in animpact: Impact fault finding 03B-104B CONSUMABLES - PRODUCTSVehicle: Parts andconsumables for the repair 04B-1 3. Vehicle: Specifications 01AVEHICLE MECHANICAL SPECIFICATIONS01A-1Dimensions in metres:1449004X2 TRANSMISSION(A) 0.822(B) 2.673(C) 0.820(D) 4.315(E) 1.560(F) (unladen) 1.690(G) 1.567(H) 1.822 4. Vehicle: Specifications 01AVEHICLE MECHANICAL SPECIFICATIONS01A-24X4 TRANSMISSIONDimensions in metres:(A) 0.822(B) 2.671(C) 0.822(D) 4.315(E) 1.560(F) (unladen) 1.682(G) 1.570(H) 1.822Engine GearboxEmissionsEngine type Engine suf- standardfixCubic capac-ity(cc)Gearbox type Gearbox suffix TransmissiontypeK4M 606 1598 TL8 002 4x4 EURO 4EURO 5690 JR5 187 4x2 EURO 4K9K7961461JR5 189 4x2 EURO 4884 TL8 000 4x4EURO 1EURO 3EURO 4898 EURO 5 5. Vehicle: Identification 01CVEHICLE BODYWORK SPECIFICATIONS01C-1I - LOCATION OF VEHICLE IDENTIFICATIONPLATE (A)II - LOCATION OF THE VEHICLE IDENTIFICATIONNUMBER (B)III - DETAILED VIEW OF THE VEHICLEIDENTIFICATION PLATEPlate (A)145261145260Note:If the complete body is being replaced, it must bemarked in compliance with the current regulations.19031(1) Vehicle type and type number;this information also appears onmarking (B)(2) MGVW (Maximum Gross Vehi-cleWeight)(3) GTW (Gross train weight, vehi-cleunder load with trailer)(4) Maximum permissible front axleload(5) Maximum permissible rear axleload(6) Vehicle technical specifications(7) Paintwork reference number(8) Equipment level(9) Vehicle type(10) Upholstery code(11) Additional equipment details(12) Production number(13) Interior trim code 6. VEHICLE BODYWORK SPECIFICATIONSVehicle panel gaps: Adjustment value 01C01C-2WARNINGThe clearance values are given for information pur-poses.When adjusting clearances, certain rules have to befollowed:- maintain symmetry with respect to the oppositeside,- ensure the flush fitting is correct,- check correct operation of the opening, and water/air-tightness.145389No. Location Clearances (mm)(1) bonnet / headlight 5 2(2) bonnet / front wing 4 1.5(3) headlight / front wing 2 1.5(4) front bumper / front wing 0.5(5) front side door / front wing 4.5 1(6) front side door / windscreen pillar 18 1 7. VEHICLE BODYWORK SPECIFICATIONSVehicle panel gaps: Adjustment value 01C(7) windscreen / roof 4.5 1(8) side doors / roof 18 1(9) front side door / rear side door 4.5 1(10) rear side door / rear wing panel 4.5 1(11) side doors / sill panel 6 201C-3145390No. Location Clearances (mm)No. Location Clearances (mm)(12) rear wing panel / fuel filler flap cover 3 1.5(13) rear wing panel / rear bumper 0.5(14) roof / tailgate 5 1(15) tailgate rear screen / rear wing panel 4.5 2(16) tailgate / rear wing panel 4.5 1.5(17) tailgate / rear bumper 7 2(18) rear quarter panel window / rear wing panel 3 1 8. LIFTING EQUIPMENT02AVehicle: Towing and lifting 02A-1I - TOWING1 - Position of front attachment point2 - Position of rear attachment pointII - LIFTING BY TROLLEY JACKEquipment requiredsafety strap(s)WARNINGSee the current towing regulations in each country.Never use the driveshafts, axle assembly compo-nentsor suspension components as attachmentpoints.Tighten and lock the towing ring before use.Always pull in the direction of the rod's length inorder to avoid breaking it.Vehicles fitted with automatic transmission:- It is preferable to transport the vehicle on a flatbedor to tow it by lifting the front wheels; as an excep-tion,the vehicle can be towed with the wheels onthe ground, but at a speed of less than 12 mph (20km/h) over a maximum distance of 18 miles (30km) (with the gear lever in neutral).145262145263IMPORTANTAppropriate axle stands must be used if a trolleyjack is used.WARNINGThe subframe of this vehicle is protected by prod-uctsproviding a 6-year anti-corrosion warranty.Never use equipment not fitted with rubber pads, toavoid direct metal to metal contact which coulddamage the original protection.The vehicle must not be raised by support pointsunder the front suspension arms or under the rearaxle. 9. LIFTING EQUIPMENT02AVehicle: Towing and lifting 108416108418To raise a front or rear wheel, use (1) as the supportpoint.To mount the vehicle on axle stands, the entire vehiclemust be lifted on one side and axle stands must beplaced under the jacking points for the tool kit jack (1) .III - LIFTING ON A LIFT1 - Safety advice reminderIf it is necessary to remove heavy components from thevehicle, it is preferable to use a four-post lift.After removing certain components (e.g. engine andtransmission assembly, rear axle, fuel tank, etc.), thereis a danger that the vehicle will tip on a two post lift.When the vehicle is raised on an underbody two postlift, fit safety strap(s), part no. 77 11 172 554 availablefrom the Parts Department.02A-214894 10. LIFTING EQUIPMENT02AVehicle: Towing and lifting 02A-32 - Fitting the strapsFor safety purposes, the straps must always be in per-fectcondition; replace them if they are damaged.When fitting the straps, check that the seats and fragileparts of the vehicle are correctly protected.a - Tilting towards the frontPass the strap under the rear right-hand arm of the lift.Pass the strap through the inside of the vehicle.Pass the strap under the rear left-hand arm of the lift.Pass the belt through the inside of the vehicle again.Tighten the strap.b - Tilting towards the rearPass the strap under the front right-hand arm of the lift.Pass the strap through the inside of the vehicle.Pass the strap under the front left-hand arm of the lift.Pass the belt through the inside of the vehicle again.Tighten the strap.3 - Permitted jacking pointsTo raise the vehicle, position the pads of the lift armsas indicated below taking care not to damage the endof the front wing or the underside of the sill panel.At the frontPosition the lift arms under the end of the sill panelbody flanges.At the rearPosition the lift arms under the end of the sill panelbody flanges.108420IMPORTANTOnly the jacking points described in this sectionallow the vehicle to be raised in complete safety.Do not raise the vehicle using points other thanthose described in this section.108419108417 11. COLLISION03BVehicle involved in an impact: Impact fault finding 03B-1aI - CHECKING THE SUBFRAMEChronological order of checksa FRONT impactCompare the following distances between diagonal-lyopposite points:- 1: B1 - G2 = B2 - G1- 2: G1 - C2 = G2 - C1a REAR impactCompare the following distances between diagonal-lyopposite points- 1: G2 - B1 = G1 - B2- 2: B1 - J2 = B2 - J1145391 12. COLLISION03BVehicle involved in an impact: Impact fault finding 03B-2II - DETAILED VIEW OF INSPECTION POINTSPoint B1 - B2Point G1 - G2Point C1 - C2Point J1 - J2a145397145393145392145395 13. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair 04B-1Consumables for mechanical repair:DEFINITION PACKAGING PART NUMBERMECHANICAL SEALANTSSILICORsealing paste85 g tube 77 11 236 470MASTIXOJoint face seal100 g tube 77 11 236 172BEARING SEALING KITFor crankshaft bearing cap sidesealingKit 77 11 237 896SILICONE ADHESIVE SEALEngine and gearbox sealing paste100 g cartridge 77 11 227 484TRANSPARENT SEALING MAS-TIC45 g tube 77 11 223 369SILICOJOINT 90 g tube 77 11 236 469LOCTITE ADHESIVE 597Cartridge 77 11 219 705Sealing paste for PXX gearboxesRESIN ADHESIVE or SEALINGRESINSealing resin for engine and gear-boxcovers25 ml tube 77 11 237 640EXHAUST MASTICFor exhaust pipe union seals1.5 kg tin 77 01 421 161LEAK DETECTOR 400 ml aerosol 77 11 236 176ADHESIVESFRENETANCHESealing the threading at low andmedium pressure50 ml bottle 77 11 236 471HIGH-STRENGTH THREADLOCKFor locking bolts50 ml bottle 77 11 230 112SEALING RESINFor locking the bearings50 ml bottle 77 11 236 472LUBRICANT CLEANERSNTELECAvoid bad contacts in electrical cir-cuits150 ml aerosol 77 11 225 871 14. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair INJECTOR CLEANER 355 ml container 77 11 224 188 or 77 11 225 539CLOTH FOR INJECTION SYSTEM 77 11 211 707SUPER RELEASING AGENT 500 ml aerosol 77 11 236 166SUPER RELEASING AGENT 250 ml aerosol 77 11 420 439SUPER CLEANER FOR JOINT300 ml aerosol 77 11 238 181FACESFor cleaning joint facesSURFACE CLEANER 5 L container 77 01 404 178SILICONE LUBRICANT 500 ml aerosol 77 11 236 168SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 16704B-2BRAKE CLEANER600 ml aerosol 77 11 422 413150 ml aerosol 77 11 422 414BIO BRAKE CLEANER 750 ml spray bottle 77 11 427 217AIR CONDITIONING CLEANER 250 ml aerosol 77 11 230 498CARBURETTOR CLEANER Aerosol 77 11 236 177IXTAR ENGINE CLEANER 400 ml can 77 11 229 365GREASEBR2+ GREASEFor:- the lower arm bearings,- the anti-roll bar grooves,- the driveshaft splines.1 kg pack 77 01 421 145SILICONE GREASEFor:- the tubular rear axle bushes,- the anti-roll bar bushes.100 g tube 77 11 419 216COPPER ANTI-SEIZE GREASEGrease for turbochargers (hightemperature)85 g tube 77 11 236 173COPPER-ALUMINIUM LUBRI-CANTGrease for turbochargers (hightemperature)500 ml aerosol 77 11 236 169GREASEFor driveshaft seals180 g sachets 77 11 420 011 15. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair 04B-3WHITE GREASEFor wheel sensors400 ml aerosol 77 11 236 174MULTIPURPOSE GREASE500 ml aerosol 77 11 236 170250 ml aerosol 77 11 236 171FLUORSTAR 2LSilicone-free electric sealing grease100 g tube 82 00 168 855LACQUERJELT ARGENTVarnish for repairing heated rearscreens5 g bottle 77 11 230 111BRAKEDOT 4, ISO CLASS 6, RENAULTSTANDARD: 03-50-006,For vehicles with and without elec-tronicstability program (ESP)0.5 L container 77 11 218 5895 L container 77 11 238 31825 L container 77 11 238 319DOT 4, ISO CLASS 4, RENAULTSTANDARD: 03-50-005Authorised for vehicles without ESP0.5 L container 77 11 172 3815 L container 77 01 395 50325 L container 77 11 171 926DOT 4Authorised for vehicles withoutESP, without clutch with hydraulictappet0.5 L container 86 71 000 0005 L container 86 71 014 27725 L container 86 71 014 278COOLING SYSTEMANTIFREEZE (TYPE D) 1 L container 77 11 170 548COOLANT (TYPE D)1 L container 77 11 171 5892 L container 77 11 170 5455 L container 77 11 170 546OILENGINE OIL (see Engine oil: Specifications) (Technical Note 6013A, 04A, Lubri-cants)GEARBOX OIL(see Manual gearbox oil: Specifications) (Technical Note 6012A, 04A,Lubricants)(see Automatic gearbox oil: Specifications) (Technical Note 6012A,04A, Lubricants)(see Sequential gearbox oil: Specifications) (Technical Note 6012A,04A, Lubricants) 16. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair AXLE OIL (see Rear axle oil: Specifications) (Technical Note 6012A, 04A, Lubri-cants)04B-4ELF RENAULT MATIC D2Oil for power-assisted steering:Pump connected, pump assembly(except Laguna III)2 L container 77 01 402 037TOTAL POWER-ASSISTEDSTEERING FLUIDOil for power-assisted steering:Pump assembly (Laguna III)1 L container no part numberPLANETELF PAG 488250 ml container77 11 172 668SANDEN SP 10Oil for air conditioning compressor77 01 419 313UNIVIS J26Oil for retractable roof hydraulicsystem250 ml container 77 11 172 160TYRESTYRE PASTE1 kg pack 77 11 223 0525 kg pack 77 11 223 053TYRE REPAIR AGENT400 ml tube 77 11 221 296300 ml tube 77 11 222 802BLANKING PLUGEngine type Injection type Part no.F5R 77 01 206 382F8Q 77 01 206 340F9Q 77 01 208 229G9T AND G9U 77 01 208 229K9K DELPHI 77 01 206 804K9K SIEMENS 77 01 476 857M9R 77 01 209 062P9X 77 01 474 730ZD3 77 01 208 229MISCELLANEOUSGREY ABRASIVE PAD 77 01 405 943 17. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair 04B-5Consumables for bodywork repair:HOLLOW SECTION WAXSPR CC 1 L container 77 11 172 672SPR CC SPRAY 500 ml aerosol 77 11 211 654STRUCTURAL ADHESIVESTRUCTURAL ADHESIVE Kit =2 80 ml cartridges 77 11 219 885HIGH PERFORMANCE STRUC-TURALADHESIVE1 195 ml cartridge 77 11 419 113GLAZING PRODUCTS AND ADHESIVESMONOPAC EVOLUTION ADHE-SIVEKIT310 ml cartridge 77 11 421 430MONOPAC EVOLUTION ADDI-TIONALCARTRIDGE + NOZZLE310 ml cartridge 77 11 421 431S-P KIT ADHESIVE KIT 310 ml cartridge 77 11 421 432ADDITIONAL S-P KIT CAR-TRIDGE+ NOZZLE310 ml cartridge 77 11 421 433BIPAC EVOLUTION ADHESIVEKIT2 225 ml cartridges 77 11 421 434LINT-FREE CLOTH Box of 340 cloths 77 11 237 262WINDOW SEALING MASTIC 310 ml cartridge 77 11 170 222SPECIAL ADHESIVE FOR WIN-DOWS77 11 425 759ADHESION PROMOTERFor bonding double-sided adhesivetapeCloth 77 11 423 222MISCELLANEOUSDOUBLE-SIDED ADHESIVE 18 mm wide 77 11 226 308DOUBLE-SIDED ADHESIVE 8 mm wide 77 11 427 869FRENETANCHE 50 ml bottle 77 11 236 471ADHESIVE PATCH 82 00 043 181ADHESIVE PAD 77 05 042 163SEALSBLACK MJ PRO (Electroweldable) 310 ml cartridge 77 11 172 676WHITE MJ PRO II (Electroweld-able)310 ml cartridge 77 11 426 951 18. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair 04B-6PREFORMED SEALING MASTICBEAD2.6 m roll 77 01 423 330BRUSH MASTIC 1 kg pack 77 11 228 113FILLER MASTIC 60 beads 6 mm by 0.3 m 77 11 170 230GREASEWHITE GREASE 400 ml aerosol 77 11 236 174OPENING ELEMENT MECHA-NISMGREASE20 g sachets 77 11 419 865SILICONE LUBRICANT 500 ml aerosol 77 11 236 168SILICONE-FREE LUBRICANT 500 ml aerosol 77 11 236 167SOUNDPROOFINGSPR GREY EVOLUTION 1 l cartridge 77 11 419 114SPR GREY EVOLUTION SPRAY 400 ml aerosol 77 11 419 116SPR BLACK EVOLUTION II 1 l cartridge 77 11 419 115SOUNDPROOFING PAD (3.5 Kg/Pack of 10 77 01 423 546m)SOUNDPROOFING PAD (6.5 Kg/m)Pack of 5 77 01 423 269POLISHINGPOLISHING LIQUID 1 L container 77 11 420 288FINISHING LIQUID 1 L container 77 11 420 289MASTICUniversal masticGALAXI 2.5 kg pack 77 11 172 238OPTIMAX 1.23 l cartridge 77 11 172 239EXCELLENCE +For finishing plastic repair960 g cartridge 77 11 423 5391 kg pack 77 11 423 540Plugging masticXFIBRE FIBREGLASS MASTIC 975 kg pack 77 11 172 235STANDARD BASIX POLYESTER1.975 kg pack 77 11 172 234MASTICALUX ALUMINIUM MASTIC 975 kg pack 77 11 172 236Sprayable mastic 19. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair 04B-7PIXTO SPRAYABLE POLYESTERMASTIC1.5 kg tin 77 11 172 237Finishing masticIXTRA POLYESTER MASTIC 1.625 kg pack 77 11 172 233Anti-grit masticMAG PRO 1 310 ml cartridge 77 11 172 679MAG PRO 3 (Dual component) 1.5 kg tin 77 11 218 364SURFACE CLEANERHEPTANE 500 ml container 77 11 170 064SOLVENT SURFACE CLEANER 5 L container 77 01 404 178WATER-BASED SURFACE5 L container 77 11 421 337CLEANERANTISTATIC THINNER (for plasticmaterials)400 ml aerosol 77 01 408 493COMPOSITE MATERIAL REPAIR BY BONDINGPLASTIC REPAIR KIT 77 11 170 064NOZZLE FOR PLASTIC REPAIRKIT77 11 423 523PLASTIC REPAIR CLEANER 1 L container 77 11 423 517PLASTIC REPAIR PRIMER 150 ml bottle 77 11 423 518PLASTIC REPAIR ADHESIVE 2 x 25 ml bicomponent cartridge 77 11 423 519PLASTIC REPAIR CLOTH 90 m roller 77 11 423 520PLASTIC REPAIR NOZZLES 12 nozzles 77 11 423 522COMPOSITE MATERIAL REPAIR BY WELDINGPLASTIC WELD REPAIR SET 77 11 425 742PROTECTIVE STRIPS Bag of 10 protective strips 77 11 425 744STAINLESS STEEL MESH Bag of 2 meshes 77 11 425 743COOLER 400 ml aerosol 77 11 425 745BRUSH Box of 10 brushes 77 11 237 793WINDOW MASKING TAPE10 MM WINDSCREEN TAPE 77 11 171 70820 MM WINDSCREEN TAPE 77 11 171 709PROTECTIVE WELDING 20. CONSUMABLES - PRODUCTS04BVehicle: Parts and consumables for the repair ANTI-SPLASH SPRAY 400 ml aerosol 77 11 218 270SPECIFIED UNDERCOAT04B-8PRE-TREATMENT PRIMER WITH-OUTZINC CHROMATE (I-Alpha) +THINNER1 L container77 11 420 027 (Primer)77 11 420 028 (Thinner)I-PREMIA REACTIVE PRIMER (donot use on aluminium)3.5 l container77 11 239 243 (Primer)77 11 228 654 (Thinner)I-PREMIA REACTIVE PRIMER (donot use on aluminium)400 ml aerosol 77 11 419 416ADHRA SPRAY (adhesion pro-moterfor thermoplastics)400 ml aerosol 77 11 423 734PRIMARA BLACK (adhesion pro-moter/primer for thermoplastics)1 L container77 11 423 73577 11 171 514 (Activator)PRIMARA (adhesion promoter/primer for thermoplastics)1 L container77 11 171 51377 11 171 514 (Activator)UNDERCOATLEVIA 3.5 l container 77 11 228 651FORTIA 3.5 l container 77 11 228 650 21. 1 Engine and peripherals10A ENGINE AND CYLINDER BLOCK ASSEMBLY11A TOP AND FRONT OF ENGINEX79NOVEMBER 2009 EDITION ANGLAISE"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".All rights reserved by Renault.Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault. Renault s.a.s 200712A FUEL MIXTURE12B TURBOCHARGING13A FUEL SUPPLY13B DIESEL INJECTION13C PREHEATING14A ANTIPOLLUTION16A STARTING - CHARGING17A IGNITION17B PETROL INJECTION 22. X79NOVEMBER 2009 EDITION ANGLAISE"The repair procedures given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.The procedures may be modified as a result of changes introduced by the manufacturer inthe production of the various component units and accessories from which the vehicles areconstructed".All rights reserved by Renault.Copying or translating, in part or in full, of this document or use of the service part referencenumbering system is forbidden without the prior written authority of Renault. Renault s.a.s 200719A COOLING19B EXHAUST19C TANK19D ENGINE MOUNTING 23. DUSTER - Chapitre 1ContentsPagesDUSTER - Chapitre 1ContentsPages10AENGINE AND CYLINDER BLOCKASSEMBLYCrankshaft seal on timingend: Removal - Refitting 10A-1Crankshaft seal, gearboxend: Removal - Refitting 10A-5Lower cover: Removal -Refitting 10A-9Conrod bearing shell:Removal - Refitting 10A-24Engine oil: Draining -Refilling 10A-32Oil filter: Removal - Refitting 10A-34Oil-coolant heat exchanger:Removal - Refitting 10A-37Oil pressure sensor:Removal - Refitting 10A-42Oil pump: Removal -Refitting 10A-44Oil pressure: Check 10A-46Multifunction support:Removal - Refitting 10A-48Engine - gearbox assembly:Removal - Refitting 10A-54Flywheel: Removal - Refitting 10A-7511A TOP AND FRONT OF ENGINEPressure at end ofcompression: Check 11A-1Accessories belt: Removal -Refitting 11A-2Crankshaft accessoriespulley: Removal - Refitting 11A-10Timing belt: Removal -Refitting 11A-17Rocker cover: Removal -Refitting 11A-42Camshaft: Removal -Refitting 11A-49Camshaft seal, timing end:Removal - Refitting 11A-56Oil decanter: Removal -Refitting 11A-6812A FUEL MIXTUREAir inlet: Description 12A-1Air resonator: Removal -Refitting 12A-2Air filter: Removal - Refitting 12A-3Air filter unit: Removal -Refitting 12A-6Air flowmeter: Removal -Refitting 12A-10 24. Contents12A FUEL MIXTUREThrottle valve: Removal -Refitting 12A-11Inlet distributor: Removal -Refitting 12A-12Injector holder shim:Removal - Refitting 12A-14Exhaust manifold: Removal -Refitting 12A-1612B TURBOCHARGINGTurbocharger: Removal -Refitting 12B-1Turbocharger oil pipe:Removal - Refitting 12B-4Intercooler: Removal -Refitting 12B-813A FUEL SUPPLYFuel circuit: Operatingdiagram 13A-1Manual priming pump:Removal - Refitting 13A-3Diesel filter: Removal -Refitting 13A-5Fuel pressure: Check 13A-9Fuel flow: Check 13A-1113B DIESEL INJECTIONDiesel injection: List andlocation of components 13B-1Diesel injection computer:Removal - Refitting 13B-5Camshaft position sensor:Removal - Refitting 13B-713B DIESEL INJECTIONCrankshaft position sensor:Removal - Refitting 13B-8High pressure pump:Removal - Refitting 13B-9Flow actuator: Removal -Refitting 13B-14Venturi: Removal - Refitting 13B-16High pressure pipe: Check 13B-18High pressure pipe betweenpump and rail: Removal -Refitting 13B-19High pressure pipe betweenrail and injector: Removal -Refitting 13B-22Injector rail: Removal -Refitting 13B-25Fuel temperature sensor:Removal - Refitting 13B-28Injector leak flow: Check 13B-30Diesel injector: Removal -Refitting 13B-32Accelerometer: Removal -Refitting 13B-3713C PREHEATINGPre-postheating unit:Removal - Refitting 13C-1Heater plugs: Removal -Refitting 13C-214A ANTIPOLLUTIONExhaust gas recirculation:List and location ofcomponents 14A-1Fuel vapour absorber:Removal - Refitting 14A-2 25. Contents14A ANTIPOLLUTION 19A COOLINGExhaust gas recirculationsolenoid valve: Removal -Refitting 14A-4Exhaust gas cooler: Removal- Refitting 14A-7Exhaust gas recirculationassembly: Removal -Refitting 14A-9Exhaust gas recirculationrigid pipe: Removal -Refitting 14A-1216A STARTING - CHARGINGAlternator: Removal -Refitting 16A-1Starter: Removal - Refitting 16A-8Alternator pulley: Removal -Refitting 16A-1217A IGNITIONCoils: Removal - Refitting 17A-117B PETROL INJECTIONPetrol injection: List andlocation of components 17B-1Oxygen sensors: Removal -Refitting 17B-4Throttle valve potentiometer:Removal -Refitting 17B-6Petrol injection computer:Removal - Refitting 17B-7Crankshaft position sensor:Removal - Refitting 17B-9Injector rail - Injectors:Removal - Refitting 17B-10Engine cooling system:Operating diagram 19A-1Engine cooling system:Specifications 19A-2Engine cooling system:Check 19A-3Engine cooling circuit: Listand location of components 19A-5Cooling system: Draining -Refilling 19A-6Cooling radiator: Removal -Refitting 19A-9Coolant pump: Removal -Refitting 19A-13Thermostat: Removal -Refitting 19A-19Water chamber: Removal -Refitting 19A-22Engine cooling fan assembly:Removal - Refitting 19A-27Coolant pump inlet pipe:Removal - Refitting 19A-34Expansion bottle: Removal -Refitting 19A-38Coolant temperature sensor:Removal - Refitting 19A-4019B EXHAUSTExhaust: List and location ofcomponents 19B-1Exhaust: Precautions for therepair 19B-6Catalytic converter: Removal- Refitting 19B-10Expansion chamber:Removal - Refitting 19B-17 26. Contents19B EXHAUSTIntermediate pipe: Removal -Refitting 19B-18Silencer: Removal - Refitting 19B-2019C TANKFuel tank: Draining 19C-1Fuel tank: Removal -Refitting 19C-3Fuel level sensor module:Removal - Refitting 19C-819D ENGINE MOUNTINGSuspended enginemounting: Tightening torque 19D-1Left-hand suspended enginemounting: Removal -Refitting 19D-2Right-hand suspendedengine mounting: Removal -Refitting 19D-4Lower engine tie-bar:Removal - Refitting 19D-8 27. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting10A-1K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-fitting)(80A, Battery).a Remove:- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting, page 11A-17) ,- the timing belt sprocket (see 11A, Top and front ofengine, Timing belt: Removal - Refitting, page11A-17) .II - REMOVAL OPERATIONa Fit the end piece (2) onto the tool (3) .a Position the jaws of the toolonto the crankshaft nose(4) .a Push on the tooluntil contact is made between theends (5) of the jaws and the crankshaft seal.105257105260105261 28. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting10A-2K9K10Aa Separate the jaws by screwing the nutof the tool (6) .a Screw down the threaded rod (7) of the.a Refit the crankshaft seal at the timing end using thetool.REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: Crankshaft seal ontiming end.a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consuma-bles- Products) to clean and degrease:- the crankshaft seal mating face,- the crankshaft seal housing in the crankshaft clo-surepanel.II - REFITTING OPERATIONa105262105263WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-germarks).18687Note:This type of seal is extremely fragile.Only touch the protective part (8) when handlingthe gasket. It is strictly forbidden to touch theseal (9) ; this is to prevent any oil leaks once theoil seal is fitted to the engine. 29. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting10A-3K9K10Aa Screw the threaded rod (10) of theinto the crank-shaft.a On the crankshaft, fit the spacer (11) of the.a Fit the protector with the new seal in place on thespacer, taking care not to touch the seal.a Fit the cover (12) and nut (13) (with the thread (14)of the nut towards the outside of the engine) of the.20772207712077020769 30. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal on timing end: Removal - Refitting10A-4K9K10Aa Screw on the nut until the cover touches the spacer.a Remove the nut, the cup, the protector and thethreaded rod.III - FINAL OPERATIONa Refit:- the timing belt sprocket (see 11A, Top and front ofengine, Timing belt: Removal - Refitting, page11A-17) ,- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting, page 11A-17) ,- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres).a Connect the battery (see Battery: Removal - Refit-ting)(80A, Battery).207682076720766 31. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - Refitting10A-5K4M or K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-fitting)(80A, Battery).a Remove:- the gearbox (see Manual gearbox: Removal - Re-fitting)(21A, Manual gearbox),- the clutch (see Pressure plate - Disc: Removal -Refitting) (20A, Clutch),- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-75) (20A, Clutch).II - REMOVAL OPERATIONa Remove the crankshaft seal (1) at the gearbox endusing a screwdriver.a Fit the extractorto the shaft, adjusting the fingers (2)to the diameter of the shaft using the knurled plate(3) .a Screw knurled plate (5) until it is locked to knurledplate (4) to keep the fingers in position on the shaft.a Screw the extractor into the seal using the hexago-nalnut (6) .K4M134550Note:Take care not to damage the crankshaft matingface.K9K2275922759-1 32. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - Refitting10A-6K4M or K9K10Aa Extract the crankshaft seal at the gearbox end byscrewing the threaded rod (7) .REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: Crankshaft seal ongearbox end.a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consuma-bles- Products) to clean and degrease:- the crankshaft seal mating face,- the crankshaft seal housing on the cylinder block.II - REFITTING OPERATIONa22760WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-germarks).K9K18687Note:This type of seal is extremely fragile.Only touch the protective part (8) when handlingthe gasket. It is strictly forbidden to touch theseal (9) ; this is to prevent any oil leaks once theoil seal is fitted to the engine. 33. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - Refitting10A-7K4M or K9K10Aa Mount theon the crankshaft, securing it using bolts(10) .a Fit the protector with its seal in place on the, takingcare not to touch the seal.a Fit the cover (11) and nut (12) (with the thread (13)of the nut towards the outside of the engine) of the.a Tighten the nut until the cover touches the cylinderblock.20760207612076220763 34. ENGINE AND CYLINDER BLOCK ASSEMBLYCrankshaft seal, gearbox end: Removal - Refitting10A-8K4M or K9K10Aa Remove the nut, the cover, the protector and thebase plate.a Refit the crankshaft seal at the gearbox end, usingthe tool (14) .III - FINAL OPERATIONa Refit:- the flywheel (see 10A, Engine and cylinder blockassembly, Flywheel: Removal - Refitting, page10A-75) (20A, Clutch),- the clutch (see Pressure plate - Disc: Removal -Refitting) (20A, Clutch),- the gearbox (see Manual gearbox: Removal - Re-fitting)(21A, Manual gearbox).a Connect the battery (see Battery: Removal - Refit-ting)(80A, Battery).a Perform the following operations:- fill the manual gearbox (see Manual gearbox oils:Draining - Filling) (21A, Manual gearbox),- bleed the clutch control circuit (see Clutch circuit:Bleed) (37A, Mechanical component controls).2076420765K4M134544 35. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-9K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove the front bumper (see Front bumper as-sembly:Exploded view) and (see Exterior bodyfront trim assembly: Exploded view) (55, Exteriorprotection).a Remove:- the engine undertray bolts,- the engine undertray.a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-32) .a Remove:- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),- the front wheel arch side liners,- the lower engine tie-bar (see 19D, Engine mount-ing,Lower engine tie-bar: Removal - Refitting,page 19D-8) .a Extract the lower arm ball joints from the stub axlecarrier (see Front driveshaft lower arm: Removal- Refitting) (31A, Front axle components).a Remove (see Steering box: Removal - Refitting)(36A, Steering assembly):- the heat shield bolts on the steering box,- the steering box heat shield,- the steering box bolts on the front axle subframe.a Attach the steering rack to the body.a Remove:- the catalytic converter upstream strut bolts (1) ,- the catalytic converter upstream strut.Special tooling requiredTav. 1747 Threaded rods for carryingout subframe operations.Tightening torquesmoil pump bolts 25 N.msump bolts on the cylin-derblock14 N.msump bolts on the gear-box44 N.msump bolts on the multi-functionsupport25 N.mpower assisted steeringpump support bolt onthe sump25 N.mbracket bolts 62 N.mrelay bearing bolts 44 N.mright-hand driveshaft21 N.mflange bolt(s) on therelay bearingfront axle subframe tie-rodupper bolts21 N.mpower-assisted steeringlow pressure pipe bolton the front axle sub-frame25 N.m106546 36. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-10K9K10Aa Remove the power-assisted steering low pressurepipe bolt (2) on the front axle subframe.a Remove the cooling pipe support bolt (3) on thesump.a Remove the front axle subframe tie-rod upper bolts(5) .a Remove:- the right-hand driveshaft flange bolt (9) on the relaybearing,- the bolts (10) from the relay bearing,- the relay bearing.24762145789144756135708 37. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-11K9K10Aa Remove:- the bracket bolts (12) ,- one by one, the front axle subframe bolts (11) andreplace them in turn with the threaded rods of the(Tav. 1747).a Lower the front axle subframe 120 mm, graduallyloosening the nuts of the (Tav. 1747).144755Note:Make sure the threaded rod of the (Tav. 1747) issufficiently screwed into the threaded hole andthat the nut of the tool is correctly resting on thefront axle subframe.108645108644 38. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-12K9K10AII - REMOVAL OPERATIONa Remove the power-assisted steering pump supportbolt (13) on the sump.a Remove the bolt from the sump on the multifunctionsupport.a Remove:- the engine-gearbox coupling bolts (14) ,- the sump bolts,- the sump.REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: engine oil sumpseal.a parts always to be replaced: Front sub-framebolt.STANDARD HEATING RECIRCULATION24761AIR CONDITIONING107936Note:If the sump cannot be extracted because it is incontact with the oil pump strainer, do not forcethe removal of the sump as this may damage theoil splash plate.Loosen the oil pump bolts by a few turns (the tipof your finger should pass between the bolt headand the oil pump casing) using 10 mm and 13mm open-jawed spanners and while tilting thesump towards the front of the vehicle.WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks. 39. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-13K9K10Aa Clean the cylinder block joint face using SUPERCLEANING AGENT FOR JOINT FACES (see Ve-hicle:Parts and consumables for the repair)(04B, Consumables - Products).a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consuma-bles- Products) to degrease:- the sump joint face if it is to be reused,- the cylinder block gasket face.a Apply:- four beads (15) of SILICONE ADHESIVE SEAL-ANT(see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) with adiameter of 5 mm,- two drops (16) of SILICONE ADHESIVE SEAL-ANT(see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) with adiameter of 5 mm at the intersection between thecylinder block and the crankshaft closure panel.WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-germarks).WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-tureof sealant and fluid could damage certaincomponents (engine, radiator, etc.).2016620167 40. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-14K9K10AII - REFITTING OPERATIONa20170Note:When refitting the sump, ensure that:- the oil splash plate tabs (17) are positioned cor-rectlyin the slots (18) ,- the coupling faces of the sump and cylinderblock are correctly aligned, to prevent the clutchhousing being deformed when fitting the gear-box.Refit the oil splash plate. 41. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-15K9K10Aa Refit the oil sump fitted with a new seal.a Tighten until contact:- the sump bolts on the cylinder block,- the sump bolts on the gearbox.a Torque tighten:- in order the sump bolts on the cylinder block (14N.m),- the sump bolts on the gearbox (44 N.m).a Refit the sump bolt on the multifunction support.a Torque tighten the sump bolts on the multifunc-tionsupport (25 N.m).a Refit the power-assisted steering pump support onthe sump.a Torque tighten the power assisted steering pumpsupport bolt on the sump (25 N.m).III - FINAL OPERATIONa Fit the front axle subframe.a Refit the brackets.a Torque tighten the bracket bolts (62 N.m).10793620171Note:If the oil pump was loosened beforehand in orderto extract the sump, position the sump in order toslide the oil pump strainer into the oil splash plateof the sump.Position a component jack to support the sump.Lean the sump towards the front of the vehicle inorder to access the oil pump bolts.Torque tighten the oil pump bolts (25 N.m)using the small torque wrench 77 11 226 888.Note:Before pressing the sump on the cylinder block,check that the sump seal is still in place and thatit has not come out of the grooves on the sides.AIR CONDITIONINGSTANDARD HEATING RECIRCULATION 42. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-16K9K10Aa One by one, remove the threaded rods of the (Tav.1747) and replace them in turn with new front axlesubframe bolts.a Refit:- the relay bearing bolts,- the right-hand driveshaft flange bolt(s) on the relaybearing.a Tighten to torque and in order:- the relay bearing bolts (44 N.m),- the right-hand driveshaft flange bolt(s) on therelay bearing (21 N.m).a Refit the front axle subframe tie-rod upper bolts.a Torque tighten the front axle subframe tie-rod up-perbolts (21 N.m).a Refit the cooling pipe support bolt on the sump.a Refit the power-assisted steering low pressure pipebolt on the front axle subframe.a Torque tighten the power-assisted steering lowpressure pipe bolt on the front axle subframe (25N.m).a Refit the catalytic converter upstream stay (see 19B,Exhaust, Catalytic converter: Removal - Refit-ting,page 19B-10) .a Refit the steering box bolts on the front axle sub-frame(see Steering box: Removal - Refitting)(36A, Steering assembly).a Refit:- the steering box heat shield,- the lower arm ball joints (see Front driveshaftlower arm: Removal - Refitting) (31A, Front axlecomponents),- the lower engine tie-bar (see 19D, Engine mount-ing,Lower engine tie-bar: Removal - Refitting,page 19D-8) .a Refit the front bumper (see Front bumper assem-bly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55, Exterior pro-tection).a Refit:- the engine undertray,- the front wheel arch side liners,- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).a Top up the engine oil (see 10A, Engine and cylin-derblock assembly, Engine oil: Draining - Refill-ing,page 10A-32) . 43. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-17K4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove the front bumper (see Front bumper as-sembly:Exploded view) and (see Exterior bodyfront trim assembly: Exploded view) (55A, Exteri-orprotection).a Remove:- the engine undertray bolts,- the engine undertray.a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-32) .a Remove:- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),- the front wheel arch side liners,- the lower engine tie-bar (see 19D, Engine mount-ing,Lower engine tie-bar: Removal - Refitting,page 19D-8) .a Extract the lower arm ball joints from the stub axlecarrier (see Front driveshaft lower arm: Removal- Refitting) (31A, Front axle components).a Unclip the downstream oxygen sensor wiring on theheat shield on the steering box.a Remove (see Steering box: Removal - Refitting)(36A, Steering assembly):- the heat shield bolts on the steering box,- the steering box heat shield,- the steering box bolts on the front axle subframe.a Attach the steering rack to the body.a Remove the power-assisted steering low pressurepipe bolt (1) on the front axle subframe.Special tooling requiredTav. 1747 Threaded rods for carryingout subframe operations.Tightening torquesmsump bolts on the cylin-derblock14 N.msump bolts on the gear-box44 N.msump bolt on the multi-functionsupport25 N.mbracket bolts 62 N.mfront axle subframebolts110 N.mrelay bearing bolts 44 N.mright-hand driveshaft21 N.mflange bolt(s) on therelay bearingfront axle subframe tie-rodupper bolts21 N.mpower-assisted steeringlow pressure pipe bolton the front axle sub-frame21 N.msteering box bolts on thefront axle subframe105 N.m24762 44. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-18K4M10Aa Remove the cooling pipe support bolt (2) on thesump.a Remove the front axle subframe tie-rod upper bolts(4) .a Remove:- the right-hand driveshaft flange bolt (5) on the relaybearing,- the bolts (6) from the relay bearing,- the relay bearing.145789144756135708 45. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-19K4M10Aa Remove:- the bracket bolts (11) ,- one by one, the front axle subframe bolts (10) andreplace them in turn with the threaded rods of the(Tav. 1747).a Lower the front axle subframe by at least 120 mm,gradually loosening the nuts of the (Tav. 1747).144755Note:Make sure the threaded rod of the (Tav. 1747) issufficiently screwed into the threaded hole andthat the nut of the tool is correctly resting on thefront axle subframe.108645108644 46. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-20K4M10AII - REMOVAL OPERATIONa Remove:- the sump bolt from the multifunction support,- the engine-gearbox coupling bolts (12) ,- the sump bolts on the cylinder block,- the sump,- the oil splash plate.REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: engine oil sumpseal.a parts always to be replaced: Front sub-framebolt.a Clean the cylinder block joint face using SUPERCLEANING AGENT FOR JOINT FACES (see Ve-hicle:Parts and consumables for the repair)(04B, Consumables - Products).a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consuma-bles- Products) to degrease:- the sump joint face if it is to be reused,- the cylinder block gasket face.107936WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-germarks).WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-tureof sealant and fluid could damage certaincomponents (engine, radiator, etc.). 47. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-21K4M10Aa Apply:- four beads (13) of SILICONE ADHESIVE SEAL-ANT(see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) with adiameter of 5 mm,- two drops (14) of SILICONE ADHESIVE SEAL-ANT(see Vehicle: Parts and consumables forthe repair) (04B, Consumables - Products) with adiameter of 5 mm at the intersection between thecylinder block and the crankshaft closure panel.II - REFITTING OPERATIONa201662016720170Note:When removing the sump, ensure that:- the oil splash plate tabs (15) are positioned cor-rectlyin the slots (16) ,- the coupling faces of the sump and cylinderblock are correctly aligned, to prevent the clutchhousing being deformed when fitting the gear-box.Refit the oil splash plate. 48. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-22K4M10Aa Refit the oil sump fitted with a new seal.a Tighten until contact:- the sump bolts on the cylinder block,- the bolts from the sump on the gearbox,- the sump bolts from the multifunction support.a Torque tighten:- in order the sump bolts on the cylinder block (14N.m),- the sump bolts on the gearbox (44 N.m),- the sump bolt on the multifunction support (25N.m).III - FINAL OPERATIONa Fit the front axle subframe.a Refit the brackets.a Torque tighten the bracket bolts (62 N.m).a One by one, remove the threaded rods of the (Tav.1747) and replace them in turn with new front axlesubframe bolts.a Torque tighten the front axle subframe bolts (110N.m).a Refit:- the relay bearing bolts,- the right-hand driveshaft flange bolt(s) on the relaybearing.a Tighten to torque and in order:- the relay bearing bolts (44 N.m),- the right-hand driveshaft flange bolt(s) on therelay bearing (21 N.m).a Refit the front axle subframe tie-rod upper bolts.a Torque tighten the front axle subframe tie-rod up-perbolts (21 N.m).a Refit the cooling pipe support bolt on the sump.a Refit the power-assisted steering low pressure pipebolt on the front axle subframe.a Torque tighten the power-assisted steering lowpressure pipe bolt on the front axle subframe (21N.m).a Refit the steering box bolts on the front axle sub-frame.a Tighten to torque the steering box bolts on thefront axle subframe (105 N.m).a Refit:- the steering box heat shield,- the lower arm ball joints (see Front driveshaftlower arm: Removal - Refitting) (31A, Front axlecomponents),- the lower engine tie-bar (see 19D, Engine mount-ing,Lower engine tie-bar: Removal - Refitting,page 19D-8) .10793620171K4M 49. ENGINE AND CYLINDER BLOCK ASSEMBLYLower cover: Removal - Refitting10A-23K4M10Aa Refit the front bumper (see Front bumper assem-bly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55A, Exterior pro-tection).a Refit:- the engine undertray,- the front wheel arch side liners,- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres).a Top up the engine oil (see 10A, Engine and cylin-derblock assembly, Engine oil: Draining - Refill-ing,page 10A-32) . 50. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-24K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove the engine undertray.a Drain the oil from the engine (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-32) .a Remove the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-34) .a Remove the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting,page 19D-8) .a Strap the radiator to the vehicle using safetystrap(s).a Remove the front axle subframe (see Front axlesubframe: Removal - Refitting) (31A, Front axlecomponents).a Remove the relay bearing of the front right-handwheel driveshaft.a Disconnect the oil level sensor connector (ifequipped) (2) .Equipment requiredsafety strap(s)component jackindelible penciltorque wrenchDiagnostic toolTightening torquesmcon rod cap bolts 20 N.m + 45 6oil pump bolts 25 N.mIMPORTANTTo avoid all risk of damage to the systems, applythe safety and cleanliness instructions and opera-tionrecommendations before carrying out anyrepair (see Vehicle: Precautions for the repair) .IMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.123838123834 51. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-25K9K10Aa Remove the catalytic converter upstream stay (3) .aUndo the bolts of the engine oil sump.a Fit a component jack to support the engine oilsump.a Remove the bolts from the engine oil sump.a Detach the engine oil sump, while supporting it withthe component jack.a Tilt the engine oil sump forwards in order to accessthe oil pump bolts.a Partially loosen the oil pump bolts 3 mm to 5 mm.a Detach the oil pump from its position in order to re-movethe engine oil sump.a Remove:- the engine oil sump,- the engine oil sump seal,- the oil pump.112328140940WARNINGFailure to observe the following procedure maydamage the oil pump strainer.140917 52. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-26K9K10AII - REMOVAL OPERATION FOR THE CON RODBEARING SHELLS NO.2a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables- Products) to clean the big ends.a Mark the position of the con rod cap in relation to thecon rod body using a indelible pencil.a Position the crankshaft at Top Dead Centre.a Remove:- the con rod bolts,- the con rod cap,- the lower con rod bearing shell.a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables- products) to clean the bearing mating face onthe con rod cap.139306139300Note:If reusing the con rod bearing shells, mark theposition of the lower con rod bearing shell in rela-tionto the con rod cap. 53. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting139310 13931510A-27K9K10Aa Fit the tie rod of the toolon the con rod body.a Push the con rod upwards to release the con rodfrom the crankpin.a Turn the crankshaft 90 clockwise (timing end).aWARNINGFailure to observe the following procedure maydamage the piston base cooling jets.Pull the con rod - piston assembly using the tie rod ofthe tool, taking care not to allow the piston to touchthe piston base cooling jets.a Remove the upper con rod bearing shell.Note:If reusing the con rod bearing shells, mark theposition of the upper con rod bearing shell inrelation to the con rod body.a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables- products) to clean the bearing mating face onthe con rod body.REFITTINGI - REFITTING OPERATION FOR THE CON RODBEARING SHELLS ON CYLINDER NO.2a parts always to be replaced: con rod cap bolts 54. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-28K9K10AaFit the head of the toolwith the marking " K9K INF "on the threaded sleeve of the tool.a Position the lower con rod bearing shell on the tool.aFit the lower con rod bearing shell on the con rodcap using the tool.a Position the lower con rod bearing shell so that theends do not protrude beyond the con rod cap.a Lubricate the surface of the con rod bearing shell(crankshaft end) using new engine oil.Note:Always replace con rod bearing shells with awidth of 20 mm by con rod bearing shells with awidth of 18 mm.If the set of con rod bearing shells only includescon rod bearing shells which are 18mm wide,only use the head of the toolwith the marking "K9K SUP ".133814133815Note:The contact surface between the bearing shelland the con rod must be dry and free of grease. 55. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-29K9K10Aa Remove the tool head with the marking " K9K INF "and fit the head with the marking " K9K SUP ".a Position the upper con rod bearing shell on the tool.a Fit the upper con rod bearing shell on the con rodbody using the tool.a Position the upper con rod bearing shell so that theends do not protrude beyond the con rod body.a Lubricate the surface of the con rod bearing shell(crankshaft end) using new engine oil.a Push the con rod - piston assembly back up intoplace.a Turn the crankshaft 90 anticlockwise.a Lubricate the crankpin with new engine oil.a Pull the con rod - piston assembly to position the conrod on the crankshaft.aRefit:- the con rod cap according to the mark made duringremoval,- the new con rod bolts.a Torque and angle tighten the con rod cap bolts (20N.m + 45 6).II - REMOVAL - REFITTING OPERATIONS FOR THECON ROD BEARING SHELLS ON CYLINDERSNO.3, 1 AND 4a Perform the same removal - refitting operations asfor the con rod bearing shells on cylinder no. 2.III - FINAL OPERATIONa parts always to be replaced: engine oil sumpsealparts always to be replaced: Oil filterparts always to be replaced: Drain plug seal onengine oil sumpa Use a wooden spatula or an ABRASIVE PAD toclean the joint face of the cylinder block and engineoil sump.a Refit the oil pump.a Fit without tightening the oil pump bolts, while keep-inga clearance of 3 mm to 5 mm.a Fit the engine oil sump seal.139318Note:Before refitting the con rod cap, ensure that thereare no impurities (filings, cloth lint, etc.) on thecon rod body or cap surfaces.Note:For removing and refitting the con rod bearingshells on cylinders no. 1 and no. 4, position thepistons at Bottom Dead Centre before performingthe same removal and refitting operations as forthe con rod bearing shells on cylinder no. 2.WARNINGDo not scrape the joint faces of the aluminium,any damage caused to the joint face will result ina risk of leaks.WARNINGTo ensure proper sealing, the gasket surfacesmust be clean, dry and not greasy (avoid any fin-germarks).WARNINGApplying excess sealant could cause it to besqueezed out when parts are tightened. A mix-tureof sealant and fluid could damage certaincomponents (engine, radiator, etc.). 56. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting10A-30K9K10Aa Apply SILICONE ADHESIVE SEALANT (see Vehi-cle:Parts and consumables for the repair) :- four beads with a diameter of 5 mm at (A) ,- two drops with a diameter of 5 mm at (B) .a Fit the engine oil sump while supporting it using acomponent jack.a Tilt the engine oil sump forwards in order to accessthe oil pump bolts.a Torque tighten the oil pump bolts (25 N.m) usingthe torque wrench PROSTEEL, part number 77 11226 888 starting with the 13 mm bolt.aa Refit the engine oil sump bolts.a Torque tighten in order the engine oil sump bolts(see 10A, Engine and cylinder block assembly,Lower cover: Removal - Refitting, page 10A-9) .a Refit the catalytic converter upstream stay (see 19B,Exhaust, Catalytic converter: Removal - Refit-ting,page 19B-10) .a Connect the connector to the oil level sensor.a Refit the relay bearing of the front right-hand wheeldriveshaft (see Front right-hand driveshaft: Re-moval- Refitting) .a Refit the front axle subframe (see Front axle sub-frame:Removal - Refitting) (31A, Front axle com-ponents).a Remove the safety strap(s) from the radiator.a Refit the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting,page 19D-8) .2016620167140918Note:Check that the engine oil sump seal is definitelyin place before tightening the engine oil sumpbolts. 57. ENGINE AND CYLINDER BLOCK ASSEMBLYConrod bearing shell: Removal - Refitting12382410A-31K9K10Aa Disconnect the crankshaft position sensor (4) to pre-ventthe engine from starting.a Refit the oil filter (see 10A, Engine and cylinderblock assembly, Oil filter: Removal - Refitting,page 10A-34)a Fill up the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-32) .a Start the engine using the starter until the engine oilwarning light goes out.a Connect the crankshaft position sensor.a Refit the engine undertray.a Clear the present faults using the Diagnostic tool. 58. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - Refilling10A-32K4M or K9K10ADRAININGI - AVERAGE CAPACITY OF ENGINE OILa 4.7 litres (without oil filter replacement).a 4.8 litres (with oil filter replacement).a 4.0 litres (without oil filter replacement).a 4.1 litres (with oil filter replacement).II - RECOMMENDATIONS FOR REPAIRaIII - PARTS AND CONSUMABLES FOR REPAIRa parts always to be replaced: Drain plug seal onengine oil sump.a Consumable:- Engine oil (see Engine oil: Specifications) .IV - OIL SERVICEa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove:- the engine oil filler cap (1) ,- the dipstick.a Place the oil recovery tray under the engine.Equipment requiredoil recovery trayoil change wrenchtorque wrenchoil change end piece with an 8 mm square driveTightening torquesmdrain plug 20 N.mK4MK9KWARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(could destroy the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.Note:When filling up the engine oil, always leave atleast 10 minutes for the oil to drain down beforechecking with a dipstick.144629 59. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine oil: Draining - Refilling10A-33K4M or K9K10Aa Remove the drain plug (2) using theor a oil changewrench.a Let the engine oil flow out completely.a Remove the drain plug seal.Rubber-lipped seala Refit a new seal to the drain plug (no direction of fit-ting).a Refit the drain plug.a Torque tighten the drain plug (20 N.m) using atorque wrench fitted with a oil change end piecewith an 8 mm square drive.a Clean any oil run-off from the engine oil sump usinga cloth.a Remove the oil recovery tray.V - FILLINGa Fill the engine with oil, respecting the recommendedquantity.a Wait at least 10 minutes.a Check the oil level using the dipstick.a Top up the engine oil level if necessary.a Refit:- the engine oil filler cap,- the dipstick.144757113765 60. ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting10A-34K9K10AREMOVALOPERATION FOR REMOVAL OF PARTCONCERNEDa Position the (Mot. 1329) (1) with an extension pieceand a ratchet on the oil filter.a Remove the oil filter.REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: Oil filter.a Lubricate the new oil filter seal with new engine oil.II - REFITTING OPERATION FOR PARTCONCERNEDa Tighten the oil filter by hand until the oil filter sealmakes contact with the oil filter support.a Tighten the oil filter 3/4 of a turn manually or usingthe tool (Mot. 1329).III - FINAL OPERATIONa Wipe any oil run-off with a cloth.a Check the oil level with the dipstick.a Top up the oil level (if necessary).Special tooling requiredMot. 1329 Oil filter removing tool (76mm diameter)WARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(could destroy the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.Note:When topping up the engine oil, always leave atleast 10 minutes for the oil to drain down beforechecking with a dipstick.24739 61. ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting10A-35K4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove:- the engine undertray bolts,- the engine undertray.a Place the oil recovery tray under the engine.a Remove the injector rail protector.II - REMOVAL OPERATIONa Remove the oil filter using the (Mot. 1329) (1) .REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: Oil filter.a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consum-ables- Products) to clean and degrease the cylinderblock joint face.a Lubricate the oil filter seal with new engine oil.II - REFITTING OPERATIONa Fit a new oil filter.a Tighten the oil filter until it makes contact with theengine.a Manually tighten the oil filter by 3/4 of a turn.III - FINAL OPERATIONa Refit the injector rail protector.a Remove the oil recovery tray.a Wipe any oil run-off with a cloth.a Top up with engine oil recommended by the manu-facturer(see Engine oil: Specifications) .a Start the engine and wait until the oil pressure warn-inglight goes out on the instrument panel.a Check for leaks from the oil filter.a Refit the engine undertray.a Wait at least 10 minutes.a Check the oil level using the dipstick.Special tooling requiredMot. 1329 Oil filter removing tool (76mm diameter)Equipment requiredoil recovery trayIMPORTANTWear leaktight gloves (Nitrile type) for this opera-tion.WARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(could destroy the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.Note:When filling up the engine oil, always leave at least10 minutes for the oil to drain down before check-ingwith a dipstick.When removing the oil filter, check that the oil filterseal is not still stuck to the cylinder block or the oilfilter support.116556 62. ENGINE AND CYLINDER BLOCK ASSEMBLYOil filter: Removal - Refitting10A-36K4M10Aa Top up the engine oil level to the dipstick if neces-sary(see 10A, Engine and cylinder block assem-bly,Engine oil: Draining - Refilling, page 10A-32). 63. ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting10A-37K9K, and 79610AaREMOVALREMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove:- the engine cover,Tightening torquesmoil heat exchanger bolt 39 N.moil filter support bolt 28 N.m106794- the engine undertray,- the closure panel component under the diesel filter.a Drain the cooling system (see 19A, Cooling, Cool-ingsystem: Draining - Refilling, page 19A-6) .(1) Oil filter holder mounting bolt(2) Oil filter(3) Oil filter holder(4) Coolant - oil heat exchangermounting bolts(5) Coolant - oil heat exchanger(6) Oil pressure sensor 64. ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting10A-38K9K, and 79610Aa Disconnect the air outlet duct (7) on the intercooler.a Move aside the air outlet duct.a Remove the air outlet duct support (8) from the fanassembly mounting.a Disconnect the oil pressure sensor connector (9) .a Place a container under the engine on the oil filterside.a Remove the bolt (10) from the oil filter support.a Remove the oil filter support.a Remove the seal (11) from the oil filter support.2482124811113894133518 65. ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting113895 10730610A-39K9K, and 79610Aa Remove:- the bolt (12) from the oil-coolant heat exchanger,- the oil-water heat exchanger.a Using a clean cloth, clean up any oil and coolantruns on the cylinder block and on the oil filter sup-port.REFITTINGI - REFITTING PREPARATION OPERATIONa parts always to be replaced: coolant-engine oilheat exchanger seal on the cylinder block.a Always replace:- the seals of the oil filter support bolt,- the oil filter support seal.a Remove the oil-water heat exchanger seals (13) .a Use SURFACE CLEANER (see Vehicle: Partsand consumables for the repair) (04B, Consuma-bles- Products) to clean and degrease:- the housing of each seal in the oil-water heat ex-changerif it is to be reused,- the oil-coolant heat exchanger seal face if it is to bereused,- the mating face of each seal on the coolant pumpinlet pipe,- the joint face on the cylinder block,- the housing of each oil filter support seal,- the housing of each seal in the oil filter support. 66. ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting10A-40K9K, and 79610Aa Refit new seals (14) and (15) on the oil-water heatexchanger.a Apply soapy water to the two seals (15) in contactwith the coolant pump inlet pipe.II - REFITTING OPERATION FOR PARTCONCERNEDa Refit the oil-water heat exchanger.a Torque tighten the oil heat exchanger bolt (39N.m).III - FINAL OPERATIONa Refit:- a new seal in the housing of the oil filter support,- the oil filter support, positioning the lug (16) in thehole (17) of the oil-water heat exchanger.a Refit the oil filter holder bolt.a Torque tighten the oil filter support bolt (28 N.m).a Connect the oil pressure sensor connector.a Refit the air outlet duct support on the fan assemblymounting.107306133518107857 67. ENGINE AND CYLINDER BLOCK ASSEMBLYOil-coolant heat exchanger: Removal - Refitting10A-41K9K, and 79610Aa Connect the air outlet duct to the intercooler.a Fill the cooling system (see 19A, Cooling, Coolingsystem: Draining - Refilling, page 19A-6) .a Refit:- the closure panel component under the diesel filter,- the engine undertray,- the engine cover.a Bleed the cooling system (see 19A, Cooling, Cool-ingsystem: Draining - Refilling, page 19A-6) . 68. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure sensor: Removal - Refitting10A-42K9K10Aoil pressure sensor 33 N.mREMOVALTightening torquesmI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove the engine undertray.II - OPERATION FOR REMOVAL OF PARTCONCERNEDa Disconnect the oil pressure sensor connector.a Remove the oil pressure sensor (2) using the.REFITTINGI - REFITTING OPERATION FOR PARTCONCERNEDa Refit the oil pressure sensor.a Torque tighten the oil pressure sensor (33 N.m).a Connect the oil pressure sensor connector.II - FINAL OPERATIONa Refit the engine undertray.113894 69. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure sensor: Removal - Refitting10A-43K4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Remove:- the engine undertray bolts,- the engine undertray.II - REMOVAL OPERATIONa Disconnect the oil pressure sensor connector (1) .a Remove the oil pressure sensor.REFITTINGI - REFITTING OPERATIONa Degrease the mating face of the oil pressure sensoron the cylinder block using SURFACE CLEANER(see Vehicle: Parts and consumables for the re-pair)(04B, Consumables - Products).a Refit the oil pressure sensor.a Torque tighten the oil pressure sensor (35 N.m).II - FINAL OPERATIONa Connect the oil pressure sensor connector.a Refit the engine undertray.Tightening torquesmoil pressure sensor 35 N.m116639 70. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pump: Removal - Refitting10A-44K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-32) .a Remove the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting,page 10A-9) .II - OPERATION FOR REMOVAL OF PARTCONCERNEDa Remove:- the oil pump bolts (1) ,- the oil pump.REFITTINGI - REFITTING PREPARATION OPERATIONa Check for oil pump centering rings on the cylinderblock.II - REFITTING OPERATION FOR PARTCONCERNEDa Refit the oil pump.a Torque tighten the oil pump bolts (25 N.m).III - FINAL OPERATIONa Refit the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting,page 10A-9) .a Top up the engine oil (see 10A, Engine and cylin-derblock assembly, Engine oil: Draining - Refill-ing,page 10A-32) .Tightening torquesmoil pump bolts 25 N.m108646 71. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pump: Removal - Refitting10A-45K4M10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Drain the engine oil (see 10A, Engine and cylinderblock assembly, Engine oil: Draining - Refilling,page 10A-32) .a Remove the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting,page 10A-9) .II - REMOVAL OPERATIONa Remove:- the oil pump bolts (1) ,- the oil pump.REFITTINGI - REFITTING PREPARATION OPERATIONa Check for centering rings on the oil pump.II - REFITTING OPERATIONa Refit the oil pump.a Torque tighten the oil pump bolts (25 N.m).III - FINAL OPERATIONa Refit the sump (see 10A, Engine and cylinderblock assembly, Lower cover: Removal - Refit-ting,page 10A-9) .a Top up the engine oil (see 10A, Engine and cylin-derblock assembly, Engine oil: Draining - Refill-ing,page 10A-32) .Tightening torquesmoil pump bolts 25 N.m108646 72. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: Check10A-46K4M or K9K10AOil pressure tables:End pieces to be used:I - REMOVAL PREPARATION OPERATIONaII - CHECKa Remove the oil pressure sensor (see 10A, Engineand cylinder block assembly, Oil pressure sen-sor:Removal - Refitting, page 10A-42) .a In place of the oil pressure sensor, fit thewith suit-ableadapters using theor a 22 mm long socket.a Start the vehicle.a Monitor the engine oil pressure as the oil tempera-turerises (approximately 80C or the first time theengine cooling fan is activated); it should not be lessthan the pressure at idle speed.a If the oil pressure is lower than the pressure at idlespeed, check that:- the oil filter is not clogged,- dirt or swarf is not present in the engine oil,- the oil pump is in good condition and being correct-lydriven.a Check the oil pressure in comparison with the valuesgiven in the table above.a Switch off the engine.a Remove thewith the end pieces.a Refit the oil pressure sensor (see 10A, Engine andcylinder block assembly, Oil pressure sensor:Removal - Refitting, page 10A-42) .a Wipe any oil run-off with a cloth.a Wait at least 10 minutes.a Check the oil level using the dipstick.EngineMinimum oil pressure(bar)Maxi-mumoilpressure(bar)Idlingspeed3000 rpm 3000 rpmD4D, D4F 1.5 3.9 5.3K7J, K7M 1.3 3.7 5.0EngineMinimum oil pressure(bar)Maxi-mumoilpressure(bar)Idlingspeed4000 rpm 4000 rpmK4M 0.5 3.1 4.4K9K 0.8 3.4 5.2Engine End piecesD4D, D4F C + FK4M, K7J, K7M, K9K E + C + FWARNINGAlways check the oil level using the dipstick.Do not exceed the maximum level on the dipstick(could destroy the engine).Correct the engine oil level if necessary beforedelivering the vehicle to the customer.Note:When topping up the engine oil, always leave atleast 10 minutes before checking the level with adipstick.87363 73. ENGINE AND CYLINDER BLOCK ASSEMBLYOil pressure: Check10A-47K4M or K9K10Aa Top up the engine oil level if necessary (see Engineoil: Specifications) .a Start the vehicle and check that there are no oilleaks at the oil pressure sensor. 74. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING10A-4810AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-fitting)(80A, Battery).a Remove:- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),- the front right-hand wheel arch side liner,- the injector rail protector,- the engine undertray bolts,- the engine undertray.a Remove the front bumper (see Front bumper as-sembly:Exploded view) and (see Exterior bodyfront trim assembly: Exploded view) (55A, Exteri-orprotection).a Disconnect fuel supply pipe on the injector rail.a Remove:- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-2) ,- the alternator (see 16A, Starting - Charging, Al-ternator:Removal - Refitting, page 16A-1) .a Remove (see Power-assisted steering pump: Re-moval- Refitting) (36B, Power-assisted steering):- the bolt from the power-assisted steering highpressure pipe on the cylinder block,- the bolts from the power-assisted steering pump onthe multifunction support (without opening the cir-cuit).a Attach the power-assisted steering pump to the frontend panel.a Disconnect the connector from the air conditioningcompressor.a Remove the air conditioning compressor bolts (with-outopening the circuit) (see Compressor: Remov-al- Refitting) (62A, Air conditioning).a Attach the air conditioning compressor to the sub-frame.II - REMOVAL OPERATIONa Remove:- the multifunction support bolts (1) ,- the multifunction support.Tightening torquesmmultifunction supportbolts on the cylinderblock44 N.mlower bolt of the multi-functionsupport on thesump25 N.m145181 75. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - RefittingK4M, and POWER ASSISTED STEERING, and AIR CONDITIONING10A-4910AREFITTINGI - REFITTING OPERATIONa Refit the multifunction support.a Position bolts (1) to (6) without tightening them.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Loosen bolts (1) and (2) of the multifunction supportby one half-turn.a Pretighten the multifunction support bolt (6) on thesump 5 N.m.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Pretighten in order (3) , (4) , (5) , (6) the multifunctionsupport bolts on the cylinder block (5 N.m).a Torque tighten in order (1) , (2) , (3) , (4) , (5) themultifunction support bolts on the cylinderblock (44 N.m).a Torque tighten the lower bolt of the multifunctionsupport on the sump (25 N.m) (6) .II - FINAL OPERATIONa Refit the air conditioning compressor (see Com-pressor:Removal - Refitting) (62A, Air condition-ing).a Connect the air conditioning compressor connector.a Refit (see Power-assisted steering pump: Remo-val- Refitting) (36B, Power-assisted steering):- the power-assisted steering pump,- the bolt of the power-assisted steering high pres-surepipe on the cylinder block.a Refit:- the alternator (see 16A, Starting - Charging, Al-ternator:Removal - Refitting, page 16A-1) ,- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-2) .a Connect the fuel supply pipe on the injector rail.a Refit the front bumper (see Front bumper assem-bly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55A, Exterior pro-tection).a Refit:- the engine undertray,- the injector rail protector.a Connect the battery (see Battery: Removal - Refit-145181 ting) (80A, Battery). 76. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting10A-50K4M, and STANDARD HEATING RECIRCULATION10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-fitting)(80A, Battery).a Remove:- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),- the front right-hand wheel arch side liner,- the engine undertray bolts,- the engine undertray.a Remove the front bumper (see Front bumper as-sembly:Exploded view) and (see Exterior bodyfront trim assembly: Exploded view) (55A, Exteri-orprotection).a Remove:- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-2) ,- the alternator (see 16A, Starting - Charging, Al-ternator:Removal - Refitting, page 16A-1) .a Remove (see Power-assisted steering pump: Re-moval- Refitting) (36B, Power-assisted steering):- the power-assisted steering pump bolts,- the high pressure pipe bolt on the cylinder block.a Attach the power-assisted steering pump to the frontend panel.II - REMOVAL OPERATIONa Remove:- the multifunction support bolts (2) ,- the multifunction support.Tightening torquesmmultifunction supportbolts on the cylinderblock44 N.mmultifunction supportbolt on the sump25 N.mPOWER ASSISTED STEERING102265 77. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting10A-51K4M, and STANDARD HEATING RECIRCULATION10AREFITTINGI - REFITTING OPERATIONa Refit the multifunction support.a Position bolts (1) to (7) without tightening them.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Loosen bolts (1) and (2) a half-turn.a Pretighten the multifunction support bolt (7) on thesump 5 N.m.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Pretighten the multifunction support bolts (3) , (4) ,(5) , (6) on the cylinder block 5 N.m.a Torque tighten in order (1), (2), (3), (4), (5), (6) themultifunction support bolts on the cylinderblock (44 N.m).a Torque tighten the multifunction support bolt onthe sump (25 N.m) (7) .II - FINAL OPERATIONa Refit (see Power-assisted steering pump: Remo-val- Refitting) (36B, Power-assisted steering):- the power-assisted steering pump,- the power-assisted steering pump bolts,- the high pressure pipe bolt on the cylinder block.a Refit:- the alternator (see 16A, Starting - Charging, Al-ternator:Removal - Refitting, page 16A-1) ,- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-2) .a Refit the front bumper (see Front bumper assem-bly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55A, Exterior pro-tection).a Refit the front right-hand wheel (see Wheel: Re-moval- Refitting) (35A, Wheels and tyres).a Connect the battery (see Battery: Removal - Refit-ting)(80A, Battery).102265POWER ASSISTED STEERING 78. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting10A-52K9K10AREMOVALI - REMOVAL PREPARATION OPERATIONa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Disconnect the battery (see Battery: Removal - Re-fitting)(80A, Battery).a Remove:- the front right-hand wheel (see Wheel: Removal -Refitting) (35A, Wheels and tyres),- the front right-hand wheel arch side liner,- the engine undertray bolts,- the engine undertray,- the front bumper (see Front bumper assembly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55A, Exteriorprotection),- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting,page 11A-2) ,- the alternator (see 16A, Starting - Charging, Al-ternator:Removal - Refitting, page 16A-1) .a Remove the bolts from the power-assisted steeringpump on the multifunction support (without openingthe circuit) (see Power-assisted steering pump:Removal - Refitting) (36B, Power-assisted steer-ing).a Attach the power-assisted steering pump to the frontend panel.a Disconnect the air conditioning compressor connec-tor.a Remove the air conditioning compressor bolts (with-outopening the circuit) (see Compressor: Remov-al- Refitting) (62A, Air conditioning).a Attach the air conditioning compressor to the lowerfront cross member.a Unpick the wiring harness on the multifunction sup-port.II - REMOVAL OPERATIONa Remove:- the multifunction support bolts (1) ,- the multifunction support.Tightening torquesmmultifunction supportbolts on the cylinderblock44 N.mmultifunction supportbolt on the sump25 N.mPOWER ASSISTED STEERING, and STANDARDHEATING RECIRCULATIONAIR CONDITIONING19704 79. ENGINE AND CYLINDER BLOCK ASSEMBLYMultifunction support: Removal - Refitting10A-53K9K10AREFITTINGREFITTING OPERATIONa Refit the multifunction support.a Position bolts (1) to (7) without tightening them.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Loosen bolts (1) and (2) a half-turn.a Pretighten the multifunction support bolt (7) on thesump 5 N.m.a Pretighten the multifunction support bolts (1) and (2)on the cylinder block 5 N.m.a Pretighten the multifunction support bolts (3) , (4) ,(5) , (6) on the cylinder block 5 N.m.a Torque tighten in order (1) , (2) , (3) , (4) , (5) , (6) themultifunction support bolts on the cylinderblock (44 N.m).a Torque tighten the multifunction support bolt onthe sump (25 N.m) (7) .a Proceed in the reverse order to removal.19704 80. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-54K4M10AREMOVALI - REMOVAL PREPARATION OPERATIONaa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Drain the refrigerant circuit using the tool refrigerantcharging station (see Refrigerant circuit: Drain-ing- Filling) (62A, Air conditioning).a Remove:- the air inlet sleeve,- the battery (see Battery: Removal - Refitting)(80A, Battery),- the air resonator (see 12A, Fuel mixture, Air res-onator:Removal - Refitting, page 12A-2) ,- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting, page 12A-6) ,- the injector rail protector,- the battery tray,- the injection computer (see 17B, Petrol injection,Petrol injection computer: Removal - Refitting,page 17B-7) .Special tooling requiredMot. 1448 Remote operation pliers forhose clips.Mot. 1390 Support for removal - refittingof engine - gearbox assemblyEquipment requiredrefrigerant charging stationTightening torquesmnut on the rubber padsupport of the left-handsuspended enginemounting62 N.mexhaust flange bolts 21 N.mfront axle subframe tie-rodupper bolts21 N.manti-roll bar tie rodupper bolts37 N.mearth strap bolt on thegearbox21 N.mpower-assisted steeringlow pressure pipe bolton the front axle sub-frame21 N.mpower-assisted steeringpipe bolts on the gear-boxsupport21 N.mpower-assisted steeringpipe bolts on the gear-box21 N.mpower-assisted steeringpipe bolt on the cylinderblock21 N.mIMPORTANTWear cut-resistant gloves during the operation.IMPORTANTTo prevent the vehicle from falling, lash it to thevehicle lift using a strap.AIR CONDITIONING 81. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-55K4M10Aa Disconnect the accelerator cable on the throttlevalve at (1) .a Remove the accelerator cable from the inlet distribu-torat (2) .a Remove the engine wiring bolt (3) on the batterymounting.a Unclip the battery wiring at (4) .a Remove the earth strap bolt (5) on the batterymounting.a Remove the fuse and relay box cover.a Remove the side protector (6) of the fuse and relaybox.a Disconnect the engine harness - front wiring con-nector(7) .a Unclip the engine harness fuse holders and relays(8) from their mountings on the fuse and relay box inthe engine compartment.a Position the engine harness, fuses and relays on theengine.a Remove:- the front wheels (see Wheel: Removal - Refitting)(35A, Wheels and tyres),- the engine undertray bolts,- the engine undertray,- the front bumper (see Front bumper assembly:Exploded view) and (see Exterior body fronttrim assembly: Exploded view) (55A, Exteriorprotection),- the front wheel arch liners (see Exterior bodyfront trim assembly: Exploded view) (55A, Exte-riorprotection).a Drain:- the engine oil if necessary (see 10A, Engine andcylinder block assembly, Engine oil: Draining -Refilling, page 10A-32) ,- the gearbox oil (see Manual gearbox oils: Drain-ing- Filling) (21A, Manual gearbox),116654145508145507 82. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-56K4M10A- the cooling system (see 19A, Cooling, Coolingsystem: Draining - Refilling, page 19A-6) .a Disconnect:- the fuel supply pipe (9) on the injector rail,- the petrol vapour rebreather pipe (10) .a Fit blanking plugs on the fuel supply pipe.a Unclip the pipes at (11) .a Disconnect the connector (12) from the fuel vapourrecirculation solenoid valve.a Disconnect (see Power-assisted steering pump:Removal - Refitting) (36B, Power-assisted stee-ring):- the power-assisted steering low pressure hose onthe power-assisted steering pump using the (Mot.1448) and drain the circuit,- the power-assisted steering high pressure pipe onthe power-assisted steering pump,- the connector from the power-assisted steeringpressure switch.145510WARNINGTo avoid any corrosion or damage, protect theareas on which fuel is likely to run.145509 83. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-57K4M10Aa Remove:- the power-assisted steering low pressure pipe (13)on the oil reservoir using the (Mot. 1448),- the power assisted steering oil reservoir (14) ,- the bolt of the power-assisted steering high pres-surepipe on the cylinder block.a Unclip the power-assisted steering pipes on the fanassembly mounting at (15) .a Disconnect the fan assembly connector (16) .a Remove:- the power-assisted steering low pressure pipe (17)on the oil reservoir using the (Mot. 1448),- the power assisted steering oil reservoir (18) ,- the bolt of the power-assisted steering high pres-surepipe on the cylinder block.a Unclip the power-assisted steering pipes on the fanassembly mounting at (19) .a Disconnect the connectors (20) from the fan assem-bly.a Unclip the fan assembly wiring at (21) .STANDARD HEATING RECIRCULATION145498AIR CONDITIONING145497 84. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-58K4M10Aa Remove the power-assisted steering low pressurepipe bolt (22) on the front axle subframe.a Remove:- the power-assisted steering high pressure pipe bolt(23) on the gearbox,- the power-assisted steering high pressure pipe bolt(24) on the gearbox support,- the earth strap bolt (25) on the gearbox.a Remove (see Compressor: Removal - Refitting)(62A, Air conditioning):- the pipe retaining bracket bolt on the compressor,- the pipe union bolts on the compressor.a Disconnect the compressor pipes.a Fit blanking plugs in the pipe openings.a Disconnect the air conditioning pressostat connec-tor.a Move aside the cooling hose clips (26) on the cool-antpump inlet pipe using the (Mot. 1448).a Disconnect:- the cooling hoses on the coolant pump inlet pipe,- the vacuum pipe on the inlet distributor chamber.24762145559AIR CONDITIONINGNote:Plugs must be fitted on the hoses to preventmoisture from entering the system.116559 85. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-59K4M10Aa Move aside the clips (27) of the coolant hoses on thewater chamber using the (Mot. 1448).a Disconnect the cooling hoses from the water cham-ber.a Unclip the downstream oxygen sensor wiring on thesteering box heat shield.a Disconnect the downstream oxygen sensor connec-tor.a Remove the cooling pipe support bolt (28) on thesump.a Remove (see ) (36A, Steering assembly):- the heat shield bolts on the steering box,- the steering box heat shield,- the steering box bolts on the front axle subframe.a Attach the steering rack to the body.a Remove:- the front axle subframe tie-rod upper bolts (29) ,- the anti-roll bar tie rod upper bolts (30) ,- the front right-hand wheel driveshaft (see Frontright-hand driveshaft: Removal - Refitting)(29A, Driveshaft),- the front left-hand wheel driveshaft (see Front left-handdriveshaft: Removal - Refitting) (29A,Transmission).a Pass the power-assisted steering low pressure pipeover the gearbox cover.116637145789144756 86. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-60K4M10Aa Unclip:- the gear control cables on the gearbox at (31) us-inga screwdriver,- the gear control cables from the sleeve stops bypressing at (A) .a Move the gear control cables away from the gear-box.aa Disconnect the clutch control pipe on the clutchslave cylinder by pressing the clip (32) .a Recover the brake fluid in a container.a Fit blanking plugs on the pipe openings.a Remove the lower engine tie-bar (see 19D, Enginemounting, Lower engine tie-bar: Removal - Refit-ting,page 19D-8) .11888210914924810WARNINGDo not pull the clip. If it is incorrectly handled inany way, the pipe will need to be replaced. 87. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-61K4M10Aa Remove:- the bolts (33) from the exhaust flange,- the exhaust bracket ring.a Move aside the exhaust pipe.a Remove the front axle subframe (see Front axlesubframe: Removal - Refitting) (31A, Front axlecomponents).II - REMOVAL OPERATIONa Mark the positions of the suspended engine mount-ingson the body.a Support the engine - gearbox assembly on the en-ginemarks (34) using the (Mot. 1390).a Remove the right-hand suspended engine mounting(see 19D, Engine mounting, Right-hand sus-pendedengine mounting: Removal - Refitting,page 19D-4) .135949Note:Pull the exhaust pipe backwards.136472 88. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting107929 12354210A-62K4M10Aa Remove the nut (35) on the rubber pad support ofthe left-hand suspended engine mounting.a Strike the gearbox stud with a copper hammer toseparate the engine - gearbox assembly from thebody.a Lift the vehicle to remove the engine - gearbox as-sembly.Note:Ensure that no component obstructs the move-mentof the body around the engine - gearboxassembly.a Remove the engine - gearbox assembly.REFITTINGI - REFITTING PREPARATION OPERATIONa For standard engine replacements (see Engine:Standard replacement) (Technical Note 6006A,10A, Engine and peripherals).a parts always to be replaced: ring between ex-haustmanifold and catalytic converterII - REFITTING OPERATIONa Fit the engine - gearbox assembly.a Refit the nut on the rubber pad support of the left-handsuspended engine mounting.a Torque tighten the nut on the rubber pad supportof the left-hand suspended engine mounting (62N.m).a Refit the right-hand suspended engine mounting(see 19D, Engine mounting, Right-hand sus-pendedengine mounting: Removal - Refitting,page 19D-4) . 89. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-63K4M10Aa Remove the (Mot. 1390) from the engine - gearboxassembly.III - FINAL OPERATIONa Proceed in the reverse order to removal.a Torque tighten:- the exhaust flange bolts (21 N.m),- the front axle subframe tie-rod upper bolts (21N.m),- the anti-roll bar tie rod upper bolts (37 N.m),- the earth strap bolt on the gearbox (21 N.m),- the power-assisted steering low pressure pipebolt on the front axle subframe (21 N.m),- the power-assisted steering pipe bolts on thegearbox support (21 N.m),- the power-assisted steering pipe bolts on thegearbox (21 N.m),- the power-assisted steering pipe bolt on thecylinder block (21 N.m).a Perform the following operations:- top up the engine oil (see 10A, Engine and cylin-derblock assembly, Engine oil: Draining - Re-filling,page 10A-32) ,- fill up the gearbox oil (see Manual gearbox oils:Draining - Filling) (21A, Manual gearbox),- fill and bleed the cooling circuit (see 19A, Cooling,Cooling system: Draining - Refilling, page 19A-6) ,- bleed the clutch circuit (see Clutch circuit: Bleed)(37A, Mechanical component controls).a Fill the refrigerant circuit using the tool refrigerantcharging station (see Refrigerant circuit: Drain-ing- Filling) (62A, Air conditioning).a Fill up the power-assisted steering circuit.a First, bleed the power-assisted steering circuit byturning the steering wheel fully from left to right withthe engine off.a Bleed the power-assisted steering circuit by turningthe steering wheel fully from lock to lock with the en-ginerunning.a Top up the oil in the power-assisted steering oil res-ervoir.a Check that there are no leaks.AIR CONDITIONING 90. ENGINE AND CYLINDER BLOCK ASSEMBLYEngine - gearbox assembly: Removal - Refitting10A-64K9K, and 79610AREMOVALI - REMOVAL PREPARATION OPERATIONaa Position the vehicle on a two-post lift (see Vehicle:Towing and lifting) (02A, Lifting equipment).a Drain the refrigerant circuit using the tool refrigerantcharging station (see Refrigerant circuit: Drain-ing- Filling) (62A, Air conditioning).a Remove:- the engine cover,- the air inlet sleeve,- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting, page 12A-6) ,- the battery (see Battery: Removal - Refitting)(80A, Battery),- the battery tray,- the injection computer (see 17B, Petrol injection,Petrol injection computer: Removal - Refitting,page 17B-7) .Special tooling requiredMot. 1448 Remote operation pliers forhose clips.Mot. 1390 Support for removal - refittingof engine - gearbox assemblyEquipment requiredrefrigerant charging stationTightening torquesmnut on the rubber padsupport of the left-handsuspended enginemounting62 N.mexhaust flange bolts 21 N.mfront axle subframe tie-rodupper bolts21 N.manti-roll bar tie rodupper bolts37 N.mearth strap bolt on thegearbox21 N.mpower-assisted steeringlow pressure pipe bolton the front axle sub-frame21 N.mpower-assisted steeringpipe bolts on the gear-boxsupport21 N.mpower-assisted steeringpipe bolts on the gear-box21 N.mp