TOP AND FRONT OF ENGINE

Pressure at end of compression: Check 11A

K4M
II - TEST OPERATION
Equipment required a Press the vehicle start button to trigger the engine
starting phase.
petrol compression gauge

Diagnostic tool
Note:
The engine will be driven by the starter for 20
CHECK seconds, without being started.

a Measure the compression of cylinder no.1.

I - PREPARATION OPERATION FOR CHECK
a Fully depress the accelerator pedal in order to open
a Remove: the throttle valve during the compression measure-
ments.
- the engine cover,

- the ignition coils (see Coils: Removal - Refitting) , Note:

Put the vehicle under forced + after ignition feed

cardiagn.com
- the spark plugs (see Plugs: Removal - Refitting) .
as soon as the starter has stopped (in order to
a Disconnect the injector connectors. maintain the inhibition of the engine starting and
to be able to measure the compression of the
other cylinders).

Note:
It is necessary to wait for at least 10 seconds
before starting the engine each time (the starter
will not run due to its thermal protection).

a Measure the compression of the other cylinders.

III - FINAL OPERATION

a Disconnect the petrol compression gauge.

a Connect the injector connectors.

a Refit:

- the spark plugs (see Plugs: Removal - Refitting) ,

136451 - the ignition coils (see Coils: Removal - Refitting) ,

a Connect a petrol compression gauge (1) . - the engine cover.

a Run command with Diagnostic tool : a Remove the card from the reader to interrupt the +
after ignition feed and wait for the loss of communi-
- RZ003 : "ADAPTATIFS MOTEUR", cation message to appear on the Diagnostic tool.

- VP036 : "INHIBITION ALIMENTATION CAR-

BURANT". Note:

a Put the vehicle under starting conditions: If the message does not appear, wait 9 minutes.

- gear lever in neutral position for manual gearbox, a When the loss of communication message appears
or after waiting 9 minutes, force the vehicle's + after
- brake pedal depressed. ignition feed.

11A-1
 TOP AND FRONT OF ENGINE
Pressure at end of compression: Check 11A
K9K

Equipment required K9K, and 830 or 838

diesel compression gauge

self-contained starter

Diagnostic tool

CHECK

I - PREPARATION OPERATION FOR CHECK

a Remove the preheater plugs (see 13C, Preheating,
Heater plugs: Removal - Refitting, page 13C-2) .

K9K, and 832 or 842

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135874

a Disconnect the connector (5) from the fuel pressure

regulation solenoid valve.

II - TEST OPERATION

134706
a Disconnect:
- the connector (1) for the fuel pressure regulation
solenoid valve,
- the connector (2) from the fuel flow regulating sole-
noid valve.

136734

a Use an open-jawed spanner to moderately tighten:

- the hose end piece,

11A-2
 TOP AND FRONT OF ENGINE
Pressure at end of compression: Check 11A
K9K
- the adapter of the diesel compression gauge on a Undo:
the.
- the diesel compression gauge on the hose end
piece,
- the flexible end pieceusing an open-jawed span-
ner.
a Remove the flexible end piecewhich was fitted in
place of one of the removed plugs.

III - FINAL OPERATION

a Connect the connector to the fuel pressure regula-
tion solenoid valve.

K9K, and 832 or 842

a Connect the connector to the fuel flow regulation so-
lenoid valve.

cardiagn.com
a Refit the heater plugs (see 13C, Preheating, Heater
136733 plugs: Removal - Refitting, page 13C-2) .
a Moderately tighten the unions of the diesel com-
pression gauge using an open-jawed spanner.
a Connect the self-contained starter.
a Force the vehicle's + after ignition feed.
a Connect the Diagnostic tool.
a Run commands:
- RZ009 "Apprentissage fonctions véhicule",
- VP036 "Inhibition alimentation carburant.
a Operate the starter for 15 seconds until the needle
of the diesel compression gauge stabilises to ob-
tain the maximum value.
a Make progress with the diagram sheet.
a Carry out the same procedure for the other cylin-
ders.
a Check that the cylinder compression values are all
approximately equal.

Note:
The pressure value after compression must be at
least 18 bar.

a Run the command VP037 "Arrêt inhibition alimen-

tation carburant.
a Disconnect:
- the Diagnostic tool,
- the self-contained starter.

11A-3
 TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K4M

Tightening torquesm

tensioning roller bolt 40 N.m

bolts of the fairing sup- 21 N.m

port under the engine

IMPORTANT
Wear protective gloves during the operation.

WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.

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143770

REMOVAL a Remove:

- the bolts (1) of the fairing support under the engine,

I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle: - the fairing support under the engine.
Towing and lifting) (02A, Lifting equipment).
a Remove: II - OPERATION FOR REMOVAL OF PART
CONCERNED
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection).

135891

a Turn the accessories belt auto tensioner clockwise

using a 16 mm spanner.

a Remove the accessories belt.

11A-4
 TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K4M
a Remove:
- the tensioning roller bolt,
- the tensioning roller.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Accessories belt
(10,10,01,03).
a parts always to be replaced: Accessories belt
tensioning roller (10,10,01,04).
a Use a brush to remove any deposits from the crank-
shaft pulley V-grooves.

II - REFITTING OPERATION FOR PART

cardiagn.com
CONCERNED
a Refit a new tensioning roller.
a Tighten to torque the tensioning roller bolt (40
N.m).
a Turn the accessories belt tensioning roller clockwise
using a 16 mm spanner.
a Refit a new accessories belt.
a Rotate the crankshaft clockwise twice to balance the
accessories belt tension on every pulley.
a Refit the fairing support under the engine.
a Torque tighten the bolts of the fairing support un-
der the engine (21 N.m).

III - FINAL OPERATION

a Refit:
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).

11A-5
 TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Equipment required

offset spanner

Tightening torquesm

new accessories belt 40 N.m

tensioning roller bolt

IMPORTANT
Wear protective gloves during the operation.

WARNING

cardiagn.com
Do not run the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.

135477
REMOVAL a Turn the accessories belt tensioning roller clockwise
at (1) using a 16 mm offset spanner.
I - REMOVAL PREPARATION OPERATION a Remove the accessories belt.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the engine undertray bolts,
- the engine undertray.

135490
a Remove:
- the accessories belt tensioning roller bolt (2) ,
- the accessories belt tensioning roller.

11A-6
 TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A
K9K

REFITTING

I - REFITTING PREPARATION OPERATION

a

WARNING
Only use brushes with plastic or non-corrosive
metal (brass) bristles.

a Use a brush to remove any deposits from the crank-

shaft accessories pulley V grooves.
a parts always to be replaced: Accessories belt
(10,10,01,03).
a parts always to be replaced: Accessories belt
tensioning roller (10,10,01,04).
a parts always to be replaced: Accessories ten-
sioning roller bolt (10,10,01,09).

cardiagn.com
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit a new accessories belt tensioning roller.
a Torque tighten the new accessories belt tension-
ing roller bolt (40 N.m).
a Refit a new accessories belt.
a Rotate the crankshaft clockwise through two revolu-
tions (timing end).

III - FINAL OPERATION

a Refit:
- the engine undertray,
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).

11A-7
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

crankshaft accessories 120 N.m + 95˚

pulley bolt ± 15˚

TDC pin plug 23 N.m

WARNING
Do not run the engine without the accessories belt
to avoid damaging the crankshaft accessories pul-
ley.

IMPORTANT
Wear protective gloves during the operation.

cardiagn.com
REMOVAL
135491
I - REMOVAL PREPARATION OPERATION
a Remove:
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). - the crankshaft accessories pulley bolt (3) ,

a Remove: - the crankshaft accessories pulley (4) .

- the engine cover,

REFITTING
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
I - REFITTING PREPARATION OPERATION
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re- a parts always to be replaced: Crankshaft acces-
fitting) (55A, Exterior protection), sories pulley bolts (10,03,03,10).
- the engine undertray bolts,
- the engine undertray, WARNING
Only use brushes with plastic or non-corrosive
- the accessories belt (see 11A, Top and front of metal (brass) bristles.
engine, Accessories belt: Removal - Refitting,
page 11A-4) . a If reusing the crankshaft accessories pulley, clean
the crankshaft accessories pulley V-grooves with a
brush to eliminate any deposits.

11A-8
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K9K

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107272 135471
a Refit the old crankshaft accessories pulley bolt (5) a Screw toolinto the cylinder block.
with a spacer (6) .
a Remove the old bolt from the crankshaft accessories
a Turn the crankshaft clockwise (timing end) using the pulley fitted with its spacer.
old bolt of the crankshaft accessories pulley, until
the collet of the crankshaft timing pinion (7) is almost
II - REFITTING OPERATION FOR PART
vertical and facing upwards.
CONCERNED
a Refit:
- the crankshaft accessories pulley,
- a new crankshaft accessories pulley bolt.

135472
a Remove the TDC setting pin plug (8) .

11A-9
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K9K

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14489

a Turn the crankshaft clockwise (timing end) smoothly

using the bolt of the crankshaft accessories pulley,
until the crankshaft presses against the tool (9) .

a Torque tighten the crankshaft accessories pulley

bolt (120 N.m + 95˚ ± 15˚).

III - FINAL OPERATION

a Remove thefrom the cylinder block.

a Apply a drop of SILICONE ADHESIVE SEALANT

(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products) to the thread
of the TDC pin plug.

a Tighten to torque the TDC pin plug (23 N.m).

a Refit:

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the engine undertray,

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the front right-hand wheel (see Wheel: Removal -

Refitting) (35A, Wheels and tyres),

- the engine cover.

11A-10
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K4M

Special tooling required

Mot. 1489 TDC locating pin.

Tightening torquesm

new bolt of the crank- 40 N.m + 145˚

shaft accessories pulley ± 15˚

lifting eye bolts 10 N.m

dipstick guide tube bolt 10 N.m

TDC pin plug 25 N.m

cardiagn.com
IMPORTANT
Wear protective gloves during the operation. 136454
a Remove:
- the nut (2) securing the engine wiring on the lifting
eye,
WARNING
Do not run the engine without the accessories belt - the dipstick guide bolt (3) from the lifting eye.
to avoid damaging the crankshaft accessories pul-
a Unclip the engine wiring connector (4) from the lifting
ley.
eye.
a Move aside the engine wiring.
REMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).

a Remove:

- the throttle valve (see 12A, Fuel mixture, Throttle

valve: Removal - Refitting, page 12A-12) ,

- the front right-hand wheel (see Wheel: Removal -

Refitting) (35A, Wheels and tyres),

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the engine undertray bolts,

135260
- the engine undertray,
a Remove:
- the accessories belt (see 11A, Top and front of
- the lifting eye bolts (5) ,
engine, Accessories belt: Removal - Refitting,
page 11A-4) . - the lifting eye.

11A-11
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K4M

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14491 14489

a Pierce the centre of the plugs (6) at the camshaft a Turn the crankshaft in its operating direction (clock-
ends with a screwdriver. wise at timing end), until the crankshaft presses
against the TDC setting pin (Mot. 1489).
a Remove:
- the plugs from the camshaft ends with a screwdriv-
er,
- the TDC setting pin plug (7) .

135905
a The camshaft grooves (10) must be horizontal and
offset downwards.
a Remove the TDC setting pin (Mot. 1489).
14491-1

a Position the camshaft grooves (8) almost horizontal-

ly and offset towards the bottom turning the crank-
shaft in the operating direction (clockwise at timing
end).
a Screw in the TDC setting pin (Mot. 1489) (9) .

11A-12
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K4M

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Crankshaft acces-
sories pulley bolts (10,10,01,11).
a parts always to be replaced: Inlet camshaft cap
(10,02,02,11).
a parts always to be replaced: Exhaust camshaft
cap (10,02,02,12).

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135257
a Lock the flywheel using a screwdriver.

II - OPERATION FOR REMOVAL OF PART

CONCERNED

135240
a Fit:
- the timing tool (12) fitted with the (13) ,
- a lifting eye bolt (14) to secure the timing toolfitted
with the.

135907
a Remove:
- the crankshaft accessories pulley bolt (11) ,
- the crankshaft accessories pulley.

11A-13
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K4M
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the accessories crankshaft pulley with a new
bolt.
a Torque tighten the new bolt of the crankshaft ac-
cessories pulley (40 N.m + 145˚ ± 15˚).

III - FINAL OPERATION

a Remove:
- the TDC setting pin (Mot. 1489),
- the lifting eye bolt from the timing toolfitted with the,
- the timing toolfitted with the.
a Refit:
- a new inlet camshaft plug using the,

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- a new exhaust camshaft plug using the,
14489-2
- the lifting eye.
a Screw in the TDC setting pin (Mot. 1489).
a Torque tighten the lifting eye bolts (10 N.m).
a Check that the crankshaft is pressing against the
TDC setting pin. a Fit the engine wiring on the lifting eye.

a The crankshaft groove must be upwards.

K4M
a Clip the engine wiring connector on the lifting eye.
a Refit:

- the engine wiring retaining bolt on the lifting eye,

- the dipstick guide on the lifting eye.
a Torque tighten the dipstick guide tube bolt (10
N.m).

a Place a drop of SILICONE ADHESIVE SEALANT

(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products) on the thread
of the TDC setting pin plug.
a Refit the TDC setting pin plug.
a Torque tighten the TDC pin plug (25 N.m).
135257 a Refit:
a If the crankshaft is not pressing against the TDC set- - the accessories belt (see 11A, Top and front of
ting pin, bring the crankshaft back by turning the fly- engine, Accessories belt: Removal - Refitting,
wheel using a screwdriver. page 11A-4) ,
- the engine undertray,
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

11A-14
 TOP AND FRONT OF ENGINE
Crankshaft accessories pulley: Removal - Refitting 11A
K4M
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-12) .

cardiagn.com

11A-15
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

Equipment required K9K, and 830 or 838

offset spanner a Remove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

Tightening torquesm

timing belt tensioning 27 N.m

roller bolt

camshaft pulley hub 14 N.m

bolts

new crankshaft acces- 120 N.m + 95 ±

sories pulley bolt 15˚

TDC setting pin plug 25 N.m

cardiagn.com
REMOVAL

I - REMOVAL PREPARATION OPERATION

a 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). 107272
a Refit the old crankshaft accessories pulley bolt with
a Remove: a spacer (which does not cover the crankshaft timing
sprocket mark) on the crankshaft.
- the engine cover,
a Remove the right-hand suspended engine mounting
(see 1 9 D , Engine mounting, Right-hand sus-
- the front wheels (see Wheel: Removal - Refitting)
pended engine mounting: Removal - Refitting,
(35A, Wheels and tyres), page 19D-5) .
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray,

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) .

11A-16
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

K9K, and 832 or 842

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135493

135495

135492

135494

11A-17
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

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135475

135476

a Remove:

- the upper timing cover (1) by pressing on the clips

(2) ,

- the bolt (3) from the intermediate timing cover (4) ,

- the intermediate timing cover (4) by pressing on the

clips (5) ,

- the lower timing cover (6) by pressing on the clips

(7) .

11A-18
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

K9K, and 830 or 838

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136660

136654

136662
a Unclip the upper timing cover at (8) .
136656 a Remove:
- the bolt (9) from the upper timing cover,
- the upper timing cover,
- the lower timing cover by pressing the clips (10) .

11A-19
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

K9K, and 832 or 842 K9K, and 830 or 838

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135496
136658
a Remove the bolts (11) from the right-hand suspend-
ed engine mounting support on the cylinder head. a Remove the bolts (12) from the right-hand suspend-
ed engine mounting support on the cylinder head.

a Remove the right-hand suspended engine mounting

support.

135472

a Remove the TDC setting pin plug (13) .

11A-20
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED

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14489-1
a Turn the crankshaft clockwise (timing end) smoothly
107270 until the crankshaft comes in contact with the.
a Turn the crankshaft clockwise (timing end) using the
old crankshaft accessories pulley bolt and its spacer
to position the hole (14) of the camshaft pulley hub
almost opposite the hole (15) in the cylinder head.

109049
a Insert the tool (17) in the holes of the camshaft pul-
ley hub and the hole of the cylinder head.

135471
a Screw tool (16) into the cylinder block.

11A-21
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
II - REFITTING OPERATION FOR PART
CONCERNED

K9K, and 832 or 842

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109046
a Undo the timing belt tensioning roller bolt (18) .
a Loosen the timing belt tensioning roller by turning
the eccentric cam using a 6 mm Allen key.
a Remove: 109042

- the timing belt,

- the timing belt tensioning roller bolt,
- the timing belt tensioning roller.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Timing belt (10,02,
04,02).
a parts always to be replaced: Timing belt tension-
ing roller (10,02,04,04).
a parts always to be replaced: Crankshaft acces-
sories pulley bolts (10,03,03,10).
a Always replace the timing belt tensioning roller bolt.

109043

a Refit the new timing belt tensioning roller.

a Fit the timing belt tensioning roller lug (19) in the cyl-
inder head groove (20) .

a Check that:

- the mark (21) on the high-pressure pump is offset

by one tooth to the right of the vertical axis (22) ,

11A-22
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
- the crankshaft is resting on the tool(the cotter (23)
of the crankshaft timing sprocket must be vertical
and upwards). K9K, and 830 or 838

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136389

109043
a Refit the new timing belt tensioning roller.
a Fit the timing belt tensioning roller lug (29) in the cyl-
inder head groove (30) .
a Check that:
- Check that the mark (31) on the high pressure
pump is opposite the bolt head (32) .

11A-23
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
- the crankshaft is resting on the tool(the cotter (33)
of the crankshaft timing sprocket upwards).

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14489

a Check that the crankshaft is resting on the toolwhile

turning the crankshaft clockwise using the old crank-
shaft accessories pulley bolt and its spacer.

109049

a Remove the bolt (34) from the camshaft pulley hub.

a Loosen the other bolts of the camshaft pulley hub by

one turn.

11A-24
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

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109044

a Fit the new timing belt starting with the crankshaft

sprocket.
a Align the timing belt marks with the marks:
- of the crankshaft timing sprocket,
- of the camshaft pulley,
- of the high pressure pump pulley.

Note:
There should be 19 timing belt tooth grooves
between the marks on the camshaft pulley and
the high pressure pump pulley and 51 timing belt
tooth grooves between the marks on the crank-
shaft timing sprocket and the high pressure
pump pulley.

19658

a Bring the timing belt tensioning roller adjustable in-

dex (35) opposite the lug (36) using a 6 mm Allen
key, turning it anti-clockwise.
a Tighten the timing belt tensioning roller bolt.

11A-25
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

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109047
a

Note:
Check that the camshaft pulley hub bolts are not
fully up against the camshaft pulley wheel.

11A-26
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

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109045
a Refit the camshaft pulley hub lower bolt (37) .
a Tighten the camshaft pulley hub bolts.
a Remove:
- the,
- the.

11A-27
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K

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107270 109048
a
a Turn the crankshaft two turns clockwise (timing end)
using the old crankshaft accessories pulley bolt and Note:
its spacer until the hole (38) of the camshaft pulley
hub is opposite the hole (39) in the cylinder head: If the tooldoes not engage correctly:
-loosen the camshaft pulley hub bolts by up to
- screw toolinto the cylinder block, one turn,

- turn the crankshaft clockwise (timing end) smoothly -tur n the camshaft pulley hub using an 18mm
using the old crankshaft accessories pulley bolt offset spanner to set the camshaft pulley hub,
and its spacer, until the crankshaft comes into con- -do not retighten the camshaft pulley hub bolts.
tact with the.
a Loosen the camshaft pulley hub bolts by one turn.

Note:
After the two turns, the adjustable index of the
tensioning roller may be in two different positions.
The rotation of the tension wheel eccentric
depends on the position.

109049

a Set the camshaft pulley hub using the tool (40) .

11A-28
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
First position of the index of the timing belt Second position of the adjustable index of the
tensioning roller timing belt tensioning roller

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111083 111082

111081
111081
a Loosen the timing belt tensioning roller bolt by up to
one turn while holding the adjustable index with a 6 a Loosen the timing belt tensioning roller bolt by up to
mm Allen key. one turn while holding the adjustable index with a 6
mm Allen key.
a Gradually align the adjustable index of the timing
belt tensioning roller in the middle of the timing win- a Gradually position the adjustable index of the timing
dow by turning the key anticlockwise. belt tensioning roller in the middle of the timing win-
dow by turning the key clockwise.

a Torque tighten:

- the timing belt tensioning roller bolt (27 N.m),

- the camshaft pulley hub bolts (14 N.m).

11A-29
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
a Remove:
- the,
- the.
a Turn the crankshaft two turns clockwise (timing end)
using the old crankshaft accessories pulley bolt and
its spacer until the hole of the camshaft pulley hub is
opposite the hole in the cylinder head.
a Screw toolinto the cylinder block.
a Turn the crankshaft clockwise (timing end) smoothly
using the old crankshaft accessories pulley bolt and
its spacer, until the crankshaft comes into contact
with the tool.

cardiagn.com
123839

a Refit the lower timing cover by positioning the lower

timing cover tab in the inner cover opening.

K9K, and 832 or 842

a Clip on the lower timing cover.

a Refit the intermediate timing cover.

a Clip on the intermediate timing cover.

a Refit:

109049 - the intermediate timing cover bolt,

a Set the camshaft pulley hub using the tool.
- the upper timing cover.
a If the tooldoes not engage, repeat the timing belt re-
fitting operation. a Clip on the upper timing cover.

III - FINAL OPERATION

a Refit the right-hand suspended mounting support.

K9K, and 830 or 838

a Clip on the lower timing cover.

a Refit:

- the upper timing cover,

- the upper timing cover bolt.

a Clip on the upper timing cover.

11A-30
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K9K
a Remove the tool.
K9K, and 830 or 838 a Apply a drop of SILICONE ADHESIVE SEALANT
(see Vehicle: Parts and consumables for the re-
a Refit the camshaft position sensor (see 13B, Diesel pair) (04B, Consumables - Products) to the thread
injection, Camshaft position sensor: Removal - of the TDC setting pin plug.
Refitting, page 13B-8) .
a Torque tighten the TDC setting pin plug (25 N.m).
a Refit:
- the accessories belt (see 11A, Top and front of
a Refit the right-hand suspended engine mounting engine, Accessories belt: Removal - Refitting,
(see 1 9 D , Engine mounting, Right-hand sus- page 11A-4) ,
pended engine mounting: Removal - Refitting,
page 19D-5) . - the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),

K9K, and 830 or 838 - the engine undertray,

- the front section of the front wheel arch liners (see
a Refit the lower engine tie-bar (see 19D, Engine
Front wheel arch liner: Removal - Refitting)
mounting, Lower engine tie-bar: Removal - Refit-
(55A, Exterior protection),

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ting, page 19D-10) .
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the engine cover.
a Remove the old crankshaft accessories pulley bolt
with its spacer. a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
a Refit:
- the crankshaft accessories pulley,
- a new crankshaft accessories pulley bolt.

14489
a Turn the crankshaft clockwise (timing end) smoothly
using the bolt of the crankshaft accessories pulley,
until the crankshaft presses against the tool.
a Torque tighten a new crankshaft accessories pul-
ley bolt (120 N.m + 95 ± 15˚).

11A-31
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839
- the lower engine tie-bar (see 19D, Engine mount-
Special tooling required ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,
Mot. 1489 TDC locating pin.
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,
Tightening torquesm
- the right-hand suspended engine mounting (see
timing fixed roller bolt 50 N.m 19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
nut of the timing ten- 7 N.m 19D-5) .
sioning roller (initial
torque)

lower timing cover bolts 12 N.m

exhaust camshaft 30 N.m + 84˚ ±

sprocket nut 4

camshaft dephaser bolt 100 N.m

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timing tension wheel nut 27 N.m

flywheel end lifting eye 10 N.m

bolts

TDC pin plug 20 N.m

upper timing cover bolts 46 N.m

upper timing cover nuts 46 N.m

REMOVAL
135906
a Remove:
I - REMOVAL PREPARATION OPERATION
- the bolts (1) from the upper timing cover,
a Position the vehicle on a two-post lift (see Vehicle:
- the upper timing cover nuts (2) ,
Towing and lifting) (02A, Lifting equipment).
- the upper timing cover,
a Disconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery). - the lower timing cover bolts (3) ,

a Remove: - the lower timing cover.

- the throttle valve (see 12A, Fuel mixture, Throttle

valve: Removal - Refitting, page 12A-12) ,

- the front right-hand wheel (see Wheel: Removal -

Refitting) (35A, Wheels and tyres),

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray,

- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

11A-32
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839
II - OPERATION FOR REMOVAL OF PART a parts always to be replaced: Exhaust camshaft
CONCERNED cap (10,02,02,12).
a parts always to be replaced: Crankshaft acces-
sories pulley bolts (10,03,03,10).
a parts always to be replaced: Camshaft dephaser
sprocket bolt (10,02,02,06).
a parts always to be replaced: Exhaust camshaft
pulley nut (10,02,02,13).

II - REFITTING OPERATION FOR PART

CONCERNED
a Remove the camshaft dephaser (see 11A, Top and
front of engine, Camshaft dephaser: Removal -
Refitting, page 11A-87) .

1 - Adjusting the timing

cardiagn.com
a

Note:

103268
If the stud is loosened with the nut (see 11A, Top
and front of engine, Camshaft: Removal -
a Loosen the nut (4) of the timing tensioning roller. Refitting, page 11A-54) .

Note:
WARNING
Do not drop the crankshaft timing sprocket when
removing the timing belt. Always degrease:
- the end of the crankshaft (timing end),
a Remove:
- the timing sprocket pressure faces and bore of
- the bolt (5) of the timing fixed roller, the crankshaft,
- the timing fixed roller, - the crankshaft accessories pulley bearing
- the timing belt, faces,

- the timing tensioning roller nut, - the camshaft ends (timing end),
- the camshaft sprocket bores and bearing faces.
- the timing tensioning roller,
This is to avoid timing slippage.
- the crankshaft timing sprocket.
This slippage leads to engine damage.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Timing belt (10,02,
04,02).
a parts always to be replaced: Timing belt tension-
ing roller (10,02,04,04).
a parts always to be replaced: Timing fixed roller
(10,02,04,05).
a parts always to be replaced: Inlet camshaft cap
(10,02,02,11).

11A-33
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839

cardiagn.com
14490 111337

a Fit thewith the (6) .

103261
a Position the camshaft grooves horizontally and be-
111336
low the centre line, by turning the camshafts with
theif necessary. a Fit:
- the (7) fitted with theon the end of the camshaft,

- a lifting eye bolt (8) to secure the toolequipped with

the tool.
a Refit:

- the camshaft dephaser (see 11A, Top and front of

engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-87) ,
- the crankshaft timing sprocket.

11A-34
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839

cardiagn.com
14489 135257
a Refit the tool (Mot. 1489) (9) on the cylinder block.

132387
a Use a screwdriver to check that the flywheel does
not turn (clockwise at the timing end), otherwise
bring the crankshaft back into contact with the tool
(Mot. 1489) (9) using the screwdriver; the crank-
shaft groove (11) should be at the top.

11A-35
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839
2 - Refitting

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130492
a Position: 108879
a Refit a new timing tensioning roller by positioning the
- the RENAULT badge (12) etched on the stem of
lug of the timing tensioning roller in the groove (15) .
the exhaust camshaft sprocket vertically and point-
ing upwards, a Screw on the timing tensioning roller nut without
tightening it.
- the camshaft dephaser mark (13) vertically and
pointing upwards.
a Make a mark (14) with a pencil between the cam-
shaft dephaser gear and the rocker cover.

11A-36
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839

cardiagn.com
130495 130497
a Refit a new timing belt starting with the sprocket of a Refit a new timing fixed roller (17) .
each camshaft (without moving the sprocket of each
camshaft). a Torque tighten the timing fixed roller bolt (50
a Fit the tool (16) on the camshaft sprockets (use the N.m).
bolt and nut of the upper timing cover to fit the tool).
3 - Timing belt tension
Note:
Take care to properly tighten the timing belt
between the two camshaft sprockets.

Note:
Take care to properly tighten the timing belt
between the exhaust camshaft sprocket and the
crankshaft timing sprocket.

103263

a Position the adjustable index (18) opposite the mark

(19) , by turning the eccentric (20) clockwise using
an Allen key.

a Torque tighten the nut of the timing tensioning

roller (initial torque) (7 N.m).

11A-37
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839

cardiagn.com
130497 109052
a Refit the lower timing cover (21) . a Remove:
a Tighten to torque the lower timing cover bolts (12 - the timing flap from the lower timing cover,
N.m).
- the lifting eye bolt from the,
a Refit the crankshaft accessories pulley (see 11A,
- thefitted with the,
Top and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) . - the tool (Mot. 1489) from the cylinder block,
a Torque tighten: - the.
- and angle tighten the exhaust camshaft sprocket
nut (30 N.m + 84˚ ± 4), 4 - Checking the tension
- the camshaft dephaser bolt (100 N.m). a Rotate the crankshaft twice clockwise at the timing
end and before aligning the marks made previously
a Refit the camshaft dephaser plug.
by the operator (on the camshaft dephaser), screw
the tool (Mot. 1489) into the cylinder block.
a Move the crankshaft slowly and smoothly until it
comes into contact with the tool (Mot. 1489).
a Remove the tool (Mot. 1489).

11A-38
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839
5 - Checking the timing
a Ensure that the index and the notch on the timing
tensioning roller are in the correct position before
checking the timing.
a Screw tool (Mot. 1489) into the cylinder block.
a Move the crankshaft slowly and smoothly until it
comes into contact with the tool (Mot. 1489).

cardiagn.com
109051

14490
a Position (without forcing) the toolequipped with the
tool(the camshaft end grooves must be horizontal
and offset downwards).

Note:
If the toolequipped with the toolcannot be
engaged, readjust the timing and the tension.

a Remove:
- the timing toolfitted with the,

103263
- the (Mot. 1489) from the cylinder block.

a Check through the lower timing cover window that

the adjustable index (22) is opposite the notch (23) ,
if this is not the case:

- loosen the timing tensioning roller nut by up to one

turn while holding the eccentric with an Allen key,

- gradually move the adjustable index marker (22)

opposite the mark (23) turning the eccentric cam
(24) clockwise.

a Torque tighten the timing tension wheel nut (27

N.m).

11A-39
 TOP AND FRONT OF ENGINE
Timing belt: Removal - Refitting 11A
K4M, and 838 or 839
a Refit:
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,
- the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the engine undertray,
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the front right-hand wheel (see Wheel: Removal -

cardiagn.com
Refitting) (35A, Wheels and tyres),
- the throttle valve (see 12A, Fuel mixture, Throttle
109052
valve: Removal - Refitting, page 12A-12) .
a Refit the lower timing cover flap, checking that the a Connect the battery (see Battery: Removal - Refit-
locating pin (25) fits properly in the notch (26) . ting) (80A, Battery).

III - FINAL OPERATION

a Refit:

- a new inlet camshaft plug using the,

- a new exhaust camshaft plug using the,

- the lifting eye on the flywheel end.

a Torque tighten the flywheel end lifting eye bolts

(10 N.m).

a Fit the engine wiring.

a Refit the engine wiring nut.

a Clip the engine wiring connector onto the flywheel

end lifting eye.

a Apply a drop of SILICONE ADHESIVE SEALANT

(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products) to the thread
of the TDC pin plug.

a Tighten to torque the TDC pin plug (20 N.m).

a Refit the upper timing cover.

a Torque tighten:

- the upper timing cover bolts (46 N.m),

- the upper timing cover nuts (46 N.m).

11A-40
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K

Special tooling required

K9K, and 832 or 842
Mot. 1448 Remote operation pliers for
hose clips.

Tightening torquesm

rocker cover bolts 11 N.m

IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.

REMOVAL

cardiagn.com
I - REMOVAL PREPARATION OPERATION
a Remove:
- the engine cover,
135494
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the engine undertray bolts,
- the engine undertray,
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).

K9K, and 830 or 838

a Remove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

a Remove the right-hand suspended engine mounting 135495

(see 1 9 D , Engine mounting, Right-hand sus-
a Remove the upper timing cover (1) by pressing the
pended engine mounting: Removal - Refitting,
clips (2) .
page 19D-5) .

K9K, and 830 or 838

a Remove the camshaft position sensor (see 13B,
Diesel injection, Camshaft position sensor: Re-
moval - Refitting, page 13B-8) .

11A-41
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K

K9K, and 830 or 838 K9K, and 832 or 842

a Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting, page 12A-9) .

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136654

136656

a Remove:

- the bolt (3) from the upper timing cover,

- the upper timing cover by pressing the clips (4) .

a Remove the turbocharger outlet air pipe (see 12B,

Turbocharging, Intercooler air inlet pipe: Re-
moval - Refitting, page 12B-12) .

11A-42
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K

K9K, and 830 or 838

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135845

135880

112325

a Disconnect the oil vapour rebreathing pipe union

135879 from the air filter unit air outlet pipe at (9) .
a Remove the oil vapour rebreathing pipe clip (10)
from the oil vapour rebreathing valve using the (Mot.
1448).
a Disconnect the oil vapour rebreathing pipe from the
oil vapour rebreathing valve.
a Remove the nut (11) from the gearbox breather pipe
support.
a Separate the gearbox breather pipe support.
a Remove:

11A-43
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K
- the bolts (12) of the oil vapour rebreathing valve
bracket,
K9K, and 830 or 838
- the oil vapour rebreathing valve bracket.
a Disconnect the brake servo pipe union from the vac-
uum pump.
a Remove:
- the nuts (13) of the oil vapour rebreathing valve,
- the oil vapour rebreathing valve,
- the oil vapour rebreathing valve seal from the oil
vapour rebreathing valve.

K9K, and 832 or 842

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135878
a Unclip the injector rail protector cover at (17) .
a Remove:
- the injector rail protector cover bolt (18) ,
- the injector rail protector cover,

134699
a Unclip the injector rail protector cover at (14) .
a Remove:
- the injector rail protector cover bolt (15) ,
- the injector rail protector cover nut (16) ,
- the injector rail protector cover,

11A-44
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K

K9K, and 832 or 842

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134702
a Remove:
- the injector rail protector cover mounting bolts (21) 134700
, a Unclip the fuel return rail from the rocker cover at
- the injector rail protector cover mounting. (23) .

K9K, and 832 or 842

134701
a Unclip the diesel injector wiring from the rocker cov-
er at (22) .

11A-45
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED
K9K, and 830 or 838

K9K, and 832 or 842

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135489

a Remove:
- the rocker cover bolts (31) ,
135860
a Unclip the fuel return rail from the rocker cover at - the rocker cover,
(24) . - the rocker cover seal.

K9K, and 832 or 842

K9K, and 830 or 838
a Disconnect the oil vapour rebreathing pipe from the
rocker cover.

135876

a Remove:
- the rocker cover bolts (32) ,

11A-46
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K
- the rocker cover,
- the rocker cover seal.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: rocker cover seal
(10,02,01,12).

WARNING
19712-1
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in a
a risk of leaks. WARNING

cardiagn.com
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
WARNING
ture of sealant and fluid could damage certain
To ensure proper sealing, the gasket surfaces components (engine, radiator, etc.).
must be clean, dry and not greasy (avoid any fin-
ger marks). a Apply four beads (35) of SILICONE ADHESIVE
SEALANT (see Vehicle: Parts and consumables
a Clean the gasket surface of the cylinder head using for the repair) (04B, Consumables - Products) 2
GREY ABRASIVE PADS (see Vehicle: Parts and mm in diameter and 10 mm long.
consumables for the repair) (04B, Consumables -
Products).
If replacing the rocker cover
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to degrease: K9K, and 832 or 842
- the cylinder head joint face, a Remove:
- the rocker cover seal housing in the rocker cover if - the bolt from the camshaft position sensor,
it is to be reused. - the camshaft position sensor from the rocker cover.
a Refit:
- the camshaft position sensor onto the new rocker
cover,
- the camshaft position sensor bolt.

11A-47
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K
II - REFITTING OPERATION FOR PART
CONCERNED
K9K, and 830 or 838

a Refit:

- a new seal on the oil vapour rebreathing valve,

- the oil vapour rebreathing valve,

- the oil vapour rebreathing valve nuts.

a Connect the brake servo pipe union to the vacuum

pump.

a Refit:

- the oil vapour rebreathing valve bracket,

135489
- the oil vapour rebreathing valve bracket bolts.
a Refit the rocker cover, fitted with a new gasket.

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a Fit the gearbox breather pipe mounting.
a Tighten to torque and in order the rocker cover
bolts (11 N.m). a Refit the nut of the gearbox breather pipe mounting.

III - FINAL OPERATION a Connect the oil vapour rebreathing pipe to the oil va-
pour rebreathing valve.

K9K, and 832 or 842 a Fit the oil vapour rebreathing pipe clip on the oil va-
pour rebreathing valve using the tool (Mot. 1448).
a Connect the oil vapour rebreathing pipe onto the
rocker cover. a Connect the oil vapour rebreathing pipe to the air fil-
ter box air outlet pipe.

a Clip on the rocker cover:

- the fuel return rail,
- the diesel injector wiring. K9K, and 832 or 842
a Refit the injector rail protector cover mounting. a Refit the damper valve (see 12A, Fuel mixture,
a Refit the injector rail protector cover. Damper valve: Removal - Refitting, page 12A-9) .
a Clip the injector rail protector cover into place.

a Refit the turbocharger air outlet pipe (see 12B, Tur-

bocharging, Intercooler air inlet pipe: Removal -
Refitting, page 12B-12) .

a Refit the upper timing cover.

a Clip on the upper timing cover.

K9K, and 830 or 838

a Refit the upper timing cover bolt.

11A-48
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K9K

K9K, and 830 or 838

a Refit the camshaft position sensor (see 13B, Diesel
injection, Camshaft position sensor: Removal -
Refitting, page 13B-8) .

a Refit the right-hand suspended engine mounting

(see 1 9 D , Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-5) .

K9K, and 830 or 838

a Refit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

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a Refit:
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the engine undertray,
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the engine cover.

11A-49
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K4M
- the oil decanter (see 11A, Top and front of en-
gine, Oil decanter: Removal - Refitting, page
Tightening torquesm 11A-102) .
rocker cover bolts 23, 14 N.m
18, 19, and 24 K4M, and 838 or 839

rocker cover bolts 1 to 12 N.m a Remove:

17, 20, 21, and 22 - the camshaft dephaser solenoid valve (see 11A,
Top and front of engine, Camshaft dephaser
solenoid valve: Removal - Refitting, page 11A-
REMOVAL 90) ,
- the camshaft position sensor (see Camshaft posi-
I - REMOVAL PREPARATION OPERATION tion sensor: Removal - Refitting) .

a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).
a Disconnect the battery (see Battery: Removal - Re- a Position the toolon the camshaft pulleys.
fitting) (80A, Battery).

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a Remove: K4M, and 838 or 839
- the engine cover, a Remove (see 11A, Top and front of engine,
Camshaft dephaser: Removal - Refitting, page
- the throttle valve (see 12A, Fuel mixture, Throttle 11A-87) :
valve: Removal - Refitting, page 12A-12) .
- the camshaft dephaser,
a Remove:
- the exhaust camshaft sprocket.
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the engine undertray bolts,
- the engine undertray,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,
- the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the ignition coils (see Coils: Removal - Refitting) ,
- the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-14) ,

11A-50
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K4M
II - OPERATION FOR REMOVAL OF PART a
CONCERNED
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.

WARNING
Do not allow this product to drip onto the paint-
work.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.

cardiagn.com
WARNING
To ensure proper sealing, the gasket surfaces
136589 must be clean, dry and not greasy (avoid any fin-
ger marks).
a Remove the rocker cover bolts.
a Clean the gasket face of the rocker cover and cylin-
der head with SUPER CLEANING AGENT FOR
Note:
GASKET FACES (see Vehicle: Parts and con-
The rocker cover bolts are not the same length; sumables for the repair) (04B, Consumables -
mark their positions. Products) to dissolve any pieces of seal that are still
attached.
a Remove the rocker cover vertically by tapping the
a Apply the product to the part to be cleaned, wait ap-
lugs (3) with a copper hammer.
proximately 10 minutes, then remove the residue
a Remove: with a wooden spatula.
- the rocker cover,
- the exhaust camshaft, Note:

- the exhaust camshaft seal, Do not put oil on the gasket face of the cylinder
head cover.
- the inlet camshaft,
a Lubricate the cylinder head camshaft bearings with
- the inlet camshaft seal.
engine oil.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Exhaust camshaft
pulley nut (10,02,02,13).

K4M, and 838 or 839

a parts always to be replaced: Camshaft dephaser
sprocket bolt (10,02,02,06).

11A-51
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K4M
II - REFITTING OPERATION FOR PART
CONCERNED
a Refit the camshafts while positioning them correctly
(see Camshaft: Check) (Technical Note 6023A,
10A, Engine and peripherals).

cardiagn.com
14517

136589

a Refit the rocker cover.

a Tighten to torque and in order:
- rocker cover bolts 23, 18, 19, and 24 (14 N.m),
- rocker cover bolts 1 to 17, 20, 21, and 22 (12
N.m).

III - FINAL OPERATION

a Refit the timing end camshaft seals (see 11A, Top
and front of engine, Camshaft seal, timing end:
Removal - Refitting, page 11A-91) .

K4M, and 838 or 839

126216
a Refit (see 11A, Top and front of engine, Camshaft
a Using a stipple roller, apply RESIN ADHESIVE (see
dephaser: Removal - Refitting, page 11A-87) :
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the joint face until - the camshaft dephaser with a new bolt,
it is well coated.
- the exhaust camshaft sprocket with a new nut.

WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain K4M, and 838 or 839
components (engine, radiator, etc.). a Refit:
a Use a cloth to remove any RESIN ADHESIVE in the - the camshaft position sensor (see Camshaft posi-
rocker cover bearings (4) . tion sensor: Removal - Refitting) ,

11A-52
 TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting 11A
K4M
- the camshaft dephaser solenoid valve (see 11A,
Top and front of engine, Camshaft dephaser
solenoid valve: Removal - Refitting, page 11A-
90) .

a Refit:

- the oil decanter (see 11A, Top and front of en-

gine, Oil decanter: Removal - Refitting, page
11A-102) ,

- the inlet distributor (see 12A, Fuel mixture, Inlet

distributor: Removal - Refitting, page 12A-14) ,

- the ignition coils (see Coils: Removal - Refitting) ,

cardiagn.com
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,

- the right-hand suspended engine mounting (see

19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,

- the lower engine tie-bar (see 19D, Engine mount-

ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the engine undertray,

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the front right-hand wheel (see Wheel: Removal -

Refitting) (35A, Wheels and tyres).

a Refit:

- the throttle valve (see 12A, Fuel mixture, Throttle

valve: Removal - Refitting, page 12A-12) ,

- the engine cover.

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

ting) (80A, Battery).

11A-53
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K4M
- the oil decanter (see 11A, Top and front of en-
gine, Oil decanter: Removal - Refitting, page
Equipment required
11A-102) ,
roller-type stud removal tool a Remove:
- the camshaft dephaser solenoid valve (see 11A,
Top and front of engine, Camshaft dephaser
Tightening torquesm solenoid valve: Removal - Refitting, page 11A-
90) ,
the camshaft dowel 8 N.m
- the camshaft position sensor (see Camshaft posi-
tion sensor: Removal - Refitting) ,
REMOVAL - the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
I - REMOVAL PREPARATION OPERATION ting, page 11A-87) ,
- the exhaust camshaft pulley.
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). a Remove:

a Disconnect the battery (see Battery: Removal - Re- - the rocker cover (see 11A, Top and front of en-

cardiagn.com
fitting) (80A, Battery). gine, Rocker cover: Removal - Refitting, page
11A-41) ,
a Remove the throttle valve (see 12A, Fuel mixture,
Throttle valve: Removal - Refitting, page 12A-12) - the timing end camshaft seals (see 11A, Top and
. front of engine, Camshaft seal, timing end: Re-
moval - Refitting, page 11A-91) .
a Remove:

- the front right-hand wheel (see Wheel: Removal - II - OPERATION FOR REMOVAL OF PART
Refitting) (35A, Wheels and tyres), CONCERNED

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray,

- the lower engine tie-bar (see 19D, Engine mount-

ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the right-hand suspended engine mounting (see 134576

19D, Engine mounting, Right-hand suspended a Remove:
engine mounting: Removal - Refitting, page
19D-5) , - the inlet camshaft (1) ,

- the crankshaft accessories pulley (see 11A, Top - the exhaust camshaft (2) .
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,

- the timing belt (see 11A, Top and front of engine,

Timing belt: Removal - Refitting, page 11A-16) ,

- the inlet distributor (see 12A, Fuel mixture, Inlet

distributor: Removal - Refitting, page 12A-14) ,
- the ignition coils (see Coils: Removal - Refitting) ,

11A-54
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K4M
Replacing a camshaft dowel
a

Note:
It is essential to replace the camshaft dowel if it
comes loose at the same time as the nut.

a - Removal
a Place the camshaft in a vice with aluminium jaws.

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14499
a Remove:
- the valve rockers (3) ;
- the hydraulic tappets (4) .

Note:
To prevent any risk of unpriming the hydraulic
tappets make sure that they are vertical.

109050
REFITTING
a Remove the dowel using a roller-type stud remov-
al tool (5) .
I - REFITTING PREPARATION OPERATION
a Refit the camshafts while positioning them correctly b - Cleaning the camshaft
(see Top of engine: Specifications) (Technical
Note 6023A, 10A, Engine and peripherals). a

a
Note:
Note:
Clean the thread hole of the camshaft carefully to
It is essential to reprime the hydraulic tappets as prevent foreign bodies from entering the latter.
these may become drained if removed for a long
time.
c - Refitting
a To check if re-priming is necessary, press the top of
the tappet with your thumb. If the tappet piston de- a Place the camshaft in a vice with aluminium jaws.
presses, immerse the tappets in a container full of
diesel then reprime them.

11A-55
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K4M
- the camshaft position sensor (see Camshaft posi-
tion sensor: Removal - Refitting) ,
- the camshaft dephaser solenoid valve (see 11A,
Top and front of engine, Camshaft dephaser
solenoid valve: Removal - Refitting, page 11A-
90) .
a Refit:
- the oil decanter (see 11A, Top and front of en-
gine, Oil decanter: Removal - Refitting, page
11A-102) ,
- the ignition coils (see Coils: Removal - Refitting) ,
- the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-14) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the crankshaft accessories pulley (see 11A, Top

cardiagn.com
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,
109050
a Refit the new camshaft dowel (precoated section (6) - the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
on the camshaft side).
engine mounting: Removal - Refitting, page
a Torque tighten the camshaft dowel (8 N.m) using a 19D-5) ,
roller-type stud removal tool (7) .
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
II - REFITTING OPERATION FOR PART page 11A-4) ,
CONCERNED
- the lower engine tie-bar (see 19D, Engine mount-
a Refit: ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,
- the hydraulic tappets,
- the engine undertray,
- the valve rockers,
- the front section of the front right-hand wheel arch
- the inlet camshaft, by lubricating the inlet camshaft liner (see Front wheel arch liner: Removal - Re-
bearings, fitting) (55A, Exterior protection),
- the exhaust camshaft, by lubricating the exhaust - the front right-hand wheel (see Wheel: Removal -
camshaft bearings. Refitting) (35A, Wheels and tyres).
a Refit the throttle valve (see 12A, Fuel mixture,
III - FINAL OPERATION Throttle valve: Removal - Refitting, page 12A-12)
a Refit: .
a Connect the battery (see Battery: Removal - Refit-
- the rocker cover (see 11A, Top and front of en-
ting) (80A, Battery).
gine, Rocker cover: Removal - Refitting, page
11A-41) ,
- the timing end camshaft seals (see 11A, Top and
front of engine, Camshaft seal, timing end: Re-
moval - Refitting, page 11A-91) .
a Refit:
- the exhaust camshaft pulley.
- the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-87) ,

11A-56
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K9K

Tightening torquesm K9K, and 830 or 838

bolts of the camshaft 10 N.m a Remove the camshaft position sensor (see 13B,
bearings Diesel injection, Camshaft position sensor: Re-
moval - Refitting, page 13B-8) .

REMOVAL
a Remove:
I - REMOVAL PREPARATION OPERATION - the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment). - the turbocharger air outlet pipe (see 12B, Turbo-
charging, Intercooler air inlet pipe: Removal -
a Disconnect the battery (see Battery: Removal - Re- Refitting, page 12B-12) .
fitting) (80A, Battery).

a Remove:

cardiagn.com
K9K, and 832 or 842

- the engine cover, a Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting, page 12A-9) .
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

- the front section of the front wheel arch liners (see

a Remove:
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection), - the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
- the engine undertray bolts, 11A-41) ,
- the engine undertray, - the vacuum pump (see Vacuum pump: Removal
- Refitting) (37A, Mechanical component controls).
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) .

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) .

K9K, and 830 or 838

a Remove the lower engine tie-bar (see 19D, Engine

mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

a Remove the right-hand suspended engine mounting

118982
(see 1 9 D , Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting, a Increase the hole (1) of the (2) using an 8.5 mm drill
page 19D-5) . bit.

11A-57
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED

113563

cardiagn.com
118983
a Undo the camshaft pulley hub bolts (3) .
a Fit theon the cylinder head to lock the camshaft pul-
ley wheel.
a Tighten the camshaft pulley hub bolts (3) .
a Remove:
- the nut (4) from the camshaft pulley,
- the,
- the camshaft pulley.
113565

a Mark the position of the camshaft bearings.

a Remove:

- the camshaft bearings bolts (5) ,

- the camshaft bearings,

- the camshaft,

- the timing end camshaft seal.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Camshaft seal on

timing end (10,02,02,02).

a Use GREY ABRASIVE PADS (see Vehicle: Parts

and consumables for the repair) (04B, Consum-
ables - Products) to clean the bearing faces of the
camshaft bearings.

11A-58
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K9K
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:

- the bearing faces of the camshaft bearings on the

cylinder head,

- the bearing faces of the camshaft bearings on the

camshaft bearings.

WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
113563

WARNING a Refit the camshaft bearing bolts (1) , (3) , (4) and (2)
in order.
Applying excess sealant could cause it to be

cardiagn.com
squeezed out when parts are tightened. A mix- a Tighten the camshaft bearing bolts (1) , (3) , (4) and
ture of sealant and fluid could damage certain (2) in order.
components (engine, radiator, etc.).
a Refit the camshaft bearing bolts in order.

a Tighten to torque and in order the bolts of the cam-

WARNING
shaft bearings (10 N.m).
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks. III - FINAL OPERATION

a Refit:

- the camshaft seal (see 11A, Top and front of en-

gine, Camshaft seal, timing end: Removal - Re-
fitting, page 11A-91) ,

- the vacuum pump (see Vacuum pump: Removal

- Refitting) (37A, Mechanical component controls),

- the rocker cover (see 11A, Top and front of en-

gine, Rocker cover: Removal - Refitting, page
11A-41) .

K9K, and 832 or 842

20064-1
a Refit the damper valve (see 12A, Fuel mixture,
a Apply four beads (6) of RESIN ADHESIVE (see Ve- Damper valve: Removal - Refitting, page 12A-9) .
hicle: Parts and consumables for the repair)
(04B, Consumables - Products) 7 mm in diameter
on the cylinder head.
a Refit:
II - REFITTING OPERATION FOR PART
CONCERNED - the turbocharger air outlet pipe (see 12B, Turbo-
charging, Intercooler air inlet pipe: Removal -
a Position the camshaft by positioning the timing end Refitting, page 12B-12) ,
camshaft groove vertically.
- the timing belt (see 11A, Top and front of engine,
a Refit the camshaft bearings. Timing belt: Removal - Refitting, page 11A-16) .

11A-59
 TOP AND FRONT OF ENGINE
Camshaft: Removal - Refitting 11A
K9K

K9K, and 830 or 838

a Refit the camshaft position sensor (see 13B, Diesel
injection, Camshaft position sensor: Removal -
Refitting, page 13B-8) .

a Refit the right-hand suspended engine mounting

(see 1 9 D , Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-5) .

K9K, and 830 or 838

a Refit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

cardiagn.com
a Refit:
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
- the engine undertray,
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),
- the front right-hand wheels (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the engine cover.
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

11A-60
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

Special tooling required

IMPORTANT
Mot. 1448 Remote operation pliers for
hose clips.
Use the diagnostic tool before any operation is car-
ried out on the injection circuit to check:
Equipment required
- that the rail is not under pressure,
cylinder head rule - that the fuel temperature is not too high.
set of feeler gauges Working on the circuit with the engine running is
strictly forbidden.

Tightening torquesm

new cylinder head bolts 20 N.m

REMOVAL
(initial torque)

new cylinder head bolts 25 N.m I - REMOVAL PREPARATION OPERATION

270˚ ± 10˚ a Position the vehicle on a two-post lift (see Vehicle:

cardiagn.com
new cylinder head bolts
Towing and lifting) (02A, Lifting equipment).
alternator lower bolt 25 N.m
a Disconnect the battery (see Battery: Removal - Re-
alternator upper bolt 25 N.m fitting) (80A, Battery).
air filter unit air outlet 5.5 N.m a Remove:
pipe clip on the turbo-
charger - the engine cover,
rocker cover bolts 11 N.m - the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),

IMPORTANT - the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
To avoid all risk of damage to the systems, apply (55A, Exterior protection),
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any - the engine undertray bolts,
repair:
- the engine undertray,
- (see Diesel injection: Precautions for the
repair) , - the front bumper (see Front bumper: Removal -
- (see Vehicle: Precautions for the repair) (01D, Refitting) (55A, Exterior protection).
Mechanical introduction).
a Remove:

- the windscreen wiper arms (see Windscreen wip-

IMPORTANT er arm: Removal - Refitting) (85A, Wiping -
Washing),
Wear leaktight gloves (Nitrile type) for this opera-
tion.
- the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),

- the scoop under the scuttle panel grille (see Scoop

under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment).

a Remove the catalytic converter (see 19B, Exhaust,

Catalytic converter: Removal - Refitting, page
19B-6) .

11A-61
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) .

K9K, and 830 or 838

a Remove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

cardiagn.com
139188
K9K, and 830 or 838
a Remove the bolts (1) from the exhaust bracket.
a Remove the camshaft position sensor (see 13B,
a Move the exhaust pipe to one side. Diesel injection, Camshaft position sensor: Re-
moval - Refitting, page 13B-8) .

a Remove:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the intercooler air outlet pipe (see 12B, Turbo-
charging, Intercooler air outlet pipe: Removal -
Refitting, page 12B-17) .
a Remove the turbocharger outlet air pipe (see 12B,
Turbocharging, Intercooler air inlet pipe: Re-
moval - Refitting, page 12B-12) .

K9K, and 832 or 842

a Remove the damper valve (see 12A, Fuel mixture,
Damper valve: Removal - Refitting, page 12A-9) .

139205
a Remove:
- the bolts (2) from the bracket of the exhaust gases
duct at the outlet of the turbocharger,
- the bracket from the exhaust gases duct at the out-
let of the turbocharger.
a Remove:
- the turbocharger oil return pipe (see 12B, Turbo-
charging, Turbocharger oil pipe: Removal - Re-
fitting, page 12B-4) ,

11A-62
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 830 or 838

cardiagn.com
135845

135880

112325

a Disconnect the oil vapour rebreathing pipe union

135879 from the air filter unit air outlet pipe at (6) .
a Remove the oil vapour rebreathing pipe clip (7) from
the oil vapour rebreathing valve using the (Mot.
1448).
a Disconnect the oil vapour rebreathing pipe from the
oil vapour rebreathing valve.
a Remove the nut (8) from the gearbox breather pipe
support.
a Separate the gearbox breather pipe support.
a Remove:

11A-63
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
- the bolts (9) of the oil vapour rebreathing valve
bracket,
K9K, and 830 or 838
- the oil vapour rebreathing valve bracket.
a Disconnect the brake servo pipe union from the vac-
uum pump.
a Remove:
- the nuts (10) of the oil vapour rebreathing valve,
- the oil vapour rebreathing valve,
- the seal of the oil vapour rebreathing valve.

K9K, and 832 or 842

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135878
a Unclip the injector rail protector cover at (14) .
a Remove:
- the injector rail protector cover bolt (15) ,
- the injector rail protector cover,

134699
a Unclip the injector rail protector cover at (11) .
a Remove:
- the injector rail protector cover bolt (12) ,
- the injector rail protector cover nut (13) ,
- the injector rail protector cover,

11A-64
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 832 or 842

cardiagn.com
134702
a Remove:
- the injector rail protector cover mounting bolts (18) 134700
, a Unclip the diesel injector fuel return rail from the
- the injector rail protector cover mounting. rocker cover at (20) .

K9K, and 832 or 842

K9K, and 830 or 838

a Remove the fuel return rail (see 13B, Diesel injec-
tion, Diesel injector fuel return rail: Removal -
Refitting, page 13B-32) .

K9K, and 832 or 842

a Disconnect the oil vapour rebreathing pipe from the
rocker cover.

134701
a Unclip the diesel injector wiring from the rocker cov-
er at (19) .

11A-65
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
- the rocker cover seal.
K9K, and 832 or 842

135489

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a Remove:

- the rocker cover bolts (35) ,

- the rocker cover,

- the rocker cover seal.

134703

a Remove:

- the dipstick,
K9K, and 830 or 838 - the dipstick guide bolts (39) .

a Move aside the dipstick guide.

135876

a Remove:
134704
- the rocker cover bolts (36) ,
a Disconnect the vacuum pipe (40) from the vacuum
- the rocker cover, pump.

11A-66
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
a Unclip the hose of the turbocharging pressure regu-
lator solenoid valve from the cylinder head.
K9K, and 830 or 838

K9K, and 832 or 842

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135875
a Disconnect the hose (44) of the turbocharging pres-
135487 sure regulator solenoid valve from the turbocharger.
a Disconnect the hose (41) of the turbocharging pres-
sure regulator solenoid valve from the turbocharger.

134705
a Disconnect the connector (45) from the exhaust gas
recirculation solenoid valve.

11A-67
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 832 or 842 K9K, and 830 or 838

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135410 136639
a Undo the air filter unit air outlet pipe clip (55) from a Undo the air filter unit air outlet pipe clip (56) from
the turbocharger. the turbocharger.
a Disconnect the air filter unit air outlet pipe from the a Disconnect the air filter unit air outlet pipe from the
turbocharger. turbocharger.

a Drain the cooling system (see 19A, Cooling, Cool-

ing system: Draining - Refilling, page 19A-8) .

11A-68
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

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135484 139156
a Unclip the heater matrix cooling hose from the water a Separate the heater matrix cooling hose clip (65)
chamber (57) . from the water chamber cooling hose using the tool
(Mot. 1448).
a Separate the heater matrix cooling hose clip (58)
from the exhaust cooler cover using the tool (Mot. a Disconnect the heater matrix cooling hose from the
1448). water chamber cooling hose (66) .
a Disconnect the heater matrix cooling hose from the a Disconnect the coolant temperature sensor connec-
exhaust gas cooler cover (59) . tor.

135485
a Separate the clip (63) of the cooling radiator top
cooling hose (64) from the water chamber using the
tool (Mot. 1448).
a Disconnect the cooling radiator top cooling hose
from the water chamber (64) .

11A-69
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
- the fuel temperature sensor connector (70) ,
K9K, and 832 or 842 - the connector (71) for the fuel pressure regulation
solenoid valve,

- the connector (72) for the fuel flow regulation sole-

noid valve,
- all heater plug connectors,

- the connector for each diesel injector.

a Unclip the injection wiring clip (73) .

a Remove the nut from the injection wiring bracket.

K9K, and 830 or 838

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134706

135874

a Disconnect:

- the connector (85) from the injector rail pressure

sensor,
- the fuel temperature sensor connector (86) ,
134706
- the connector (87) for the fuel flow regulation sole-
a Unclip:
noid valve,
- the expansion bottle bottom cooling hose from the - all heater plug connectors,
high pressure pump protector (67) ,
- the connector for each diesel injector.
- the alternator wiring from the injector rail protector
at (68) . a Unclip the injection wiring clips (88) .

a Disconnect:

- the connector (69) from the injector rail pressure

sensor, a Move aside the injection wiring.

11A-70
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 832 or 842

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134707
a Disconnect the fuel supply pipe union (89) from the
high pressure pump.
a Fit a suitable blanking plug to:
- the fuel supply pipe union opening,
- the high pressure pump opening.

11A-71
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
- the fuel supply pipe union opening,

K9K, and 830 or 838 - the high pressure pump opening.

K9K, and 832 or 842

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135873

135468
a Disconnect the fuel drain pipe from the injector rail
protector (97) .

135872

a Unclip the high pressure pump fuel return union from

the high pressure pump protector at (94) .
a Remove:

- the bolt (95) of the high pressure pump protector,

- the high pressure pump protector.
a Disconnect the fuel supply pipe (96) from the high
pressure pump.
a Fit a suitable blanking plug to:

11A-72
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 832 or 842 K9K, and 830 or 838

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123969 136665
a Remove the alternator upper bolt (99) . a Remove the alternator upper bolt (105) .
a Loosen the alternator lower bolt (100) . a Loosen the alternator lower bolt (106) .
a Tilt the alternator slightly towards the front of the ve- a Tilt the alternator slightly towards the front of the ve-
hicle. hicle.
a Remove: a Remove:
- the bolts (101) from the inner cover, - the bolts (107) from the inner cover,
- the inner cover. - the inner cover.

II - OPERATION FOR REMOVAL OF PART

CONCERNED
a

Note:
The operation to remove the cylinder head
requires two people.

11A-73
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

REFITTING
K9K, and 832 or 842
I - REFITTING PREPARATION OPERATION
a Remove the tool.
a
Note: IMPORTANT
Tur n the camshaft slightly to facilitate the removal Wear goggles with side protectors for this opera-
of the cylinder head bolt on the camshaft position tion.
sensor target.

a Insert the toolin the holes of the camshaft pulley hub IMPORTANT
and the hole of the cylinder head.
Wear leaktight gloves (Nitrile type) for this opera-
tion.

WARNING
Do not scrape the joint faces of the aluminium,

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any damage caused to the joint face will result in
a risk of leaks.

WARNING
Do not allow this product to drip onto the paint-
work.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
Failure to follow this advice could lead to the
19712
blocking of the various oil inlet galleries, which
a Remove: would quickly result in engine damage.
- the cylinder head bolts (108) ,
- the cylinder head from the cylinder block, WARNING
- the cylinder head gasket. To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

a parts always to be replaced: cylinder head bolts

(10,02,01,14).
a parts always to be replaced: Cylinder head gas-
ket (10,02,01,04).
a parts always to be replaced: rocker cover seal
(10,02,01,12).
a Always replace the seal for the turbocharger air inlet
pipe.
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to clean and
degrease:
- the rocker cover seal housing,
- the cylinder head joint face.

11A-74
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
a The maximum deformation is 0.05 mm.
K9K, and 830 or 838
a Always replace the seal of the oil vapour rebreathing Note:
valve. If the cylinder head is faulty:
-strip down the cylinder head (see Stripping the
cylinder head) (Technical Note 6006A, 10A,
Engine and cylinder block assembly),
1 - Cleaning the cylinder head joint face -test the cylinder head for possible cracks using
the cylinder head test kit,
a
-rebuild the cylinder head (see Reassembling
WARNING the cylinder head) (Technical Note 6006A, 10A,
Protect the oilway so that foreign bodies do not Engine and cylinder block assembly).
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid deteri- 3 - Cleaning the joint face of the rocker cover
oration of the camshaft. a

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a Clean the gasket surface using GREY ABRASIVE WARNING
PADS (see Vehicle: Parts and consumables for Do not scrape the joint faces of the aluminium,
the repair) (04B, Consumables - Products): any damage caused to the joint face will result in
- the cylinder head, a risk of leaks.
- the cylinder block.
a Use a SURFACE CLEANER (see Vehicle: Parts WARNING
and consumables for the repair) (04B, Consuma- To ensure proper sealing, the gasket surfaces
bles - Products) and CLEAN CLOTHS to degrease must be clean, dry and not greasy (avoid any fin-
the joint faces: ger marks).
- the cylinder head,
a Clean the gasket surface of the cylinder head using
- of the cylinder block, GREY ABRASIVE PADS (see Vehicle: Parts and
- of the exhaust gas cooler mounting on the gearbox consumables for the repair) (04B, Consumables -
side, Products).

- of the oil vapour rebreathing valve. a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to degrease:
2 - Checking the gasket face
- the cylinder head joint face,
a Check with a cylinder head rule and a set of feeler
gauges to determine if the joint face has been de- - the rocker cover housing.
formed.

4 - Cleaning the joint face of the turbocharger air

WARNING inlet pipe
No regrinding of the cylinder head is permitted.
a Clean the gasket surface of the turbocharger using
GREY ABRASIVE PADS (see Vehicle: Parts and
consumables for the repair) (04B, Consumables -
Products).

a Use SURFACE CLEANER (see Vehicle: Parts

and consumables for the repair) (04B, Consuma-
bles - Products) and CLEAN CLOTHS to degrease:

- the turbocharger joint face,

- the housing of the turbocharger air inlet pipe.

11A-75
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
II - REFITTING OPERATION FOR PART a Check that all of the new cylinder head mounting
CONCERNED bolts are tightened to the correct torque (25 N.m).
a Bring the pistons to mid-stroke position to prevent a Angle tighten in order the new cylinder head bolts
any risk of contact with the valves when tightening (270˚ ± 10˚).
the cylinder head.
III - FINAL OPERATION
Note: a Refit the inner cover.
The operation to refit the cylinder head requires a Fit the alternator in place.
two people.
a Refit the alternator upper bolt.
a Torque tighten:
Note: - the alternator lower bolt (25 N.m),
The cylinder head gasket has a foolproofing
- the alternator upper bolt (25 N.m).
device which must be positioned on the cylinder
block inlet side.
K9K, and 832 or 842
a Fit:

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a Connect the fuel drain pipe to the injector rail protec-
- a new cylinder head gasket, centred by two dow- tor.
els,
- the cylinder head on the cylinder block.
a Remove the blanking plug:
WARNING - the opening of the high pressure pump,
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which - on the fuel supply pipe union opening.
may be in the cylinder head mounting holes. a Connect the fuel supply pipe to the high pressure
pump.

WARNING
K9K, and 830 or 838
Do not oil the new bolts. Be sure to oil bolts
being reused. a Refit the high pressure pump protector.
a Clip the high pressure pump fuel return union onto
the high pressure pump protector.

a Fit the injection wiring.

19712

a Refit in order the new cylinder head bolts.

a Pretighten to torque and in order the new cylinder
head bolts (initial torque) (20 N.m).
a Tighten to torque and in order the new cylinder
head bolts (25 N.m).

11A-76
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 832 or 842 K9K

a Refit the injection wiring bracket nut. a Connect the heater matrix cooling hose to the ex-
haust gas cooler cover.
a Clip on the injection wiring clip.
a Fit the heater matrix cooling hose clip on the exhaust
a Connect: gas cooler cover using the tool (Mot. 1448).
- the connector for each diesel injector,
- all heater plug connectors,
- the connector for the fuel flow regulation solenoid a Clip the heater matrix cooling hose onto the water
valve, chamber.

- the connector for the fuel pressure regulation sole-

noid valve, K9K
- the fuel temperature sensor connector, a Connect the air filter unit air outlet pipe to the turbo-
charger.
- the injector rail pressure sensor connector.
a Torque tighten the air filter unit air outlet pipe clip

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a Clip: on the turbocharger (5.5 N.m).
- the alternator wiring on the injector rail protector,
- the expansion bottle bottom cooling hose on the
high pressure pump protector. a Connect:
- exhaust gas recirculation solenoid valve connector
,
- the turbocharging pressure regulation solenoid
K9K, and 830 or 838 valve hose to the turbocharger.

a Clip on the injection wiring clips.

K9K
a Connect:
a Clip on the turbocharging pressure regulation sole-
- the connector for each diesel injector, noid valve hose.
- all heater plug connectors,
- the connector for the fuel flow regulation solenoid
valve, a Connect the turbocharging pressure regulation sole-
noid valve hose to the vacuum pump.
- the fuel temperature sensor connector,
a Fit the dipstick guide tube.
- the injector rail pressure sensor connector.
a Refit:
- the dipstick guide bolts,

a Connect: - the dipstick.

- the coolant temperature sensor connector,

- the heater matrix cooling hose to the water cham-
ber cooling hose.
a Fit the heater matrix cooling hose clip onto the water
chamber cooling hose using the tool (Mot. 1448).
a Connect the cooling radiator top cooling hose to the
coolant outlet unit.
a Fit the cooling radiator top cooling hose clip on the
coolant outlet unit using the tool (Mot. 1448).

11A-77
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K
a Refit the injector rail protector cover mounting.
a Refit the injector rail protector cover.
a Clip on the injector rail protector cover.

K9K, and 830 or 838

a Refit:
- the new oil vapour rebreathing valve seal on the oil
vapour rebreathing valve,
- the oil vapour rebreathing valve.
a Connect the brake servo pipe union to the vacuum
pump.
19712-1 a Refit the oil vapour rebreathing valve bracket.
a a Fit the breather mounting on the gearbox.
WARNING a Refit the nut of the breather mounting on the gear-

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Applying excess sealant could cause it to be box.
squeezed out when parts are tightened. A mix- a Connect the oil vapour rebreathing pipe to the oil va-
ture of sealant and fluid could damage certain pour rebreathing valve.
components (engine, radiator, etc.).
a Fit the oil vapour rebreathing pipe clip on the oil va-
a Place beads (109) of SILICONE ADHESIVE SEAL- pour rebreathing valve using the tool (Mot. 1448).
ANT (see Vehicle: Parts and consumables for a Connect the oil vapour rebreathing pipe union to the
the repair) (04B, Consumables - Products) 2 mm in air filter unit air outlet pipe.
diameter and 10 mm long.
a Refit the rocker cover, fitted with a new gasket.
a Torque tighten the rocker cover bolts (11 N.m).

K9K, and 832 or 842

K9K, and 832 or 842
a Refit the damper valve (see 12A, Fuel mixture,
a Connect the oil vapour rebreathing pipe onto the Damper valve: Removal - Refitting, page 12A-9) .
rocker cover.

a Refit the turbocharger air outlet pipe (see 12B, Tur-

bocharging, Intercooler air inlet pipe: Removal -
K9K, and 830 or 838 Refitting, page 12B-12) .

a Refit the diesel injector fuel return rail (see 13B, Die- a Refit:
sel injection, Diesel injector fuel return rail: Re- - the intercooler air outlet pipe (see 12B, Turbo-
moval - Refitting, page 13B-32) . charging, Intercooler air outlet pipe: Removal -
Refitting, page 12B-17) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) .
K9K, and 832 or 842
K9K, and 830 or 838
a Clip on the rocker cover:
a Refit the camshaft position sensor (see 13B, Diesel
- the diesel injector fuel return rail,
injection, Camshaft position sensor: Removal -
- the diesel injector wiring. Refitting, page 13B-8) .

11A-78
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K9K

K9K, and 830 or 838

a Refit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

a Refit:

- the right-hand suspended engine mounting (see

19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

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- the turbocharger oil return pipe (see 12B, Turbo-
charging, Turbocharger oil pipe: Removal - Re-
fitting, page 12B-4) .

a Refit the catalytic converter (see 19B, Exhaust,

Catalytic converter: Removal - Refitting, page
19B-6) .
a Refit:

- the scoop under the scuttle panel grille (see Scoop

under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),

- the scuttle panel grille (see Scuttle panel grille:

Removal - Refitting) (56A, Exterior equipment),

- the windscreen wiper arms (see Windscreen wip-

er arm: Removal - Refitting) (85A, Wiping -
Washing).
a Refit:

- the front bumper (see Front bumper: Removal -

Refitting) (55A, Exterior protection),

- the engine undertray,

- the front section of the front wheel arch liners (see

Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the front wheels (see Wheel: Removal - Refitting)

(35A, Wheels and tyres),

- the engine cover.

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

ting) (80A, Battery).
a Fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-8) .

11A-79
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
Tightening torquesm engine mounting: Removal - Refitting, page
19D-5) .
cylinder head bolts (ini- 20 N.m
tial torque)

cylinder head bolts 240˚ ± 6˚

lifting eye bolts 10 N.m

IMPORTANT
Wear protective gloves during the operation.

REMOVAL

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I - REMOVAL PREPARATION OPERATION
a 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). 136392

a Remove:
a Remove:
- the bolts (1) from the exhaust flange,
- the engine cover,
- the throttle valve (see 12A, Fuel mixture, Throttle - the ring between the exhaust manifold and the cat-
valve: Removal - Refitting, page 12A-12) . alytic converter.

a Remove:
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the engine undertray bolts,
- the engine undertray.
a Drain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-8) .
a Remove:
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
136470
pulley: Removal - Refitting, page 11A-8) ,
a Remove:
- the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting, - the exhaust manifold strut nut (2) from the exhaust
page 19D-10) , manifold,

11A-80
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
- the exhaust manifold strut bolt (3) from the cylinder
block,
K4M, and 838 or 839
- the exhaust manifold stay,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the ignition coils (see Coils: Removal - Refitting) ,
- the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-14) ,
- the spark plugs (see Plugs: Removal - Refitting) .

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136454

a Remove:

- the dipstick guide bolt (5) ,

- the dipstick guide.

135260
a Unclip the wiring from the lifting eye.
K4M, and 838 or 839
a Remove:
a Remove:
- the engine wiring retaining nut,
- the camshaft position sensor (see Camshaft posi-
- the lifting eye bolts (4) ,
tion sensor: Removal - Refitting) ,
- the lifting eye.
- the camshaft dephaser solenoid valve (see 11A,
Top and front of engine, Camshaft dephaser
solenoid valve: Removal - Refitting, page 11A-
90) ,

- the camshaft dephaser (see 11A, Top and front of

engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-87) .

a Remove:

- the oil decanter (see 11A, Top and front of en-

gine, Oil decanter: Removal - Refitting, page
11A-102) ,

11A-81
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
- the rocker cover (see 11A, Top and front of en-
gine, Rocker cover: Removal - Refitting, page
11A-41) ,
- the camshafts (see 11A, Top and front of engine,
Camshaft: Removal - Refitting, page 11A-54) ,
- the timing end camshaft seals (see 11A, Top and
front of engine, Camshaft seal, timing end: Re-
moval - Refitting, page 11A-91) ,
- the injector rail (see Injector rail - Injectors: Re-
moval - Refitting) .

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136546
a Disconnect the upstream oxygen sensor connector
(9) .

134583
a Using theororremove:
- the top hose clip (7) from the coolant outlet unit,
- the heater matrix hose clip (8) .
a Disconnect:
- the top hose from the coolant outlet unit,
- the heater matrix hose,
- the coolant temperature sensor connector.

11A-82
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
II - OPERATION FOR REMOVAL OF PART
CONCERNED

134573

134578
a Remove:

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- the cylinder head bolts,
- the cylinder head.
a Mount the cylinder head on the cylinder head sup-
port.
a Remove the cylinder head gasket from the cylinder
block.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: cylinder head bolts
(10,02,01,14).
a parts always to be replaced: Cylinder head gas-
134575 ket (10,02,01,04).
a a parts always to be replaced: ring between ex-
haust manifold and catalytic converter (10,08,02,
Note: 20).
To prevent any risk of unpriming the hydraulic
tappets, make sure that they are vertical.

a Remove:
- the valve rockers (12) ,
- the hydraulic tappets (11) .

11A-83
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
1 - Cleaning the cylinder head joint face - the cylinder block gasket face.
a
2 - Checking the gasket face
IMPORTANT
a Check for gasket face deformation using a ruler and
Wear goggles with side protectors for this opera-
a set of shims.
tion.

WARNING
IMPORTANT No regrinding of the cylinder head is permitted.
Wear leaktight gloves (Nitrile type) for this opera-
tion. a The maximum deformation is 0.05 mm.

Note:
WARNING
Do not scrape the joint faces of the aluminium, If the cylinder head is faulty:
any damage caused to the joint face will result in - strip down the cylinder head (see Cylinder
a risk of leaks. head: Stripping - Rebuilding) (Technical Note
6023A, 10A, Engine and peripherals),

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WARNING - test the cylinder head in order to detect any
possible cracks using the cylinder head test kit
Do not allow this product to drip onto the paint- (see Cylinder head test tank: Use) (Technical
work. Note 6026A, 11A, Top and front of engine),
Clean the cylinder head carefully to avoid any - rebuild the cylinder head (see Cylinder head:
foreign bodies entering the oil return and supply Stripping - Rebuilding) (Technical Note
pipes. 6023A, 10A, Engine and peripherals).
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage. II - REFITTING OPERATION FOR PART
CONCERNED
a Bring the pistons to mid-stroke position to prevent
WARNING any risk of contact with the valves when tightening
To ensure proper sealing, the gasket surfaces the cylinder head.
must be clean, dry and not greasy (avoid any fin-
ger marks).
WARNING
To ensure proper sealing, the gasket surfaces
WARNING must be clean, dry and not greasy (avoid any fin-
ger marks).
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head. a Check that the centring dowel is present on the cyl-
Failure to follow this instruction could lead to the inder block.
blocking of the oilways, resulting in a rapid deteri-
oration of the camshaft.

a Use SUPER CLEANING AGENT FOR JOINT FA-

CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean:
- the cylinder head gasket face if being reused,
- the cylinder block gasket face.
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to degrease:
- the cylinder head gasket face if being reused,

11A-84
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
a Fit: III - FINAL OPERATION
- a new cylinder head gasket,
- the cylinder head equipped with new bolts on the
cylinder block.

WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.

WARNING
Do not oil the new bolts. Be sure to oil bolts
being reused.

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14499

Note:
Because this engine is equipped with hydraulic
tappets, there is no valve clearance adjustment.

a Reprime the hydraulic tappets (hydraulic tappets

may empty after a long down time).
134578
a Without tightening, fit the cylinder head bolts in or- a To check if repriming is necessary, press the top of
der. the tappet (13) with your thumb.

a Pretighten to torque and in order the cylinder head a If the tappet piston sinks, dip the tappet in a contain-
bolts (initial torque) (20 N.m). er filled with diesel.
a Check that all the cylinder head bolts are tightened a Press on the top of the tappet to expel air bubbles.
to the correct torque of 20 N.m.
a Refit:
a Angle tighten in order the cylinder head bolts (240˚
± 6˚). - the hydraulic tappets,

- the valve rockers.

Note:
a Connect:
Do not retighten the cylinder head bolts after
applying this procedure. - the upstream oxygen sensor connector,

- the coolant temperature sensor connector,

- the hose to the heater matrix,

- the top hose to the water chamber.

a Using theororfit:

- the clip on the heater matrix hose,

- the top hose clip on the water chamber.

11A-85
 TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting 11A
K4M
a Refit: - the exhaust bracket,
- the injector rail (see Injector rail - Injectors: Re- - the right-hand suspended engine mounting (see
moval - Refitting) , 19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
- the camshafts (see 11A, Top and front of engine,
19D-5) ,
Camshaft: Removal - Refitting, page 11A-54) ,
- the lower engine tie-bar (see 19D, Engine mount-
- the rocker cover (see 11A, Top and front of en- ing, Lower engine tie-bar: Removal - Refitting,
gine, Rocker cover: Removal - Refitting, page page 19D-10) ,
11A-41) ,
- the crankshaft accessories pulley (see 11A, Top
- the oil decanter (see 11A, Top and front of en- and front of engine, Crankshaft accessories
gine, Oil decanter: Removal - Refitting, page pulley: Removal - Refitting, page 11A-8) ,
11A-102) ,
- the accessories belt (see 11A, Top and front of
- the timing end camshaft seals (see 11A, Top and engine, Accessories belt: Removal - Refitting,
front of engine, Camshaft seal, timing end: Re- page 11A-4) ,
moval - Refitting, page 11A-91) .
- the engine undertray,
a Refit:
- the front section of the front right-hand wheel arch

cardiagn.com
- the camshaft dephaser (see 11A, Top and front of liner (see Front wheel arch liner: Removal - Re-
engine, Camshaft dephaser: Removal - Refit- fitting) (55A, Exterior protection),
ting, page 11A-87) ,
- the front right-hand wheel (see Wheel: Removal -
- the camshaft dephaser solenoid valve (see 11A, Refitting) (35A, Wheels and tyres).
Top and front of engine, Camshaft dephaser
solenoid valve: Removal - Refitting, page 11A- a Refit:
90) , - the throttle valve (see 12A, Fuel mixture, Throttle
- the camshaft position sensor (see Camshaft posi- valve: Removal - Refitting, page 12A-12) ,
tion sensor: Removal - Refitting) . - the engine cover.
a Connect the battery (see Battery: Removal - Refit-
K4M, and 838 or 839 ting) (80A, Battery).
a Refit the dipstick guide. a Fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
a Torque tighten the dipstick guide tube bolt (10 19A-8) .
N.m).

a Refit the lifting eye.

a Torque tighten the lifting eye bolts (10 N.m).
a Fit the engine wiring on the lifting eye.
a Clip the wiring onto the lifting eye.
a Refit:
- the spark plugs (see Plugs: Removal - Refitting) ,
- the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-14) ,
- the ignition coils (see Coils: Removal - Refitting) ,
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the exhaust manifold stay,
- a new ring between the exhaust manifold and the
catalytic converter,

11A-86
 TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting 11A
K4M, and 838 or 839
II - OPERATION FOR REMOVAL OF PART
CONCERNED
Tightening torquesm

new nut on the exhaust 30 N.m + 84˚ ±

camshaft pulley 4˚

new bolt on the cam- 100 N.m

shaft dephaser

REMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).

a Disconnect the battery (see Battery: Removal - Re-

cardiagn.com
fitting) (80A, Battery).

a Remove:

- the engine cover, 136530

a Position the tool (1) on the camshaft pulleys.
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-12) . a Remove the camshaft dephaser blanking cover (2) .

a Remove:

- the front right-hand wheel (see Wheel: Removal -

Refitting) (35A, Wheels and tyres),

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray,

- the lower engine tie-bar (see 19D, Engine mount-

ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) ,

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the right-hand suspended engine mounting (see

103264
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page a Undo:
19D-5) , - the camshaft dephaser bolt (3) ,
- the crankshaft accessories pulley (see 11A, Top - the exhaust camshaft sprocket nut (4) .
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) , a Remove the toolfrom the camshaft pulleys.
a Remove:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) . - the exhaust camshaft pulley nut,

11A-87
 TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting 11A
K4M, and 838 or 839
- the exhaust camshaft pulley.
- the camshaft dephaser bolt,
- the camshaft dephaser.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Camshaft dephaser
sprocket bolt (10,02,02,06).
a parts always to be replaced: Exhaust camshaft
pulley nut (10,02,02,13).

WARNING
Failure to adhere to the following procedure may
cause the timing belt to be incorrectly timed.

cardiagn.com
a If fitting a new camshaft dephaser, check that it is
locked by following the procedure described below: 111340

a Fit a stud to the camshaft dephaser hub and tighten a Mechanically lock the camshaft dephaser by rotating
it. it to the left or right using a tubular hexagon box
spanner.
a Check that the camshaft dephaser is correctly
locked (no rotation of the hub in relation to the wheel
to the left or right).
a If there is a rotation of the hub in relation to the
wheel, the camshaft dephaser is faulty and must be
replaced.
a Degrease the end of the camshaft (timing end) and
clean the bores and bearing faces of the camshaft
dephaser.

II - REFITTING OPERATION FOR PART

CONCERNED
a Refit:
- the exhaust camshaft pulley.
- the camshaft dephaser,
- a new nut on the exhaust camshaft pulley,
111339
- a new bolt on the camshaft dephaser.
a Place the camshaft dephaser in a vice fitted with
jaws. a Position the toolon the camshaft pulleys.
a Torque tighten:
- the new nut on the exhaust camshaft pulley (30
N.m + 84˚ ± 4˚),
- the new bolt on the camshaft dephaser (100
N.m).
a Refit the blanking cover on the camshaft dephaser.
a Remove the toolfrom the camshaft pulleys.

11A-88
 TOP AND FRONT OF ENGINE
Camshaft dephaser: Removal - Refitting 11A
K4M, and 838 or 839
III - FINAL OPERATION
a Refit:
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
- the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,

cardiagn.com
page 19D-10) ,
- the engine undertray,
- the front section of the front right-hand wheel arch
liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
- the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
a Refit:
- the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-12) ,
- the engine cover.
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

11A-89
 TOP AND FRONT OF ENGINE
Camshaft dephaser solenoid valve: Removal - Refitting 11A
K4M, and 838 or 839

Tightening torquesm

camshaft dephaser 10 N.m

solenoid valve bolt

REMOVAL

I - OPERATION FOR REMOVAL OF PART

CONCERNED

cardiagn.com
136578
a Remove:
- the bolt (2) from the camshaft dephaser solenoid
valve,
- the camshaft dephaser solenoid valve.

REFITTING

I - REFITTING OPERATION FOR PART

CONCERNED
136579
a Refit the camshaft dephaser solenoid valve.
a Disconnect the connector (1) from the camshaft
dephaser solenoid valve. a Torque tighten the camshaft dephaser solenoid
valve bolt (10 N.m).
a Connect the camshaft dephaser solenoid valve con-
nector.

11A-90
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K4M

REMOVAL II - OPERATION FOR REMOVAL OF PART

CONCERNED

I - REMOVAL PREPARATION OPERATION

a 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 engine cover,

- the throttle valve (see 12A, Fuel mixture, Throttle

valve: Removal - Refitting, page 12A-12) .

a Remove:

- the front right-hand wheel (see Wheel: Removal -

cardiagn.com
Refitting) (35A, Wheels and tyres),

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
fitting) (55A, Exterior protection),
105257
- the engine undertray bolts,
a
- the engine undertray,
Note:
- the lower engine tie-bar (see 19D, Engine mount- The camshaft seal is removed from the timing
ing, Lower engine tie-bar: Removal - Refitting, end using the.
page 19D-10) ,
a Always remove the end piece (3) of the tool.
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting, a Completely unscrew the nut (4) and the boltof the (5)
page 11A-4) , .
- the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,

- the timing belt (see 11A, Top and front of engine,

Timing belt: Removal - Refitting, page 11A-16) .

K4M, and 838 or 839

a Remove (see 11A, Top and front of engine,

Camshaft dephaser: Removal - Refitting, page
11A-87) :

- the exhaust camshaft sprocket,

- the camshaft dephaser.

135237
a Position the claws of theon the camshaft.

11A-91
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K4M

cardiagn.com
135237 135232
a Push the tooluntil contact is made between the ends a Remove the camshaft seal by turning the bolt (7)
of the claws and the camshaft seal. clockwise.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Camshaft seal on
timing end (10,02,02,02).
a parts always to be replaced: Exhaust camshaft
pulley nut (10,02,02,13).

K4M, and 838 or 839

a parts always to be replaced: Camshaft dephaser
sprocket bolt (10,02,02,06).

135236
a Separate the claws by turning the bolt (6) clockwise
using an open-jawed spanner.

11A-92
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K4M
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to degrease:
- the camshaft seal mating face on each camshaft,
- the camshaft seal housings.

WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.

WARNING
To ensure proper sealing, the gasket surfaces 105531
must be clean, dry and not greasy (avoid any fin-
ger marks).

cardiagn.com
II - REFITTING OPERATION FOR PART
CONCERNED

135231
a Fit the protector fitted with a new seal (11) on the in-
let and exhaust camshaft, taking care not to touch
the seal.
a Screw on the stud (10) of the toolon the inlet and ex-
haust camshafts.
18687
a

Note:
Always hold the camshaft seal with the protector
(8) when handling, as this type of seal is very
FRAGILE. It is strictly forbidden to touch the seal
(9) in order to prevent any oil leaks once the
camshaft seal is fitted to the engine.

11A-93
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K4M

K4M, and 838 or 839

a Refit (see 11A, Top and front of engine, Camshaft

dephaser: Removal - Refitting, page 11A-87) :

- the camshaft dephaser with a new bolt,

- the exhaust camshaft sprocket with a new nut.

III - FINAL OPERATION

a Refit:

cardiagn.com
- the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-16) ,
135229
a Fit the cover (12) and the collar nut (13) of the. - the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) ,

- the right-hand suspended engine mounting (see

19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-5) ,

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4) ,

- the lower engine tie-bar (see 19D, Engine mount-

ing, Lower engine tie-bar: Removal - Refitting,
page 19D-10) .

- the engine undertray,

- the front section of the front right-hand wheel arch

liner (see Front wheel arch liner: Removal - Re-
135229
fitting) (55A, Exterior protection),

a Screw on the collar nut (14) until the cover touches - the front right-hand wheel (see Wheel: Removal -
the cylinder head. Refitting) (35A, Wheels and tyres),
a Remove:
a Refit:
- the collar nut from the,
- the cover of the tool, - the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-12) ,
- the stud of the tool.
- the engine cover.

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

ting) (80A, Battery).

11A-94
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K

Equipment required K9K, and 830 or 838

offset spanner a Remove the camshaft position sensor (see 13B,

Diesel injection, Camshaft position sensor: Re-
moval - Refitting, page 13B-8) .
Tightening torquesm

camshaft pulley nut 30 N.m + 86˚ ±

6˚. a Remove the timing belt (see 11A, Top and front of
engine, Timing belt: Removal - Refitting, page
11A-16) .
REMOVAL

I - REMOVAL PREPARATION OPERATION

a Position the vehicle on a two-post lift (see Vehicle:

Towing and lifting) (02A, Lifting equipment).

cardiagn.com
a Disconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
a Remove:

- the engine cover,

- the front wheels (see Wheel: Removal - Refitting)

(35A, Wheels and tyres),

- the front section of the front wheel arch liners (see

Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

- the engine undertray bolts,

- the engine undertray, 118982

- the front bumper (see Front bumper: Removal - a Increase the hole (1) of the (2) using an 8.5 mm drill
Refitting) (55A, Exterior protection), bit.

- the accessories belt (see 11A, Top and front of

engine, Accessories belt: Removal - Refitting,
page 11A-4)

- the crankshaft accessories pulley (see 11A, Top

and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-8) .

K9K, and 830 or 838

a Remove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

a Remove the right-hand suspended engine mounting

(see 1 9 D , Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-5) .

11A-95
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K
II - OPERATION FOR REMOVAL OF PART
CONCERNED

cardiagn.com
118983
a Undo the camshaft pulley hub bolts (3) .
123970
a Fit theon the cylinder head to lock the camshaft pul-
ley wheel.
a Tighten the camshaft pulley hub bolts (3) .
a Remove:
- the nut (4) from the camshaft pulley,
- the,
- the camshaft pulley.

105257
a

Note:
The timing end camshaft seal (5) is removed
using the toolwhich is not equipped with the end
piece (A) to enable it to be fitted on the camshaft
pulley stud.

a Loosen bolts (6) and (7) fully from the.

11A-96
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K

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105270 105272
a Position the claws of theon the camshaft. a Separate the claws by turning the bolt (9) clockwise
using an open-jawed spanner.

105271
a Push the tooluntil contact is made between the ends 105273
(8) of the claws and the camshaft seal.
a Remove the camshaft seal by turning the bolt (10)
clockwise.

REFITTING

I - REFITTING PREPARATION OPERATION

a parts always to be replaced: Camshaft seal on

timing end (10,02,02,02).

11A-97
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K
a parts always to be replaced: camshaft timing
sprocket nut (10,02,02,18).
a Clean and degrease with SURFACE CLEANER
(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products) and a CLEAN
CLOTH :
- the camshaft seal mating face on the camshaft,
- the camshaft seal housing in the cylinder head.

II - REFITTING OPERATION FOR PART

CONCERNED

cardiagn.com
21687-1
a Fit a new camshaft seal on the camshaft.

Note:
For camshaft seals delivered fitted to a protective
sleeve:
105531
-do not remove the camshaft seal from its protec-
tive sleeve,
-fit the sleeve fitted with the camshaft seal on the
camshaft,
-push the protective sleeve towards the cylinder
head until the camshaft seal is in full contact with
the cylinder head,
-fit the seal on the camshaft by following the rec-
ommendations below.

21687
a Screw the stud (11) of theonto the camshaft.

11A-98
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K
1 - First fitting of the camshaft seal 2 - Second fitting of the camshaft seal

cardiagn.com
21687-2 123076
a Depending on the case, the Parts Department deliv-
a Fit the cover (12) and the collar nut (13) of the.
ers seals (14) equipped with a spacer (15) amongst
other things.

21687-3

a Screw on the collar nut until the cover touches the 123075
cylinder head. a

a Remove: Note:
- the collar nut from the, The spacer (16) is used to fit the seal (17) . It is
used with the tool (18) .
- the cover from the,

- the stud of the,

- the protective sleeve.

11A-99
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K
a Remove:
- the collar nut from the,
- the cover from the,
- the stud of the,
- the protection sleeve.

3 - Continued for both methods

a Refit:
- the camshaft pulley,
- a new camshaft pulley nut.

cardiagn.com
21687-2
a Fit the cover (19) equipped with the spacer on the
camshaft seal end and the collar nut (20) of the tool.

Note:
The spacer fits on the cover of the toolso that the
edge of the spacer is on the side of the camshaft
seal.

116756
a Undo the camshaft pulley hub bolts (21) .
a Fit theon the cylinder head to lock the camshaft pul-
ley wheel.
a Tighten:
- the camshaft pulley hub bolts,
- to torque and angle the camshaft pulley nut (30
N.m + 86˚ ± 6˚.)
a Remove the tool.

21687-3
a Screw on the collar nut until the spacer fitted on the
cover touches the cylinder head.

11A-100
 TOP AND FRONT OF ENGINE
Camshaft seal, timing end: Removal - Refitting 11A
K9K
III - FINAL OPERATION - the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
- the engine cover.
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).

cardiagn.com
109049

a Set the camshaft pulley hub using the tool.

Note:
If the tooldoes not fit, turn the camshaft pulley
hub using an 18 mm offset spanner to adjust
the camshaft pulley hub.

a Refit the timing belt (see 11A, Top and front of en-
gine, Timing belt: Removal - Refitting, page 11A-
16) .
a Refit the right-hand suspended engine mounting
(see 1 9 D , Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-5) .

K9K, and 830 or 838

a Refit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-10) .

a Refit:
- the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-4) ,
- the engine undertray,
- the front section of the front wheel arch liners (see
Front wheel arch liner: Removal - Refitting)
(55A, Exterior protection),

11A-101
 TOP AND FRONT OF ENGINE
Oil decanter: Removal - Refitting 11A
K4M

REFITTING
Tightening torquesm
I - REFITTING PREPARATION OPERATION
oil separator bolts 15 N.m
a parts always to be replaced: oil decanter bolt
(11,04,06,23).
REMOVAL
WARNING
I - REMOVAL PREPARATION OPERATION When cleaning par ts, it is essential that the parts
do not impact on each other, otherwise their mat-
a Remove the throttle valve (see 12A, Fuel mixture, ing faces may be damaged and therefore their
Throttle valve: Removal - Refitting, page 12A-12)
adjustments may be altered, which could dam-
.
age the engine.
a Remove:
- the three ignition coils on the flywheel end (see
WARNING
Coils: Removal - Refitting) ,
Do not scrape the joint faces of the aluminium,
- the inlet distributor (see 12A, Fuel mixture, Inlet any damage caused to the joint face will result in

cardiagn.com
distributor: Removal - Refitting, page 12A-14) . a risk of leaks.

II - OPERATION FOR REMOVAL OF PART a Use SUPER CLEANING AGENT FOR JOINT FA-
CONCERNED CES (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to clean:
- the joint face on the oil separator if it is to be re-
used,
- the joint face on the rocker cover.
a Use SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to degrease:
- the joint face on the oil separator if it is to be re-
used,
- the joint face on the rocker cover.

WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

WARNING
136587
Applying excess sealant could cause it to be
a Remove: squeezed out when parts are tightened. A mix-
- the oil decanter bolts, ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
- the oil decanter.

11A-102
 TOP AND FRONT OF ENGINE
Oil decanter: Removal - Refitting 11A
K4M
a Torque tighten in order the oil separator bolts (15
N.m).

III - FINAL OPERATION

a Refit:
- the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-14) ,
- the three ignition coils on the flywheel end (see
Coils: Removal - Refitting) .
a Refit the throttle valve (see 12A, Fuel mixture,
Throttle valve: Removal - Refitting, page 12A-12)
.

cardiagn.com
102738

a Apply RESIN ADHESIVE (see Vehicle: Parts and

consumables for the repair) (04B, Consumables -
Products) using a stipple roller on the joint face of
the oil separator until the joint face is completely
coated.

II - REFITTING OPERATION FOR PART

CONCERNED

136587

a Refit:

- the oil decanter,

- new bolts on the oil decanter.

11A-103