Page 43 of 2492

Contents
Consumables
Identification
Oil consumption
Oil pressure
Engine - Gearbox
Engine and transmission assembly
Sump10-1
10-1
10-2
10-3
10-4
10-19
10-43
TOP AND FRONT OF ENGINE
Timing belt
Cylinder head gasketPage Page
11
Engine and
peripherals
11-1
11-12 ENGINE AND PERIPHERALS
10FUEL SUPPLY - PUMPS -
PREHEATING
Fuel supply
Fuel cut-out on impact
Fuel gallery
Injectors
Fuel filter
Pump flow
Supply pressure
Diesel equipment
Specifications
Description of the pump
Tightening torques (in daN.m)
Special notes
Idle speed settings
Microswitches
Pump
Pump - timing
Coded solenoid valve
Operating diagram
Pre-post-heating unit
Injector holder - heater plug
Fuel filter
Coolant temperature sensor
Inlet - exhaust manifolds
Pump
Brake assistance vacuum pump
Mechanical power assisted steering
pump13-1
13-3
13-8
13-9
13-10
13-11
13-15
13-16
13-17
13-18
13-20
13-22
13-23
13-27
13-28
13-29
13-30
13-36
13-37
13-39
13-40
13-41
13-4213
FUEL MIXTURE
Specifications
Throttle body
Inlet manifold
Exhaust manifold
Manifolds12-1
12-7
12-15
12-18
12-2012
Page 47 of 2492
87363R1
ENGINE AND PERIPHERALS
Oil pressure
10
SPECIAL TOOLING
Mot. 836 -05 Oil pressure testing kit
SPECIAL EQUIPMENT
Long 22 mm socket
CHECKING
The oil pressure must be checked when the engine
is warm (approximately 80°C).
Composition of the kit Mot. 836-05.
USE
F engine
E and K engine
B + FC + E + F
ENGINE CHECK
E and K engines
Idle1 bar
3 000 rpm.3 bar
F engine
1 000 rpm.1.2 bar
3 000 rpm.3.5 bar.
10-3
Page 112 of 2492
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
- the cylinder head, the gasket.
Fit the liner retaining flanges
Mot. 588 (except K7M).
92062R
CLEANING
It is very important not to scratch the gasket faces
of parts in aluminium.
Use Décapjoint to dissolve any gasket remaining
on the metal.
Apply the product to the area to be cleaned; wait
approximately ten minutes then remove using a
wooden spatula.
Gloves should be worn during this operation.
Remember that this operation should be carried
out with extreme care to avoid the risk of foreign
bodies being introduced into the oilways bringing
oil under pressure to the rocker shaft (oilways are
located in both the cylinder head and the cylinder
block).
If this recommendation is not observed there is a
risk that the rocker jets may become blocked and
damage may occur rapidly to the rocker cams and
tappets.
E7J - K7M ENGINE
11-14
Page 115 of 2492
TOP AND FRONT OF ENGINE
Cylinder head gasket
11 F3R ENGINE
Remove:
- the timing belt (see section 11-Timing belt),
- the spark plug caps.
98899R
98900S
Disconnect:
- the pinking sensor,
- the cylinder reference sensor,
- the absolute pressure sensor and its pipe,
- the idle speed valve,
- the air and coolant sensors,
- the throttle potentiometer,
- the injectors,
- the canister solenoid valve pipe,
- the oil vapour rebreathing pipe,
- the brake servo pipe,
- the accelerator cable,
- the fuel supply and return pipes (gallery end),
- the coolant temperature sensor (9).
Remove:
- the air filter,
- hoses 3, 4, 5, 6, 7, 8,
99222R
11-17
Page 118 of 2492
TOP AND FRONT OF ENGINE
Cylinder head gasket
11 F3R ENGINE
CLEANING
It is very important not to scratch the gasket faces
of parts in aluminium.
Use Décapjoint to dissolve any gasket remaining
on the metal.
Apply the product to the area to be cleaned; wait
approximately ten minutes then remove using a
wooden spatula.
Gloves should be worn during this operation.
Remember that this operation should be carried
out with extreme care to avoid the risk of foreign
bodies being introduced into the oilways bringing
oil under pressure to the camshaft (oilways are
located in both the cylinder head and the cylinder
block).
If this recommendation is not observed there is a
risk that the rocker jets may become blocked and
damage may occur rapidly to the rocker cams and
tappets.
CHECKING THE GASKET FACE
Use a straight edge and a set of shims to check for
gasket face deformation.
Maximum bow 0.05 mm.
The cylinder head may not be re-ground.
87474S
11-20
Page 120 of 2492

TOP AND FRONT OF ENGINE
Cylinder head gasket
11F8Q ENGINE
REMOVAL
Put the vehicle on a 2 post lift.
Disconnect the battery.
Remove the engine undertray.
Drain the cooling circuit via the lower radiator
hose (radiator end).
SPECIAL TOOLING REQUIRED
TIGHTENING TORQUES (in daN.m)
Wheel bolt 9
Crankshaft pulley bolt 12
Suspended engine mounting cover bolt 6
Suspended engine mounting limiter bolt 4
Tensioner nut 5
EQUIPMENT REQUIRED
Star socket ST X 14 FACOM for example
Star socket EX 255 FACOM for example
Engine support tool DESVIL M300 for example
99174R
Mot. 251-01 Dial gauge mounting
Mot. 252-01 Pressure plate for measuring cylinder liner protrusion
Mot. 1311-06 Tool for removing fuel pipe
Mot. 591-02 Index
Mot. 591-04 Angular wrench for tightening the cylinder head
Mot. 1054
TDC pin
Mot. 1159 Tool for retaining the engine on the sub-frame
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1281-01 Oil filter wrench
Mot. 1289-03 Fork for centring suspended engine mounting limiter
Remove:
- the timing belt (see section 11 - timing belt),
- bolts (A) mounting the tensioner, together
with bolt (B) for the alternator drive belt ten-
sion strut mounting,
11-22
Page 129 of 2492

FUEL MIXTURE
Specifications
12
DESCRIPTION MAKE/TYPE SPECIAL NOTES
ComputerSIEMENS FENIX 555 tracks
Injection Semi-sequential regulated multipoint injection
Ignition Static with two dual output coils
Power module integral in computer
One pinking sensor
Plugs
EYQUEM FC 52 LS
CHAMPION C10YCGap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
Air filter Replace every other oil change
Fuel filter Mounted in front of the fuel tank under the vehicle
Replace at major service
Fuel pump
WALBROSubmerged in fuel tank
Flow: 80 litres/hour minimum for regulated
pressure of 3 bars and voltage of 12 V
Pressure regulator Regulated pressure
Zero vacuum: 3 ± 0.2 bars
Vacuum of 500 mbar : 2.5 ± 0.2 bars
Solenoid injector
SIEMENSVoltage: 12 V
Resistance : 14.5 ± 1 Ω
Throttle body
PIERBURG
714 186Diameter 44 mm
Idle speed regulation stepping
motor
EGR (K7M 703) solenoid valve
PIERBURG
72213000Voltage: 12 V
Resistance : 30 ± 3 Ω
Fuel vapour recirculation
canister
Solenoid valve
CAN 10
DELCO REMY
Voltage: 12 V
Resistance : 35 ± 5 Ω
Heated oxygen sensor NGK Voltage at 850°C
Rich mixture: > 625 mvolt
Lean mixture: 0 to 80 mvolt
Tightening torque: 4.5 daN.m
Fault finding
FICHE n° 27
CODE D13
SELECTOR ON S8
Throttle potentiometer
Idle speed regulation: 5 ≤ #17 ≤ 47
Full load: 164 ≤ #17 ≤ 253
R.C.O. idle speed: 4 % ≤ #12 ≤ 14 % (K7M 720)
6 % ≤ #12 ≤ 15 % (K7M 702/703 in P and N)
10 % ≤ #12 ≤ 20 % (K7M 703 in D)
Adaptive R.C.O
idle speed: - 2.4 % ≤ #21 ≤ + 6.2%
Adaptive richness
operation: 0 ≤ #30 ≤ 208
Adaptive richness
idle speed: 100 ≤ #31 ≤ 255 (K7M 720)
104 ≤ #31 ≤ 255 (K7M 702/703)
12-4
Page 131 of 2492

FUEL MIXTURE
Specifications
12
DESCRIPTION MAKE/TYPE SPECIAL NOTES
ComputerSIEMENS FENIX 555 tracks
Injection Sequential regulated multipoint injection
Ignition Static with two dual output coils
Power module integral in computer
One pinking sensor
Plugs
EYQUEM C 52 LS
CHAMPION N7YCX
BOSCH W7DCOGap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
Air filter Replace every other oil change
Fuel filter Mounted in front of the fuel tank under the vehicle
Replace at major service
Fuel pump
WALBROSubmerged in fuel tank
Flow: 80 litres/hour minimum for regulated
pressure of 3 bars and voltage of 12 V
Pressure regulator WEBER
BOSCHRegulated pressure
Zero vacuum: 3 ± 0.2 bars
Vacuum of 500 mbar : 2.5 ± 0.2 bars
Solenoid injector
SIEMENSVoltage: 12 V
Resistance: 14.5 ± 1 Ω
Throttle body SOLEX
Diameter 60 mmReference: 127 F3R 751 without AC - F3R 750
Reference: 132 F3R 751 AC
Idle speed regulation solenoid
HITACHI
AESP 207-17Voltage: 12 V
Resistance: 9.5 ± 1 Ω
Fuel vapour recirculation
canister
Solenoid valve
CAN 10
DELCO REMY
Voltage: 12 V
Resistance: 35 ± 5 Ω
Heated oxygen sensor
BOSCH LSH 25Voltage at 850°C
Rich mixture: > 625 mvolt
Lean mixture: 0 to 80 mvolt
Tightening torque: 4.5 daN.m
Fault finding
FICHE n° 27
CODE D13
SELECTOR ON S8
Throttle potentiometer
Idle speed regulation: 8 ≤ #17 ≤ 38
Full load: 188 ≤ #17 ≤ 245
R.C.O. idle speed: 20 % ≤ #12 ≤ 40 % (F3R 750)
18 % ≤ #12 ≤ 38 % (F3R 751)
Adaptive R.C.O
idle speed: - 6.2 % or - 8.6 ≤ #21 ≤ + 6.2 %
Adaptive richness
operation: 82 ≤ #30 ≤ 224
Adaptive richness idle speed: 32 ≤ #31 ≤ 224
12-6