Page 2 of 52
Downloaded from www.Manualslib.com manuals search engine Contents
Page
07
10
11
12
16
VALUES AND SETTINGS
Capacities - Grades 07-1
Tightening the cylinder head 07-2
ENGINE AND PERIPHERALS
Identification 10-1
Oil pressure 10-2
Engine and transmission assembly 10-3
TOP AND FRONT OF ENGINE
Accessories belt 11-1
Timing belt 11-2
Cylinder head gasket 11-8
TURBOCHARGING - FUEL
MIXTURE
Turbocharger 12-1
Air inlet 12-3
Exhaust manifold 12-7
Inlet manifold 12-8
STARTING - CHARGING
Alternator 16-1
Starter 16-4Page
19
21
61
62
COOLING SYSTEM
Filling - bleeding 19-1
Diagram 19-2
Coolant pump 19-3
Suspended mountings 19-4
Cooling system 19-5
MANUAL GEARBOX
Identification 21-1
Gears 21-2
Lubricants 21-3
Remove and refit 21-4
HEATING
Additional heating 61-1
AIR CONDITIONING
Air conditioning compressor 62-1
Page 3 of 52
Downloaded from www.Manualslib.com manuals search engine VALUES AND SETTINGS
Capacities - Grades
07
107VALUES AND SETTINGS
Capacities - Grades
* Adjust using the dipstick
(1) After replacing the oil filterComponentsCapacity in
litres
(approx.)*Grade
Diesel engine
(oil)
G9TFor oil
changes
7.7
8.3 (1)European Union countries
Other countries
ComponentsCapacity in
litresGrade Special notes
Gearbox
PK13.1All countries: TRANSELF TRX 75 W 80 W
(Standards API GL5 or MIL-L 2105 G or D)
Coolant circuit
G9T 7.5Glacéol RX
(type D)Protection to - 35 ˚C ± 2 ˚C for all countries
07-1
Page 5 of 52
Downloaded from www.Manualslib.com manuals search engine ENGINE AND PERIPHERALS
Identification
10
110ENGINE AND PERIPHERALS
Identification
Manual to consult: Mot. G9 Vehicle type Engine GearboxCapacity
(cm
3)Bore
(mm)Stroke
(mm)Compression
ratio
JE0 K
JE0 S G9T PK1 2188 87 92 18/1
10-1
Page 7 of 52
Downloaded from www.Manualslib.com manuals search engine ENGINE AND PERIPHERALS
Engine and transmission assembly
10
10-3
Engine and transmission assembly
Parts to order: high pressure circuit plugs kit
Part No.: 77 01 206 381. SPECIAL TOOLING REQUIRED
Mot. 1390 Universal mounting
Mot. 1410 Tool for unlocking the snap
couplings in the refrigerant
circuit
Dir. 1282 -01 Spanner for undoing the
steering rack union
Dir. 1282 -02 Spanner for undoing the
steering rack union
ESSENTIAL SPECIAL TOOLING
Two-post lift
Safety pad or belts
TIGHTENING TORQUES (in daN.m)
Shock absorber base mounting bolts
Ø M16 x 200 20
Driveshaft gaiter mounting bolt 2.5
Wheel bolts 10
Engine tie-bar bolts 10
Suspended mounting bolt to gearbox 5.5 to 6.5
Rubber suspended mounting nut to
the front left side member 5.5 to 8
Mounting bolt for front right
suspended mounting cover to engine 6.2
Mounting bolt for the movement
limiter of the upper front right hand
suspended engine mounting 10.5
Mounting nut for the rubber pad on
the front right suspended engine
mounting cover 3 to 4.5
Page 9 of 52
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Engine and transmission assembly
10
10-5
Disconnect the air conditioning compressor pipe
connections.
Remove the complete heater exhaust line (if fitted).Remove:
–the exhaust pre catalytic converter,
–the engine tie-bar.
Disconnect the olives on the gearbox control cable.
10442M
Page 12 of 52
Downloaded from www.Manualslib.com manuals search engine ENGINE AND PERIPHERALS
Engine and transmission assembly
10
10-8
Prepare the universal mounting tool Mot. 1390 and
position it beneath the engine and transmission
assembly (two people).Remove:
–the right-hand suspended mounting cover,
–the travel limiter linkage located just behind this
cover,
–the left-hand suspension axis mounting nut.
Gently raise the vehicle in relation to the engine (two-
person operation).
IMPORTANT: when lifting, hold on to the gearbox
control cables to prevent them from becoming trapped
and being damaged.
14935M1
Page 13 of 52
Downloaded from www.Manualslib.com manuals search engine ENGINE AND PERIPHERALS
Engine and transmission assembly
10
10-9
REFITTING - Special points
Pre-position the gearbox control cables.
Position the engine/gearbox assembly in its
compartment. Check the rear of the gearbox in relation
to the sub-frame.
Fitting suspended mountings: see section 19
"Suspended mountings".
Tighten all the bolts, nuts and studs to the
recommended torques.
Refitting is the reverse of removal.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
Reprogram all the components deprogrammed by
disconnecting the battery.
Fill the refrigerant circuit using the filling station (see
section 62 "Air conditioning").
Refrigerant fluid R134a: 800 ± 20 g.
Carry out:
–filling and bleeding of the cooling circuit (see
section 19),
–filling and bleeding of the power assisted steering
circuit,–bleed the hydraulic clutch circuit.
Damage to the union leads to replacement of the
master cylinder, and thus removal/refitting of the
gearbox.IT IS ESSENTIAL THAT YOU FOLLOW THE
BLEEDING METHOD GIVEN BELOW
VERY IMPORTANT:
When bleeding use a 19 mm ring spanner to
immobilise the rotating union (C) while tightening
and loosening the bleed screw (A) so as not to
damage the slave cylinder and the union.
15583R
Page 42 of 52
Downloaded from www.Manualslib.com manuals search engine MANUAL GEARBOX
Identification
21
121MANUAL GEARBOX
Identification
JE0 K - JE0 S vehicles with G9T turbo engines, are fitted with PK1 manual gearboxes.
A mark on the gearbox casing shows:
At A: the gearbox type
At B: the homologation number
At C: the gearbox suffix
At D: the factory of manufacture
At E: the fabrication number
21-1
