Page 364 of 652

13B-3
DIESEL INJECTION
Diesel injection: Precautions for the repair
K9K
13B
2 - Using the brake cleaner
Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Spray the brake cleaner onto the unions to be opened.
Clean the unions carefully using fresh cleaning cloths.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Check that no
bristles from the brush have come away and that the
area is clean.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with com-
pressed air. Use cleaning cloths only, if necessary.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
WARNING
To prevent impurities from entering, once the fuel
circuit is opened, it must not be blasted with com-
pressed air. Use cleaning cloths only, if necessary.
Page 404 of 652

13B-43
DIESEL INJECTION
Injector rail: Removal - Refitting
K9K
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment)
aRemove the front engine cover.
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aDisconnect:
-the heater plug connectors (1) ,
-the connectors (2) from the injectors. Special tooling required
Mot. 1746Offset wrench for tightening
High Pressure pump pipes.
Tightening torquesm
studs of the injection rail
on the cylinder head8 Nm
injector rail nuts28 Nm
unions for the high pres-
sure pipes between the
rail and the yellow-
coloured injector24 Nm
unions for the high pres-
sure pipes between the
rail and the silver-
coloured injector28 Nm
unions for the high pres-
sure pipes between the
pump and the yellow-
coloured r ail24 Nm
unions for the high pres-
sure pipes between the
pump and the silver-
coloured r ail28 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 13B, Diesel injection, Diesel injec-
tion: Precautions for the repair, page 13B-1) .
IMPORTANT
Use the diagnostic tool before any operation is car-
ried out on the injection circuit to check:
-that the rail is not under pressure,
-that the fuel temperature is not too high.
Working on the circuit with the engine running is
strictly forbidden.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
IMPORTANT
Wear leaktight gloves (nitrile type) for this opera-
tion.
WARNING
To prevent impurities from entering the circuit, place
protective plugs on all fuel circuit components
exposed to the open air.
127895
Page 422 of 652

14A-4
ANTIPOLLUTION
Fuel vapour absorber: Removal - Refitting
D4F or D7F or K4M, and TECHNICAL REG: GERMANY or TECHNICAL REG: AUSTRIA or TECHNICAL REG:
BALKANS or TECHNICAL-LEGISLATIVE BELGIUM or TECHNICAL REG: BOSNIA or TECHNICAL REG:
CYPRUS-MALTA or CZECH REP AND SLOVAKIA or TECHNICAL REG: DENMARK or TECHNICAL REG: DOM
(FRENCH OVERSEAS SUBDIVISION) or TECHNICAL REG: SPAIN or TECHNICAL REG: FINLAND or
TECHNICAL REG: FRANCE or TECHNICAL REG: GREAT BRITAIN or TECHNICAL REG: GREECE or
TECHNICAL-LEGISLATIVE HOLLAND or TECHNICAL REG: HUNGARY or TECHNICAL REG: IRELAND or
TECHNICAL REG: ICELAND or TECHNICAL REG: ISRAEL or TECHNICAL REG: ITALY or TECHNICAL REG:
JAPAN or TECHNICAL REG: NORTH or TECHNICAL REG: NORWAY or TECHNICAL REG: POLAND or
TECHNICAL REG: PORTUGAL or TECHNICAL REG: SLOVENIA or TECHNICAL REG: SWEDEN or TECHNICAL
REG: SWITZERLAND or TECHNICAL REG: TOM (FRENCH OVERSEAS TERRITORIES)
14A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
II - REMOVAL OPERATION
aUnclip:
-the fuel filter on the fuel vapour absorber in the di-
rection of the arrow (1) ,
-the fuel vapour absorber in the direction of the ar-
row (2) . IMPORTANT
During this oper ation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting the
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
Keep the pipe unions away from contaminated
areas.
WARNING
To prevent impurities from entering the circuit, place
protective plugs on all fuel circuit components
exposed to the open air.
D4F or D7F
120513
Page 424 of 652

14A-6
ANTIPOLLUTION
Fuel vapour absorber: Removal - Refitting
D4F, and SOUTH AFRICA
14A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting)
aDisconnect the battery (see Battery: Removal - Re-
fitting)
aRemove the rear left-hand wheel (see Wheel: Re-
moval - Refitting)
aRemove the rear left-hand wheel arch liner (see ) II - OPERATION FOR REMOVAL OF PART
CONCERNED
aUnclip the petrol vapour absorber pipe.
aRemove:
-the petrol vapour absorber bolts.
-the petrol vapour absorber.
REFITTING
REFITTING OPERATION FOR PART CONCERNED
aRefit.
-the petrol vapour absorber.
-the petrol vapour absorber bolts
aClip on the petrol vapour absorber pipe.
FINAL OPERATION
aRefit the rear left-hand wheel arch liner (see )
aRefit the rear left-hand wheel (see Wheel: Removal
- Refitting)
aReconnect the battery (see Battery: Removal - Re-
fitting) IMPORTANT
During this oper ation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting the
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
WARNING
Keep the pipe unions away from contaminated
areas.
WARNING
To prevent impurities from entering the circuit, place
protective plugs on all fuel circuit components
exposed to the open air.
143884
Page 426 of 652

14A-8
ANTIPOLLUTION
Fuel vapour absorber bleed solenoid valve: Removal - Refitting
K4M
14A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-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).II - REMOVAL OPERATION
aDisconnect:
-the fuel vapour absorber bleed solenoid valve con-
nector (3) ,
-the fuel vapour absorber bleed solenoid valve
pipes (4) .
aInsert the blanking plugs.
aUnclip the fuel vapour absorber bleed solenoid
valve.
REFITTING
I - REFITTING OPERATION
aClip on the fuel vapour absorber bleed solenoid
valve.
aRemove the blanking plugs.
aConnect:
-the fuel vapour absorber bleed solenoid valve
pipes,
-the fuel vapour absorber bleed solenoid valve con-
nector. IMPORTANT
During this oper ation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting the
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
131766
WARNING
To prevent impur ities from entering the circuit,
place protective plugs on all fuel circuit compo-
nents exposed to the open air.
Page 473 of 652
17A-17
IGNITION
Plugs: Removal - Refitting
D4F, and 772
17A
Spark plug electrode gap
REMOVAL
I - REMOVAL PREPARATION OPERATION
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .a
Disconnect the spark plug wiring.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the spark plugs using the (Ele. 1933) (1)
equipped with the (Ele. 1382-01) (2) . Special tooling required
Ele. 193323 N.m tightening wrench for
spar k plugs
Ele. 1382-0114 mm Plug spanner.
Equipment required
set of feeler gauges
Tightening torquesm
spar k plugs23 N.m
Type of spark plug Gap (mm)
CHAMPION 0.90 ± 0.05
NGK 0.85 ± 0.05
132677
WARNING
To disconnect the spark plug leads, pull on the
extensions and not on the leads.
132700
Page 504 of 652
17B-29
PETROL INJECTION
Injector rail - Injectors: Removal - Refitting
D4F, and 780 or 782
17B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (80A, Battery).
a
aDisconnect the air filter unit air inlet pipe (3) on the
air filter unit cover.
aMove aside the air inlet pipe from the air filter unit.
aRemove the bolt (4) of the intercooler air inlet pipe
from the throttle valve. Tightening torquesm
injector rail - injector
bolts4.5 N.m
IMPORTANT
During this oper ation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting the
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
122833
122673
Note:
If the tightening clip (1) of the intercooler air inlet
pipe is removed, the flexible rubber pipe (2) and
the tightening clip (1) must be replaced.
Page 508 of 652

17B-33
PETROL INJECTION
Injector rail - Injectors: Removal - Refitting
K4M
17B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (80A, Battery).
aRemove:
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-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
aDisconnect the fuel supply pipe (1) from the injector
rail.
aInsert the blanking plugs.
aRemove the inlet distributor (see 12A, Fuel mixture,
Inlet distributor: Removal - Refitting, page 12A-
29) . Tightening torquesm
injector rail bolts10 N.m
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
IMPORTANT
During this oper ation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting the
union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
131767
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to r un.