Page 436 of 652

14A-18
ANTIPOLLUTION
Exhaust gas recirculation assembly: Removal - Refitting
K9K
14A
aRefit:
-new seals on the coolant circulation cover,
-the coolant circulation cover on the exhaust gas
cooler.
aTorque tighten the coolant circulation cover bolts
on the exhaust gas cooler (12 N.m).
aRemove the tool (Ms. 583) from the coolant inlet and
outlet hoses of the exhaust gas cooler.
III - FINAL OPERATION
aFit the intercooler air outlet pipe at the damper valve
end.
aConnect the intercooler air outlet pipe on the side of
the damper valve.
aTorque tighten the intercooler air outlet pipe clip
at the damper valve end (5.5 N.m).
aRefit the intercooler air outlet pipe nut on the lifting
eye.
aConnect the turbocharging pressure regulator vacu-
um pipe.
aClip:
-the turbocharging pressure regulator vacuum pipe,
-the vacuum pipe from the brake servo.
aConnect the brake servo vacuum pipe.
aFit the intercooler air inlet pipe at the turbocharger
end.
aRefit the intercooler air inlet pipe nut at the turbo-
charger end on the lifting eye.
aConnect the intercooler air inlet pipe at the turbo-
charger end.
aClip on the intercooler air inlet pipe clip at the turbo-
charger end.
aRefit the air outlet pipe onto the air filter unit.
aTighten the air filter unit air outlet pipe clip on the tur-
bocharger.
aConnect the oil vapour rebreathing pipe.
aRefit:
-the exhaust gas recirculation rigid pipe (see 14A,
Antipollution, Exhaust gas recirculation rigid
pipe: Removal - Refitting, page 14A-19) ,-the catalytic converter (see 19B, Exhaust, Cata-
lytic converter: Removal - Refitting, page 19B-
12) ,
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the EGR solenoid valve (see 14A, Antipollution,
Exhaust gas recirculation solenoid valve: Re-
moval - Refitting, page 14A-10) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-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),
aConnect the battery (see ) (80A, Battery).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aRefit the engine cover. K9K, and 718
Page 449 of 652
16A-10
STARTING - CHARGING
Starter: Removal - Refitting
D4F or D7F
16A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see ) (80A, Battery).
aRemove the engine oil dipstick.
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aDisconnect the air filter unit air inlet pipe from the air
filter unit cover (1) .
aMove the air filter unit air inlet pipe away from the air
filter unit cover.aDisconnect the pinking sensor connector (2) .
aRemove the engine wiring channel bolt from the
gearbox.
aUnclip the engine wiring channel from the gearbox.
aMove aside the engine wiring channel. Tightening torquesm
starter upper bolt44 N.m
starter electrical supply
nut8N.m
D4F, and 772
D4F, and 780 or 782
122833
120512
120414
Page 452 of 652
16A-13
STARTING - CHARGING
Starter: Removal - Refitting
D4F or D7F
16A
aClip the engine wiring channel onto the gearbox.
aRefit the engine wiring channel bolt to the gearbox.
aTighten the engine wiring channel bolt on the gear-
box.
aConnect the pinking sensor connector.
aFit the air filter unit air inlet pipe on the air filter unit
cover.
aConnect the air filter unit air inlet pipe on the air filter
unit cover.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aRefit the engine oil dipstick.
aConnect the battery (see ) (80A, Battery). D4F, and 780 or 782
D4F, and 772
Page 476 of 652
17B-1
PETROL INJECTION
Petrol injection: List and location of components
D4F, and 772
17B
121740
(1) Petrol vapour rebreathing sole-
noid valve
(2) Intake air pressure sensor
(3) Motorised throttle valve
(4) Injection computer
121739
(5) Intake air temperature sensor
(6) Pinking sensor
(7) Coolant temper ature sensor
(8) Engine speed and flywheel posi-
tion sensor
113044
(9) Ignition coil
Page 479 of 652
17B-4
PETROL INJECTION
Petrol injection: List and location of components
D7F, and 800
17B
(8) Coolant temper ature sensor
(9) Engine speed and position sen-
sor
120404
(10) Ignition coil
121732
(11) Upstream oxygen sensor
120415
(12) Downstream oxygen sensor
Page 480 of 652
17B-5
PETROL INJECTION
Petrol injection: List and location of components
D4F, and 780 or 782
17B
122387
(1) Fuel vapour recirculation sole-
noid valve
(2) Upstream oxygen sensor
(3) Petrol injection computer
(4) Motorised throttle valve
(5) Ignition coil
(6) Engine compar tment connec-
tion unit
(7) Intake distributor pressure sen-
sor
(8) Turbocharger
108254
(9) Fuel injection computer
Page 520 of 652

19A-10
COOLING
Cooling system: Draining - Refilling
D4F or D7F or K4M or K9K
19A
2 - Filling method without special tools
a
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aRemove the front engine cover.
aOpen the bleed screws (1) and (2) .
aFill the cooling system with engine coolant recom-
mended by the manufacturer (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) via the expansion bottle until it
overflows.
aClose all the bleed screws as soon as the coolant
starts to flow in a continuous stream.aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aRefit the engine cover.
aPressurise the system using the (Ms. 554-07) to
check that there are no leaks (see 19A, Cooling,
Engine cooling system: Check, page 19A-2) .
aRefit the expansion bottle cap.
aClean any surfaces soiled by the coolant.
IV - BLEEDING
a
aStart the engine.
aMaintain the engine speed at 2500 rpm using the
pedal press for 5 min.
aStabilise the engine speed at 2000 rpm until the fan
assembly has been activated twice.
aMaintain the engine speed at 2500 rpm, using the
pedal press for 5 minutes.
aStabilise the engine speed at 2000 rpm until the fan
assembly is activated.
aNote the coolant level in the expansion bottle after
this first activation.
aAccelerate at a minimum of 4000 rpm for several
seconds, until the level of coolant fluid in the expan-
sion bottle drops. WARNING
It is essential to open all of the bleed screws to
remove as much as air as possible in the cooling
system. Failure to perform this procedure may
prevent the cooling system from filling properly
and may damage the engine.
D4F, and 772 – K4M
K9K
120526
D4F, and 772 – K4M
K9K
WARNING
Do not open the bleed screw whilst the engine is
running; this would damage the engine.
D4F, and 772 – D7F, and 800
D4F, and 780 or 782
Page 555 of 652

19A-45
COOLING
Water chamber: Removal - Refitting
K9K
19A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit the thermostat to the water chamber.
aRefit:
-a new water chamber seal,
-the water chamber.
aTorque tighten the water chamber bolts (10 N.m).
III - FINAL OPERATION
aConnect the cooling hoses on the water chamber.
aPosition the cooling hose clips on the water chamber
using the tool (Mot. 1448).
aClip on the cooling hose of the coolant-oil heat ex-
changer.
aConnect the intercooler air outlet pipe on the side of
the damper valve.
aTorque tighten the intercooler air outlet pipe clip
at the damper valve end (5.5 N.m).
aConnect the brake servo vacuum pipe.
aClip:
-the turbocharging pressure regulator vacuum pipe,
-the vacuum pipe from the brake servo.
aConnect the turbocharging pressure regulator vacu-
um pipe.
aRefit the nuts of the air hoses on the lifting eye.
aConnect the intercooler air inlet pipe at the turbo-
charger end.
aClip on the intercooler air inlet pipe clip at the turbo-
charger end.
aFill the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) .
aRefit the engine cover. K9K, and 718