Page 441 of 652
16A-2
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and STANDARD HEATING
16A
aRemove:
-the filler neck bolt (1) ,
-the filler neck in the direction of the arrow (2) ,
-the dipstick.
aDisconnect the fuel pipe (3) from the injector rail.II - REMOVAL OPERATION FOR PART
CONCERNED
aDisconnect the connector (4) from the alternator wir-
ing harness.
aRemove:
-the alternator wiring harness nut (5) ,
-the alternator bolts,
-the alternator.
REFITTING
I - REFITTING PREPARATIONS OPERATION
aClean the alternator pulley V-grooves to remove any
deposits. D4F, and 780
122392
IMPORTANT
During this operation, 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 latex gloves during the operation.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
109727
Page 442 of 652

16A-3
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and STANDARD HEATING
16A
aPress in the rings (6) using pliers or a vice to make
the fitting operation easier.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the alternator,
-the alternator bolts.
aTorque tighten the alternator bolts (25 Nm).
aRefit:
-the power lead on the alternator,
-the power lead nut on the alternator.
aConnect the alternator excitation lead connector.
III - FINAL OPERATION
aConnect the fuel pipe to the injector rail.
aRefit:
-the dipstick,
-the filler neck,
-the filler neck bolt.
aAlways replace the accessories belt.aRefit the new accessories belt (see 11A, Top and
front of engine, Accessories belt: Removal - Re-
fitting, page 11A-3) .
aFit the sub-frame tie-rod.
aRefit the upper bolt on the sub-frame tie-rod.
aTorque tighten:
-the sub-frame tie-rod lower bolt (62 Nm),
-the sub-frame tie-rod upper bolt (21 Nm).
aRefit:
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (MR 412,
55A, Exterior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (MR 411, 35A, Wheels and tyres).
aConnect the battery (see ) (MR 411, 80A, Battery).
18987
D4F, and 780
Page 443 of 652

16A-4
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and AIR CONDITIONING
16A
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).
aRemove:
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres),
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) .
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aRemove the inlet distributor (see 12A, Fuel mixture,
Inlet distributor: Removal - Refitting, page 12A-
29) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the alternator connector.
aRemove the alternator positive terminal nut.
aRemove:
-the alternator bolts,
-the alternator. Tightening torquesm
alter nator bolts25 N.m
D4F
120519
Page 444 of 652

16A-5
STARTING - CHARGING
Alternator: Removal - Refitting
D4F or D7F, and AIR CONDITIONING
16A
REFITTING
I - REFITTING PREPARATION OPERATION
aPush in the alternator rings using pliers or a vice to
facilitate fitting the alternator.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the alternator,
-the alternator bolts.
aTorque tighten the alternator bolts (25 N.m).
aRefit the alternator positive terminal nut.
aConnect the alternator connector.
III - FINAL OPERATION
aRefit the inlet distributor (see 12A, Fuel mixture, In-
let distributor: Removal - Refitting, page 12A-29)
.
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .aRefit:
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
18987
D4F
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 455 of 652

16A-16
STARTING - CHARGING
Starter: Removal - Refitting
K4M
16A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
II - REMOVAL OPERATION
aRemove:
-the starter supply cable nut (1) ,
-the starter excitation cable nut (2) .
aMove the starter wiring aside.aRemove:
-the starter bolts (3) ,
-the starter.
REFITTING
I - REFITTING PREPARATION OPERATION
aCheck that the centring dowel is in place.
II - REFITTING OPERATION
aRefit the starter.
aFit the starter wiring.
aTorque tighten:
-the starter supply cable nut (8 N.m),
-the starter excitation cable nut (5 N.m).
III - FINAL OPERATION
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery). Tightening torquesm
starter supply cable nut8 N.m
starter excitation cable
nut5 N.m
132366
132367
Page 459 of 652
17A-3
IGNITION
Coils: Removal - Refitting
D4F, and 772
17A
PARTS AND CONSUMABLES FOR THE
REPAIR WORK
aConsumable (see Vehicle: Parts and consuma-
bles for the repair) :
-Fluostar 2L.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery (see Battery: Removal - Re-
fitting) .
aRemove the air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
a
aDisconnect:
-the ignition coil high voltage wiring harness,
-the ignition coil connector.aRemove:
-the ignition coil bolts ,
-the ignition coil.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the ignition coil,
-the ignition coil bolts.
120300
WARNING
To disconnect the spark plug leads, pull on the
extensions and not on the leads.
113044