10A-110
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).aRemove:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine - gearbox » assembly (see 10A, En-
gine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) (21A, Manual gearbox),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) ,
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch).
II - REMOVAL OPERATION
aRemove:
-the flywheel bolts,
-the (Mot. 1677) (1) , Special tooling required
Mot. 1677Flywheel locking tool.
Equipment required
refrigerant charging station
Tightening torquesm
flywheel bolts70 N.m
109158
10A-111
ENGINE AND CYLINDER BLOCK ASSEMBLY
Flywheel: Removal - Refitting
K4M
10A
-the flywheel.
REFITTING
I - REFITTING PREPARATION OPERATION
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the flywheel bearing face if reusing,
-the crankshaft bearing face.
aAlways replace the flywheel bolts.
II - REFITTING OPERATION
aFit the flywheel.
aFit the new flywheel bolts without tightening them.
aPosition the (Mot. 1677).
aTighten to torque and in order the flywheel bolts
(70 N.m).
III - FINAL OPERATION
aRefit:
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aPerform the following operations:
-fill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) ,
-fill the gearbox (see Manual gearbox oils: Drain-
ing - Filling) (21A, Manual gearbox).
-fill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the engine undertray.
109158
11A-66
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D7F
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aDisconnect the battery ( (see Battery: Removal -
Refitting) ).
aRemove:
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aUnclip:
-The harness from the heat shield,
-the brake servo pipe from the heat shield.
aDisconnect the ignition coil supply.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the rocker cover bolts,
-the rocker cover.ON THE WORKBENCH
aRemove:
-the ignition coil,
-the heat shield.
REFITTING
I - REFITTING PREPARATIONS OPERATION
ON THE WORKBENCH
aRefit:
-the heat shield,
-the ignition coil.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the rocker cover,
-the rocker cover bolts.
aTorque tighten the rocker cover bolts (10 Nm).
III - FINAL OPERATION.
aConnect the ignition coil supply.
aClip:
-the brake servo pipe onto the heat shield,
-the harness onto the heat shield.
aRefit:
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the intake distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) .
aConnect the battery ( (see Battery: Removal - Re-
fitting) ). Tightening torquesm
rocker cover bolts10 Nm
110422
11A-69
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 772
11A
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) ,
-the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) .
aUnclip the rocker cover electric wiring harnesses.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the rocker cover bolts,
-the rocker cover,
-the rocker cover gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aClean the joint faces with SUPER CLEANER FOR
JOINT FACES (see Vehicle: Parts and consum-
ables for the repair) (04B, Consumables - Prod-
ucts) to dissolve any part of the seal still adhering.
aparts always to be replaced: rocker cover seal.
110422
WARNING
Do not allow this product to dr ip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
11A-70
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 772
11A
II - REFITTING OPERATION FOR PART
CONCERNED
aApply a bead (1) of SILICONE ADHESIVE SEAL-
ANT (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products) to the
camshaft bearings 1 and 5, as well as around the
rocker cover rear bolts.
aFit the rocker cover with a new gasket.aTighten the rocker cover bolts in order.
III - FINAL OPERATION
aRefit:
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
aClip on the rocker cover electric wiring harnesses.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
18441
20005
110422
11A-73
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
aDisconnect the oil vapour rebreathing circuit unions
(9) .
-on the inlet distributor,
-on the air filter box outlet air pipe,
-on the rocker cover.
aRemove the oil vapour rebreathing circuit.
aDisconnect the fuel vapour rebreathing circuit
unions (10) .
-on the air filter box outlet air pipe,
-to the inlet distributor.
aMove the fuel vapour rebreathing pipes to one side.
aDisconnect the vacuum pipe from the brake servo
(11) .
aMove the brake servo vacuum pipe to one side.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the rocker cover bolts,
-the rocker cover,
-the rocker cover gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
aClean the joint faces with SUPER CLEANER FOR
JOINT FACES (see Vehicle: Parts and consum-
ables for the repair) (04B, Consumables - Prod-
ucts) to dissolve any part of the seal still adhering.
aparts always to be replaced: rocker cover seal.
122828
121026
WARNING
Do not allow this product to dr ip onto the paint-
work.
Clean the cylinder head carefully to prevent for-
eign bodies from entering the oil supply and
return galleries.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
11A-74
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
D4F, and 780 or 782 or 784
11A
II - REFITTING OPERATION FOR PART
CONCERNED
aApply beads (1) of MASTIXO (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) around the rocker cover rear bolts
(lower bolts, exhaust side) and on camshaft bearing
no.5.
aFit the new rocker cover seal, starting with bearing
No. 5, then gradually insert the seal studs as the
rocker cover fits into the groove.aRefit:
-the rocker cover fitted with a new seal,
-the rocker cover bolts.
aPretighten to torque and in order the rocker cover
bolts (initial torque) (5 N.m).
aTorque tighten in order the rocker cover bolts (13
N.m).
III - FINAL OPERATION
aFit the brake servo vacuum pipe.
aConnect the brake servo vacuum pipe.
aFit the fuel vapour rebreathing pipes.
aConnect the fuel vapour rebreathing circuit unions:
-on the inlet distributor,
-on the air filter box outlet air pipe.
aFit the oil vapour rebreathing circuit.
aConnect the oil vapour rebreathing circuit unions:
-on the rocker cover,
-on the air filter box outlet air pipe,
-to the inlet distributor.
aRefit:
-the ignition coil (see 17A, Ignition, Coils: Remov-
al - Refitting, page 17A-1) ,
-the filler neck,
-the filler neck bolt,
-the heat shield,
-the heat shield bolts.
aTorque tighten the heat shield bolts (8 N.m).
18441
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
121026
11A-76
TOP AND FRONT OF ENGINE
Rocker cover: Removal - Refitting
K4M
11A
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 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),
-the coils (see 17A, Ignition, Coils: Removal - Re-
fitting, page 17A-1) ,
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-the inlet distributor (see 12A, Fuel mixture, Inlet
distributor: Removal - Refitting, page 12A-29) ,
-the oil decanter (see 11A, Top and front of en-
gine, Oil decanter: Removal - Refitting, page
11A-147) ,
-the engine undertray,
-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 front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) ,
-the camshaft seals on the timing end (see 11A,
Top and front of engine, Camshaft seal, timing
end: Removal - Refitting, page 11A-138) . Tightening torquesm
rocker cover bolts 22,
23, 20 and 13 (initial
torque)8 N.m
rocker cover bolts 1 to
12, 14 to 19 and 21 to
2413 N.m
rocker cover bolts 22,
23, 20 and 1313 N.m
camshaft sensor bolt8 N.m
camshaft dephaser
solenoid valve bolt10 N.m