Dacia Logan User Manual

1

Engine and lower engine
assembly

10A

11A

12A

13A

14A

16A

17A

ENGINE AND LOWER ENGINE ASSEMBLY

TOP AND FRONT OF ENGINE

FUEL MIXTURE

FUEL SUPPLY

ANTIPOLLUTION

STARTING - LOAD

IGNITION

17B

19A

19B

19C

"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are

constructed."

PETROL INJECTION

COOLING SYSTEM

EXHAUST

RESERVOIR

© Renault s.a.s. 2004

X90

APRIL 2004 Edition Anglaise

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.

19D

ENGINE MOUNTING

"The repair methods given by the manufacturer in this document are based on the technical
specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the
production of the various component units and accessories from which his vehicles are

constructed."

© Renault s.a.s. 2004

X90

APRIL 2004 Edition Anglaise

All copyrights reserved by Renault.

The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.

L90 - Section 1ContentsPage

L90 - Section 1

Contents

10A ENGINE AND LOWER ENGINE ASSEMBLY

Engine identification

Oil filter 10A-1

Oil consumption 10A-3

Oil pressure 10A-4

Engine/gearbox assembly 10A-5

Sump 10A-31

Oil pump 10A-41

Multifunction support 10A-43

11A TOP AND FRONT OF ENGINE

Accessories belt 11A-1

Timing belt 11A-19

Cylinder head gasket 11A-29

13A FUEL SUPPLY

Petrol supply circuit 13A-1

Injector rail - Injectors 13A-2

Fuel pressure
regulator:Checking 13A-6

Electric fuel: Checking 13A-7

14A ANTIPOLLUTION

Petrol vapour rebreathing:
Operation 14A-1

Fuel vapour rebreathing:
Checking 14A-2

Fuel vapour canister 14A-3

Fuel vapour
canister:Checking 14A-4

12A FUEL MIXTURE

Specifications 12A-1

Air inlet 12A-7

Air filter: Replacement 12A-9

Air filter unit 12A-11

Inlet manifold 12A-13

Exhaust manifold 12A-19

Throttle valve 12A-23

Throttle body: Connection 12A-25

16A STARTING - LOAD

Alternator: General
information 16A-1

Alternator 16A-2

Starter: Identification 16A-12

Starter motor 16A-13

17A IGNITION

coils 17A-1

Spark plugs 17A-5

Contents

17B PETROL INJECTION

Location of components 17B-1

Oxygen sensors 17B-7

Position and speed sensor 17B-11

Fuel supply computer 17B-13

Computer: Connection 17B-19

Special notes 17B-21

Injection warning light 17B-23

Immobiliser function 17B-24

Injection - air conditioning
programming 17B-25

Throttle body potentiometer 17B-26

Idle speed correction 17B-28

Richness regulation 17B-29

Central coolant temperature
management 17B-30

Special notes on the system
(when driving) 17B-31

19A COOLING SYSTEM

Water pump 19A-14

Thermostat 19A-18

Engine cooling fan assembly 19A-19

19B EXHAUST

General information 19B-1

Pipe assembly 19B-3

Catalytic converter 19B-5

Expansion chamber 19B-9

Silencer 19B-10

19C RESERVOIR

Draining the fuel tank 19C-1

Fuel tank 19C-3

Conditions for carrying out
fault finding (when driving) 17B-32

Combustion misfire fault
finding 17B-33

Catalytic converter fault
finding 17B-34

Oxygen sensor fault finding 17B-35

19A COOLING SYSTEM

General information 19A-1

Specifications 19A-2

Checking 19A-3

Diagram 19A-4

Bleeding and filling the
cooling circuit. 19A-6

Bleeding the cooling circuit 19A-8

Pump / sender unit / filter 19C-7

Fuel level sensor: Distinctive 19C-10

19D ENGINE MOUNTING

Suspended engine mounting 19D-1

Cooling radiator 19A-9

ENGINE AND LOWER ENGINE ASSEMBLY

Oil filter

L90, and K7J, and 710

Essential special tooling

Mot. 1329 Oil filter cover - 76 mm

diameter

REPLACING THE OIL FILTER

10A

109223

Remove the oil filter using tool (Mot. 1329).

Coat the sealing ring of the new oil filter with engine
oil.

Tighten the oil filter by hand.

10A-1

ENGINE AND LOWER ENGINE ASSEMBLY

Oil filter

L90, and K7M, and 710

Essential special tooling

Mot. 1329 Oil filter cover - 76 mm

diameter

REPLACING THE OIL FILTER

10A

109223

Remove the oil filter using tool (Mot. 1329).

Coat the sealing ring of the new oil filter with engine
oil.

Tighten the oil filter by hand.

10A-2

ENGINE AND LOWER ENGINE ASSEMBLY

Oil consumption

L90, and K7J or K7M

PROCEDURE FOR MEASURING OIL
CONSUMPTION

1 - Filling to the maximum level

Note:

The operation should be carried out with the
engine warm after the fan assembly has cut in
once.

Turn the engine off.

Wait 2 minutes for all the oil to flow into the oil sump.

Carry out a visual inspection using the dipstick.

Top up to the "MAX" mark.

10A

Make a paint mark on both the filler plug and the
sump drain plug in order to be able to check later that

it has not been removed.

2 - Customer driving

Ask the customer to drive approximately 1240 miles
(2000 km) in the vehicle without letting the oil level

reach the "MIN" mark.

3 - Topping up

Note:

The operation should be carried out with the
engine warm after the fan assembly has cut in

once.

Turn the engine off.

Wait 2 minutes for all the oil to flow into the oil sump.

Carry out a visual inspection using the dipstick.

Top up to the "MAX" mark.

Note the quantity of oil added and the mileage cove­red since the last top-up to maximum level.

4 - Measurement of the oil consumption

Oil consumption = Quantity of topping up oil (in
litres) / number of kilometres (in thousands).

10A-3

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pressure

L90, and K7J or K7M

I -CHECKING

Special tooling required

Mot. 36-05 Oil pressure gauge kit

Ensure that the engine oil level is between the "MIN"
and "MAX" marks.

F

A

B

E

10A

C

D

G

Use the tool (Mot. 836-05) and a long dowel of 22 mm.

The oil pressure check must be carried out with the en­gine warm (approximately 80˚C).

II - USE

K7J
engine

C + E + F

K7M
engine

H

87363

Connect the pressure gauge in place of the oil pressure
switch.

III - ENGINE MANAGEMENT

K7J/K7M engine:

- Idling : 1 bar

- 3000 rpm: 3 bar

Torque tighten the oil switch (3.5 daNm).

10A-4

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

Essential special tooling

Mot. 1202-01 Clip pliers for cooling

system hose clips
(large model)

Mot. 1202-02 Clip pliers for cooling

system hose clips
(small model)

Mot. 1448 Remote operation

pliers for cooling sys­tem hose clips

Mot. 1453 Multiple-adjusting

engine mounting sup­port with retaining

straps

Mot. 1159-03 Engine mounting on

right-hand side mem­ber for operations not
requiring removal of
the engine

10A

Tightening torquesm

shock absorber base
bolts

brake calliper mounting
bolts

track rod end nuts 3.7 daNm

engine tie-bar mounting
bolts

wheel bolts 10.5 daNm

REMOVAL

Note:

The « engine and gearbox » assembly can be
removed by removing the « engine and gearbox/
driveshafts/half-axles/sub-frame » assembly.

10,5 daNm

10.5 daNm

10.5 daNm

Mot. 1390 Support for removing

and refitting the engine
and gearbox assembly

Tav. 1747 Threaded rods for

removing the sub­frame

Essential equipment

filling station

Tightening torquesm

gearbox rubber moun­ting mounting bolts

gearbox cover moun­ting nut on the gearbox
rubber mounting

sub-frame mounting
bolts

10.5 daNm

6.2 daNm

10.5 daNm

Place the vehicle on a two-post lift.

IMPORTANT

During this operation, use a strap to secure the
vehicle to the lift to prevent it from becoming
unbalanced.

For the strap fitting procedure, (see 02A, Lifting
equipment, Underbody lift).

sub-frame tie-rod upper
mounting bolts

sub-frame tie-rod lower
mounting bolts

steering rack mounting
bolts

2.1 daNm

6.2 daNm

10.5 daNm

10A-5

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

3

Engine/gearbox assembly

1

10A

107846

Disconnect the battery, starting with the negative ter­minal.

Remove:

- fuse and relay cover (1),

- the fuse holders and relays from their supports (2),

- battery mounting clamp (3),

- the battery.

2

107845

109184

10A-6

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

Engine/gearbox assembly

Drain:

- the engine oil if necessary,

- the gearbox oil if necessary,

- the cooling circuit via the bottom hose, using tool
(Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

DIRECTION MANUELLE, and BASIC HEATING

4

4

10A

Remove:

108564

7

5

6

109398

Disconnect fan assembly connector (6).

Unclip the electrical harness from fan assembly (7).

108562

- the injection computer protector in (4),

- the injection computer in (5),

- the fuse and relay supports,

- the electrolyte recovery tray under the battery,

- the air suction sleeve on the body,

- the front wheels,

- the engine undertray,

- the bumper mounting bolts under the sub-frame.

10A-7

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

DIRECTION ASSISTEE, and BASIC HEATING

10A

11

9

Remove the power assisted steering pipe mounting
bolts:

8

- from the top of sub-frame (11),

107924

109398

Disconnect fan assembly connector (8).

Unhook the electrical harness from fan assembly (9).

10

- on the multifunction support,

- on the rear of the cylinder block.

Disconnect:

- the low pressure hose on the power assisted stee­ring pump and drain the circuit,

- the high-pressure pipe from the power assisted
steering pump,

- the high-pressure pipe from the steering rack.

Remove the power assisted steering high-pressure
pipe.

109397

Disconnect connector (10) of the power assisted
steering pressure switch.

10A-8

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

DIRECTION MANUELLE, and AIR CONDITIONING

12

10A

DIRECTION ASSISTEE, and AIR CONDITIONING

14

109396

Disconnect fan assembly connectors (12).

13

108107

Disconnect connector (13) from the refrigerant pres­sure sensor.

Drain the air conditioning circuit using filling station.

Disconnect the air conditioning pipe unions on the air
conditioning compressor.

109396

Disconnect connectors (14) of the fan assembly.

15

109397

Disconnect connector (15) of the power assisted
steering pressure switch.

WARNING

Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre­vent moisture from getting into the circuit.

10A-9

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

16

107924

Remove the power assisted steering pipe mounting
bolts:

- from the top of sub-frame (16),

10A

Drain the air conditioning circuit using the filling sta­tion.

Disconnect the air conditioning pipe unions on the air
conditioning compressor.

WARNING

Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre­vent moisture from getting into the circuit.

19

- on the multifunction support,

- on the rear of the cylinder block.

Disconnect:

- the low pressure hose on the power assisted stee­ring pump and drain the circuit,

- the high-pressure pipe from the power assisted
steering pump,

- the high-pressure pipe from the steering rack.

Remove the power assisted steering high-pressure
pipe.

18

107356

Disconnect:

- ball joint (18) of the throttle valve control cable,

-cable sleeve stop (19) of the throttle valve control
cable.

17

108107

Disconnect connector (17) of the refrigerant pressu-
re sensor.

10A-10

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

21

Engine/gearbox assembly

20

22

10A

2222

107357

Disconnect:

- the petrol vapour absorber bleeding solenoid valve
connector,

- the brake servo pipe from the inlet manifold,

- petrol vapour rebreather pipe (20) from the inlet
manifold.

- the fuel supply pipe (21) from the injection rail.

IMPORTANT

Be careful of petrol splashing out when discon­necting the fuel supply union.

Wear gloves during the operation.

108565

Disconnect cooling hoses (22).

23

109493

Remove cooling hoses (23) from their support.

10A-11

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

24

Engine/gearbox assembly

27

10A

25

26

107934

Remove mounting bolt (24) from the earth strap on
the gearbox.

107935

28

99070

Remove:

10A-12

- brake callipers (25) and attach them to the shock
absorbers,

- track rod ends (26),

- bolts (27) from the shock absorber bases,

- upper mounting bolts (28) of the sub-frame tie rods,

- the two mounting bolts from the steering rack.

Attach the steering rack to the body.

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

Engine/gearbox assembly

29

30

10A

32

Remove:

- the clutch control cable from clutch fork (29),

- the clutch control cable from sleeve stop (30).

109494

31

109214

Remove mounting bolt (32) from the gear lever fork.

Attach the gearbox control linkage to the body.

108648

Remove the engine tie-bar.

Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter).

109213

Remove rubber protection (31) from the gear lever.

10A-13

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

109495

Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the timing end lifting eye as an ancho­ring point.

35

10A

34

33

108649

Remove:

- the suspended engine mounting cover mounting
bolts,

- the suspended mounting from engine (33).

109229

Put a shim under the engine on the right-hand side
of the sub-frame:

- put a rubber shim under multifunction support (34),

- fit tool (Mot. 1159-03) to the rear of engine (35),

-lower the engine to fix it in place on the right-hand
side of the sub-frame.

107930

Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the flywheel end lifting eye as an an­choring point.

10A-14

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

36

37

Engine/gearbox assembly

Place tool (Mot. 1390) under the sub-frame.

Lower the vehicle down onto the four pads of tool
(Mot. 1390).

10A

17765

107929

Remove mounting nut (36) of the gearbox cover on
the gearbox rubber mounting.

Strike the gearbox mounting stud with a copper ham­mer to uncouple « engine and gearbox » assembly
from the body.

Remove gearbox rubber mounting (37).

3939

108574

Adjust the pad position to ensure the sub-frame is
stable on tool (Mot. 1390).

Bring the pads into contact with the underside of the
sub-frame in (39).

Lift the vehicle to separate « engine and gearbox/dri­veshafts/half-axle/sub-frame » assembly from the
body.

38

109230

Put a shim under the gearbox on the left-hand side
of the sub-frame:

- put a rubber shim under gearbox (38),

-lower the gearbox to fix it in place on the left-hand
side of the sub-frame.

WARNING

Ensure that no component obstructs the move­ment of the body around the « engine and
gearbox » assembly.

10A-15

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

REFITTING

Use two threaded rods of tool (Tav. 1747) on the
sub-frame front mountings to guide the sub-frame
when fitting the « engine and gearbox » assembly.

10A

Torque tighten:

- the gearbox rubber mounting mounting bolts
(10.5 daNm),

- the gearbox cover mounting nut on the gearbox
rubber mounting (6.2 daNm),

- the sub-frame mounting bolts (10.5 daNm),

-the sub-frame tie-rod upper mounting bolts (2.1
daNm),

-the sub-frame tie-rod lower mounting bolts (6.2
daNm),

- the steering rack mounting bolts (10.5 daNm)

107927

- the shock absorber base bolts (10,5 daNm),

- the brake calliper mounting bolts (10.5 daNm),

109495

- the track rod end nuts (3.7 daNm),

- the engine tie-bar mounting bolts (10.5 daNm),

- the wheel bolts (10.5 daNm).

Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter).

Perform the following operations:

- top up the engine oil if necessary,

- top up the gearbox oil if necessary,

- fill up and bleed the cooling circuit (see 19A, Coo-
ling, Draining - Filling the cooling circuit).

DIRECTION ASSISTEE, and BASIC HEATING

Fill up the power assisted steering circuit.

Bleed the power assisted steering circuit by turning
the steering wheel fully in one direction then the
other with the engine running.

107930

Use tool (Mot. 1453) to fit the suspended engine
mounting of the « engine and gearbox » assembly.

Coat the brake calliper mounting bolts with LOCTITE
FRENBLOC.

DIRECTION MANUELLE, and AIR CONDITIONING

Fill up the air conditioning circuit with filling station.

10A-16

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

DIRECTION ASSISTEE, and AIR CONDITIONING

Fill up the power assisted steering circuit.

Bleed the power assisted steering circuit by turning
the steering wheel fully in one direction then the

other with the engine running.

Fill up the air conditioning circuit with filling station.

Proceed in the reverse order to removal.

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see

80A, Battery: Remove and Refit).

10A

10A-17

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

Essential special tooling

Mot. 1202-01 Clip pliers for cooling

system hose clips
(large model)

Mot. 1202-02 Clip pliers for cooling

system hose clips
(small model)

Mot. 1448 Remote operation

pliers for cooling sys­tem hose clips

Mot. 1453 Multiple-adjusting

engine mounting sup­port with retaining

straps

Mot. 1159-03 Engine mounting on

right-hand side mem­ber for operations not
requiring removal of
the engine

10A

Tightening torquesm

shock absorber base
bolts

brake calliper mounting
bolts

track rod end nuts 3.7 daNm

engine tie-bar mounting
bolts

wheel bolts 10.5 daNm

REMOVAL

Note:

The « engine and gearbox » assembly can be
removed by removing the « engine and gearbox/
driveshafts/half-axle/sub-frame » assembly.

10.5 daNm

10.5 daNm

10.5 daNm

Mot. 1390 Support for removing

and refitting the engine
and gearbox assembly

Tav. 1747 Threaded rods for

removing the sub­frame

Essential equipment

filling station

Tightening torquesm

gearbox rubber moun­ting mounting bolts

gearbox cover moun­ting nut on the gearbox
rubber mounting

sub-frame mounting
bolts

10.5 daNm

6.2 daNm

10.5 daNm

Place the vehicle on a two-post lift.

IMPORTANT

During this operation, secure the vehicle onto the
lift with a strap to prevent it from becoming unba­lanced.

For the strap fitting procedure, (see 02A, Lifting
equipment, Underbody lift).

sub-frame tie-rod upper
mounting bolts

sub-frame tie-rod lower
mounting bolts

steering rack mounting
bolts

2.1 daNm

6.2 daNm

10.5 daNm

10A-18

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

3

Engine/gearbox assembly

1

10A

107846

Disconnect the battery, starting with the negative ter­minal.

Remove:

- fuse and relay cover (1),

- the fuse holders and relays from their supports (2),

- battery mounting clamp (3),

- the battery.

2

107845

109184

10A-19

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

Engine/gearbox assembly

Drain:

- the engine oil if necessary,

- the gearbox oil if necessary,

- the cooling circuit via the bottom hose, using tool
(Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

DIRECTION MANUELLE, and BASIC HEATING

44

10A

Remove:

108564

7

5

Disconnect fan assembly connector (6).

Unclip the electrical harness from fan assembly (7).

108562

6

109398

- the injection computer protector in (4),

- the injection computer in (5),

- the fuse and relay supports,

- the electrolyte recovery tray under the battery,

- the air suction sleeve on the body,

- the front wheels,

- the engine undertray,

- the bumper mounting bolts under the sub-frame.

10A-20

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

DIRECTION ASSISTEE, and BASIC HEATING

10A

11

9

Remove the power assisted steering pipe mounting
bolts:

8

- from the top of sub-frame (11),

107924

109398

Disconnect fan assembly connector (8).

Unhook the electrical harness from fan assembly (9).

10

- on the multifunction support,

- on the rear of the cylinder block.

Disconnect:

- the low pressure hose on the power assisted stee­ring pump and drain the circuit,

- the high-pressure pipe from the power assisted
steering pump,

- the high-pressure pipe from the steering rack.

Remove the power assisted steering high-pressure
pipe.

109397

Disconnect connector (10) of the power assisted
steering pressure switch.

10A-21

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

DIRECTION MANUELLE, and AIR CONDITIONING

12

10A

DIRECTION ASSISTEE, and AIR CONDITIONING

14

109396

Disconnect fan assembly connectors (12).

13

108107

Disconnect connector (13) from the refrigerant pres­sure sensor.

Drain the air conditioning circuit using filling station.

Disconnect the air conditioning pipe unions on the air
conditioning compressor.

109396

Disconnect fan assembly connectors (14).

15

109397

Disconnect connector (15) of the power assisted
steering pressure switch.

WARNING

Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre­vent moisture from getting into the circuit.

10A-22

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

16

107924

Remove the power assisted steering pipe mounting
bolts:

- from the top of sub-frame (16),

- on the multifunction support,

10A

Drain the air conditioning circuit using filling station.

Disconnect the air conditioning pipe unions on the air
conditioning compressor.

WARNING

Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre­vent moisture from getting into the circuit.

19

18

- on the rear of the cylinder block.

Disconnect:

- the low pressure hose on the power assisted stee­ring pump and drain the circuit,

- the high-pressure pipe from the power assisted
steering pump,

- the high-pressure pipe from the steering rack.

Remove the power assisted steering high-pressure
pipe.

17

107356

Disconnect:

- ball joint (18) of the throttle valve control cable,

-cable sleeve stop (19) of the throttle valve control
cable.

108107

Disconnect connector (17) of the refrigerant pressu-
re sensor.

10A-23

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

21

Engine/gearbox assembly

20

22

22

10A

22

107357

Disconnect:

- the petrol vapour absorber bleeding solenoid valve
connector,

- the brake servo pipe from the inlet manifold,

- petrol vapour rebreather pipe (20) from the inlet
manifold,

- fuel supply pipe (21) from the injection rail.

IMPORTANT

Be careful of petrol splashing out when discon­necting the fuel supply union.

Wear gloves during the operation.

108565

Disconnect the cooling hoses (22).

23

109493

Remove cooling hoses (23) from their support.

10A-24

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

24

Engine/gearbox assembly

10A

27

25

26

107934

Remove mounting bolt (24) from the earth strap on
the gearbox.

107935

28

99070

Remove:

10A-25

- brake callipers (25) and attach them to the shock
absorbers,

- track rod ends (26),

- bolts (27) of the shock absorber bases,

- upper mounting bolts (28) of the sub-frame tie rods,

- the two mounting bolts from the steering rack.

Attach the steering rack to the body.

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

Engine/gearbox assembly

29

30

10A

32

Remove:

- the clutch control cable from clutch fork (29),

- the clutch control cable from sleeve stop (30).

109494

31

109214

Remove mounting bolt (32) from the gear lever fork.

Attach the gearbox control linkage to the body.

108648

Remove the engine tie-bar.

Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter).

109213

Remove rubber protection (31) from the gear lever.

10A-26

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

109495

Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the timing end lifting eye as an ancho­ring point.

35

10A

34

33

108649

Remove:

- the suspended engine mounting cover mounting
bolts,

- the suspended mounting from engine (33).

109229

Put a shim under the engine on the right-hand side
of the sub-frame:

- put a rubber shim under multifunction support (34),

- fit tool (Mot. 1159-03) to the rear of the engine (35),

-lower the engine to fix it in place on the right-hand
side of the sub-frame.

107930

Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the flywheel end lifting eye as an an­choring point.

10A-27

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

36

37

Engine/gearbox assembly

Place tool (Mot. 1390) under the sub-frame.

Lower the vehicle onto the four pads of tool (Mot.

1390).

10A

17765

107929

Remove mounting nut (36) of the gearbox cover on
the gearbox rubber mounting.

Strike the gearbox mounting stud with a copper ham­mer to uncouple the « engine and gearbox » assem­bly from the body.

Remove gearbox rubber mounting (37).

39

39

108574

Adjust the pad position to ensure the sub-frame is
stable on tool (Mot. 1390).

Bring the pads into contact with the underside of the
sub-frame in (39).

Lift the vehicle to separate the « engine and gear­box/driveshafts/half-axle/sub-frame » assembly
from the body.

38

109230

Put a shim under the gearbox on the left-hand side
of the sub-frame:

- put a rubber shim under gearbox (38),

-lower the gearbox to fix it in place on the left-hand
side of the sub-frame.

WARNING

Ensure that no component obstructs the move­ment of the body around the « engine and
gearbox » assembly.

10A-28

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

REFITTING

Use two threaded rods of tool (Tav. 1747) on the
sub-frame front mountings to guide the sub-frame
when fitting the « engine and gearbox » assembly.

10A

Torque tighten:

- the gearbox rubber mounting mounting bolts
(10.5 daNm),

- the gearbox cover mounting nut on the gearbox
rubber mounting (6.2 daNm),

- the sub-frame mounting bolts (10.5 daNm),

-the sub-frame tie-rod upper mounting bolts (2.1
daNm),

-the sub-frame tie-rod lower mounting bolts (6.2
daNm),

- the steering rack mounting bolts (10.5 daNm)

107927

- the shock absorber base bolts (10.5 daNm),

- the brake calliper mounting bolts (10.5 daNm),

109495

- the track rod end nuts (3.7 daNm),

- the engine tie-bar mounting bolts (10.5 daNm),

- the wheel bolts (10.5 daNm).

Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter).

Perform the following operations:

- top up the engine oil if necessary,

- top up the gearbox oil if necessary,

- fill up and bleed the cooling circuit (see 19A, Coo-
ling, Draining - Filling the cooling circuit).

DIRECTION ASSISTEE, and BASIC HEATING

Fill up the power assisted steering circuit.

Bleed the power assisted steering circuit by turning
the steering wheel fully in one direction then the
other with the engine running.

107930

Use tool (Mot. 1453) to fit the suspended engine
mounting of the « engine and gearbox » assembly.

Coat the brake calliper mounting bolts with LOCTITE
FRENBLOC.

DIRECTION MANUELLE, and AIR CONDITIONING

Fill up the air conditioning circuit with filling station.

10A-29

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

DIRECTION ASSISTEE, and AIR CONDITIONING

Fill up the power assisted steering circuit.

Bleed the power assisted steering circuit by turning
the steering wheel fully in one direction then the

other with the engine running.

Fill up the air conditioning circuit with filling station.

Proceed in the reverse order to removal.

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see

80A, Battery: Remove and Refit).

10A

10A-30

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

Essential special tooling

Tav. 1747 Threaded rods for

removing the sub­frame

Tightening torquesm

sump mounting bolts 1.4 daNm

engine to gearbox cou­pling bolts

sub-frame mounting
bolts

steering rack mounting
bolts

sub-frame tie-rod upper
mounting bolts

sub-frame tie-rod lower
mounting bolts

engine tie-bar mounting
bolts

4.4 daNm

(10.5 daNm)

10.5 daNm

2.1 daNm

6.2 daNm

10.5 daNm

10A

108648

Remove:

- the engine tie-bar,

- the front wheels,

- the lower ball joints,

- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter),

- the two mounting bolts from the steering rack.

Attach the steering rack to the body.

wheel bolts 10.5 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove:

- the engine undertray,

- the bumper mounting bolts under the sub-frame.

Drain the engine oil.

DIRECTION ASSISTEE

1

107924

Remove mounting bolt (1) of the power assisted
steering pipe on the top of the sub-frame.

10A-31

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

2

Sump

10A

107934

Remove mounting bolt (2) of the sub-frame tie-rods.

3

3

107924

Remove sub-frame mounting bolts (3) one at a time,
then replace them by the threaded rods of tool (Tav.

1747).

IMPORTANT

Make sure the threaded rod of tool (Tav. 1747) is
sufficiently screwed into the threaded hole and
that the nut of the tool is properly resting on the
sub-frame.

108645

108644

Lower the sub-frame by at least 120 mm by progres­sively unscrewing the nuts of tool (Tav. 1747).

10A-32

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

Sump

4

4

10A

Remove:

- coupling bolts (4) of the engine and gearbox,

- the sump mounting bolts,

- the sump.

REFITTING

WARNING

Replace:

- the sump gasket,

- the sub-frame mounting bolts.

107936

10A-33

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

5

Sump

Note:

6

Excess sealant could be squeezed out when the
parts are tightened. The sealing compound/fluid

mixture can cause damage to certain compo­nents (engine, radiator, etc.).

10A

Apply:

20166

5

20167

- four beads (5) of RHODORSEAL 56615 mm in dia-

meter,

- two spots (6) of RHODORSEAL 5661 of a diameter
of 7 mm at the intersection of the crankshaft closing
panel and the cylinder block.

Note:

The gasket faces must be clean, dry and free
from grease (avoid finger marks).

10A-34

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7J, and 710

Sump

10A

- the steering rack mounting bolts (10.5 daNm),

-the sub-frame tie-rod upper mounting bolts (2.1
daNm),

-the sub-frame tie-rod lower mounting bolts (6.2
daNm),

- the engine tie-bar mounting bolts (10.5 daNm),

- the wheel bolts (10.5 daNm).

Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter).

Proceed in the reverse order to removal.

Top up the engine oil.

12

4

8

1

16

20

19

15

11

7

Pretighten to torque and in order:

2

3

107936

5

9

13

17

18

10

6

14

107792

- the sump mounting bolts (0.8 daNm),

- the engine to gearbox coupling bolts (0.8
daNm).

Torque tighten in order:

- the sump mounting bolts (1.4 daNm),

- the engine to gearbox coupling bolts (4.4
daNm).

Torque tighten:

- the sub-frame mounting bolts ((10.5 daNm)),

10A-35

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

Essential special tooling

Tav. 1747 Threaded rods for

removing the sub­frame

Tightening torquesm

sump mounting bolts 1.4 daNm

engine to gearbox cou­pling bolts

sub-frame mounting
bolts

steering rack mounting
bolts

sub-frame tie-rod upper
mounting bolts

sub-frame tie-rod lower
mounting bolts

engine tie-bar mounting
bolts

4.4 daNm

(10.5 daNm)

10.5 daNm

2.1 daNm

6.2 daNm

10.5 daNm

10A

108648

Remove:

- the engine tie-bar,

- the front wheels,

- the lower ball joints,

- the catalytic converter (see 19B, Exhaust, Cataly-
tic converter),

- the two mounting bolts from the steering rack.

Attach the steering rack to the body.

wheel bolts 10.5 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove:

- the engine undertray,

- the bumper mounting bolts under the sub-frame.

Drain the engine oil.

2

107934

Remove mounting bolt (2) of the sub-frame tie-rods.

10A-36

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

3

3

107924

Remove sub-frame mounting bolts (3) one at a time,
then replace them by one of the threaded rods of tool
(Tav. 1747).

10A

IMPORTANT

Make sure the threaded rod of tool (Tav. 1747) is
sufficiently screwed into the threaded hole and
that the nut of the tool is properly resting on the
sub-frame.

108645

108644

Lower the sub-frame by at least 120 mm by progres­sively unscrewing the nuts of tool (Tav. 1747).

10A-37

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

Sump

4

4

10A

Remove:

- the coupling bolts (4) of the engine and gearbox,

- the sump mounting bolts,

- the sump.

REFITTING

WARNING

Replace:

- the sump gasket,

- the sub-frame mounting bolts.

107936

10A-38

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

5

Sump

Note:

6

Excess sealant could be squeezed out when the
parts are tightened. The sealing compound/fluid

mixture can cause damage to certain compo­nents (engine, radiator, etc.).

10A

Apply:

20166

5

20167

- four beads (5) of RHODORSEAL 56615 mm in dia-

meter,

- two spots (6) of RHODORSEAL 5661 of a diameter
of 7 mm at the intersection of the crankshaft closing
panel and the cylinder block.

Note:

The gasket faces must be clean, dry and free
from grease (avoid finger marks).

10A-39

ENGINE AND LOWER ENGINE ASSEMBLY

L90, and K7M, and 710

Sump

10A

- the steering rack mounting bolts (10.5 daNm),

-the sub-frame tie-rod upper mounting bolts (2.1
daNm),

-the sub-frame tie-rod lower mounting bolts (6.2
daNm),

- the engine tie-bar mounting bolts (10.5 daNm),

- the wheel bolts (10.5 daNm).

Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter).

Proceed in the reverse order to removal.

Top up the engine oil.

12

4

8

1

16

20

19

15

11

7

Pretighten to torque and in order:

2

3

107936

5

13

9

17

18

14

10

6

107792

- the sump mounting bolts (0.8 daNm),

- the engine to gearbox coupling bolts (0.8
daNm).

Torque tighten in order:

- the sump mounting bolts (1.4 daNm),

- the engine to gearbox coupling bolts (4.4
daNm).

Torque tighten:

- the sub-frame mounting bolts ((10.5 daNm)),

10A-40

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pump

L90, and K7J, and 710

Tightening torquesm

oil pump mounting bolts 2.5 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove the sump (see 10A, Engine and periphe-
rals, Sump).

1

10A

Remove:

- the mounting (1) bolts of the oil pump,

- the oil pump.

REFITTING

Tighten to torque the oil pump mounting bolts (2.5
daNm).

Refit the sump (see 10A, Engine and peripherals,
Sump).

108646

10A-41

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pump

L90, and K7M, and 710

Tightening torquesm

oil pump mounting bolts 2.5 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove the sump (see 10A, Engine and periphe-
rals, Sump).

1

10A

Remove:

- the mounting (1)bolts of the oil pump,

- the oil pump.

REFITTING

Tighten to torque the oil pump mounting bolts (2.5
daNm).

Refit the sump (see 10A, Engine and peripherals,
Sump).

108646

10A-42

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

- the power assisted steering pump mounting

bolts (2.1 daNm).

Tightening torquesm

multifunction support
mounting bolts

power assisted steering
pump mounting bolts

4.4 daNm

2.1 daNm

REMOVAL

Mount the vehicle on a two-post lift.

Remove:

- the engine undertray,

- the alternator (see 16A, Starting - Charge, Alter-
nator).

Remove the power assisted steering pump mounting
bolts.

Refit the alternator (see 16A, Starting - Charge, Al-
ternator).

Proceed in the reverse order to removal.

10A

Attach the power assisted steering pump to the sub­frame.

1

1

1

109226

Remove:

- the mounting (1) bolts of the multifunction support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the multifunction support mounting bolts (4.4
daNm),

10A-43

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

Tightening torquesm

multifunction support
mounting bolts

air conditioning com­pressor mounting bolts

REMOVAL

Place the vehicle on a two-post lift.

Remove the engine undertray.

1

4.4 daNm

2.1 daNm

33

10A

22

109227

Disconnect the connector (1) of the air conditioning
compressor.

Remove:

- the air conditioning compressor belt (see 11A, Top
and front of engine, Accessories belt),

- the three mounting (2) bolts of the air conditioning
compressor.

109228

Remove:

- the mounting (3) bolts of the multifunction support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the multifunction support mounting bolts (4.4
daNm),

- the air conditioning compressor mounting bolts
(2.1 daNm).

Refit the air conditioning compressor belt (see 11A,
Top and front of engine, Accessories belt).

Proceed in the reverse order to removal.

Attach the air conditioning compressor to the sub­frame.

10A-44

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

Tightening torquesm

M10 mounting bolts of
the multifunction sup-

port

M8 mounting bolts of the
multifunction support

4.4 daNm

2.1 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove:

- the engine undertray,

- the alternator (see 16A, Starting - Charge, Alter-
nator).

2

10A

1

1

1

2

Remove:

109224

109221

10A-45

- the mounting bolts (1) and (2) of the multifunction
support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the M10 mounting bolts of the multifunction

support (4.4 daNm)(1),

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

-the M8 mounting bolts of the multifunction sup-
port (2.1 daNm)(2).

Refit the alternator (see 16A, Starting - Charge, Al-
ternator).

Proceed in the reverse order to removal.

10A

10A-46

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7M, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

- the power assisted steering pump mounting

bolts (2.1 daNm).

Tightening torquesm

multifunction support
mounting bolts

power assisted steering
pump mounting bolts

4.4 daNm

2.1 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove:

- the engine undertray,

- the alternator (see 16A, Starting - Charge, Alter-
nator).

Remove the power assisted steering pump mounting
bolts.

Refit the alternator (see 16A, Starting - Charge, Al-
ternator).

Proceed in the reverse order to removal.

10A

Attach the power assisted steering pump to the sub­frame.

1

1

1

109226

Remove:

- the mounting (1) bolts of the multifunction support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the multifunction support mounting bolts (4.4
daNm),

10A-47

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

Tightening torquesm

multifunction support
mounting bolts

air conditioning com­pressor mounting bolts

REMOVAL

Place the vehicle on a two-post lift.

Remove the engine undertray.

4.4 daNm

2.1 daNm

33

10A

212

109227

Disconnect the connector (1) of the air conditioning
compressor.

Remove:

- the air conditioning compressor belt (see 11A, Top
and front of engine, Accessories belt),

-the mounting (2) bolts of the air conditioning com­pressor.

109228

Remove:

- the mounting (3) bolts of the multifunction support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the multifunction support mounting bolts (4.4
daNm),

- the air conditioning compressor mounting bolts
(2.1 daNm).

Refit the air conditioning compressor belt (see 11A,
Top and front of engine, Accessories belt).

Proceed in the reverse order to removal.

Attach the air conditioning compressor to the sub­frame.

10A-48

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

Tightening torquesm

M10 mounting bolts of
the multifunction sup-

port

M8 mounting bolts of the
multifunction support

4.4 daNm

2.1 daNm

REMOVAL

Place the vehicle on a two-post lift.

Remove the engine undertray.

Remove the alternator (see 16A, Starting - Charge,
Alternator).

2

1

1

1

10A

2

Remove:

109224

109221

10A-49

- the mounting bolts (1) and (2) of the multifunction
support,

- the multifunction support.

REFITTING

Position the multifunction support.

Torque tighten:

- the five M10 mounting bolts of the multifunction

support (4.4 daNm)(1) ,

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

-the two M8 mounting bolts of the multifunction
support (2.1 daNm)(2).

Refit the alternator (see 16A, Starting - Charge, Al-
ternator).

Proceed in the reverse order to removal.

10A

10A-50

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting bolt 2.1 daNm

alternator mounting bolt 4.4 daNm

wheel bolts 10.5 daNm

REMOVAL

1

2

11A

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right-hand wheel.

109237

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).

Remove the accessories belt.

REFITTING

WARNING

Replace any belt that has been removed.

11A-1

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and BASIC HEATING

4

5

3

11A

16300

(3)Crankshaft

(4) Alternator

(5) Measuring point

Refit the accessories belt.

Tension the belt by turning the alternator.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 305 Hz ±±±± 10, (see Technical

Note 3786A, Engine and peripherals, 10A, Belt
tension tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Torque tighten:

- the alternator mounting bolt (2.1 daNm),

- the alternator mounting bolt (4.4 daNm).

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

11A-2

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting
screw

alternator mounting bolt 4.4 daNm

wheel bolts 10.5 daNm

2.1 daNm

REMOVAL

II - REMOVING THE ALTERNATOR BELT

1

2

11A

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right wheel.

I -REMOVING THE AIR CONDITIONING
COMPRESSOR BOLT

109236

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).

Remove the alternator belt.

REFITTING

WARNING

Replace any belt that has been removed.

I -REFITTING THE ALTERNATOR BELT

Refit the alternator belt.

109636

Cut the air conditioning compressor belt using cut­ting pliers.

11A-3

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

II - REFITTING THE AIR CONDITIONING
COMPRESSOR BELT

Note:

4

3

5

The air conditioning compressor belt does not
have a tension wheel, as it is tensioned automati­cally, and it is refitted using a tool supplied with
the belt.

11A

16300

(3)Crankshaft

(4) Alternator

(5) Measuring point

Tension the belt by turning the alternator.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 305 ±±±± 10 Hz, (see Technical

Note 3786A, Engine and peripherals, 10A, Belt
tension tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Torque tighten:

- the alternator mounting screw (2.1 daNm),

- the alternator mounting bolt (4.4 daNm).

6

109635

Air conditioning compressor belt fitting tool (6).

109637

Clip the belt fitting tool on the crankshaft pulley as
shown in the diagram.

11A-4

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

109638

Mount the belt and slide round the belt fitting tool by
hand clockwise by approximately 90˚.

Rotate the crankshaft clockwise until the belt is in
place on the crankshaft pulley.

11A

109640

7

109639

Position hook (7) as shown in the diagram, with the
longest end of the hook behind the multifunction sup­port.

Note:

The air conditioning compressor belt fitting tool is
single-use, and must be discarded after use.

109641

Turn the crankshaft through two revolutions to cor­rectly position the air conditioning compressor belt.

11A-5

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see

80A, Battery: Remove and Refit).

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

REFITTING

Tightening torquesm

tension wheel mounting
bolt

pulley mounting bolt 2.1 daNm

wheel bolts 10.5 daNm

2.1 daNm

REMOVAL

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

WARNING

Replace any belt that has been removed.

WARNING

When replacing the belt, be sure to replace the
tension wheels and idler pulleys.

Torque tighten:

- the tension wheel mounting bolt (2.1 daNm),

- the pulley mounting bolt (2.1 daNm).

11A

6

Remove the front right-hand wheel.

1

2

14494-3

Turn the tension wheel clockwise, using a wrench
(1), to loosen the belt.

5

8

7

3

4

105998

(3)Crankshaft

(4) Air conditioning compressor

(5) Alternator

(6)Power assisted steering pump

(7) Idler pulley

Lock the tension wheel using a 6 mm Allen key (2).

Remove the accessories belt.

(8) Tension wheel

11A-6

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

11A

106001

Refit the accessories belt. Remove the 6 mm Allen key.

Turn the engine through three revolutions to position

WARNING

Make sure that the inner tooth on all the pulleys
remains free.

the belt correctly.

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

109238

11A-7

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

tension wheel mounting
bolts

wheel bolts 10.5 daNm

2.1 daNm

REMOVAL

REFITTING

WARNING

Replace any belt that has been removed.

WARNING

The tension wheel must be replaced when the
belt is replaced.

11A

3

5

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right-hand wheel.

1

2

4

6

106045

(2)Crankshaft

(3) Alternator

(4)Power assisted steering pump

(5) Tension wheel

(6) Measuring point

Slacken the tension wheel mounting bolts (1).

Remove the accessories belt.

109235

11A-8

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

11A

7

105999

Refit the accessories belt. Insert a long bolt (7) on the multifunction support.

Tension the belt using the bolt (7).

WARNING

Make sure that the outer tooth on all the pulleys
remains free.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 204 ±±±± 5 Hz, (see Technical Note

3786A, Engine and peripherals, 10A, Belt tension
tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Remove the bolt (7).

Torque tighten the tension wheel mounting bolts
(2.1 daNm).

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

109235

11A-9

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting
screw

alternator mounting bolt 4.4 daNm

wheel bolts 10.5 daNm

2.1 daNm

REMOVAL

II - REMOVING THE ALTERNATOR BELT

1

2

11A

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right-hand wheel.

I -REMOVING THE AIR CONDITIONING
COMPRESSOR BELT

109236

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).

Remove the alternator belt.

REFITTING

WARNING

Replace any belt that has been removed.

I -REFITTING THE ALTERNATOR BELT

Refit the alternator belt.

109636

Cut the air conditioning compressor belt using cut­ting pliers.

11A-10

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

II - REFITTING THE AIR CONDITIONING
COMPRESSOR BELT

Note:

4

5

3

The air conditioning compressor belt does not
have a tension wheel, as it is tensioned automati­cally, and it is refitted using a tool supplied with
the belt.

11A

16300

(3)Crankshaft

(4) Alternator

(5) Measuring point

Tension the belt by turning the alternator.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 305 Hz ±±±± 10, (see Technical

Note 3786A, Engine and peripherals, 10A, Belt
tension tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Torque tighten:

- the alternator mounting screw (2.1 daNm),

- the alternator mounting bolt (4.4 daNm).

6

109635

Air conditioning compressor belt fitting tool (6).

109637

Clip the belt fitting tool on the crankshaft pulley as
shown in the diagram.

11A-11

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION MANUELLE, and AIR CONDITIONING

109638

Mount the belt and slide round the belt fitting tool by
hand clockwise by approximately 90˚.

Rotate the crankshaft clockwise until the belt is in
place on the crankshaft pulley.

11A

109640

7

109639

Position the hook (7) as shown in the diagram, with
the longest end of the hook behind the multifunction
support.

Note:

The air conditioning compressor belt fitting tool is
single-use, and must be discarded after being

used.

109641

Turn the crankshaft through two revolutions to cor­rectly position the air conditioning compressor belt.

11A-12

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see

80A, Battery: Remove and Refit).

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

tension wheel mounting
bolts

wheel bolts 10.5 daNm

2.1 daNm

REMOVAL

REFITTING

WARNING

Replace any belt that has been removed.

WARNING

The tension wheel must be replaced when the
belt is replaced.

11A

3

5

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right-hand wheel.

1

2

4

6

106045

(2)Crankshaft

(3) Alternator

(4)Power assisted steering pump

(5) Tension wheel

(6) Measuring point

Slacken the tension wheel mounting bolts (1).

Remove the accessories belt.

109235

11A-13

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7J, and 710, and DIRECTION ASSISTEE, and BASIC HEATING

11A

7

105999

Refit the accessories belt. Insert a long bolt (7) into the multifunction support.

Tension the belt using bolt (7).

WARNING

Make sure that the outer tooth on all the pulleys
remains free.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 204 ±±±± 5 Hz, (see Technical Note

3786A, Engine and peripherals, 10A, Belt tension
tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Remove the bolt (7).

Torque tighten the tension wheel mounting bolts
(2.1 daNm).

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

109235

11A-14

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

REFITTING

Tightening torquesm

tension wheel mounting
bolt

idler pulley mounting
bolt

wheel bolts 10.5 daNm

2.1 daNm

2.1 daNm

REMOVAL

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

WARNING

Replace any belt that has been removed.

WARNING

When replacing the belt, be sure to replace the
tension wheels and idler pulleys.

Torque tighten:

- the tension wheel mounting bolt (2.1 daNm),

- the idler pulley mounting bolt (2.1 daNm).

11A

6

Remove the front right-hand wheel.

1

Turn the tension wheel clockwise, using a wrench
(1), to relax the belt.

Lock the tension wheel using a 6 mm Allen key (2).

2

14494-3

5

8

7

3

4

105998

(3)Crankshaft

(4) Air conditioning compressor

(5) Alternator

(6)Power assisted steering pump

(7) Idler pulley

(8) Tension wheel

Remove the accessories belt.

11A-15

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION ASSISTEE, and AIR CONDITIONING

11A

106001

Refit the accessories belt. Remove the 6 mm Allen key.

Turn the engine through three revolutions to position

WARNING

Make sure that the inner tooth on all the pulleys
remains free.

the belt correctly.

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

109238

11A-16

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting bolt 2.1 daNm

alternator mounting bolt 4.4 daNm

wheel bolts 10.5 daNm

REMOVAL

1

2

11A

WARNING

Never run the engine against its operating direc­tion.

Mount the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

Remove the front right wheel.

109237

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).

Remove the accessories belt.

REFITTING

WARNING

Replace any belt that has been removed.

11A-17

TOP AND FRONT OF ENGINE

Accessories belt

L90, and K7M, and 710, and DIRECTION MANUELLE, and BASIC HEATING

4

3

5

11A

16300

(3)Crankshaft

(4) Alternator

(5) Measuring point

Refit the accessories belt.

Tension the belt by turning the alternator.

Set the belt tension using tool (Mot. 1505) or (Mot.

1715) to a value of 305 Hz ±±±± 10, (see Technical

Note 3786A, Engine and peripherals, 10A, Belt
tension tester: Use).

Turn the engine through three revolutions to position
the belt correctly.

Check the belt tension using tool (Mot. 1505) or (Mot.

1715).

If the belt tension is outside tolerance, readjust it.

Torque tighten:

- the alternator mounting bolt (2.1 daNm),

- the alternator mounting bolt (4.4 daNm).

Proceed in the reverse order to removal.

Torque tighten the wheel bolts (10.5 daNm).

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery: Remove and Refit).

11A-18

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

Essential special tooling

Mot. 1453 Multiple-adjusting

engine mounting sup­port with retaining

straps

Mot. 1489 Top dead centre loca-

ting pin

Mot. 1501 Timing belt prestres-

sing tool

Mot. 1135-01 Timing gear belt ten-

sioner tool

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

11A

Remove:

- the engine undertray,

- the accessories belt (see 11A, Top and front of
engine, Accessories belt ).

- the crankshaft accessories pulley by locking the
flywheel using a screwdriver.

Essential equipment

low torque wrench

Tightening torquesm

the tension wheel moun­ting nut

crankshaft pulley moun­ting bolt

M10 mounting bolts of
the upper timing cover

M8 mounting bolts of the
upper timing cover

lower t i min g co ver
mounting bolts

suspended engine
mounting cover moun­ting bolts

5 daNm

3 daNm + 80˚ ±±

4.4 daNm

2.2 daNm

0.8 daNm

6.2 daNm

109495

Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the timing end lifting eye as an ancho­ring point.

±±

5

1

WARNING

Never turn the engine against its operating direc­tion.

REMOVAL

Place the vehicle on a two-post lift.

108649

Remove suspended engine mounting (1).

11A-19

TOP AND FRONT OF ENGINE

L90, and K7J, and 710

Timing belt

2

11A

33

Remove TDC pin plug (2).

107359

Remove:

107498

4

44

107499

11A-20

- lower timing cover (3),

- upper timing cover (4).

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

ADJUSTING THE TIMING

5

6

Rescrew the crankshaft accessories pulley bolt with
a spacer.

Turn the crankshaft clockwise to bring the camshaft
sprocket one tooth before the vertical axle of the
sprocket (top point (5)) and the crankshaft sprocket
mark one tooth before the vertical axle of the sproc­ket (low point (6)).

107497

11A

7

107494

Remove:

- tension wheel mounting nut (7),

- the timing belt,

- the tension wheel.

REFITTING

Insert TDC setting rod (Mot. 1489).

Turn the crankshaft clockwise by pushing on TDC
setting rod (Mot. 1489) until the crankshaft times.

WARNING

Replace any belt that has been removed.

WARNING

The tension wheel must be replaced when the
belt is replaced.

WARNING

It is essential to replace the crankshaft accesso­ries pulley mounting bolt.

Refit the tension wheel.

11A-21

TOP AND FRONT OF ENGINE

L90, and K7J, and 710

8

9

Timing belt

11A

10

Fit the timing belt by aligning the belt markings with
those of the sprockets of camshaft (8) and cranks­haft (9).

Rolling order:

- crankshaft pulley,

- tension wheel,

- camshaft pulley,

- water pump pulley.

PROCEDURE FOR TENSIONING TIMING BELT

Make the tension wheel push onto the timing belt.

Lightly tighten the tension wheel mounting nut.

Remove TDC setting rod (Mot. 1489).

107494

107493

11

16293

Fit timing belt pretensioning torque tool (Mot. 1501)
on camshaft sprocket (10).

11A-22

Apply pretensioning torque to the timing belt section

( 11), with a low torque wrench adjusted to torque 1
daNm.

Remove the tool (Mot. 1501).

TOP AND FRONT OF ENGINE

L90, and K7J, and 710

12

Timing belt

11A

Angle tighten to torque the crankshaft pulley
mounting bolt (3 daNm + 80˚ ±±±± 5), by blocking the

flywheel with a screwdriver.

1313

14

107492

Fit the auxiliary timing belt tensioner tool (Mot. 1135-

01)(12).

Tighten the timing belt, by pivoting the tension wheel
with tool (Mot. 1135-01) anti-clockwise.

Adjust the belt tension with tool (Mot. 1505) or (Mot.

1715) to the value 165 Hz ±±±± 10, (see Technical Note

3786A, Engine and peripherals, 10A, Belt tension
tester: Use).

Tighten to torque the tension wheel mounting nut
(5 daNm).

Rotate the crankshaft clockwise through two revolu­tions.

Set the engine at Top Dead Centre using tool (Mot.

1489).

Remove the TDC setting rod (Mot. 1489).

Refit the timing belt pretensioning torque tool (Mot.

1501) on the camshaft sprocket

Apply pretensioning torque to the timing belt section,
with a low torque wrench adjusted to torque 1

daNm

107499

Coat the upper timing cover mounting bolts with
LOCTITE FRENETANCH.

Torque tighten:

- the M10 mounting bolts of the upper timing co-
ver (4.4 daNm)(13),

- the M8 mounting bolts of the upper timing cover
(2.2 daNm)(14),

-the lower timing cover mounting bolts (0.8
daNm),

- the suspended engine mounting cover moun-
ting bolts (6.2 daNm).

Refit the accessories belt (see 11A, Top and front
of engine, accessories belt).

Remove the tool (Mot. 1501).

Check using tool (Mot. 1505) or (Mot. 1715), that the
timing belt tension is 165 Hz ±±±± 10.

If the tension value is outside tolerances, adjust it by
starting the tensioning process from the beginning.

11A-23

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

Essential special tooling

Mot. 1453 Multiple-adjusting

engine mounting sup­port with retaining

straps

Mot. 1489 Top dead centre loca-

ting pin

Mot. 1501 Timing belt prestres-

sing tool

Mot. 1135-01 Timing gear belt ten-

sioner tool

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

11A

Remove:

- the engine undertray,

- the accessories belt (see 11A, Top and front of
engine, Accessories belt ).

- the crankshaft accessories pulley by locking the
flywheel using a screwdriver.

Essential equipment

low torque wrench

Tightening torquesm

the tension wheel moun­ting nut

crankshaft pulley moun­ting bolt

M10 mounting bolts of
the upper timing cover

M8 mounting bolts of the
upper timing cover

lower t i min g co ver
mounting bolts

suspended engine
mounting cover moun­ting bolts

5 daNm

3 daNm + 80˚ ±±

4.4 daNm

2.2 daNm

0.8 daNm

6.2 daNm

109495

Fit the engine support tool (Mot. 1453) with the retai­ning belt, by taking the timing end lifting eye as an
anchoring point.

±±

5

1

WARNING

Never turn the engine against its operating direc­tion.

REMOVAL

Place the vehicle on a two-post lift.

108649

Remove the suspended engine mounting (1).

11A-24

TOP AND FRONT OF ENGINE

L90, and K7M, and 710

Timing belt

2

11A

33

Remove the TDC pin plug (2).

107359

107498

444

107499

Remove:

11A-25

- the lower timing cover (3),

- the upper timing cover (4).

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

ADJUSTING THE TIMING

5

6

Rescrew the crankshaft accessories pulley bolt with
a spacer.

Turn the crankshaft clockwise to bring the camshaft
sprocket one tooth before the vertical axle of the
sprocket (top point (5)) and the crankshaft sprocket
mark one tooth before the vertical axle of the sproc­ket (low point (6)).

107497

11A

7

107494

Remove:

- tension wheel mounting nut (7),

- the timing belt,

- the tension wheel.

REFITTING

Insert TDC setting rod (Mot. 1489).

Turn the crankshaft clockwise by pushing on TDC
setting rod (Mot. 1489) until the crankshaft times.

WARNING

Replace any belt that has been removed.

WARNING

The tension wheel must be replaced when the
belt is replaced.

WARNING

It is essential to replace the crankshaft accesso­ries pulley mounting bolt.

Refit the tension wheel.

11A-26

TOP AND FRONT OF ENGINE

L90, and K7M, and 710

8

9

Timing belt

11A

10

Fit the timing belt by aligning the belt markings with
those of the camshaft sprockets (8) and crankshaft
sprockets (9).

Rolling order:

- crankshaft pulley,

- tension wheel,

- camshaft pulley,

- water pump pulley.

PROCEDURE FOR TENSIONING TIMING BELT

Make the tension wheel push onto the timing belt.

Lightly tighten the tension wheel mounting nut.

Remove TDC setting rod (Mot. 1489).

107494

107493

11

16293

Fit timing belt pretensioning torque tool (Mot. 1501)
on camshaft sprocket.(10).

11A-27

Apply pretensioning torque to the timing belt section

( 11), with a low torque wrench adjusted to torque 1
daNm.

Remove tool (Mot. 1501).

TOP AND FRONT OF ENGINE

L90, and K7M, and 710

12

Timing belt

11A

Angle tighten to torque the crankshaft pulley
mounting bolt (3 daNm + 80˚ ±±±± 5), by blocking the

flywheel with a screwdriver.

13

13

14

107492

Fit timing auxiliary belt tensioner tool (Mot. 1135-

01)(12).

Tighten the timing belt, by pivoting the tension wheel
with tool (Mot. 1135-01) anti-clockwise.

Adjust the belt tension with tool (Mot. 1505) or (Mot.

1715) to the value 165 Hz ±±±± 20, (see Technical Note

3786A, Engine and peripherals, 10A, Belt tension
tester: Use).

Tighten to torque the tension wheel mounting nut
(5 daNm).

Rotate the crankshaft clockwise through two revolu­tions.

Set the engine at Top Dead Centre using tool (Mot.

1489).

Remove TDC setting rod (Mot. 1489).

Refit timing belt pretensioning torque tool (Mot.

1501) on the camshaft sprocket

Apply pretensioning torque to the timing belt section,
with a low torque wrench adjusted to torque 1

daNm

107499

Coat the upper timing cover mounting bolts with
LOCTITE FRENETANCH.

Torque tighten:

- the M10 mounting bolts of the upper timing co-
ver (4.4 daNm)(13),

- the M8 mounting bolts of the upper timing cover
(2.2 daNm)(14),

-the lower timing cover mounting bolts (0.8
daNm),

- the suspended engine mounting cover moun-
ting bolts (6.2 daNm).

Refit the accessories belt (see 11A, Top and front
of engine, accessories belt).

Remove tool (Mot. 1501).

Check using tool (Mot. 1715) or (Mot. 1489) that the
timing belt tension is 165 Hz ±±±± 20.

If the tension value is outside tolerances, adjust it by
starting the tensioning process from the beginning.

11A-28

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

Essential special tooling

Mot. 1672 Lower engine support

Mot. 1202-01 Clip pliers for cooling

system hose clips
(large model)

Mot. 1202-02 Clip pliers for cooling

system hose clips
(small model)

Mot. 1448 Remote operation

pliers for cooling sys­tem hose clips

Essential equipment

cylinder head testing tool

11A

DIRECTION ASSISTEE, and AIR CONDITIONING

Tightening torquesm

cylinder head mounting
bolts

rocker cover mounting
bolts

multifunction support
mounting bolts

220˚ ±±±± 10

1 daNm

2.1 daNm

REMOVAL

Place the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

1

108649

Remove mounting bolt (1) from the multifunction
support.

109492

11A-29

Set up engine support tool (Mot. 1672).

Remove:

- the accessories belt (see 11A, Top and front of
engine, Accessories belt ).

- the timing belt (see 11A, Top and front of engine,
Timing belt),

Drain the cooling circuit via the bottom hose using
tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

2

2

108423

Remove mounting bolts (2) from of the air filter box.

11A

4

107358

Disconnect connector (4) of the ignition coil.

Remove the ignition spark plug leads.

3

107361

Disconnect:

- oil vapour rebreather pipe (3) from the base of air
filter box,

- the air suction sleeve on the body.

Remove the air filter box.

Note:

The ignition spark plug leads are marked on the
ignition coil (cylinder number 1 engine flywheel
end).

6

11A-30

5

107486

Remove the inlet manifold reinforcement stay loca­ted between cylinder block and inlet manifold (5).

Disconnect fuel supply pipe (6) on the injection rail.

IMPORTANT

Be careful of petrol splashing out when discon­necting the fuel supply union.

Wear gloves during the operation.

TOP AND FRONT OF ENGINE

L90, and K7J, and 710

7

Cylinder head gasket

- pipe (12) from the brake servo on the inlet manifold,

- petrol vapour rebreather pipe (13) from the inlet
manifold.

Disconnect:

- ball joint (14) from the throttle valve control cable,

8

- cable sleeve stop (15) from the throttle valve control
cable.

11A

1616

Disconnect:

11

15

14

10

13

12

107357

9

107356

108565

Disconnect the three cooling hoses (16) with tool
(Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

- the injector connectors,

- connector (7 ) from the idle speed control motor,

- connector (8) from the throttle valve position sen­sor,

- connector (9) from the inlet air temperature sensor,

- connector (10) from the supply air depression sen­sor,

-connector (11) from the coolant temperature sen-
sor,

11A-31

TOP AND FRONT OF ENGINE

L90, and K7J, and 710

Cylinder head gasket

17

Remove:

- the rocker cover mounting bolts,

- the rocker cover.

11A

10016

Remove:

- the earth cable from the lifting eye,

- hose support mounting (17) on the lifting eye.

19

18

109493

10015

Remove:

- the cylinder head mounting bolts,

- the « cylinder head-inlet manifold » assembly,

- the cylinder head gasket.

109216

Remove retaining bolt (18) from the dipstick guide tu­be.

Unhook electrical harness (19).

Remove the exhaust manifold (see 12A, Burnt mix-
ture, Exhaust manifold).

11A-32

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

I -CLEANING THE CYLINDER HEAD

Clean the cylinder head.

IMPORTANT

- Do not scratch the aluminium gasket faces.

- Wear goggles.

- Wear gloves during the operation.

- Clean the gasket faces with DECAPJOINT to

dissolve any seals which are still cemented.

-Apply the product to the section to be cleaned;
Wait approximately ten minutes, then remove

the residue using a wooden spatula.

WARNING

Do not allow this product to drip onto the pain­twork.

11A

REFITTING

WARNING

In order to ensure that the bolts are correctly tigh­tened, use a syringe to remove any oil which may
be in the cylinder head mounting holes.

WARNING

Be sure to replace all seals that have been remo­ved.

Bring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.

Fit the cylinder head with a new gasket.

Clean the cylinder head carefully to prevent
foreign bodies from entering the oil inlet and
return pipes.

Failure to follow this advice could lead to the bloc­king of the various oil inlet ducts, which would
quickly result in engine damage.

WARNING

All cylinder head bolts must always be changed
after removal.

II - CHECKING THE GASKET FACE

With a ruler and shim set, check for gasket face bow.

The maximum deformation is 0.05 mm.

WARNING

No regrinding of the cylinder head is permitted.

Test the cylinder head for any cracks using the cy-

linder head testing tool (see Garage Equipment
Catalogue).

9

5

1

4

8

10

6

2

3

7

107772

Tightening the cylinder head:

-Pretighten in order and to torque the cylinder head
mounting bolts (2 daNm),

Refer to Technical Note 6010A for the cylinder head
stripping down procedure.

- Check that all the cylinder head mounting bolts
are properly tightened to 2 daNm,

-angle tighten in order the cylinder head mounting

bolts (220˚ ±±±± 10).

WARNING

Do not retighten the cylinder head bolts after
applying this procedure.

11A-33

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

8

6

Fit the rocker cover with a new gasket.

Tightening the rocker cover:

4

2 1

11A

3

7

5

10016

- pretighten in order and to torque the rocker cover
mounting bolts (0.2 daNm).

- Torque tighten in order the rocker cover moun-
ting bolts (1 daNm).

Refit:

- the timing belt (see 11A, Top and front of engine,
Timing belt),

- the accessories belt (see 11A, top and front of en-
gine, Accessories belt)

- the exhaust manifold (see 11A, Top and front of
engine, Exhaust manifold).

DIRECTION ASSISTEE, and AIR CONDITIONING

Torque tighten the multifunction support moun-
ting bolts (2.1 daNm).

Proceed in the reverse order to removal.

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery, Battery: Removal - Refitting).

Fill up and bleed the cooling circuit (see 19A, Coo-
ling, Draining - Filling the cooling circuit).

11A-34

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

Essential special tooling

Mot. 1672 Lower engine support

Mot. 1202-01 Clip pliers for cooling

system hose clips
(large model)

Mot. 1202-02 Clip pliers for cooling

system hose clips
(small model)

Mot. 1448 Remote operation

pliers for cooling sys­tem hose clips

Essential equipment

cylinder head testing tool

11A

DIRECTION ASSISTEE, and AIR CONDITIONING

Tightening torquesm

cylinder head mounting
bolts

rocker cover mounting
bolts

multifunction support
mounting bolts

220˚ ±±±± 10

1 daNm

2.1 daNm

REMOVAL

Place the vehicle on a two-post lift.

Disconnect the battery, starting with the negative ter­minal.

1

108649

Remove mounting bolt (1) from the multifunction
support.

109492

11A-35

Set up engine support tool (Mot. 1672).

Remove:

- the accessories belt (see 11A, Top and front of
engine, Accessories belt ).

- the timing belt (see 11A, Top and front of engine,
Timing belt),

Drain the cooling circuit via the bottom hose using
tool (Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

22

108423

Remove mounting bolts (2) from of the air filter box.

11A

4

107358

Disconnect connector (4) of the ignition coil.

Remove the ignition spark plug leads.

3

107361

Disconnect:

- oil vapour rebreather pipe (3) from the base of air
filter box,

- the air suction sleeve on the body.

Remove the air filter box.

Note:

The ignition spark plug leads are marked on the
ignition coil (cylinder number 1 engine flywheel
end).

6

11A-36

5

107486

Remove the inlet manifold reinforcement stay loca­ted between the cylinder block and inlet manifold (5).

Disconnect fuel supply pipe (6) on the injection rail.

IMPORTANT

Be careful of petrol splashing out when discon­necting the fuel supply union.

Wear gloves during the operation.

TOP AND FRONT OF ENGINE

L90, and K7M, and 710

7

Cylinder head gasket

- pipe (12) from the brake servo on the inlet manifold,

- petrol vapour rebreather pipe (13) from the inlet
manifold.

Disconnect:

- ball joint (14) from the throttle valve control cable,

8

- cable sleeve stop (15) from the throttle valve control
cable.

11A

1616

Disconnect:

11

15

14

10

13

12

107357

9

107356

108565

Disconnect the three cooling hoses (16) with tool
(Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.

1448).

- the injector connectors,

- connector (7 ) from the idle speed control motor,

- connector (8) from the throttle valve position sen­sor,

- connector (9) from the inlet air temperature sensor,

- connector (10) from the supply air depression sen­sor,

-connector (11) from the coolant temperature sen-
sor,

11A-37

TOP AND FRONT OF ENGINE

L90, and K7M, and 710

Cylinder head gasket

17

Remove:

- the rocker cover mounting bolts,

- the rocker cover.

11A

10016

Remove:

- the earth cable from the lifting eye,

- hose support mounting (17) on the lifting eye.

19

18

109493

10015

Remove:

- the ten cylinder head mounting bolts,

- the « cylinder head-inlet manifold » assembly,

- the cylinder head gasket.

109216

Remove retaining bolt (18) from the dipstick guide tu­be.

Unhook the electrical harness (19).

Remove the exhaust manifold (see 12A, Burnt mix-
ture, Exhaust manifold).

11A-38

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

I -CLEANING THE CYLINDER HEAD

Clean the cylinder head.

IMPORTANT

- Do not scratch the aluminium sealing surfaces.

- Wear goggles.

- Wear gloves during the operation.

- Clean the gasket faces with DECAPJOINT to

dissolve any seals which are still cemented.

-Apply the product to the section to be cleaned;
Wait approximately ten minutes, then remove

the residue using a wooden spatula.

WARNING

Do not allow this product to drip onto the pain­twork.

11A

REFITTING

WARNING

In order to ensure that the bolts are correctly tigh­tened, use a syringe to remove any oil which may
be in the cylinder head mounting holes.

WARNING

Be sure to replace all seals that have been remo­ved.

Bring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.

Fit the cylinder head with a new gasket.

Clean the cylinder head carefully to prevent
foreign bodies from entering the oil inlet and
return pipes.

Failure to follow this advice could lead to the bloc­king of the various oil inlet ducts, which would
quickly result in engine damage.

WARNING

All cylinder head bolts must always be changed
after removal.

II - CHECKING THE GASKET FACE

With a ruler and shim set, check for gasket face bow.

The maximum deformation is 0.05 mm.

WARNING

No regrinding of the cylinder head is permitted.

Test the cylinder head for any cracks using the cy-

linder head testing tool (see Garage Equipment
Catalogue).

9

5

1

4

8

10

6

2

3

7

107772

Tightening the cylinder head:

-Pretighten in order and to torque the cylinder head
mounting bolts (2 daNm),

Refer to Technical Note 6010A for the cylinder head
stripping down procedure.

- Check that all the cylinder head mounting bolts
are properly tightened to 2 daNm,

-angle tighten in order the cylinder head mounting

bolts (220˚ ±±±± 10).

WARNING

Do not retighten the cylinder head bolts after
applying this procedure.

11A-39

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

2

Fit the rocker cover with a new gasket.

Tightening of the rocker cover:

11A

34

1

78

56

10016

- Pretighten in order and to torque the rocker cover
mounting bolts (0.2 daNm),

- Torque tighten in order the rocker cover moun-
ting bolts (1 daNm).

Refit:

- the timing belt (see 11A, Top and front of engine,
Timing belt),

- the accessories belt (see 11A, top and front of en-
gine, Accessories belt)

- the exhaust manifold (see 11A, Top and front of
engine, Exhaust manifold).

DIRECTION ASSISTEE, and AIR CONDITIONING

Torque tighten the multifunction support moun-
ting bolts (2.1 daNm).

Proceed in the reverse order to removal.

WARNING

Connect the battery, starting with the positive ter­minal; carry out the necessary programming (see
80A, Battery, Battery: Removal - Refitting).

Fill up and bleed the cooling circuit (see 19A, Coo-
ling, Draining - Filling the cooling circuit).

11A-40

FUEL MIXTURE

Specifications

K7J, and 710

Engine

Vehicle
type

LS0A

LS0C

Without
OBD

(1)

for a coolant temperature above 80˚C and after the

engine speed has stabilised at 2,500 rpm for 30 se-
conds approx.

(2)

octane rating 91 unleaded compatible

Type Suffix Depol-

lution
stan­dard

K7J 710 Euro 3

Idling
speed

(rpm)

752 +/­40

12A

Test carried out at idle speed

Pollutant emissions

CO (%)

(4)

0.5

maxi­mum

(3)

for the legal values, see specifications by country

(4)

at 2000 rpm CO should be 0.3 % maximum

CO2
(%)

14.5

maxi­mum

HC
(ppm)

100

(1)

(3)

Lambda
(λ)

0.97

<λ<

1.03

(2)

Fuel

(mini­mum

octane

rating)

Super
unleaded
(Octane
rating 95)

Temperatures in ˚C +/- 1 -40 -10 25 50 80 110 120

Negative temperature coefficient air
temperature sensor (resistance in Ω)

Negative temperature coefficient coo­lant temperature sensor (resistance in
Ω)

Description Brand - Type Special notes

Injection computer SIEMENS-SIRIUS 32 90-track computer

Ignition coils JCAE Dual-output single unit coils

Injectors BOSCH EV14 Resistance: 12 Ω at 20˚C

49930
± 6790

75780
± 6970

9540 ±
10440

12460
± 1121

2050 ±
123

2250 ±
112

4-track connector

- A: cylinder coil controls 1 and 4

- B: cylinder coil controls 2 and 3

- C: + 12 V supply

-D: not wired

810 ±47309 ±17135 ± 8 105 ± 7

810 ±38280 ± 9 114 ± 3 87 ± 2

2 track connector

- 1: supply

- 2: earthing

12A-1

FUEL MIXTURE

Specifications

K7J, and 710

Description Brand - Type Special notes

Manifold pressure sensor SIEMENS 5WK9681 Piezo-resistive sensor

3-track connector:

- A: earth

- B: signal

- C: + 5 V supply

Injection order 1, 3, 4, 2 (number 1 flywheel end)

Fault finding Fault finding tool CLIP only

Throttle potentiometer CTS 3-track connector:

- A: earth

- B: + 5 V supply

-C: signal

Track resistance: 1200 ±±±± 240 Ω

12A

Pinking sensor JCAE Piezoelectric type sensor

Tightening torque: 20 Nm

Engine speed and position
sensor

Upstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust

SIEMENS Integrated connector

Resistance: 200 to 270 Ω

gas temperature rises above 650˚C.

Heating resistor: 3.3 Ω at 20˚C

4-track connector

- A: heating resistor supply

- B: heating resistor earth

-C: + signal

-D: - signal

Warm engine:

- Rich mixture >850 mV

- Lean mixture <100 mV

12A-2

FUEL MIXTURE

Specifications

K7J, and 710

Description Brand - Type Special notes

Downstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust

gas temperature rises above 650˚C.

Heating resistor: 6 Ω at 20˚C

4-track connector

- A: heating resistor supply

- B: heating resistor earth

-C: + signal

-D: - signal

Warm engine:

- Rich mixture >850 mV

- Lean mixture <100 mV

Fuel vapour absorber sole­noid valve

JCAE Built into the fuel vapour absorber

Resistance: 26 ±±±± 4 Ω at 20˚C

12A

2-track connector

- 1: supply

- 2: earthing

Coolant temperature sensor SYLEA Negative temperature coefficient thermistor (see pre-

vious table)

Air temperature sensor DAV IATS 04 Negative temperature coefficient thermistor (see pre-

vious table)

CHAMPION

RYCLC87

Spark plugs

SAGEM

RFN58LZ

Refrigerant pressure sensor TEXAS INSTRUMENT 3-track connector:

Vehicle speed sensor HALMO 3-track connector:

Gap: 0.95 ±±±± 0.05 mm

Torque: 25 to 30 Nm

- A: earth

- B: + 5 V supply

-C: signal

Power assisted steering
pressostat

- A: supply

- B1: signal

- B2: earth

TEXAS INSTRUMENT Contact: open to the rest position

12A-3

FUEL MIXTURE

Specifications

K7M, and 710

Engine

Vehicle
type

LS0B

LS0D

Without
OBD

(1)

for a coolant temperature above 80˚C and after the

engine speed has stabilised at 2,500 rpm for 30 se-
conds approx.

(2)

octane rating 91 unleaded compatible

Type Suffix Emis-

sion
control

K7M 710 Euro 3

Idling
speed

(rpm)

752 +/­40

12A

Test carried out at idle speed

Pollutant emissions

CO (%)

(4)

0.5

maxi­mum

(3)

for the legal values, see specifications by country

(4)

at 2000 rpm CO should be 0.3 % maximum

CO2
(%)

14.5

maxi­mum

HC
(ppm)

100

(1)

(3)

Lambda
(λ)

0.97

<λ<

1.03

(2)

Fuel

(mini­mum

octane

rating)

Super
unleaded
(Octane
rating 95)

Temperatures in ˚C +/- 1 -40 -10 25 50 80 110 120

Negative temperature coefficient air
temperature sensor (resistance in Ω)

Negative temperature coefficient coo­lant temperature sensor (resistance in
Ω)

Description Brand - Type Special notes

Injection computer SIEMENS-SIRIUS 32 90-track computer

Ignition coils JCAE Dual-output single unit coils

Injectors BOSCH EV14 Resistance: 12 Ω at 20˚C

49930
± 6790

75780
± 6970

9540 ±
10440

12460
± 1121

2050 ±
123

2250 ±
112

4-track connector

- A: cylinder coil controls 1 and 4

- B: cylinder coil controls 2 and 3

- C: + 12 V supply

-D: not wired

810 ±47309 ±17135 ± 8 105 ± 7

810 ±38280 ± 9 114 ± 3 87 ± 2

2-track connector

- 1: supply

- 2: earthing

12A-4

FUEL MIXTURE

Specifications

K7M, and 710

Description Brand - Type Special notes

Manifold pressure sensor SIEMENS 5WK9681 Piezo-resistive sensor

3-track connector:

- A: earth

- B: signal

- C: + 5 V supply

Injection order 1, 3, 4, 2 (number 1 flywheel end)

Fault finding Diagnostic tool CLIP only

Throttle potentiometer CTS 3-track connector:

- A: earth

- B: + 5 V supply

-C: signal

Track resistance: 1200 ±±±± 240 Ω

12A

Pinking sensor JCAE Piezoelectric type sensor

Tightening torque: 20 Nm

Engine speed and position
sensor

Upstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust

SIEMENS Integrated connector

Resistance: 200 to 270 Ω

gas temperature rises above 650˚C.

Heating resistor: 3.3 Ω at 20˚C

4-track connector

- A: heating resistor supply

- B: heating resistor earth

-C: + signal

-D: - signal

Warm engine:

- Rich mixture >850 mV

- Lean mixture <100 mV

12A-5

FUEL MIXTURE

Specifications

K7M, and 710

Description Brand - Type Special notes

Downstream oxygen sensor NTK 6 L The sensor heating is interrupted when the exhaust

gas temperature rises above 650˚C.

Heating resistor: 6 Ω at 20˚C

4-track connector

- A: heating resistor supply

- B: heating resistor earth

-C: + signal

-D: - signal

Warm engine:

- Rich mixture >850 mV

- Lean mixture <100 mV

Petrol vapour absorber sole­noid valve

JCAE Built into the petrol vapour absorber

Resistance: 26 ±±±± 4 Ω at 20˚C

12A

2-track connector

- 1: supply

- 2: earthing

Coolant temperature sensor SYLEA Negative temperature coefficient thermistor (see pre-

vious table)

Air temperature sensor DAV IATS 04 Negative temperature coefficient thermistor (see pre-

vious table)

CHAMPION

RYCLC87

Spark plugs

SAGEM

RFN58LZ

Refrigerant pressure sensor TEXAS INSTRUMENT 3-track connector:

Vehicle speed sensor HALMO 3-track connector:

Gap: 0.95 ±±±± 0.05 mm

Torque: 25 to 30 Nm

- A: earth

- B: + 5 V supply

-C: signal

Power assisted steering
pressostat

- A: supply

- B1: signal

- B2: earth

TEXAS INSTRUMENT Contact: open to rest position

12A-6