Logan X90 Assembly

© Renault s.a.s. 2004

"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."

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.

APRIL 2004 Edition Anglaise

X90

1

Engine and lower engine
assembly

10A

ENGINE AND LOWER ENGINE ASSEMBLY

11A

TOP AND FRONT OF ENGINE

12A

FUEL MIXTURE

13A

FUEL SUPPLY

14A

ANTIPOLLUTION

16A

STARTING - LOAD

17A

IGNITION

17B

PETROL INJECTION

19A

COOLING SYSTEM

19B

EXHAUST

19C

RESERVOIR

© Renault s.a.s. 2004

"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."

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.

APRIL 2004 Edition Anglaise

X90

19D

ENGINE MOUNTING

L90 - Section 1

Contents

L90 - Section 1ContentsPage

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

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

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

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
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
Cooling radiator 19A-9

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
Pump / sender unit / filter 19C-7
Fuel level sensor: Distinctive 19C-10

19D ENGINE MOUNTING

Suspended engine mounting 19D-1

19A COOLING SYSTEM

10A-1

ENGINE AND LOWER ENGINE ASSEMBLY

Oil filter

L90, and K7J, and 710

10A

REPLACING THE OIL FILTER

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.

Essential special tooling

Mot. 1329 Oil filter cover - 76 mm

diameter

109223

10A-2

ENGINE AND LOWER ENGINE ASSEMBLY

Oil filter

L90, and K7M, and 710

10A

REPLACING THE OIL FILTER

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.

Essential special tooling

Mot. 1329 Oil filter cover - 76 mm

diameter

109223

10A-3

ENGINE AND LOWER ENGINE ASSEMBLY

Oil consumption

L90, and K7J or K7M

10A

PROCEDURE FOR MEASURING OIL
CONSUMPTION

1 - Filling to the maximum level

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.
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

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 cove-

red 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).

Note:
The operation should be carried out with the

engine warm after the fan assembly has cut in
once.

Note:
The operation should be carried out with the

engine warm after the fan assembly has cut in
once.

10A-4

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pressure

L90, and K7J or K7M

10A

I -CHECKING

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

Use the tool (Mot. 836-05) and a long dowel of 22 mm.
The oil pressure check must be carried out with the en-

gine warm (approximately 80˚C).

II - USE

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).

Special tooling required

Mot. 36-05 Oil pressure gauge kit

87363

K7J
engine

K7M
engine

C + E + F

H

F

E

G

D

C

B

A

10A-5

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

REMOVAL

Place the vehicle on a two-post lift.

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

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

10.5 daNm

gearbox cover moun­ting nut on the gearbox
rubber mounting

6.2 daNm

sub-frame mounting
bolts

10.5 daNm

sub-frame tie-rod upper
mounting bolts

2.1 daNm

sub-frame tie-rod lower
mounting bolts

6.2 daNm

steering rack mounting
bolts

10.5 daNm

shock absorber base
bolts

10,5 daNm

brake calliper mounting
bolts

10.5 daNm

track rod end nuts 3.7 daNm
engine tie-bar mounting

bolts

10.5 daNm

wheel bolts 10.5 daNm

Note:
The « engine and gearbox » assembly can be

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

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).

Tightening torquesm

10A-6

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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.

107846

107845

3

1

2

109184

10A-7

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

Remove:

-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.

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).

Disconnect fan assembly connector (6).
Unclip the electrical harness from fan assembly (7).

108564

108562

4

4

5

DIRECTION MANUELLE, and BASIC HEATING

109398

7

6

10A-8

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

Disconnect fan assembly connector (8).
Unhook the electrical harness from fan assembly (9).

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

Remove the power assisted steering pipe mounting
bolts:

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

- 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.

DIRECTION ASSISTEE, and BASIC HEATING

109398

109397

9

8

10

107924

11

10A-9

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

Disconnect fan assembly connectors (12).

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.

Disconnect connectors (14) of the fan assembly.

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

DIRECTION MANUELLE, and AIR CONDITIONING

109396

108107

WARNING

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

12

13

DIRECTION ASSISTEE, and AIR CONDITIONING

109396

109397

14

15

10A-10

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

Remove the power assisted steering pipe mounting
bolts:

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

- 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.

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

Drain the air conditioning circuit using the filling sta-
tion.

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

Disconnect:

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

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

107924

108107

16

17

WARNING

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

107356

19

18

10A-11

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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.

Disconnect cooling hoses (22).

Remove cooling hoses (23) from their support.

107357

IMPORTANT

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

Wear gloves during the operation.

21

20

108565

109493

2222

22

23

10A-12

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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

Remove:

- 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.

107934

24

107935

99070

26

25

27

28

10A-13

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

Remove:

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

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

Remove rubber protection (31) from the gear lever.

Remove mounting bolt (32) from the gear lever fork.
Attach the gearbox control linkage to the body.

Remove the engine tie-bar.
Remove the catalytic converter (see 19B, Exhaust,

Catalytic converter).

109494

109213

30

29

31

109214

108648

32

10A-14

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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

Remove:

-the suspended engine mounting cover mounting
bolts,

-the suspended mounting from engine (33).

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.

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

109495

108649

33

109229

107930

35

34

10A-15

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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).

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.

Place tool (Mot. 1390) under the sub-frame.
Lower the vehicle down onto the four pads of tool

(Mot. 1390).

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.

107929

109230

36

37

38

17765

108574

WARNING

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

3939

10A-16

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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.

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.

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)

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

- the brake calliper mounting bolts (10.5 daNm),

- 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).

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.

107927

109495

107930

DIRECTION ASSISTEE, and BASIC HEATING

DIRECTION MANUELLE, and AIR CONDITIONING

10A-17

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7J, and 710

10A

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.

DIRECTION ASSISTEE, and AIR CONDITIONING

WARNING

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

10A-18

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

REMOVAL

Place the vehicle on a two-post lift.

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

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

10.5 daNm

gearbox cover moun­ting nut on the gearbox
rubber mounting

6.2 daNm

sub-frame mounting
bolts

10.5 daNm

sub-frame tie-rod upper
mounting bolts

2.1 daNm

sub-frame tie-rod lower
mounting bolts

6.2 daNm

steering rack mounting
bolts

10.5 daNm

shock absorber base
bolts

10.5 daNm

brake calliper mounting
bolts

10.5 daNm

track rod end nuts 3.7 daNm
engine tie-bar mounting

bolts

10.5 daNm

wheel bolts 10.5 daNm

Note:
The « engine and gearbox » assembly can be

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

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).

Tightening torquesm

10A-19

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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.

107846

107845

3

1

2

109184

10A-20

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

Remove:

-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.

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).

Disconnect fan assembly connector (6).
Unclip the electrical harness from fan assembly (7).

108564

108562

44

5

DIRECTION MANUELLE, and BASIC HEATING

109398

7

6

10A-21

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

Disconnect fan assembly connector (8).
Unhook the electrical harness from fan assembly (9).

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

Remove the power assisted steering pipe mounting
bolts:

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

- 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.

DIRECTION ASSISTEE, and BASIC HEATING

109398

109397

9

8

10

107924

11

10A-22

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

Disconnect fan assembly connectors (12).

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.

Disconnect fan assembly connectors (14).

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

DIRECTION MANUELLE, and AIR CONDITIONING

109396

108107

WARNING

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

12

13

DIRECTION ASSISTEE, and AIR CONDITIONING

109396

109397

14

15

10A-23

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

Remove the power assisted steering pipe mounting
bolts:

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

- 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.

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

Drain the air conditioning circuit using filling station.
Disconnect the air conditioning pipe unions on the air

conditioning compressor.

Disconnect:

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

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

107924

108107

16

17

WARNING

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

107356

19

18

10A-24

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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.

Disconnect the cooling hoses (22).

Remove cooling hoses (23) from their support.

107357

IMPORTANT

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

Wear gloves during the operation.

21

20

108565

109493

22

22

22

23

10A-25

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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

Remove:

- 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.

107934

24

107935

99070

26

27

25

28

10A-26

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

Remove:

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

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

Remove rubber protection (31) from the gear lever.

Remove mounting bolt (32) from the gear lever fork.
Attach the gearbox control linkage to the body.

Remove the engine tie-bar.
Remove the catalytic converter (see 19B, Exhaust,

Catalytic converter).

109494

109213

30

29

31

109214

108648

32

10A-27

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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

Remove:

-the suspended engine mounting cover mounting
bolts,

-the suspended mounting from engine (33).

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.

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

109495

108649

33

109229

107930

35

34

10A-28

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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).

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.

Place tool (Mot. 1390) under the sub-frame.
Lower the vehicle onto the four pads of tool (Mot.

1390).

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.

107929

109230

36

37

38

17765

108574

WARNING

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

39

39

10A-29

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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.

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.

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)

- the shock absorber base bolts (10.5 daNm),

- the brake calliper mounting bolts (10.5 daNm),

- 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).

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.

107927

109495

107930

DIRECTION ASSISTEE, and BASIC HEATING

DIRECTION MANUELLE, and AIR CONDITIONING

10A-30

ENGINE AND LOWER ENGINE ASSEMBLY

Engine/gearbox assembly

L90, and K7M, and 710

10A

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.

DIRECTION ASSISTEE, and AIR CONDITIONING

WARNING

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

10A-31

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

10A

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.

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.

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

Essential special tooling

Tav. 1747 Threaded rods for

removing the sub­frame

Tightening torquesm

sump mounting bolts 1.4 daNm
engine to gearbox cou-

pling bolts

4.4 daNm

sub-frame mounting
bolts

(10.5 daNm)

steering rack mounting
bolts

10.5 daNm

sub-frame tie-rod upper
mounting bolts

2.1 daNm

sub-frame tie-rod lower
mounting bolts

6.2 daNm

engine tie-bar mounting
bolts

10.5 daNm

wheel bolts 10.5 daNm

108648

DIRECTION ASSISTEE

107924

1

10A-32

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

10A

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

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

1747).

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

107934

107924

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.

2

3

3

108645

108644

10A-33

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

10A

Remove:

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

-the sump mounting bolts,

-the sump.

REFITTING

107936

WARNING

Replace:

-the sump gasket,

-the sub-frame mounting bolts.

4

4

10A-34

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

10A

Apply:

-four beads (5) of RHODORSEAL 56615 mm in dia­meter,

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

20166

20167

Note:
The gasket faces must be clean, dry and free

from grease (avoid finger marks).

6

5

5

Note:
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-35

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7J, and 710

10A

Pretighten to torque and in order:

-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)),

- 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.

107936

107792

13

17

19

18

14

20

10

16

6

12

2

4

3

1

7

5

11

9

15

8

10A-36

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

10A

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.

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.

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

Essential special tooling

Tav. 1747 Threaded rods for

removing the sub­frame

Tightening torquesm

sump mounting bolts 1.4 daNm
engine to gearbox cou-

pling bolts

4.4 daNm

sub-frame mounting
bolts

(10.5 daNm)

steering rack mounting
bolts

10.5 daNm

sub-frame tie-rod upper
mounting bolts

2.1 daNm

sub-frame tie-rod lower
mounting bolts

6.2 daNm

engine tie-bar mounting
bolts

10.5 daNm

wheel bolts 10.5 daNm

108648

107934

2

10A-37

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

10A

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

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

107924

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.

3

3

108645

108644

10A-38

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

10A

Remove:

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

-the sump mounting bolts,

-the sump.

REFITTING

107936

WARNING

Replace:

-the sump gasket,

-the sub-frame mounting bolts.

4

4

10A-39

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

10A

Apply:

-four beads (5) of RHODORSEAL 56615 mm in dia­meter,

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

20166

20167

Note:
The gasket faces must be clean, dry and free

from grease (avoid finger marks).

5

6

5

Note:
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-40

ENGINE AND LOWER ENGINE ASSEMBLY

Sump

L90, and K7M, and 710

10A

Pretighten to torque and in order:

-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)),

- 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.

107936

107792

13

17

19

18

14

20

10

16

6

12

2

4

3

1

7

5

11

9

15

8

10A-41

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pump

L90, and K7J, and 710

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove the sump (see 10A, Engine and periphe-

rals, Sump).

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).

Tightening torquesm

oil pump mounting bolts 2.5 daNm

108646

1

10A-42

ENGINE AND LOWER ENGINE ASSEMBLY

Oil pump

L90, and K7M, and 710

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove the sump (see 10A, Engine and periphe-

rals, Sump).

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).

Tightening torquesm

oil pump mounting bolts 2.5 daNm

108646

1

10A-43

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

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.

Attach the power assisted steering pump to the sub­frame.

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),

- the power assisted steering pump mounting
bolts (2.1 daNm).

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

Proceed in the reverse order to removal.

Tightening torquesm

multifunction support
mounting bolts

4.4 daNm

power assisted steering
pump mounting bolts

2.1 daNm

109226

1

1

1

10A-44

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove the engine undertray.

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.

Attach the air conditioning compressor to the sub­frame.

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.

Tightening torquesm

multifunction support
mounting bolts

4.4 daNm

air conditioning com­pressor mounting bolts

2.1 daNm

109227

22

1

109228

33

10A-45

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove:

- the engine undertray,

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

Remove:

- 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),

Tightening torquesm

M10 mounting bolts of
the multifunction sup-

port

4.4 daNm

M8 mounting bolts of the
multifunction support

2.1 daNm

109224

109221

2

1

1

1

2

10A-46

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

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

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

Proceed in the reverse order to removal.

10A-47

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

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.

Attach the power assisted steering pump to the sub­frame.

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),

- the power assisted steering pump mounting
bolts (2.1 daNm).

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

Proceed in the reverse order to removal.

Tightening torquesm

multifunction support
mounting bolts

4.4 daNm

power assisted steering
pump mounting bolts

2.1 daNm

109226

1

1

1

10A-48

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove the engine undertray.

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.

Attach the air conditioning compressor to the sub­frame.

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.

Tightening torquesm

multifunction support
mounting bolts

4.4 daNm

air conditioning com­pressor mounting bolts

2.1 daNm

109227

212

109228

33

10A-49

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

REMOVAL

Place the vehicle on a two-post lift.
Remove the engine undertray.

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

Remove:

- 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) ,

Tightening torquesm

M10 mounting bolts of
the multifunction sup-

port

4.4 daNm

M8 mounting bolts of the
multifunction support

2.1 daNm

109224

109221

2

1

1

1

2

10A-50

ENGINE AND LOWER ENGINE ASSEMBLY

Multifunction support

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

10A

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

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

Proceed in the reverse order to removal.

11A-1

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).
Remove the accessories belt.

REFITTING

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

WARNING

Never run the engine against its operating direc­tion.

109237

WARNING

Replace any belt that has been removed.

2

1

11A-2

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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).

16300

(3)Crankshaft
(4) Alternator
(5) Measuring point

WARNING

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

5

4

3

11A-3

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right wheel.

I -REMOVING THE AIR CONDITIONING
COMPRESSOR BOLT

Cut the air conditioning compressor belt using cut­ting pliers.

II - REMOVING THE ALTERNATOR BELT

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).
Remove the alternator belt.

REFITTING

I -REFITTING THE ALTERNATOR BELT

Refit the alternator belt.

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting
screw

2.1 daNm

alternator mounting bolt 4.4 daNm
wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

109636

109236

WARNING

Replace any belt that has been removed.

2

1

11A-4

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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).

II - REFITTING THE AIR CONDITIONING
COMPRESSOR BELT

Air conditioning compressor belt fitting tool (6).

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

16300

(3)Crankshaft
(4) Alternator
(5) Measuring point

5

4

3

Note:
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.

109635

109637

6

11A-5

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

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

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

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

Torque tighten the wheel bolts (10.5 daNm).

109638

109639

7

109640

Note:
The air conditioning compressor belt fitting tool is

single-use, and must be discarded after use.

109641

WARNING

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

11A-6

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

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

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

REFITTING

Torque tighten:

- the tension wheel mounting bolt (2.1 daNm),

- the pulley mounting bolt (2.1 daNm).

Tightening torquesm

tension wheel mounting
bolt

2.1 daNm

pulley mounting bolt 2.1 daNm
wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

14494-3

2

1

WARNING

Replace any belt that has been removed.

WARNING

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

105998

(3)Crankshaft
(4) Air conditioning compressor
(5) Alternator

(6)Power assisted steering pump
(7) Idler pulley
(8) Tension wheel

3

4

5

6

7

8

11A-7

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

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

Proceed in the reverse order to removal.
Torque tighten the wheel bolts (10.5 daNm).

106001

WARNING

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

109238

WARNING

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

11A-8

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

Slacken the tension wheel mounting bolts (1).
Remove the accessories belt.

REFITTING

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

2.1 daNm

wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

109235

1

WARNING

Replace any belt that has been removed.

WARNING

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

106045

(2)Crankshaft
(3) Alternator
(4)Power assisted steering pump
(5) Tension wheel
(6) Measuring point

2

6

5

4

3

11A-9

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

Tension the belt using the bolt (7).
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).

105999

WARNING

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

109235

WARNING

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

7

11A-10

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

I -REMOVING THE AIR CONDITIONING
COMPRESSOR BELT

Cut the air conditioning compressor belt using cut­ting pliers.

II - REMOVING THE ALTERNATOR BELT

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).
Remove the alternator belt.

REFITTING

I -REFITTING THE ALTERNATOR BELT

Refit the alternator belt.

Essential special tooling

Mot. 1505 Belt tension setting

tool (frequency meter)

Mot. 1715 Belt tension setting

tool (frequency meter)

Tightening torquesm

alternator mounting
screw

2.1 daNm

alternator mounting bolt 4.4 daNm
wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

109636

109236

WARNING

Replace any belt that has been removed.

2

1

11A-11

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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).

II - REFITTING THE AIR CONDITIONING
COMPRESSOR BELT

Air conditioning compressor belt fitting tool (6).

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

16300

(3)Crankshaft
(4) Alternator
(5) Measuring point

5

4

3

Note:
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.

109635

109637

6

11A-12

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

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

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

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

Torque tighten the wheel bolts (10.5 daNm).

109638

109639

7

109640

Note:
The air conditioning compressor belt fitting tool is

single-use, and must be discarded after being
used.

109641

WARNING

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

11A-13

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

Slacken the tension wheel mounting bolts (1).
Remove the accessories belt.

REFITTING

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

2.1 daNm

wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

109235

1

WARNING

Replace any belt that has been removed.

WARNING

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

106045

(2)Crankshaft
(3) Alternator
(4)Power assisted steering pump
(5) Tension wheel
(6) Measuring point

5

4

3

2

6

11A-14

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

Tension the belt using bolt (7).
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).

105999

WARNING

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

109235

WARNING

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

7

11A-15

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right-hand wheel.

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

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

REFITTING

Torque tighten:

- the tension wheel mounting bolt (2.1 daNm),

- the idler pulley mounting bolt (2.1 daNm).

Tightening torquesm

tension wheel mounting
bolt

2.1 daNm

idler pulley mounting
bolt

2.1 daNm

wheel bolts 10.5 daNm

WARNING

Never run the engine against its operating direc­tion.

14494-3

2

1

WARNING

Replace any belt that has been removed.

WARNING

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

105998

(3)Crankshaft
(4) Air conditioning compressor
(5) Alternator

(6)Power assisted steering pump
(7) Idler pulley
(8) Tension wheel

6

5

4

3

8

7

11A-16

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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

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

Proceed in the reverse order to removal.
Torque tighten the wheel bolts (10.5 daNm).

106001

WARNING

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

109238

WARNING

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

11A-17

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

REMOVAL

Mount the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.
Remove the front right wheel.

Slacken:

- the alternator mounting screw (1),

- the alternator mounting bolt (2).
Remove the accessories belt.

REFITTING

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

WARNING

Never run the engine against its operating direc­tion.

109237

WARNING

Replace any belt that has been removed.

2

1

11A-18

TOP AND FRONT OF ENGINE

Accessories belt

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

11A

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).

16300

(3)Crankshaft
(4) Alternator
(5) Measuring point

WARNING

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

5

4

3

11A-19

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

11A

REMOVAL

Place the vehicle on a two-post lift.

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.

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

Remove suspended engine mounting (1).

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)

Essential equipment

low torque wrench

Tightening torquesm

the tension wheel moun­ting nut

5 daNm

crankshaft pulley moun­ting bolt

3 daNm + 80˚ ±±

±±

5

M10 mounting bolts of
the upper timing cover

4.4 daNm

M8 mounting bolts of the
upper timing cover

2.2 daNm

lower timing cover
mounting bolts

0.8 daNm

suspended engine
mounting cover moun­ting bolts

6.2 daNm

WARNING

Never turn the engine against its operating direc­tion.

109495

108649

1

11A-20

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

11A

Remove TDC pin plug (2).

Remove:

- lower timing cover (3),

- upper timing cover (4).

107359

2

107498

107499

33

4

44

11A-21

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

11A

ADJUSTING THE TIMING

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)).

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

setting rod (Mot. 1489) until the crankshaft times.

Remove:

- tension wheel mounting nut (7),

- the timing belt,

- the tension wheel.

REFITTING

Refit the tension wheel.

107497

5

6

107494

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.

7

11A-22

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

11A

Fit the timing belt by aligning the belt markings with
those of the sprockets of camshaft (8) and cranks-
haft (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).

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

Apply pretensioning torque to the timing belt section

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

Remove the tool (Mot. 1501).

107494

8

9

107493

16293

10

11

11A-23

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7J, and 710

11A

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

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.

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

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).

107492

12

107499

1313

14

11A-24

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

11A

REMOVAL

Place the vehicle on a two-post lift.

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.

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

Remove the suspended engine mounting (1).

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)

Essential equipment

low torque wrench

Tightening torquesm

the tension wheel moun­ting nut

5 daNm

crankshaft pulley moun­ting bolt

3 daNm + 80˚ ±±

±±

5

M10 mounting bolts of
the upper timing cover

4.4 daNm

M8 mounting bolts of the
upper timing cover

2.2 daNm

lower timing cover
mounting bolts

0.8 daNm

suspended engine
mounting cover moun­ting bolts

6.2 daNm

WARNING

Never turn the engine against its operating direc­tion.

109495

108649

1

11A-25

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

11A

Remove the TDC pin plug (2).

Remove:

- the lower timing cover (3),

- the upper timing cover (4).

107359

2

107498

107499

33

444

11A-26

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

11A

ADJUSTING THE TIMING

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)).

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

setting rod (Mot. 1489) until the crankshaft times.

Remove:

- tension wheel mounting nut (7),

- the timing belt,

- the tension wheel.

REFITTING

Refit the tension wheel.

107497

6

5

107494

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.

7

11A-27

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

11A

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).

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

Apply pretensioning torque to the timing belt section

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

Remove tool (Mot. 1501).

107494

9

8

107493

16293

10

11

11A-28

TOP AND FRONT OF ENGINE

Timing belt

L90, and K7M, and 710

11A

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

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.

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

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).

107492

12

107499

14

13

13

11A-29

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

REMOVAL

Place the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.

Remove mounting bolt (1) from the multifunction
support.

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).

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

Tightening torquesm

cylinder head mounting
bolts

220˚ ±±±± 10

rocker cover mounting
bolts

1 daNm

multifunction support
mounting bolts

2.1 daNm

DIRECTION ASSISTEE, and AIR CONDITIONING

108649

109492

1

11A-30

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

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

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.

Disconnect connector (4) of the ignition coil.
Remove the ignition spark plug leads.

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

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

108423

107361

2

2

3

107358

Note:
The ignition spark plug leads are marked on the

ignition coil (cylinder number 1 engine flywheel
end).

107486

IMPORTANT

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

Wear gloves during the operation.

4

6

5

11A-31

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

Disconnect:

-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,

- 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,

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

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

1448).

107357

107356

8

7

10

9

15

14

13

12

11

108565

1616

11A-32

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

Remove:

-the earth cable from the lifting eye,

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

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

Unhook electrical harness (19).
Remove the exhaust manifold (see 12A, Burnt mix-

ture, Exhaust manifold).

Remove:

- the rocker cover mounting bolts,

- the rocker cover.

Remove:

- the cylinder head mounting bolts,

- the « cylinder head-inlet manifold » assembly,

- the cylinder head gasket.

109493

109216

17

19

18

10016

10015

11A-33

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

I -CLEANING THE CYLINDER HEAD

Clean the cylinder head.

II - CHECKING THE GASKET FACE

With a ruler and shim set, check for gasket face bow.
The maximum deformation is 0.05 mm.

Test the cylinder head for any cracks using the cy-

linder head testing tool (see Garage Equipment
Catalogue).

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

REFITTING

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.

Tightening the cylinder head:

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

- 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).

IMPORTANT

-Do not scratch the aluminium gasket faces.

-Wear goggles.

-Wear gloves during the operation.

-Clean the gask et 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.

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.

WARNING

No regrinding of the cylinder head is permitted.

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.

107772

WARNING

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

8

7

6

5

4

3

2

1

10

9

11A-34

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7J, and 710

11A

Fit the rocker cover with a new gasket.
Tightening the rocker cover:

-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).

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

Proceed in the reverse order to removal.

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

10016

DIRECTION ASSISTEE, and AIR CONDITIONING

WARNING

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

3

2 1

8

7

6

5

4

11A-35

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

REMOVAL

Place the vehicle on a two-post lift.
Disconnect the battery, starting with the negative ter-

minal.

Remove mounting bolt (1) from the multifunction
support.

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).

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

Tightening torquesm

cylinder head mounting
bolts

220˚ ±±±± 10

rocker cover mounting
bolts

1 daNm

multifunction support
mounting bolts

2.1 daNm

DIRECTION ASSISTEE, and AIR CONDITIONING

108649

109492

1

11A-36

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

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

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.

Disconnect connector (4) of the ignition coil.
Remove the ignition spark plug leads.

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

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

108423

107361

22

3

107358

Note:
The ignition spark plug leads are marked on the

ignition coil (cylinder number 1 engine flywheel
end).

107486

IMPORTANT

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

Wear gloves during the operation.

4

5

6

11A-37

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

Disconnect:

-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,

- 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,

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

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

1448).

107357

107356

8

7

9

10

11

12

13

14

15

108565

1616

11A-38

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

Remove:

-the earth cable from the lifting eye,

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

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).

Remove:

- the rocker cover mounting bolts,

- the rocker cover.

Remove:

- the ten cylinder head mounting bolts,

- the « cylinder head-inlet manifold » assembly,

- the cylinder head gasket.

109493

109216

17

18

19

10016

10015

11A-39

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

I -CLEANING THE CYLINDER HEAD

Clean the cylinder head.

II - CHECKING THE GASKET FACE

With a ruler and shim set, check for gasket face bow.
The maximum deformation is 0.05 mm.

Test the cylinder head for any cracks using the cy-

linder head testing tool (see Garage Equipment
Catalogue).

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

REFITTING

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.

Tightening the cylinder head:

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

- 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).

IMPORTANT

-Do not scratch the aluminium sealing surfaces.

-Wear goggles.

-Wear gloves during the operation.

-Clean the gask et 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.

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.

WARNING

No regrinding of the cylinder head is permitted.

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.

107772

WARNING

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

2

1

3

4

5

6

7

8

9

10

11A-40

TOP AND FRONT OF ENGINE

Cylinder head gasket

L90, and K7M, and 710

11A

Fit the rocker cover with a new gasket.
Tightening of the rocker cover:

-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).

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

Proceed in the reverse order to removal.

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

10016

DIRECTION ASSISTEE, and AIR CONDITIONING

WARNING

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

1

2

34

56

78

12A-1

FUEL MIXTURE

Specifications

K7J, and 710

12A

(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

(3)

for the legal values, see specifications by country

(4)

at 2000 rpm CO should be 0.3 % maximum

Vehicle
type

Engine

Test carried out at idle speed

(1)

Fuel

(2)

(mini­mum

octane
rating)

Pollutant emissions

(3)

Type Suffix Depol-

lution
stan­dard

Idling
speed

(rpm)

CO (%)

(4)

CO2
(%)

HC
(ppm)

Lambda
(λ)

LS0A

K7J 710 Euro 3

752 +/­40

0.5
maxi-

mum

14.5
maxi-

mum

100

0.97
<λ<

1.03

Super
unleaded
(Octane
rating 95)

LS0C
Without

OBD

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

Negative temperature coefficient air
temperature sensor (resistance in Ω)

49930
± 6790

9540 ±
10440

2050 ±
123

810 ±47309 ±17135 ± 8 105 ± 7

Negative temperature coefficient coo­lant temperature sensor (resistance in
Ω)

75780
± 6970

12460
± 1121

2250 ±
112

810 ±38280 ± 9 114 ± 3 87 ± 2

Description Brand - Type Special notes

Injection computer SIEMENS-SIRIUS 32 90-track computer
Ignition coils JCAE Dual-output single unit coils

4-track connector

- A: cylinder coil controls 1 and 4

- B: cylinder coil controls 2 and 3

-C: + 12 V supply

-D: not wired

Injectors BOSCH EV14 Resistance: 12 Ω at 20˚C

2 track connector

- 1: supply

- 2: earthing

12A-2

FUEL MIXTURE

Specifications

K7J, and 710

12A

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

Pinking sensor JCAE Piezoelectric type sensor

Tightening torque: 20 Nm

Engine speed and position
sensor

SIEMENS Integrated connector

Resistance: 200 to 270 Ω

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

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

Description Brand - Type Special notes

12A-3

FUEL MIXTURE

Specifications

K7J, and 710

12A

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 sole-

noid valve

JCAE Built into the fuel vapour absorber

Resistance: 26 ±±±± 4 Ω at 20˚C
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)

Spark plugs

CHAMPION
RYCLC87

Gap: 0.95 ±±±± 0.05 mm
Torque: 25 to 30 Nm

SAGEM
RFN58LZ

Refrigerant pressure sensor TEXAS INSTRUMENT 3-track connector:

- A: earth

- B: + 5 V supply

-C: signal
Vehicle speed sensor HALMO 3-track connector:

- A: supply

- B1: signal

- B2: earth
Power assisted steering

pressostat

TEXAS INSTRUMENT Contact: open to the rest position

Description Brand - Type Special notes

12A-4

FUEL MIXTURE

Specifications

K7M, and 710

12A

(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

(3)

for the legal values, see specifications by country

(4)

at 2000 rpm CO should be 0.3 % maximum

Vehicle
type

Engine

Test carried out at idle speed

(1)

Fuel

(2)

(mini­mum

octane
rating)

Pollutant emissions

(3)

Type Suffix Emis-

sion
control

Idling
speed

(rpm)

CO (%)

(4)

CO2
(%)

HC
(ppm)

Lambda
(λ)

LS0B

K7M 710 Euro 3

752 +/­40

0.5
maxi-

mum

14.5
maxi-

mum

100

0.97
<λ<

1.03

Super
unleaded
(Octane
rating 95)

LS0D
Without

OBD

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

Negative temperature coefficient air
temperature sensor (resistance in Ω)

49930
± 6790

9540 ±
10440

2050 ±
123

810 ±47309 ±17135 ± 8 105 ± 7

Negative temperature coefficient coo­lant temperature sensor (resistance in
Ω)

75780
± 6970

12460
± 1121

2250 ±
112

810 ±38280 ± 9 114 ± 3 87 ± 2

Description Brand - Type Special notes

Injection computer SIEMENS-SIRIUS 32 90-track computer
Ignition coils JCAE Dual-output single unit coils

4-track connector

- A: cylinder coil controls 1 and 4

- B: cylinder coil controls 2 and 3

-C: + 12 V supply

-D: not wired

Injectors BOSCH EV14 Resistance: 12 Ω at 20˚C

2-track connector

- 1: supply

- 2: earthing

12A-5

FUEL MIXTURE

Specifications

K7M, and 710

12A

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

Pinking sensor JCAE Piezoelectric type sensor

Tightening torque: 20 Nm

Engine speed and position
sensor

SIEMENS Integrated connector

Resistance: 200 to 270 Ω

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

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

Description Brand - Type Special notes

12A-6

FUEL MIXTURE

Specifications

K7M, and 710

12A

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 sole-

noid valve

JCAE Built into the petrol vapour absorber

Resistance: 26 ±±±± 4 Ω at 20˚C
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)

Spark plugs

CHAMPION
RYCLC87

Gap: 0.95 ±±±± 0.05 mm
Torque: 25 to 30 Nm

SAGEM
RFN58LZ

Refrigerant pressure sensor TEXAS INSTRUMENT 3-track connector:

- A: earth

- B: + 5 V supply

-C: signal
Vehicle speed sensor HALMO 3-track connector:

- A: supply

- B1: signal

- B2: earth
Power assisted steering

pressostat

TEXAS INSTRUMENT Contact: open to rest position

Description Brand - Type Special notes