Page 1
Technical Note6006A
GETtheMANUALS.org
KXX, and K9K
K9K engine
Engine workshop repair manual
Edition 2
77 11 328 422 MARCH 2004 Edition Anglaise
"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. 2006
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.
Page 2
K9K engine ContentsPage
GETtheMANUALS.org
K9K engine
Contents
Page
10A ENGINE AND LOWER ENGINE ASSEMBLY
Engine: Specifications 10A-1
Engine: Precautions for
repair 10A-4
Engine: Parts and
consumables for the repair
work 10A-14
Upper engine: Tightening
torque 10A-15
Lower engine: Tightening
torque 10A-20
Diesel injection: Tightening
torque 10A-23
Accessories belt: Tightening
torque 10A-26
Upper engine: Specifications 10A-28
Engine peripherals:
Specifications 10A-36
10A ENGINE AND LOWER ENGINE ASSEMBLY
Piston base cooling jet:
Removal 10A-207
Lower engine: Cleaning 10A-209
Lower engine: Check 10A-211
Piston base cooling jet:
Refitting 10A-224
Running gear Refitting 10A-227
Cylinder block: Refitting 10A-239
Timing - cylinder head:
Refitting 10A-280
Accessories belt: Refitting 10A-326
Engine: Refitting 10A-329
Timing belt: Removal 10A-336
Timing belts: Refitting 10A-351
Standard replacement 10A-46
Special tooling 10A-47
Equipment 10A-65
Engine: Dismantling 10A-84
Accessories belt: Removal 10A-89
Timing - cylinder head:
Removal 10A-90
Cylinder head: Dismantling 10A-113
Upper engine: Cleaning 10A-129
Upper engine: Checking 10A-135
Cylinder head: Refitting 10A-144
Cylinder block: Dismantling 10A-192
Running gear:Removal 10A-204
Page 3
ENGINE AND LOWER ENGINE ASSEMBLY
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I - ENGINE IDENTIFICATION
Engine: Specifications
Details of markings
The markings consist of:
- (1) : the engine type
10A
19858
107307
113741
The engine can be identified by markings (6) located
on the cylinder block.
- (2) : the engine approval letter
- (3) : the engine suffix
- (4) : the factory where the engine was fitted
- (5) : the engine production number
10A-1
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Specifications
II - ENGINE SPECIFICATION TABLES
Vehicle After-
Sales
Type:
XB07
XB1W
XB24
XB08 702
Renault
CLIO II
XB07 704
XB24 704
XB23
XB2E
XB09 710 18.25:1
Engine
type
K9K
Engine
suffix
700
706
Cubic capacity (cc)
1461 76
Bore
(mm)
Stroke
(mm)
80.5
10A
Compression
ratio
18.25:1
17.9:1
Renault
KANGOO
Renault
MEGANE II
XB2G 712 17.9:1
XC07
XC08
XC1S
XC07
XC08
XC1R 704 17.6: 1
XC09 710 18.25:1
XC1E 714
XC1G 718
XM0F
XM0T 722 17.6:1
XM1F 724 17.9:1
XM02 728, 729 17.9:1
K9K
K9K
700
702
704
722
18.25:1
1461 76 80.5
17.9:1 XC1F 716
18.25:1
1461 76 80.5
XM13 728 17.6: 1
XM1E 732 15.3:1
XR0H
Renault
CLIO III
XR0F 766
XR0G 768
K9K
764
15.3:1
1461 76 80.5
17.9:1
10A-2
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ENGINE AND LOWER ENGINE ASSEMBLY
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Vehicle After-
Sales
Type:
XP0D
XP08
XP0E
Renault
MODUS
Renault
DACIA
Nissan
ALMERA
XP0F 760
XP0G 762 ,768
XP0H 764 15.3:1
XP0F 766 17.9:1
XS0J
XS0K 792
- K9K 260 1461 76 80.5 18.25:1
Engine: Specifications
Engine
type
K9K
K9K
Engine
suffix
750
752
790
Cubic capacity (cc)
1461 76 80.5
1461 76 80.5 17.9:1
Bore
(mm)
Stroke
(mm)
10A
Compression
ratio
17.6: 1
17.9:1
Nissan
MICRA
- K9K 270, 272,
274, 276
1461 76 80.5 18.25:1
10A-3
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
Equipment required
offset thread repair kit
I - SAFETY
General information
All information contained in these manuals is intended
exclusively for automotive industry professionals.
The documentation is intended to cover all vehicles in
the RENAULT range throughout the world, but may not
cover equipment designed for use in specific countries.
The methods and fault finding procedures recommended and described in this manual have been designed
by automotive industry repair professionals.
a - General recommendations
Observe basic principles of vehicle repair.
The quality of repair depends first and foremost on the
care exercised by the person in carrying it out.
To ensure good repair:
- use recommended professional products and original
Renault parts,
- observe the tightening torques,
- replace the recommended roll pins, nuts or bolts, after
each removal,
- clean and degrease the sections to be bonded, to ensure they bond correctly.
The design quality of our vehicles demands that nothing is left to chance in making a good repair, and it is
essential to refit parts or components exactly as they
were originally (for instance: heat shields, wiring routing, pipe routing).
Use professional products and apply them with care,
for example do not apply too much sealant to the joint
face.
10A
c - Reliability - updating
Since component specifications are subject to change
during their commercial life, it is essential to check
whether there are any Technical Note updates when
seeking information.
d - Safety
Certain devices and parts must be handled with particular attention to safety and cleanliness and, above all,
with due care.
The safety symbol used in this manual indicates that
special attention must be paid to the procedure or the
tightening torque values.
WARNING
Do not use flammable products to clean parts.
Working safely:
- use appropriate tools which are in good condition
(using « multipurpose » tools, such as adjustable
pliers, should be avoided wherever possible),
- adopt a correct posture and technique when performing heavy work or lifting loads,
- check that the working area is clean and tidy during
the operation,
- use personal protection (gloves, safety goggles, work
shoes, masks, skin barrier creams, etc.),
- always follow the safety instructions associated with
the operation to be performed,
- do not smoke when working on vehicles,
- do not use toxic products in unventilated rooms,
- do not ingest any chemicals (brake fluid, coolant,
etc.).
Respecting the environment:
- sort waste according to its particular qualities,
- do not burn waste products (tyres, etc.).
e - Conclusion
b - Special tooling - ease of use
The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and
quality of repair.
The equipment we have approved has undergone ca-
reful research and testing, and must be used and maintained with care.
The procedures contained in this document merit your
attention. Please read them carefully in order to reduce
the risk of injury, and avoid using incorrect procedures
that could damage the vehicle or make it dangerous to
use.
Following the recommended procedures will help you
to provide a quality of service which will ensure the vehicles achieve the highest levels of performance and
reliability.
10A-4
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
Maintenance and repair operations must be carried out
under the proper conditions to ensure that our vehicles
run safely and reliably.
II - CLEANLINESS
Risks relating to contamination
The high-pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are:
- damage to or destruction of the high-pressure injection system,
- a component seizing,
- a component not being properly sealed.
All After-Sales operations must be performed under
very clean conditions. Having carried out an operation
in good conditions means that no impurities (particles a
few microns in size) have penetrated the system during
dismantling.
The cleanliness principle must be applied from the filter
to the injectors.
10A
The use of rags or ordinary paper towels is prohibited:
these produce lint and lose fibres, which then contaminate the fuel circuit.
Each cloth must only be used once.
b - Blanking plugs
The blanking plugs are used to cap the fuel circuit once
it is opened and to therefore prevent contaminants
from entering.
A set of blanking plugs should be used once only and
used plugs must be discarded after use: once used,
the plugs are soiled and cleaning them is not sufficient
to make them reusable.
Unused plugs must also be discarded and not used
again for any other operation on an injection system.
Blanking plug kit part number:
- K9K ( DELPHI injection): 77 01 206 804
- K9K ( SIEMENS injection): 77 01 476 857
What are the sources of contamination?
- metal or plastic chips,
- paint,
- fibres:
• cardboard,
• brushes,
• paper,
• clothing,
• cloth,
- foreign bodies such as hair,
- ambient atmosphere,
- etc.
WARNING
Cleaning the engine using a high-pressure washer
is prohibited because of the risk of damaging connections. In addition, moisture may collect in the
connectors and create electrical connection faults.
c - Protective bags
Use hermetically resealable plastic bags, using adhesive tape, for example, to store components which will
be refitted and reused. Stored parts will therefore be
less subject to the risk of contamination.
These bags must be used once only: once they have
been used, they are to be discarded.
d - Cleaning products
Two cleaning products can be used:
- an aerosol spray brake cleaner (part number 77 11
226 128 ).
- an injector cleaner (part number 77 11 224 188 ),
To use the injector cleaner, be sure to have a clean
brush in good condition (the brush must not lose any
bristles) as well as a clean container which has no impurities in it.
a - Cleaning cloths
Use lint free cleaning cloths (part number 77 11 211
707 ).
Note:
Use a new injector cleaner each time work is car-
ried out (a used cleaning agent will contain impurities).
10A-5
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
III - GENERAL RECOMMENDATIONS
1 - Advice to be followed before any operation
1) Carry out the work in a clean working area and take
care to protect removed components from dust using
plastic bags which are hermetically resealable, for
example.
2) Always order the following from the Parts Department before carrying out work:
- a new blanking plug kit ; these are specific to the
engine
- a sufficient number of lint free cleaning cloths .
- one of the two cleaning products for fuel pipe
unions,
- the parts always to be replaced after each removal
operation mentioned in the operational procedures
specific to the vehicle.
10A
After opening the fuel circuit, the use of brushes, cleaning agents, air blow guns, rifle-type brushes or standard cloths is strictly prohibited: These items are likely
to allow impurities to enter the system.
When replacing a component with a new one or when
refitting it after storing it in a plastic bag, do not unpack
it until it is time to fit it on the vehicle.
3 - Cleaning
There are currently two procedures for cleaning the
fuel circuit before opening it in order to carry out work in
the workshop.
These procedures enable the fuel circuit to be cleaned
to prevent contamination from entering: they both have
the same end result and neither is preferred over the
other.
a - Using the injector cleaning agent
3) Wear safety goggles fitted with side shields to pre-
vent the cleaning product from splashing the eyes.
4) Wear latex safety gloves to avoid prolonged contact
with the skin.
Note:
If wearing leather protective gloves, cover these
with latex gloves.
5) Before any operation on the injection system, using
plastic bags or clean cloths, protect:
- the accessories and timing belts,
- the electrical accessories (starter, alternator, powerassisted steering pump, sensors and electrical connectors),
- the flywheel face.
2 - Instructions to be followed during the operation
Wash your hands before and while carrying out the
work.
Change the latex safety gloves if they become soiled or
damaged.
All components removed from the injection system
must be stored in a hermetically sealed plastic bag
once they have been capped.
Reseal the bag hermetically using adhesive tape, for
example, even if the bag must be opened shortly afterwards: ambient air can be a source of pollution.
Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Pour the injector cleaning agent into a container which
is free from impurities.
IMPORTANT
Wear latex safety gloves when using the cleaning
agent.
Dip a clean brush, which is not shedding bristles, into
the container of injector cleaning agent.
IMPORTANT
Wear safety goggles fitted with side shields during
this operation.
Clean the unions carefully using the brush and the injector cleaning agent.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Make sure
there are no brush bristles remaining and that the area
is clean.
Wipe the sections that were cleaned with fresh cleaning cloths.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.
10A-6
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
WARNING
Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary.
b - Using the brake cleaning agent
Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
IMPORTANT
Wear latex safety gloves when using the cleaning
agent.
10A
IMPORTANT
Wear safety goggles fitted with side shields during
this operation.
Spray the brake cleaning agent onto the unions to be
opened.
Clean the unions carefully using fresh cleaning cloths.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Make sure
there are no brush bristles remaining and that the area
is clean.
Open the circuit at the unions and immediately fit the
relevant blanking plugs.
WARNING
Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary.
10A-7
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
4 - Instructions for fitting the plugs
K9K, and 732 or 764
10A
10A-8
Page 11
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
Part no. 77 01 476 857
10A
113430
10A-9
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
10A
10A-10
Page 13
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or
706 or 710 or 712 or 714 or 716 or 718 or 722 or
724 or 728 or 729 or 750 or 752 or 760 or 762 or
766 or 768 or 790
10A
10A-11
Page 14
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
Part no. 77 01 206 804
10A
20977
10A-12
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Precautions for repair
5 - Engine cleaning
Protect the various accessories to prevent water and
cleaning products splashing on them.
Do not allow water to enter the inlet pipes.
6 - Cleaning the engine parts
WARNING
When cleaning parts, it is essential to not knock the
parts against each other, or their mating faces may
be damaged and therefore their adjustments may
be altered, which could damage the engine.
7 - Fitting relieved threads
10A
The tapped holes of all parts including the engine (except the rocker cover) may be repaired using the offset
thread repair kit .
10A-13
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Parts and consumables for the repair work
I - PARTS ALWAYS TO BE REPLACED AFTER
REPAIRING THE ENGINE
- All seals
- The oil filter
- The copper washers on the injector holders,
- The high pressure injection pipes,
- The pipe plugs,
- The valve guides
- The valve stem seals
- The cooling jets at the bottom of the piston
- The engine flywheel bolts
- The crankshaft bearing cap bolts
- The con rod cap bolts
Type Quantity Component concerned Part no.
- The camshaft pulley nut
- The tensioning rollers and pulleys for the accessories
and timing belts
- The bolts for the accessories belt mechanical tensioning roller
- The accessories and timing belts
- The crankshaft accessories pulley bolt
- The cooling circuit hoses if they are damaged
- The thermostat
- The turbocharger plastic pipes.
II - CONSUMABLES
10A
DÉCAPJOINT Coat The joint faces 77 01 405 952
SILICONE ADHESIVE
SEAL
LOCTITE 518 Bead Camshaft bearing caps no. 1 and
"VARYBOND 12-71"
HIGH STRENGTH
THREADLOCK
DEGREASER Coat The joint faces 77 11 224 559
CLEANING CLOTHS - Injection circuit 77 11 211 707
SET OF BLANKING
PLUGS
SET OF BLANKING
PLUGS
INJECTOR CLEANING
PRODUCT
BRAKE CLEANER Coat Injection system 77 11 226 128
Bead Crankshaft bearing cap no. 1
Cylinder block-sump connection
no. 6
1 - 2 drops Coolant pump bolts 77 11 230 112
- Injection system DELPHI 77 01 206 804
- Injection system SIEMENS 77 01 476 857
Coat Injection system 77 11 224 188
77 11 227 484
77 01 421 162
GREY SCUFF PAD - The joint faces 77 01 405 943
10A-14
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ENGINE AND LOWER ENGINE ASSEMBLY
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UPPER ENGINE
Upper engine: Tightening torque
10A
10A-15
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ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Tightening torque
10A
113915
10A-16
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ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Tightening torque
Tightening torques in Nm and/or in degrees
(1) cylinder marking sensor bolt 8 ±±±± 0.8
(2) Rocker cover bolts 12 ±±±± 1.2
(3) Lifting eye bolts (timing end) Bolt H M8x125-16 21 ±±
2.1
Bolt H M6x100-23 10 ±±±± 1
(4) Cylinder head bolts 25 ±±±± 2.5 + 255˚±±±± 10˚
(5) Camshaft bearing cap bolts 11 ±±±± 1.1
(6) Vacuum pump bolt 21 ±±±± 2.1
(7) Exhaust manifold nut 26 ±±±± 2.6
(8) Exhaust manifold stud 8 ±±±± 0.8
10A
±±
(9) EGR cooler cover bolt 12 ±±±± 1.2
(10) Cylinder head coolant pipe housing outlet bolt 11 ±±±± 1.1
(11) Engine lifting eye bolts (flywheel end) 13 ±±±± 1.3
(12) Inner timing cover bolt 9 ±±±± 0.9
(13) Heater plug 15 ±±±± 1.5
(14) Timing tension wheel bolt 27 ±±±± 2.7
(15) Camshaft pulley stud 10 ±±±± 1 at 14 ±±±± 1.4
(16) Camshaft pulley nut 30 ±±±± 3 + 86˚±±±± 6˚
(17) Camshaft pulley ring gear bolt 14 ±±±± 1.4
(18) Cylinder marking sensor bolt 8 ±±±± 0.8
(19) Cylinder head suspended mounting bolt 25 ±±±± 2.5
10A-17
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ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Tightening torque
10A
113916
Couple de serrage en N.m et / ou degrés
(20) Downstream catalytic converter stay nut and bolt (gearbox side) 21 ±±±± 2.1
(21) Upstream catalytic converter stay bolt (engine side) 44 ±±±± 4.4
(22) Upstream stay bolt on the catalytic converter 26 ±±±± 2.6
(23) Catalytic converter-turbocharger nut 26 ±±±± 2.6
(24) Downstream stay bolt on the catalytic converter 21 ±±±± 2.1
(25) Turbocharger stud 9 ±±±± 0.9
(26) Turbocharger oil supply pipe bolt on the turbocharger. 23 ±±±± 2.3
(27) Turbocharger nut on the manifold 26 ±±±± 2.6
(28) Turbocharger oil supply pipe bolt on the cylinder head Collar nut to 35 ±±±± 3.5
(without high strength
threadlock)
Collarless nuts to 23 ±±
2.3 (with high strength
threadlock)
±±
(29) Turbocharger stud 9 ±±±± 0.9
10A-18
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ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Tightening torque
Couple de serrage en N.m et / ou degrés
(30) Turbocharger oil return pipe bolt 12 ±±±± 1.2
(31) Timing end cooler support bolt 25 ±±±± 2.5
(32) Exhaust gas cooler bolt 12 ±±±± 1.2
(33) EGR solenoid valve bolt 10 ±±±± 1
(34) Flywheel end cooler support bolt 25 ±±±± 2.5
(35) Exhaust gas inlet pipe bolts 35 ±±±± 3.5
(36) Timing end cooler support bolt 12 ±±±± 1.2
(37) Exhaust gas recirculation solenoid valve bolt 12 ±±±± 1.2
(38) Exhaust gas recirculation solenoid valve stud 4 ±±±± 0.4
(39) Exhaust gas recirculation solenoid valve nut 12 ±±±± 1.2
10A
(40) Solenoid valve support bolts 21 ±±±± 2.1
10A-19
Page 22
ENGINE AND LOWER ENGINE ASSEMBLY
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LOWER ENGINE:
Lower engine: Tightening torque
10A
10A-20
Page 23
ENGINE AND LOWER ENGINE ASSEMBLY
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Lower engine: Tightening torque
10A
113917
10A-21
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ENGINE AND LOWER ENGINE ASSEMBLY
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Lower engine: Tightening torque
Couple de serrage en N.m et / ou degrés
(1) coolant pump bolts 11 ±±±± 1.1
(2) Crankshaft cover bolts 11 ±±±± 1.1
(3) Dipstick guide tube bolts 10 ±±±± 1
(4) Coolant pump inlet pipe bolts 22 ±±±± 2.2
(5) The water-coolant heat exchanger union 45 ±±±± 4.5
(6) Oil filter bracket bolt 45 ±±±± 4.5
(7) Coolant pump inlet pipe bolts 22 ±±±± 2.2
(8) Crankshaft accessories pulley bolt Bolt M12: 60 ±±±± 6 +100˚ ±±±± 10˚
Bolt M14: 120 ±±±± 12 + 95˚ ±±±± 15˚
(9) Oil pump bolts 25 ±±±± 2.5
10A
(10) Oil sump bolts 14 ±±±± 1.4
(11) Oil level sensor 25 ±±±± 2.5
(12) Drain plug 20 ±±±± 4
(13) Clutch pressure plate bolts Bolt H M7x100-16: 20 ±±±± 2
Bolt CBLX M6x100-18: 14 ±±±± 1.4
(14) Flywheel bolts
Dual-mass flywheel bolts
(15) Con rod cap bolt 20 ±±±± 2 + 45˚±±±± 6˚
(16) Oil pressure switch 30 ±±±± 3 to 35 ±±±± 3.5
(17) TDC pin plug 20 ±±±± 2
(18) Crankshaft bearing cap bolts 25 ±±±± 2.5 + 47˚ ±±±± 6˚
(19) Accelerometer 20 ±±±± 2
(20) Oil filter 14 ±±±± 2
55 ±±±± 5.5
20 ±±±± 2 + 36˚±±±± 6˚
10A-22
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ENGINE AND LOWER ENGINE ASSEMBLY
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Diesel injection: Tightening torque
INJECTION SYSTEM
10A
10A-23
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ENGINE AND LOWER ENGINE ASSEMBLY
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Diesel injection: Tightening torque
10A
113914
10A-24
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ENGINE AND LOWER ENGINE ASSEMBLY
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Diesel injection: Tightening torque
Tightening torque in Nm and/or degrees
(1) High pressure guard mounting nut and bolt 10 ±±±± 1
(2) High pressure pump bolt 21 ±±±± 2.1
(3) Rail-injector high pressure pipe nuts See insert
(4) Injector bracket bolt 30 ±±±± 3
(5) High pressure rail stud 8 ±±±± 0.8
(6) High pressure rail nut 28 ±±±± 2.8
(7) High pressure pump-rail high pressure pipe See insert
(8) Lower high pressure guard nut and bolt 21 ±±±± 2.1
(9) High pressure guard cover bolt 10 ±±±± 1
(10) High pressure pump sprocket nut 55 ±±±± 5.5
10A
(11) Rail-injector high pressure pipe nuts 24 ±±±± 2.4
(12) Injector bracket bolt 28 ±±±± 2.8
(13) High pressure rail nut 28±±±± 2.8
(14) High pressure pump-rail high pressure pipe 24 ±±±± 2.4
(15) Lower high pressure guard and hose bracket nuts 21 ±±±± 2.1
(16) Lower high pressure guard bolts 10 ±±±± 1
(17) High pressure guard cover bolt 10 ±±±± 1
(18) High pressure guard bracket bolts 10 ±±±± 1
(19) High pressure pump bolts 21 ±±±± 2.1
WARNING
Tighten to a torque of 38 ±±±± 3.8 Nm the pump-rail
and rail-injector high pressure pipes, part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 .
For high pressure pipes with different part numbers,
tighten to a torque of 24 ±±±± 2.4 Nm .
10A-25
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ENGINE AND LOWER ENGINE ASSEMBLY
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Accessories belt: Tightening torque
I - ACCESSORIES PANEL ON VEHICLES WITHOUT
AIR CONDITIONING
10A
Tightening torque in Nm and/or degrees
(1) Pulley bolt 21 ±±±± 2.1
(2) Power-assisted steering pump bolt 21 ±±±± 2.1
(3) Power-assisted steering pump stay bolt 21 ±±±± 2.1
(4) Multifunction support bolts 44 ±±±± 4.4
(5) Tensioning roller bolts 35 ±±±± 3.5
(6) Alternator bolt 21 ±±±± 2.1
106962
10A-26
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ENGINE AND LOWER ENGINE ASSEMBLY
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Accessories belt: Tightening torque
II - ACCESSORIES PANEL ON VEHICLES WITH AIR
CONDITIONING
10A
Tightening torque in Nm and/or degrees
(1) Air conditioning compressor bolt 21 ±±±± 2.1
(2) Alternator bolts 21 ±±±± 2.1
(3) Auto tensioner bolts 40 ±±±± 4
(4) Multifunction support bolts 44 ±±±± 4.4
(5) Multifunction support lower bolt 21 ±±±± 2.1
106963
10A-27
Page 30
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
I - POSITION OF THE CYLINDERS
Cylinder no. 1 is at the flywheel end.
II - INJECTION SEQUENCE
The injection sequence is 1-3-4-2 .
III - HEATER PLUG
Type of plug Resistance
BERU
CHAMPION
IV - CYLINDER HEAD GASKET
0.6 Ω
10A
Engine type Thickness of
the cylinder
head gasket in
mm
K9K 260-270-272
K9K 700-702-704-710 up
until 19/05/2004 .
K9K 722 up until 16/07/
2004 .
K9K 700-702-704-710 from
19/05/2004 .
K9K 722 from 16/07/2004 .
K9K 274-276-706-712-714-
716-718-724-728-729-732750-752-760-762-764-766-768-790-792
0.68 ±±±± 0.03
0.71 ±±±± 0.03
20059
The thickness of the cylinder head gasket is measured
at (1) .
V - CYLINDER HEAD
21702
1 - Cylinder head height
The cylinder head height (2) is 127mm .
2 - Cylinder head gasket face bow
The maximum cylinder head gasket face bow is
0.05mm .
10A-28
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ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
3 - Cylinder block gasket face bow
The maximum cylinder block gasket face bow is
0.03mm .
4 - Cylinder head testing
Test the cylinder head for possible cracks using the cy-
linder head test kit .
5 - Cylinder head regrinding
WARNING
No regrinding is permitted.
VI - TAPPET
1 - Tappet type
The tappet is the monobloc type.
10A
3 - Diameter of the tappet housing in the cylinder
head
The diameter of the tappet housing in the cylinder head
is 35.02 ±±±± 0.02mm
4 - Clearance between the tappet and its housing
The clearance between the tappet and its housing is
between 0.015 and 0.075mm .
VII - ADJUSTING VALVE CLEARANCES
Valves Cold valve clearance
in mm
Inlet 0.20 + 0.05 / - 0.075
Exhaust 0.40 + 0.05 / - 0.075
2 - Outer diameter of tappet
103157
The outer diameter of the tappet is 34.975 ±±±± 0.01mm .
Inlet valve Exhaust valve
Diameter (D) of the valve stem is
measured at point (X1)
(D) = 5.977 ±±±± 0.008mm at
(X1) = 41mm .
VIII - VALVES
102778
(D) = 5.963 ±±±± 0.008mm at
(X1) = 31mm .
Diameter (D) of the valve face 33.5 ±±±± 0.12mm 29 ±±±± 0.12mm
Thickness (T) of the valve head 1mm 1mm
Length (L) of the valve 100.95 ±±±± 0.21mm 100.75 ±±±± 0.21mm
Valve seat angle (A) 90˚ 90˚
Valve lift 8mm 8.6mm
10A-29
Page 32
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
IX - VALVE SEATS
Internal diameter of the valve seat
housing (D) in the cylinder head
10A
87428
Inlet valve seat Exhaust valve seat
34.459 ±±±± 0.015mm 29.97 ±±±± 0.015mm
Outer diameter (D) of the valve seat 34.542 ±±±± 0.008mm 30.042 + 0.006 / - 0.007mm
Valve seat housing depth (H) in the
cylinder head
Valve seat height (H) 4.65 ±±±± 0.04mm 5.67 ±±±± 0.04mm
Width of mating faces X 1.8mm 1.8mm
Angle α of the valve seat 89˚30’ 89˚30’
X - VALVE GUIDES
6mm 7mm
21702
10A-30
Page 33
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
Inlet guide Exhaust guide
Length of the valve guide 40.5 ±±±± 0.15mm
External diameter of guide: 11 + 0.062 / + 0.044mm
Diameter of the guide housing in the
cylinder head:
Internal diameter of the valve guide
Non machined
Machined * 5 + 0.12 / 0mm
Valve guide angle of inclination (A) 90˚
Valve guide position (X) 14mm 14.2mm
Clearance between the valve guide
and the valve
0.02 to 0.05mm 0.03 to 0.063mm
11mm
6.009 ±±±± 0.009mm
10A
* This dimension is measured with the guide fitted
in the cylinder head.
XI - VALVE STEM SEALS
The inlet and exhaust guides have valve stem seals.
These must be replaced each time the valves are re-
moved.
98503
The removal of the valve stem seals is carried out
using ( Mot. 1335 ).
18077
10A-31
Page 34
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
The valve stem seals are refitted using either:
- a suitable tool, or
- tool ( Mot. 1511-01 ).
10A
19675
XII - VALVE SPRINGS
The inlet and exhaust valve springs are identical.
16051-1
Free length 43.31mm
Length under a load of:
- 230 ±±±± 12 N
- 500 ±±±± 23 N 33.80mm
24.80mm
Length, coils touching 23.40mm
Diameter of the wire 3.45mm
Internal diameter:
- at the base of the spring
- at the top of the spring
External diameter:
- at the base of the spring
- at the top of the spring
18.80 ±±±± 0.2mm
14.10 ±±±± 0.2mm
25.70 ±±±± 0.2mm
21 ±±±± 0.2mm
102776
The valve springs are the conical type and part (3) of
the spring must face upwards.
WARNING
CE MOTEUR NE POSSEDE PAS DE RONDEL-
LES INFERIEURES DE RESSORT DE SOUPAPE.
10A-32
Page 35
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
Spring perpendicularity 1.2mm
XIII - CAMSHAFT
10A
3 - Camshaft radial play
The radial play must be between 0.04 and 0.081mm .
4 - Camshaft eccentricity.
102774
1 - Identifying the camshaft
113568
With certain engines the camshaft has a target (4) for
aligning the cylinders.
Engine type Camshaft type
K9K 260-270-272-274276-700-702-704-706710-712-714-716-718722-724-728-729-750752-760-762-766-768790-792
WITHOUT the target (4)
103148
The camshaft eccentricity is 0.05mm .
5 - Number of camshaft bearings
The camshaft has 6 bearings.
K9K 732 - 764 WITH the target (4)
2 - Camshaft longitudinal play
The longitudinal play must be between 0.08 and
0.178mm .
10A-33
Page 36
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
6 - Camshaft bearing diameters
Number of bearings Diameter of camshaft bearings
on the camshaft
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6 27.9895 ±±±± 0.0105mm 28.05 ±±±± 0.01mm
Note:
The no. 1 camshaft bearing is located at the
flywheel end.
24.9895 ±±±± 0.0105mm 25.05 ±±±± 0.01mm
10A
Diameter of camshaft bearings
on the cylinder head
8 - Valve timing
7 - Cam height
Inlet Exhaust
Cam height 44.015 ±±
0.03mm
±±
44.595 ±±
0.03mm
103149
±±
- 1 TDC fixed marking on the cylinder block,
- 2 TDC movable marking on the flywheel,
- 3 BDC movable marking on the flywheel,
- 4 Inlet Opening Retardation ROA
- 5 Exhaust Closing Advance AFE
- 6 Inlet Closing Retardation RFA ,
- 7 Exhaust Opening Advance AOE ,
- 8 Crankshaft direction of rotation (flywheel end).
*
,
**
,
11953
10A-34
Page 37
ENGINE AND LOWER ENGINE ASSEMBLY
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Upper engine: Specifications
Note:
*If the
ROA is negative, the valve will open after
TDC.
**If the
AFE is negative, the valve will close before
TDC.
10A
Theoretical settings for a lift of 0.7mm (no
clearance)
Inlet Exhaust
Inlet Opening Retardation ROA
Inlet Closing Retardation RFA
Exhaust
Opening
Advance
AOE
Exhaust Closing
Advance
AFE
-9˚ -
20˚ -
- 27˚
- -7˚
XIV - TURBOCHARGER
Turbocharging pressure regulation valve
Pressure regulation valve value in bar
Engine type
K9K 272-700-704-710-752790
K9K 260-270-702-706-722750
K9K 712-728-729-732-764 - 0.5 1.7
K9K 276-718-724-760-766 - 0.6 7 ±±±± 0.5
K9K 274-714-716-762-768-
792
Pressure Vacuum
1.3 - 1.95 ±±±± 0.6
1.4 - 4.3 ±±±± 0.6
1.1 - 2.2 ±±±± 0.5
Valve rod movement
value in mm
10A-35
Page 38
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
I - PISTONS
1 - Piston brand
These engines are fitted with FEDERAL MOGUL pistons.
2 - Piston combustion chamber volume
10A
3 - Piston markings
102694
Engine type Piston combustion
chamber volume
K9K 260-270-272274-276-700-702-704706-710-712-714-716718-722-724-728-729750-752-760-762-766768-790-792
K9K 732-764 19.96 ±±±± 0.25 cc
16.418 ±±±± 0.25 cc
21703
(1) Direction of fitting the piston Λ facing the flywheel.
(2) Gudgeon pin height class which corresponds to the
height between the gudgeon pin and the piston crown.
(3) Used by the supplier only.
(4) Used by the supplier only.
(5) Used by the supplier only.
(6) Piston axis of symmetry.
(7) Gudgeon pin hole axis.
(8) Offset between gudgeon pin hole and piston axis of
symmetry is 0.3mm .
10A-36
Page 39
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
4 - Gudgeon pin height classes Dimension (X1) represents the height of the gudgeon
pin.
Dimension (D) represents the gudgeon pin diameter.
10A
Engine type
K9K 260-700-702704-710-722 up until
25/11/2002
102694
Diameter of gudgeon pin D =
25mm
Piston category
K* 41.646 to
L* 41.688 to
M* 41.731 to
N* 41.773 to
P 41.815 to
--K* 41.646 to
Gudgeon pin
height in mm
41.687
41.730
41.772
41.814
41.856
Diameter of gudgeon pin D =
26mm
Piston category
--
--
--
--
--
Gudgeon pin
height in mm
41.687
K9K 260-700-702704-710-722 from 25/
11/2002
K9K 270-272-274706-714-716-750-752762-768-790-792
--L* 41.688 to
41.730
--M* 41.731 to
41.772
--N* 41.773 to
41.814
--P 41.815 to
41.856
10A-37
Page 40
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
Engine type
K9K 276-712-718724-728-729-732-760764-766
10A
Diameter of gudgeon pin D =
25mm
Piston category
--J 41.605 to
--K* 41.647 to
--L* 41.689 to
--M* 41.731 to
--N 41.773 to
Gudgeon pin
height in mm
Diameter of gudgeon pin D =
26mm
Piston category
Gudgeon pin
height in mm
41.646
41.688
41.730
41.772
41.814
Note:
* = piston sold by the Parts Department.
WARNING
- For engines K9K 260-270-274-700-702-704-706710-714-716-722-750-752-762-768-790-792 fitted
with gudgeon pins of diameter D = 25 or 26mm ,
the Parts Department will only supply four categories of piston K, L, M, N .
- If the engine is fitted with a category P piston,
replace it with a category N piston.
WARNING
- For engines K9K 276-712-718-724-728-729-732760-764-766 , the Parts Department will only sup-
ply three categories of piston K, L, M .
- If the engine is fitted with a category J piston,
replace it with a category K piston.
- If the engine is fitted with a category N piston,
replace it with a category M piston.
5 - Piston diameter
X2
10027
The piston diameter must be measured with (X2) =
56mm
Engine type Piston diameter in
mm
K9K 260-270-272274-700-702-704-706710-714-716-722-750752-762-768-790-792
75.949 ±±±± 0.007
10A-38
K9K 276-712-718724-728-729-732-760764-766
6 - Gudgeon pin
Fitting the free floating pin in the con rod and in the piston.
75.945 ±±±± 0.007
Page 41
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
The gudgeon pin is retained by circlips. 7 - Piston protrusion
WARNING
The dial gauge rod must not be in a valve clearance.
12962
Gudgeon pin
dimensions in
mm
Engine type
10A
Length (L) 60 +0 / -0.3 All K9K
25 +0 / -0.005 K9K 260-700-702-
704-710-722 up
until 25/11/2002
26 +0 / -0.005 K9K 260-700-702-
704-710-722 from
External diameter (D)
13.75 +0.1 / -
0.2
13.5 +0.1 / -0.2 K9K 260-700-702-
Internal diameter (d)
25/11/2002
K9K 270-272-274276-706-712-714716-718-724-728729-732-750-752760-762-764-766768-790-792
K9K 260-700-702704-710-722 up
until 25/11/2002
704-710-722 from
25/11/2002
K9K 270-272-274276-706-712-714-
716-718-724-728729-732-750-752-
760-762-764-766768-790-792
20174
Engine type Piston protrusion in
mm
K9K 260-700-702-704710-722 up until 25/11/
2002
K9K 260-700-702-704710-722 from 25/11/
2002
K9K 270-272-706-750752-790
K9K 274-276-712-714716-718-724-728-729732-760-762-764-766768-792
0.192 ±±±± 0.093
0.154 ±±±± 0.130
0.159 ±±±± 0.129
Chamfer diameter (C)
Chamfer
length (l)
20 ±±±± 0.25
6
K9K 732-764
10A-39
Page 42
ENGINE AND LOWER ENGINE ASSEMBLY
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II - PISTON RINGS
T
1
2
3
Engine peripherals: Specifications
III - CON RODS
1 - Type of con rod
10A
Piston rings are supplied ready adjusted.
(T) = TOP
1 - Thickness of the piston rings
Piston rings Thickness (in mm)
Compression ring (1) 2 -0.01 / -0.03
Sealing ring (2) 2 -0.01 / -0.03
Scraper ring (3) 2.5 -0.01 / -0.03
2 - Piston ring clearance in groove
Piston rings Piston ring clearance
in mm
Compression 0.2 to 0.35
12115
16242
The con rods are of the "SPLIT" type.
Note: The con rod small end bushes cannot be
replaced.
2 - Guidelines for marking con rods
Sealing 0.7 to 0.9
Scraper 0.25 to 0.5
103280
10A-40
Page 43
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
WARNING
Do not use a punch or an etching tool to mark the
con rod caps to match their bodies, to prevent incipient breakage of the con rod.
Use an indelible marker pen.
3 - Weigh difference for the con rod-pistongudgeon pin assembly
The maximum weight difference for the con rod-pistongudgeon pin assembly for the same engine must be 25
g .
4 - Con rod dimensions
Con rod
dimensions
in mm
Engine type
10A
IV - CRANKSHAFT
1 - Crankshaft markings
Marking one
Distance
between big
end and little
end centres
Big end diameter
Small end
diameter
(with bush)
5 - Big end longitudinal play
133.75 All K9K
47.619 ±±
0.009
25.019 ±±
0.006
26.019 ±±
0.006
±±
All K9K
±±
K9K 260-700-702704-710-722 up
until 25/11/2002
±±
K9K 260-700-702704-710-722 from
25/11/2002
K9K 270-272-274276-706-712-714716-718-724-728729-732-750-752760-762-764-766768-790-792
14512-1
Marking two
The longitudinal play must be between 0.205 and
0.467mm .
6 - Big end radial play
The radial play must be between 0.010 and 0.064mm .
103689
10A-41
Page 44
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
Marking "A" in detail
107878
(5) : line indicating the diameter category of the journals,
(6) : diameter category of journal no. 1, flywheel end,
(7) : diameter category of journal no. 5, timing end,
(8) : diameter category of crankpin no. 1, flywheel end,
10A
4 - Crankshaft lateral play:
The lateral play of the crankshaft must be between:
- Without crankshaft lateral shim wear 0.045 and
0.252mm ,
- With crankshaft lateral shim wear 0.045 and
0.852mm .
5 - Journal radial play
The radial play of the journals must be between 0.010
and 0.054mm .
6 - Number of journals
There are 5 journals.
V - CYLINDER BLOCK
1 - Diameter of the shafts
This engine only has one category of shaft diameter
76.009 ±±±± 0.015mm
(9) : diameter category of crankpin no. 4, timing end,
(10) : line indicating the diameter category of the
crankpins.
2 - Categories of journal diameters
Table of journal diameter categories
Journal category
mark on the
crankshaft
A, G, K, R,W D1 = 47.990 to 47.997
B, H, L, S,Y D2 = 47.997 inclusive to
C, J, O, T, Z D3 = 48.003 inclusive to
3 - Crankshaft dimensions
Journal diameter categories (mm)
exclusive
48.003 exclusive
48.010
2 - Identifying the bearing journal diameters on the
cylinder block
10021
Diameter of the journals 48 ±±±± 0.01mm
Crankpin diameter 43.97 ±±±± 0.01
Maximum run-out allowed
on the flywheel bearing
face of the flywheel
0.6mm
10A-42
Page 45
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
X
7
10A
21697
The cylinder block bearing diameters (6) are marked
with a drill hole on it (7) located above the oil filter.
For every engine there can only be one category of
crankshaft bearing diameter.
3 - Table of bearing diameter classes
Positions
of hole (7)
X = 33mm 1 or Blue 51.936 to 51.942
X = 43mm 2 or Red 51.942 inclusive
4 - Cylinder block gasket face bow
The maximum cylinder block gasket face bow is
0.03mm .
Category
marking
Cylinder block
bearing diameter
(mm)
exclusive
to 51.949
15197
The crankshaft bearing shells are fitted on the cylinder
block and the bearings using the Mot. 1493-01 .
a - Direction of fitting the journal shells
VI - BEARING SHELLS
1 - Crankshaft bearing shells
The engine is fitted with bearing shells without foolproofing.
20159
Fit the grooved bearing shells on all the bearings on
the cylinder block
10A-43
Page 46
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
Fit the non-grooved bearing shells on the bearing
caps.
b - Matching the journal shells to the cylinder block
10A
20158
Cylinder block bearing diameter cate-
gories
1C1
2
D1 D2 D3
1.949 to 1.955
Yellow
C4
1.953 to 1.959
Red
Crankshaft journal diameter category
Bearing shell thickness and category
C2
1.946 to 1.952
Blue
C1
1.949 to 1.955
Yellow
C3
1.943 to 1.949
Black
C2
1.946 to 1.952
Blue
10A-44
Page 47
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine peripherals: Specifications
2 - Conrod bearing shells
10A
17680
The engine is fitted with bearing shells without foolproofing.
The con rod bearing shells are fitted using tools ( Mot.
1492 ) and ( Mot. 1492-03 ).
Bearing shell width
Note:
The upper and lower con rod bearing shells are not
the same width.
Bearing shell width:
- Con rod shank bearing: 20.625 ±±±± 0.125mm ,
- Con rod cap bearing: 17.625 ±±±± 0.125mm .
3 - Crankshaft lateral shims
a - Direction of fitting of lateral shims
Position the lateral shim grooves facing the crankshaft .
b - Position of lateral shims
The lateral shims are located on crankshaft bearing
no. 3 .
c - Thickness of lateral shims
There are two lateral shim thicknesses: 2.80mm and
2.85mm .
10A-45
Page 48
ENGINE AND LOWER ENGINE ASSEMBLY
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Standard replacement
STANDARD EXCHANGE ENGINE
1 - Preparation of the old engine for return
Clean the engine.
Drain the oil and coolant from the old engine.
Secure the old engine to the stand and in the same
conditions as the standard exchange engine:
- fit plastic plugs and covers,
- fit the cardboard cover over the whole assembly.
2 - Parts to leave on the old engine
Parts to leave on the old engine or to include in the return box:
- the dipstick,
- the oil filter,
- the oil filter seat,
10A
- the inlet manifold,
- the exhaust manifold,
- the turbocharger,
- the exhaust gas recirculation valve,
- the catalytic converter,
- the accessories (alternator, air conditioning compressor, power-assisted steering pump),
- the accessories multifunction support.
- the oil cooler,
- the oil level sensor,
- the rocker cover,
- the coolant pump,
- the vacuum pump,
- the high-pressure pump,
- the injector rail,
- the injectors,
- the heater plugs,
- the entire timing end (crankshaft sprocket, belt, tensioner, camshaft sprocket),
- the timing covers,
- the crankshaft accessories pulley,
- the flywheel or the drive plate,
- the clutch pressure plate and driven plate,
- the lifting eyes,
- the cylinder head suspended mounting.
3 - Parts to remove from the old engine
Parts to remember to remove from the old engine:
- all the coolant system pipes,
- the oil pressure switch,
- the pinking sensor,
- the coolant inlet hose,
- the coolant outlet unit,
10A-46
Page 49
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 11 No longer availa-
ble from the Parts
Department (see
Equipment required)
68603
10A
Description
Crankshaft spigot bush extractor
83812
Mot. 251-01 00 00 025 101 Dial gauge sup-
port used with
Mot. 252-01
Mot. 252-01 00 00 025 201 Pressure plate
for measuring
piston protrusion, which is to
be used with
Mot. 251-01 .
83812-1
10A-47
Page 50
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 445 00 00 044 500 Oil filter strap
69716
10A
Description
wrench.
99614
Mot. 582-01 00 00 058 201 Flywheel loc-
king tool.
Mot. 588 00 00 058 800 Cylinder block
liner clamps.
76666
10A-48
Page 51
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 591-02 00 00 059 102 Magnetic hose
77889
10A
Description
for angle tightening.
78181
Mot. 591-04 00 00 059 104 Cylinder Head
bolt tightening
gauge (1/2"
drive).
Mot. 792-03 00 00 079 203 Engine stand
plate.
10099
10A-49
Page 52
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 799-01 00 00 079 901 Pinion locking
80359
10A
Description
tool.
14274
Mot. 856-02 00 00 085 602 Dial gauge sup-
port.
10A-50
Page 53
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 923 00 00 092 300 Engine lifting
10A
Description
eye.
84757
97160
Mot. 1018 00 00 101 800 Oil change
wrench
Mot. 1319-01 00 00 131 901 Crankpin height
measuring tool.
Mot. 1329 00 00 132 900 Oil filter remo-
ving tool 76mm diameter.
10A-51
Page 54
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1335 00 00 133 500 Pliers for remo-
98503
10A
Description
ving valve stem
seals.
84900
Mot. 1378 00 00 137 800 Support studs X
and Y which can
be fitted to the
engine stand
plate Mot. 792-
03 .
Mot. 1430 00 00 143 000 Pin set for
timing adjustment.
13293
10A-52
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ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1485-01 00 00 148 501 Tool for remo-
15868
10A
Description
ving piston cooling jets.
14924
Mot. 1489 00 00 148 900 TDC setting pin.
Mot. 1492 00 00 149 200 Tool for fitting
main bearing
shells.
15867
10A-53
Page 56
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1492-03 00 00 149 203 Adapter kit for
17584
10A
Description
fitting the conrod bearing
shells.
16360
Mot. 1493-01 00 00 149 301 Tool for fitting
crankshaft bearing shells.
Mot. 1494 00 00 149 400 Tool for fitting
piston cooling
jets.
15863
10A-54
Page 57
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1502 00 00 150 200 Valve spring
16088
10A
Description
compression
tool.
16171
Mot. 1505 No longer availa-
ble in the Parts
Department,
replaced by Mot.
1715
Mot. 1511-01 00 00 151 101 Valve stem seal
Frequency
meter for belt
tension.
tool.
19675
10A-55
Page 58
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1525 00 00 152 500 High pressure
17588
10A
Description
pump sprocket
extractor.
17589
Mot. 1525-02 00 00 152 502 High pressure
pump sprocket
extractor claws.
Mot. 1566 00 00 156 600 Spanner for
high pressure
pipe nuts.
19672
10A-56
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ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1567 00 00 151 300 Long reach
13476
10A
Description
EGR clip pliers.
17670
Mot. 1573 00 00 157 300 Cylinder head
support.
Mot. 1585 00 00 158 500 Tool for fitting
crankshaft seal
(flywheel end).
18896
10A-57
Page 60
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1586 00 00 158 600 Tool for fitting
18897
10A
Description
crankshaft seal
(timing end).
18895
Mot. 1632 00 00 163 200 Camshaft oil
seal fitting tool
(timing end).
Mot. 1638 00 00 163 800 Accessories belt
tension tool.
21419
10A-58
Page 61
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1666 00 00 166 600 Balancing shaft
10A
Description
timing tool.
101777
13284
Mot. 1677 00 00 167 700 Flywheel loc-
king tool.
Mot. 1714 77 11 381 714 Adapter for Mot.
1586 for cranks-
hafts with M14
thread hole.
10A-59
Page 62
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1715 77 11 381 715 Frequency
10A
Description
meter for belt
tension.
106507
107634
Mot. 1729 77 11 381 729 E GR valve
removal spanner.
10A-60
Page 63
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1723 77 11 381 723 Engine stand.
10A
Description
111831
114801
Mot. 1746 77 11 381 746 Offset spanner
for high pressure pipes
10A-61
Page 64
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Mot. 1757 77 11 381 757 EGR valve clea-
10A
Description
ning tool.
113191
114797
Mot. 1768 77 11 381 768 High pressure
pump sprocket
extractor claws.
10A-62
Page 65
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Emb. 880 00 00 088 000 Pin extractor.
84328
10A
Description
19854
Emb. 1596 00 00 159 600 24mm socket.
10A-63
Page 66
ENGINE AND LOWER ENGINE ASSEMBLY
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Special tooling
Illustration Tool number Tool part num-
ber
Emb. 1780 77 11 381 780 Clutch centring
10A
Description
device.
110418
69306-1
Rou. 15-01 00 01 331 601 Protective end
piece.
10A-64
Page 67
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Engine stand.
10A
100606
113553
Cleaning bench.
10A-65
Page 68
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Cleaning fountain.
10A
113592
Portable crane.
Load positioner.
114806
10A-66
Page 69
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Relieved thread kit.
10A
114792
114790
Stud extractor kit.
10A-67
Page 70
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Bearing extractor kit.
10A
114786
113494
Torque/angle torque wrench.
10A-68
Page 71
ENGINE AND LOWER ENGINE ASSEMBLY
GETtheMANUALS.org
Equipment
Illustration Description
Torque wrench.
113493
Bolt tightening gauge (angular measuring type).
10A
114798
10A-69
Page 72
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Standard 1/2" (12.7mm) square drive 8/12/14 f emale
torx socket .
10A
114812
114814
Radial play measuring tape.
Oil change end piece fitted with an 8mm square drive
Engine oil change wrench
Pair of protective gloves
Protective goggles
Tool for checking the valve spring loading
10A-70
Page 73
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Indelible marker
Brushes with plastic or non-scratch metal (brass) brist-
les
Compressed air gun
Pressure/vacuum pump
Marking gauge
10A
114805
10A-71
Page 74
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Sliding calliper.
10A
114791
114783
10A-72
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ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Depth gauge
10A
114789
114782
10A-73
Page 76
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Micrometer.
10A
114787
114796
Body jig bench and a pair of v-blocks.
10A-74
Page 77
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Magnetic holder.
10A
114802
114804
Multimeter.
10A-75
Page 78
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Cylinder head testing tool.
10A
12624
18077
Toolkit for fitting valve stem seals
10A-76
Page 79
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Valve spring compressor.
10A
114803
114813
Tweezers.
10A-77
Page 80
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Cylinder head straight edge.
10A
114784
19672
Spanner for the high pressure pipes.
10A-78
Page 81
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Crow foot spanner.
10A
19670
19668
Wrench with hinge for heater plugs.
10A-79
Page 82
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Ring for fitting pistons in the cylinder block.
10A
113579
113581
Tool for removing and refitting piston rings.
10A-80
Page 83
ENGINE AND LOWER ENGINE ASSEMBLY
GETtheMANUALS.org
Equipment
Illustration Description
Gun for adhesive silicone seal cartridges.
114793
Standard 1/2" 22mm long socket (12.7mm square
drive)
10A
114807
10A-81
Page 84
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Roll pin punch.
10A
114808
10A-82
Page 85
ENGINE AND LOWER ENGINE ASSEMBLY
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Equipment
Illustration Description
Male torx socket.
10A
114810
114811
Hexagon drive socket.
10A-83
Page 86
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Dismantling
Special tooling required
Mot. 1378 Engine support studs
X & Y for use with stud
A for Desvil engine
support
Mot. 792-03 Engine support plate
for Desvil engine stand
Mot. 582-01 Flywheel locking tool.
Mot. 1677 Flywheel locking tool.
Mot. 1723 Engine support for
DESVIL engine support stand.
Mot. 1018 Sump plug tool.
I - RECOMMENDATIONS FOR REPAIR
10A
- Workshop crane,
- Load positioner
- Male torx socket,
- 8mm Square drive drain plug spanner
- Protective gloves.
III - PREPARING THE ENGINE TO BE MOUNTED
ON THE STAND
There are two procedures for securing the engine to
the stand:
- by fitting tool ( Mot. 792-03 ) to the cylinder block
(oil filter end),
- by fitting tool ( Mot. 1723 ) to the cylinder block
(flywheel end).
1 - Fitting the engine to the stand fitted with Mot.
792-03 (oil filter end)
100606
IMPORTANT
In order to work on the engine in complete safety,
it is essential to use the new stand, or have the
old stand modified by the manufacturer. When
the engine is on the stand, it is essential to fit
mounting pads (1) .
This mounting refers to the following engines
only: K9K 260-270-272-700-702-704-706-710-722750-752-790.
a - Engine without air conditioning
21861
Loosen the tensioning roller mounting bolts (4) .
Remove:
II - EQUIPMENT REQUIRED
-Engine stand,
- the accessories belt,
- the accessory belt tensioning roller,
- the alternator mounting bolts (5) ,
- the alternator.
10A-84
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Dismantling
b - Engine with air conditioning
10A
111079
Remove:
-the power-assisted steering pump or dummy pulley
mounting bolts (6) ,
-the power-assisted steering pump or dummy pulley.
19651
Rotate the tensioning roller using a wrench (7) to
slacken the belt.
Remove the accessories belt.
Remove:
-the multifunction support mounting bolts,
-the multifunction support.
111057
19703
Remove:
- the alternator mounting bolts (8) ,
- the alternator,
- the air conditioning compressor mounting bolts (9) ,
- the air conditioning compressor.
10A-85
Page 88
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Dismantling
10A
Remove:
-the auto tensioner,
-the multifunction support mounting bolts,
-the multifunction support.
19704
19705
Fit the support studs (X) , (Y) of (Mot. 1378) and the
support stud (A) of (Mot. 792-03) to the cylinder
block.
10099
Fit the ( Mot. 792-03 ) plate onto the engine fitted
with support studs by lining up:
Remove:
-the coolant hoses (10) from the coolant pump inlet
pipe,
-the coolant pump inlet pipe mounting bolt (11) ,
-the coolant pump inlet pipe.
- the support stud (A) with hole 20 on the plate,
- the support stud (X) with hole 33 on the plate,
- the support stud (Y) with hole 32 on the plate.
19706
Fit the engine complete with plate onto the engine
stand.
2 - Fitting the engine to the stand fitted with Mot.
1723 (flywheel end)
This fitting relates to all K9K engines .
10A-86
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ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Dismantling
Note:
The flywheel must be removed on engines with
the starter motor at the exhaust end.
10A
19652
Fit flywheel locking tool (Mot. 582-01) or (Mot. 1677)
.
Remove:
-the clutch pressure plate securing bolt,
-the clutch pressure plate,
-the friction plate.
20172
Remove:
- the flywheel mounting bolts,
- the flywheel,
- the flywheel locking tool ( Mot. 582-01 ) or ( Mot.
1677 ).
10A-87
Page 90
ENGINE AND LOWER ENGINE ASSEMBLY
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Engine: Dismantling
10A
111972
111832
Fit the support stud of (Mot. 1723) to the cylinder
block.
111973
111833
Fit the ( Mot. 1723 ) plate onto the engine fitted with
support studs by lining up:
- the support studs with holes 5, 6 and 7 on the plate
(for engines with starter on the exhaust side),
- the support studs with holes 1, 2, 10 and 12 on the
plate (for engines with starter on the oil filter side).
Fit the engine complete with plate onto the engine
stand.
Remove the engine wiring harness.
Remove the drain plug from the sump using (Mot.
1018) or using a drain plug spanner (8mm square
drive) .
10A-88
Page 91
ENGINE AND LOWER ENGINE ASSEMBLY
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Accessories belt: Removal
I - RECOMMENDATIONS FOR REPAIR
IMPORTANT
Wear protective gloves during every operation.
II - EQUIPMENT REQUIRED
-Protective gloves.
III - REMOVAL
1 - Engine without air conditioning
10A
2 - Engine with air conditioning
Undo the tensioning roller mounting bolts (1) .
Remove:
-the accessories belt,
-the accessories belt tensioning roller.
19651
Rotate the tensioning roller using a wrench (2) to
slacken the belt.
Remove the accessories belt.
21861
19703
Remove:
- the accessories belt tensioning roller mounting bolt
(3) ,
- the accessories belt tensioning roller.
10A-89
Page 92
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
Special tooling required
Mot. 1489 TDC locating pin.
Mot. 1430 Set of 5 crankshaft
and camshaft pulley
timing pins.
Mot. 582-01 Flywheel locking tool.
Mot. 1677 Flywheel locking tool.
Mot. 1573 Cylinder head support
I - TIMING GEAR REMOVAL
II - GUIDELINES FOR REPAIRS TO THE TIMING
GEAR
IMPORTANT
Wear protective gloves during every operation.
III - EQUIPMENT REQUIRED FOR THE TIMING
GEAR
- Protective gloves,
- Large screwdriver,
- Allen key ( 6mm ),
10A
- Female torx socket ( 14 ).
IV - REMOVAL
Remove the upper timing cover by unclipping both
tabs (1) .
19654
10A-90
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ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
Remove:
-the high pressure pump position sensor (2) ,
-the plastic bolt (3) .
Unclip the three tabs (4) .
Remove the lower timing cover.
19654-1
10A-91
Page 94
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
Remove the cylinder head suspended mounting.
19654-2
19702
Remove the TDC setting pin plug using a number 14
female torx socket.
19650
Turn the crankshaft to position the hole (5) of the
camshaft pulley almost opposite the hole (6) in the
cylinder head.
10A-92
Page 95
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
19650-1
Screw in the TDC setting pin (1) (Mot. 1489) .
14489
Turn the crankshaft clockwise (timing end) smoothly
until the crankshaft comes into contact with the TDC
setting pin.
19655
Insert the pin (Mot. 1430) (2) in the camshaft pulley
and cylinder head holes.
Remove:
- the camshaft pulley timing pin (Mot. 1430) ,
- the TDC setting pin (Mot. 1489)
10A-93
Page 96
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
19652
Fit flywheel locking tool (Mot. 582-01) or (Mot. 1677)
.
Note:
For engines that have already had the flywheel
removed, screw two used flywheel bolts into the
crankshaft to lock it using a large screwdriver.
10A-94
Page 97
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
Remove the crankshaft accessories pulley.
19656
10A-95
Page 98
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
10A
Slacken the tensioning roller bolt (7) .
Loosen the timing tensioning roller by turning the ec-
centric cam using a 6mm Allen key.
Remove:
-the timing belt taking care not to let the crankshaft
timing sprocket fall out,
-the timing tensioning roller.
V - CYLINDER HEAD REMOVAL
VI - GUIDELINES FOR REPAIRS TO THE CYLINDER
HEAD
IMPORTANT
Wear protective gloves during every operation.
VII - EQUIPMENT REQUIRED FOR THE CYLINDER
HEAD
19656-1
- Female torx socket.
-Male torx socket,
10A-96
Page 99
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
VIII - REMOVAL
Loosen the clip (11) .
Remove the oil vapour rebreathing pipe (12) from
the rocker cover.
10A
19709
19710
Remove:
-the inner timing cover mounting bolts (10) ,
-the inner timing cover (by tilting the alternator if necessary).
Undo the turbocharger oil supply pipe nut (13) .
19708
Remove:
Remove:
-the clip (8) ,
-the air filter unit mounting bolt (9) ,
-the air filter unit.
19707
- the turbocharger oil supply pipe bolt (14) using a
male torx socket,
- the turbocharger oil supply pipe.
Remove:
- the turbocharger oil return pipe bolts (18) ,
- the catalytic convertor stay bolts (16) ,
- the exhaust flange bolts (15) on the turbocharger.
10A-97
Page 100
ENGINE AND LOWER ENGINE ASSEMBLY
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Timing - cylinder head: Removal
K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or
760 or 762 or 790
Remove the turbocharger-catalytic converter assembly, taking care not to damage the turbochar-
ger oil return pipe (18) .
10A
19711
Unclip the fuel return pipe from the rocker cover (19)
.
Remove:
-the dipstick guide tube (21) ,
-the rocker cover mounting bolts (20) ,
-the rocker cover.
20073
Fit the cylinder head onto the cylinder head support
(Mot. 1573) .
Remove the cylinder head gasket from the cylinder
block.
Remove:
-the cylinder head bolts in the order specified using
a female torx socket,
-the cylinder head.
19712
10A-98
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