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Duster 2007
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10A
-
36
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil filter: Removal - Refitting
K4M
10A
a
Top up the engine oil level to the dipstick if neces-
sary (see
10A
,
Engine and cylinder block assem-
bly
,
Engine oil: Draining - Refilling
, page
10A-32
)
.
61
63
Table of Contents
Main Page
Duster - Chapitre 1
23
Table of Contents
23
Crankshaft Seal on Timing End: Removal - Refitting
27
Crankshaft Seal, Gearbox End: Removal - Refitting
31
Lower Cover: Removal - Refitting
35
Conrod Bearing Shell: Removal - Refitting
50
Engine Oil: Draining - Refilling
58
Oil Filter: Removal - Refitting
60
Oil-Coolant Heat Exchanger: Removal - Refitting
63
Oil Pressure Sensor: Removal - Refitting
68
Oil Pump: Removal - Refitting
70
Oil Pressure: Check
72
Multifunction Support: Removal - Refitting
74
Engine - Gearbox Assembly: Removal - Refitting
80
Flywheel: Removal - Refitting
101
Top and Front of Engine
104
Pressure at End of Compression: Check
104
Accessories Belt: Removal - Refitting
105
Crankshaft Accessories Pulley: Removal - Refitting
113
Timing Belt: Removal - Refitting
120
Rocker Cover: Removal - Refitting
145
Camshaft: Removal - Refitting
152
Camshaft Seal, Timing End: Removal - Refitting
159
Oil Decanter: Removal - Refitting
171
Fuel Mixture
174
Air Inlet: Description
174
Air Resonator: Removal - Refitting
175
Air Filter: Removal - Refitting
176
Air Filter Unit: Removal - Refitting
179
Fuel Mixture
179
Throttle Valve: Removal - Refitting
184
Inlet Distributor: Removal - Refitting
185
Injector Holder Shim: Removal - Refitting
187
Exhaust Manifold: Removal - Refitting
189
Turbocharging
195
Turbocharger: Removal - Refitting
195
Turbocharger Oil Pipe: Removal - Refitting
198
Intercooler: Removal - Refitting
202
Fuel Circuit: Operating Diagram
204
Fuel Supply
204
Manual Priming Pump: Removal - Refitting
206
Diesel Filter: Removal - Refitting
208
Fuel Pressure: Check
212
Fuel Flow: Check
214
Diesel Injection
217
Diesel Injection: List and Location of Components
217
Diesel Injection Computer: Removal - Refitting
221
Camshaft Position Sensor: Removal - Refitting
223
Diesel Injection
223
Crankshaft Position Sensor: Removal - Refitting
224
High Pressure Pump: Removal - Refitting
225
Flow Actuator: Removal - Refitting
230
Venturi: Removal - Refitting
232
High Pressure Pipe: Check
234
High Pressure Pipe between Pump and Rail: Removal - Refitting
235
High Pressure Pipe between Rail and Injector: Removal - Refitting
238
Injector Rail: Removal - Refitting
241
Fuel Temperature Sensor: Removal - Refitting
244
Injector Leak Flow: Check
246
Diesel Injector: Removal - Refitting
248
Accelerometer: Removal - Refitting
253
Pre-Postheating Unit: Removal - Refitting
255
Heater Plugs: Removal - Refitting
256
Exhaust Gas Recirculation: List and Location of Components
258
Antipollution
258
Fuel Vapour Absorber: Removal - Refitting
259
Antipollution
261
Exhaust Gas Recirculation Solenoid Valve: Removal - Refitting
261
Exhaust Gas Cooler: Removal - Refitting
264
Exhaust Gas Recirculation Assembly: Removal - Refitting
266
Exhaust Gas Recirculation Rigid Pipe: Removal - Refitting
269
Starting - Charging
271
Alternator: Removal - Refitting
271
Starter: Removal - Refitting
278
Alternator Pulley: Removal - Refitting
282
Ignition
289
Coils: Removal - Refitting
289
Petrol Injection
291
Petrol Injection: List and Location of Components
291
Oxygen Sensors: Removal - Refitting
294
Throttle Valve Potentiometer: Removal -Refitting
296
Petrol Injection Computer: Removal - Refitting
297
Crankshaft Position Sensor: Removal - Refitting
299
Injector Rail - Injectors: Removal - Refitting
300
Engine Cooling System: Operating Diagram
302
Engine Cooling System: Specifications
303
Engine Cooling System: Check
304
Engine Cooling Circuit: List and Location of Components
306
Cooling System: Draining - Refilling
307
Cooling Radiator: Removal - Refitting
310
Coolant Pump: Removal - Refitting
314
Thermostat: Removal - Refitting
320
Water Chamber: Removal - Refitting
323
Engine Cooling Fan Assembly: Removal - Refitting
328
Coolant Pump Inlet Pipe: Removal - Refitting
335
Expansion Bottle: Removal - Refitting
339
Coolant Temperature Sensor: Removal - Refitting
341
Exhaust
346
Exhaust: List and Location of Components
346
Exhaust: Precautions for the Repair
351
Catalytic Converter: Removal - Refitting
355
Expansion Chamber: Removal - Refitting
362
Intermediate Pipe: Removal - Refitting
363
Exhaust
363
19B
363
Silencer: Removal - Refitting
365
19C
366
Tank
366
Fuel Tank: Draining
366
Fuel Tank: Removal - Refitting
368
Fuel Level Sensor Module: Removal - Refitting
373
19D
376
Engine Mounting
376
Suspended Engine Mounting: Tightening Torque
376
Left-Hand Suspended Engine Mounting: Removal - Refitting
377
Right-Hand Suspended Engine Mounting: Removal - Refitting
379
Lower Engine Tie-Bar: Removal - Refitting
383
Duster - Chapitre 2
385
Clutch
386
Clutch: Precautions for the Repair
386
Clutch: Specifications
387
Pressure Plate - Disc: Removal - Refitting
389
Clutch Thrust Bearing: Removal - Refitting
391
Manual Gearbox
392
Manual Gearbox Oils: Draining - Filling
392
Differential Output Seal: Removal - Refitting
393
Manual Gearbox: Removal - Refitting
395
5Th Gear Housing: Removal - Refitting
409
5Th Gear Sprockets and Synchronisers: Removal - Refitting
412
Input Shaft Lip Seal: Removal - Refitting
416
Reverse Gear Switch: Removal - Refitting
417
Driveshafts
418
Front Left-Hand Driveshaft: Removal - Refitting
418
Front Right-Hand Driveshaft: Removal - Refitting
421
Relay Shaft Bearing: Removal - Refitting 29A-6
423
Front Driveshaft Gaiter, Wheel Side: Removal - Refitting
424
Front Right-Hand Driveshaft Gaiter, Gearbox Side: Removal - Refitting
428
Front Left-Hand Driveshaft Gaiter, Gearbox Side: Removal - Refitting
433
Duster - Chapitre 3
439
Brake Circuit: Operating Diagram
442
General Information
442
Brake Circuit: Precautions for the Repair
443
Braking Circuit: Bleed
445
Brake Circuit: Tightening Torque
447
Rigid Brake Pipe: Repair
448
Brake Fluid: Specifications
453
Brake: Specifications
454
Steering: Tightening Torque
455
Axle Assemblies: Check
456
Front Axle System: Tightening Torque
457
Front Axle System: Adjustment
459
Rear Axle System: Tightening Torque
460
Front Axle Components
461
Front Axle Components: Precautions for the Repair
461
Front Brake Pads: Removal - Refitting
463
Front Axle Components
465
Front Brake Hose: Removal - Refitting
465
Front Brake Calliper: Removal - Refitting
467
Front Brake Calliper: Repair
469
Front Brake Calliper Mounting: Removal - Refitting
471
Front Brake Disc Protector: Removal - Refitting
473
Front Brake Disc: Removal - Refitting
475
Front Brake Disc: Description
478
Hydraulic Unit - Master Cylinder Brake Pipe: Removal - Refitting
479
Hydraulic Unit - Underbody Union Brake Pipe: Removal - Refitting
481
Hydraulic Unit - Front Left-Hand Calliper Brake Pipe: Removal - Refitting
483
Hydraulic Unit - Front Right-Hand Calliper Brake Pipe: Removal - Refitting
485
Front Driveshaft Hub Carrier: Removal - Refitting
487
Front Hub Carrier Bearing: Removal - Refitting
490
Front Shock Absorber and Spring: Removal - Refitting
493
Front Axle Components
499
Front Driveshaft Lower Arm: Removal - Refitting
499
Front Driveshaft Lower Arm Ball Joint: Check
501
Front Axle Subframe: Removal - Refitting
502
Front Anti-Roll Bar: Removal - Refitting
506
Rear Axle Components
507
Rear Axle Components: Precautions for the Repair
507
Rear Brake Lining: Removal - Refitting
508
Rear Brake Cylinder: Removal - Refitting
511
Rear Brake Drum: Removal - Refitting
513
Rear Brake Drum: Description
515
Rigid Brake Pipe: Removal - Refitting
516
Shock Absorber: Removal - Refitting
518
Rear Suspension Spring: Removal - Refitting
520
Rear Axle Rubber Bearing: Removal - Refitting
522
Complete Rear Axle System: Removal - Refitting
525
Wheel: Removal - Refitting
528
Wheels and Tyres
528
Wheel: Balancing
531
Wheels and Tyres
531
Tyre: Precautions for the Repair
534
Tyres: Identification
535
Tyres: Removal - Refitting
536
Tyre: Repair
538
Wheel Rim: Identification
541
Emergency Spare Wheel Carrier: Removal - Refitting
542
Steering Assembly
544
Steering: List and Location of Components
544
Steering: Precautions for the Repair
545
Track Rod: Removal - Refitting
547
Axial Ball Joint Linkage: Removal - Refitting
548
Steering Column: Removal - Refitting
550
Steering Box Gaiter: Removal - Refitting
552
Bulkhead Seal: Removal - Refitting
553
Steering Column Adjustment Handle: Removal - Refitting
554
Steering Wheel: Removal - Refitting
556
Power Assisted Steering
558
Power-Assisted Steering Pump Pressure: Check
558
Power Assisted Steering
562
Power-Assisted Steering Pump: Removal - Refitting
562
Power-Assisted Steering
563
Power-Assisted Steering Pump Assembly: Removal - Refitting
570
Power-Assisted Steering Pipes: Removal - Refitting
572
Brake Mechanism: Precautions for the Repair
584
Mechanical Component Controls
584
Master Cylinder: Removal - Refitting
585
Master Cylinder - Front Right-Hand Calliper Brake Pipe: Removal - Refitting
588
Master Cylinder - Front Left-Hand Calliper Brake Pipe: Removal - Refitting
590
Brake Servo Non-Return Valve: Removal - Refitting
592
Brake Servo: Removal - Refitting
594
Vacuum Pump: Removal - Refitting
597
Pedal Yoke: Removal - Refitting
599
Accelerator Pedal: Removal - Refitting
603
Accelerator Pedal Cable: Removal - Refitting
607
Brake Pedal: Removal - Refitting
609
Brake Pedal Switch: Removal - Refitting
610
Parking Brake Lever: Removal - Refitting
612
Mechanical Component Controls
613
Parking Brake Lever: Adjustment
613
Clutch Control: List and Location of Components
614
Clutch Pedal: Removal - Refitting
616
Clutch Pedal Switch: Removal - Refitting
618
Clutch Circuit: Bleed
620
Clutch Master Cylinder: Removal - Refitting
627
Clutch Circuit: Removal - Refitting
630
Gear Control Unit: Removal - Refitting
633
Parking Brake Cables: Removal - Refitting
636
Brake Servo: Check
638
ABS: List and Location of Components
639
Anti-Lock Braking System
639
ABS: Precautions for the Repair
642
Hydraulic Brake Unit: Removal - Refitting
643
Front Wheel Speed Sensor: Removal - Refitting
645
Rear Wheel Speed Sensor: Removal - Refitting
647
Duster - Section 5
650
Front Side Door Window Winder Handle: Removal - Refitting
652
Side Opening Element Mechanisms
652
Rear Side Door Window Winder Handle: Removal - Refitting
653
Front Side Door Check Strap: Removal - Refitting
654
Front Side Door Striker Panel: Removal - Refitting
655
Front Side Door Lock: Removal - Refitting
656
Front Side Door Lock Barrel: Removal - Refitting
658
Exterior Door Handle: Removal - Refitting
659
Front Side Door Interior Opening Control: Removal - Refitting
660
Front Side Door Electric Window Mechanism: Removal - Refitting
661
Front Side Door Manual Window Winder Mechanism: Removal - Refitting
663
Rear Side Door Striker Panel: Removal - Refitting
665
Rear Side Door Lock: Removal - Refitting
666
Side Opening Element Mechanisms
666
Rear Side Door Interior Opening Control: Removal - Refitting
668
Rear Side Door Manual Window Winder Mechanism: Removal - Refitting
669
Rear Side Door Slide Mounting: Removal - Refitting
671
Front Side Door Slide Mounting: Removal - Refitting
672
Rear Side Door Check Strap: Removal - Refitting
674
Exterior Rear Opening Element Assembly: Exploded View
675
Non-Side Opening Element Mechanisms
675
Non-Side Opening Element Mechanisms
676
Tailgate Strut: Removal - Refitting
683
Tailgate Exterior Opening Control: Removal - Refitting
684
Windscreen: Removal - Refitting
685
Front Side Door Sliding Window: Removal - Refitting
687
Rear Side Door Sliding Window: Removal - Refitting
689
Rear Quarter Panel Window: Removal - Refitting
691
Rear Screen: Removal - Refitting
692
Exterior Protection
693
Front Bumper Assembly: Exploded View
693
Rear Bumper Assembly: Exploded View
695
Exterior Body Front Trim Assembly: Exploded View
697
Front Bumper: Removal - Refitting
698
Rear Bumper: Removal - Refitting
701
Front Wheel Arch Liner: Removal - Refitting
702
Rear Wheel Arch Liner: Removal - Refitting
703
Exterior Body Side Trim Assembly: Exploded View
704
Exterior Equipment
704
Door Mirror: Removal - Refitting
705
Door Mirror Glass: Removal - Refitting
706
Rear Badges: Removal - Refitting
707
Dashboard: Removal - Refitting
708
Interior Equipment
708
Dashboard: Stripping - Rebuilding
713
Dashboard Air Vent: Removal - Refitting
714
Glovebox Cover: Removal - Refitting
716
Centre Console: Removal - Refitting
717
Interior Rear-View Mirror: Removal - Refitting
719
Sun Visor: Removal - Refitting
720
Grab Handle: Removal - Refitting
721
Duster - Chapitre 6
723
Heating
724
Heating: List and Location of Components
724
Cabin Filter: Removal - Refitting
731
Front Air Distribution Duct: Removal - Refitting
732
Rear Air Distribution Duct: Removal - Refitting
733
Recirculation Control Cable: Removal - Refitting
734
Air Distribution Cable: Removal - Refitting
736
Air Mixing Cable: Removal - Refitting
738
Distribution Unit: Removal - Refitting
740
Heater Matrix: Removal - Refitting
744
Fan Assembly: Removal - Refitting
747
Heating Resistor Relays: Removal - Refitting
748
Heating Resistors: Removal - Refitting
749
Passenger Compartment Fan Assembly Control Unit: Removal - Refitting
751
Control Panel: Removal - Refitting
752
Air Conditioning
753
Air Conditioning: List and Location of Components
753
Air Conditioning: Parts and Consumables for the Repair
761
Condenser: Removal - Refitting
762
Compressor: Removal - Refitting
764
Expansion Valve: Removal - Refitting
768
Refrigerant Pipe Seal: Removal - Refitting
770
Refrigerant Circuit Pipe: Removal - Refitting
773
Pressure Sensor: Removal - Refitting
775
Duster - Chapitre 7
859
Body Internal Trim
860
Interior Body Side Trim Assembly: Exploded View
860
Roof Trim Assembly: Exploded View
862
Floor Trim Assembly: Exploded View
863
Floor Carpet: Removal - Refitting
864
Windscreen Pillar Trim: Removal - Refitting
867
B-Pillar Trim: Removal - Refitting
868
Front Side Door Trim: Removal - Refitting
871
Side Opening Element Trim
871
Rear Side Door Trim: Removal - Refitting
873
Non-Side Opening Elements Trim
876
Rear Opening Element
876
Front Seat Assembly: Exploded View
877
Front Seat Frames and Mechanisms
877
Duster - Chapitre 8
887
Battery: Precautions for the Repair
891
Battery: Removal - Refitting
892
Headlight Assembly: Exploded View
895
Headlight: Removal - Refitting
896
Headlight: Adjustment
897
Headlight Bulb: Removal - Refitting
899
Front Fog Light Bulb: Removal - Refitting
900
Front Fog Light: Removal - Refitting
901
Side Indicator: Removal - Refitting
902
Remote Headlight Beam Adjustment Actuator: Removal - Refitting
903
Rear Light Assembly: Exploded View
904
Rear Lighting
904
Rear Wing Light: Removal - Refitting
905
Rear Light Bulb: Removal - Refitting
906
3Rd Brake Light: Removal - Refitting
907
High Level Brake Light Bulb: Removal - Refitting
908
Number Plate Light: Removal - Refitting
909
Interior Lighting
910
Interior Lighting: List and Location of Components
910
Radio: List and Location of Components
960
Radio: Removal - Refitting
962
Radio Aerial: Removal - Refitting
963
Front Speakers: Removal - Refitting
964
Rear Speakers: Removal - Refitting
965
Radio Control Satellite: Removal - Refitting
966
Passenger Compartment Connection Unit
967
UCH: Removal - Refitting
967
Electric Window: List and Location of Components
968
Electric Windows - Sunroof
968
Front Electric Window Switch: Removal - Refitting
969
Rear Electric Window Switch: Removal - Refitting
970
Engine Compartment Connection Unit
971
Engine Compartment Connection Unit: List and Location of Components
971
Computers: List and Location of Components
973
Wiring Harness
973
Diagnostic Socket: List and Location of Components
974
Wiring Harness
974
Wiring: Precautions for the Repair
975
Front Bumper Wiring: Removal - Refitting
976
Engine Wiring: Removal - Refitting
977
Passenger Compartment Front Wiring: Removal - Refitting
997
Passenger Compartment Rear
1006
Air Bag and Pretensioners
1014
Airbag and Pretensioners
1015
Airbag and Pretensioners
1016
Airbag Computer: Removal - Refitting
1017
Driver's Frontal Airbag: Removal - Refitting
1019
Passenger's Frontal Airbag: Removal - Refitting
1022
Front (Chest-Level) Side
1025
Side Impact Sensor: Removal - Refitting
1027
Front Seat Belt Buckle: Removal - Refitting
1029
Rear Seat Belt Buckle: Removal - Refitting
1030
Front Side Seat Belt: Removal - Refitting
1031
Rear Side Seat Belt: Removal - Refitting
1035
Section 8
1040
Fault Finding - Introduction
1041
Fault Finding - List and Location of Components
1043
Fault Finding - Role of Components
1044
Fault Finding - Function
1045
Fault Finding - Configuration
1047
Fault Finding - Conformity Check
1048
Fault Finding - Status Summary Table
1050
Fault Finding - Interpretation of Statuses
1051
Fault Finding - Command Summary Table
1060
Fault Finding - Interpretation of Commands
1061
Fault Finding - Customer Complaints
1067
Fault Finding - Fault Finding Chart
1068
Section 9
1101
Access - Safety
1102
Fault Finding - Introduction
1102
Vdiag No.: 09
1102
Fault Finding - List and Location of Components
1108
Fault Finding - Role of Components
1109
Fault Finding - Function
1110
Fault Finding - Configuration
1113
Fault Finding - Programming
1115
Fault Finding - Fault Summary Table
1118
Fault Finding - Interpretation of Faults
1119
Fault Finding - Conformity Check
1123
Fault Finding - Status Summary Table
1126
Fault Finding - Interpretation of Statuses
1127
Fault Finding - Parameter Summary Table
1130
Fault Finding - Interpretation of Parameters
1131
Fault Finding - Command Summary Table
1132
Fault Finding - Interpretation of Commands
1133
Fault Finding - Customer Complaints
1138
Fault Finding - Fault Location Chart
1140
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